Page 1 SEN03763-13 HYDRAULIC PC130 EXCAVATOR 80001 SERIAL NUMBERS and up...
Page 3 SEN03765-13 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 00 Index and foreword Index Composition of shop manual .......................... 2 Table of contents ............................. 4 PC130-8...
Page 4 General information on troubleshooting SEN04118-02 Troubleshooting by failure code, Part 1 SEN04119-01 Troubleshooting by failure code, Part 2 SEN04120-03 SEN04121-02 q Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 4 SEN04122-01 Troubleshooting of electrical system (E-mode) SEN04123-01 PC130-8...
Page 5 Engine and cooling system SEN04127-02 Power train SEN04128-01 Undercarriage and frame SEN04129-02 Hydraulic system SEN04130-01 Work equipment SEN04131-00 Cab and its attachments SEN04132-01 Electrical system SEN04134-00 90 Diagrams and drawings SEN03783-02 Hydraulic diagrams and drawings SEN03784-00 SEN03785-02 q Electrical diagrams and drawings PC130-8...
Page 6: Table Of Contents
Hydraulic equipment layout drawing ................... Valve control..........................Hydraulic tank and filter ....................... Hydraulic pump ........................... Hydraulic system, Part 2 SEN03774-01 Control valve ..........................CLSS ............................12 Functions and operation by valve....................16 Hydraulic system, Part 3 SEN03775-04 PPC valve............................ PC130-8...
Page 7 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 PC130-8...
Page 8 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 PC130-8...
Page 9 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 PC130-8...
Page 10 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 PC130-8...
Page 11 Removal and installation of travel motor and final drive assembly ..........Disassembly and assembly of travel motor and final drive assembly ......... Removal and installation of swing motor and swing machinery assembly........41 Disassembly and assembly of swing machinery assembly............43 PC130-8...
Page 12 Electrical circuit diagram (1/6) ..................... Electrical circuit diagram (2/6) ..................... Electrical circuit diagram (3/6) ..................... Electrical circuit diagram (4/6) ..................... Electrical circuit diagram (5/6) ..................... 11 Electrical circuit diagram (6/6) ..................... 13 Connectors table and arrangement drawing ................15 PC130-8...
Page 13 00 Index and foreword SEN03765-13 PC130-8...
Page 15 SEN03766-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 00 Index and foreword Foreword and general information 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...
Page 16: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 17 Accord- damage. Always use slings which have ample capacity and install them to proper ingly, open the windows and doors to ven- places. Operate the hoist or crane slowly tilate well. PC130-8...
Page 18 If you grasp them, your fingers as large as 39.2 kN {4,000 kg}. may be caught. After the wire ropes are stretched, stop the crane and check the condi- tion of the slung load, wire ropes, and pads. PC130-8...
Page 19 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immedi- ately in an emergency. PC130-8...
Page 20 When connecting the refrigerant pip- ing, apply compressor oil for refriger- ant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings. PC130-8...
Page 21: How To Read The Shop Manual
Engine volume This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. PC130-8...
Page 22 Places where oil, etc. must be drained, and quantity to be drained. Units In this shop manual, the units are indicated with International System of units (SI). For reference, con- ventionally used Gravitational System of units is indicated in parentheses { }. PC130-8...
Page 23: Explanation Of Terms For Maintenance Standard
The tightness of fit is decided by the toler- ance. Indication of size of rotating shaft and hole and relationship drawing of them Example: Tolerance Standard size Shaft Hole –0.030 +0.046 –0.076 PC130-8...
Page 24 If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from vari- ous tests or experiences in most cases, however, it must be judged after consider- ing the operating condition and customer's requirement. PC130-8...
Page 25: Handling Of Electric Equipment And Hydraulic Component
The pins of the male and female connec- tors are in contact at the crimped terminal or soldered portion, but if there is exces- sive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. PC130-8...
Page 26 If there is oil or water in the com- pressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air com- pletely before cleaning with com- pressed air. PC130-8...
Page 27 If the machine is left disassem- bled for a long time, it is particu- larly easy for improper contact to occur, so always cover the con- nector. PC130-8...
Page 28 If the connector cannot be cor- rected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. PC130-8...
Page 29 (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks PC130-8...
Page 30 After completely drying the con- n e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble. PC130-8...
Page 31 If there is any change, there is proba- bly defective contact in that circuit. PC130-8...
Page 32 If an oil clean- ing device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method. PC130-8...
Page 33 The oil cleaning equipment is used to remove the ultra fine (about 3 ) particles that the filter built in the hydraulic equipment can- not remove, so it is an extremely effective device. PC130-8...
Page 34: Handling Of Connectors Newly Used For Engines
Even if lock (L2) is pressed, connec- tor (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screw- driver while press lock (L2), and then pull out connector (1) toward you. PC130-8...
Page 35 If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connec- tor with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow. PC130-8...
Page 36 Insert the connector to the end, while setting its groove. Turn housing (H1) in the direction of the arrow until it “clicks”. Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up. PC130-8...
Page 37: How To Read Electric Wire Code
(Nominal No. 3 and below) Insulator Soft polyvinyl chloride automobile Conduc- Annealed copper for elec- Heat-resis- General wiring in extremely tric appliance tant low-volt- –50 to +110 cold district, wiring at high-tem- age wire for Heat-resistant crosslinked perature place Insulator automobile polyethylene PC130-8...
Page 38 (mm d (approx.) 10.4 12.0 13.6 Standard – – – – – – – – – Cov- Standard 10.8 11.4 13.0 13.6 16.0 17.6 er D Standard 10.8 11.4 13.0 13.6 16.0 17.6 “f” of nominal No. denotes flexible”. PC130-8...
Page 39 – – – Others – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – PC130-8...
Page 40: Precautions When Carrying Out Operation
07378-10400 07371-30400 07379-00500 07378-10500 07371-30500 If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 11.5 07049-01620 13.5 07049-01822 07049-02025 07049-02228 18.5 07049-02430 07049-02734 22.5 PC130-8...
Page 41 If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it. PC130-8...
Page 42 If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”. PC130-8...
Page 43: Method Of Disassembling And Connecting Push-Pull Type Coupler
After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however. PC130-8...
Page 44 2), pull out whole body (7) to discon- nect it. (Fig. 8) Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 9) PC130-8...
Page 45 2), pull out whole body (9) to discon- nect it. (Fig. 12) Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 13) PC130-8...
Page 46: Standard Tightening Torque Table
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.) PC130-8...
Page 47 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0} PC130-8...
Page 48 Tightening torque Thread size Bolts and nuts 10 ± 2 1.02 ± 0.20 24 ± 4 2.45 ± 0.41 43 ± 6 4.38 ± 0.61 77 ± 12 7.85 ± 1.22 — — PC130-8...
Page 49 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51 PC130-8...
Page 50: Conversion Table
2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 PC130-8...
Page 51 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153 PC130-8...
Page 52 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4 PC130-8...
Page 53 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542 PC130-8...
Page 54 23.9 167.0 65.6 302.0 –14.4 42.8 105.8 24.4 168.8 68.3 311.0 –13.9 44.6 107.6 25.0 170.6 71.1 320.0 –13.3 46.4 109.4 25.6 172.4 73.9 329.0 –12.8 48.2 111.2 26.1 174.2 76.7 338.0 –12.2 50.0 113.0 26.7 176.0 79.4 347.0 PC130-8...
Page 55 00 Index and foreword SEN03766-02 PC130-8...
Page 57: Specification
SEN03768-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 01 Specification Specification and technical data Specification dimension drawings ........................2 Working range diagram........................... 3 Specifications ..............................4 List of weights ..............................8 List of lubricant and coolant to be filled......................10...
Page 58: Specification Dimension Drawings
Item Unit PC130-8 Machine weight (Standard specification) 12,700 Bucket capacity 0.50 Engine type — Komatsu SAA4D95LE-5 Diesel engine Net [ISO 9249/SAE J1349] 68.4{91.7}/2,200 Engine rated output kW{HP}/rpm Gross [SAE J1955] 72.1{96.6}/2,200 A Overall length (Standard specification) 7,590 B Overall height...
Page 59: Working Range Diagram
01 Specification SEN03768-01 Working range diagram Unit: mm Working range (mm) PC130-8 Maximum digging reach 8,290 Maximum digging depth 5,520 Maximum digging height 8,650 Maximum vertical wall digging depth 4,980 Maximum dumping height 6,210 Minimum swing radius of work 2,450...
Page 60: Specifications
SEN03768-01 01 Specification Specifications PC130-8 Machine model Standard specification Serial No. 80001 and up Bucket capacity 0.50 Operating weight 12,700 Max. digging depth 5,520 Max. vertical wall depth 4,980 Max. digging reach 8,290 Max. reach at ground level 8,170 Max. digging height 8,650 Max.
Page 61 01 Specification SEN03768-01 PC130-8 Machine model Standard specification Serial No. 80001 and up Model SAA4D95LE-5 4-cycle, water-cooled, in-line, vertical, direct injection, with Type turbocharger and air cooled aftercooler No. of cylinders-bore x stroke 95 x 115 l{cc} Piston displacement 3.260{3,260} Rated horsepower •...
Page 62 SEN03768-01 01 Specification PC130-8 Machine model Standard specification Serial No. 80001 and up Type Reciprocating piston type Cylinder inner diameter ø 105 Piston rod diameter ø 70 Stroke Max. length between pins 2,510 Min. length between pins 1,515 Type Reciprocating piston type Cylinder inner diameter ø...
Page 63 01 Specification SEN03768-01 PC130-8...
Page 64: List Of Weights
SEN03768-01 01 Specification List of weights This weight table is prepared for your reference when handling or transporting the components. Unit: kg PC130-8 Machine model Standard specification Serial No. 80001 and up Engine assembly (excl. water, oil) • Engine (excl. water, oil) •...
Page 65 01 Specification SEN03768-01 Unit: kg PC130-8 Machine model Standard specification Serial No. 80001 and up Boom assembly Arm assembly Bucket link assembly 122.9 Bucket assembly • 980 mm width (incl. side cutter) Boom cylinder assembly 100.3 x 2 Arm cylinder assembly Bucket cylinder assembly 77.8...
Page 66: List Of Lubricant And Coolant To Be Filled
List of lubricant and coolant to be filled a For details of the notes (Note. 1, 2, 3, 4) in the table, see the Operation and Maintenance Manual. a The details refer to an Operation and Maintenance Manual about Recommended Komatsu fluids again. PC130-8...
Page 67 01 Specification SEN03768-01 Unit: l Reservoir Specified capacity Refill capacity Engine oil pan 11.5 11.0 Swing machinery case Final drive case (each side) PTO case 0.75 — Hydraulic system Fuel tank — Cooling system 13.9 13.9 PC130-8...
Page 69: Structure, Function And Maintenance Standard
SEN03770-01 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Engine and cooling system Engine mount..............................2 PTO................................. 3 Cooling system ............................... 4 PC130-8...
Page 70: Engine Mount
SEN03770-01 10 Structure, function and maintenance standard Engine mount PC130-8...
Page 71: Pto
10 Structure, function and maintenance standard SEN03770-01 a PTO: Abbreviation for Power Take Off Flywheel Coupling Hydraulic pump shaft Drain plug Oil filler plug Oil level plug PC130-8...
Page 72: Cooling System
SEN03770-01 10 Structure, function and maintenance standard Cooling system PC130-8...
Page 73 Total heat dissipation surface 12.96 27.82 8.79 0.59 (m²) (6.48 x 2) Pressure valve cracking 49.0 ± 14.7 pressure — — — {0.5 ± 0.15} (kPa{kg/cm²}) Vacuum valve cracking pressure -4.9 – 0 — — — (kPa{kg/cm²}) {-0.05 – 0} PC130-8...
Page 75: Power Train Sen03771-01
SEN03771-01 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Power train Power train..............................2 Swing circle..............................3 Swing machinery............................. 4 PC130-8...
Page 76 6. Hydraulic pump Control valve 7. Engine 2a. Self pressure reducing valve 8. Swing motor 2nd travel speed select solenoid valve 9. Center swivel joint Swing holding brake solenoid valve 10. Swing machinery Travel motor (Final drive) 11. Swing circle PC130-8...
Page 77: Swing Circle
0.5 – 1.6 Swing circle bearing lubrication Inner race soft zone position Swing circle pinion lubrication Outer race soft zone position Outer race Ball Specifications Seal Reduction ratio 90/11=8.182 Inner race (Number of teeth: 90) Grease G2-LI Grease quantity (l) PC130-8...
Page 78: Swing Machinery
(rpm) 8. No. 1 planetary carrier 9. No. 1 sun gear (Number of teeth: 14) 10. Swing motor 11. No. 1 planetary gear (Number of teeth: 24) 12. No. 2 planetary gear (Number of teeth: 22) 13. Drain plug PC130-8...
Page 79 Back lash between Swing pin- 0.13 – 1.16 ion and swing circle Standard size Tolerance Repair limit Outside diameter of oil seal Repair by hard contacting surface on swing chrome-plating ø 145 ø 144.8 pinion collar or replace -0.100 PC130-8...
Page 81 SEN03772-01 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Undercarriage and frame Track frame ..............................2 Idler cushion..............................3 Idler ................................. 4 Track roller ..............................5 Carrier roller ..............................6 Sprocket ................................7 Track shoe ..............................
Page 82: Track Frame
Length at idler guide frame Idler Rebuilding or support replace Track Rebuilding frame Width at idler guide Idler Rebuilding or support replace Idler 7. Sprocket Track frame 8. Track roller Carrier roller 9. Idler cushion Travel motor (Final drive) 10. Track shoe PC130-8...
Page 83: Idler Cushion
Recoil spring length load load Replace 84.3 kN 75.0 kN 501.4 {8,600 kg} {7,650 kg} 2. Idler Specifications 3. Support Grease G2-LI 4. Rod Grease quantity (cc) 5. Cylinder 6. U-packing 7. Pilot 8. Nut 9. Valve 10. Grease fitting PC130-8...
Page 84: Idler
0.057 – — +0.087 0.117 Standard clearance Clearance limit Side clearance of idler (each side) 0.18 – 0.38 Basic dimension Repair limit Tread thickness Rebuilding or (at tread center) replace — Oil capacity 90 cc (engine oil: SAE30CD) — PC130-8...
Page 85: Track Roller
+0.140 0.220 Standard clearance Clearance limit Side clearance of track roller (each side) 0.41 – 0.90 Standard size Repair limit Tread thickness Rebuilding or (at tread center) replace — Oil capacity 145 – 155 cc (engine oil: SAE30CD) — PC130-8...
Page 86: Carrier Roller
Side clearance of carrier roller (each side) 0.363 – 0.537 Tread thickness Standard size Repair limit Rebuilding or (at 10 mm from roller outer replace 17.7 12.7 edge) — Oil capacity 68 – 76 cc (engine oil: SAE30CD) — PC130-8...
Page 87: Sprocket
+1.0 ø 547.4 ø 535 -2.0 Wear on tooth tip diameter ø 607 — ø 595 Rebuilding or replace Wear on tooth tip width — Wear on tooth bottom width ±1.5 +0.465 Thickness at tooth bottom 111.7 105.5 -1.160 PC130-8...
Page 88: Track Shoe
SEN03772-01 10 Structure, function and maintenance standard Track shoe Triple grouser shoe, road liner *1. Triple grouser shoe *2. Road liner a P portion shows the link of bushing press fitting end. PC130-8...
Page 89 Bushing 39.2 – 137.3 kN {4 – 14 ton} Regular pin 78.5 – 186.3 kN {8 – 19 ton} Press-fit force — Master pin 39.2 – 98.1 kN {4 – 10 ton} *: In case of dry type track. PC130-8...
Page 90 0.178 – 0.270 -0.020 -0.250 Tolerance Standard Standard size clearance Clearance between master pin Shaft Hole and bushing -0.200 +0.830 ø 30 0.530 – 1.130 -0.300 +0.330 26 Grouser height (road liner) Replace *: In case of dry type track. PC130-8...
Page 91 10 Structure, function and maintenance standard SEN03772-01 Triple grouser shoe Unit: mm Item Criteria Remedy Standard size Repair limit Grouser height Shoe height 29.5 19.5 Plate thickness Rebuilding or replace Grouser bottom length Grouser tip length PC130-8...
Page 93: Hydraulic System, Part 1
SEN03773-00 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Hydraulic system, Part 1 Hydraulic equipment layout drawing ....................... 2 Valve control ..............................4 Hydraulic tank and filter ..........................6 Hydraulic pump ............................... 8...
Page 94: Hydraulic Equipment Layout Drawing
10. R.H. travel motor (R.H. Final drive) 11. Oil cooler 12. L.H. travel motor (L.H. Final drive) 13. L.H. work equipment PPC valve 14. R.H. work equipment PPC valve 15. Center swivel joint 16. Travel PPC valve 17. Attachment PPC valve (Machine ready for attachment) PC130-8...
Page 95 10 Structure, function and maintenance standard SEN03773-00 PC130-8...
Page 96: Valve Control
13. Attachment PPC valve and bucket control) (Machine ready for attachment) L.H. work equipment control lever (for arm and 14. Attachment control pedal swing control) (Machine ready for attachment) L.H. work equipment PPC valve 15. Lock pin Lock lever PC130-8...
Page 97 10 Structure, function and maintenance standard SEN03773-00 PC130-8...
Page 98: Hydraulic Tank And Filter
Hydraulic tank Specifications Suction strainer Hydraulic tank capacity (l) Filter element Bypass valve Oil level in hydraulic tank (l) Drain plug Bypass valve set pressure 0.15 ± 0.03 Sight gauge (MPa{kg/cm²}) {1.53 ± 0.3} Oil filler cap combined with breather PC130-8...
Page 99 If the pressure in the tank rises above the set value, bottom plate (2) is pushed up to release the pressure in the tank. (Exhaust valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm²}) PC130-8...
Page 100: Hydraulic Pump
SEN03773-00 10 Structure, function and maintenance standard Hydraulic pump Type: HPD56+56 PC130-8...
Page 101 PLS : Load pressure input port PLSC : Load pressure pickup port : PC mode selector pressure pick-up port : Pump suction port Main pump LS valve PC valve PC-EPC valve Shuttle valve No. 1 check valve No. 2 check valve PC130-8...
Page 102 SEN03773-00 10 Structure, function and maintenance standard Shaft 7. Cylinder block Cradle 8. Valve plate Case 9. End cap Rocker cam 10. Servo piston Shoe 11. PC valve Piston PC130-8...
Page 103 (5) is caulked to it to form one unit. Piston (6) and shoe (5) constitute the spherical bearing. Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement. PC130-8...
Page 104 (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suc- tioned. PC130-8...
Page 105 (PEN) at the large diameter piston end, and the ratio between the area receiving the pres- sure of the small diameter piston and the large diameter piston controls the movement of servo piston (12). PC130-8...
Page 106 (PP) — (PLS)], called the LS differential pres- sure (the difference between main pump pres- sure (PP) and control valve outlet port pressure (PLS)). Main pump pressure (PP), pressure (PLS) (called the LS pressure) coming from the con- trol valve output enters this valve. PC130-8...
Page 107 LS pressure (PLS) will be set to 0 MPa {0 kg/cm }. (It is intercon- nected to the drain circuit via the control valve spool) Spool (6) is pushed to the left, and port (C) and port (D) will be connected. PC130-8...
Page 108 (12) becomes drain pressure (PT), and pump pressure (PP) enters port (J) at the small diameter end, so servo piston (12) is pushed to the right side. Therefore, the swash plate is moved in the direction to make the delivery larger. PC130-8...
Page 109 (12), it is pushed to the left. As the result, the servo piston (12) moves into the direction of reducing the swash plate angle. PC130-8...
Page 110 At this point, the relationship between the pres- sure receiving areas across servo piston (12) is (A0) : (A1) = 1 : 2, so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 2 : 1. PC130-8...
Page 111 PC-EPC valve solenoid. The controller continues counting the actual engine speed. If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed. PC130-8...
Page 112 (4) and (6) as well as the pump pressures (PP1) (check valve output pressure) and (PP2) (shuttle valve output pres- sure). PC130-8...
Page 113 10 Structure, function and maintenance standard SEN03773-00 PC130-8...
Page 114 (3) will be positioned in the right If the command current (X) to PC-EPC valve side. solenoid (1) changes, so does the force push- Port (C) and (D) are connected, and the pres- ing piston (2). sure entering the LS valve becomes drain pressure (PT). PC130-8...
Page 115 (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve gener- ates and the pushing force of springs (4) and (6) are balanced. PC130-8...
Page 116 When servo piston (9) moves to the left, half of the main pump pressure (PP). springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the right, the opening of port (C) and port (D) becomes larger. PC130-8...
Page 117 (3), so the relationship between the aver- age pump pressure (PP1 + PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased. PC130-8...
Page 118 SEN03773-00 10 Structure, function and maintenance standard 2. As the emergency pump drive switch is turned on due to failure on the pump controller When the main pump is under light load PC130-8...
Page 119 (9) also becomes the drain pressure (PT) through the LS valve. Since the pressure on the small diameter end of the piston is large, servo piston (9) moves in the direction to make the delivery larger. PC130-8...
Page 120 SEN03773-00 10 Structure, function and maintenance standard When the main pump is under heavy load PC130-8...
Page 121 PC-EPC valve solenoid through the resistor. The curve resulting when the emergency pump drive switch is ON is situated further to the left (B) than when the pump controller is normal (A). PC130-8...
Page 122 SEN03773-00 10 Structure, function and maintenance standard PC-EPC valve C : To PC valve P : From self pressure reducing valve T : To tank Connector Coil Body Spring Spool Plunger PC130-8...
Page 123 Spool (5) is pushed to the left by spring (4). Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the PC valve. The pressurized oil from the PC valve is drained to the tank through port (C) and port (T). PC130-8...
Page 124 (7) may be balanced with pressure of port (C) + spring load of spring (4). The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the size of the signal current. PC130-8...
Page 125 (2). Since (PA1) > (PA2), however, poppet valve (2) is kept closed and (PA1) is output to (PP1). 2. When (PA1) < (PA2) Reversely to 1., poppet valve (1) is kept closed and (PA2) is output to (PP1). PC130-8...
Page 126 Since poppet valves (1) and (2) push each other through pin (3), either one of them receiving higher pressure is closed and the other one receiving lower pressure is opened. Accordingly, lower discharge pressure of the 2 main pumps is output. PC130-8...
Page 127 10 Structure, function and maintenance standard SEN03773-00 PC130-8...
Page 129: Hydraulic System, Part 2
SEN03774-01 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Hydraulic system, Part 2 Control valve ..............................2 CLSS................................12 Functions and operation by valve ......................... 16 PC130-8...
Page 130: Control Valve
11. Swing bleeding valve Bucket valve 12. LS check valve Arm valve 13. Travel junction valve + LS check valve Boom valve 14. Arm regeneration valve Right travel valve 15. Boom hydraulic drift prevention valve Left travel valve 16. Merge-divider valve block PC130-8...
Page 131 10 Structure, function and maintenance standard SEN03774-01 PC130-8...
Page 132 SEN03774-01 10 Structure, function and maintenance standard PC130-8...
Page 133 42.4 × 28 — {22.6 kg} {18.1 kg} 230 N 184 N 37 Spool return spring 45.6 × 28 — {23.5 kg} {18.8 kg} 203 N 163 N 38 Spool return spring 45.81 × 28 — {20.7 kg} {16.6 kg} PC130-8...
Page 134 SEN03774-01 10 Structure, function and maintenance standard PC130-8...
Page 135 Outside diameter length load load If damaged or deformed, 5.88 N 4.71 N 41.5 x 8.5 31.5 — replace spring {0.6 kg} {0.48 kg} 2.94 N 2.35 N 21 Check valve spring 20.3 x 13.7 — {0.3 kg} {0.24 kg} PC130-8...
Page 136 SEN03774-01 10 Structure, function and maintenance standard PC130-8...
Page 137 58.9 × 13 — {8.5 kg} {6.8 kg} 98.1 N 78.5 N 27 Spool return spring 49.8 × 18.8 — {10 kg} {8 kg} 13.7 N 11.0 N 28 Check valve spring 16.4 × 8.9 11.5 — {1.4 kg} {1.12 kg} PC130-8...
Page 138 SEN03774-01 10 Structure, function and maintenance standard PC130-8...
