Komatsu PC130-8 Shop Manual Download Page 791

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40 Troubleshooting

SEN04125-02

PC130-8

S-4 Engine stops during operations

*1: Displayed failure codes [CA559] and [CA2249]

General causes why engine stops during opera-
tions

Internal parts of engine seized

Insufficient supply of fuel

There is overheating

Defective hydraulic pump

Causes

Brok

namic valve sy

(

alve,

roc

er arm

, et

Brok

en,

seized pist

on,

connec

Brok

en,

seized crank

haf

t bearing

Brok

en,

seized gear t

Ins

fic

ient

uel in

tank

Clogged

air breat

her hol

nk cap

Leaking,

clogged f

piping

Clogging of

uel f

ilt

Clogging f

eed pum

p g

auze

filt

Brok

en,

seized f

pum

Brok

en s

upply pum

shaf

tuc

ed s

pply pum

ung

Brok

en aux

iliary

equipm

ent

(pum

com

ressor

, et

)

Def

tive hydr

aul

pum

Def

tiv

e engine

ont

rol

ler power s

upply

wiring

Def

tiv

e s

tarti

ng s

witc

wiring

ues

ons

Confirm recent repair history

Degree of use of machine

Operated for long period

E E

Condition when engine
stopped

Abnormal noise was heard and engine
stopped suddenly

w w w w

Q w Q w w

Engine overheated and stopped

w Q

Engine stopped slowly

Q Q

There was hunting and engine stopped

w Q

Q Q Q

Q Q

Non-specified fuel is being used

Q Q Q

Replacement of filters has not been carried out according to Operation
and Maintenance Manual

w w

Fuel level monitor indicates low level

When fuel tank is inspected, it is found to be empty

Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping

ck i

tem

Rust and water are found when fuel tank is drained

w w

Metal particles are found when oil pan is drained

w w

Q Q

When engine is cranked by
hand

Does not turn at all

w w

Turns in opposite direction

Moves by amount of gear backlash

Supply pump shaft does not turn

Engine turns, but stops when load is applied to machine

roubleshoot

ing

Inspect dynamic valve system directly

Carry

out

roubleshoo

applicable

machine

Inspect piston, connecting rod directly

Inspect crankshaft bearing directly

Inspect gear train directly

Inspect fuel filter directly

Inspect feed pump gauge filter directly

Inspect feed pump directly

Carry out troubleshooting according to “No-pressure feed by supply
pump (*1)” indicated by code

q q

Engine rotates when pump auxiliary equipment (pump, compressor,
etc.) is removed

Check controller power supply wiring

Check starting switch wiring

Remedy

Rep

lac

Rep

lac

Rep

lac

Rep

lac

Cor

rec

Rep

lac

Rep

lac

Rep

lac

Rep

lac

Rep

lac

—

Cor

rec

Cor

rec

Summary of Contents for PC130-8

Page 1: ...HYDRAULIC EXCAVATOR SEN03763 13 PC130 8 SERIAL NUMBERS 80001 and up ...

Page 2: ......

Page 3: ...PC130 8 1 SEN03765 13 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130 8 Machine model Serial number PC130 8 80001 and up 00 Index and foreword 1 Index Composition of shop manual 2 Table of contents 4 ...

Page 4: ...N03765 13 q Foreword and general information SEN03766 02 01 Specification SEN03767 01 Specification and technical data SEN03768 01 10 Structure function and maintenance standard SEN03769 06 Engine and cooling system SEN03770 01 Power train SEN03771 01 Undercarriage and frame SEN03772 01 Hydraulic system Part 1 SEN03773 00 Hydraulic system Part 2 SEN03774 01 Hydraulic system Part 3 SEN03775 04 Work...

Page 5: ...eral information on disassembly and assembly SEN04126 02 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 Electrical diagrams and drawings SEN03785 ...

Page 6: ... Specification Specification and technical data SEN03768 01 Specification dimension drawings 2 Working range diagram 3 Specifications 4 List of weights 8 List of lubricant and coolant to be filled 10 10 Structure function and maintenance standard Engine and cooling system SEN03770 01 Engine mount 2 PTO 3 Cooling system 4 Power train SEN03771 01 Power train 2 Swing circle 3 Swing machinery 4 Underc...

Page 7: ...esting compression pressure 14 Testing blow by pressure 16 Testing engine oil pressure 17 Reduced cylinder mode operation 18 No injection cranking 18 Handling fuel system parts 19 Releasing residual pressure from fuel system 19 Testing fuel pressure 20 Testing fuel return rate and fuel leakage 21 Bleeding air from fuel circuit 23 Checking fuel circuit for leakage 24 Testing and adjusting alternato...

Page 8: ...ontroller lock caution 1 3 Failure code 989M00 Engine controller lock caution 2 3 Failure code 989N00 Engine controller lock caution 3 4 Failure code AA10NX Air cleaner clogging 5 Failure code AB00KE Charge voltage low 6 Failure code B BAZG Eng oil press low 8 Failure code B BAZK Eng oil level low 9 Failure code B BCNS Eng coolant overheat 10 Failure code B BCZK Eng water level low 12 Failure code...

Page 9: ...2249 Rail press very low error 32 Failure code CA2311 Abnormality in IMV solenoid 33 Failure code D110KB Battery relay drive short 34 Failure code D19JKZ Personal code relay abnormality 36 Failure code D862KA GPS antenna discon 38 Failure code DA22KK Pump solenoid power low error 40 Failure code DA25KP 5V sensor 1 power abnormality 42 Failure code DA26KP 5V sensor 2 power abnormality 45 Failure co...

Page 10: ...by machine monitor are different from applicable machine 31 E 13 Machine monitor does not display some items 31 E 14 Function switch does not work 31 E 15 Auto decelerator does not operate normally 32 E 16 Working mode does not change 33 E 17 Travel speed does not change 34 E 18 Alarm buzzer cannot be stopped 35 E 19 Windshield wiper and window washer do not operate 36 E 20 Power maximizing functi...

Page 11: ...nsumption is excessive or exhaust smoke is blue 17 S 9 Oil becomes contaminated quickly 18 S 10 Fuel consumption is excessive 19 S 11 Oil is in coolant or coolant spurts back or coolant level goes down 20 S 12 Oil pressure drops 21 S 13 Oil level rises Entry of coolant or fuel 22 S 14 Coolant temperature becomes too high overheating 23 S 15 Abnormal noise is made 24 S 16 Vibration is excessive 25 ...

Page 12: ...i drop valve assembly 37 Disassembly and assembly of hydraulic cylinder assembly 38 Work equipment SEN04131 00 Removal and installation of work equipment assembly 2 Cab and its attachments SEN04132 01 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 15 Removal and installation of flo...

Page 13: ...00 Index and foreword SEN03765 13 PC130 8 11 ...

Page 15: ...2 How to read the shop manual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Handling of connectors newly used for engines 20 How to read electric wire code 23 Precautions when carrying out operation 26 Method of disassembling and connecting push pull type coupler 29 Standard tightening torque table 32 Conversion table 36 ...

Page 16: ...ar safety shoes and helmet Do not wear loose work clothes or clothes with buttons missing q Always wear safety glasses when hit ting parts with a hammer q Always wear safety glasses when grinding parts with a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before starting any step of the...

Page 17: ...s and hooks are free from damage Always use slings which have ample capacity and install them to proper places Operate the hoist or crane slowly to prevent the component from hitting any other part Do not work with any part still raised by the hoist or crane 6 When removing a cover which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen th...

Page 18: ... hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in kN kg when hoisting is made with 2 ropes each of which is allowed to sling up to 9 8 kN 1 000 kg vertically at various hanging angles When the 2 ropes sling a load vertically up to 19 6 kN 2 000 kg of ...

Page 19: ...e the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the ground and check safety and then lift it up 9 Consider the travel route in advance and lift up a load to a safe height 10 Place the control switch on a position where it will not be an obstacle to work and ...

Page 20: ...in your eyes or contacts your skin you may lose your sight and your skin may be frozen Accordingly put on safety glasses safety gloves and safety clothes when recover ing or adding the refrigerant Refrigerant gas must be recovered and added by a qualified person 2 Connection 1 When installing the air conditioner cir cuit hoses and tubes take care that dirt dust water etc will not enter them 2 When...

Page 21: ... standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them The troubleshooting is divided by failure modes The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume In this case see the Chassis volume ...

Page 22: ...ed with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are necessary when performing work a Caution Special technical precautions or other precautions for preserving stan dards are necessary when performing work 4 Weight Weight of parts of component or parts Cautio...

Page 23: ... is called the standard size and the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in the text and a table as standard size upper limit of tolerance lower limit of tolerance Example 120 0 022 0 126 q Usually the size of a hole and the size of the shaft t...

Page 24: ... in the standard range 4 Repair limit and allowable value or allow able dimension q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the repair limit q If a part is worn to the repair limit it must be replaced or repaired q The performance and function of a prod uct lowers while it is used A value which the product can be used without ...

Page 25: ...ore likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely to suffer deformation or damage For this reason it is necessary to be extremely careful when handling wiring harnesses 2 Main failures occurring in wiring harness 1 Defective contact of connectors defe...

Page 26: ...er does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short circuited by the water so if any water gets in immediately dry the connector or take other appropriate action before passing electricity through it 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating sur face bet...

Page 27: ...ull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip pull the connector in a parallel direction to the clip for removing stop pers a If the connector is twisted up and down or to the left or right the housing may break 3 Action to take after removing conn...

Page 28: ...s will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For connectors with the lock stopper push in the connector until the stop per clicks into position 3 Correct any protrusion of the boot and any misalignment of the wiring har ness For connectors fitted with bo...

Page 29: ... 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 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 q Disconnection q Connection Example of inco...

Page 30: ...the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use a dryer to dry the connector a Hot air from the dryer can be used but regulate the time that the hot air is used in order not to make the connector or related parts too hot as this will cause deformati...

Page 31: ...nnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the power OFF before discon necting or connecting connectors 2 Before carrying out troubleshooting check that all the related connectors are properly inserted a Disconnect and connect the related connectors s...

Page 32: ...assembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings After any piping or equipment is removed the openings should be sealed with caps tapes or vinyl bags to prevent any dirt or dust from entering If the opening is left open or is blocked with a rag there...

Page 33: ... oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and old oil from the hydraulic circuit Normally flushing is carried out twice primary flushing is carried out with flushing oil and secondary flushing is carried out with the specified hydraulic oil 7 Clea...

Page 34: ...V140 engines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1 toward you a 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 ou...

Page 35: ...the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor with flat head screwdriver 1 pull out connector 3 in the direction of the arrow q 107 114 engines Example Intake air pressure temperature sensor in intake manifold SUMITOMO 04 3 While pressing lock D pul...

Page 36: ...up 4 Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn housing H1 in the direction of the arrow a When connector is unlocked housing H1 becomes heavy to turn 2 Pull out housing H1 in the direction of the arrow a Housing H1 is left on the wiring har ness s...

Page 37: ...icates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since AV and AVS are classified by size nominal No they are not indi cated Table 1 Type Sym bol Material Using temperature range C Example of use Low voltage wire for autom...

Page 38: ...3 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diam eter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0 80 169 0 80 217 0 80 Sectional area mm2 7 95 13 36 20 61 35 19 42 73 54 29 63 84 84 96 109 1 d approx 3 7 4 8...

Page 39: ...e White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White GR Green Red RY Red Yellow GW Green White Sb Sky Blue GY Green Yellow Y Yellow L Blue YB Yellow Black LB Blue Black YG Yellow Green Lg Light green YL Yellow Blue LgB Light green Black YR Yellow Red Lg...

Page 40: ...use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal a Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly ...

Page 41: ...e cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for the first time after repair or long storage follow the same procedure 3 Precautions when completing the operation 1 Refilling with coolant oil and grease q If the coolant has been drained tighten the dra...

Page 42: ...f any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 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 ...

Page 43: ...r 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig 2 3 Hold hose adapter 1 or hose 5 and pull it out Fig 3 a Since some hydraulic oil flows out prepare an oil receiving container 2 Connection 1 Hold hose adapter 1 or hose 5 and insert it in mating ada...

Page 44: ...hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to discon nect it Fig 8 2 Connection q 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 ...

Page 45: ...Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 and 2 pull out whole body 9 to discon nect it Fig 12 2 Connection q Hold the tightening portion and push body 9 straight until the sliding prevention ring contacts contact surface b of the hexag onal port...

Page 46: ... bolts shown in Fig B Values of tightening torques shown in the table for Fig A are applied Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 157 196 16 20 16 24 245 309 25 31 5 18 27 343 427 35 43 5 20 30 490 608 50 62 22 32 662 829 67 5 84 5 24 36 824 1 030 84 105 27 41 1 180 1 470 ...

Page 47: ...dth across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10 12 33 363 480 37 0 49 0 422 43 0 14 42 746 1 010 76 0 103 883 90 0 Nominal No Thread diameter Width across flats Tightening torque Nm kgm mm mm Range Target 08 8 14 5 88 8 82 0 6 0 9 7 35 0 75 10 10 1...

Page 48: ...series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diameter mm Reference 02 19 34 54 3 5 5 5 44 4 5 9 16 18UN 14 3 34 63 3 5 6 5 14 03 22 54 93 5 5 9 5 74 7 5 11 16 16UN 17 5 24 59 98 6 0 10 0 78 8 0 18 04 27 84 132 8 5 13 5 103 10 5 22 13 16 16UN 20 6 05 32 12...

Page 49: ... are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque mm Nm kgm 6 8 2 0 81 0 20 8 10 2 1 02 0 20 10 12 2 1 22 0 20 12 24 4 2 45 0 41 14 36 5 3 67 0 51 Tightening torque Material In cast iron or steel In aluminum Thread size inch Nm kgm Nm kgm 1 16 15 2 1 53 0 20 5 1 0 51 0 10 1 8 20 2 2 04 0 20 15 2 1 53 ...

Page 50: ...o divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches Millimeters to inches B 1 mm 0 03937 in 0 1 2 3 4 5 6 7...

Page 51: ...9 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141 10 143 30 145 51 147 71 149 91 152 12 70 154 32 156 53 158 73 160 94 163 14 165 35 167 55 169 76 171 96 174 17 80 176 37 178 57 180 78 182 98 185 19 187 39 189 60 191 80 194 01 196 21 90 198 42 200 62 2...

Page 52: ...3 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 6 397 8 405 1 412 3 419 5 426 8 60 434 0 441 2 448 5 455 7 462 9 470 2 477 4 484 6 491 8 499 1 70 506 3 513 5 520 8 528 0 535 2 542 5 549 7 556 9 564 2 571 4 80 578 6 585 9 593 1 600 3 607 6 614 8 622 0 629 3 ...

Page 53: ... 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877 1 892 1 906 1 920 1 934 1 949 1 963 1 977 140 1 991 2 005 2 020 2 034 2 048 2 062 2 077 2 091 2 105 2 119 150 2 134 2 148 2 162 2 176 2 190 2 205 2 219 2 233 2 247 2 262 160 2 276 2 290 2 304 2 318 2 333...

Page 54: ...2 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8...

Page 55: ...00 Index and foreword SEN03766 02 PC130 8 41 ...

Page 57: ...NUAL 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: ...700 Bucket capacity m3 0 50 Engine type Komatsu SAA4D95LE 5 Diesel engine Engine rated output Net ISO 9249 SAE J1349 kW HP rpm 68 4 91 7 2 200 Gross SAE J1955 72 1 96 6 2 200 A Overall length Standard specification mm 7 590 B Overall height mm 2 875 C Overall width mm 2 500 D Shoe width mm 500 E Tail swing radius mm 2 190 F Crawler overall length mm 3 610 G Distance between tambler center mm 2 880...

Page 59: ...orking range mm PC130 8 A Maximum digging reach 8 290 B Maximum digging depth 5 520 C Maximum digging height 8 650 D Maximum vertical wall digging depth 4 980 E Maximum dumping height 6 210 F Minimum swing radius of work equipment 2 450 G Maximum reach at ground level 8 170 ...

Page 60: ...e bucket kN kg 93 4 9 520 Swing speed rpm 11 0 Swing max slope angle Degree 20 0 Travel speed Low High km h 2 9 5 5 Gradeability deg 35 Ground pressure kPa kg cm2 39 9 0 41 Dimension Overall length for transport mm 7 590 Overall width mm 2 500 Overall height for transport mm 2 875 Overall height for work mm 2 855 Ground clearance of counterweight mm 895 Min ground clearance mm 400 Tail swing radiu...

Page 61: ...ing speed rpm 1 100 Min fuel consumption ratio g kWh g HPh 224 167 Starting motor 24 V 4 5 kW Alternator 24 V 35 A Battery 1 12 V 64 Ah x 2 Radiator core type 4 array aluminum mesh core Aftercooler core type Aluminum mesh core Undercarriage Carrier roller 1 on each side Track roller 7 on each side Track shoe iron shoe road liner Assembly type triple grouser shoe 43 on each side Assembly type road ...