Page 139 {6.8 kg} deformed, replace spring 168 N 134 N 33 Spool return valve spring 67.47 × 20.6 42.5 — {17.1 kg} {13.7 kg} 5.88 N 4.71 N 34 Valve spring 41.5 × 8.5 31.5 — {0.6 kg} {0.48 kg} PC130-8...
Page 140: Clss
The hydraulic pump is configured with pump Controllability enabling digging even with fine body, PC valve and LS valve. control Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations Energy saving using variable pump control PC130-8...
Page 141 (when the actuator load pressure is low), the discharge pressure (PP) — LS pressure (PLS)] pump swash plate angle shifts toward the minimum position. LS differential pressure ( PLS) and pump swash plate angle a For details of functions, see the "Hydraulic pump" paragraph. PC130-8...
Page 142 (pres- sure). The flow of oil from the pump is divided (com- pensated) in proportion to the area of opening (S1) and (S2) of each valve. PC130-8...
Page 143 10 Structure, function and maintenance standard SEN03774-01 PC130-8...
Page 144: Functions And Operation By Valve
SEN03774-01 10 Structure, function and maintenance standard Functions and operation by valve Hydraulic circuit diagram and the name of valves PC130-8...
Page 145 28. Suction safety valve Set pressure: 36.8 MPa {375 kg/cm²} 29. Suction safety valve Set pressure: 24.5 MPa {250 kg/cm²} 30. Main relief valve Set pressure: 31.9 MPa {325 kg/cm²} In one-touch power maximizing mode: 34.5 MPa {352 kg/cm²} 31. Unload valve PC130-8...
Page 146 (LS2), and (LS3) are also merged. Operation Pump discharge pressures (P1) and (P2) are applied to pump pressure receiving (SA) face of unload spool (1). LS pressures (LS1) and (LS2) are applied to LS pressure receiving (SB) face. [(P1) = (P2), (LS1) = (LS2)] PC130-8...
Page 147 (P1) and (P2) are merged. LS pressures (LS1), by spring (2). (LS2), and (LS3) are also merged. As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump discharge amount (Q) flows to the actuator circuit. PC130-8...
Page 148 In other words, the excessive oil (maximum becomes maximum. (For details, see the sec- pump discharge mount - demand flow) above tions on the pump merge-divider valve.) the strokes of both travel valves flows into tank circuit (T). PC130-8...
Page 149 (2), so spool (1) is pushed to the right by spring (2). As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump discharge amount (Q) flows to the actuator circuit. PC130-8...
Page 150 (P2) side flows into tank circuit (T). and right one is at HOLD. When the left travel valve is operated to the stroke end, LS pressure (LS1) is generated and acts on the face (SB) of unload spool (1). PC130-8...
Page 151 10 Structure, function and maintenance standard SEN03774-01 PC130-8...
Page 152 (3). (LS1), (LS2), and (LS3) are also merged. At this time, (P1) = (P2) and (LS1) = (LS2) = (LS3) and the pump swash plate is controlled by the difference between (P) and (LS). PC130-8...
Page 153 At this time, higher one of (P1) and (P2) is applied through pump merge-divider spool (3) to the output port of the LS pressure. As a result, there is not difference between (P) and (LS) and the pump swash plate is set to the maximum position. PC130-8...
Page 154 At the same time, reducing valve (3) also moves to the right, so pump discharge pres- sure (PP) is reduced by the pressure loss at notch (c). It goes to LS circuit (PLS), and then goes to spring chamber (PLSS). PC130-8...
Page 155 Actuator circuit pressure (PA) (= A) is intro- duced through the check valve (5) into LS cir- cuit (PLS). a The travel circuit is different from the work equipment circuit: actuator circuit pressure (PA) is directly introduced into LS circuit (PLS). PC130-8...
Page 156 (a) of LS bypass valve (2) through orifice (b) to causes a pressure loss in the throttled flow in tank circuit (T). the reducing valve, and that lowers the effec- tive LS differential pressure to improve the sta- bility. PC130-8...
Page 157 Since pump merge-divider spool (1) is at the tank circuit (T). separate position, LS circuits (PLS1) and (PLS2) are separated. The hydraulic oil (PLS1) flows from tip filter (a) of LS bypass valve (2) through orifice (b) to tank circuit (T). PC130-8...
Page 158 SEN03774-01 10 Structure, function and maintenance standard Pressure compensation valve PC130-8...
Page 159 So, the pressure differences between the upstream pressures (PPA) and the down- stream pressures (PA) of the both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch (a). PC130-8...
Page 160 (3) ratio. When the ratio is less than 1.00: The expression (PP) – (PPB) < (PLS) – (PA) (= A) can be held, and the flow is dis- tributed more than the spool opening area ratio. PC130-8...
Page 161 Operation When the boom is lowered and falls due to its own weight, the bottom side pressure (A) in the boom cylinder (1) will rise above the head side pressure (B). PC130-8...
Page 162 Operation When the boom is lowered and is in the load process, the head side pressure (B) of the boom cylinder (1) rises above the bottom side pressure (A). PC130-8...
Page 163 Operation When the arm falls for digging due to its own weight, the head side pressure (A) in the arm cylinder (1) will rise above the bottom side pressure (B). PC130-8...
Page 164 When the arm is in the digging process, the bottom side pressure (B) of the arm cylinder (1) will rise, close the check valve (3) and inter- rupt the circuits on the head side and the bot- tom side. PC130-8...
Page 165 (5). surized oil from leaking from the boom bottom As a result, the main pressure from the control through spool (1) to prevent the boom from valve flows through the valve into the boom drifting hydraulically. cylinder bottom. PC130-8...
Page 166 (5) and the pressurized oil flowing in through orifice (a) is blocked by pilot spool (3). Accordingly, the boom is held. PC130-8...
Page 167 (b) is low- ered by orifice (a). If the pressure in chamber (b) is lowered below the pressure in port (Aa), poppet (5) opens and the pressurized oil from port (Ab) flows through port (Aa) into the control valve. PC130-8...
Page 168 PPC pressure (PA) rises. In the fine control area, notch (b) chokes the bleed- off circuit and determines the intermediate pressure before the lowered pressure is applied to pump discharge pressure (PP) and LS pressure (PLS). PC130-8...
Page 169 (PP) pushes the valve (1) to open it and is led to the pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure (PLS) suitable for the load pressure, and the pressure is led to the pump LS valve. PC130-8...
Page 170 (PLS), but the LS pressure (PLS) caused by the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. The pilot pressure (BP) depends on the control lever stroke. PC130-8...
Page 171 When the machine is steered, outside pilot the left stroke end and the junction circuit pressure (PST) closes the travel junction valve between port (PTL) (Left travel circuit) and to secure high steering performance. (PTR) (Right travel circuit) is closed. PC130-8...
Page 172 (P) and (PR). The (P) pressure is lowered and controlled to a constant pres- sure (set pressure) by the opening ratio at this time and supplied as the (PR) pressure. PC130-8...
Page 173 Piston (1) is so balanced that oil cooler inlet [(PB) C 0 kg/cm pressure (PB) will be as follows. (PB) – (PT) = Force of spring (5) / Area of pis- ton (1) at diameter (d2) [(PT) C 0 kg/cm PC130-8...
Page 175: Hydraulic System, Part 3
SEN03775-04 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Hydraulic system, Part 3 PPC valve ............................... 2 Swing motor ..............................17 Travel motor ..............................25 Center swivel joint............................34 Solenoid valve............................... 36 Accumulator ..............................
Page 176: Ppc Valve
P2 : L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port P3 : L.H. PPC valve: Swing LEFT port/R.H PPC valve: Bucket CURL port P4 : L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port : To tank PC130-8...
Page 177 10 Structure, function and maintenance standard SEN03775-04 PC130-8...
Page 178 Centering spring  29.4 N 23.5 N 44.45 × 15.5 — (for ports P1 and P2) {3 kg} {2.40 kg} 16.7 N 13.3 N 12 Metering spring 26.53 × 8.15 24.9 — {1.7 kg} {1.36 kg} PC130-8...
Page 179 (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1). PC130-8...
Page 180 (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the cham- ber with pressurized oil. PC130-8...
Page 181 10 Structure, function and maintenance standard SEN03775-04 Travel PPC valve : From self-pressure reducing valve P1 : L.H. REVERSE P2 : L.H. FORWARD P3 : R.H. REVERSE P4 : R.H. FORWARD : To hydraulic tank PC130-8...
Page 182 SEN03775-04 10 Structure, function and maintenance standard PC130-8...
Page 183 Outside diameter length load load If damaged or deformed, 108 N 86.3 N 48.57 × 15.5 32.5 — replace spring. {11 kg} {8.8 kg} 16.7 N 13.3 N Metering spring 26.53 × 8.15 24.9 — {1.7 kg} {1.36 kg} PC130-8...
Page 184 (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1). PC130-8...
Page 185 (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the cham- ber with pressurized oil. PC130-8...
Page 186 SEN03775-04 10 Structure, function and maintenance standard Attachment PPC valve  (with EPC valve) a For the details of operation, see the paragraph of "Work equipment and swing PPC valve". PC130-8...
Page 187 If damaged or deformed, 125 N 100 N 33.88 × 15.3 28.4 — replace spring. {12.7 kg} {10.2 kg} 16.7 N 13.3 N 10 Metering spring 22.73 × 8.10 22 .0 — {1.70 kg} {1.36 kg} PC130-8...
Page 188 Standard size Repair limit If damaged or Free length × Installation Installation Installation Free length deformed, Return spring Outside diameter length load load replace EPC 3.1 N 2.6 N valve assembly. 9.5 × 11.4 — {0.32 kg} {0.26 kg} PC130-8...
Page 189 Spool (11) is pushed to the right by spring (12). Port (P) closes and the pressurized oil from the front pump does not flow to the control valve. The pressurized oil from the control valve is drained to the tank via port (C) and port (T). PC130-8...
Page 190 (6) may be balanced with pressure of port (C) + spring load of spring (3). The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current. PC130-8...
Page 191: Swing Motor
MB: From control valve Theoretical displacement : 143.8 cm³/rev From control valve Safety valve set pressure : 27.1 MPa {276 kg/cm²} To tank Rated speed : 2,111 rpm Brake release pressure : 1.1 MPa {11 kg/cm²} Reverse prevention valve Safety valve PC130-8...
Page 192 SEN03775-04 10 Structure, function and maintenance standard PC130-8...
Page 193 Outside diameter length load load If damaged or deformed, 8.63 N 6.86 N 43.3 × 6 36.5 — replace spring. {0.88 kg} {0.70 kg} 1.96 N 1.57 N 18 Shuttle valve spring 13 × 6.5 — {0.2 kg} {0.16 kg} PC130-8...
Page 194 After entering chamber (a), the pressurized oil Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes the brake is applied. brake piston (8) up. Disc (5) is separated from plate (6), releasing the brake. PC130-8...
Page 195 The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. The pressurized oil from the outlet port of the motor passes from port (MB) through the con- trol valve (6) and returns to the tank. PC130-8...
Page 196 SEN03775-04 10 Structure, function and maintenance standard Reverse prevention valve PC130-8...
Page 197 SEN03775-04 MA: From control valve MB: From control valve T1: To tank T2: To tank Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side) Explanatory drawing of effects PC130-8...
Page 198 Port (MB) chamber (e) will be intercon- nected. Since pressure (MA) is lower than the set pres- sure of spring (3), spool (2) does not move and the pressurized oil is kept in. Thus the braking force is ensured. PC130-8...
Page 199: Travel Motor
From center swivel joint, port D2 (L.H. travel motor) From center swivel joint, port A2 (R.H. travel motor) D: To center swivel joint, port DR2 From center swivel joint, port E2 Oil filler plug Oil level plug Drain plug PC130-8...
Page 200 23. Piston 9. Plate 24. Floating seal 10. Swash plate 25. Spindle 11. Pivot 26. Cylinder 12. Bearing 27. Timing plate 13. Hub 28. Regulator valve 14. Planetary pinion B 29. Check valve 15. Planetary pinion A 30. Piston PC130-8...
Page 201 Brake valve Consists of various valves. Provides the follow- ing functions: stops the hydraulic motor smoothly, prevents runway of hydraulic motor, prevents generation of abnormally high pres- sure when the hydraulic motor is stopped sud- denly. PC130-8...
Page 202 The pressurized oil in control chamber (C) is drained from port (D) through oil passage (e) of 12. Brake valve regulator valve (2). Swash plate (7) reaches its maximum tilt angle, and the machine travels at low speed with the maximum motor capacity. PC130-8...
Page 203 (C), and is used to push to 10. Pump merge-divider valve regular piston (5) to the left. 11. Self pressure reducing valve Swash plate (7) reaches its minimum tilt angle, 12. Brake valve and the machine travels at high speed with the minimum motor capacity. PC130-8...
Page 204 This releases the parking brake and gradually closed by controlling the movement the motor starts to rotate. speed of counterbalance valve (2) and by using its cutout portion. By this, the motor is smoothly stopped. PC130-8...
Page 205 (B) is well balanced with the pressure by the weight of machine itself and the pressure at port (A). The motor speed is controlled according to the pump delivery by controlling the opening of hydraulic oil output circuit. PC130-8...
Page 206 The hydraulic pressure at port (D) at the inlet The hydraulic pressure at port (C) at the inlet side is controlled so that the motor is smoothly side is controlled so that the motor is smoothly stopped. started to rotate. PC130-8...
Page 207 10 Structure, function and maintenance standard SEN03775-04 PC130-8...
Page 208: Center Swivel Joint
To L.H. travel motor REVERSE port B From 2nd travel speed select solenoid valve To L.H. and R.H. travel motor port P DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D Cover O-ring Body Shaft Slipper seal PC130-8...
Page 209 10 Structure, function and maintenance standard SEN03775-04 Unit: mm Item Criteria Remedy Standard size Standard clearance Clearance limit Clearance between rotor and Replace shaft ø 80 0.056 – 0.105 0.111 PC130-8...
Page 210: Solenoid Valve
SEN03775-04 10 Structure, function and maintenance standard Solenoid valve PC130-8...
Page 211 4. 2nd travel speed select solenoid valve 5. Swing holding brake solenoid valve 6. 2-stage relief solenoid valve Solenoid valve 7. Coil (ON/OFF type) 8. Push pin 9. Valve spool 10. Sleeve 11. Block 12. Plug Check valve 13. Plunger 14. Plug PC130-8...
Page 212 (4). As ports (P) and (A) are opened, the pilot pres- sure is fed to the actuator through port (A). At the same time, port (T) is closed, shutting off the oil from the actuator to the hydraulic tank. PC130-8...
Page 213 10 Structure, function and maintenance standard SEN03775-04 PC130-8...
Page 214: Accumulator
Therefore, the spool can be operated to the lower the work equipment by its own weight. Specifications Gas to be used: Nitrogen gas Gas capacity: 300 cc Sealed gas pressure: 1.18 MPa {12 kg/cm²} (at 80°C) Maximum operating pressure: 6.86 MPa {70 kg/cm²} PC130-8...
Page 215 Gas capacity: 500 cc Gas capacity: 480 cc Sealed gas pressure: Sealed gas pressure: 0.1 MPa {1 kg/cm²} (at 80°C) 5.88 MPa {60 kg/cm²} (at 80°C) Maximum operating pressure: 0.69 MPa {7 kg/cm²} Maximum operating pressure: 20.6 MPa {210 kg/cm²} PC130-8...
Page 216: Anti-Drop Valve For Boom
SEN03775-04 10 Structure, function and maintenance standard Anti-drop valve for boom (Machine with anti-drop valve for boom) a General view PC130-8...
Page 217 {1.3 kg} {1.04 kg} Function This valve prevents the work equipment from sud- den lowering by thwarting the counterflow of pres- surized oil from the work equipment when the piping between the control valve and the work equipment cylinder breaks. PC130-8...
Page 218 Chambers (b) of anti-drop valves on the right and left are interconnected at port (PCY). The pressures of chambers (b) are the same even when there is a difference of leakage amount between the antidrop valves on the right and left. PC130-8...
Page 219 (2) (area of circle "d"). Spool (1) moves rightward further, and cham- ber (a) and chamber (b) are interconnected. (The second stroke) The pressurized oil returns from the work equipment cylinder to the control valve. PC130-8...
Page 220 (a) leaks through the damaged part to the out- side, but it is supplied from chamber (b). The pressurized oil flows through the opening (C) of spool (1), and it prevents the work equip- ment from sudden lowering. PC130-8...
Page 221: Anti-Drop Valve For Arm
10 Structure, function and maintenance standard SEN03775-04 Anti-drop valve for arm (Machine with anti-drop valve for arm) a General view PC130-8...
Page 222 {1.3 kg} {1.04 kg} Function This valve prevents the work equipment from sud- den lowering by thwarting the counterflow of pres- surized oil from the work equipment when the piping between the control valve and the work equipment cylinder breaks. PC130-8...
Page 223 (a) and chamber (b) are disconnected. The pressure of the work equipment is held to prevent the work equipment from sudden low- The pressure of the work equipment is held to ering. prevent the work equipment from sudden low- ering. PC130-8...
Page 224 (a) leaks through the damaged part to the out- side, but it is supplied from chamber (b). The pressurized oil flows through the opening (C) of spool (1), and it prevents the work equip- ment from sudden lowering. PC130-8...
Page 225 10 Structure, function and maintenance standard SEN03775-04 PC130-8...
Page 226: Hydraulic Cylinder
SEN03775-04 10 Structure, function and maintenance standard Hydraulic cylinder Boom cylinder Arm cylinder Bucket cylinder PC130-8...
Page 227 0.250 -0.030 +0.190 0.120 – Boom ø 70 -0.100 +0.090 0.290 Clearance between cylinder bottom  -0.030 +0.190 0.120 – ø 70 support shaft and -0.100 +0.090 0.290 bushing -0.030 +0.170 0.100 – Bucket ø 65 -0.080 +0.070 0.250 PC130-8...
Page 229: Work Equipment Sen03776-00
SEN03776-00 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Work equipment Work equipment .............................. 2 Dimensions of components..........................4 PC130-8...
Page 230 0.213 Clearance between mounting -0.030 +0.132 0.105 – ø 65 pin and bushing of link and link -0.080 +0.075 0.212 Clearance between mounting -0.030 +0.130 0.108 – pin and bushing of link and ø 60 -0.080 +0.078 0.210 bucket PC130-8...
Page 231 10 Structure, function and maintenance standard SEN03776-00 PC130-8...
Page 232: Dimensions Of Components
SEN03776-00 10 Structure, function and maintenance standard Dimensions of components PC130-8...
Page 233 ±0.2 — ±0.5 — 374.9 — — 1,251 — -0.030 +0.200 — ø 60 -0.080 Link side -1.0 Bucket side ±1.0 -0.030 +0.200 — ø 60 -0.080 Arm side -0.5 +2.0 Bucket side Min. 1,378 — Max. 2,263 — PC130-8...
Page 234 SEN03776-00 10 Structure, function and maintenance standard Bucket PC130-8...
Page 235 — — — +1.0 — — — — ø 110 — — ø 130 — — ø 132 — — ø 108 — +2.0 — — — — — — 100.5 — — 115.3 — — — — — PC130-8...
Page 237: Cab And Its Attachments Sen03777-00
SEN03777-00 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Cab and its attachments Air conditioner ..............................2 PC130-8...
Page 238: Air Conditioner
SEN03777-00 10 Structure, function and maintenance standard Air conditioner Air conditioner piping Air conditioner unit Fresh air Hot water pickup piping Recirculated air Air conditioner compressor C: Hot air/cold air Refrigerant piping Condenser Hot water return piping Duct PC130-8...
Page 239 10 Structure, function and maintenance standard SEN03777-00 PC130-8...
Page 241 SEN03778-03 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 10 Structure, function and maintenance standard Electrical system Electronic control system ..........................2 Machine monitor system ..........................34 KOMTRAX system............................48 Sensor................................50 PC130-8...
Page 242: Electronic Control System
SEN03778-03 10 Structure, function and maintenance standard Electronic control system Machine control system diagram PC130-8...
Page 243 10 Structure, function and maintenance standard SEN03778-03 PC130-8...
Page 244 11. Fuel control dial 12. Safety relay 13. Starting motor 14. Fuel supply pump 15. Sensors 16. Engine controller power cut-off relay A 17. Engine controller power cut-off relay B 18. Machine monitor 19. KOMTRAX terminal PC130-8...
Page 245 (5) to engine controller (6) is cut off, and consequently the command current to fuel sup- ply pump (14) is cut off. Fuel supply pump (14) stops fuel feed, causing the engine speed to go down and the engine stops. PC130-8...
Page 246 Network“ in an in-vehicle standard. 14. Oil pressure sensor 15. Oil pressure switch 16. Hydraulic pump 16a. Servo 16b. LS valve 16c. PC valve 17. Control valve 17a. Pump merge-divider valve 17b. Self pressure reducing valve 18. PC-EPC valve PC130-8...
Page 247 When the engine speed is lowered, the con- troller prevents the engine from stopping by throttling the pump absorption torque. PC130-8...
Page 248 (Q) to increase the engine speed to the matching point. If the pressure drops, the con- troller increases the pump delivery to increase the engine speed to the matching point. PC130-8...
Page 249 The controller controls pump delivery (Q) so that the engine torque can be kept at a con- stant level along the equal engine horsepower curve. PC130-8...
Page 250 Normal a Emergency pump drive switch (1) is of the alternative type. If the machine is operated after the switch is set to "Emergency (a)" even through the machine is normal, user code "E02" is displayed on the display. PC130-8...
Page 251 Solenoid valve change signal Oil pressure sensor signal These setting are automatically reset after 8.5 Throttle signal seconds when the switch is pressed. Fuel supply pump control signal Sensor signals Knob switch signal Note.1: CAN is cf. 6 page. PC130-8...
Page 252 Fuel supply pump control signal 7. Oil pressure sensor Sensor signals 8. Oil pressure switch 9. Hydraulic pump Note.1: CAN is cf. 6 page. 10. Control valve 10a. Pump merge-divider valve 10b. Self pressure reducing valve 11. PPC lock solenoid valve PC130-8...
Page 253 “NATURAL“ B : All work equipment control levers “OPERATED“ C: Fuel control dial set speed D: Engine control speed (approx. 1,400 rpm) E : 4 sec. F : Max. 2 sec. G: Max. 0.2 sec. PC130-8...
Page 254 Note.1: CAN is cf. 6 page. 11. Fuel supply pump 12. Sensors 13. Hydraulic oil temperature sensor 14. Hydraulic pump 14a. Servo 14b. LS valve 14c. PC valve 15. Control valve 15a. Pump merge-divider valve 15b. Self pressure reducing valve 16. PC-EPC valve PC130-8...
Page 255 Auto Coolant temperature: Min. 60 °C Duration of automatic warming-up: Min. 10 minutes Ambient temperature: min. 10 °C Man- Fuel control dial: held at over 70% of maximum speed for 3 seconds or more Cancellation Engine speed: as desired PC130-8...
Page 256 Engine speed: Low idle Coolant temperature: Min. 105°C (MIN) position. Alarm monitor: ON Hydraulic oil temperature: Min. 105°C • Alarm monitor: Sounds The original conditions are restored if Traveling status check: Any quirements are met (man- above re ual restoration). PC130-8...
Page 257 Start engine Duration of turbocharger protection (approx. 0 – 20 sec) C: Modulating time (approx. 1.5 sec) D: 500 rpm 1,100 rpm 2,300 rpm (*1) *1. Working mode: Mode P Fuel control dial: Full rotation position Travel lever operated PC130-8...
Page 258 Oil pressure switch signal 8. Machine monitor 9. Oil pressure switch Note.1: CAN is cf. 6 page. 10. Hydraulic pump 11. Control valve 11a. Pump merge-divider valve 11b. Self pressure reducing valve 12. Swing motor 13. Swing holding brake solenoid valve PC130-8...
Page 259 L.H. work equipment control lever “SWING“ (Swing holding brake “RELEASE“) L.H. work equipment control lever “NEUTRAL “ C: Swing holding brake “OPERATED“ D: 5 sec PC130-8...
Page 260 Swing holding brake release switch (2) is of the alternator type. When the switch is turned to “RELEASE (a)“ position, the swing lock mon- itor in the machine monitor will blink. PC130-8...
Page 261 11b. Self pressure reducing valve Sensor signals 11c. Travel junction valve 11d. Pump merge-divider valve Note.1: CAN is cf. 6 page. 12. Travel motor 13. 2nd travel speed select solenoid valve 14. Travel junction solenoid valve 15. Pump merge-divider solenoid valve PC130-8...
Page 262 MPa {180 kg/cm²} continues for 0.1 travel. seconds or more, the travel motor For straight-travel, a signal is sent to the pump capacity is switched back to the set merge-divider solenoid valve, dividing the speed of “Hi“ automatically. pump delivery, to improve travel performance. PC130-8...
Page 263 7. PPC lock switch cut-off, causing neither the work equipment nor 8. Hydraulic pump machine moves even if levers or pedal is oper- 9. Control valve ated. 9a. Pump merge-divider valve 9b. Self pressure reducing valve 10. PPC lock solenoid valve PC130-8...
Page 264 12. Oil flow adjuster EPC valve for attachment the attachment when the attachment control 13. PC-EPC valve pedal is depressed all the way. 14. Attachment circuit selector valve 15. Attachment PC130-8...
Page 265 The following is the list of the symbols used for signal classification in the input/output signal chart. A: Power supply B: Input C: Ground/shield/return D: Output E: Communication DTP-4P [CN-CE03] Signal Pin No. Signal name classification — Constant power supply (24 V) — PC130-8...
Page 266 — — — — — — — CAN (–) — — — — — — — — Engine controller power cut-off relay — — Fuel control dial (5 V) — Fuel control dial (–) — — — — — PC130-8...
Page 267 10 Structure, function and maintenance standard SEN03778-03 Pump controller PC130-8...
Page 268 PC-EPC Output Solenoid power supply Input Oil flow adjuster EPC for attachment Output GND (solenoid) Input — Solenoid power supply Input — Wiper motor (+) Output — GND (solenoid) Input Swing holding brake solenoid Output Solenoid power supply Input PC130-8...
Page 269 (5), and a throttle signal is sent to the controller. The hatched areas in the graph are error detection areas. If the throttle voltage is within the area, the engine drops down to low idle. PC130-8...
Page 270 For PC-EPC valve: 30 Function Sends an electric current to each EPC valve that is appropriate for each condition, when the emergency pump drive switch is turned to “ON “. a No electric current flows in the normal condi- tion. PC130-8...
Page 271 10 Structure, function and maintenance standard SEN03778-03 Engine oil pressure switch Connector Sensor O-ring Specifications Contact type: Normal close Function Installed in the cylinder block. Detects engine oil pressure, and turns the switch “ON“ when the pressure goes below the specified value. PC130-8...
Page 272 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm Function Installed (8 places) in the connecting valve. Detects the PPC oil pressure when each actu- ator is operated, and turns the switch “ON“ when the pressure exceeds the specified value. PC130-8...
Page 273 10 Structure, function and maintenance standard SEN03778-03 PC130-8...
Page 274: Machine Monitor System
Machine status display (coolant tempera- ture, hydraulic oil temperature and fuel Power supply CAN signal (Note.1) level) Sensor and switch signals The switches on the machine monitor controls Drive signal the machine. Camera signal Note.1: CAN is cf. 6 page. PC130-8...
Page 275 This phenomenon does not indicate a failure or a defect. Blue points can never be a problem as the screen has usually blue or white background. (White in the LCD is made up of red, green and blue.) PC130-8...
Page 276 Camera power supply (8 V) Output GND (Camera power supply) — Camera NTSC signal 1 Input GND (Camera signal 1) — Camera NTSC signal 2 Input GND (Camera signal 2) — Camera NTSC signal 3 Input GND (Camera signal 3) — PC130-8...
Page 277 10 Structure, function and maintenance standard SEN03778-03 Display PC130-8...
Page 278 If the hydraulic oil temperature goes High or Low while the hydraulic oil temperature gauge is dis- played at the center of the screen, the screen displays only hydraulic oil temperature monitor (2b). C: Screen with maintenance interval reminder PC130-8...
Page 279 INT: Intermittent • Indicates front glass wiper operating Wiper ON: Continuous status. Pilot Light OFF: Stop Swing hold- Swing lock ing brake Monitor switch release display switch Swing lock • Indicates swing lock operating status. Blink Blink PC130-8...
Page 280 • Indicates the position of camera. 2: Right camera *2: Included in the star-up check. After the staring switch is turned “ON“, the monitor turns ON for 2 sec- onds, and changes to a normal operation screen if no error is found. PC130-8...
Page 281 Sprays washer fluid onto the front glass. switch is released. [Numeric keypad: 6] [When wiper is working intermittently] OFF: Wiper works twice continuously and returns to intermittent operation after the switch is released. *1: When the working mode is changed, the auto-decelerator function turns “ON“. PC130-8...
Page 282 *2: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at “High“. Even if the set temperature is reached, the fan speed remains the same. *3: When the fan is set at Stop, the air conditioner does not start even if the switch is pressed. PC130-8...
Page 283 Switching clock/service meter Switches clock/service meter display. Moves selection up one item. Move selection (To the bottom item from the top item.) Holds the mon- itor. Moves selection to the right. Move selection (To the leftmost item from the rightmost item.) PC130-8...
Page 284 SEN03778-03 10 Structure, function and maintenance standard Guidance Function switch Item Function icon Selecting maintenance screen Selects maintenance screen. Return Returns to the previous screen or condition. Selecting user mode screen Selects user mode screen. Fixes selected/displayed item. PC130-8...
Page 285 Display and setting of some functions require special operation of the switch. Items available in the operator mode are as follows: Display order (*2) Category Item (*1) Display of KOMATSU logo Display of inputting password — — — Display of start-up check Display of warning after start-up check —...
Page 286 Language setting The language used in the machine monitor can be changed in the “Language setting“ of the user mode. The available languages are as follows: English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian and Thai PC130-8...
Page 287 Display of KOMTRAX Condition of positioning and communication system setting KOMTRAX terminal serial number (Model TH300) Display of KOMTRAX message a For how to operate the service mode functions, see “Special functions of machine monitor“ in Testing and adjusting. PC130-8...
Page 288: Komtrax System
The information available from the KOMTRAX system are as follows: 1. Operation map 2. Service meter 3. Machine location 4. Error record a To provide the services, you need to make an arrangement for starting the KOMTRAX sys- tem service separately. PC130-8...
Page 289 — allowed. — — — AMP-10P [CN-CK02] Input/output Pin No. Signal name signal RS232C DCD Output RS232C RXD Output RS232C TXD Input RS232C DTR Input RS232C SGND Input RS232C DSR Output — — — — PC130-8...
Page 290: Sensor
Installed in the bracket on the side face of the cylinder block. Detects the ambient pressure and outputs variable voltage. Boost pressure, temperature sensor Connector Sensor O-ring Function Installed in the intake manifold. Detects the boost pressure and boost temperature, and outputs signal as a variable voltage for pressure, and a resistance change for temperature. PC130-8...
Page 291 Function The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is installed in the gear of the camshaft. Each of the sensors outputs a pulse voltage according to the gear rotation. PC130-8...
Page 292 Engine oil level sensor Connector Float Bracket Switch Function The engine oil level sensor is installed to the side of the oil pan. If the oil level lowers below the specified level, the float lowers and the switch is turned “OFF“. PC130-8...
Page 293 This sensor is installed on the side face of the fuel tank. The float moves up and down according to the fuel level. The float moves the variable resistor through the arm. The resistance changes according to the fuel level and a signal voltage is generated from the source voltage according to the change of the resis- tance. PC130-8...
Page 294 SEN03778-03 10 Structure, function and maintenance standard Air cleaner clogging sensor Coolant level sensor Reserve tank Float Sensor Connector PC130-8...
Page 295 Installed in the suction pipe of the hydraulic pump. Detects the temperature change and outputs signal as a resistance change of the thermistor. Pump oil pressure sensor O-ring Output characteristics Sensor Connector Function The pump oil pressure sensor is installed in the control valve. Detects the pump discharge pressure and outputs variable voltage. PC130-8...
Page 296 PPC oil pressure sensor (For travel operation) O-ring Output characteristics Sensor Connector Function The PPC oil pressure sensor is installed in the control valve connecting part of the pilot circuit for travel operation. Detects the pilot pressure and outputs variable voltage. PC130-8...
Page 297 10 Structure, function and maintenance standard SEN03778-03 PC130-8...
Page 299: Standard Value Table
SEN04113-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 20 Standard value table Standard service value table Standard value table for engine related parts ....................2 Standard value table for chassis related parts ....................3...
Page 300: Standard Value Table For Engine Related Parts
SEN04113-02 20 Standard value table Standard value table for engine related parts Applicable model PC130-8 Engine SAA4D95LE-5 Standard value for Cate- Item Test conditions Unit Service limit value gory new machine High idle 2,150 ± 60 — • Coolant Low idle 1,100 ±...
Page 301: Standard Value Table For Chassis Related Parts
20 Standard value table SEN04113-02 Standard value table for chassis related parts Applicable model PC130-8 Standard value for Cate- Item Test conditions Unit Service limit value gory new machine • Hydraulic oil temperature: 45 – 55°C • Engine oil pressure: At 1-pump relief 2,050 ±...
Page 302 SEN04113-02 20 Standard value table Applicable model PC130-8 Standard value for Cate- Item Test conditions Unit Service limit value gory new machine +1.5 • Hydraulic oil temperature: 29.2 ± 1.0 29.2 –2.5 Swing relief 45 – 55°C {298 ± 10} {298 –25...
Page 303 20 Standard value table SEN04113-02 Applicable model PC130-8 Standard value for Cate- Item Test conditions Unit Service limit value gory new machine • For testing posture, see Swing • Engine stopped • Hydraulic oil temperature: 45 – 55°C • Bucket at rated load Hydraulic drift of •...
Page 304 SEN04113-02 20 Standard value table Applicable model PC130-8 Standard value for Cate- Item Test conditions Unit Service limit value gory new machine • Engine at high idle • Hydraulic oil temperature: Leakage from travel l/min 45 – 55°C Max. 1.1 Max.
Page 305 20 Standard value table SEN04113-02 Applicable model PC130-8 Standard value for Cate- Item Test conditions Unit Service limit value gory new machine • For testing posture, see Work equipment 5 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C Boom •...
Page 306 Pump delivery Q in the graph is the delivery from 1 side of the pump. PC130-8...
Page 307 Travel 2: Travel speed (actual run), travel deviation test procedure Swing 1: Swing brake angle, time taken to start swing, time taken to swing Travel 3: Travel deviation Swing 2: Hydraulic drift of swing Travel 4: Hydraulic drift of travel Travel 1: Travel speed (without load) PC130-8...
Page 308 20 Standard value table Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed equipment Work equipment 5: Boom time lag Work equipment 2: Boom speed Work equipment 6: Arm time lag Work equipment 3: Arm speed PC130-8...
Page 309 20 Standard value table SEN04113-02 Work equipment 7: Bucket time lag PC130-8...
Page 311: Testing And Adjusting Testing And Adjusting, Part
SEN04114-06 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 30 Testing and adjusting Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting..................... 3 Sketches of special tools ..........................8 Testing engine speed ............................9 Testing exhaust temperature.........................
Page 312 Releasing residual pressure from hydraulic circuit..................50 Testing oil leakage............................53 Bleeding air from each part ........................... 56 Checking cab tipping stopper........................58 Installation and adjustment of mirrors and camera ..................59 Inspection of air conditioner Recirc/Fresh air filter ..................70 PC130-8...
Page 313: Tools For Testing, Adjusting, And Troubleshooting
1 Internal dimensions: Approx. 12 mm available Testing fuel return rate Commercially and leakage Hose 1 Internal dimensions: Approx. 9 mm available Commercially Measuring cylinder available Commercially Stopwatch available Testing swing circle bear- Commercially Dial gauge ing clearance available PC130-8...
Page 314 {25, 60, 400, 600 kg/cm Pressure gauge: 60 MPa Testing PPC valve output 790-261-1204 Digital hydraulic tester {600 kg/cm pressure 2 799-401-3100 Adapter 1 Size: 02 799-101-5220 Nipple 2 Size: 10 x 1.25 mm 07002-11023 O-ring Commercially Testing oil leakage Measuring cylinder available PC130-8...
Page 315 For DT6P (Does not include 799-601- 799-601-9050 • Adapter for DT 4100 and 799-601-4201) For DT12P (Does not include 799- 799-601-9110 • Adapter for DT (Gray) 601-4100 and 799-601-4201) For AMP3P (Does not include 799- 799-601-9420 • Adapter for AMP 601-9000 and 799-601-9200) PC130-8...
Page 316 — 795-799-6210 Deep socket Inside diameter: 24.5 mm switch 21 mm deep socket Removal and installation Commercially (MITOLOY 4ML-21 or equivalent) of engine coolant temper- — Socket available Applicable engine serial No.: ature sensor 500001 - 502653 PC130-8...
Page 317 For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Trou- bleshooting (General information on troubleshooting), List of T-boxes and T-adapters". PC130-8...
Page 318: Sketches Of Special Tools
SEN04114-06 30 Testing and adjusting Sketches of special tools Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Socket PC130-8...
Page 319: Testing Engine Speed
(MAX) position. Set the working mode in the power mode (P) and turn the auto-decelerator OFF. Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed. PC130-8...
Page 320: Testing Exhaust Temperature
Remove exhaust temperature pickup plug (1) from the side of the center of the exhaust man- ifold. After finishing test, remove the testing instru- ment and return the removed parts. Install sensor [1] of digital thermometer R and connect it to thermometer [2]. PC130-8...
Page 321: Checking Exhaust Gas Color
Insert probe [1] of smoke meter A2 in the value. outlet of the exhaust pipe and fix it to the After finishing checking, remove the exhaust pipe with a clip. checking tools and return the removed parts. PC130-8...
Page 322: Adjusting Valve Clearance
No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn. PC130-8...
Page 323 Q i n t h e v a l v e arrangement drawing similarly to those marked with q. PC130-8...
Page 324: Testing Compression Pressure
If the injector is stuck and is not removed easily, pass a wire under the fuel inlet and pull it up to remove the injector. a Do not apply an external force to the terminal at the injector top. PC130-8...
Page 325 After finishing test, remove the testing instru- ments and return the removed parts. a Install the injector and spill hose connector according to the following procedure. Fit O-ring (8) and gasket (9) to injector (1). a Do not fit O-ring (8) to groove (a). PC130-8...
Page 326: Testing Blow-By Pressure
If the swing lock switch is turned ON, the main relief valve is set for high-pressure relief. While running the engine at high idle, relieve the arm circuit and test the blow-by pressure. a Read the gauge when the pointer is stabi- lized. PC130-8...
Page 327: Testing Engine Oil Pressure
Install adapter E3 and connect the discon- nected hose again. Install nipple E4 and connect it to hydraulic tes- ter E2. Start the engine and heighten the engine cool- ant temperature to the operating range. PC130-8...
Page 328: Reduced Cylinder Mode Operation
Defect in electrical system Since the common rail fuel injection system controls the injector of each cylinder electroni- cally, the operator can perform the reduced cyl- inder mode operation easily with switches to find out a defective cylinder. PC130-8...
Page 329: Handling Fuel System Parts
Precautions for replacing fuel filter cartridge stopped. a Before the fuel circuit is checked and its parts Be sure to use the Komatsu genuine fuel filter cartridge. are removed, the residual pressure in the fuel Since the common rail fuel injection system circuit must be released completely.
Page 330: Testing Fuel Pressure
Fuel pressure pickup plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Install adapter F2 and nipple [1] of the hydraulic tester F1 and connect them to gauge of boost gauge kit F3. PC130-8...
Page 331: Testing Fuel Return Rate And Fuel Leakage
Connect test hose G4 to the end of joint Connect test hose G5 to connector (6) side of spill hose (4). a Bind the connecting part of the test hose with a wire etc. to prevent it from coming off. PC130-8...
Page 332 1,600 1,700 1,800 1,900 2,000 After finishing test, stop the engine. After finishing test, stop the engine. After finishing test, remove the testing tools and return the removed parts. Joint bolt: 3.9 – 6.9 Nm {0.4 – 0.7 kgm} PC130-8...
Page 333: Bleeding Air From Fuel Circuit
Move the knob until it becomes heavy. a The plug at the top of the fuel main filter does not need to be removed. After bleeding air, push in and tighten knob (1). PC130-8...
Page 334: Checking Fuel Circuit For Leakage
If any fuel leakage is detected, repair it and check again from step 2. Run the engine at high idle and load it. a Relieve the arm circuit at the IN stroke end. PC130-8...
Page 335: Testing And Adjusting Alternator Belt Tension
(4) is loosened. If the former is turned to the left, the latter is tightened. After adjusting the belt tension, tighten alterna- tor fixing bolts (1) and (2). Check again that the tension of alternator belt (4) is in the standard range. PC130-8...
Page 336: Checking And Adjusting Air Conditioner Compressor Belt Tension
Press the intermediate point of the belt between fan pulley and compressor pulley with a finger and measure deflection (a) of the belt. Belt pressing force: 60 N {6.1 kg} After finishing test, return the removed parts. PC130-8...
Page 337: Testing Swing Circle Bearing Clearance
At this time the front of the upper structure lowers and the rear rises. Set dial gauge H to the 0 point. PC130-8...
Page 338: Checking And Adjusting Track Shoe Tension
You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. If the tension is still low, the pins and bushings are worn much. In this case, reverse or replace the pins and bushings. PC130-8...
Page 339 To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. After adjusting, check the track shoe ten- sion again according to the above proce- dure. PC130-8...
Page 340: Testing And Adjusting Oil Pressure In Work Equipment, Swing, And Travel Circuits
Run the engine at high idle, set all the levers and pedals for work equipment con- trol, swing control, and travel in neutral, and test the oil pressure. a The pressure tested when the unload valve is unloaded is indicated. PC130-8...
Page 341 The swing relief pressure is lower than the main relief pressure. Testing travel relief pressure Run the engine and lock the travel mecha- nism. Put pin [2] between the sprocket and track frame to lock the travel mechanism securely. PC130-8...
Page 342 Approx. 20.5 MPa {Approx. 209 kg/cm While fixing holder (5), tighten locknut (6). Locknut: 49 – 58.8 Nm {5 – 6 kgm} After finishing adjustment, check again that the oil pressure is normal according to the above described test procedure. PC130-8...
Page 343: Testing Control Circuit Basic Pressure
After finishing test, remove the testing tools and return the removed parts. a The control circuit basic pressure may be tested with oil pressure pickup plug (2) on the hydraulic pump side. a Do not adjust the relief valve for control circuit basic pressure. PC130-8...
Page 344: Testing And Adjusting Oil Pressure In Pump Pc Control Circuit
(1) and (2). (1): Pump discharge pressure pickup plug (2): PC valve output pressure pickup plug Start the engine and move the arm cylin- der to the IN stroke end. Set the working mode in the power mode (P). PC130-8...
Page 345 Engine Output pressure lever Approx. 2.9 MPa All control Low idle {Approx. 30 kg/cm levers and pedals in Approx. 0 MPa High idle neutral {Approx. 0 kg/cm After finishing test, remove the testing tools and return the removed parts. PC130-8...
Page 346 Turn the adjustment screw Clockwise when the work equipment speed is low (to increase pump absorption torque) and Counterclockwise when the engine speed lowers (to decrease pump absorption torque). Tighten locknut (5). Locknut: 27 – 34 Nm {2.8 – 3.5 kgm} PC130-8...
Page 347: Testing And Adjusting Oil Pressure In Pump Ls Control Circuit
Start the engine and push up the track shoe on the side to be tested with the work equipment and prepare for running the track shoe idle. Since the raised track shoe will be run idle during test, secure a suffi- cient working area. PC130-8...
Page 348 Test the pump discharge pressure and LS pressure (actuator load pressure) simulta- neously and calculate the difference between them. Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). (1): Pump discharge pressure pickup plug PC130-8...
Page 349 After finishing test, remove the testing tools and return the removed parts. After finishing adjustment, check again that the Insert the removed connector V5 of the LS differential pressure is normal according to solenoid valve in its original position. the above described test procedure. PC130-8...
Page 350: Testing Solenoid Valve Output Pressure
Travel speed selector solenoid valve Swing holding brake solenoid valve 2-stage relief solenoid valve a Since hose (1) is installed under the cab, remove the cab undercover (rear one). Run the engine and heighten the hydraulic oil temperature to the operating range. PC130-8...
Page 351 Almost same as control ON (Energized) basic pressure (See standard values table) After finishing test, remove the testing tools and return the removed parts. Table for functioning conditions - PPC lock solenoid valve Operating condition Functioning LOCK Work equipment lock lever RESET PC130-8...
Page 352 When any of them is ON Arm in signal Elapsed time after failure of above condition < 5 sec Other than above Table for functioning conditions - travel junction solenoid valve Functioning condition Functioning Steering judgment ON Other than above PC130-8...
Page 353 30 Testing and adjusting SEN04114-06 Functioning conditions - merge/divider solenoid valve PC130-8...
Page 354: Testing Ppc Valve Output Pressure
(1) – (8) are installed to the PPC junction block in the rear of the cab. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. a Turn OFF the auto-decelerator switch. PC130-8...
Page 355: Adjusting Play Of Work Equipment And Swing Ppc Valves
4 pistons (4). Fix disc (3) and tighten locknut (2) to the speci- fied torque. Locknut: 69 – 88 Nm {7 – 9 kgm} Install bellows (1). Install the work equipment and swing PPC valve assembly. PC130-8...
Page 356: Checking Parts Which Cause Hydraulic Drift Of Work Equipment
(the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased. PC130-8...
Page 357 5 seconds to heighten the pressure in the accumulator. a If there is a difference in the lowering dis- tance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect). PC130-8...
Page 358: Testing And Adjusting Travel Deviation
Run up for 10 m with the engine speed at high idle and continue travel under the same condi- tion for 20 m and test the deviation (a). a Install an oil pressure gauge and check that the P1 and P2 discharge pressures of the hydraulic pump are even. PC130-8...
Page 359 Locknut: 2.9 – 4.9 Nm {0.3 – 0.5 kgm} adjustment. Do not loosen the plugs on a After tightening the locknut, seal its hole both sides. with a vinyl tape. After finishing adjustment, check travel devia- tion again according to the procedure for inspection described above. PC130-8...
Page 360: Releasing Residual Pressure From Hydraulic Circuit
Pressure of accumulator drops with the fuel control dial at MIN (Low idle) gr adu ally a fte r stop ping th e position for approximately 5 seconds to engine. Be sure to perform this increase the pressure in the accumulator. PC130-8...
Page 361 FREE position, and then operate the right and left work equip- ment control levers forward and back- ward, and to the right and left. PC130-8...
Page 362 The work equipment is operated by the pressure in the accumula- tor. Pressure in the accumulator is lost by operating the work equipment control levers 2 or 3 times. PC130-8...
Page 363: Testing Oil Leakage
Run the engine at high idle and relieve the boom circuit by raising the boom. Take care not to "lower the boom". Start testing the oil leakage 30 seconds after relieving is started and test for 1 min- ute. After finishing test, return the removed parts. PC130-8...
Page 364 Run the engine at high idle and relieve the bucket circuit by curling the bucket. Take care not to "dump the bucket". Start testing the oil leakage 30 seconds after relieving is started and test for 1 min- ute. After finishing test, return the removed parts. PC130-8...
Page 365 Start testing the oil leakage 30 sec- onds after relieving is started and test for 1 minute. a Test several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time. PC130-8...
Page 366: Bleeding Air From Each Part
While running the engine at high idle, per- form step 2). While running the engine at low idle, move the piston rod to the stroke end and relieve the oil. Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4). PC130-8...
Page 367 Connect hose (1) under its normal condi- tion. Near line H Bleeding air from travel motor Remove the travel motor cover and dis- connect motor drain hose (2). Run the engine at low idle and check that oil flows out of nipple (3). PC130-8...
Page 368: Checking Cab Tipping Stopper
Bolt (2): 98 – 123 Nm {10 – 12.5 kgm} [Reference] The tightening torque of mounting bolt (4) of cab tipping stopper (3) is different from that of a common bolt 30 mm in diameter. Take care. Bolt (4): 245 – 309 Nm {25 – 31.5 kgm} PC130-8...
Page 369: Installation And Adjustment Of Mirrors And Camera
19° to the side of the machine body. exterior parts. a If the mirrors are not installed to the cor- rect positions, they may interfere with the exterior parts. PC130-8...
Page 370 30 cm in diameter) at the right and left rear ends of the machine. a Take care not to over-tighten stay mount- ing bolts (3) and (4) (If they are tightened too strongly, the stay may be broken since it is made by die-casting). PC130-8...