Page 62: ... Stroke mm 995 Max length between pins mm 2 510 Min length between pins mm 1 515 Arm cylinder Type Reciprocating piston type Cylinder inner diameter mm ø 115 Piston rod diameter mm ø 75 Stroke mm 1 175 Max length between pins mm 2 798 Min length between pins mm 1 623 Bucket cylinder Type Reciprocating piston type Cylinder inner diameter mm ø 95 Piston rod diameter mm ø 65 Stroke mm 885 Max length ...

Page 63: ...01 Specification SEN03768 01 PC130 8 7 ...

Page 64: ...Aftercooler 7 5 Fuel cooler excl fuel 0 53 Revolving frame 1 190 Operator cab 480 Operator seat 35 Fuel cooler excl fuel 105 Hydraulic tank excl hydraulic oil 97 Control valve 95 Counterweight 2 455 Swing motor incl brake valve 20 Swing circle 153 Swing machinery 71 6 Center swivel joint 28 6 Track frame assembly excl track shoe 2 300 Track frame 1 305 Idler assembly 79 x 2 Recoil spring assembly ...

Page 65: ...t kg Machine model PC130 8 Standard specification Serial No 80001 and up Boom assembly 787 Arm assembly 406 Bucket link assembly 122 9 Bucket assembly 980 mm width incl side cutter 454 Boom cylinder assembly 100 3 x 2 Arm cylinder assembly 135 Bucket cylinder assembly 77 8 ...

Page 66: ... 8 List of lubricant and coolant to be filled 1 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 ...

Page 67: ... PC130 8 11 Unit l Reservoir Specified capacity Refill capacity Engine oil pan 11 5 11 0 Swing machinery case 2 5 2 5 Final drive case each side 2 1 2 1 PTO case 0 75 Hydraulic system 145 90 Fuel tank 246 Cooling system 13 9 13 9 ...

Page 69: ... 8 1 SEN03770 01 HYDRAULIC EXCAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Engine and cooling system Engine mount 2 PTO 3 Cooling system 4 ...

Page 70: ...SEN03770 01 10 Structure function and maintenance standard 2 PC130 8 Engine mount 1 ...

Page 71: ... Structure function and maintenance standard SEN03770 01 PC130 8 3 PTO 1 a PTO Abbreviation for Power Take Off 1 Flywheel 2 Coupling 3 Hydraulic pump shaft 4 Drain plug 5 Oil filler plug 6 Oil level plug ...

Page 72: ...SEN03770 01 10 Structure function and maintenance standard 4 PC130 8 Cooling system 1 ...

Page 73: ...r inlet hose 13 Aftercooler outlet hose 14 Fan guard 15 Oil cooler inlet 16 Aftercooler inlet hose 17 Drain cock Specifications Radiator Oil cooler Aftercooler Fuel cooler Core type 4 array aluminum mesh core CF40 Aluminum mesh core Drawn cup Fine pitch mm 3 5 2 3 5 2 4 0 2 4 0 2 Total heat dissipation surface m 27 82 12 96 6 48 x 2 8 79 0 59 Pressure valve cracking pressure kPa kg cm 49 0 14 7 0 ...

Page 75: ...130 8 1 SEN03771 01 HYDRAULIC EXCAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Power train Power train 2 Swing circle 3 Swing machinery 4 ...

Page 76: ...Power train 1 1 Idler 2 Control valve 2a Self pressure reducing valve 3 2nd travel speed select solenoid valve 4 Swing holding brake solenoid valve 5 Travel motor Final drive 6 Hydraulic pump 7 Engine 8 Swing motor 9 Center swivel joint 10 Swing machinery 11 Swing circle ...

Page 77: ...ircle pinion lubrication 4 Outer race 5 Ball 6 Seal 7 Inner race Number of teeth 90 a Inner race soft zone position b Outer race soft zone position Specifications Unit mm No Item Criteria Remedy 1 Bearing clearance Basic clearance Clearance limit Replace 0 5 1 6 2 6 Reduction ratio 90 11 8 182 Grease G2 LI Grease quantity l 9 1 ...

Page 78: ...No 2 planetary carrier 6 No 2 sun gear Number of teeth 17 7 Ring gear Number of teeth 61 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 Specifications Reduction ratio 14 61 14 17 61 17 24 58 Swing reduction ratio 24 58 8 182 201 11 Swing speed rpm 11 0 ...

Page 79: ... 0 15 0 34 0 7 4 Backlash between No 1 plane tary carrier and No 2 sun gear 0 14 0 34 0 7 5 Backlash between No 2 sun gear and No 2 planetary gear 0 13 0 31 0 6 6 Backlash between No 2 plane tary gear and ring gear 0 15 0 34 0 7 7 Backlash between No 2 plane tary carrier and swing pinion 0 08 0 19 0 4 8 Back lash between Swing pin ion and swing circle 0 13 1 16 2 3 9 Outside diameter of oil seal c...

Page 80: ...6 PC130 8 SEN03771 01 10 Structure function and maintenance standard PC130 8 GALEO Hydraulic excavator Form No SEN03771 01 2017 KOMATSU All Rights Reserved Printed in Japan 03 17 01 ...

Page 81: ...EXCAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Undercarriage and frame Track frame 2 Idler cushion 3 Idler 4 Track roller 5 Carrier roller 6 Sprocket 7 Track shoe 8 ...

Page 82: ...vel motor Final drive 7 Sprocket 8 Track roller 9 Idler cushion 10 Track shoe Unit mm No Item Criteria Remedy 1 Length at idler guide Standard size Repair limit Rebuilding Track frame 84 89 Idler support 82 77 Rebuilding or replace 2 Width at idler guide Track frame 185 193 Rebuilding Idler support 183 175 Rebuilding or replace ...

Page 83: ...Cylinder 6 U packing 7 Pilot 8 Nut 9 Valve 10 Grease fitting Specifications Unit mm No Item Criteria Remedy 1 Recoil spring Standard size Repair limit Replace Free length Installed length Installed load Free length Installed load 501 4 390 84 3 kN 8 600 kg 489 75 0 kN 7 650 kg Grease G2 LI Grease quantity cc 118 ...

Page 84: ...building or replace 7 Clearance between idler gear and bushing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 54 0 250 0 280 0 074 0 0 250 0 354 1 5 8 Interference between bushing and link Standard size Tolerance Standard interfer ence Interfer ence limit Shaft Hole 61 0 117 0 087 0 030 0 0 057 0 117 9 Side clearance of idler each side Standard clearance Clearance li...

Page 85: ...ance between Shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole ø 50 0 220 0 240 0 190 0 030 0 250 0 430 1 5 7 Interference between roller and bushing Standard size Tolerance Standard interfer ence Interfer ence limit Shaft Hole ø 54 0 190 0 140 0 030 0 110 0 220 8 Side clearance of track roller each side Standard clearance Clearance limit 0 41 0 90 1 5...

Page 86: ...dard clearance Clearance limit Replace Shaft Hole ø 40 0 055 0 035 0 261 0 200 0 145 0 226 4 Interference between collar and bushing Standard size Tolerance Standard interfer ence Interfer ence limit Shaft Hole ø 47 0 061 0 036 0 025 0 0 011 0 061 5 Side clearance of carrier roller each side Standard clearance Clearance limit 0 363 0 537 1 5 6 Tread thickness at 10 mm from roller outer edge Standa...

Page 87: ...em Criteria Remedy 1 Wear on tooth bottom diameter Standard size Tolerance Repair limit Rebuilding or replace ø 547 4 1 0 2 0 ø 535 2 Wear on tooth tip diameter ø 607 ø 595 3 Wear on tooth tip width 27 22 4 Wear on tooth bottom width 42 1 5 39 5 Thickness at tooth bottom 111 7 0 465 1 160 105 5 ...

Page 88: ...EN03772 01 10 Structure function and maintenance standard 8 PC130 8 Track shoe 1 Triple grouser shoe road liner 1 Triple grouser shoe 2 Road liner a P portion shows the link of bushing press fitting end ...

Page 89: ...andard size Repair limit Repair or replace 86 81 5 Link thickness bushing press fit part 24 19 Replace 6 Shoe bolt pitch 102 4 7 86 4 8 57 9 Link Internal width 52 4 Repair or replace 10 Overall width 35 11 Tread width 30 1 12 Pin projection 3 Adjust or replace 13 Regular bushing projection 3 75 14 Pin overall length 168 15 Bushing overall length master bushing 86 7 16 Spacer thickness 17 Press fi...

Page 90: ...ce Standard interference Adjust or replace Shaft Hole ø 46 0 387 0 347 0 062 0 074 0 285 0 387 22 Interference between regular pin and link ø 30 0 150 0 050 0 198 0 250 0 198 0 400 23 Clearance between regular pin and bushing Standard size Tolerance Standard clearance Shaft Hole ø 30 0 150 0 050 0 830 0 330 0 180 0 830 24 Interference between master pin and link Standard size Tolerance Standard in...

Page 91: ...772 01 PC130 8 11 Triple grouser shoe Unit mm No Item Criteria Remedy 1 Grouser height Standard size Repair limit Rebuilding or replace 20 10 2 Shoe height 29 5 19 5 3 Plate thickness 9 5 4 Grouser bottom length 20 5 20 6 Grouser tip length 14 7 13 8 15 ...

Page 93: ...CAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 1 Hydraulic equipment layout drawing 2 Valve control 4 Hydraulic tank and filter 6 Hydraulic pump 8 ...

Page 94: ...4 Solenoid valve 5 Accumulator for PPC circuit 6 Boom cylinder 7 Hydraulic tank 8 Swing motor 9 Hydraulic pump 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 ...

Page 95: ...10 Structure function and maintenance standard SEN03773 00 PC130 8 3 ...

Page 96: ...R H work equipment control lever for boom and bucket control 6 L H work equipment control lever for arm and swing control 7 L H work equipment PPC valve 8 Lock lever 9 R H work equipment PPC valve 10 Travel lever 11 Travel pedal 12 Travel PPC valve 13 Attachment PPC valve Machine ready for attachment 14 Attachment control pedal Machine ready for attachment 15 Lock pin ...

Page 97: ...10 Structure function and maintenance standard SEN03773 00 PC130 8 5 ...

Page 98: ...nk and filter 1 1 Hydraulic tank 2 Suction strainer 3 Filter element 4 Bypass valve 5 Drain plug 6 Sight gauge 7 Oil filler cap combined with breather Specifications Hydraulic tank capacity l 130 Oil level in hydraulic tank l 90 Bypass valve set pressure MPa kg cm 0 15 0 03 1 53 0 3 ...

Page 99: ... this negative pressure generation seam valve 4 is opened to draw the atmo sphere to the tank Intake valve set pressure 0 0 49 kPa 0 0 005 kg cm Prevention of pressure rise in tank q When the hydraulic circuit is operating the pressure in the hydraulic tank increases as the hydraulic cylinder operates and the oil level and temperature increase in the tank If the pressure in the tank rises above th...

Page 100: ...SEN03773 00 10 Structure function and maintenance standard 8 PC130 8 Hydraulic pump 1 Type HPD56 56 ...

Page 101: ... when the machine is steered q The double pump has simpler structure than the tandem pump BMP Breather mounting port IM PC mode selector current OCP Oil level pick up port OFP Oil filler port P1T Travel deviation control orifice P2T Travel deviation control orifice PA1 Pump discharge port PA1C Pump discharge pressure pick up port PA2 Pump discharge port PA2C Pump discharge pressure pick up port PB...

Page 102: ...SEN03773 00 10 Structure function and maintenance standard 10 PC130 8 1 Shaft 2 Cradle 3 Case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 End cap 10 Servo piston 11 PC valve ...

Page 103: ...stitute the spherical bearing q Rocker cam 4 has flat surface A and shoe 5 is always pressed against this surface while sliding in a circular movement q Rocker cam 4 conducts high pressure oil to the cylinder surface B with cradle 2 which is secured to the case and forms a static pres sure bearing when it slides q Piston 6 carries out relative movement in the axial direction inside each cylinder c...

Page 104: ... way piston 6 slides on the inside of cylinder block 7 so a difference between vol umes E and F is created inside cylinder block 7 q A single piston 6 suctions and discharges the oil by the amount F E q As cylinder block 7 rotates and the volume of chamber E becomes smaller the pressurized oil is discharged q On the other hand the volume of chamber F grows larger and in this process the oil is suc...

Page 105: ... rocker cam 4 slides on the surface while continuing revolving movement q Space of the pressure receiving area of servo piston 12 are not identical on the left side and right side Main pump discharge pressure check valve output pressure PP is always brought to the pressure chamber of the small diameter piston side q Output pressure PEN of the LS valve is brought to the chamber receiving the pressu...

Page 106: ... Control pressure input port 6 Sleeve Function q The LS load sensing valve detects the load and controls the delivery q This valve controls main pump delivery Q according to differential pressure PLS PP PLS called the LS differential pres sure the difference between main pump pres sure PP and control valve outlet port pressure PLS q Main pump pressure PP pressure PLS called the LS pressure coming ...

Page 107: ...ine the position of spool 6 q Before the engine is started servo piston 12 is pushed to the left See the diagram on the right q If the control lever is at the neutral position when the engine is started LS pressure PLS will be set to 0 MPa 0 kg cm2 It is intercon nected to the drain circuit via the control valve spool q Spool 6 is pushed to the left and port C and port D will be connected q Pump p...

Page 108: ...ght by the combined force of LS pressure PLS and the force of spring 4 q When spool 6 moves port D and port E are interconnected and connected to the PC valve q The PC valve is connected to the drain port so the pressure across circuits D and K becomes drain pressure PT The operation of the PC valve is explained later q The pressure at the large diameter end of servo piston 12 becomes drain pressu...

Page 109: ... delivery of servo piston 12 pump pressure PP pushes spool 6 to the left q When spool 6 moves main pump pressure PP flows from port C to port D and from port K it enters the large diameter end of the piston q Main pump pressure PP also enters port J of the small diameter end of the piston but because of the difference in area between the large diameter end and the small diameter end on servo pisto...

Page 110: ...n ship is A0 PP A1 PEN servo pis ton 12 will stop in that position q The swash plate of the pump will be held at the intermediate position Spool 6 will be stopped at a position where the distance of the opening from port D to port E and the dis tance from port C to port D is almost the same q At this point the relationship between the pres sure receiving areas across servo piston 12 is A0 A1 1 2 s...

Page 111: ...hat it may not exceed the engine hose power q If the pump discharge pressure PP1 increases due to increased load during operation this valve decreases the pump delivery q And if the pump delivery pressure goes low it increases the pump delivery q In this case relation between the mean average discharge pressure of the pump PP1 PP2 2 and the pump delivery Q will becomes as shown in the diagram if t...

Page 112: ...to output the signal pressure in order to modify the force pushing piston 2 q Spool 3 stops at a position where the com bined spool pushing force is balanced by the setting force of springs 4 and 6 as well as the pump pressures PP1 check valve output pressure and PP2 shuttle valve output pres sure q The pressure port C pressure output from PC valve is changed depending on the above position q The ...

Page 113: ...10 Structure function and maintenance standard SEN03773 00 PC130 8 21 ...

Page 114: ...nds or compresses springs 4 and 6 q If the command current X to PC EPC valve solenoid 1 changes so does the force push ing piston 2 q Spring load of springs 4 and 6 is also affected by the command current X to PC EPC valve solenoid q Port C of the PC valve is connected to port E of the LS valve q Check valve output pressure PP1 enters port B and the small diameter end of servo piston 9 and shuttle...

Page 115: ...mes weaker q As the spring force is weakened spool 3 moves to the left the connecting between port C and port D is shut off and the pump dis charge pressure ports B and C are con nected q As a result the pressure on port C rises and the pressure on the large diameter end of the piston also rises Thus the rightward move of servo piston 9 is stopped q Servo piston 9 stop position Pump deliv ery is d...

Page 116: ... and D through LS valve At the end this flow level of this pressure becomes approximately half of the main pump pressure PP Operation q When port E and port G of the LS valve are connected this pressure from port J enters the large diameter end of servo piston 9 stopping servo piston 9 q If main pump pressure PP increases further and spool 3 moves further to the left main pump pressure PP1 flows t...

Page 117: ...because springs 4 and 6 form the double springs q The relationship between the average pump pressure PP1 PP2 2 and average pump delivery Q becomes as shown below q If command current X sent to PC EPC valve solenoid 1 increases further the relationship between average pump pressure PP1 PP2 2 and pump delivery Q is proportional to the force of the PC EPC valve solenoid and moves in parallel q Namely...

Page 118: ...SEN03773 00 10 Structure function and maintenance standard 26 PC130 8 2 As the emergency pump drive switch is turned on due to failure on the pump controller 1 When the main pump is under light load ...

Page 119: ...oid 1 q The current becomes constant so the force pushing piston 2 is also constant q If the main pump pressures PP1 and PP2 are low the combined force of the pump pres sure and the PC EPC valve solenoid 1 is weaker than the spring set force so spool 3 is balanced at a position to the right q The port C is connected to the drain pressure of the port D and the large diameter end of the servo piston...

Page 120: ...SEN03773 00 10 Structure function and maintenance standard 28 PC130 8 2 When the main pump is under heavy load ...

Page 121: ... at the position in the figure above q In this case the pressure from port A flows to port C so servo piston 9 moves to the left smaller pump delivery and stops at a position to the further to the left then when the load on the pump is light q When the emergency pump drive switch is turned on too the pump pressure PP and pump delivery Q have a relationship as shown with the curve in the figure cor...