Page 371 Adjustment of rear view monitor camera DQJOH ★ 0DFKLQH ZLWK RQH FDPHUD Adjust the rear view monitor camera so that the operator can see persons on the ground at 1 m around the machine from the operator's seat. PC130-8...
Page 372 A part of the machine is projected on the monitor. If the image projected on the monitor deviates, After adjusting, tighten bolt (5). remove cover (4) and adjust installed angle (A) of the rear view monitor camera. PC130-8...
Page 373 (5) will be set to 4th scale mark (B) from the bottom. a A part of the machine is projected on the monitor. After adjusting, tighten bolt (5). PC130-8...
Page 374 Adjust the camera so that the image of the counterweight occupy about 10 to 15% of the monitor screen. Remove two bolts (4). Remove cover (2). After adjusting, tighten bolts (5). Camera mounting bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} Install covers (2) and (3). PC130-8...
Page 375 (A) of the 3 stopping positions where the mirror is extracted most and at an angle of about 19° to the side of the machine body. a If the mirrors are not installed to the cor- rect positions, they may interfere with the exterior parts. PC130-8...
Page 376 30 cm in diameter) at the right and left rear ends of the machine. a Take care not to over-tighten stay mount- ing bolts (3) and (4) (If they are tightened too strongly, the stay may be broken since it is made by die-casting). PC130-8...
Page 377 Remove 2 bolts (4) and remove cover (1). Adjustment of rear view monitor camera DQJOH ★ 0DFKLQH ZLWK RQH FDPHUD Adjust the rear view monitor camera so that the operator can see persons on the ground at 1 m around the machine from the operator's seat. PC130-8...
Page 378 A part of the machine is projected on the monitor. If the image projected on the monitor deviates, After adjusting, tighten bolt (5). remove cover (4) and adjust installed angle (A) of the rear view monitor camera. PC130-8...
Page 379 (5) will be set to 4th scale mark (B) from the bottom. a A part of the machine is projected on the monitor. After adjusting, tighten bolt (5). PC130-8...
Page 380: Inspection Of Air Conditioner Recirc/Fresh Air Filter
Since fresh air filter (3) has directional properties, insert it with longer side (L) ahead. If it is inserted with shorter side (S) ahead, cover (2) cannot be closed. PC130-8...
Page 381 30 Testing and adjusting SEN04114-06 PC130-8...
Page 383: Testing And Adjusting, Part 2
SEN04115-04 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 30 Testing and adjusting Testing and adjusting, Part 2 Special functions of machine monitor ......................2 PC130-8...
Page 384: Special Functions Of Machine Monitor
SEN04115-04 30 Testing and adjusting Special functions of machine monitor Air conditioner specification PC130-8...
Page 385 Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effec- tive, according to the display condition of multi- display. PC130-8...
Page 386 This mode is used for special setting, testing, adjusting, or troubleshooting. Page Page t Operator mode (Outline) Service mode A Display of KOMATSU logo Monitoring A Display of inputting password Mechanical Systems Abnormality A Display of check of breaker mode...
Page 387 A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi- nary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch PC130-8...
Page 388 When the starting switch is turned ON, the before starting KOMATSU logo is displayed for 2 seconds. Display of ending of maintenance a After the KOMATSU logo is displayed for 2 — — — — 3 interval seconds, the screen changes to "Display of...
Page 389 SEN04115-04 Display of inputting password Display of check before starting After the KOMATSU logo is displayed, the screen When the screen changes to the check-before- to input the engine start lock password is displayed. starting screen, the check before starting is carried a This screen is displayed only when the engine out for 2 seconds.
Page 390 If the check before starting is finished normally, the screen to check the working mode and travel speed is displayed for 2 seconds. a After display of check of the working mode and travel speed is finished, the screen changes to "Display of ordinary screen". PC130-8...
Page 391 Function switches [F3]: Move to lower working mode PC130-8...
Page 392 Even if the alarm buzzer cancel switch is dow washer switch is pressed, the washing liquid is pressed, the screen does not change. splashed only while the switch is held down. a Even if the window washer switch is pressed, the screen does not change. PC130-8...
Page 393 When an error that there is a user code occurs perature caution is not displayed there, how- in the camera mode, if you do not touch any ever). control lever for 10 seconds, the screen changes to the ordinary screen and displays the error information. PC130-8...
Page 394 When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the sum- mer time with the user mode function. a To reset the time left after finishing mainte- nance, more operations are necessary. PC130-8...
Page 395 There are following items in the user menu. Breaker/Attachment Settings User Message Screen Adjustment Clock Adjustment Language Economy Mode Adjustment a The breaker/attachment setting menu is dis- played only when "With attachment" is set in the service mode. PC130-8...
Page 396 (a) in the screen. a On the camera mode screen, the caution mon- itor flashes at the left upper of the screen when the caution is generated. PC130-8...
Page 397 Operations are possible, but have inspection carried out pressure, oil pressure) system error immediately. Operations are possible, but have inspection carried out Abnormality in travel system immediately. Operate machine to a safe posture and have inspection carried Network error out immediately. PC130-8...
Page 398 (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the func- tion switch. PC130-8...
Page 399 [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the mes- sage to input the password again is dis- played. PC130-8...
Page 400 SEN04115-04 30 Testing and adjusting If the screen to notify completion of setting is displayed and then the ordinary screen is dis- played, the password is changed successfully. PC130-8...
Page 401 [F4]: Move to upper menu [F5]: Return to ordinary screen (operator mode) [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6]. PC130-8...
Page 402 Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items. PC130-8...
Page 403 Holding monitoring information The monitoring information can be held and reset with the function switches. [F3]: Reset holding [F4]: Hold information (displayed data) [F5]: Return to monitoring selection menu screen PC130-8...
Page 404 Charge pressure-abs kg/cm indicated by absolute val- ues. 36700 Engine torque ratio 18700 Engine output torque lbft 03000 Fuel dial pos sens volt 04200 Fuel level sensor volt 04105 Coolant temp sens volt 04402 Hyd temp sens volt PUMP PC130-8...
Page 405 Model select 3 ON•OFF PUMP Model select 4 ON•OFF PUMP Model select 5 ON•OFF PUMP 03701 Controller output 2 Travel alarm ON•OFF PUMP Key switch ON•OFF Start ON•OFF 04500 Monitor input 1 Preheat ON•OFF Light ON•OFF Rad. lever ON•OFF PC130-8...
Page 406 — PUMP a Monitoring code "00200" "00201" is not applied following serial number. PC130-8 : 83167 and up a Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen.
Page 407 The following figure shows the display of the air conditioner specification. The heater specification and heaterless speci- fication are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heater- less specification. PC130-8...
Page 408 The following figure shows the display of table. the air conditioner specification. The heater specification and heaterless speci- fication are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heater- less specification. PC130-8...
Page 409 To reset all items together: Press [F2], and all the items are reset, regardless of selection of the items. a If [E] is displayed on the left of a fail- ure code, the resetting operation is accepted but the information is not reset. PC130-8...
Page 410 Sensor sup. 1 volt. high error Electrical system CA435 Abnormality in engine oil pressure switch Electrical system CA441 Battery voltage low error Electrical system CA442 Battery voltage high error Electrical system CA449 Rail press. very high error Electrical system PC130-8...
Page 411 Electrical system DW91KA Travel junction sol discon PUMP Electrical system DW91KB Travel junction sol short PUMP Electrical system DWJ0KA Merge-divider sol discon PUMP Electrical system DWJ0KB Merge-divider sol short PUMP Electrical system DWK0KA 2-stage relief sol discon PUMP Electrical system PC130-8...
Page 412 PUMP: The pump controller is in charge of detection of abnormality. a Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record. PC130-8...
Page 413 [F6]: Confirm selection a You may enter a 2-digit code with the been reset, the display changes to Normal. numeral input switches to select the record of that code and confirm it with [F6]. PC130-8...
Page 414 [F2]: Move to previous page (screen) [F3]: Move to lower item [F4]: Move to upper item [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code. PC130-8...
Page 415 [F5]: Return to service menu screen applied. a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6]. PC130-8...
Page 416 [F5], the setting is tion completion screen is displayed. Then, effective. if the "Maintenance Mode Change" screen a If the set value of an item set to "ON" is is displayed, initialization is completed. changed after 1 or more operating hours PC130-8...
Page 417 Up to 14 digits can be input from the left. Input nothing in the surplus positions. a If one of the input digits is wrong, move to that digit (orange background) and over- write it with the correct digit. PC130-8...
Page 418 Power Mode: [P] is displayed when key is Economy Mode: [E] is displayed when key is ON Lifting Mode: [L] is displayed when key is Breaker Mode: [B] is displayed when key is ON Attachment Mode: [ATT] is displayed when key is ON PC130-8...
Page 419 After the "Unit" screen is displayed, select the unit to be set with the function switches. [F3]: Move to lower unit [F4]: Move to upper unit [F5]: Cancel selection and return to "Default" screen [F6]: Confirm selection and return to "Default" screen PC130-8...
Page 420 When attachment is not installed With Attachment: When attachment is installed [F3] : Move to lower item [F4] : Move to upper item [F5] : Cancel selection and return to Default screen [F6] : Confirm selection and return to Default screen PC130-8...
Page 421 If the password setting is changed from Enable to Disable, the password is reset to the default. When Enable is set again, be sure to set a new password. a The attachment/maintenance password is different from the engine start lock pass- word. PC130-8...
Page 422 Accordingly, the image of a Select this item similarly to an item on the the camera cannot be used. "Service Menu" Screen. a When a camera is installed, check that the displayed image is not inverted horizon- tally. PC130-8...
Page 423 [F5] : Cancel setting before confirmation and return to "Default" screen [F6] : Confirm selection in each line a After confirming the setting of the upper and lower lines with [F6], return to the "Default" screen with [F5], and the setting is effective. PC130-8...
Page 424 "Service Menu" screen. value +39.2 Nm {+4 kgm} +29.4 Nm {+3 kgm} +19.6 Nm {+2 kgm} +9.8 Nm {+1 kgm} 0 Nm {0 kgm} –9.8 Nm {–1 kgm} –19.6 Nm {–2 kgm} –29.4 Nm {–3 kgm} –39.2 Nm {–4 kgm} PC130-8...
Page 425 Select this item similarly to an item on the bution of flow to attachment "Service Menu" screen. Distribution of flow to Code value attachment 50 % 70 % 100 % 40 % PC130-8...
Page 426 - d e c e l e r a t i o n f u n c t i o n c a n b e selected. If the auto-deceleration is turned ON, auto-deceleration monitor (b) is dis- played. PC130-8...
Page 427 Answer with the function switch. [F5]: Do not perform (Return to Service menu screen) [F6]: Perform a While the screen is changing to the follow- ing screen, the screen of "Communication between controllers is being checked" is displayed. PC130-8...
Page 428 "Engine is running" is displayed on the screen. Finishing no injection cranking After completing the no injection cranking operation, press [F6], and finish of no injection cranking is displayed and the screen returns to the "Service Menu" screen automatically. PC130-8...
Page 429 The display unit of the fuel changes according to the unit set with the default (unit setting) function. SI and meter: l/h inch: gal/h PC130-8...
Page 430 Select this item similarly to an item on the Service menu screen. The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is dis- played. PC130-8...
Page 431 Select this item similarly to an item on the "Service Menu" screen. The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is dis- played. PC130-8...
Page 432 Select "KOMTRAX Settings" on the "Service Menu" screen. Selecting sub menu After the "KOMTRAX Settings" screen is dis- played, select "Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen. PC130-8...
Page 433 This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the ser- viceman, the message monitor is not dis- played when it is received as in the operator mode. PC130-8...
Page 435: Testing And Adjusting, Part 3
SEN04116-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 30 Testing and adjusting Testing and adjusting, Part 3 Handling voltage circuit of engine controller ....................2 Preparation work for troubleshooting of electrical system ................3 Procedure for testing diodes ...........................
Page 436: Handling Voltage Circuit Of Engine Controller
If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position. PC130-8...
Page 437: Preparation Work For Troubleshooting Of Electrical System
When disconnecting them, loosen the screws. a When returning connectors CE01 and CE02, tighten the screws to the spec- ified torque. Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm} Remove 1 mounting bolt and duct (3). PC130-8...
Page 438 Install the adapters to only the wiring (8). harness side. Remove fuse box cover (9) and cover (10). a Since the underside of cover (10) is clamped, pull it up. Remove the 7 mounting bolts and cover (11). PC130-8...
Page 439 Connection: (d) Connect connector – (e) Lock – (f) Slide lever. a a a a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. See "Tools for testing, adjusting, and troubleshooting". PC130-8...
Page 440 In this case, pinch the lock in direction (a) nect connector. with bent-nose nippers [1] (commercially Connection: (c) Connect connector – (d) available), and the lock is reset. Lock. Since the lock clicks when it is reset, dis- connect the connector after a click is heard. PC130-8...
Page 441 Connection: (c) Connect connector – (d) Lock. a a a a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine coolant tem- perature sensor. See "Tools for testing, adjusting, and troubleshooting". PC130-8...
Page 442: Procedure For Testing Diodes
The indicated value does not change: The diode does not have conductivity (Defective). The indicated value changes: The diode has conductivity (Normal). Note: In the case of a silicon diode, a value in the range from 460 to 600 is indi- cated. PC130-8...
Page 443: Pm Clinic Service
30 Testing and adjusting SEN04116-00 Pm Clinic service Model name Serial No. Service meter T PC130-8 User's name Date of execution Inspector Specifications Main components Attachments Shoe width T Standard T ( T Breaker T 500 mm Boom T Standard T (...
Page 444 Work- Check item Unit value for new sured value control Checking posture, etc. machine value dial mode Boom top horizontal Hydraulic drift of Engine stopped Arm cylinder retracted fully Max. 310 Max. 460 bucket tip 15 min Bucket loaded PC130-8...
Page 445 Servo piston Arm out relief — Checked oil pressure Unit Standard value for new machine Service limit value H1 : H2 = 1 : 0.6 H (Servo control pressure) — (Oil pressure ratio) PC130-8...
Page 446 J2 (PC-EPC valve output pressure 2) Approx. 0.3 {Approx. 3} J3 (PC-EPC valve output pressure 3) Approx. 0.5 {Approx. 5} {kg/cm J4 (PC-EPC valve output pressure 4) Approx. 0.4 {Approx. 5} J5 (PC-EPC valve output pressure 5) Approx. 0.4 {Approx. 5} PC130-8...
Page 447 30 Testing and adjusting SEN04116-00 PC130-8...
Page 449: Troubleshooting
SEN04117-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Failure code table and fuse locations Failure code table ............................2 Fuse locations..............................6 PC130-8...
Page 450: Failure Code Table
Electrical CA222 Ambient air press. sensor low error system Electrical CA227 Sensor sup. 2 volt. high error system Mechanical — CA234 Eng. overspeed system Electrical CA238 Ne speed sensor sup. volt. error system Electrical CA271 IMV/PCV1 short error system PC130-8...
Page 451 CA2249 Rail press. very low error system Electrical CA2311 Abnormality in IMV solenoid system Electrical — D110KB Battery relay drive short PUMP system Electrical D19JKZ Personal code relay abnormality MON2 system Electrical — D862KA GPS antenna discon MON2 system PC130-8...
Page 452 Electrical DXA8KA PC-EPC sol discon PUMP system Troubleshooting Electrical DXA8KB PC-EPC sol short PUMP system by failure code, Part 4 Electrical — DXE4KA Service current EPC discon PUMP system SEN04122-01 Electrical — DXE4KB Service current EPC short PUMP system PC130-8...
Page 453 PUMP: The pump controller is in charge of detection of abnormality. a Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record. PC130-8...
Page 454: Fuse Locations
Switch power supply (65A) Relay for cab light Optional power supply (1) Optional power supply (2) Radio backup, room lamp Constant power supply (30A) Machine monitor, pump controller, starting switch (B) (Spare) Engine controller Starting switch Switch power supply Engine controller PC130-8...
Page 455 40 Troubleshooting SEN04117-03 Locations of fusible links Location of fuse box and fuse Nos. PC130-8...
Page 457 SEN04118-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting General information on troubleshooting 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........................
Page 458: Points To Remember When Troubleshooting
Has the same kind of failure occurred gate why the problem occurred. Then, remove before? the root cause. Check before troubleshooting Is there any sign of irregularities of the machine? Make checks before starting day's work. Make checks of other items. PC130-8...
Page 459: Sequence Of Events In Troubleshooting
40 Troubleshooting SEN04118-02 Sequence of events in troubleshooting PC130-8...
Page 460: Checks Before Troubleshooting
7. Check of alternator voltage (while engine speed After operating for several Replace is at middle or higher) minutes: 27.5 – 29.5 V 8. Check of battery relay for operating sound (when — Replace starting switch is turned ON or OFF) PC130-8...
Page 461: Classification And Procedures For Troubleshooting
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble- shooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode". PC130-8...
Page 462: Information In Troubleshooting Table
Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side. PC130-8...
Page 463 Connector No.: Indicates (Model – Number of pins) and (Color). “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. Arrow ( ): Roughly shows the location on the machine. PC130-8...
Page 464: Phenomena Looking Like Troubles And Troubleshooting Nos
Phenomena related to work equipment 30 Speed or power of boom is low 31 Speed or power of arm is low 32 Speed or power of bucket is low 33 Work equipment does not move in its single operation PC130-8...
Page 465 64 Windshield wiper and window washer do not operate E-19 Air conditioner does not operate normally (including air conditioner E-23 abnormality record) 66 While starting switch is in OFF position, service meter is not displayed E-24 67 Machine monitor cannot be set in service mode E-25 PC130-8...
Page 466 SEN04118-02 40 Troubleshooting Troubleshooting Phenomena looking like troubles Display E-mode H-mode S-mode of code 68 Monitoring function does not display lever control signal normally E-26 Other phenomena 69 KOMTRAX system does not operate normally E-27 PC130-8...
Page 467: Connection Table For Connector Pin Numbers
40 Troubleshooting SEN04118-02 Connection table for connector pin numbers (Rev. 2009.04) a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing. PC130-8...
Page 468 SEN04118-02 40 Troubleshooting PC130-8...
Page 469 40 Troubleshooting SEN04118-02 PC130-8...
Page 470 SEN04118-02 40 Troubleshooting PC130-8...
Page 471 40 Troubleshooting SEN04118-02 PC130-8...
Page 472 SEN04118-02 40 Troubleshooting PC130-8...
Page 473 40 Troubleshooting SEN04118-02 PC130-8...
Page 474 SEN04118-02 40 Troubleshooting PC130-8...
Page 475 40 Troubleshooting SEN04118-02 PC130-8...
Page 476 SEN04118-02 40 Troubleshooting PC130-8...
Page 477 40 Troubleshooting SEN04118-02 PC130-8...
Page 478 SEN04118-02 40 Troubleshooting PC130-8...
Page 479 40 Troubleshooting SEN04118-02 PC130-8...
Page 480 SEN04118-02 40 Troubleshooting PC130-8...
Page 481 40 Troubleshooting SEN04118-02 PC130-8...
Page 482 SEN04118-02 40 Troubleshooting PC130-8...
Page 483 40 Troubleshooting SEN04118-02 PC130-8...
Page 484 SEN04118-02 40 Troubleshooting PC130-8...
Page 485 40 Troubleshooting SEN04118-02 PC130-8...
Page 486 SEN04118-02 40 Troubleshooting PC130-8...
Page 487 40 Troubleshooting SEN04118-02 PC130-8...
Page 488 SEN04118-02 40 Troubleshooting PC130-8...
Page 489 40 Troubleshooting SEN04118-02 PC130-8...
Page 490 SEN04118-02 40 Troubleshooting PC130-8...
Page 491 40 Troubleshooting SEN04118-02 PC130-8...
Page 492 SEN04118-02 40 Troubleshooting PC130-8...
Page 493 40 Troubleshooting SEN04118-02 PC130-8...
Page 494 SEN04118-02 40 Troubleshooting PC130-8...
Page 495 40 Troubleshooting SEN04118-02 PC130-8...
Page 496 SEN04118-02 40 Troubleshooting PC130-8...
Page 497 40 Troubleshooting SEN04118-02 PC130-8...
Page 498 SEN04118-02 40 Troubleshooting PC130-8...
Page 499 40 Troubleshooting SEN04118-02 PC130-8...
Page 500 SEN04118-02 40 Troubleshooting PC130-8...
Page 501 40 Troubleshooting SEN04118-02 PC130-8...
Page 502 SEN04118-02 40 Troubleshooting PC130-8...
Page 503: T- Branch Box And T- Branch Adapter Table
799-601-7060 Adapter for SWP SW8P 799-601-7310 Adapter for SWP SW12P 799-601-7070 Adapter for SWP SW14P 799-601-7320 Adapter for SWP SW16P 799-601-7080 Adapter for M (T-adapter) q q q 799-601-7090 Adapter for M q q q 799-601-7110 Adapter for M PC130-8...
Page 504 799-601-9240 Adapter for HD30-18 D18-21 799-601-9250 Adapter for HD30-24 D24-9 799-601-9260 Adapter for HD30-24 D24-16 799-601-9270 Adapter for HD30-24 D24-21 799-601-9280 Adapter for HD30-24 D24-23 799-601-9290 Adapter for HD30-24 D24-31 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO) PC130-8...
Page 505 799-601-4280* Box for controller (PUMP) — 799-601-9720 Adapter for controller (HST) HST16A 799-601-9710 Adapter for controller (HST) HST16B 799-601-9730 Adapter for controller (HST) HST26A Multi-adapter for 799-601-9890 — DT2 – 4 and DTM2 “*” Shows not T-adapter but socket. PC130-8...
Page 507: Troubleshooting By Failure Code, Part 1
SEN04119-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Troubleshooting by failure code, Part 1 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..................
Page 508 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 PC130-8...
Page 509: Failure Code [989L00] Engine Controller Lock Caution 1
This trouble may be caused by replacement of machine monitor. and standard monitor value in normal If this failure code is displayed while machine monitor is not state 2 Defective machine monitor replaced, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 510: Failure Code [989N00] Engine Controller Lock Caution 3
Standard value in normal state/Remarks on troubleshooting Possible causes and standard If this failure code is displayed repeatedly, engine controller may be value in normal 1 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be state carried out.) PC130-8...
Page 511: Failure Code [Aa10Nx] Air Cleaner Clogging
If cause 1 is not detected, air cleaner clogging monitor system may Defective air cleaner clog- state be defective. Carry out troubleshooting for "E-7 Caution item ging monitor system flashes while engine is running" in E-mode. PC130-8...
Page 512: Failure Code [Ab00Ke] Charge Voltage Low
– J02 – M22 (female) (1) and circuit branch Min. 1Mz cuit) tance end and chassis ground Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective machine monitor CM01 Engine speed Voltage Between (11) – Operation Min. 7.8 V chassis ground PC130-8...
Page 513 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 514: Failure Code [B@Bazg] Eng Oil Press. Low
(when system is nor- low. value in normal mal) state Defective engine oil pressure If cause 1 is not detected, engine oil pressure switch system may switch system be defective. Carry out troubleshooting for failure code [CA435]. PC130-8...
Page 515: Failure Code [B@Bazk] Eng Oil Level Low
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CM02 Engine oil level Voltage 4 Defective machine monitor Value in normal state Max. 1 V Between (2) – Value when oil level chassis ground 20 – 30 V is low Circuit diagram related PC130-8...
Page 516: Failure Code [B@Bcns] Eng Coolant Overheat
If cause 1 is not detected, engine coolant temperature sensor sys- state Defective engine coolant tem may be defective. Carry out troubleshooting for failure codes temperature sensor system [CA144] and [CA145]. PC130-8...
Page 517 40 Troubleshooting SEN04119-01 PC130-8...
Page 518: Failure Code [B@Bczk] Eng Water Level Low
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CM02 Radiator coolant level Voltage 4 Defective machine monitor Value in normal state Max. 1 V Between (3) – Value when coolant chassis ground 20 – 30 V level is low PC130-8...
Page 519 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 520: Failure Code [B@Hans] Hydr Oil Overheat
If cause 1 is not detected, hydraulic oil temperature gauge system Defective hydraulic oil tem- state may be defective. Carry out troubleshooting for "E-10 Hydraulic oil perature gauge system temperature gauge does not work normally" in E-mode. PC130-8...
Page 521 40 Troubleshooting SEN04119-01 PC130-8...
Page 522: Failure Code [Ca111] Ecm Critical Internal Failure
Wiring harness between CE03 (female) (3) Resis- Max. 1 z – R24 (5) tance Wiring harness between R23 (female) (3) – Resis- Max. 1 z battery (+) tance Wiring harness between R24 (female) (3) – Resis- Max. 1 z battery (+) tance PC130-8...
Page 523 Wiring harness between R24 (female) (3) – Resis- Min. 1 Mz battery (+) and chassis ground tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 5 Defective engine controller CE03 Voltage Between (3) – (1) 20 – 30 V PC130-8...
Page 524 SEN04119-01 40 Troubleshooting Circuit diagram related PC130-8...
Page 525: Failure Code [Ca115] Eng Ne And Bkup Speed Sensor Error
Check Ne speed sensor and Bkup speed sensor directly for defec- connection) tive connection (wrong connection). If causes 1 – 5 are not detected, engine controller may be defec- 6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 526: Failure Code [Ca122] Charge Air Press Sensor High Error
(Short circuit with GND cir- Wiring harness between ENG1 (female) Resis- Min. 1 Mz cuit) (36) – PTIM (female) (3) and chassis ground tance Wiring harness between ENG1 (female) Resis- Min. 1 Mz (48) – PTIM (female) (1) and chassis ground tance PC130-8...
Page 527 ENG1 (female) (48) – PTIM tance (female) (1) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 6 Defective engine controller ENG1 Voltage Between (36) – (48) Power supply 4.75 – 5.25 V Circuit diagram related PC130-8...
Page 528: Failure Code [Ca123] Charge Air Press Sensor Low Error
(Code: 36501 Boost pressure sensor voltage). information • Method of reproducing failure code: Turn starting switch ON. Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA122]. state PC130-8...
Page 529 40 Troubleshooting SEN04119-01 PC130-8...
Page 530: Failure Code [Ca131] Throttle Sensor High Error
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE02 Voltage 5 Defective engine controller Between (27) – (28) Power supply 4.75 – 5.25 V Between (35) – (28) Signal 0.5 – 4.5 V PC130-8...
Page 531 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 532: Failure Code [Ca132] Throttle Sensor Low Error
(Code: 03000 Fuel control dial voltage) information • Method of reproducing failure code: Turn starting switch ON. Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA131]. state PC130-8...
Page 533 40 Troubleshooting SEN04119-01 PC130-8...
Page 534: Failure Code [Ca144] Coolant Temp. Sensor High Error
ON. ENG1 (female) Coolant temperature Resistance 0°C 30 – 37 kz 4 Defective engine controller 25°C 9.3 – 10.7 kz Between (47) – (49) 50°C 3.2 – 3.8 kz 80°C 1.0 – 1.3 kz 700 – 800 z 95°C PC130-8...
Page 535 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 536: Failure Code [Ca145] Coolant Temp. Sensor Low Error
(Code: 04105 Engine coolant temperature sensor voltage) information • Method of reproducing failure code: Turn starting switch ON. Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting failure code [CA144]. state PC130-8...
Page 537 40 Troubleshooting SEN04119-01 PC130-8...
Page 538: Failure Code [Ca153] Charge Air Temp. Sensor High Error
ON. Intake air ENG1 (female) Resistance temperature 4 Defective engine controller 0°C 29 – 36 kz 25°C 9 – 11 kz Between (11) – (48) 40°C 4.9 – 5.8 kz 600 – 700 z 100°C PC130-8...
Page 539 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 540: Failure Code [Ca154] Charge Air Temp. Sensor Low Error
Outlet temperature of turbocharger may be abnormally high. state charger outlet temperature Check related parts directly. If causes 1 – 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 541: Failure Code [Ca187] Sensor Sup. 2 Volt. Low Error
Problem that appears on machine Related • Method of reproducing failure code: Turn starting switch ON. information Possible causes Causes Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA227]. state PC130-8...
Page 542: Failure Code [Ca221] Ambient Air Press. Sensor High Error
Wiring harness between ENG1 (female) (Short circuit with GND cir- Resis- (20) – PAMB (female) (2) and chassis Min. 1 Mz cuit) tance ground Wiring harness between ENG1 (female) Resis- (48) – PAMB (female) (1) and chassis Min. 1 Mz tance ground PC130-8...
Page 543 Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG1 Voltage 6 Defective engine controller Between (36) – (48) 4.75 – 5.25 V Between (20) – (48) 0.3 – 4.7 V Circuit diagram related PC130-8...
Page 544: Failure Code [Ca222] Ambient Air Press. Sensor Low Error
(Code: 37401 Ambient pressure sensor voltage) information • Method of reproducing failure code: Turn starting switch ON. Possible causes Causes Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA221]. state PC130-8...
Page 545: Failure Code [Ca227] Sensor Sup. 2 Volt. High Error
Standard value in normal state/Remarks on troubleshooting Possible causes a Prepare with starting switch OFF, then turn starting switch ON and standard and carry out troubleshooting. value in normal Defective engine controller CE02 Voltage state Between (26) – (22) 4.75 – 5.25V Circuit diagram related PC130-8...
Page 546: Failure Code [Ca234] Eng. Overspeed
Way of use may be improper. Teach proper way of use to operator. value in normal If causes 1 and 2 are not detected, engine controller may be defec- state 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 547 40 Troubleshooting SEN04119-01 PC130-8...
Page 548: Failure Code [Ca238] Ne Speed Sensor Sup. Volt. Error
Min. 1 Mz tance (female) (44) – NE (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller ENG1 Voltage Between (26) – (44) 4.75 – 5.25 V PC130-8...
Page 549 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 550: Failure Code [Ca271] Imv/Pcv1 Short Error
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. ENG1 (female) Resistance 4 Defective engine controller 2.3 – 5.3 z Between (10) – (14) Between (10), (14) – chassis Min. 1 Mz ground Circuit diagram related PC130-8...
Page 551: Failure Code [Ca272] Imv/Pcv1 Open Error
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. ENG1 (female) Resistance 4 Defective engine controller 2.3 – 5.3 z Between (10) – (14) Between (10) (14) – chassis Min. 1 Mz ground Circuit diagram related PC130-8...
Page 552: Failure Code [Ca322] Injector #1 (L #1) System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. ENG1 (female) Resistance 5 Defective engine controller 0.4 – 1.1 z Between (57) – (53) Between (57), (53) – chassis Min. 1 Mz ground PC130-8...
Page 553 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 554: Failure Code [Ca324] Injector #3 (L #3) System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. ENG1 (female) Resistance 5 Defective engine controller 0.4 – 1.1 z Between (55) – (59) Between (55), (59) – chassis Min. 1 Mz ground PC130-8...
Page 555 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 556: Failure Code [Ca331] Injector #2 (L #2) System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. ENG1 (female) Resistance 5 Defective engine controller 0.4 – 1.1 z Between (45) – (58) Between (45), (58) – chassis Min. 1 Mz ground PC130-8...
Page 557 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 558: Failure Code [Ca332] Injector #4 (L #4) System Open/Short Error
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. ENG1 (female) Resistance 5 Defective engine controller 0.4 – 1.1 z Between (56) – (51) Between (56), (51) – chassis Min. 1 Mz ground PC130-8...
Page 559 40 Troubleshooting SEN04119-01 Circuit diagram related PC130-8...
Page 561: Troubleshooting By Failure Code, Part 2
SEN04120-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Troubleshooting by failure code, Part 2 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.
Page 562 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 PC130-8...
Page 563: Failure Code [Ca342] Calibration Code Incompatibility
Standard value in normal state/Remarks on troubleshooting Possible causes and standard 1 Defect in related system If another failure code is displayed, carry out troubleshooting for it. value in normal Engine controller may be defective. (Troubleshooting cannot be 2 Defective engine controller state carried out.) PC130-8...
Page 564: Failure Code [Ca351] Inj. Drive Circuit Error
Wiring harness between CE03 (female) (3) Resis- Max. 1 z – R24 (5) tance Wiring harness between R23 (female) (3) – Resis- Max. 1 z battery (+) tance Wiring harness between R24 (female) (3) – Resis- Max. 1 z battery (+) tance PC130-8...
Page 565 Wiring harness between R24 (female) (3) – Resis- Min. 1 Mz battery (+) and chassis ground tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 6 Defective engine controller CE03 Voltage Between (3) – (1) 20 – 30 V PC130-8...
Page 566 SEN04120-03 40 Troubleshooting Circuit diagram related PC130-8...
Page 567: Failure Code [Ca352] Sensor Sup. 1 Volt. Low Error
• Output drops. machine Related • Method of reproducing failure code: Turn starting switch ON. information Possible causes Causes Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA386]. state PC130-8...
Page 568: Failure Code [Ca386] Sensor Sup. 1 Volt. High Error
Wiring harness between ENG1 (female) tance (48) – each sensor (female) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller ENG1 Voltage Between (36) – (48) 4.75 – 5.25V PC130-8...
Page 569 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 570: Failure Code [Ca435] Abnormality In Engine Oil Pressure Switch
(With all connectors of wiring harness dis- tance connected) a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. 4 Defective engine controller ENG1 (female) Resistance Max. 1 z Between (32) – chassis ground Circuit diagram related PC130-8...
Page 571: Failure Code [Ca441] Battery Voltage Low Error
• Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related • Method of reproducing failure code: Turn starting switch ON. information Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA111]. state PC130-8...
Page 572: Failure Code [Ca442] Battery Voltage High Error
• Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related • Method of reproducing failure code: Turn starting switch ON. information Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA111]. state PC130-8...
Page 573: Failure Code [Ca449] Rail Press. Very High Error
• Common rail pressure can be checked with monitoring function. Related (Code: 36400 Common rail pressure) information • Method of reproducing failure code: Start engine. Possible causes Causes Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA553]. state PC130-8...
Page 574: Failure Code [Ca451] Rail Press. Sensor High Error
Wiring harness between ENG1 (female) (Short circuit with GND cir- Resis- (29) – PFUEL (female) (2) and chassis Min.1 Mz cuit) tance ground Wiring harness between ENG1 (female) Resis- (48) – PFUEL (female) (1) and chassis Min.1 Mz tance ground PC130-8...
Page 575 Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. ENG1 Voltage 6 Defective engine controller Between (36) – (48) 4.75 – 5.25 V Between (29) – (48) 0.25 – 4.6 V Circuit diagram related PC130-8...
Page 576: Failure Code [Ca452] Rail Press. Sensor Low Error
(Code: 36401 Common rail pressure sensor voltage) information • Method of reproducing failure code: Turn starting switch ON. Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA451]. state PC130-8...
Page 577: Failure Code [Ca488] Chg Air Temp High Torque Derate
Outlet temperature of turbocharger may be abnormally high. state charger outlet temperature Check related parts directly. If causes 1 – 2 are not detected, engine controller may be defec- 3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 578: Failure Code [Ca553] Rail Press. High Error
Check overflow valve directly for broken spring, worn seat, and 5 Defective overflow valve stuck ball. 6 Clogging of overflow piping Check overflow piping directly for clogging. 7 Defective pressure limiter Check pressure limiter directly for mechanical defect. PC130-8...
Page 579: Failure Code [Ca559] Rail Press. Low Error
3) Sticking and wear of feed pump and clogging of filter 4) Leakage through and clogging of low-pressure fuel piping 5) Clogging of fuel filter 6) Replace the fuel filters when trouble doesn’t cancel it even if clogging is checked. PC130-8...
Page 580 Max. 20 (*) Equivalent to rating 1,600 rpm cc/min Equivalent to rating 1,700 rpm cc/min Speed: Return rate from injector Equivalent to rating 1,800 rpm cc/min Return rate: Equivalent to rating 1,900 rpm cc/min Equivalent to rating 2,000 rpm cc/min PC130-8...
Page 581 A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)". Rating or equivalent: Relieve the circuit under the following condition. 1) Engine: Full throttle 2) Mode: P 3) Boom: Raise PC130-8...
Page 582: Failure Code [Ca689] Eng. Ne Speed Sensor Error
(crankshaft pulley) part directly for defect. If causes 1 – 5 are not detected, engine Ne speed sensor may be Defective engine Ne speed defective. (Since trouble is in system, troubleshooting cannot be sensor carried out.) PC130-8...
Page 583 Possible causes and standard If causes 1 – 6 are not detected, engine controller may be defec- value in normal 7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried state out.) Circuit diagram related PC130-8...
Page 584: Failure Code [Ca731] Eng. Bkup Speed Sensor Phase Error
Engine Ne speed sensor may be defective. Carry out trouble- and standard sensor system shooting for failure code [CA698]. value in normal Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble- state speed sensor system shooting for failure code [CA778]. PC130-8...
Page 585: Failure Code [Ca757] All Persistent Data Lost Error
• Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related • Method of reproducing failure code: Turn starting switch ON. information Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA111]. state PC130-8...
Page 586: Failure Code [Ca778] Eng. Bkup Speed Sensor Error
(Since trouble is in system, troubleshooting cannot be speed sensor carried out.) If causes 1 – 6 are not detected, engine controller may be defec- 7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 587 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 588: Failure Code [Ca1633] Komnet Datalink Timeout Error
120 ± 12 z Between (A) – (B) If causes 1 – 4 are not detected, engine controller may be defec- 5 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 589 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 590: Failure Code [Ca2185] Throttle Sens. Sup. Volt. High Error
– P20 (female) (1) and between CE02 Min.1 Mz tance (female) (28) – P20 (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller CE02 Voltage Between (27) – (28) 4.75 – 5.25 V PC130-8...
Page 591 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 592: Failure Code [Ca2186] Throttle Sens. Sup. Volt. Low Error
• Common rail pressure can be checked with monitoring function. Related (Code: 36400 Common rail pressure) information • Method of reproducing failure code: Start engine. Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard value in normal Carry out troubleshooting for failure code [CA559]. state PC130-8...
Page 593: Failure Code [Ca2311] Abnormality In Imv Solenoid
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. ENG1 (female) Resistance 5 Defective engine controller 2.3 – 5.3 z Between (10) – (14) Between (10) – chassis ground Min. 1 Mz Circuit diagram related PC130-8...
Page 594: Failure Code [D110Kb] Battery Relay Drive Short
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Turn starting switch 3 Defective pump controller CP02 (female) Voltage OFF. Between (108) – 20 – 30 V ON o OFF chassis ground (4 – 7 sec.) PC130-8...
Page 595 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 596: Failure Code [D19Jkz] Personal Code Relay Abnormality
Min. 1 Mz CM01 (female) (6) and chassis ground tance If causes 1 – 4 are not detected, machine monitor (KOMTRAX) Defective machine monitor may be defective. (Since trouble is in system, troubleshooting can- (KOMTRAX section) not be carried out.) PC130-8...
Page 597 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 598: Failure Code [D862Ka] Gps Antenna Discon
Standard value in normal state/Remarks on troubleshooting Possible causes and standard Possible causes are defective GPS antenna, disconnection or Defective GPS antenna or value in normal short circuit in antenna cable, and defective connection of antenna antenna cable state cable connector (GPS). Configuration drawing PC130-8...
Page 599 40 Troubleshooting SEN04120-03 PC130-8...
Page 600: Failure Code [Da22Kk] Pump Solenoid Power Low Error
R03A and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective pump controller CP01 (female), CP02 (female) Voltage Between CP02 (116), (118), 20 – 30 V (121) – CP01 (2), (5) PC130-8...
Page 601 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 602: Failure Code [Da25Kp] 5V Sensor 1 Power Abnormality
– P03 (female) (2) and chassis ground Resis- Min. 1 Mz [Swing RIGHT PPC pressure switch sys- tance tem] Wiring harness between CP01 (female) (17) – P04 (female) (2) and chassis ground Resis- Min. 1 Mz [Arm DIGGING PPC pressure switch sys- tance tem] PC130-8...
Page 603 – P25 (female) (3) and chassis ground Voltage Max. 1 V [Pump pressure sensor system] If causes 1 – 3 are not detected, pump controller may be defective. 4 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 604 SEN04120-03 40 Troubleshooting Circuit diagram related PC130-8...
Page 605: Failure Code [Da26Kp] 5V Sensor 2 Power Abnormality
Max. 1 V – A08 (female) (7) and chassis ground If causes 1 – 2 are not detected, pump controller may be defective. 3 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related PC130-8...
Page 606: Failure Code [Da29Kq] Model Selection Abnormality
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP01 (female) Resistance 4 Defective pump controller Between (39), (58), (77) – chas- Min. 1 Mz sis ground Between (21), (40) – chassis Max. 1 z ground PC130-8...
Page 607 40 Troubleshooting SEN04120-03 Circuit diagram related PC130-8...
Page 609: Troubleshooting By Failure Code, Part 3
SEN04121-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Troubleshooting by failure code, Part 3 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....................
Page 610 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 PC130-8...
Page 611 40 Troubleshooting SEN04121-02 PC130-8...
Page 612: Failure Code [Da2Rmc] Can Discon (Pump Controller Detected)
Resistance cuit or disconnection) 120 ± 12 z Between (A) – (B) If causes 1 – 4 are not detected, pump controller may be defective. 5 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 613 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 614: Failure Code [Daf8Kb] Short Circuit In Camera Power Supply
4. Turn starting switch to ON position. Hot short (Contact with 24V (Disconnect camera and check that it is not defective in circuit) in wiring harness advance.) Between CM05 (1) and (6) Voltage Max. 10 V Between CM05 (1) and (7) Voltage Max. 10 V PC130-8...
Page 615 40 Troubleshooting SEN04121-02 Circuit diagram related to rear view monitor PC130-8...
Page 616: Failure Code [Dafgmc] Gps Module Error
ON). Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard GPS module of machine monitor may be defective. (Since trouble value in normal 1 Defective machine monitor is in system, troubleshooting cannot be carried out.) state PC130-8...
Page 617 40 Troubleshooting SEN04121-02 PC130-8...
Page 618: Failure Code [Dafrmc] Can Discon (Monitor Detected)
120 ± 12 z Between (A) – (B) If causes 1 – 4 are not detected, machine monitor may be defec- 5 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 619 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 620: Failure Code [Dgh2Kb] Hydr Oil Sensor Short
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP01 (female) Resistance 3 Defective pump controller Between (29) – (46) 3.5 – 90 kz Between (29) – chassis ground Min. 1 Mz Circuit diagram related PC130-8...
Page 621 40 Troubleshooting SEN04121-02 PC130-8...
Page 622: Failure Code [Dhpama] Pump Press Sensor Abnormality
Wiring harness between CP01 (female) (49) Voltage Max. 1 V – P25 (female) (2) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. 6 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 623 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 624: Failure Code [Dhsfma] Travel Left Forward Ppc Press Sensor Abnormality
Wiring harness between CP01 (female) (69) Voltage Max. 1 V – P11 (female) (2) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. 6 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 625 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 626: Failure Code [Dhsgma] Travel Right Forward Ppc Press Sensor Abnormality
Wiring harness between CP01 (female) (55) Voltage Max. 1 V – P09 (female) (2) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. 6 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 627 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 628: Failure Code [Dhshma] Travel Left Reverse Ppc Press Sensor Abnormality
Wiring harness between CP01 (female) (13) Voltage Max. 1 V – P12 (female) (2) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. 6 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 629 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 630: Failure Code [Dhsjma] Travel Right Reverse Ppc Press Sensor Abnormality
Wiring harness between CP01 (female) (36) Voltage Max. 1 V – P10 (female) (2) and chassis ground If causes 1 – 5 are not detected, pump controller may be defective. 6 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 631 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 632: Failure Code [Dhx1Ma] Overload Sensor Abnormality (Analog)
Method of reproducing failure code: Turn starting switch ON. information Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard Pump controller may be defective. (Since trouble is in system, trou- value in normal 1 Defective pump controller bleshooting cannot be carried out.) state PC130-8...
Page 633: Failure Code [Dv20Kb] Travel Alarm Short Circuit
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. CP02 Travel lever Voltage 3 Pump controller defective Neutral Max. 1 V Between (107) – chassis ground Operated 20 – 30 V Circuit diagram related PC130-8...
Page 634: Failure Code [Dw43Ka] Travel Speed Sol Discon
(115), (117), (120) – V04 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. 3 Defective pump controller CP02 (female) Resistance Between (87) – (115), (117), 20 – 60 z (120) Circuit diagram related PC130-8...
Page 635: Failure Code [Dw43Kb] Travel Speed Sol Short
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP02 (female) Resistance 3 Defective pump controller Between (87) – (115), (117), 20 – 60 z (120) Between (87) – chassis ground Min. 1 Mz Circuit diagram related PC130-8...
Page 636: Failure Code [Dw45Ka] Swing Brake Sol Discon
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP02 (female) Disconnect D01 and Resistance 5 Defective pump controller connect pins (3) and Between (101) – 20 – 60 z (7) on female side (115), (117), (120) directly. PC130-8...
Page 637 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 638: Failure Code [Dw45Kb] Swing Brake Sol Short
ON. CP02 (female) Resistance Disconnect D01 and 3 Defective pump controller Between (101) – 20 – 60 z connect pins (3) and (115), (117), (120) (7) on female side Between (101) – directly. Min. 1 Mz chassis ground PC130-8...
Page 639 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 640: Failure Code [Dw91Ka] Travel Junction Sol Discon
(115), (117), (120) – V03 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. 3 Defective pump controller CP02 (female) Resistance Between (110) – (115), (117), 20 – 60 z (120) PC130-8...
Page 641 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 642: Failure Code [Dw91Kb] Travel Junction Sol Short
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP02 (female) Resistance 3 Defective pump controller Between (110) – (115), (117), 20 – 60 z (120) Between (110) – chassis ground Min. 1 Mz PC130-8...
Page 643 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 644: Failure Code [Dwj0Ka] Merge-Divider Sol Discon
(115), (117), (120) – V02 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. 3 Defective pump controller CP02 (female) Resistance Between (112) – (115), (117), 20 – 60 z (120) PC130-8...
Page 645 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 646: Failure Code [Dwj0Kb] Merge-Divider Sol Short
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP02 (female) Resistance 3 Defective pump controller Between (112) – (115), (117), 20 – 60 z (120) Between (112) – chassis ground Min. 1 Mz PC130-8...
Page 647 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 648: Failure Code [Dwk0Ka] 2-Stage Relief Sol Discon
(115), (117), (120) – V06 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. 3 Defective pump controller CP02 (female) Resistance Between (109) – (115), (117), 20 – 60 z (120) PC130-8...
Page 649 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 650: Failure Code [Dwk0Kb] 2-Stage Relief Sol Short
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP02 (female) Resistance 3 Defective pump controller Between (109) – (115), (117), 20 – 60 z (120) Between (109) – chassis ground Min. 1 Mz PC130-8...
Page 651 40 Troubleshooting SEN04121-02 Circuit diagram related PC130-8...
Page 653: Troubleshooting By Failure Code, Part 4
SEN04122-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Troubleshooting by failure code, Part 4 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 ..................
Page 654: Troubleshooting
Max. 1 z V11 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. 4 Defective pump controller CP02 (female) Resistance Between (96) – (115), (117), 7 – 14 z (120) PC130-8...
Page 655 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 656: Failure Code [Dxa8Kb] Pc-Epc Sol Short
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP02 (female) Resistance 4 Defective pump controller Between (96) – (115), (117), 7 – 14 z (120) Between (96) – chassis ground Min. 1 Mz PC130-8...
Page 657 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 658: Failure Code [Dxe4Ka] Service Current Epc Discon
(115), (117), (120) – V30 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. 3 Defective pump controller CP02 (female) Resistance Between (97) – (115), (117), 7 – 14 z (120) PC130-8...
Page 659 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 660: Failure Code [Dxe4Kb] Service Current Epc Short
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CP02 (female) Resistance 3 Defective pump controller Between (97) – (115), (117), 7 – 14 z (120) Between (97) – chassis ground Min. 1 Mz PC130-8...
Page 661 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 662: Failure Code [Dy20Ka] Wiper Working Abnormality
ON. CP01 (female) Wiper blade Resistance Max. 1 z 3 Defective pump controller Operating range top Between (56) – Other than operating chassis ground Min. 1 Mz range top Max. 20 z Between (114) – (119) All range PC130-8...
Page 663 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 664: Failure Code [Dy20Ma] Wiper Parking Abnormality
ON. CP01 (female) Wiper blade Resistance 3 Defective pump controller Max. 1 z Storage area Between (75) – chassis ground Working area Min. 1 Mz Max. 20 z Between (114) – (119) All range PC130-8...