Page 122: ...SEN03773 00 10 Structure function and maintenance standard 30 PC130 8 PC EPC valve C To PC valve P From self pressure reducing valve T To tank 1 Connector 2 Coil 3 Body 4 Spring 5 Spool 6 Rod 7 Plunger ...

Page 123: ...e in proportion to the size of the signal and outputs it to the PC valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the controller to coil 2 coil 2 is de ener gized q Spool 5 is pushed to the left by spring 4 q Port P closes and the pressurized oil from the self pressure reducing valve does not flow to the PC valve q The pressurized oil...

Page 124: ...nd port T are connected q Spool 5 moves up and down so that the pro pulsion force of plunger 7 may be balanced with pressure of port C spring load of spring 4 q The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the size of the signal current 3 When signal current is maximum coil is energized q As the signal current flows to coil 2 coil 2 is energized q When...

Page 125: ...2 Poppet valve Function q A set of 2 check valves is used to select and output the higher discharge pressure of the 2 main pumps Operation 1 When PA1 PA2 q Discharge pressures PA1 and PA2 of the main pumps are applied to poppet valves 1 and 2 Since PA1 PA2 however poppet valve 2 is kept closed and PA1 is output to PP1 2 When PA1 PA2 q Reversely to 1 poppet valve 1 is kept closed and PA2 is output ...

Page 126: ...The shuttle valve selects and outputs the lower discharge pressure of the 2 main pumps Operation q The discharge pressures PA1 and PA2 of the 2 main pumps are applied to poppet valves 1 and 2 respectively q 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 q Accordingly lower dischar...

Page 127: ...10 Structure function and maintenance standard SEN03773 00 PC130 8 35 ...

Page 128: ...36 PC130 8 SEN03773 00 10 Structure function and maintenance standard PC130 8 GALEO Hydraulic excavator Form No SEN03773 00 2007 KOMATSU All Rights Reserved Printed in Japan 11 07 02 ...

Page 129: ...774 01 HYDRAULIC EXCAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 2 Control valve 2 CLSS 12 Functions and operation by valve 16 ...

Page 130: ...avel reverse PPC valve PA4 From boom raise PPC valve PA5 From arm dump PPC valve PA6 From bucket dump PPC valve PA7 From attachment 1 PPC valve PA8 From attachment 2 PPC valve PB1 From swing left PPC valve PB2 From left travel reverse PPC valve PB3 From right travel forward PPC valve PB4 From boom lower PPC valve PB5 From arm in PPC valve PB6 From bucket curl PPC valve PB7 From attachment 1 PPC va...

Page 131: ...10 Structure function and maintenance standard SEN03774 01 PC130 8 3 ...

Page 132: ...SEN03774 01 10 Structure function and maintenance standard 4 PC130 8 ...

Page 133: ...Check item Criteria Remedy 28 Suction valve spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installed length Installed load Free length Installed load 46 8 7 5 40 6 5 49 N 0 56 kg 4 41 N 0 45 kg 29 Piston return spring 72 7 20 6 42 5 135 N 13 8 kg 108 N 11 0 kg 30 Suction valve spring 39 2 4 45 33 5 5 1 N 0 52 kg 4 12 N 0 42 kg 31 Spool return s...

Page 134: ...SEN03774 01 10 Structure function and maintenance standard 6 PC130 8 ...

Page 135: ...ure compensation valve F Left travel 13 Pressure compensation valve F Right travel 14 Merge divider valve spool 15 Pressure compensation valve F Boom 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 F Flow control valve R Pressure reducing valve Unit mm No Check item Criteria Remedy 20...

Page 136: ...SEN03774 01 10 Structure function and maintenance standard 8 PC130 8 ...

Page 137: ...er valve spool F Flow control valve R Pressure reducing valve Unit mm No Check item Criteria Remedy 21 Check valve spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installed length Installed load Free length Installed load 23 3 12 5 23 3 92 N 0 4 kg 3 14 N 0 32 kg 22 Check valve spring 21 9 5 15 8 1 96 N 0 2 kg 1 57 N 0 16 kg 23 Retainer spring 9...

Page 138: ...SEN03774 01 10 Structure function and maintenance standard 10 PC130 8 ...

Page 139: ...sure compensation valve R Service valve 1 22 Pressure compensation valve F 23 Suction safety valve 24 Suction safety valve 25 Spool 26 Pressure compensation valve R Service valve 2 27 Pressure compensation valve F 28 Suction safety valve 29 Suction safety valve 30 Spool 31 Pressure compensation valve R F Flow control valve R Pressure reducing valve Unit mm No Check item Criteria Remedy 32 Valve re...

Page 140: ...uenced by load q Controllability enabling digging even with fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q Energy saving using variable pump control Configuration q CLSS is configured with variable capacity piston pumps control valves and respective actuators q The hydraulic pump is configured with pump body PC...

Page 141: ...s constant q LS differential pressure PLS Pump discharge pressure PP LS pressure PLS q The pump swash plate angle shifts toward the maximum position if LS differential pressure PLS is lower than the set pressure of the LS valve when the actuator load pressure is high q If it becomes higher than the set pressure when the actuator load pressure is low the pump swash plate angle shifts toward the min...

Page 142: ...e of the control valve to bal ance the load q When actuators are operated together the pressure difference P between the upstream inlet port and downstream outlet port of the spool of each valve becomes the same regardless the size of the load pres sure q The flow of oil from the pump is divided com pensated in proportion to the area of opening S1 and S2 of each valve ...

Page 143: ...10 Structure function and maintenance standard SEN03774 01 PC130 8 15 ...

Page 144: ...SEN03774 01 10 Structure function and maintenance standard 16 PC130 8 Functions and operation by valve 1 Hydraulic circuit diagram and the name of valves 1 ...

Page 145: ...ice 2 spool 17 Pressure compensation valve 18 Suction valve 19 LS selector valve 20 Merge divider valve 21 Arm regeneration valve 22 Self pressure reducing valve 23 Travel junction valve 24 Lift check valve 25 Cooler bypass valve 26 Boom hydraulic drift prevention valve 27 Swing bleeding valve 28 Suction safety valve Set pressure 36 8 MPa 375 kg cm 29 Suction safety valve Set pressure 24 5 MPa 250...

Page 146: ...sures P1 and P2 are merged LS pressures LS1 LS2 and LS3 are also merged Operation q Pump discharge pressures P1 and P2 are applied to pump pressure receiving SA face of unload spool 1 q LS pressures LS1 and LS2 are applied to LS pressure receiving SB face P1 P2 LS1 LS2 q When the control valve is at HOLD LS pres sures LS1 and LS2 are not generated so only pump discharge pressures P1 and P2 act and...

Page 147: ...lve is at the merge position pump discharge pressures P1 and P2 are merged LS pressures LS1 LS2 and LS3 are also merged Operation q When any work equipment valve is operated for a long stroke LS pressures LS1 and LS2 are generated and act on the face SB of unload spool 1 P1 P2 LS1 LS2 q For this reason the difference between pump discharge pressure P1 and P2 and LS pres sure LS1 and LS2 does not r...

Page 148: ...of the pump becomes maximum so the pump discharge amount becomes maximum For details see the sec tions on the pump merge divider valve Operation q When fine control is carried out on both travel valves LS pressures LS1 and LS2 are gen erated and act on the face SB of spool 1 P1 P2 LS1 and LS2 are separated q When the difference between pump discharge pressure P1 and P2 and LS pressure LS1 and LS2 ...

Page 149: ... becomes maximum For details see the sec tions on the pump merge divider valve Operation q When both travel valves are operated to the stroke ends LS pressures LS1 and LS2 are generated and act on the face SB of unload spool 1 P1 P2 LS1 and LS2 are sep arated q The area of the openings of both travel valve spools is large so LS pressures LS1 and LS2 are not so different from pump discharge pressur...

Page 150: ... end and right one is at HOLD q 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 q The area of the openings of left travel valve spool is large so LS pressures LS1 is not so different from pump discharge pressures P1 q For this reason the difference between pump discharge pressure P1 and LS pressure LS1 does not reach t...

Page 151: ...10 Structure function and maintenance standard SEN03774 01 PC130 8 23 ...

Page 152: ... divider valve 1 When oil is merged PS 0 kg cm2 Function q Pump discharge pressures P1 and P2 are merged in pump merge divider spool 3 LS1 LS2 and LS3 are also merged q At this time P1 P2 and LS1 LS2 LS3 and the pump swash plate is controlled by the difference between P and LS ...

Page 153: ...e pressures P1 and P2 are divided in pump merge divider spool 3 LS1 LS2 and LS3 are also divided q 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 q As a result there is not difference between P and LS and the pump swash plate is set to the maximum position ...

Page 154: ...pool and bridge pas sage b to actuator circuit A q 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 q When this happens LS circuit PLS is con nected to tank circuit T from LS bypass valve 4 See the section on the LS bypass valve q The areas at both ends ...

Page 155: ...ure PP flows from flow control valve 2 through notch a in the spool and bridge pas sage b to actuator circuit A q 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 ...

Page 156: ...ssure PLS q This lowers the rising speed of LS pressure PLS In addition the discarded throttled flow causes a pressure loss in the throttled flow in the reducing valve and that lowers the effec tive LS differential pressure to improve the sta bility Operation q Since pump merge divider spool 1 is at the merge position the hydraulic oil in LS circuits PLS1 PLS2 and PLS3 flows from tip filter a of L...

Page 157: ...nly one travel valve Operation q Since pump merge divider spool 1 is at the separate position LS circuits PLS1 and PLS2 are separated q The hydraulic oil PLS1 flows from tip filter a of LS bypass valve 2 through orifice b to tank circuit T q The hydraulic oil PLS2 flows from tip filter c of LS bypass valve 3 through orifice d to tank circuit T ...

Page 158: ...SEN03774 01 10 Structure function and maintenance standard 30 PC130 8 Pressure compensation valve ...

Page 159: ...another actuator is applied to the spring chamber PLS1 and pushes the pressure reducing valve 1 and the flow control valve 2 to the left side q The flow control valve 2 throttles the opening area between the pump circuit PP and the spool upstream PPA and causes a pressure loss between PP and PPA q The flow control valve 2 and the pressure reducing valve 1 balance each other where the pressure diff...

Page 160: ...of the piston 3 S2 Area of the pressure reducing valve 1 area of the piston 3 Area ratio S1 S2 and compensation charac teristics q When the ratio is 1 00 The expression Pump discharge pres sure PP Spool notch upstream pres sure PPB C LS circuit pressure PLS Actuator circuit pressure PA A can be held and the flow is distributed as per the spool opening area ratio q When the ratio is more than 1 00 ...

Page 161: ... this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed Operation q 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 q At the time part of the return flow on the bot tom side passes through the regeneration pas sage a of the boom spool 2 pushes the chec...

Page 162: ...is in the load process the check valve 3 will be closed and the circuits on the head side and the bottom side will be interrupted Operation q 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 q At the time the head side pressure B and the spring 4 close the check valve 3 and the circuits on the head side and t...

Page 163: ...her than the bottom pressure B during arm digging this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed Operation q 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 q At the time part of the return flow on the head side passes through the regeneration passa...

Page 164: ...pressure B of the cylinder 1 rises above the head pressure A and the arm enters the digging process the check valve 3 will be closed and the circuits on the head side and the bottom side will be inter rupted Operation q 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 t...

Page 165: ...ated the hydraulic drift prevention valve prevents pres surized oil from leaking from the boom bottom through spool 1 to prevent the boom from drifting hydraulically Operation q If the boom is raised out the main pressure from the control valve pushes up poppet 5 As a result the main pressure from the control valve flows through the valve into the boom cylinder bottom ...

Page 166: ...ral Operation q If the control lever is returned to the neutral position while the boom is raised out the hold ing pressure in the boom cylinder bottom and arm cylinder head is blocked by poppet 5 and the pressurized oil flowing in through orifice a is blocked by pilot spool 3 Accordingly the boom is held ...

Page 167: ...and the pressurized oil in chamber b in the poppet is drained q The pressurized oil in port Ab is raised by the pressurized oil from the boom cylinder bottom but the pressurized oil in chamber b is low ered by orifice a q 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 ...

Page 168: ...pump circuit PP bleed off circuit and LS circuit are connected through piston 2 q Bleeding spool 3 moves to the left in propor tion as swing 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 q Accordingly the intermediate pressure is se...

Page 169: ...the boom RAISE speed from reducing by securing the pump flow at the time of swing drive Operation q The pilot pressure is not generally applied to the pilot port BP except for boom RAISE operation q In this state the pump discharge pressure 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...

Page 170: ...and reaches a pressure that is stron ger than the spring 3 the piston 2 will be pushed to the left side the valve 1 will close and the pump discharge pressure PP will not come to flow to the pressure reducing valve 4 of the swing valve q Then the swing pressure does not cause LS pressure PLS but the LS pressure PLS caused by the boom RAISE pressure is led to the pump LS valve and the pump delivery...

Page 171: ...l travel straight q When the machine is steered outside pilot pressure PST closes the travel junction valve to secure high steering performance Operation When pilot pressure is turned ON q If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring 2 travel junction spool 1 moves to the left stroke end and the junction circuit between port PTL Left travel ...

Page 172: ...fferential pressure is generated over orifice a in spool 4 and spool 4 moves in the direction to close the opening between ports 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 When abnormally high pressure is generated q If the PR pressure of the self pressure reduc ing valve is raised abnorma...

Page 173: ...re will be as follows q PA PB Force of spring 3 Area of pis ton 2 at diameter d1 PB C 0 kg cm2 Cooler bypass valve Function q The cooler bypass valve protects oil cooler 4 from breakage when the return flow rate from the control valve increases and oil cooler inlet pressure PB increases q The cooler bypass valve returns the return oil to the tank directly without passing it through oil cooler 4 Op...

Page 175: ...mber PC130 8 80001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 3 PPC valve 2 Swing motor 17 Travel motor 25 Center swivel joint 34 Solenoid valve 36 Accumulator 40 Anti drop valve for boom 42 Anti drop valve for arm 47 Hydraulic cylinder 52 ...

Page 176: ... PPC valve 1 P From self pressure reducing valve P1 L H PPC valve Arm OUT port R H PPC valve Boom LOWER port 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 T To tank ...

Page 177: ...10 Structure function and maintenance standard SEN03775 04 PC130 8 3 ...

Page 178: ...Remedy 10 Centering spring for ports P3 and P4 Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length Installation load 42 48 15 5 34 17 7 N 1 8 kg 14 1 N 1 44 kg 11 Centering spring for ports P1 and P2 44 45 15 5 34 29 4 N 3 kg 23 5 N 2 40 kg 12 Metering spring 26 53 8 15 24 9 16 7 N 1 7 kg 13 3 N 1 36 kg ...

Page 179: ... becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 q As a result spool 1 moves up and down until the force of metering spring 2 is balanced with the pressure at port P1 q The relationship of the position of spool 1 and body 10 fine control hole f is i...

Page 180: ...ied until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber 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 4 At full stroke q Disc 5 pushes down piston 4 and retainer ...

Page 181: ...10 Structure function and maintenance standard SEN03775 04 PC130 8 7 Travel PPC valve P From self pressure reducing valve P1 L H REVERSE P2 L H FORWARD P3 R H REVERSE P4 R H FORWARD T To hydraulic tank ...

Page 182: ...SEN03775 04 10 Structure function and maintenance standard 8 PC130 8 ...

Page 183: ...it mm No Check item Criteria Remedy 7 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length Installation load 48 57 15 5 32 5 108 N 11 kg 86 3 N 8 8 kg 8 Metering spring 26 53 8 15 24 9 16 7 N 1 7 kg 13 3 N 1 36 kg ...

Page 184: ...1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 q As a result spool 1 moves up and down until the force of metering spool 2 is balanced with the pressure at port P1 q The relationship of the position of spool 1 and body 10 fine control hole f is i...

Page 185: ...d until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber 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 4 At full stroke q Lever 5 pushes down piston 4 and retainer 9...

Page 186: ...SEN03775 04 10 Structure function and maintenance standard 12 PC130 8 Attachment PPC valve with EPC valve 1 a For the details of operation see the paragraph of Work equipment and swing PPC valve ...

Page 187: ...ever 4 Plate 5 Retainer 6 Block 7 Body 8 EPC valve Unit mm No Check item Criteria Remedy 9 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length Installation load 33 88 15 3 28 4 125 N 12 7 kg 100 N 10 2 kg 10 Metering spring 22 73 8 10 22 0 16 7 N 1 70 kg 13 3 N 1 36 kg ...

Page 188: ...ydraulic tank 1 Body 2 Plug 3 Spool 4 Push pin 5 Coil 6 Plunger 7 Connector Unit mm No Check item Criteria Remedy 8 Return spring Standard size Repair limit If damaged or deformed replace EPC valve assembly Free length Outside diameter Installation length Installation load Free length Installation load 9 5 11 4 8 4 3 1 N 0 32 kg 2 6 N 0 26 kg ...

Page 189: ...sure in proportion to the size of the signal and outputs it to the control valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the controller to coil 14 coil 14 is de ener gized q Spool 11 is pushed to the right by spring 12 q Port P closes and the pressurized oil from the front pump does not flow to the control valve q The pressurized oil...

Page 190: ...are con nected q Spool 2 moves up and down so that the pro pulsion force of plunger 6 may be balanced with pressure of port C spring load of spring 3 q The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current 3 When signal current is maximum coil is energized q As the signal current flows to coil 5 coil 5 is energized q When thi...

Page 191: ...ding brake solenoid valve MA From control valve MB From control valve S From control valve T To tank 1 Reverse prevention valve 2 Safety valve Specifications Type KMF45ABE 5 Theoretical displacement 143 8 cm rev Safety valve set pressure 27 1 MPa 276 kg cm Rated speed 2 111 rpm Brake release pressure 1 1 MPa 11 kg cm ...

Page 192: ...SEN03775 04 10 Structure function and maintenance standard 18 PC130 8 ...

Page 193: ...lve plate 13 Center shaft 14 Center spring 15 Check valve 16 Shuttle valve Unit mm No Check item Criteria Remedy 17 Check valve spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length Installation load 43 3 6 36 5 8 63 N 0 88 kg 6 86 N 0 70 kg 18 Shuttle valve spring 13 6 5 9 5 1 96 N 0 2 kg 1 57 N 0 16 ...

Page 194: ...cuit T q Brake piston 8 is pushed down by brake spring 1 q Disc 5 and plate 6 are pushed together and the brake is applied 2 When solenoid valve is energized Operation q As the swing holding brake solenoid valve is energized the valve is switched q The pressurized oil from the self pressure reducing valve is conducted brake chamber a via port B q After entering chamber a the pressurized oil compre...

Page 195: ...ue is generated in the motor and the motor starts to rotate q 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 2 When swing is stopped q When the swing control lever is returned to neutral the supply of pressurized oil from the pump to port MA is stopped q The pressurized oil from the motor outlet can t return to the tan...

Page 196: ...SEN03775 04 10 Structure function and maintenance standard 22 PC130 8 Reverse prevention valve ...

Page 197: ... standard SEN03775 04 PC130 8 23 MA From control valve MB From control valve T1 To tank T2 To tank 1 Valve body 2 Spool MA side 3 Spring MA side 4 Plug MA side 5 Spool MB side 6 Spring MB side 7 Plug MB side Explanatory drawing of effects ...

Page 198: ...n areas of circles øD1 øD2 of spool 5 and moves spool 5 to the left side q Port MB o chamber e will be intercon nected q 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 2 When motor is stopped temporarily q The motor rotation is reversed by the closing pressure generated at port MB 1st time rev...

Page 199: ... center swivel joint port B2 L H travel motor From center swivel joint port C2 R H travel motor B 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 P From center swivel joint port E2 1 Oil filler plug 2 Oil level plug 3 Drain plug ...

Page 200: ...alve 6 End cover 7 Brake piston 8 Disc 9 Plate 10 Swash plate 11 Pivot 12 Bearing 13 Hub 14 Planetary pinion B 15 Planetary pinion A 16 Cover 17 Sun gear A 18 Carrier A 19 Sun gear B 20 Carrier B 21 Regulator piston 22 Shaft 23 Piston 24 Floating seal 25 Spindle 26 Cylinder 27 Timing plate 28 Regulator valve 29 Check valve 30 Piston ...

Page 201: ...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 4 2nd travel speed selector mechanism Consists of the regulator valve and regulator piston Changes the rotation speed in 2 stages by changing the stroke volume of the hydraulic motor 5 Parking brake Multiple disc type brake m...

Page 202: ...lve q Since 2nd travel speed select solenoid valve 1 is de energized the pressurized oil from self pressure reduction valve 11 is not fed to port P q Regulator valve 2 is pushed down with spring 3 reaction force q The main pressurized oil sent from the control valve through check valve 4 is controlled by regulator valve 2 and used to shuts off the cir cuit to regular piston 5 q The pressurized oil...

Page 203: ...alve 12 Brake valve q When 2nd travel speed select solenoid valve 1 is energized the pressurized oil from self pressure reduction valve 11 is fed to port P q Regulator valve 2 is pushed up with the pres surized oil that is sent to port P q The main pressurized oil from the control valve passes through check valve 4 and passes through oil passage F in regulator valve 2 to control chamber C and is u...

Page 204: ...y the hydraulic pressure This releases the parking brake and the motor starts to rotate Operation when pressure is shut off q When the travel lever is returned to its neutral position the hydraulic oil circuit from the con trol valve is closed And counterbalance valve 2 starts to return to the left by spring 3 reac tion force q The hydraulic oil in chamber G tends to flow to port A through orifice...

Page 205: ...aulic oil in chamber J tends to flow to port B through orifice h However the back pressure is generated by closing of orifice h controlling the return speed of counterbal ance 2 to the right q When ports D and B are closed and when the hydraulic pressure at port D increases a resistance is generated in motor rotation to protect the machine from running away q Counterbalance valve 2 is moved to the...

Page 206: ...raulic pressure at port C at the inlet side is controlled so that the motor is smoothly started to rotate When stopping q When the hydraulic oil from the control valve is stopped ports A and C are closed At the same time ports D and B are closed but the motor continues to rotate by the inertia q When the hydraulic pressure at port D exceeds the specified value relief valve 1b is pushed up and the ...

Page 207: ...10 Structure function and maintenance standard SEN03775 04 PC130 8 33 ...

Page 208: ... valve R H travel REVERSE D1 From control valve L H travel REVERSE E1 From 2nd travel speed select solenoid valve DR1 To hydraulic tank 1 Cover 2 Body 3 Slipper seal A2 To R H travel motor FORWARD port B B2 To L H travel motor FORWARD port A C2 To R H travel motor REVERSE port A D2 To L H travel motor REVERSE port B E2 To L H and R H travel motor port P DR2 From L H and R H travel motor port D 4 O...

Page 209: ...ture function and maintenance standard SEN03775 04 PC130 8 35 Unit mm No Item Criteria Remedy 1 Clearance between rotor and shaft Standard size Standard clearance Clearance limit Replace ø 80 0 056 0 105 0 111 ...

Page 210: ...SEN03775 04 10 Structure function and maintenance standard 36 PC130 8 Solenoid valve 1 ...

Page 211: ...wing motor port B A6 To control valve port Px T To hydraulic tank ACC To accumulator for PPC circuit 1 PPC lock solenoid valve 2 Merge flow divider solenoid valve 3 Travel junction solenoid valve 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 va...

Page 212: ...ergized circuit is closed q Coil 1 is de energized when no signal current is supplied to coil 1 q Spool 2 is pushed back to the left with spring 3 reaction force q As ports P and A are closed the pilot pres sure is not fed to the actuator through port A At the same time port T is opened allowing the oil from the actuator to drain to the hydrau lic tank When solenoid valve is energized circuit is c...

Page 213: ...10 Structure function and maintenance standard SEN03775 04 PC130 8 39 ...

Page 214: ...pped with the work equipment is kept at an elevated position the pilot pressure is supplied to the control valve by the pressure of the com pressed nitrogen gas in the 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 cm at 80 C Maximum operating pressur...

Page 215: ...piping Specifications Gas to be used Nitrogen gas Gas capacity 480 cc Sealed gas pressure 0 1 MPa 1 kg cm at 80 C Maximum operating pressure 0 69 MPa 7 kg cm For high pressure 1 Cap 2 Core 3 Locknut 4 Gas port 5 Bladder 6 Shell Outline q Connected to the attachment piping When the breaker operates the oil pulsation is absorbed by the pressure of compressed nitrogen gas of the accumulator to protec...

Page 216: ...SEN03775 04 10 Structure function and maintenance standard 42 PC130 8 Anti drop valve for boom 1 Machine with anti drop valve for boom a General view ...

Page 217: ...he counterflow of pres surized oil from the work equipment when the piping between the control valve and the work equipment cylinder breaks Unit mm No Check item Criteria Remedy 2 Spool return spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length Installation load 41 1 9 6 35 0 58 8 N 6 0 kg 47 1 N 4 8...

Page 218: ...he work equipment cylinder is held 6 When the pressure inside the work equipment cylinder is abnormally high holding pressure of the work equipment cylinder operates safety valve 4 7 Chambers b of anti drop valves on the right and left are interconnected at port PCY 8 The pressures of chambers b are the same even when there is a difference of leakage amount between the antidrop valves on the right...

Page 219: ...he pressure of chamber b and spring 6 3 Check valve 5 closes and chamber a and chamber b are disconnected 4 The pressure of the work equipment is held to prevent the work equipment from sudden low ering When the pressurized oil returns from the work equipment cylinder to the control valve When there is no damage in the piping 1 Holding pressure of the work equipment cylin der is led to chamber b a...

Page 220: ...e is a damage in the piping A between the control valve and the work equip ment cylinder the pressurized oil of chamber a leaks through the damaged part to the out side but it is supplied from chamber b 2 The pressurized oil flows through the opening C of spool 1 and it prevents the work equip ment from sudden lowering ...

Page 221: ...10 Structure function and maintenance standard SEN03775 04 PC130 8 47 Anti drop valve for arm 1 Machine with anti drop valve for arm a General view ...

Page 222: ...he counterflow of pres surized oil from the work equipment when the piping between the control valve and the work equipment cylinder breaks Unit mm No Check item Criteria Remedy 2 Spool return spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length Installation load 41 1 9 6 35 0 58 8 N 6 0 kg 47 1 N 4 8...

Page 223: ...hamber b are disconnected 2 The pressure of the work equipment is held to prevent the work equipment from sudden low ering When the pressurized oil flows from the control valve to the work equipment cylinder When there is no damage in the piping 1 The pressurized oil which is led from the con trol valve to chamber a becomes higher than the combined force of the pressure of chamber b of work equipm...

Page 224: ...a and chamber b are not intercon nected 5 The pilot pressure rises further The pilot pres sure is larger than the force of spring 2 area of circle d 6 Spool 1 moves rightward further and cham ber a and chamber b are interconnected The second stroke 7 The pressurized oil returns from the work equipment cylinder to the control valve When there is a damage in the piping 1 When there is a damage in th...

Page 225: ...10 Structure function and maintenance standard SEN03775 04 PC130 8 51 ...

Page 226: ...SEN03775 04 10 Structure function and maintenance standard 52 PC130 8 Hydraulic cylinder 1 Boom cylinder Arm cylinder Bucket cylinder ...

Page 227: ...30 0 076 0 279 0 065 0 095 0 355 0 455 Bucket ø 65 0 030 0 076 0 250 0 055 0 085 0 326 0 426 2 Clearance between piston rod support shaft and bushing Boom ø 70 0 030 0 100 0 190 0 090 0 120 0 290 1 0 Arm ø 70 0 030 0 100 0 190 0 090 0 120 0 290 1 0 Bucket ø 65 0 030 0 080 0 170 0 070 0 100 0 250 1 0 3 Clearance between cylinder bottom support shaft and bushing Boom ø 70 0 030 0 100 0 190 0 090 0 1...

Page 229: ...130 8 1 SEN03776 00 HYDRAULIC EXCAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Work equipment Work equipment 2 Dimensions of components 4 ...

Page 230: ...Clearance between mounting pin and bushing of boom and arm ø 70 0 030 0 100 0 145 0 065 0 095 0 245 0 8 3 Clearance between mounting pin and bushing of arm and bucket ø 60 0 030 0 080 0 129 0 074 0 104 0 209 0 8 4 Clearance between mounting pin and bushing of arm and link ø 60 0 030 0 080 0 133 0 075 0 105 0 213 0 8 5 Clearance between mounting pin and bushing of link and link ø 65 0 030 0 080 0 1...

Page 231: ...10 Structure function and maintenance standard SEN03776 00 PC130 8 3 ...

Page 232: ...SEN03776 00 10 Structure function and maintenance standard 4 PC130 8 Dimensions of components 1 Arm ...

Page 233: ... 1 0 0 Cylinder head side 80 1 2 3 Boom side 226 0 5 0 Arm side 226 0 2 0 7 4 ø 70 0 030 0 100 0 100 0 5 264 2 0 6 213 5 1 0 7 640 6 0 5 8 2 491 9 2 101 9 1 5 10 290 4 0 5 11 493 0 2 12 422 0 5 13 374 9 14 1 251 15 ø 60 0 030 0 080 0 200 0 16 Link side 259 0 1 0 Bucket side 261 1 0 17 ø 60 0 030 0 080 0 200 0 18 Arm side 226 0 0 5 Bucket side 274 2 0 0 19 Min 1 378 Max 2 263 ...

Page 234: ...SEN03776 00 10 Structure function and maintenance standard 6 PC130 8 Bucket ...

Page 235: ... No Measurement point Standard size Tolerance 1 371 3 0 5 2 51 6 0 5 3 97 9 4 374 9 5 1 236 6 6 189 5 7 5 8 0 9 ø 60 0 2 0 10 ø 64 11 ø 80 0 25 0 12 261 1 0 13 50 14 85 15 380 1 0 0 16 18 17 ø 110 18 ø 130 19 ø 132 20 ø 108 21 274 2 0 0 22 51 23 34 24 100 5 25 115 3 26 74 27 65 ...

Page 236: ...8 PC130 8 SEN03776 00 10 Structure function and maintenance standard PC130 8 GALEO Hydraulic excavator Form No SEN03776 00 2007 KOMATSU All Rights Reserved Printed in Japan 11 07 02 ...

Page 237: ...PC130 8 1 SEN03777 00 HYDRAULIC EXCAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Cab and its attachments Air conditioner 2 ...

Page 238: ...tandard 2 PC130 8 Air conditioner 1 Air conditioner piping 1 Air conditioner unit 2 Hot water pickup piping 3 Air conditioner compressor 4 Refrigerant piping 5 Condenser 6 Hot water return piping 7 Duct A Fresh air B Recirculated air C Hot air cold air ...

Page 239: ...10 Structure function and maintenance standard SEN03777 00 PC130 8 3 ...

Page 240: ...4 PC130 8 SEN03777 00 10 Structure function and maintenance standard PC130 8 GALEO Hydraulic excavator Form No SEN03777 00 2007 KOMATSU All Rights Reserved Printed in Japan 11 07 02 ...

Page 241: ...YDRAULIC EXCAVATOR PC130 8 Machine model Serial number PC130 8 80001 and up 10 Structure function and maintenance standard 1 Electrical system Electronic control system 2 Machine monitor system 34 KOMTRAX system 48 Sensor 50 ...

Page 242: ...SEN03778 03 10 Structure function and maintenance standard 2 PC130 8 Electronic control system 1 Machine control system diagram ...

Page 243: ...10 Structure function and maintenance standard SEN03778 03 PC130 8 3 1 ...

Page 244: ...2 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 Function 1 The neutral safety circuit is employed to secure safety when the engine is started q The engine does not start until the lock lever is set in the LOCK position 2 The KOMTRAX engine cut circuit is empl...

Page 245: ...tion at this time the neutral safety mecha nism works so that starting motor cut out relay 9 will cut off the starting current to starting motor 13 to prevent the engine from starting q Upon receipt of the engine cut off command from the external source KOMTRAX terminal 19 sends the signal to machine monitor 18 Machine monitor 18 causes starting motor cut out relay 10 to cut off the starting curre...

Page 246: ...re sensor 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 Input and output signals a Constant power supply b CAN signal Note 1 c PC EPC valve drive signal d Solenoid valve GND e Oil pressure sensor signal f Oil pressure switch signal g Throttle signal h...

Page 247: ...ding on the work In the default setting of the service mode only 3 modes P E L are available in which Without is selected for the attachment q According to the pump absorption torque set at each mode based on the engine governor set speed with the fuel control dial and the actual engine speed the controller controls so that the pump absorbs all torques at each engine output point q When the engine...

Page 248: ... the pressure rises the engine speed N lowers At the time the controller reduces the pump deliv ery 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 Working mode Matching point P ATT Travel 68 4 kW 2 200 rpm 91 7 HP 2 200 rpm Working At arm digging 64 4 kW 2 050 rpm 86 4 HP 2 05...

Page 249: ... torque to decrease the engine speed while keeping the engine torque at a constant level along the equal engine horsepower curve q 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 Working mode Partial output B 75 L 70 Working mode Matching point B 50 9 kW 1 870 rpm 68 2 HP 1 870 rpm L 47 8 kW 1 640 rpm 64 1 H...

Page 250: ...roller gets out of order and no work is possible because the hydraulic pump does not work properly turning on emergency pump drive switch 1 temporarily enables to main tain functions of the machine with absorption torques quite similar to those in E Mode In this case a constant current flows from the battery to the PC EPC valve and the valve detects the oil pressure only a Emergency b Normal a Eme...

Page 251: ... control signal g Sensor signals h Knob switch signal Note 1 CAN is cf 6 page Function q The one touch power maximizing function allows the operator to increases power for a certain time by operating the left knob switch q This function is used to increase digging force for a certain period of time e g when digging up a large rock q Pressing the L H knob switch in P E or ATT mode increases a hydra...