Page 665 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 666: Failure Code [Dy2Cka] Washer Drive Discon
Min. 1 Mz tance (7) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective pump controller CP01 (female) Voltage Between (3) – chassis ground 20 – 30 V PC130-8...
Page 667 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 668: Failure Code [Dy2Ckb] Washer Drive Short
– J04 – M6A (female) (2), – D02 (female) (7) Voltage Max. 1 V and chassis ground If causes 1 and 2 are not detected, pump controller may be defec- 3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 669 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 670: Failure Code [Dy2Dkb] Wiper Drive (For) Short
Min. 1 Mz (119) – M05 (male) (3) and chassis ground tance If causes 1 and 2 are not detected, pump controller may be defec- 3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 671 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 672: Failure Code [Dy2Ekb] Wiper Drive (Rev) Short
Min. 1 Mz (114) – M05 (male) (1) and chassis ground tance If causes 1 and 2 are not detected, pump controller may be defec- 3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 673 40 Troubleshooting SEN04122-01 Circuit diagram related PC130-8...
Page 675 SEN04123-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Troubleshooting of electrical system (E-mode) 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......
Page 676 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 PC130-8...
Page 677: Before Carrying Out Troubleshooting Of Electrical System
Switch power supply (65A) Relay for cab light Optional power supply (1) Optional power supply (2) Radio backup, room lamp Constant power supply (30A) Machine monitor, pump controller, starting switch (B) (Spare) Engine controller Starting switch Switch power supply Engine controller PC130-8...
Page 678 SEN04123-01 40 Troubleshooting Locations of fusible links Location of fuse box and fuse Nos. PC130-8...
Page 679: Information In Troubleshooting Table
• Connector No.: Indicates (Model – Number of pins) and (Color). • “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow ( ): Roughly shows the location on the machine. PC130-8...
Page 680: When Starting Switch Turned On, Machine Monitor Displays Nothing
• When starting switch turned ON, machine monitor displays nothing. • When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass- word (if set), screen to check breaker mode (if set), screen of check before starting, screen to check Related infor- working mode and travel speed, and ordinary screen in order.
Page 681 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 682: When Starting Switch Turned On (Before Starting Engine), Basic Check Item Lights Up
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Sub tank coolant CM02 Voltage level 4 Defective machine monitor Between Max. 1 V Between (3) – FULL – LOW chassis ground Below LOW 20 – 30 V PC130-8...
Page 683 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 684 Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CM02 Engine oil level Voltage 4 Defective machine monitor Between H – L Max. 1 V Between (2) – chassis ground Below L 20 – 30 V Circuit diagram related PC130-8...
Page 685: Engine Does Not Start (Engine Does Not Turn)
Defective starting motor Power supply 20 – 30 V ground (Internal defect) Between C – Starting input 20 – 30 V chassis ground If power supply and starting input are normal but starting motor does not turn, starting motor is defective. PC130-8...
Page 686 Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with Wiring harness between R19 (female) (2) – 24V circuit) in wiring harness J02 – alternator L – circuit branch end and Voltage Max. 1 V chassis ground PC130-8...
Page 687 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 688: Preheater Does Not Operate
Wiring harness between battery relay R03A Resis- Max. 1 z nector) – heater relay contact terminal (R15) tance Wiring harness between heater relay R16 – Resis- Max. 1 z intake air heater M23 tance PC130-8...
Page 689 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 690: Automatic Warm-Up System Does Not Operate (In Cold Season)
If cause 1 is not detected, engine controller may be defective. 2 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried out.) Engine coolant temperature gauge and engine coolant temperature monitor PC130-8...
Page 691 40 Troubleshooting SEN04123-01 PC130-8...
Page 692: All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked
Min. 1 Mz ness (Short circuit with GND (1), – circuit branch end and chassis ground tance circuit) Wiring harness between S14 (male) (2) – Resis- V01 (female) (2), – D01 (female) (4) and Min. 1 Mz tance chassis ground PC130-8...
Page 693 Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with Wiring harness between S14 (male) (2) – 24V circuit) in wiring harness V01 (female) (2), – D01 (female) (4) and Voltage Max. 1 V chassis ground Circuit diagram related PC130-8...
Page 694: Precaution Lights Up While Engine Is Running
(11) – J02 – M22 (female) (1), – circuit Min. 1 Mz tance branch end and chassis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective machine monitor CM01 Engine Voltage Between (11) – Running Min. 7.8 V chassis ground PC130-8...
Page 695 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 696 4 Defective machine monitor (Air intake Max. 1 V resistance: *1) Between (4) – chassis ground When clogged (Air intake 20 – 30 V resistance: *2) *1: Min. –3,430 Pa {Min. –350 mmH *2: –7,470 ± 490 Pa {–762 ± 50 mmH PC130-8...
Page 697 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 698 • Lighting up blue: Hydraulic oil temperature is proper. state If cause 1 is not detected, hydraulic oil temperature gauge system Defective hydraulic oil tem- may be defective. Carry out troubleshooting for E-10 Hydraulic oil perature gauge system temperature gauge does not indicate normally. PC130-8...
Page 699: Emergency Stop Item Lights Up While Engine Is Running
(when system is nor- ing for S-12 Oil pressure lowers. value in normal mal) state Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may switch system be defective. Carry out troubleshooting for failure code [CA435]. PC130-8...
Page 700: Engine Coolant Temperature Gauge Does Not Indicate Normally
Engine coolant Coolant temperature Color of monitor light temperature level Possible causes and standard 105°C value in normal 1 Defective machine monitor 102°C state 100°C 85°C Blue 60°C 30°C White Engine coolant temperature gauge and engine coolant temperature monitor PC130-8...
Page 701: Hydraulic Oil Temperature Gauge Does Not Indicate Normally
Between (29) – chassis ground Min. 1 Mz If causes 1 – 5 are not detected, machine monitor may be defec- 6 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related PC130-8...
Page 702 Hydraulic oil temper- Color of monitor light temperature ature level Possible causes and standard 105°C value in normal 1 Defective machine monitor 102°C state 100°C 85°C Blue 40°C 20°C White Hydraulic oil temperature gauge and hydraulic oil temperature monitor PC130-8...
Page 703: Fuel Level Gauge Does Not Indicate Normally
Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. CM01 (female) Fuel level Resistance 5 Defective machine monitor 7 – 11 z FULL Between (9) – 85 – 95 z chassis ground EMPTY Circuit diagram related PC130-8...
Page 704 Color of monitor light Quantity of fuel gauge Possible causes 198 l and standard value in normal 1 Defective machine monitor 148 l state 123 l Blue 84 l 66 l 36 l Fuel level gauge and fuel level monitor PC130-8...
Page 705: Contents Of Display By Machine Monitor Are Different From Applicable Machine
(Code: 04503 Monitor function switch) Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard Machine monitor may be defective. value in normal 1 Defective machine monitor (Since trouble is in system, troubleshooting cannot be carried out.) state PC130-8...
Page 706: Auto-Decelerator Does Not Operate Normally
3 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) If cause 1 is not detected, engine controller may be defective. 4 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 707: Working Mode Does Not Change
Machine monitor may be defective. (Since trouble is in system, and standard 1 Defective machine monitor troubleshooting cannot be carried out.) value in normal Pump controller may be defective. (Since trouble is in system, state 2 Defective pump controller troubleshooting cannot be carried out.) PC130-8...
Page 708: Travel Speed Does Not Change
2 Defective machine monitor (Since trouble is in system, troubleshooting cannot be carried out.) If cause 1 is not detected, pump controller may be defective. 3 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related PC130-8...
Page 709: Alarm Buzzer Cannot Be Stopped
(Code: 04504 Monitor 1st, 2nd line switches) Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard Machine monitor may be defective. (Since trouble is in system, value in normal 1 Defective machine monitor troubleshooting cannot be carried out.) state PC130-8...
Page 710: Windshield Wiper And Window Washer Do Not Operate
When retracted to Max. 1 z rear a Prepare with starting switch OFF, then carry out troubleshoot- ing without turning starting switch ON. Defective pump controller (Wiper motor system) CP02 (female) Continuity Between (119) – (114) There is continuity PC130-8...
Page 711 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 712 (Code: 04504 Monitor 1st, 2nd line switches) Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard Machine monitor may be defective. (Since trouble is in system, value in normal 1 Defective machine monitor troubleshooting cannot be carried out.) state PC130-8...
Page 713 40 Troubleshooting SEN04123-01 PC130-8...
Page 714: Power Maximizing Function Does Not Operate Normally
5 Defective pump controller Released Min. 1 Mz Between (41) – Max. 1 z chassis ground Pressed Machine monitor may be defective. (Since trouble is in system, 6 Defective machine monitor troubleshooting cannot be carried out.) Circuit diagram related PC130-8...
Page 715 Voltage Max. 1 V (109) – V06 (female) (2) state If cause 1 is not detected, pump controller may be defective. 2 Defective pump controller (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related PC130-8...
Page 716: Swing Holding Brake Does Not Operate Normally
J02 – S04 (female) (3), – S25 (female) (14) Voltage Max. 1 V 24V circuit) in wiring harness and chassis ground Wiring harness between S04 (female) (4) – V03 (female) (1), – D03 (female) (3) and Voltage Max. 1 V chassis ground PC130-8...
Page 717 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 718: Travel Alarm Does Not Sound Or Does Not Stop Sounding
Wiring harness between CP02 (female) Resis- circuit) (107) – M14 (female) (1) and chassis Min. 1 Mz tance ground Defective travel alarm (Inter- If causes 1, 2 are not detected, travel alarm is defective. nal defect) Circuit diagram related PC130-8...
Page 719: Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)
If above voltage is normal, air conditioner controller may be defec- tive. If causes 1 – 5 are not detected, machine monitor may be defec- 6 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 720 (1) – chassis ground (T07) tance Wiring harness between P (wiring side) Resis- Max. 1 z (2) – AC (wiring side) (8) tance Wiring harness between P (wiring side) Resis- Max. 1 z (4) – AC (wiring side) (7) tance PC130-8...
Page 721 (Since trouble is in system, troubleshooting cannot be troller carried out.) If causes 1 – 5 are not detected, air conditioner system may be Defective air conditioner sys- defective. See Machine Component Volume of Shop Manual, Air conditioner, Troubleshooting. PC130-8...
Page 722 (Since trouble is in system, troubleshooting cannot be troller carried out.) If causes 1 – 7 are not detected, air conditioner system may be Defective air conditioner sys- defective. See Machine Component Volume of Shop Manual, Air conditioner, Troubleshooting. PC130-8...
Page 723 (Since trouble is in system, troubleshooting cannot be troller carried out.) If causes 1 – 4 are not detected, machine monitor may be defec- 6 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried out.) PC130-8...
Page 724 (wiring side) (2) and chassis Voltage Max. 1 V ground If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner con- defective. (Since trouble is in system, troubleshooting cannot be troller carried out.) PC130-8...
Page 725 Voltage Max. 1 V (12) – TH (wiring side) (2) If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner con- defective. (Since trouble is in system, troubleshooting cannot be troller carried out.) PC130-8...
Page 726 Voltage Max. 1 V (15) – P31 (female) (2) and chassis ground If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner con- defective. (Since trouble is in system, troubleshooting cannot be troller carried out.) PC130-8...
Page 727 (wiring side) (23) and chassis Voltage Max. 1 V ground If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner con- defective. (Since trouble is in system, troubleshooting cannot be troller carried out.) PC130-8...
Page 728 (wiring side) (22) and chassis Voltage Max. 1 V ground If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner con- defective. (Since trouble is in system, troubleshooting cannot be troller carried out.) PC130-8...
Page 729 Wiring harness between P17 (female) (2) – Resis- Max. 1 z chassis ground (T06) tance If causes 1 – 3 are not detected, air conditioner controller may be Defective air conditioner con- defective. (Since trouble is in system, troubleshooting cannot be troller carried out.) PC130-8...
Page 730 SEN04123-01 40 Troubleshooting Circuit diagram related PC130-8...
Page 731: While Starting Switch Is In Off Position, Service Meter Is Not Displayed
Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order) information Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard Machine monitor may be defective. (Since trouble is in system, value in normal 1 Defective machine monitor troubleshooting cannot be carried out.) state PC130-8...
Page 732: Monitoring Function Does Not Display Lever Control Signal Normally
Prepare with starting switch OFF, then start engine and carry out troubleshooting. Right work equip- CP01 (female) Resistance 5 Defective pump controller ment control lever Neutral Min. 1 Mz Between (53) – chas- sis ground Max. 1 z Boom raise PC130-8...
Page 733 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 734 Prepare with starting switch OFF, then start engine and carry out troubleshooting. Right work equip- CP01 (female) Resistance 5 Defective pump controller ment control lever Neutral Min. 1 Mz Between (14) – chas- Max. 1 z sis ground Boom lower PC130-8...
Page 735 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 736 Prepare with starting switch OFF, then start engine and carry out troubleshooting. Left work equipment CP01 (female) Resistance 5 Defective pump controller control lever Neutral Min. 1 Mz Between (17) – chas- Max. 1 z sis ground Arm curl PC130-8...
Page 737 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 738 Prepare with starting switch OFF, then start engine and carry out troubleshooting. Left work equipment CP01 (female) Resistance 5 Defective pump controller control lever Neutral Min. 1 Mz Between (15) – Max. 1 z chassis ground Arm out PC130-8...
Page 739 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 740 Prepare with starting switch OFF, then start engine and carry out troubleshooting. Right work equip- CP01 (female) Resistance 5 Defective pump controller ment control lever Neutral Min. 1 Mz Between (73) – chas- Max. 1 z sis ground Bucket curl PC130-8...
Page 741 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 742 Prepare with starting switch OFF, then start engine and carry out troubleshooting. Right work equip- CP01 (female) Resistance 5 Defective pump controller ment control lever Neutral Min. 1 Mz Between (34) – chas- Max. 1 z sis ground Bucket dump PC130-8...
Page 743 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 744 Prepare with starting switch OFF, then start engine and carry out troubleshooting. Left work equipment CP01 (female) Resistance control lever 5 Defective pump controller Neutral Min. 1 Mz Between (16) – chas- Swing left Max. 1 z sis ground Swing right PC130-8...
Page 745 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 746 Prepare with starting switch OFF, then start engine and carry out troubleshooting. CP01 (female) Service pedal Resistance 6 Defective pump controller Neutral Min. 1 Mz Between (52) – Max. 1 z chassis ground Forward or reverse PC130-8...
Page 747 40 Troubleshooting SEN04123-01 Circuit diagram related PC130-8...
Page 748: Komtrax System Does Not Operate Normally
Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from KOMTRAX setting” in the service menu of the “12 Display of KOMTRAX setting” in the ser- machine monitor. vice menu of the machine monitor. PC130-8...
Page 749 40 Troubleshooting SEN04123-01 PC130-8...
Page 751 SEN04124-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Troubleshooting of hydraulic and mechanical system (H-mode) 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....................
Page 752 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 PC130-8...
Page 753: Information Contained In Troubleshooting Table
• The standard values in normalcy by which to judge "good" value in normal filing and reference or "no good" about presumed causes. state purpose only. It does not • References for making judgement of "good" or "no good" stand for any priority) PC130-8...
Page 754: System Chart For Hydraulic And Mechanical Systems
SEN04124-00 40 Troubleshooting System chart for hydraulic and mechanical systems PC130-8...
Page 755 40 Troubleshooting SEN04124-00 a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems. PC130-8...
Page 756: Speed Or Power Of All Work Equipment, Swing, And Travel Are Low
6 Malfunction of servo piston The servo piston may have malfunction. Check it directly. If there is none of the causes listed above, the piston pump may 7 Piston pump defective have problems of lowering of performance, malfunction, internal defect, etc. PC130-8...
Page 757: Engine Speed Sharply Drops Or Engine Stalls
LS valve directly. Orifice or filter in servo The orifice or filter in the pump servo equipment is suspected of equipment clogged clogging. Check the equipment itself. 5 Malfunction of servo piston The servo piston may have malfunction. Check it directly. PC130-8...
Page 758: No Work Equipment, Travel And Swing Move
It is presumed that the strainer in the hydraulic tank is clogged, state Hydraulic tank strainer thereby causing negative pressure in the suction circuit. Make a clogged visual check. The piston pump is suspected of an internal failure. Check the 5 Piston pump defective pump itself. PC130-8...
Page 759: Fine Control Mode Does Not Function
If the oil pressure does not return to normalcy even after the adjust- ment, malfunction of the LS valve or its internal failure is sus- pected. In that case, check the valve itself. Malfunction of the servo piston is suspected. Check the piston 3 Malfunction of servo piston itself. PC130-8...
Page 760: Speed Or Power Of Boom Is Low
Check it directly. suction valve Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. 10 Boom cylinder defective Boom cylinder Leakage from cylinder Relieved in RAISE direction 15 cc/min PC130-8...
Page 761: Speed Or Power Of Arm Is Low
Check it directly. suction valve Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. 8 Arm cylinder defective Arm cylinder Leakage from cylinder Relieved in IN direction 15 cc/min PC130-8...
Page 762: Speed Or Power Of Bucket Is Low
Check it directly. suction valve Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. 8 Bucket cylinder defective Bucket cylinder Leakage from cylinder Relieved in CURL direction 15 cc/min PC130-8...
Page 763: Work Equipment Does Not Move In Its Single Operation
0 MPa {0 kg/cm value in normal Above 2.7 MPa state Operation {Above 28 kg/cm Malfunction of work equip- The spool in the work equipment control valve is presumed to mal- ment control valve (spool) function. Check the valve itself. PC130-8...
Page 764: Hydraulic Drift Of Work Equipment Is Large
Sealing of the suction valve of the bucket control valve (on the bot- control valve (suction valve) tom side) may be defective. Check it directly. Defective sealing of central- Sealing of the centralized safety-suction valve of the control valve ized safety-suction valve may be defective. Check it directly. PC130-8...
Page 765: Time Lag Of Work Equipment Is Large
Malfunction of 2-stage relief and standard solenoid valve 0 MPa value in normal {0 kg/cm state 2.84 – 3.43 MPa {29 – 35 kg/cm Malfunction of main relief Main relief valve may have malfunction. Check it directly. valve PC130-8...
Page 766: Work Equipment Loaded More Is Slower During Compound Operation
Standard value in normal state/Remarks on troubleshooting and standard Malfunction or defective The LS selector valve of the control valve may have a malfunction value in normal sealing of LS selector valve or its sealing may be defective. Check it directly. state PC130-8...
Page 767: Travel Speed Lowers Largely During Compound Operation Of Work Equipment/Swing + Travel
The pressure compensation valve of the swing control valve may valve (pressure compensa- have a malfunction. Check it directly. tion valve) Malfunction of travel control The pressure compensation valve of the travel control valve may valve (pressure compensa- have a malfunction. Check it directly. tion valve) PC130-8...
Page 768: Machine Deviates During Travel
10 Final drive defective checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.) Defective adjustment of Adjust travel deviation adjustment plug. For details, see Testing travel deviation adjustment and adjusting, "Testing and adjusting travel deviation". plug PC130-8...
Page 769: Travel Speed Is Low
Leakage from travel motor Below 1.7 l/min Travel circuit relieved The final drive may have a defect in it. Check it directly. (It may be 10 Final drive defective checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.) PC130-8...
Page 770: Machine Cannot Be Steered Easily Or Steering Power Is Low
The safety and check valve of the travel motor may have a mal- Malfunction of travel motor function. Check it directly. (It may be checked by exchanging the (safety and check valve) front and rear motors or the right and left motors and checking change of the phenomenon.) PC130-8...
Page 771: Travel Speed Does Not Change Or It Is Kept Low Or High
Leakage from travel motor Below 1.7 l/min Travel circuit relieved The final drive may have a defect in it. Check it directly. (It may be 5 Final drive defective checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.) PC130-8...
Page 772: Machine Does Not Swing
(safety valve) Swing circuits 29.2 ± 1.5 MPa relieved (separately {298 ± 15 kg/cm on both sides) Defective sealing of swing Sealing of the suction valve of the swing motor may be defective. motor (suction valve) Check it directly. PC130-8...
Page 773: Swing Acceleration Or Swing Speed Is Low
Sealing of the suction valve of the swing motor may be defective. motor (suction valve) Check it directly. Malfunction of swing motor Sealing of the reverse prevention valve of the swing motor may be (reverse prevention valve) defective. Check it directly. PC130-8...
Page 774: Excessive Overrun When Stopping Swing
Sealing of the suction valve of the swing motor may be defective. motor (suction valve) Check it directly. Malfunction of swing motor Sealing of the reverse prevention valve of the swing motor may be (reverse prevention valve) defective. Check it directly. PC130-8...
Page 775: When Upper Structure Stops Swinging, It Makes Large Shock
The swing machinery may have a defect in it. Check it directly. (It 4 Swing machinery defective may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.) PC130-8...
Page 776: Hydraulic Drift Of Swing Is Large
Malfunction or defective The reverse prevention valve of the swing motor may have a mal- sealing of swing motor function or its sealing may be defective. Check it directly. (reverse prevention valve) PC130-8...
Page 777: Flow Rate In Attachment Circuit Cannot Be Adjusted
Wiring harness PPC valve output Service pedal state Malfunction of service PPC connector pressure valve Disconnect connec- In NEUTRAL 0 MPa {0 kg/cm tor V30 of attachment Above 2.7 MPa flow rate adjustment Operated {Above 28 kg/cm EPC valve. PC130-8...
Page 779 SEN04125-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 40 Troubleshooting Troubleshooting of engine (S-mode) 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......................
Page 780 SEN04125-02 40 Troubleshooting S-15 Abnormal noise is made ........................24 S-16 Vibration is excessive ........................... 25 PC130-8...
Page 781 40 Troubleshooting SEN04125-02 PC130-8...
Page 782: Method Of Using Troubleshooting Chart
When narrowing the "causes", apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with . (If no items have other marks and the causes cannot be narrowed, however, you may apply them.) PC130-8...
Page 783 40 Troubleshooting SEN04125-02 PC130-8...
Page 784 Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red]. PC130-8...
Page 785 There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in the [Causes] section. The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is explained according to Step 1 – Step 3 shown below. PC130-8...
Page 786: Starting Performance Is Poor
Is voltage 20 – 30 V between alternator terminal B and terminal E with engine at low idle? When specific gravity of electrolyte and voltage of battery are measured, they are low Remedy *1: Displayed failure codes [CA559] and [CA2249] PC130-8...
Page 787: Engine Does Not Start
ON Even if terminal B and terminal C at safety relay outlet are connected, engine does not start When terminal at safety switch and terminal B at starting motor are connected, engine starts Remedy — — PC130-8...
Page 788 Inspect overflow valve directly Engine can be started in reduced cylinder mode Fuel flows out when pressure limiter return piping is disconnected Remedy *1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA271] and [CA272] PC130-8...
Page 789 When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally When starting switch is turned to HEAT, intake air heater mount does not become warm Remedy *1: Displayed failure codes [CA559] and [CA2249] PC130-8...
Page 790: Engine Does Not Pick Up Smoothly
Inspect fuel filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Remedy *1: Displayed failure codes [CA559] and [CA2249] PC130-8...
Page 791: Engine Stops During Operations
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Check controller power supply wiring Check starting switch wiring Remedy *1: Displayed failure codes [CA559] and [CA2249] PC130-8...
Page 792: Engine Does Not Rotate Smoothly
Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” indicated by code Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” indicated by code Remedy *1: Displayed failure code [CA689] *2: Displayed failure code [CA778] PC130-8...
Page 793: Engine Lacks Output (Or Lacks Power)
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Inspect charge pressure sensor mount directly Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” indicated by code Remedy *1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA122] and [CA123] PC130-8...
Page 794: Exhaust Smoke Is Black (Incomplete Combustion)
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated by code Confirm with monitoring function Remedy *1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145] PC130-8...
Page 795: Oil Consumption Is Excessive (Or Exhaust Smoke Is Blue)
Check breather and breather hose directly When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage q q q q There is external leakage of oil from engine Remedy PC130-8...
Page 796: Oil Becomes Contaminated Quickly
When compression pressure is measured, it is found to be low Check breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly Remedy — PC130-8...
Page 797: Fuel Consumption Is Excessive
If spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated by code Confirm with monitoring function Remedy *1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145] PC130-8...