Page 252: ...pply pump 6 Sensors 7 Oil pressure sensor 8 Oil pressure switch 9 Hydraulic pump 10 Control valve 10a Pump merge divider valve 10b Self pressure reducing valve 11 PPC lock solenoid valve Input and output signals a CAN signal Note 1 b Oil pressure sensor signal c Oil pressure switch signal d Throttle signal e Fuel supply pump control signal f Sensor signals Note 1 CAN is cf 6 page ...

Page 253: ...l the control levers are set to NEUTRAL for 4 seconds or more with the engine speed exceeding approx 1 400 rpm the engine speed lowers down to the control speed approx 1 400 rpm and is held until the con trol lever is operated again When any control lever is operated q With the engine speed at the control speed approx 1 400 rpm when any control lever is operated the engine speed increases immedi a...

Page 254: ... Fuel control dial 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 Input and output signals a CAN signal Note 1 b PC EPC valve drive signal c Solenoid valve GND d Hydraulic oil temperature signal e Throttle signal f Fuel supply pump...

Page 255: ...n with air conditioner Air conditioner blower ON Coolant temperature Max 55 C Ambient temperature below 5 C O O If any of operating conditions 1 is not satisfied Heater warm up is disabled normal warm up When all of operating conditions 1 are satisfied Heater warm up is enabled Operational conditions 2 all required Coolant temperature Max 30 C Fuel control dial below 70 of full speed MAX O O Opera...

Page 256: ...Operation and actions taken o Release conditions Working mode P ATT Coolant temperature Min 100 C Hydraulic oil temperature Min 100 C Traveling status check Any Engine speed Remains same Sends torque control signal to lower the pump absorption torque and reduce the engine load Coolant temperature Max 100 C Hydraulic oil temperature Max 100 C The original conditions are restored if above requiremen...

Page 257: ...e seized Controlling the engine speed prevents this problem q The duration of turbocharger protection depends on the coolant temperature A Start engine B Duration of turbocharger protection approx 0 20 sec C Modulating time approx 1 5 sec D 500 rpm E 1 100 rpm F 2 300 rpm 1 1 Working mode Mode P Fuel control dial Full rotation position Travel lever operated Operational conditions o Operating Engin...

Page 258: ...p controller 8 Machine monitor 9 Oil pressure switch 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 Input and output signals a Swing holding brake release signal b Swing holding brake solenoid valve drive sig nal c CAN signal Note 1 d Solenoid valve GND e Oil pressure switch signal Note 1 CAN is ...

Page 259: ...rk equipment control lever SWING Swing holding brake RELEASE B L H work equipment control lever NEUTRAL C Swing holding brake OPERATED D 5 sec Swing lock switch OFF ON Swing lock monitor OFF ON Function Swing holding brake Swing lock Operation When the L H work equipment control lever is set to NEU TRAL the swing holding brake works in 5 sec When the L H work equipment control lever is operated fo...

Page 260: ...ing brake is not be released while the swing lock switch is set to ON a When the swing holding brake is released only the hydraulic brake with the safety valve is effective for swing So note that when the swing stops on a slope a hydraulic drift may occur a 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 ...

Page 261: ...11c Travel junction valve 11d Pump merge divider valve 12 Travel motor 13 2nd travel speed select solenoid valve 14 Travel junction solenoid valve 15 Pump merge divider solenoid valve Input and output signals a Oil pressure sensor signal b CAN signal Note 1 c Pump merge divider solenoid valve drive sig nal d Travel junction solenoid valve drive signal e 2nd travel speed select solenoid valve drive...

Page 262: ...7 7 MPa 180 kg cm continues for 0 1 seconds or more the travel motor capacity is switched back to the set speed of Hi automatically A 17 7 MPa 180 kg cm B 32 4 MPa 330 kg cm C Min 0 1 sec D Min 0 02 sec Pump control function during travel a See Pump and engine mutual control function for details Travel junction function q When the travel lever is operated detects the pilot pressure and judges whet...

Page 263: ...Control valve 9a Pump merge divider valve 9b Self pressure reducing valve 10 PPC lock solenoid valve Function q Interlocked with the lock lever the PPC lock switch is turned OFF when operating the lock lever to LOCK position q When the PPC lock switch is turned OFF the current to the PPC lock solenoid valve is cut off causing neither the work equipment nor machine moves even if levers or pedal is ...

Page 264: ...re reducing valve 11 PPC lock solenoid valve 12 Oil flow adjuster EPC valve for attachment 13 PC EPC valve 14 Attachment circuit selector valve 15 Attachment Input and output signals a Oil flow adjuster EPC valve drive signal for attachment b Oil pressure switch signal c CAN signal Note 1 d PC EPC valve drive signal e Solenoid valve GND f Throttle signal g Fuel supply pump control signal h Sensor ...

Page 265: ...Input and output signals q 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 Pin No Signal name Signal classification 1 GND C 2 NC 3 Constant power supply 24 V A 4 NC ...

Page 266: ...bient pressure sensor B 50 NC 21 NC 51 Injector 4 C 22 NC 52 NC 23 NC 53 Injector 1 C 24 NC 54 NC 25 NC 55 Injector 3 D 26 Crankshaft speed sensor 5 V A 56 Injector 4 D 27 NC 57 Injector 1 D 28 NC 58 Injector 2 C 29 Common rail pressure sensor B 59 Injector 3 C 30 NC 60 NC DRC 60P 2 CN CE02 Pin No Signal name Signal classification Pin No Signal name Signal classification 1 CAN E 31 NC 2 NC 32 Engi...

Page 267: ...10 Structure function and maintenance standard SEN03778 03 PC130 8 27 Pump controller ...

Page 268: ... CAN_L Input output 25 NC 65 NC 26 NC 66 NC 27 NC 67 Boom angle sensor Input 28 NC 68 NC 29 Hydraulic oil temperature sensor Input 69 L H travel FORWARD oil pressure sensor Input 30 NC 70 GND analog signal Input 31 Boom cylinder bottom oil pressure sensor Input 71 NC 32 Blade RAISE oil pressure sensor Input 72 NC 33 NC 73 Bucket CURL oil pressure switch Input 34 Bucket DUMP oil pressure switch Inp...

Page 269: ... console box Potentiome ter 5 is installed inside knob 1 Turning knob 1 causes potentiometer 5 shaft to rotate q This rotation changes the resistance of the variable resistor within potentiometer 5 and a throttle signal is sent to the controller q 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 ...

Page 270: ... Resistor 1 Resistance 2 Connector Specifications For PC EPC valve 30 z Function q 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 ...

Page 271: ... 03 PC130 8 31 Engine oil pressure switch 1 Connector 2 Sensor 3 O ring Specifications Contact type Normal close Function q Installed in the cylinder block Detects engine oil pressure and turns the switch ON when the pressure goes below the specified value ...

Page 272: ...type Normal open Operating pressure to make contact point ON 490 98 1 kPa 5 0 1 0 kg cm2 Operating pressure to break contact point OFF 294 49 0 kPa 3 0 0 5 kg cm2 Function q 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 ...

Page 273: ...10 Structure function and maintenance standard SEN03778 03 PC130 8 33 ...

Page 274: ...rive signal e Camera signal Note 1 CAN is cf 6 page Outline q The monitor system keeps the operator informed of all machine functions by monitor ing the machine conditions using the sensors and switches installed in various parts of the machine and processing them instantly to dis play on the machine monitor The information displayed on the machine monitor falls into the following types 1 Alarm wh...

Page 275: ...recautions on the machine monitor display q The LCD panel may has black points points which are not lighted and bright points points which do not go off for the reason of its char acteristics If the number of the bright points and black points does not exceed 10 it does not indicate a failure or a defect q When the engine is started the battery voltage may drop suddenly depending on ambient temper...

Page 276: ... CTS Input 2 For communication terminal RS232C RXD Input 11 For communication terminal RS232C RI Input 3 For communication terminal RS232C SG 12 GND communication terminal power supply 4 GND communication terminal con trol signal 13 Communication terminal status signal CH1 Input 5 Communication terminal selection signal Input 14 Communication terminal power sup ply control signal Output 6 For comm...

Page 277: ...10 Structure function and maintenance standard SEN03778 03 PC130 8 37 Display ...

Page 278: ...ms 14 to 18 are faulty after starting the engine monitor items are displayed on the screen in chronological order from the upper left q 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 ...

Page 279: ...onding fuel level F1 198 Blue F2 148 Blue F3 123 Blue F4 84 Blue F5 66 Blue F6 36 Red 3b Caution See the column Gauge 4 ECO gauge Segment Load level Indicates average load per minute on a scale of 1 to 10 Indicates when Default ECO dis play setting of the service mode is ON Green 1 8 Light to medium Orange 9 10 Heavy 5 Service meter 00000 h 99999 h Indicates accumulated engine operat ing hours the...

Page 280: ... the monitor lights up on the screen and the alarm buzzer sounds at the same time 15 2 Engine oil pressure Light ON Abnormal range below the specified value Light OFF Normal range When an error is detected with the engine stopped the monitor lights up on the screen 16 2 Battery level Light ON Defective battery charge Charge voltage Battery voltage Light OFF Normal range When an error is detected w...

Page 281: ... low speed i o Hi high speed 4 Buzzer cancel switch Numeric keypad 4 Stops the alarm buzzer Some alarm buzzer does not stop even if the switch is pressed Stops the alarm buzzer The alarm buzzer resumes when another error is detected 5 Wiper switch Numeric keypad 5 Operates the front glass wiper INT Intermittent ON Continuous Light OFF Stop o INT o ON o OFF o I Intermittent Continuous Stop O i i i ...

Page 282: ...s 9 2 Auto switch Numeric keypad 9 Auto runs the air conditioner and air blower AUTO light ON Auto run Automatically controls the fan speed air outlet port internal external air flow accord ing to the temperature setting immediately after the air conditioner adjustment screen appears 10 3 Air conditioner switch Turns the air conditioner ON OFF AC ON lights up Manual operation Light OFF Stop Switch...

Page 283: ...asurement of spilt fuel consump tion 5 Stop Stops function Used for stopping measurement of spilt fuel con sumption F2 1 Default Sets selected item back to default Used for screen adjustment 2 Move selection Moves selection up one page To the bottom page from the top page 3 Clear Clears selected displayed item F3 1 Camera image Switches to camera image 2 Move selection Moves selection down one ite...

Page 284: ...44 PC130 8 F5 1 Selecting maintenance screen Selects maintenance screen 2 Return Returns to the previous screen or condition F6 1 Selecting user mode screen Selects user mode screen 2 Fix Fixes selected displayed item Function switch Guidance icon Item Function ...

Page 285: ...ode functions see the Operation and Maintenance Manual or Special functions of machine monitor in Testing and adjusting a For how to set the engine start lock on off see Password setting cancel manual Category 1 Item Display order 2 W X Y Z A Display of KOMATSU logo 1 1 1 1 Display of inputting password 2 Display of start up check 3 2 2 2 Display of warning after start up check 3 Display of overdu...

Page 286: ...ing of the user mode q Oil flow level can be set as follows Language setting q The language used in the machine monitor can be changed in the Language setting of the user mode q The available languages are as follows English Japanese Chinese French Spanish Portuguese Italian German Russian Turkish Indonesian and Thai Oil flow level Quantity l min Remarks 1 60 2 70 3 80 4 90 5 100 6 110 7 120 8 130...

Page 287: ...ons of machine monitor in Testing and adjusting Monitoring Abnormality record Mechanical systems Electrical systems Air conditioner system Maintenance record Change of maintenance mode Setting of telephone No Default Working mode with key ON Selection of units of measure With Without attachment Setting of attachment maintenance password Setting of camera Setting of ECO display Adjustment Pump abso...

Page 288: ...is system sends various information of the machine via wireless communication It allows operators of the KOMTRAX to obtain the machine information from the office and to pro vide various services with the customers q 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 arrang...

Page 289: ...Conditions of the KOMTRAX terminal can be checked with the Display of KOMTRAX sys tem setting in the service mode of the machine monitor q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed Input and output signals AMP 14P CN CK01 Pin No Signal name Input output signal A1 Power supply 5 V Input A2 NC A3 NC A4 Selection of power supply voltage Output A5...

Page 290: ... in the bracket on the side face of the cylinder block Detects the ambient pressure and outputs variable voltage Boost pressure temperature sensor 1 Connector 2 Sensor 3 O ring Function q 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 ...

Page 291: ...ects the temperature change and outputs signal as a resistance change Crankshaft speed sensor Camshaft speed sensor 1 Connector 2 Sensor 3 O ring Function q 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 ...

Page 292: ... Function q Installed in the common rail Detects the fuel pressure and outputs variable voltage Engine oil level sensor 1 Connector 2 Bracket 3 Float 4 Switch Function q 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 ...

Page 293: ... 7 Spacer Function q 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 ...

Page 294: ...SEN03778 03 10 Structure function and maintenance standard 54 PC130 8 Air cleaner clogging sensor Coolant level sensor 1 Reserve tank 2 Float 3 Sensor 4 Connector ...

Page 295: ...led 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 1 O ring 2 Sensor 3 Connector Function q The pump oil pressure sensor is installed in the control valve Detects the pump discharge pressure and outputs variable voltage Output characteristics ...

Page 296: ...l pressure sensor For travel operation 1 O ring 2 Sensor 3 Connector Function q 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 Output characteristics ...

Page 297: ...10 Structure function and maintenance standard SEN03778 03 PC130 8 57 ...

Page 299: ... EXCAVATOR 1SHOP MANUAL PC130 8 Machine model Serial number PC130 8 80001 and up 20 Standard value table 1 Standard service value table Standard value table for engine related parts 2 Standard value table for chassis related parts 3 ...

Page 300: ...re 40 60 C Engine speed 320 360 rpm SAE0W30E0S MPa kg cm2 Min 2 9 Min 30 2 0 20 Blow by pressure Coolant temperature operating range Arm IN relief kPa mmH2O Max 0 98 Max 100 1 47 150 Oil pressure Hydraulic oil temperature Min 80 C At sudden acceleration SAE30 Oil MPa kg cm2 0 34 0 59 3 5 6 0 0 25 2 5 SAE10W Oil 0 29 0 49 3 0 5 0 0 2 2 1 Low idle SAE30 Oil Min 0 18 Min 1 8 0 15 1 5 SAE10W Oil Min 0...

Page 301: ... control lever knob to test Fit push pull scale to tip of control pedal to test Test max value to end of travel N kg 15 7 3 9 1 6 0 4 Max 24 5 Max 2 5 Arm control lever 15 7 3 9 1 6 0 4 Max 24 5 Max 2 5 Bucket control lever 12 7 2 9 1 3 0 3 Max 21 6 Max 2 2 Swing control lever 12 7 2 9 1 3 0 3 Max 21 6 Max 2 2 Travel control lever 24 5 5 9 2 5 0 6 Max 39 2 Max 4 0 Travel pedal 74 5 18 6 7 6 1 9 Ma...

Page 302: ... 98 28 10 Travel rotating under no load Travel lever at half way position 2 2 0 1 22 5 1 Swing Overrun when stopping swing For testing posture see Swing 1 Engine at high idle Hydraulic oil temperature 45 55 C Stop after swinging one turn and test distance that swing circle moves Figure in shows movement at outside of swing circle Deg mm 75 10 730 100 Max 90 Max 870 Time taken to start swing For te...

Page 303: ...en for next 5 turns with no load Lo sec Max 39 6 Max 45 Hi Max 22 0 Max 25 Travel speed actual run For testing posture see Travel 2 Engine at high idle Hydraulic oil temperature 45 55 C Run up for at least 10 m and test time taken to travel next 20 m on flat ground Lo sec Max 31 0 Max 35 Hi Max 14 5 Max 17 Travel deviation For testing posture see Travel 2 and 3 Engine at high idle Hydraulic oil te...

Page 304: ...linder amount of extension of cylinder Max 80 Max 90 Bucket cylinder amount of retraction of cylinder Max 22 Max 40 Work equipment speed Boom Bucket teeth in contact with ground I O Cylinder fully extended For testing posture see Work equipment 2 Engine at high idle Hydraulic oil temperature 45 55 C RAISE sec 3 7 0 3 Until touching cushion Max 4 3 Until touching cushion LOWER 2 6 0 3 Max 3 2 Arm C...

Page 305: ...ucket cylinder fully then extend arm cylinder and test time taken for arm to start moving again after stopping at bottom Max 2 Max 2 Bucket For testing posture see Work equipment 7 Engine at low idle Hydraulic oil temperature 45 55 C Set top surface of boom horizontal retract arm cylinder fully then extend bucket cylinder and test time taken for bucket to start moving again after stopping at botto...

Page 306: ... on the machine if it is impossible to set the engine speed to the specified speed with the fuel control dial take the pump discharge amount and the engine speed at the point of test and use them as a base for calculating the pump discharge amount at the specified speed a Pump delivery Q in the graph is the delivery from 1 side of the pump Check point Test pump discharge pressure MPa kg cm2 Discha...

Page 307: ...erformance and test procedure Swing 1 Swing brake angle time taken to start swing time taken to swing Swing 2 Hydraulic drift of swing Travel 1 Travel speed without load Travel 2 Travel speed actual run travel deviation Travel 3 Travel deviation Travel 4 Hydraulic drift of travel ...

Page 308: ...rd value table 10 PC130 8 Work equipment 1 Hydraulic drift of work equipment Work equipment 2 Boom speed Work equipment 3 Arm speed Work equipment 4 Bucket speed Work equipment 5 Boom time lag Work equipment 6 Arm time lag ...

Page 309: ...20 Standard value table SEN04113 02 PC130 8 11 Work equipment 7 Bucket time lag ...

Page 311: ... Testing engine speed 9 Testing exhaust temperature 10 Checking exhaust gas color 11 Adjusting valve clearance 12 Testing compression pressure 14 Testing blow by pressure 16 Testing engine oil pressure 17 Reduced cylinder mode operation 18 No injection cranking 18 Handling fuel system parts 19 Releasing residual pressure from fuel system 19 Testing fuel pressure 20 Testing fuel return rate and fue...

Page 312: ...ng and adjusting oil pressure in pump PC control circuit 34 Testing and adjusting oil pressure in pump LS control circuit 37 Testing solenoid valve output pressure 40 Testing PPC valve output pressure 44 Adjusting play of work equipment and swing PPC valves 45 Checking parts which cause hydraulic drift of work equipment 46 Testing and adjusting travel deviation 48 Releasing residual pressure from ...

Page 313: ...ssure gauge 2 5 6 40 60 MPa 25 60 400 600 kg cm2 799 261 1204 Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 2 799 401 2320 Gauge 1 Pressure gauge 1 0 MPa 10 kg cm2 3 799 401 3500 Adapter 1 Size 06 02896 11018 O ring 1 4 799 101 5220 Nipple 1 Size 10 x 1 25 mm 07002 11023 O ring 1 Testing fuel pressure F 1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 6 40 60 MPa 25 60 400 600 kg...

Page 314: ...ng 2 Testing and adjusting oil pressure in pump LS con trol circuit M 1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 6 40 60 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 2 799 401 2701 Differential pressure gauge 1 50 MPa 500 kg cm2 3 799 101 5220 Nipple 2 Size 10 x 1 25 mm 07002 11023 O ring 2 Testing solenoid valve out put pressure N 1 7...

Page 315: ... 601 7100 or 799 601 7400 or 799 601 8000 T adapter assembly 1 799 601 2900 is not supplied any more 799 601 2600 Measuremen box 1 For Econo Does not include 799 601 2700 799 601 4101 or 799 601 4201 or 799 601 9000 or 799 601 9200 T adapter assembly 1 799 601 4350 Measuremen box 1 For DRC60 and Econo excluding 799 601 4201 799 601 9000 and 799 601 9200 for DT6P 799 601 9320 Measuremen box 1 For D...

Page 316: ...4P 799 601 7540 Adapter for 070 1 For 070 18P 799 601 9890 1 For DT 2 3 4 DTM 2P 799 601 4280 Box for controller PUMP 1 799 601 7310 Adapter for SWP 1 For SW12P 799 601 7360 Adapter for relay 1 For REL 5P 799 601 7370 Adapter for relay 1 For REL 6P 799 601 9410 Socket for engine CRI T2 1 Testing coolant tempera ture and oil temperature 799 101 1502 Digital thermometer 1 99 9 1 299 C Testing operat...

Page 317: ...s actuators electrical equipment and wiring harnesses see Trou bleshooting General information on troubleshooting List of T boxes and T adapters Removal and installation of engine coolant temper ature sensor 795T 981 1010 Socket 1 19 mm deep socket MITOLOY 4ML 19 or equivalent Applicable engine serial No 502654 and up Testing Adjusting item Sym bol Part No Part name Q ty Remarks ...

Page 318: ...SEN04114 06 30 Testing and adjusting 8 PC130 8 Sketches of special tools 1 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches Socket ...

Page 319: ...ntrol dial in the high idle MAX position 2 Set the working mode in the power mode P and turn the auto decelerator OFF 3 Set all the levers and pedals for work equipment control swing control and travel in neutral and test the engine speed 4 Testing pump relief speed 1 Start the engine and operate the arm cyl inder to the IN stroke end 2 Set the fuel control dial in the high idle MAX position and s...

Page 320: ...ompartment side cover and exhaust manifold cover 2 Remove exhaust temperature pickup plug 1 from the side of the center of the exhaust man ifold 3 Install sensor 1 of digital thermometer R and connect it to thermometer 2 4 Run the engine and test the exhaust tempera ture over the speed range 5 After finishing test remove the testing instru ment and return the removed parts Symbol Part No Part name...

Page 321: ...hing checking remove the test ing tools and return the removed parts 2 Checking with smoke meter A2 1 Insert probe 1 of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip 2 Connect the probe hose receptacle of the accelerator switch and air hose to smoke meter A2 a Limit the supplied air pressure to 1 5 MPa 15 kg cm2 3 Connect the power cable to an AC recep...

Page 322: ... 3 Remove plate 5 on the starting motor and insert gear B1 4 Remove compression top dead center TDC check plug 6 from the flywheel housing Rotate the crankshaft forward with gear B1 and set it so that you can see the white mark of the flywheel a When the No 1 cylinder is at the compres sion top dead center the rocker arm of the No 1 cylinder can be moved by the valve clearance with the hand If the...

Page 323: ... degree that you can move the thickness gauge lightly 3 While fixing adjustment screw 1 tighten locknut 2 3 Locknut 39 2 49 Nm 4 5 kgm a After tightening the locknut check the valve clearance again 6 Rotate the crankshaft forward 1 turn according to step 4 to set the No 4 cylinder to the com pression top dead center and adjust the valve clearances marked with Q in the valve arrangement drawing sim...

Page 324: ...tor 1 2 Move fuel scatter prevention cover 3 from the joint 3 Remove clamp 4 and high pressure pipe 5 4 Pull spill hose connector 6 out of injector 1 5 Remove holder 7 and injector 1 a 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 2 Install adapter C2 to ...

Page 325: ... is dangerous be sure to set the injectors so that they will not inject fuel before starting the check 4 Rotate the engine with the starting motor and test the compression pressure a Test the compression pressure when the gauge pointer is stabilized 5 After finishing test remove the testing instru ments and return the removed parts a Install the injector and spill hose connector according to the f...

Page 326: ...r of the hydraulic pump 2 Install tool and adapter 1 of blow by checker D1 to breather hose 1 and connect gauge 2 3 Start the engine set the working mode in the power mode P and turn the swing lock switch ON a If the swing lock switch is turned ON the main relief valve is set for high pressure relief 4 While running the engine at high idle relieve the arm circuit and test the blow by pressure a Re...

Page 327: ...4 and connect it to hydraulic tes ter E2 4 Start the engine and heighten the engine cool ant temperature to the operating range 5 Test the oil pressure during low idle and high idle 6 After finishing test remove the Testing tools and return the removed parts Symbol Part No Part name E 1 799 101 5002 Hydraulic tester 790 261 1204 Digital hydraulic tester 2 799 401 2320 Gauge 3 799 401 3500 Adapter ...

Page 328: ...ble defects are as follows q Compression leakage through cylinder head gasket q Defective injection q Defective piston piston ring or cylinder liner q Defective valve mechanism Moving valve system q Defect in electrical system 3 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 wit...

Page 329: ...tering it If a filter other than the genuine one is used the fuel system may have a trouble Accordingly never use such a filter Releasing residual pressure from fuel system 1 a Pressure is generated in the low pressure cir cuit and high pressure circuit of the fuel sys tem while the engine is running Low pressure circuit Feed pump Fuel main filter Supply pump High pressure circuit Supply pump Comm...

Page 330: ... 1 Open the engine hood and remove fuel pressure pickup plug 1 from the fuel main filter 2 Install adapter F2 and nipple 1 of the hydraulic tester F1 and connect them to gauge of boost gauge kit F3 3 Run the engine at high idle and test the pressure in the fuel low pressure circuit a If the pressure in the fuel low pres sure circuit is in the following range it is normal Reference Negative pressur...

Page 331: ...gain a Be sure to fit the gaskets to both ends of the joint 4 Connect test hose G4 to the end of joint G2 5 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 a Lay test hose G4 so that it will not slacken and put its end in the oil pan 6 Remove spill hose connector joint 5 and install plug G3 a The abo...

Page 332: ...e test hose on the pres sure limiter side connected and keep its end in the oil pan 1 Run the engine at the rated output 2 After the engine speed is stabilized test the return rate in 1 minute with measuring cylinder G6 a You may test for 20 seconds and judge by multiplying the result by 3 a If the supply pump pressure is low the engine speed may not rise In this case record the engine speed too d...

Page 333: ...evel ground and lower the work equipment to the ground 1 Fill the fuel tank with fuel a Add oil until the oil filler float reaches the maximum rising position 2 Open the side cover of the pump room 3 Loosen knob 1 of the feed pump and pull it out and then operate it forward and backward a Move the knob until it becomes heavy a The plug at the top of the fuel main filter does not need to be removed...

Page 334: ...nly around the high pressure circuit parts coated with the color checker for fuel leakage a If any fuel leakage is detected repair it and check again from step 2 4 Run the engine at low idle 5 Check the fuel piping and devices for fuel leak age a Check mainly around the high pressure circuit parts coated with the color checker for fuel leakage a If any fuel leakage is detected repair it and check ...

Page 335: ...cording to the follow ing procedure 1 Loosen alternator fixing bolts 1 and 2 a Loosen fixing bolt 2 from the rear side of the engine 2 Adjust the tension of alternator belt 4 by turn ing adjustment bolt 3 a Do not loosen double nut 5 at the adjust ment bolt end If you have loosened it apply LOCTITE LT 2 to it when tighten ing Reference If adjustment bolt 3 is tightened turned to the right the alte...

Page 336: ...tion is abnormal adjust it according to the following procedure 1 Loosen bolts 1 and 2 2 Move compressor 3 and bracket 4 together to adjust the belt tension 3 After positioning compressor 3 tighten bolts 1 and 2 a Check each pulley for breakage wear of the V groove and contact of the V belt and V groove a If the V belt is so lengthened that the adjustment allowance is eliminated or it has a cut or...

Page 337: ...ucket tip to the height of the under side of the revolving frame a At this time the front of the upper structure lowers and the rear rises 3 Set dial gauge H to the 0 point 4 Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats a At this time the front of the upper structure rises and the rear lowers 5 Under this condition read dial gauge H a The valu...

Page 338: ...ndard maximum clearance a 10 30 mm Adjusting a If the track shoe tension is abnormal adjust it according to the following procedure 1 Increasing tension 1 Add grease through grease fitting 2 with a grease gun 2 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 3 After adjusting check the track shoe ten sion...

Page 339: ...n the valve more than 1 turn If it is loosened more it may jump out because of the high pressure grease in it 2 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 3 After adjusting check the track shoe ten sion again according to the above proce dure ...

Page 340: ...pment swing and travel circuits under the following condition q Hydraulic oil temperature Within operat ing range 1 Preparation work 1 Open the side cover of the pump room and remove oil pressure pickup plugs 1 and 2 q 1 Pump discharge pressure port 1 check plug q 2 Pump discharge pressure port 2 check plug 2 Install nipples J2 and connect oil pressure gauges 1 of hydraulic tester J1 a Use the oil...

Page 341: ... the swing motor and test the oil pressure a The pressure tested when the swing motor relief valve is relieved is indi cated a The swing relief pressure is lower than the main relief pressure 5 Testing travel relief pressure 1 Run the engine and lock the travel mecha nism k Put pin 2 between the sprocket and track frame to lock the travel mechanism securely 2 Set the working mode in the power mode...

Page 342: ...s sure is increased q Turned to the left the set pres sure is decreased a Quantity of adjustment per turn of holder Approx 20 5 MPa Approx 209 kg cm2 4 While fixing holder 5 tighten locknut 6 3 Locknut 49 58 8 Nm 5 6 kgm 5 Connect pilot hose 4 6 After finishing adjustment check again that the oil pressure is normal according to the above described test procedure 2 Adjusting swing relief pressure a...

Page 343: ...le K2 and connect oil pressure gauge 1 of hydraulic tester K1 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 3 Start the engine set the working mode in the power mode P and turn the auto decelerator OFF 4 Run the engine at high idle set all the levers and pedals for work equipment control swing control and travel in neutral and test the oil pressure 5 After finishing test remove the testing too...

Page 344: ...perature Within operating range 1 Testing PC valve output pressure servo piston inlet pressure a Test the PC valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously and compare them 1 Open the side cover of the pump room and remove oil pressure pickup plugs 1 and 2 q 1 Pump discharge pressure pickup plug q 2 PC valve output pressure pickup plug 2 Install nipple...

Page 345: ...ut pressure pickup plug 2 Install nipples L2 and connect them to oil pressure gauges 1 a Use the oil pressure gauges of 5 9 MPa 60 kg cm2 3 Start the engine and set the working mode in the power mode P 4 Run the engine at high idle and low idle set all the levers and pedals for work equipment control swing control and travel in neutral and test the oil pressure at each speed a Testing condition an...

Page 346: ...p performance 1 Loosen locknut 5 a Before loosening the locknut make coun ter mark at the adjustment screw end so that you can see the position of the lock nut before the adjustment and you can return the locknut to its original position after turning it in reverse 2 Turn adjustment screw 6 clockwise or coun terclockwise to adjust a Turn the adjustment screw q Clockwise when the work equipment spe...

Page 347: ...et pressure a Test the LS valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously and compare them 1 Open the side cover of the pump room and remove oil pressure pickup plugs 1 and 2 q 1 Pump discharge pressure pickup plug q 2 LS valve output pressure pickup plug 2 Install nipple M3 and connect it to oil pres sure gauge 1 of hydraulic tester M1 a Install nipple...

Page 348: ...the side cover of the pump room and remove oil pressure pickup plugs 1 and 2 q 1 Pump discharge pressure pickup plug q 2 LS pressure pickup plug 2 Install nipples M3 and connect it to differ ential pressure gauge M2 or the oil pres sure gauge 1 of hydraulic tester M1 a When using differential pressure gauge M2 Connect the pump discharge pres sure to the high pressure side back side and connect the...

Page 349: ...owing ratio the LS valve is normal 6 After finishing test remove the testing tools and return the removed parts Insert the removed connector V5 of the solenoid valve in its original position Adjusting Adjusting LS valve a If the LS differential pressure is abnormal adjust the LS valve according to the following procedure q 3 Pump LS valve 1 While fixing adjustment screw 4 loosen lock nut 5 2 Turn ...

Page 350: ...nder the control valve remove the control valve undercover 2 Install adapter N2 and connect the discon nected hoses again 3 Install nipple N3 and connect it to pressure gauge 1 of hydraulic tester N1 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 a The testing tools installed to the outlet hose of the PPC lock solenoid valve are shown in the figure 4 Run the engine and heighten the hydraulic oi...

Page 351: ...enoid valves can be checked with the monitoring function of the machine monitor special function of the machine monitor a If the output pressure of a solenoid valve is as follows that solenoid valve is normal 6 After finishing test remove the testing tools and return the removed parts Table for functioning conditions PPC lock solenoid valve Solenoid valve Output pressure OFF De energized 0 MPa 0 k...

Page 352: ...ATT mode E mode When left knob switch is ON If signals other than swing operation only is ON If swing operation only is ON OFF In conditions other than above Functioning condition Functioning When overheat setting of the 2nd stage is ON OFF When the fuel dial indicates less than 1500 rpm When the travel speed switch is at Lo When the travel speed switch is at Hi The travel signal is OFF The travel...

Page 353: ...30 Testing and adjusting SEN04114 06 PC130 8 43 Functioning conditions merge divider solenoid valve ...

Page 354: ...hydraulic tester P1 and connect oil pressure gauge 1 a Use an oil pressure gauge with the capacity of 5 9 MPa 60 kg cm2 a The testing tools installed to the mounting part of the boom RAISE PPC oil pressure switch are shown in the figure 3 Start the engine and keep it running until the hydraulic oil temperature rises to the operating range a Turn OFF the auto decelerator switch Symbol Part No Part ...

Page 355: ...t work equipment levers have large play adjust them according to the follow ing procedure a The play of the lever terminal must be 0 5 3 mm at a position of 200 mm from the center of lever rotation 1 Remove the work equipment and swing PPC valve assembly 2 Remove bellows 1 3 Loosen locknut 2 and tighten disc 3 until it touches the heads of 4 pistons 4 4 Fix disc 3 and tighten locknut 2 to the spec...

Page 356: ... the arm control lever in the IN position q If the lowering speed is increased at this time the cylinder packing is defective q If the lowering speed does not change at this time the control valve is defec tive a Operate the control lever while the starting switch is in the ON position a If the pressure in the accumulator is lost run the engine for about 5 sec onds to heighten the pressure in the ...

Page 357: ...the lowering distance a Operate the control lever while the starting switch is in the ON position a If the pressure in the accumulator is lost run the engine for about 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 ...

Page 358: ...ure a To set the machine in the travel posture extract the bucket cylinder and arm cylin der fully and set the boom angle to 45 2 Set the working mode to P and travel speed to Lo 3 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 ...

Page 359: ...cap of the hydraulic tank slowly to release the residual pressure from the tank 1 Check the deviating direction and the locations of travel deviation adjusting plugs 1 and 2 q 1 Right deviation adjusting plug P1 pump q 2 Left deviation adjusting plug P2 pump a Loosen only the plug on either side for adjustment Do not loosen the plugs on both sides 2 Fixing plug 3 with a hexagonal wrench Width acro...