Page 798: Oil Is In Coolant (Or Coolant Spurts Back Or Coolant Level Goes Down)
Oil level has risen and oil is milky There are excessive air bubbles in radiator, coolant spurts back Pressure-tightness test of cylinder head shows there is leakage Inspect cylinder block directly Pressure-tightness test of oil cooler shows there is leakage Remedy PC130-8...
Page 799: Oil Pressure Drops
Inspect oil pan strainer, pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged Inspect oil filter directly If oil level sensor is replaced, oil level monitor indicates normally Remedy — PC130-8...
Page 800: Oil Level Rises (Entry Of Coolant Or Fuel)
When compression pressure is measured, it is found to be low Remove injector and inspect O-ring. Inspect cylinder block, liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly Remedy PC130-8...
Page 801: Coolant Temperature Becomes Too High (Overheating)
Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt, pulley directly When coolant temperature is measured, it is found to be normal Remedy — PC130-8...
Page 802: Abnormal Noise Is Made
Inspect gear train directly Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Abnormal noise is heard only when engine is started Confirm with monitoring function Remedy PC130-8...
Page 803: Vibration Is Excessive
Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Confirm with monitoring function Inspect engine mounting bolts and cushions directly Inspect output shaft or inside of damper directly Remedy PC130-8...
Page 805 SEN04126-02 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual ..........................2 Coating materials list............................4 Special tool list ..............................7 Sketch of special tool .............................11...
Page 806: Disassembly And Assembly
Nos ., pa rt nam es, and qu anti ty ar e n ot means that they are not available described. from Komatsu in Japan (i.e. must be Marks shown in the Installation Section stand made locally). for the following.
Page 807 79 T- * *** **** : Tightening torque means that they are not available from Komatsu in Japan (i.e. must be : Quantity of oil or coolant to be added made locally). Sketches of special tools Various special tools are illustrated for the con- venience of local manufacture.
Page 808: Coating Materials List
• Used to seal flywheel housing, intake mani- fold, oil pan, thermostat housing, etc. • Features: Silicon-based, heat and cold-resis- LG-8 tant, vibration-resistant, impact-resistant seal- ThreeBond 419-15-18131 100 g Tube ant. 1207B • Used to seal transfer case, etc. PC130-8...
Page 809 50 Disassembly and assembly SEN04126-02 Cate- Komatsu code Part number Q'ty Container Main features and applications gory • Used for rough surfaces such as the circle gear LG-9 top seal which does not need to be clamped, ThreeBond 790-129-9310 200 g...
Page 810 SEN04126-02 50 Disassembly and assembly Cate- Komatsu code Part number Q'ty Container Main features and applications gory • Feature: Silicone grease with wide using tem- G2-S perature range, high resistance to thermal-oxi- ThreeBond — 200 g Tube dative degradation and performance to prevent 1855 deterioration of rubber and plastic parts.
Page 811: Special Tool List
Push tool (Kit) (C) Instllation Bearing outer race 790-101-5461 For main bearing • Plate 790-101-5441 For sub bearing • Plate 790-101-5421 • Grip 01010-51240 • Bolt 790-201-2850 Spacer Instllation Bearing inner race 790-201-2750 Spacer 796T-426-1140 Push tool Instllation oil seal 790-201-2680 Plate PC130-8...
Page 812 791-620-3260 • Pin pusher 796T-432-1010 Guide Cylinder 790-101-1300 (980 kN {100 ton}) Cylinder 790-101-1600 (686 kN {70 ton}) 790-101-1102 Pump 790-101-2501 Push puller Disassembly of center Disconnection of rotor from 790-101-2510 • Block swivel joint shaft 790-101-2520 • Screw PC130-8...
Page 813 Application of boom cylinder dust seal 790-101-5021 • Grip 01010-50816 • Bolt 790-201-1500 Push tool (Kit) 790-201-1630 • Push tool Application of arm and blade cylinder bushing 790-101-5021 • Grip 01010-50816 • Bolt 790-720-1000 Expander Extension of piston ring PC130-8...
Page 814 Removal of boom foot pin boom 01643-33080 • Washer 796-270-1110 • Adapter Puller 790-101-4000 (490 kN {50 ton}) 790-101-1102 Pump 793-498-1210 Lifter (Suction cup) Removal and installation of Operator’s cab glass operator's cab glass (stuck (stuck glass) 20Y-54-13180 Adapter glass) PC130-8...
Page 815: Sketch Of Special Tool
50 Disassembly and assembly SEN04126-02 Sketch of special tool Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. F6 Push tool a Unless otherwise specified, there shall be no burrs or flushes at the corner.
Page 816 SEN04126-02 50 Disassembly and assembly Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. M2 Installer a Unless otherwise specified, there shall be no burrs or flushes at the corner. R Guide PC130-8...
Page 817 50 Disassembly and assembly SEN04126-02 Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. T2 Push tool a Unless otherwise specified, there shall be no burrs or flushes at the corner. T3 Push tool PC130-8...
Page 818 SEN04126-02 50 Disassembly and assembly Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. T4 Push tool PC130-8...
Page 819 50 Disassembly and assembly SEN04126-02 PC130-8...
Page 821 SEN04127-02 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 50 Disassembly and assembly Engine and cooling system 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 .......................
Page 822: Removal And Installation Of Fuel Supply Pump Assembly
Open and lock engine hood (2). Remove bracket (3). Disconnect connector PREG (4). Disconnect wiring clamps (5), (6) and (7). Disconnect fuel hose (8) from the supply pump. Remove 2 boots (9) from the common rail and supply pump. [*1] PC130-8...
Page 823 Remove supply pump and pump holder assembly (21). Remove 3 nuts (24) and remove supply pump (25) from pump holder (26). a The following figure shows locations (a) of mounting bolts (19). a The following figure shows locations (b) of mounting bolts (24). PC130-8...
Page 824 Never bend a high-pressure pipe for the convenience sake. The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Be sure to install the boot to the sleeve nut after installing the high-pressure pipe.
Page 825: Removal And Installation Of Fuel Injector Assembly
Cylinder No. 2: CN2 Cylinder No. 3: CN3 Cylinder No. 4: CN4 Remove pin (6) and disconnect spill hose (7). Loosen sleeve nut (8) both on the injector side and common rail side and remove high-pressure pipe (9). [*2] PC130-8...
Page 826 Never bend a high-pressure pipe for the convenience sake. The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Be sure to install the boot to the sleeve nut after installing the high-pressure hose.
Page 827 50 Disassembly and assembly SEN04127-02 [*4] When reusing injector, always replace Oring (13) and gasket (14) with new ones. PC130-8...
Page 828: Removal And Installation Of Front Oil Seal
Loosen fan belt adjust bolt (2) and remove fan belt (3). [*1] Remove engine speed sensor connector (4). Remove speed sensor mounting bolt (5) and remove speed sensor (6). [*2] Remove crankshaft pulley mounting bolt (7) and remove crankshaft pulley (8). [*3] PC130-8...
Page 829 [*1] Confirm the direction of the fan. [*2] Speed sensor mounting bolt (5): 7.0 – 11 Nm {0.7 – 1.1 kgm} [*3] Crankshaft pulley mounting bolt (7): 343 – 402 Nm {35 – 41 kgm} PC130-8...
Page 830: Removal And Installation Of Rear Oil Seal
"Removal and installation of work removable, remove the flywheel mounting equipment pump assembly". bolt (4). Lift flywheel (3) and remove it. Removal of the flywheel Flywheel: 25 kg Remove coupling mounting bolt (1) and remove coupling (2). [*1] PC130-8...
Page 831 Tighten the bolts each in two actions by applying torque as specified in the order of item 2) above. Mounting bolt: Unit: Nm{kgm} Procedure Target Range 1st time 88.2 {9.0} 58.7 – 117.7 {6.0 – 12.0} 2nd time 191.3 {19.5} 186.4 – 196.2 {19.0 – 20.0} PC130-8...
Page 832 For measurement, move the crank- shaft forward or backward to prevent error caused by an end play. Rotate the crankshaft one full turn and measure the difference of the maximum values of runout of the needle. Face runout: Max. 0.25 mm PC130-8...
Page 833: Removal And Installation Of Cylinder Head Assembly
(10) and dis- connect air conditioner compressor assem- Remove covers (3) – (5). bly (12). a Move the air conditioner compressor assembly aside and bind it with a rope, etc. so that it will not be an obstacle. PC130-8...
Page 834 Disconnect air hose (27) from air intake con- nector (28). [*3] a Make marks at the hose end and tube so that it can be reconnected correctly. Remove brackets (29) and (29a) and partition plates (30) and (31). Remove 4 muffler assembly bracket mounting bolts (22). PC130-8...
Page 835 [*5] 10) Lift off turbocharger and exhaust manifold assembly (42). Turbocharger and exhaust manifold Remove 3 mounting bolts (37) and discon- assembly: 15 kg nect air connector (38) from the turbo- charger. [*6] PC130-8...
Page 836 (57). Remove 2 high-pressure pipe clamps (58). Remove electrical intake heater Remove 8 boots (59) from injector (60) assembly (51). and common rail (61). [*10] Loosen the sleeve nuts and remove 4 high-pressure pipes (62). [*11] PC130-8...
Page 837 16. Remove the water pump according to the fol- lowing procedure. Loosen alternator mounting bolts (68) and (69). Loosen locknut (70) of the alternator belt tension adjustment bolt and fully loosen alternator belt tension adjustment bolt (71) until the alternator belt can be removed. PC130-8...
Page 838 (85). [*17] a Loosen intake exhaust adjustment screws of all the cylin- ders. Remove 3 mounting bolts (86) and 5 mounting bolts (87) and remove rocker arm assembly (88). [*18] a Record the locations of mounting bolts (86). PC130-8...
Page 839 When installing the head cover mounting nuts and washers, check that the packing is fitted to the head cover. a Check that the packing is free of damage. Cylinder head cover mounting nut: 7.84 – 9.8 Nm {0.8 – 1.0 kgm} PC130-8...
Page 840 Direct the slits of the boot out and down. a The boot is installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason. PC130-8...
Page 841 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} gasket sealant to it. Apply gasket sealant in a string of about 1 mm [*16] in diameter. Tighten water pump mounting bolt (a) to install Mounting face: Gasket sealant (LG-7) alternator mounting bracket (96), too. PC130-8...
Page 842 F denotes the front of the engine. R denotes the rear of the engine. (b) denotes a bolt for plastic-region angle tight- ening. p1 denotes a mark on the cylinder head. p2 denotes a mark on the bolt head. PC130-8...
Page 843: Removal And Installation Of Radiator Assembly
(10). Open the coolant drain valve (2) to drain. [*1] Coolant: 13.9 l Remove 2 mounting bolts (4) of plate (3) and remove the cover. Disconnect radiator lower hose (5). [*2] Remove 2 radiator mounting bolts (11). [*4] PC130-8...
Page 844 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*4] Mounting bolt: 44 ± 9.8 Nm {4.5 ± 1.0 kgm} [*5] a When installing the radiator assembly, align the convex portion (a) on the bottom of the radiator assembly with the concave portion (b) on the machine. PC130-8...
Page 845: Removal And Installation Of Aftercooler Assembly
Remove 2 air aftercooler mounting bolts (10). Remove 2 mounting bolts (2) and disconnect the air aftercooler lower hose (3). Remove 2 mounting bolts (4) and remove plate (5). Pull out air aftercooler (11). [*3] a Take care not to damage sponge around the aftercooler. PC130-8...
Page 846 Install the clamp to the clamp mark made on the hose. Tighten to torque of at least 6 Nm {0.6kgm} When using a new hose a Tighten until dimention (BDG) is 7 – 10 [*3] Mounting bolt: 44 ± 9.8 Nm {4.5 ± 1.0 kgm} PC130-8...
Page 847: Removal And Installation Of Work Equipment Oil Cooler Assembly
Remove oil cooler mounting bolts (7). Remove 2 nut mounting bolts (8). Loosen drain plug (2) of the oil cooler outlet tube and drain the oil in the piping. [*1] Remove 2 mounting bolts (9) on the side of the oil cooler. [*3] PC130-8...
Page 848 2 upper oil cooler piping mounting bolts (11) 2 upper mounting bolts (12) of oil cooler side bracket on each side [*4] 2 lower oil cooler piping mounting bolts (13) [*5] 2 lower mounting bolts (14) of oil cooler side bracket on each side [*6] PC130-8...
Page 849: Removal And Installation Of Engine And Work Equipment Pump Assembly
(2), engine undercover (3) and Open fuel drain valve (6) and drain the work equipment undercover (4). fuel. [*2] a After starting draining the fuel, open the fuel filler cap. When fuel tank is full: 247 l Open and lock engine hood (7). PC130-8...
Page 850 (15) and bracket (16) together. Remove side covers (17) and (18). a Remove mounting bolt (17a) of side cover (17), too. Remove partition plate (19). Disconnect wiring connector AC02 (24). Remove air conditioner compressor belt protective cover (25). PC130-8...
Page 851 (33), and disconnect heater hose (34) from water pump (35). Disconnect hose (36) between the turbo- charger and air cleaner from the turbo- charger. [*6] Disconnect connector (37) of the hose between the turbocharger and aftercooler from the turbocharger. [*7] PC130-8...
Page 852 Starting motor wiring M17 (48) can be disconnected more easily from under- side of the engine. Disconnect engine oil pan oil temperature sensor connector (50). a Disconnect oil temperature sensor connector (50) from underside of the engine. PC130-8...
Page 853 14. Disconnect fuel hoses (54) and (55) from fuel supply pump (56). 15. Disconnect fuel hose clamp (57). Remove fan guard (63). Remove fan pulley mounting bolt (64) and remove fan and pulley assembly (65). a Place the removed fan and pulley assembly down. PC130-8...
Page 854 10) Disconnect suction hose (82) and elbow (82a) together from the pump. [*12] Disconnect connectors V11 (71) and P22 (72). 18. Remove 4 engine mounting bolts (83). [*13] a Remove ground cable (84) installed to the front right mounting bolt. PC130-8...
Page 855 Do not use an impact wrench, when tightening the clamp. Clamp bolt (BC): Lubricanting oil (THREE- BOND PANDO 18B) When reusing the hose a Install the clamp to the clamp mark made on the hose. Tighten to torque of at least 6 Nm {0.6kgm} PC130-8...
Page 856 (elbow side). Then, referring to "[*5] Installation proce- dure for MIKALOR clamp", tighten the hose clamp. [*13] Engine mounting bolt: LT2 Engine mounting bolt: 235 – 285 Nm {23.5 – 29.5 kgm} Target: 279.6 Nm {28.5 kgm} PC130-8...
Page 857: Removal And Installation Of Fuel Tank Assembly
(4), 2 pieces each, and remove handrail (5). a To remove mounting bolts (4), open cover (6). Remove 2 cover upper mounting bolts (7) and 2 cover lower mounting bolts (9) and remove cover (8). Disconnect hose clamp (10). Disconnect fuel return hose (11). PC130-8...
Page 858 Disconnect 2 fuel hoses (13) and (14). Remove 4 fuel tank mounting bolts (15). [*2] a Height adjustment shims (16) are installed to the 2 bolts on the hydraulic tank side. 10. Lift off fuel tank assembly (17). Fuel tank assembly: 120 kg PC130-8...
Page 859 50 Disassembly and assembly SEN04127-02 PC130-8...
Page 861 SEN04128-01 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 50 Disassembly and assembly Power train 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 ...........
Page 862: Removal And Installation Of Travel Motor And Final Drive Assembly
(5) and remove mounting bolt. Lift off travel motor and final drive assembly. [*1] a Be extremely careful not to damage the nipple tool surface of the hose mount. Travel motor and final drive assembly: 150 kg Disconnect 4 travel motor hoses (2). PC130-8...
Page 863 For details, see Testing and adjusting, "Bleeding air from travel motor". Refilling with oil (hydraulic tank) a Add oil through the oil filler to the specified level.  Run the engine to circulate the oil through the system. Then check the oil level again. PC130-8...
Page 864: Disassembly And Assembly Of Travel Motor And Final Drive Assembly
SEN04128-01 50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly Component parts PC130-8...
Page 865 50 Disassembly and assembly SEN04128-01 PC130-8...
Page 866 SEN04128-01 50 Disassembly and assembly PC130-8...
Page 867 Spring Piston Orifice Spring Filter Spring Seal ball Disc Plug Plate Plug Oil seal Piston O-ring O-ring O-ring Hexagonal socket head plug THS snap ring Hexagonal socket head plug Ball bearing Hexagonal socket head plug Ball bearing Plate Needle PC130-8...
Page 868 (149) Press performance: Min. 1,960 N {200 kg} Heating temperature: Min. 100 °C Heating tank Capacity: Min. 500 x 500 x 500 Drying of cleaned parts Compressed air – Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm PC130-8...
Page 869 (110), and snap ring (145) to cylinder block (104). Used to remove spring (114) from cyl- inder block (104). Push tool [6] Used to press fit ball bearing (24) to hub (1). No. 2 holder [3] Used to remove ball bearing (149) from shaft (102). PC130-8...
Page 870 (2), and hub (1). hub (1) and spindle (2). Dimension (A) Spindle Travel motor No. 3 mounting jig [12] Used to install floating seal (29) to spindle (2). Spatula [9] Used to remove timing plate (109) from rear flange (301). PC130-8...
Page 871 50 Disassembly and assembly SEN04128-01 Pin punch [13] Used to remove the outer race from ball bearing (24). PC130-8...
Page 872 Hexagonal socket head bolt PT 1/8 12.3 ± 2.45 {1.25 ± 0.25} Weight table Part No. Part name Weight (kg) — Travel motor assembly Spindle 3 Others Carrier (A) assembly 7 Others Carrier (B) assembly 301 Others Rear flange assembly PC130-8...
Page 873 Once you remove the seals, do not reuse them but replace with new ones. A typical model is used for the illustrations in the following explanation. Even if your machine is partly different from the machine indicated for those illustrations, its assembling procedure is the same. PC130-8...
Page 874 If the drain does not flow out well, loosen the drain plug gradually. a Remove O-ring (31) of plug (30) and do not reuse it. (See "Component parts") a Set the oil container under the travel motor to receive the oil. Final drive case: 2.1 l PC130-8...
Page 875 A (5). (See "Component parts") Removal of lock washers Fix hub (1) to work stand [1] by using hex- agonal socket head bolts. PC130-8...
Page 876 Accordingly, do not hit the but sling it by using a press, etc. inner race unless you are replacing the ball bearing. a Spread a rubber mat under ball bear- ing (24) which falls when the outer race is released from hub (1). PC130-8...
Page 877 If you pry off or hit rear flange (301), timing plate (109) may fall to be dam- aged. Take care. (See "Component parts") Loosen two plugs (380), two plugs (352), and plug (357). Remove two dowel pins (34) from spindle (2). PC130-8...
Page 878 If you use a sharp tool such as a flat- head screwdriver, you may scratch mating face (a). Accordingly, do not 14. Disassembly of brake valve use such a tool. Remove two plugs (324) from rear flange (301). PC130-8...
Page 879 Do not reuse removed O-rings (336). Remove piston (381) from rear flange (301). 15. Disassembly of 2nd travel speed selector spool Remove plug (357) from rear flange (301). Remove O-ring (359) from plug (357). a Do not reuse removed O-ring (359). (See "Component parts") PC130-8...
Page 880 (112) jumps out, and that is dangerous. Accordingly, blow compressed air gradually. Place protective cover (19) for safety in advance. Remove O-rings (135) and (139) from pis- ton (112). a Do not reuse removed O-rings (135) and (139). PC130-8...
Page 881 Remove three needles (151) from cylinder joined by drawing the shoe over the block (104). spherical portion of the piston. a Replace piston (105) and shoe (109) together always. (Hereinafter, this assembly is referred to as the piston assembly) PC130-8...
Page 882 (149), too. (See "Component parts") a Shaft (102) can be removed easily by hitting it lightly from the final drive side with a plastic hammer. Remove two pivots (167) and two dowel pins (171) from spindle (2). (See "Compo- nent parts") PC130-8...
Page 883 (29) and oil seal (132). (See "Compo- Set No. 2 holder [3] on the press stand nent parts") and set shaft (102) in it. Push out shaft (102) from ball bearing (149) with the press. a Do not reuse ball bearing (149). PC130-8...
Page 884 Dry the inside of hub (1) and spindle (2) by blowing air against them in a clean and dry place. Dry the travel motor parts and gears natu- rally in a clean and dry place. a After drying the parts, apply power train oil (TO30) to them. PC130-8...
Page 885 • Both end faces are worn unevenly. Braking torque: Braking torque: Disc Min. Min. • Specified torque is not obtained. Plate 206 Nm {21.0 kgm} 206 Nm {21.0 kgm} • Parts are seized. Piston — — • There is scratch on outside surfaces. PC130-8...
Page 886 — — assembly • Shoe is worn abnormally and unevenly. (Piston + Shoe) • Outside surface is worn unevenly. Spool — — • There is scratch on outside surfaces. Piston — — • There is scratch on outside surfaces. PC130-8...
Page 887 10) A typical model is used for the illustrations in the following explanation. Even if your machine is partly different from the machine indicated for those illustrations, its assembling procedure is the same. PC130-8...
Page 888 (29) is 1 mm (37) will be positioned symmetrically. or below. Spindle (2): 30 kg a Securely tighten the two hexagonal socket head bolts (to prevent the travel motor assembly from falling off the work stand when it is reversed). PC130-8...
Page 889 "Component parts") ball bearing (24) to prevent them from floating. Select shim (23) from the following table so that clearance (e) will be +0.13 to +0.17 Clearance (e) = Dimension (c) – (d) Symbol Thickness (mm) Symbol Thickness (mm) PC130-8...
Page 890 Apply power train oil (TO30) to the sliding part of piston assembly and install it to the piston hole of spindle (2). Install two dowel pins (171) to the pin holes on the rear flange mating face of spindle (2). (See "Component parts") PC130-8...
Page 891 Install swash plate (103) to shaft (102). Mating faces of spindle (2) and swash plate (103): Grease (G2-LI) a Install two pivots (167) while aligning them with the mounting holes of the swash plate (103). (See "Component parts") PC130-8...
Page 892 (106)) and retainer plate (107) together to cylinder block (104). a Hold and install retainer plate (107) with both hands. a Securely contact the retainer plate (107) with the spherical portion of thrust ball (108). (See "Component parts") PC130-8...
Page 893 O-ring (359): Grease (G2-LI) Install discs (115) and plates (116) alter- nately to cylinder block (104). (See "Com- ponent parts") a Soak discs (115) in power train oil (TO30) in advance. PC130-8...
Page 894 (323) or spool hole of rear flange (301) is scratched, oil may leak and travel motor performance may be decreased. Install two O-rings (336) to two plugs (342). O-ring (336): Grease (G2-LI) Install two washers (325) and two springs (328) to two plugs (324). PC130-8...
Page 895 ( 3 0 1 ) a r e s t u c k w i t h t h e grease. a Perform this step to prevent timing plate (109) from falling when rear flange (301) is installed to spindle (2). (See "Component parts") PC130-8...
Page 896 Supply oil to spindle (2). In spindle (2) (Power train oil): 1.0 l (TO30) Tighten ten hexagonal socket head bolts (343) to rear flange (301). Hexagon socket head bolt (343): 102 ± 15.7 Nm {10.4 ± 1.6 kgm} PC130-8...
Page 897 (301) are shown in the following fig- ure. Port (f): For hydraulic piping Hole (g): For 2nd travel speed selection piston 16. Installation of relief valve assembly Tighten two relief valve assemblies (18). Relief valve assembly (18): 98.1 ± 19.6 Nm {10.0 ± 2.0 kgm} PC130-8...
Page 898 A (5). 20. Installation of cover Apply liquid adhesive to mating face (h) of hub (1) against cover (14). Mating face (h): Adhesive (LOC- TITE No. 515 or equivalent) a Apply liquid adhesive continuously. PC130-8...
Page 899 Install eyebolts [8] to the threaded holes of spindle (2) and lift off the travel motor assembly. Travel motor assembly: 150 kg 21. Adding oil Add oil through oil filler port (j). Final drive case: 2.1 l PC130-8...
Page 900 Check test --------- Measure the following items at low speed and judge the result. Criteria acceptance: Difference in travel motor drive pressure ----- Max. 1.57 MPa {16 kg/cm }/10 rpm Draining rate from hydraulic motor: Max. 1.2 l/min/10 rpm Accepted Rejected Install tracks Disassemble and adjust again PC130-8...