Page 360: ... and all remaining pressure is released from the piping completely With anti drop valve of boom k Place the machine on a level ground 1 Check the function of PPC accumulator 1 Retract arm cylinder and bucket cylin der to the stroke ends and hold the work equipment at height a above the ground a 1 5 m 2 Keep the arm cylinder and bucket cyl inder retracted to the stroke ends turn the starting switch...

Page 361: ...OCK position start the engine and run it with the fuel control dial at MIN Low idle position for approximately 5 seconds to increase the pressure in the accumulator 5 Repeat step 1 and 2 4 or 5 times to release the remaining pressure from the cylinders 6 Loosen oil filler cap of the hydraulic tank gradually to release the air in the tank a Leave the oil filler cap of the hydraulic tank removed a W...

Page 362: ...2 Set the work equipment lock lever to LOCK position start the engine and run it with the fuel control dial at MIN Low idle position for approximately 5 seconds to increase the pressure in the accumulator 4 Repeat step 1 and 2 4 or 5 times to release the remaining pressure from the cylinders 5 Loosen oil filler cap of the hydraulic tank gradually to release the air in the tank a Leave the oil fill...

Page 363: ... k Take care not to lower the boom 4 Start testing the oil leakage 30 seconds after relieving is started and test for 1 min ute 5 After finishing test return the removed parts 2 Testing oil leakage from arm cylinder 1 Move the arm cylinder to the IN stroke end and stop the engine k Release the residual pressure from the piping on the arm cylinder head side For details see Releas ing residual press...

Page 364: ... side 07376 70422 Plug 04 3 Run the engine at high idle and relieve the bucket circuit by curling the bucket k Take care not to dump the bucket 4 Start testing the oil leakage 30 seconds after relieving is started and test for 1 min ute 5 After finishing test return the removed parts 4 Testing oil leakage from swing motor 1 Disconnect 2 drain hoses 4 and block the hose side with plugs a Use the fo...

Page 365: ... side 07376 70422 Plug 04 4 Run the engine at high idle relieve the travel circuit and test the oil leakage k Before operating the travel lever check the position and locking direction of the locked sprocket again k Wrong operation of the lever can cause an accident Accordingly make signs and checks securely a Start testing the oil leakage 30 sec onds after relieving is started and test for 1 minu...

Page 366: ...ton rod about 100 mm before each stroke end Do not relieve the oil 3 While running the engine at high idle per form step 2 4 While running the engine at low idle move the piston rod to the stroke end and relieve the oil 5 Bleed air from the arm cylinder and bucket cylinder according to steps 2 4 Air bleeding procedure 1 2 3 4 5 6 Bleeding air from hydraulic pump Starting engine Bleeding air from c...

Page 367: ...its normal condi tion 5 Bleeding air from travel motor 1 Remove the travel motor cover and dis connect motor drain hose 2 2 Run the engine at low idle and check that oil flows out of nipple 3 6 Checking oil level and starting work 1 Run the engine retract the arm cylinder and bucket cylinder to the stroke ends lower the work equipment to the ground and stop the engine 2 Check the oil level by sigh...

Page 368: ... Remove the additional undercover from the rear of the operator s cab 2 Check the tightening torque of the mounting bolt 2 of the lock plate 1 3 Bolt 2 98 123 Nm 10 12 5 kgm Reference q 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 3 Bolt 4 245 309 Nm 25 31 5 kgm ...

Page 369: ...ed to the cor rect positions they may interfere with the exterior parts Tightening torque of mirror bolt 2 4 0 5 4 Nm 0 41 0 55 kgm Tightening torque of mirror stay bolt 3 15 Nm 1 52 kgm a If the tightening torque is low the bolts may be dragged If the former is too high the body may be broken Retract the mirror into position C when transporting the machine q Retractable mirror b1 Install at 65 mm...

Page 370: ...7 4 0 5 4 Nm 0 41 0 55 kgm 3 Adjustment of retractable mirrors 1 Adjust the retractable mirrors at position A 2 With retractable mirrors a1 and b1 open loosen mirror bolts 1 and 2 and stay mounting bolts 3 and 4 and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator s seat a Adjust the mirror so that the operator can see per...

Page 371: ...perator s seat 5 Adjustment of rear view monitor camera 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 If the image projected on the monitor deviates remove cover 4 and adjust installed angle A of the rear view monitor camera 1 To remove cover 1 insert a flat head screwdriver etc in hole 3 at the top of cove...

Page 372: ...s on the ground at 1 m around the machine from the operator s seat 3 Loosen camera mounting bolt 5 and adjust the installed angle of the camera so that the center of mounting bolt 5 will be set to 4th scale mark B from the bottom a A part of the machine is projected on the monitor 4 After adjusting tighten bolt 5 3 If the image projected on the monitor deviates remove cover 4 and adjust installed ...

Page 373: ...f the camera so that the center of mounting bolt 5 will be set to 4th scale mark B from the bottom a A part of the machine is projected on the monitor 4 After adjusting tighten bolt 5 Serial No 84241 and up a Adjust the camera so that persons in area w at 1 meter around the machine is displayed on the machine monitor in the operator cab If the image displayed on the monitor is out of posi tion rem...

Page 374: ...move two bolts 4 3 Remove cover 2 4 Loosen mounting bolts 5 of camera 1 and adjust installation angle A of camera so that the side line of camera is matched with the cor ner B of the bracket Angle A 48 2 0 a A part of the machine is displayed on the monitor screen Adjust the camera so that the image of the counterweight occupy about 10 to 15 of the monitor screen 5 After adjusting tighten bolts 5 ...

Page 375: ...ns they may interfere with the exterior parts Tightening torque of mirror bolt 2 6 0 7 0 Nm 0 61 0 71 kgm Tightening torque of mirror stay bolt 3 15 Nm 1 52 kgm a If the tightening torque is low the bolts may be dragged If the former is too high the body may be broken Retract the mirror into position C when transporting the machine q Retractable mirror b1 Install at 50 mm from the top of the stay ...

Page 376: ...7 4 0 5 4 Nm 0 41 0 55 kgm 3 Adjustment of retractable mirrors 1 Adjust the retractable mirrors at position A 2 With retractable mirrors a1 and b1 open loosen mirror bolts 1 and 2 and stay mounting bolts 3 and 4 and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator s seat a Adjust the mirror so that the operator can see per...

Page 377: ...perator s seat If the image projected on the monitor deviates remove cover 4 and adjust installed angle A of the rear view monitor camera 1 To remove cover 1 insert a flat head screwdriver etc in hole 3 at the top of cover 2 to push the inside claw and remove the cover 2 Remove 2 bolts 4 and remove cover 1 5 Adjustment of rear view monitor camera Adjust the rear view monitor camera so that the ope...

Page 378: ...s on the ground at 1 m around the machine from the operator s seat 3 Loosen camera mounting bolt 5 and adjust the installed angle of the camera so that the center of mounting bolt 5 will be set to 4th scale mark B from the bottom a A part of the machine is projected on the monitor 4 After adjusting tighten bolt 5 3 If the image projected on the monitor deviates remove cover 4 and adjust installed ...

Page 379: ... 2 to push the inside claw and remove the cover 2 Remove 2 bolts 4 and remove cover 1 3 Loosen camera mounting bolt 5 and adjust the installed angle of the camera so that the center of mounting bolt 5 will be set to 4th scale mark B from the bottom a A part of the machine is projected on the monitor 4 After adjusting tighten bolt 5 ...

Page 380: ...annot be removed with compressed air or water replace the filter with new one a Since the recirculated air filter has directional properties install it with the projection side toward the front of the machine 2 Cleaning of fresh air filter 1 Unlock cover 2 at the left rear of the operator s cab with the key starting switch key While holding cover 2 open with your hand take filter 3 out of the cove...

Page 381: ...30 Testing and adjusting SEN04114 06 PC130 8 71 ...

Page 383: ...130 8 1 SEN04115 04 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130 8 Machine model Serial number PC130 8 80001 and up 30 Testing and adjusting 1 Testing and adjusting Part 2 Special functions of machine monitor 2 ...

Page 384: ...SEN04115 04 30 Testing and adjusting 2 PC130 8 Special functions of machine monitor 1 Air conditioner specification ...

Page 385: ...t function switch is not working Lower section of machine monitor Switch sec tion 1 Numeral 1 input switch Auto decelerator switch 2 Numeral 2 input switch Working mode selector switch 3 Numeral 3 input switch Travel speed shifting switch 4 Numeral 4 input switch Alarm buzzer cancel switch 5 Numeral 5 input switch Wiper switch 6 Numeral 6 input switch Windshield washer switch 7 Numeral 7 input swi...

Page 386: ...l speed 8p A Display of ordinary screen 8p A Display of end screen 8p B Selection of auto deceleration 9p B Selection of working mode 9p B Selection of travel speed 10p B Operation to stop alarm buzzer 10p B Operation of windshield wiper 10p B Operation of window washer 10p B Operation of air conditioner heater 11p B Operation to display camera mode 11p B Operation to display clock and service met...

Page 387: ...me 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 ...

Page 388: ...s to Display of inputting password or Display of check before starting a The following screen may be displayed instead of the above Display of inputting password screen a If this screen is displayed call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy Display pattern A B C D E Display of KOMATSU logo 1 1 1 1 1 Display of inputting password 2 Display of...

Page 389: ...ydraulic components may be dam aged a After operation to check of the breaker mode is finished the screen changes to Display of check before starting If No is selected Working mode is set to econ omy mode E If Yes is selected Working mode is set to breaker mode B Display of check before starting When the screen changes to the check before starting screen the check before starting is carried out fo...

Page 390: ...speed Display of check of working mode and travel speed 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 Display of ordinary screen If the machine monitor starts normally the ordinary screen is d...

Page 391: ...ayed 2 Operate the function switches or working mode selector switch to select and confirm the work ing mode which you will use Function switches q F3 Move to lower working mode q F4 Move to upper working mode q F5 Cancel selection and return to ordi nary screen q F6 Confirm selection and return to ordi nary screen Working mode selector switch q Press Move to lower working mode q Hold down Confirm...

Page 392: ...s a Even if the alarm buzzer cancel switch is pressed the screen does not change Operation of windshield wiper While the ordinary screen is displayed if the wiper switch is pressed large wiper monitor a is dis played for 2 seconds and the windshield wiper starts or stops a Each time the wiper switch is pressed the windshield wiper setting is changed to INT ON OFF and INT again in order a When larg...

Page 393: ...n Operation to display camera mode When a camera is installed if F3 is pressed the multi display changes to the camera image Set the connection of the camera in the service mode a If a caution is generated in the camera mode the caution monitor is displayed at the left upper of the screen The low hydraulic oil tem perature caution is not displayed there how ever a Machine with two cameras a When a...

Page 394: ... and clock alternately a 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 Check of maintenance information While the maintenance monitor or ordinary screen is displayed press F5 and the maintenance table screen is displayed a To reset the time left after finishing mainte nance more operations are necessary ...

Page 395: ...r the user and the other is for the service q For user A message transmitted from the KOMTRAX base station for the user If it is received the message monitor is displayed on the ordinary screen To see the contents of the message operate User Message in the above user menu q For service A message transmitted from the KOMTRAX base station for the service Even if it is received nothing is displayed o...

Page 396: ...onitor is displayed large for a moment and then displayed at 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 Display of user code and failure code If an abnormality which displays a user code and a failure code occurs on the ordinary screen or cam era mode screen all the information of the abnor mality is displa...

Page 397: ...ngine controller drive system circuit error engine stopped Have inspection carried out immediately E11 Engine controller system error Output reduced to protect engine Operate machine to a safe posture and have inspection carried out immediately E14 Abnormality in throttle system Operate machine to a safe posture and have inspection carried out immediately E15 Engine sensor coolant temperature fuel...

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 Function of checking service meter To check the service meter while the starting switch is turned OFF operate the numeral input switches as follows At this time ...

Page 399: ...t numeral Return to ordi nary screen q 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 3 After the New password input screen is dis played input a new password with the numeral input switches and confirm it with the function switch ...

Page 400: ...SEN04115 04 30 Testing and adjusting 18 PC130 8 5 If the screen to notify completion of setting is displayed and then the ordinary screen is dis played the password is changed successfully ...

Page 401: ...witches or numeral input switches q F3 Move to lower menu q F4 Move to upper menu q F5 Return to ordinary screen operator mode q 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 a The items which can be selected in the service menu are as follows including some items which need special opera tions 01 Monitori...

Page 402: ...ion switches Select an item with F3 or F4 and confirm it with F6 a Selection with numeral input switches Enter a 5 digit code and the item of that code is selected directly Confirm that item with F6 a If the color of the selected box changes from yellow to red selection of the item of that box is confirmed a Up to 6 monitoring items can be selected at a time You may not able to set up to 6 items h...

Page 403: ... switches q F3 Reset holding q F4 Hold information displayed data q F5 Return to monitoring selection menu screen 6 Changing machine setting mode To change the setting of the working mode travel speed or auto deceleration during moni toring operate the corresponding switch under the current condition and the mode setting screen is displayed While this screen is displayed if the corre sponding swit...

Page 404: ...703 Measured ATT PPC pressure reducing EPC current value 4 mA mA mA PUMP 01704 Measured ATT PPC pressure reducing EPC current value 5 mA mA mA PUMP 42008 Lever potentiometer 1 voltage main for service flow control V V V PUMP 42009 Lever potentiometer 1 voltage sub for service flow control V V V PUMP 42010 Lever potentiometer 2 voltage main for service flow control V V V PUMP 42011 Lever potentiome...

Page 405: ...FF PUMP Attachment ON OFF PUMP 02300 Solenoid valve 1 Travel junction ON OFF PUMP Swing brake ON OFF PUMP Merge divide ON OFF PUMP 2 stage relief ON OFF PUMP Travel speed ON OFF PUMP 02200 Switch input 1 Lever switch ON OFF PUMP Swing release sw ON OFF PUMP Swing brake sw ON OFF PUMP 02201 Switch input 2 Blade spec ON OFF PUMP Overload alarm ON OFF PUMP 02202 Switch input 3 Key switch ON OFF PUMP ...

Page 406: ...a theoretical value it is a little different from the actual fuel consumption 04501 Monitor input 2 Air cleaner ON OFF MON Eng oil level ON OFF MON Battery charge ON OFF MON 04502 Monitor input 3 Swing brake sw ON OFF MON 04503 Monitor function switches F1 ON OFF MON F2 ON OFF MON F3 ON OFF MON F4 ON OFF MON F5 ON OFF MON F6 ON OFF MON 04504 Monitor 1st 2nd row switches SW1 ON OFF MON SW2 ON OFF M...

Page 407: ...peci fication are different from each other in the display of 03 Air conditioning System which may not be displayed in the heater less specification 3 Information displayed on abnormality record screen On the Mechanical Systems screen the fol lowing information is displayed a Occurrence order of abnormalities from latest one Total number of records b Failure code c Contents of trouble d Number of ...

Page 408: ...he 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 3 Information displayed on abnormality record screen On the Electrical Systems screen the follow ing information is displayed a Occurrence order of abnormalities from latest one Total number of records b Failure...

Page 409: ...t selected item a To reset items one by one Select the item to be reset with F3 or F4 and press F6 a 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 3 After the Electrical Sys Error Reset screen is displayed operate the functi...

Page 410: ...mp sensor high error ENG Electrical system E15 CA154 Charge air temp sensor low error ENG Electrical system E11 CA155 Chg air temp high speed derate ENG Electrical system E15 CA187 Sensor sup 2 volt low error ENG Electrical system E11 CA221 Ambient air press sensor high error ENG Electrical system E11 CA222 Ambient air press sensor low error ENG Electrical system E15 CA227 Sensor sup 2 volt high e...

Page 411: ...tem DA29KQ Model selection abnormality PUMP Electrical system E0E DA2RMC CAN discon Pump con detected PUMP Electrical system DAF8KB Short circuit in camera power supply MON Electrical system DAFGMC GPS module error KOM Electrical system E0E DAFRMC CAN discon Monitor detected MON Electrical system DGH2KB Hydr oil sensor short PUMP Electrical system DHPAMA Pump press sensor abnormality PUMP Electric...

Page 412: ... 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 DWK0KB 2 stage relief sol short PUMP Electrical system E02 DXA8KA PC EPC sol discon PUMP Electrical system E02 DXA8KB PC EPC sol short PUMP E...

Page 413: ... a You may enter a 2 digit code with the numeral input switches to select the record of that code and confirm it with F6 3 Information displayed on abnormality record screen On the Air conditioning System screen the following information is displayed a System Component name b Number of occurrence time c Condition Normal or abnormal q F2 Reset abnormality record q F5 Return to abnormality record sc...

Page 414: ...F1 Move to next page screen q F2 Move to previous page screen q F3 Move to lower item q F4 Move to upper item q 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 a The following items can be selected in the maintenance record 3 Items displayed on maintenance record screen The following items are displayed a Maintenance i...