Page 901: Removal And Installation Of Swing Motor And Swing Machinery Assembly
Remove lower cover (1). Using forcing screw [1], disconnect swing motor and swing machinery assembly (9) from the machine. Loosen hydraulic oil drain plug (2) and drain the hydraulic oil. Hydraulic tank: 90 l (Specified quantity of oil): 145 l PC130-8...
Page 902 Bleeding air a Bleed air from the piping, referring to "Bleeding air from each part" in Testing and adjusting. [*1] Wing machinery mounting bolt: 303.8 – 362.6 Nm {31 – 37 kgm} PC130-8...
Page 903: Disassembly And Assembly Of Swing Machinery Assembly
796T-426-1140 Push tool assembly (5). 790-201-2680 Plate Disassembly Oil drain Remove the drain plug and drain oil from the swing machinery. Swing machinery case: 2.5 l Swing motor assembly Remove oil level pipe (1). Remove 15 swing motor mounting bolts (2). PC130-8...
Page 904 Set the shaft and case assembly to the press, and push 2-piece collar (27) using a push tool to press bearing (28). Remove 2-piece collar (27). Ring gear Remove ring gear (16). Carrier No. 2 assembly Remove spacer (17). Remove carrier No. 2 assembly (18). PC130-8...
Page 905 [2], and remove shaft assembly (30) with the press using push tool [3]. Remove bearing (28). Use tool F2 to remove bearing (31) and collar (32) from shaft (33). Oil seal and bearing outer race Remove oil seal (34) from case (35). PC130-8...
Page 906 Use push tool F5 to press bearing (28) with the press to the position where the 2- piece collar can be entered. a Press-fit force: 11,760 N {1,200kg} a Press the bearing gradually by rotat- Retainer ing the case. Install retainer (26). PC130-8...
Page 907 Insert the pin, then caulk the pin of the carrier. a Check that difference (a) between Install carrier No. 2 assembly (18) to the the shaft and carrier is 0.2 mm or shaft and case assembly. less. Install spacer (17). PC130-8...
Page 908 Tighten the drain plug, and refill engine oil E030 from the oil filler port. Swing machinery case: 2.5 l Install carrier No. 1 and sun gear No.2 assembly (5) to the shaft case assembly. Install sun gear No. 1 (4). PC130-8...
Page 909: Removal And Installation Of Swing Circle Assembly
"S" symbol (a) of the inner race facing the right remove the 38 mounting bolts. [*1] side of the body as shown in the figure. Amount of circle grease sealed: 9.1 l Remove swing circle assembly (1). [*2] grease (G2-LI) Swing circle assembly : 155 kg PC130-8...
Page 911 SEN04129-02 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 50 Disassembly and assembly Undercarriage and frame Disassembly and assembly of track roller....................... 2 Disassembly and assembly of idler assembly ....................5 Disassembly and assembly of recoil spring ....................8 Spreading and installation of track shoe assembly ..................11...
Page 912: Disassembly And Assembly Of Track Roller
1 N Q 2 796T-430-1220 Installer 791-601-1000 Oil pump Disassembly Remove pin (1), then remove collar (2). Remove collar (8) from shaft (5). Remove bushings (9) and (10) from roller (4). Remove floating seal (3) from collar (2) and roller (4). PC130-8...
Page 913 Standard pressure: 0.1 MPa {1 kg/cm²} a Method of checking: The standard pressure shall be main- tained for 10 seconds and the indicator of the gauge shall not go down. PC130-8...
Page 914 50 Disassembly and assembly 10. Using tool M3, fill track roller assembly with oil, then tighten plug (11). Track roller oil: 145 – 155 cc (EO30-DH) Plug: 15 ± 5 Nm {1.5 ± 0.5 kgm} (P: To oil pump, T: To tank) PC130-8...
Page 915: Disassembly And Assembly Of Idler Assembly
It is filled with approx. 90 cc of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. Remove floating seal (6) (on opposite side) from idler (4) and shaft (5) and support assem- bly (7). PC130-8...
Page 916 O-ring and the floating with oil, and be careful not to let any dirt or seal. dust get stuck to it. a Remove all grease and oil from the con- tact surface of the O-ring and the floating seal. PC130-8...
Page 917 Using tool M3 apply standard pressure to roller oil filler port and check air leakage. a Standard pressure: 0.1 MPa {1 kg/cm a Method of checking: The standard pressure shall be main- tained for 10 seconds and the indicator of the gauge shall not down. PC130-8...
Page 918: Disassembly And Assembly Of Recoil Spring
790-201-1500 Push tool kit a Installed load of spring: • Plate 790-201-1590 84,300 N {8,600 kg} (outside: ø75) 790-101-5021 • Grip 01010-50816 • Bolt 790-201-1702 Push tool kit 780-201-1780 • Push tool 790-101-5021 • Grip 01010-50816 • Bolt PC130-8...
Page 919 Remove pilot (8), and spring (7). Remove snap ring (10), dust seal (11) and bush (12) from cylinder (9). Disassembly of yoke piston (5) assembly Remove snap ring (14), then remove U- packing (15). Remove wear ring (16) from yoke piston (13). PC130-8...
Page 920 Apply hydraulic pressure slowly to com- Fill inside of cylinder with a approximately 120 press spring, and tighten nut (6) so that cc of grease. installed length of spring is dimension Inside cylinder: Grease (G2-LI) (a). a Installed length (a) of spring: 390 mm PC130-8...
Page 921: Spreading And Installation Of Track Shoe Assembly
(3) to decrease the track shoe tension. [*1] Since the internal pressure of the adjustment cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not come out sufficiently, move the machine forward and in reverse. PC130-8...
Page 922 If the rubber part of the road liner specification (rubber pad type) is worn and broken to dam- age the mounting bolt heads, replace the shoe with new one immediately. If the bolt heads are crushed, the bolts cannot be removed. PC130-8...
Page 923: Removal And Installation Of Sprocket
Swing the work equipment by 90° and push up 323.6 – 362.8 Nm {33 – 37 kgm} the machine with it, and then set blocks [1] between the track frame and track shoe. 3.Remove the 15 mounting bolts and lift off sprocket (1). [*1] Sprocket: 35 kg PC130-8...
Page 924: Removal And Installation Of Revolving Frame Assembly
"Removal of operator cab assembly". a Carefully lift and remove them to prevent them from coming in contact with the cen- ter swivel joint or other parts. Revolving frame assembly: 6,100 kg PC130-8...
Page 925 Supply oil from the oil filler port to the specified level, start the engine to circulate oil in the pip- ing and recheck the oil level. Bleeding air Bleed the air. For details , see Testing and adjusting, "Bleeding air from each part". PC130-8...
Page 926: Removal And Installation Of Counterweight Assembly
Move the counterweight backward at first so that it will not interfere with the machine and then lift it up. Counterweight assembly (PC120-8): 2,300 kg Counterweight assembly (PC130-8): 2,500 kg Remove cover (2). Disconnect monitor camera wiring connector A40 (3).
Page 927 50 Disassembly and assembly SEN04129-02 Installation Carry out installation in the reverse order to removal. [*1] Counterweight mounting bolt: Adhesive (LT-2) Counterweight mounting bolt: 1,177 – 1,470 Nm {120 – 150 kgm} Target: 1,324 Nm {135 kgm} PC130-8...
Page 929 SEN04130-01 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 50 Disassembly and assembly Hydraulic system Removal and installation of center swivel joint assembly ................2 Disassembly and assembly of center swivel joint assembly ................4 Removal and installation of hydraulic tank assembly..................5 Removal and installation of work equipment pump assembly ................
Page 930: Removal And Installation Of Center Swivel Joint Assembly
Remove undercover (1). Disconnect hoses (for changing the speed) (18) and (19) between both travel motors and swivel joint. Loosen hydraulic oil drain plug (2) and drain the hydraulic oil. [*1] Hydraulic tank: 90 l (Specified quantity of oil): 145 l PC130-8...
Page 931 (Specified quantity of oil): 145 l Mounting bolt screw: Liquefied adhesive (LT-2) Mounting bolt: 98.1 – 123.0 Nm {10.0 – 12.5 kgm} Bleeding air Bleed air from the swing motor. For details, see Testing and adjusting, "Bleeding air from each part". PC130-8...
Page 932: Disassembly And Assembly Of Center Swivel Joint Assembly
Using tool T1, pull out swivel rotor (4) and ring Fit O-ring and install cover (1). (3) from swivel shaft (5). Swivel joint mounting bolt : 31.3 ± 2.9 Nm {3.2 ± 0.3 kgm} Remove O-rings (6) and slipper seals (7) from swivel shaft (5). PC130-8...
Page 933: Removal And Installation Of Hydraulic Tank Assembly
Remove fuel tank side cover (13). Open and lock engine hood (14). Remove undercover (1). Loosen hydraulic oil drain plug (2) and drain the hydraulic oil. [*1] Hydraulic tank: 90 l (Specified quantity of oil): 145 l PC130-8...
Page 934 Remove bracket (23). Disconnect 6 hoses (32) – (37). 10) Remove engine oil filter (24) and bracket (25) together. 11) Remove fuel prefilter (26), fuel filter (27) and bracket (28) together. 12) Remove bracket assembly (29). PC130-8...
Page 935 Tighten until dimention (BDG) is 14 – 17 diagonally. Hydraulic tank assembly : 100 kg [*3] Hydraulic oil tank mounting bolt (27): 235 – 285 Nm {23.5 – 29.5 kgm} PC130-8...
Page 936: Removal And Installation Of Work Equipment Pump Assembly
Remove side covers (13) and (14). a Remove mounting bolt (15) of side cover (13), too. 10. Remove partition plate (16). Loosen the damper case drain plug and drain the damper case oil. [*1] Damper case: 0.75 l Open and lock engine hood (3). PC130-8...
Page 937 Disconnect fuel filter assembly (24) from bolts (36), except 1 or 2. bracket (25). Disconnect fuel prefilter assembly (26) and bracket (25) together. 16. Sling work equipment pump (37) and remove remaining mounting bolts (36). 12. Disconnect connectors V11 (27) and P22 (28). PC130-8...
Page 938 50 Disassembly and assembly 17. Lift off work equipment pump (37). a Pull out work equipment pump (37) to this side almost to the end and then pull it out diagonally around the brackets on the right and left sides. PC130-8...
Page 939 Do not use an impact wrench, when tighten the clamp. Clamp bolt (BC): Lubricanting oil (THREE- BOND PANDO 18B) When reusing the hose a Install the clamp to the clamp mark made on the hose. Tighten to torque of at least 6 Nm {0.6kgm} PC130-8...
Page 940: Removal And Installation Of Control Valve Assembly
(16) Control valve (B5) - To arm bottom side a Disconnect hoses (11) – (14) from the control valve. a Disconnect hose (15) from the work equip- ment and then disconnect it from the con- trol valve. Open and lock engine hood (3). PC130-8...
Page 941 (35) (Port PB3). a Hose (35) is connected to the opposite side to connector (39). a Hose (36) is connected to the opposite side to connector (40). 10. Disconnect connectors P25 (38), P09 (39) and P12 (40). PC130-8...
Page 942 Hose (49) is connected to the rear of con- nector (53) and hose (50) is connected to the rear of connector (54). a Disconnect hose (52) from the swing motor. 12. Disconnect connectors P10 (53) and P11 (54). PC130-8...
Page 943 50 Disassembly and assembly SEN04130-01 Installation 14. Remove the 4 bolts on the underside of the control valve mount (59). Carry out installation in the reverse order to removal. 15. Lift off control valve assembly (60). PC130-8...
Page 944: Disassembly And Assembly Of Control Valve Assembly
Tighten bolts (18) in the order of [1] – [4] in 3 times. 1st time: 19.6 – 29.4 Nm {2 – 3 kgm} 2nd time: 39.2 – 49.0 Nm {4 – 5 kgm} 3rd time: 58.8 – 73.5 Nm {6 – 7.5 kgm} PC130-8...
Page 945 50 Disassembly and assembly SEN04130-01 PC130-8...
Page 946 13. Travel junction valve + LS check valve Arm valve 14. Arm regeneration valve Boom valve 15. Boom hydraulic drift prevention valve Right travel valve 16. Merge-divider valve block Left travel valve 17. Cover mounting nut Swing valve 18. Block mounting bolt PC130-8...
Page 947 50 Disassembly and assembly SEN04130-01 PC130-8...
Page 948 15. Suction safety valve (Service 1) 34. Spool return spring 16. Suction safety valve (Service 2) 35. Spool return spring 17. Suction safety valve 36. Spool return spring 18. Spool (Service 2) 37. Spool return spring 19. Spool (Service 1) 38. Spool return spring PC130-8...
Page 949 50 Disassembly and assembly SEN04130-01 PC130-8...
Page 950 16. Pressure compensation valve F (Arm) 17. Pressure compensation valve F (Bucket) 18. Pressure compensation valve F (Service 1) 19. Pressure compensation valve F (Service 2) 20. Check valve spring 21. Check valve spring Flow control valve Pressure reducing valve PC130-8...
Page 951 50 Disassembly and assembly SEN04130-01 PC130-8...
Page 952 20. Merge-divider valve spool 21. Check valve spring 22. Check valve spring 23. Retainer spring 24. Spool return hose 25. Check valve spring 26. Valve return spring 27. Spool return spring 28. Check valve spring Flow control valve R: Pressure reducing valve PC130-8...
Page 953 50 Disassembly and assembly SEN04130-01 PC130-8...
Page 954 13. Suction valve 14. Spool Flow control valve 15. Pressure compensation valve R R: Pressure reducing valve 16. Regeneration valve Bucket valve 17. Pressure compensation valve F 18. Suction valve 19. Suction valve 20. Spool 21. Pressure compensation valve R PC130-8...
Page 955 50 Disassembly and assembly SEN04130-01 PC130-8...
Page 956: Disassembly And Assembly Of Work Equipment Ppc Valve Assembly
Install spring (5) with its small diameter side on the shim (4) side. Diameter of spring (Inside diameter) Small diameter side: ø4.9, Large diameter side: ø5.55 a When installing springs (6) and (7), note that they are different and they must be installed to different hydraulic ports. PC130-8...
Page 957 Apply grease (G2-LI) to the rocking part of joint (12) and the contact surfaces of disc (13) and piston (8). Quantity of grease (G2-LI) Rocking part of joint: 2 – 4 cc/periphery Contact surfaces of disc and piston: 0.3 – 0.8 cc/place PC130-8...
Page 958: Disassembly And Assembly Of Travel Ppc Valve Assembly
Remove shaft (16) bushing (14) (14a) and lever (13) from the case. Remove valve (2) from body (1). Remove mounting bolt (11) to remove plate (10). a Check the thickness and the mounting position of washer (12). a Remove pin (24) from body (1). PC130-8...
Page 959 0.7 a Do not apply shock load to the bush- °. (If the washer thickness is reduced by 0.3 ing directly. mm, the stroke end angle is increased by 0.39 °.) Thickness of washer t: 1.0, 1.3, 1.6 PC130-8...
Page 960 Plug (25): 4 – 9 Nm {0.4 – 0.9 kgm} Screw (22): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Bolt (19): 25 – 30 Nm {2.5 – 3.2 kgm} Bolt (11): 27 – 34 Nm {2.8 – 3.5 kgm} PC130-8...
Page 961: Removal And Installation Of Anti-Drop Valve For Boom Assembly
Anti-drop valve is installed to the bot- tom side of the boom cylinder. When the work equipment is lowered with this posture, the oil in the bottom side of the boom cylinder is drained, and the remaining pressure is low. PC130-8...
Page 962 Then check the oil level again. hydraulic tank. Air bleeding a Leave the oil filler cap of the hydraulic a Bleed air from the hydraulic circuit. See tank removed. TESTING AND ADJUSTING, “BLEED AIR FROM HYDRAULIC CIRCUIT”. PC130-8...
Page 963: Removal And Installation Of Anti-Drop Valve For Arm Assembly
Anti-drop valve is installed to the arm cylinder, its head side. When the work equipment is lowered with this posture, the oil in the head side of the arm cylinder is drained, and the remaining pressure is low. PC130-8...
Page 964 TESTING AND ADJUSTING, “BLEED drop valve and the cylinder is AIR FROM HYDRAULIC CIRCUIT”. released. The remaining pressure may dam- age the O-ring, and the oil may be splashed. Use a waste cloth to pro- tect the fitting and around it. PC130-8...
Page 965: Disassembly And Assembly Of Anti-Drop Valve Assembly
Do not stand in a direction where the inside part may jump out with the reaction force of the spring when removing the bolts (1), (2), and the check valve (3). Otherwise the inside part that will jump out may hit your body. PC130-8...
Page 966: Disassembly And Assembly Of Hydraulic Cylinder Assembly
• Bolt 790-201-1500 Push tool (Kit) 790-201-1620 • Push tool 790-101-5021 • Grip 01010-50816 • Bolt 790-201-1500 Push tool (Kit) 790-201-1630 • Push tool 790-101-5021 • Grip 01010-50816 • Bolt 790-720-1000 Expander 796-120-1650 Ring 07281-01159 Clamp 796-720-1660 Ring 07281-01159 Clamp PC130-8...
Page 967 If tool (U2) is not used, use the Remove piston ring (13). four drill holes (diameter = 10) to Remove the O-ring and backup ring (14). loosen the piston assembly. Remove plunger (5). Arm cylinder and boom cylinder. Remove collar (6). Arm cylinder and boom cylinder. PC130-8...
Page 968 Sub-assembly of cylinder head assembly Press fit bushing (20) using tool U3. Engage buffer ring (19). Engage rod packing (18). Mount dust seal (17) using tool U4 and fix it with snap ring (16). Mount the backup ring and O-ring (15). PC130-8...
Page 969 Be careful not to expand the ring way matches. abutment joint too much. a Remove burrs Ring groove: Grease (G2-LI) flashes on the threaded por- tion with a file. Piston rod assembly Set piston rod assembly (2) on tool U1. PC130-8...
Page 970 (2) end surface (a). Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm} a After tightening the piston, make sure that there is some play with plunger. For the boom and arm cylinders only. PC130-8...
Page 971 Mounting bolt : Cylinder Tightening torque 172 ± 25 Nm {17.5 ± 2.5 Bucket kgm} 270 ± 39 Nm {27.5 ± 4.0 kgm} Boom 172 ± 25 Nm {17.5 ± 2.5 kgm} Blade 270 ± 39 Nm {27.5 ± 4.0 kgm} PC130-8...
Page 973 SEN04131-00 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 50 Disassembly and assembly Work equipment Removal and installation of work equipment assembly .................. 2 PC130-8...
Page 974: Removal And Installation Of Work Equipment Assembly
Sling boom cylinder (11) and lower it onto the block. a Connect the negative (–) battery cable, Disconnect attachment hoses (17) and (18). start the engine, and retract the boom cyl- inder piston. a Disconnect the cable from the negative (–) terminal of the battery again. PC130-8...
Page 975 Work equipment assembly: 1,960 kg Disconnect boom cylinder (11) on the opposite side similarly and lower it onto the block. Remove blind plug (13) of boom foot pin (12). 10. Remove mounting bolts (14) and lock plate (15). 11. Remove toolbox cover (19). PC130-8...
Page 976 "Bleeding air from hydraulic cyl- inder". Refilling with oil (Hydraulic tank) q q q q a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. PC130-8...
Page 977 50 Disassembly and assembly SEN04131-00 PC130-8...
Page 979 SEN04132-01 HYDRAULIC EXCAVATOR PC130-8 Machine model Serial number PC130-8 80001 and up 50 Disassembly and assembly Cab and its attachments Removal and installation of operator's cab assembly ..................2 Removal and installation of operator cab glass (stuck glass) ................. 5 Removal and installation of front window assembly ..................
Page 980: Removal And Installation Of Operator's Cab Assembly
Disconnect connector H15 fixed on the back from the clip. 12. Remove plate (16). Insert key (8), turn it right, and open the out- side-air filter cover. Remove outside-air filter (9). 13. Remove plate (17). 14. Remove lock pin (18) and remove duct (19). PC130-8...
Page 981 21. Disconnect cab wiring intermediate connectors H09(28), H08(29), and H16(30). a Cut tie-wrap. 22. Disconnect radio antenna (31). a (23) is removed plate. 28. Disconnect window washer hose (39). 29. Disconnect harness clamp (40). 30. Haul in antenna (36). PC130-8...
Page 982 Mounting bolt of lock plate (43): 98 – 123 Nm {10 – 12.5 kgm} [*2] Bolt (44): 245 – 309 Nm {25 – 31.5 kgm} 34. Dismount 6 mounting bolts (45) and 4 mount- ing nuts (46). a Check the bolt length beforehand. PC130-8...
Page 983: Removal And Installation Of Operator Cab Glass (Stuck Glass)
(17) : Center trim seal front window assembly is installed to the opera- (18) : Rear glass tor's cab.) a For the procedure for replacing the front win- dow assembly, see “Removal and installation of front window assembly“. PC130-8...
Page 984 Since the wire may be broken by the fric- tional heat, apply lubricant to the wire. Remove the window glass. PC130-8...
Page 985 Apply primer (10). a The using limit of primer is 4 months after the date of manufacture. Do not use the primer after this limit. a Use the primer within 2 hours after un- packing it. PC130-8...
Page 986 After applying the primer, leave it for at least 5 minutes (within 8 hours ) to dry. a Never apply the wrong primer. If the paint primer, etc. is applied by mistake, wipe it off with white gaso- line. PC130-8...
Page 987 (1) to the position as shown in the figure. a Stick dam rubber (6a) additionally to right side window glass (1). Positions to stick additional dam rub- ber to the right side window glass: (f): 50 mm (g): 90 mm (h): 250 mm PC130-8...
Page 988 Do not remove the tapes left on the Stick dam rubber (6) for front window glass (4) to the position as shown in the window glass and the operator's cab figure. before installing the window glass. PC130-8...
Page 989 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part form the nozzle tip. Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle. PC130-8...
Page 990 Apply adhesive (15) additionally to a Press the corners of the window glass additional dam rubber (6a) of right firmly. side window glass and additional dam rubber (6b) of door lower window glass. PC130-8...
Page 991 Wipe off the projected adhesive. Glass primer: Sunstar primer for glass 580 super or equivalent Adhesive: SUNSTAR penguine seal 580 super “S“ or “W“ or equivalent PC130-8...
Page 992 14 hours, that is, at least 24 hours in total, before operating the machine actually. By using styrene foam blocks [9] and rub- ber bands [10], fix the window glass and the dam rubber to fit them completely. PC130-8...
Page 993: Removal And Installation Of Front Window Assembly
2. (the portion where the rail is open) and hold them. Remove rollers (5) and (6) under the both sides of the front window. PC130-8...
Page 994 (12) from the rails, and then remove front win- dow assembly (10). Pull out the bottom of front window assembly (10) though the rail opening portion and lower it gradually. Lower front window assembly (10) completely. a Do not let the front window assembly touch the monitor. PC130-8...
Page 995 (on both sides). a Check that the locks in the rear of the operator's cab are securely fastened. Install right corner block (2). a Fully tighten the block after adjusting the “Close“ position in the following step 6. PC130-8...
Page 996 Repeat the work in 1] and 2] until the fitness of the front window glass and the working condition of locks (16) and (17) are both acceptable, and then tighten the mounting bolts of the right and left corner blocks. PC130-8...
Page 997 “Open“ position. Front window assembly (10) must be pushing the limit switch backward for 4 – 7 mm (at “Open“ position). Working condition of lock (17). After checking the above items, if it becomes necessary to do the adjust- ment. PC130-8...
Page 998 1.5 mm. a When the front window assembly is in “Open“ position, the front window assembly must be push- ing right and left rubber stoppers (18) for 1.5 – 3.0 mm. PC130-8...
Page 999 Check the latching efforts on both “Close“ side (in the front of the oper- ator's cab) and “Open“ side (in the rear of the operator's cab). [*2] Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm} Mounting bolt: Adhesive (LT-2) PC130-8...
Page 1000: Removal And Installation Of Floor Frame Assembly
° Turn the upper structure by 90 Drain the engine coolant. Coolant : Approx. 14 l Remove the operator's cab assembly by refer- ring to “Removal and installation of operator's cab assembly“. Remove cover (1). PC130-8...
Page 1001 16. Disconnect hose (20). a Check the connecting point. a Plug the hose to stop oil flow-out. 17. Disconnect heater hose (21). a Check the connecting point. 18. Remove mounting bolt (22) and disconnect air conditioner tube (23). [*1] PC130-8...

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