Page 415: ...ng items can be selected on the Change of maintenance mode screen 3 Contents of setting of Maintenance mode on off After selecting Maintenance Mode On Off if the screen is displayed set ON or OFF with the function switches q ON Functions of all maintenance items are set effective in operator mode q OFF Functions of all maintenance items are set ineffective in operator mode q F3 Move to lower item ...

Page 416: ... Lower q F5 Cancel setting before confirmation and return to Maintenance mode change screen q F6 Confirm setting of upper or lower line a After the setting of the upper and lower lines is confirmed with F6 and the screen changes to the Maintenance mode change screen with F5 the setting is effective a If the set value of an item set to ON is changed after 1 or more operating hours since the start o...

Page 417: ...g telephone No After the Phone Number Entry screen is dis played register or change the telephone No q F2 Reset all input No q F3 Move to left position if not blank q F4 Move to right position if not blank q F5 Reset input digit Return to service menu q F6 Confirm input a 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...

Page 418: ... Power Mode P is displayed when key is ON q Economy Mode E is displayed when key is ON q Lifting Mode L is displayed when key is ON q Breaker Mode B is displayed when key is ON q Attachment Mode ATT is displayed when key is ON q Mode at Previous Key off Final mode in previous operation is displayed when key is ON q F3 Move to lower item q F4 Move to upper item q F5 Cancel selection and return to D...

Page 419: ...2 Selecting sub menu After the Default screen is displayed select Unit with the function switches or numeral input switches a Select this item similarly to an item on the Service Menu screen 3 Selecting unit After the Unit screen is displayed select the unit to be set with the function switches q F3 Move to lower unit q F4 Move to upper unit q F5 Cancel selection and return to Default screen q F6 ...

Page 420: ...lect this item similarly to an item on the Service Menu screen 3 Selecting With Without After the With Without Attachment screen is displayed select the setting with the function switches q Without Attachment When attachment is not installed q With Attachment When attachment is installed q F3 Move to lower item q F4 Move to upper item q F5 Cancel selection and return to Default screen q F6 Confirm...

Page 421: ...word screen is displayed q F3 Move to lower item q F4 Move to upper item q F5 Cancel selection and return to Default screen q F6 Confirm selection and return to Default screen 4 Displaying attachment maintenance password screen When the following operation is performed the password screen is displayed in the operator mode q Maintenance mode The Maintenance table screen is changed to the Mainte nan...

Page 422: ...Image Image of connected cam era is displayed in origi nal position as in mirror used as back monitor q Reverse Image Image of connected cam era is displayed in reverse position as seen directly used as front or side mon itor q F3 Move to left item q F4 Move to right item q F5 Cancel setting before confirmation and return to Default screen q F6 Confirm selection in each line a After Camera screen ...

Page 423: ...isplay setting After the ECO Display screen is displayed select the setting with the function switches q ON Display ECO q OFF Do not display ECO q F3 Move to left item q F4 Move to right item q F5 Cancel setting before confirmation and return to Default screen q 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 F...

Page 424: ...imilarly to an item on the Service Menu screen 3 Selecting absorption torque After the Pump Absorption Torque screen is displayed select a set value on the right side with the function switches q Set value For actual torque adjustment value see table q F3 Increase set value q F4 Decrease set value q F6 Confirm setting and return to Adjust ment menu screen a The 3 digits on the left side do not var...

Page 425: ...on switches or numeral input switches a Select this item similarly to an item on the Service Menu screen 3 Selecting distribution of oil flow After the screen of Attachment Flow Adjust ment is displayed select a set value on the right side with the function switches q Set value For actual distribution of flow see table q F3 Increase set value q F4 Decrease set value q F6 Confirm setting and return...

Page 426: ...ow a One or more cylinders can be Cut Out a In the cylinder Cut Out operation the auto deceleration function can be selected If the auto deceleration is turned ON auto deceleration monitor b is dis played 3 Resetting Cut Out cylinder When changing a cylinder to be Cut Out or when Cylinder Cut Out operation is finished select a Cut Out cylinder to be reset with the function switches a This operatio...

Page 427: ...of the machine it may be worn or damaged because of insufficient lubrication with oil To prevent this the function to lubricate the engine before starting it by cranking it without injecting fuel is installed Set the no injection cranking while the engine is stopped 1 Selecting menu Select No Injection on the Service Menu screen 2 Displaying check screen If the No injection screen is displayed the...

Page 428: ...ng motor 4 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 5 Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running the mes sage that the engine is running is displayed and th...

Page 429: ...e and time side and test starts a 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 3 Display and function during test Clock mark a flashes during test a While the fuel consumption is being tested the operator can work with the operator mode and other functions Test is not finished until this screen is displayed again ...

Page 430: ...een is dis played select Terminal Status with the func tion switches or numeral input switches a Select this item similarly to an item on the Service menu screen a The following figure shows the display when Model TH300 KOMTRAX is installed When TH200 is installed 03 IP Adress is dis played 3 Contents of display of terminal status On the Terminal Status screen the following items are displayed q T...

Page 431: ...e function switches or numeral input switches a Select this item similarly to an item on the Service Menu screen a The following figure shows the display when Model TH300 KOMTRAX is installed When TH200 is installed 03 IP Adress is dis played 3 Contents of display of GPS communication status On the screen of GPS Communication Sta tus the following items are displayed q Positioning Positioning cond...

Page 432: ... of the KOMTRAX communication MODEM 1 Selecting menu Select KOMTRAX Settings on the Service Menu screen 2 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 3 Contents of display of Modem S N The serial No of TH300 Modem is displayed q F5 Return t...

Page 433: ... 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 3 Display of message with return mail function If a box to enter a value with the numeral keys is displayed under the message enter a proper number with the numeral input switches and function switches and ...

Page 435: ... Machine model Serial number PC130 8 80001 and up 30 Testing and adjusting 1 Testing and adjusting Part 3 Handling voltage circuit of engine controller 2 Preparation work for troubleshooting of electrical system 3 Procedure for testing diodes 8 Pm Clinic service 9 ...

Page 436: ...nnec tor between the engine controller and engine be sure to turn the starting switch OFF 2 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 ...

Page 437: ...shows the model of the arm crane specification equipped with a level If the machine which you are working on has the arm crane specification remove level 2 2 Remove 1 mounting bolt and duct 3 3 Insert or connect troubleshooting T adapt ers in or to connectors CM01 CM02 and CM03 of machine monitor 4 a Connectors CM02 and CM03 are of the same type When returning them check the mark plates of the mou...

Page 438: ...ll the adapters to only the wiring harness side a The connectors of the pump control ler have a special locking mecha nism Disconnect them according to steps a c and connect them according to steps d f as shown below Disconnection a Unlock b Slide lever c Disconnect connec tor Connection d Position connector e Slide lever f Lock 4 KOMTRAX communication module 1 Slide the operator s seat and seat s...

Page 439: ...s a c and connect them according to steps d f as shown below Disconnection a Slide lever b Unlock c Disconnect connector 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 6 Boost pressure and temperature sensor Bo...

Page 440: ...gine side In this case pinch the lock in direction a with bent nose nippers 1 commercially available and the lock is reset Since the lock clicks when it is reset dis connect the connector after a click is heard a a a a Precautions for connecting connector Take care not to connect the connector reversely Engage lock e on the wiring harness side with triangular notch f on the sensor side Do not enga...

Page 441: ...or has a special locking mechanism Disconnect it according to steps a b and connect it according to steps c d as shown below Disconnection a Unlock b Discon nect connector 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 troubleshooti...

Page 442: ...de does not have conductivity Defective q 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 2 When using analog circuit tester 1 Set the tester in the resistance range 2 Apply the leads of the tester as explained below and check the movement of the pointer i Apply the red lead of the tester to the an...

Page 443: ...ine oil T Hydraulic oil When necessary T Damper case oil T Final drive case oil T Machinery case oil T Ambient temperature Altitude C m Operator s opinion Result of visual inspection Mechanical equipment system fault history Electrical equipment system fault history 989EKX times 1st time h last h times 1st time h last h AB00KE times 1st time h last h times 1st time h last h B BAZG times 1st time h...

Page 444: ...tandard value for new machine Service limit value Mea sured value Good Bad Fuel control dial Work ing mode Checking posture etc 1 Boom RAISE MAX P Work equipment extended fully sec 3 4 4 1 Max 4 3 2 Arm IN Boom top horizontal sec 2 9 3 5 Max 4 0 3 Arm OUT sec 2 4 3 0 Max 3 7 4 Bucket CURL Boom top horizontal Arm cylinder retracted fully sec 2 4 2 9 Max 3 4 5 Swing 5 turns Work equipment extended f...

Page 445: ...everse relief F Left travel lock Left forward relief F Left travel lock Left reverse relief F Standard value Checked oil pressure Unit Standard value for new machine Service limit value A Control circuit basic pressure MPa kg cm2 3 0 3 4 31 35 2 7 3 7 28 35 B Work equipment relief pressure 30 9 32 8 315 335 30 9 33 8 315 345 C Unload pressure 1 8 3 8 18 38 1 8 3 8 18 38 D LS differential pressure ...

Page 446: ... F pump F R pump R LS EPC 8 PC EPC valve MIN P All levers in neutral J1 J1 MAX J2 J2 E J3 J3 L J4 J4 B J5 J5 Standard value Checked oil pressure Unit Standard value for new machine Service limit value J1 PC EPC valve output pressure 1 MPa kg cm2 Approx 1 7 Approx 18 J2 PC EPC valve output pressure 2 Approx 0 3 Approx 3 J3 PC EPC valve output pressure 3 Approx 0 5 Approx 5 J4 PC EPC valve output pr...

Page 447: ...30 Testing and adjusting SEN04116 00 PC130 8 13 ...

Page 449: ...30 8 1 SEN04117 03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130 8 Machine model Serial number PC130 8 80001 and up 40 Troubleshooting 1 Failure code table and fuse locations Failure code table 2 Fuse locations 6 ...

Page 450: ...and Bkup speed sensor error ENG Electrical system E11 CA122 Charge air press sensor high error ENG Electrical system E11 CA123 Charge air press sensor low error ENG Electrical system E14 CA131 Throttle sensor high error ENG Electrical system E14 CA132 Throttle sensor low error ENG Electrical system E15 CA144 Coolant temp sensor high error ENG Electrical system E15 CA145 Coolant temp sensor low err...

Page 451: ...lectrical system E11 CA451 Rail press sensor high error ENG Electrical system E11 CA452 Rail press sensor low error ENG Electrical system E11 CA488 Chg air temp high torque derate ENG Electrical system E15 CA553 Rail press high error ENG Electrical system E15 CA559 Rail press low error ENG Electrical system E15 CA689 Eng Ne speed sensor error ENG Electrical system E15 CA731 Eng Bkup speed sensor p...

Page 452: ...ity PUMP Electrical system E20 DHSJMA Travel right reverse PPC press sensor abnormality PUMP Electrical system DHX1MA Overload sensor abnormality Analog PUMP Electrical system DV20KB Travel alarm short circuit PUMP Electrical system DW43KA Travel speed sol discon PUMP Electrical system DW43KB Travel speed sol short PUMP Electrical system E03 DW45KA Swing brake sol discon PUMP Electrical system E03...

Page 453: ...ty ENG The engine controller is in charge of detection of abnormality 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 DY20KA Wiper working abnormality PUMP Electrica...

Page 454: ...city Destination of power Switch power supply F04 65A 1 10A Pump resistor light switch swing holding brake release switch 2 30A Pump controller 3 10A Starting motor cutout relay PPC oil pressure lock switch 4 10A Windshield washer cigar lighter electrical intake air heater 5 10A Horn Switch power supply F04 65A 6 10A Spare 7 10A Rotary lamp If equipped 8 20A Working lamp relay 9 10A Radio speaker ...

Page 455: ...40 Troubleshooting SEN04117 03 PC130 8 7 Locations of fusible links Location of fuse box and fuse Nos ...

Page 457: ...leshooting Points to remember when troubleshooting 2 Sequence of events in troubleshooting 3 Checks before troubleshooting 4 Classification and procedures for troubleshooting 5 Information in troubleshooting table 6 Phenomena looking like troubles and troubleshooting Nos 8 Connection table for connector pin numbers 11 T branch box and T branch adapter table 47 ...

Page 458: ...lso lose the confidence of the user or operator For this reason when carrying out troubleshooting it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure 2 Points to ask user or operator 1 Have any other problems occurred apart from the problem that has been reported 2 Was there anything strange about the machine before the ...

Page 459: ...40 Troubleshooting SEN04118 02 PC130 8 3 Sequence of events in troubleshooting 1 ...

Page 460: ... looseness and corrosion Retighten or replace 3 Check of starting motor terminals and wiring for looseness and corrosion Retighten or replace Hydraulic Mechanical equipment 1 Check for abnormal noise and smell Repair 2 Check for oil leakage Repair 3 Bleeding air Bleed air Electric electrical equipment 1 Check of battery voltage with engine stopped 20 30 V Replace 2 Check of electrolyte level Add o...

Page 461: ...rding to the recorded code a If an electrical system failure code is recorded delete all the codes and reproduce them and then see if the trouble is still detected a An error code of the mechanical system cannot be deleted a If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the abnormality record function carry out the corresponding troubleshooting...

Page 462: ...ontents of description Standard value in normal state to judge possible causes Remarks on judgment Troubles in wiring harness Disconnection Connector is connected imperfectly or wiring harness is bro ken Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit Hot short Wiring harness which is not connected to power source 24 V circuit ...

Page 463: ...ic circuit diagram related to trouble shooting q Connector No Indicates Model Number of pins and Color q 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 q Arrow Roughly shows the location on the machine ...

Page 464: ...bustion S 7 12 Oil consumption is excessive or exhaust smoke is blue S 8 13 Oil becomes contaminated quickly S 9 14 Fuel consumption is excessive S 10 15 Oil is in coolant or coolant spurts back or coolant level goes down S 11 16 Oil pressure drops S 12 17 Oil level rises Entry of coolant or fuel S 13 18 Coolant temperature becomes too high overheating S 14 19 Abnormal noise is made S 15 20 Vibrat...

Page 465: ...stops swinging it makes large shock H 24 51 When upper structure stops swinging it makes large sound H 25 52 Swing holding brake does not operate normally Hydraulic drift of swing is large E 21 H 26 Phenomena related to machine monitor 53 When starting switch turned ON machine monitor displays nothing E 1 54 When starting switch turned ON before starting engine basic check item lights up E 2 55 Pr...

Page 466: ...PC130 8 68 Monitoring function does not display lever control signal normally E 26 Other phenomena 69 KOMTRAX system does not operate normally E 27 No Phenomena looking like troubles Troubleshooting Display of code E mode H mode S mode ...

Page 467: ...SEN04118 02 PC130 8 11 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 ...

Page 468: ...SEN04118 02 40 Troubleshooting 12 PC130 8 ...

Page 469: ...40 Troubleshooting SEN04118 02 PC130 8 13 ...

Page 470: ...SEN04118 02 40 Troubleshooting 14 PC130 8 ...

Page 471: ...40 Troubleshooting SEN04118 02 PC130 8 15 ...

Page 472: ...SEN04118 02 40 Troubleshooting 16 PC130 8 ...

Page 473: ...40 Troubleshooting SEN04118 02 PC130 8 17 ...

Page 474: ...SEN04118 02 40 Troubleshooting 18 PC130 8 ...

Page 475: ...40 Troubleshooting SEN04118 02 PC130 8 19 ...

Page 476: ...SEN04118 02 40 Troubleshooting 20 PC130 8 ...

Page 477: ...40 Troubleshooting SEN04118 02 PC130 8 21 ...

Page 478: ...SEN04118 02 40 Troubleshooting 22 PC130 8 ...

Page 479: ...40 Troubleshooting SEN04118 02 PC130 8 23 ...

Page 480: ...SEN04118 02 40 Troubleshooting 24 PC130 8 ...

Page 481: ...40 Troubleshooting SEN04118 02 PC130 8 25 ...

Page 482: ...SEN04118 02 40 Troubleshooting 26 PC130 8 ...

Page 483: ...40 Troubleshooting SEN04118 02 PC130 8 27 ...

Page 484: ...SEN04118 02 40 Troubleshooting 28 PC130 8 ...

Page 485: ...40 Troubleshooting SEN04118 02 PC130 8 29 ...

Page 486: ...SEN04118 02 40 Troubleshooting 30 PC130 8 ...

Page 487: ...40 Troubleshooting SEN04118 02 PC130 8 31 ...

Page 488: ...SEN04118 02 40 Troubleshooting 32 PC130 8 ...

Page 489: ...40 Troubleshooting SEN04118 02 PC130 8 33 ...

Page 490: ...SEN04118 02 40 Troubleshooting 34 PC130 8 ...

Page 491: ...40 Troubleshooting SEN04118 02 PC130 8 35 ...

Page 492: ...SEN04118 02 40 Troubleshooting 36 PC130 8 ...

Page 493: ...40 Troubleshooting SEN04118 02 PC130 8 37 ...

Page 494: ...SEN04118 02 40 Troubleshooting 38 PC130 8 ...

Page 495: ...40 Troubleshooting SEN04118 02 PC130 8 39 ...

Page 496: ...SEN04118 02 40 Troubleshooting 40 PC130 8 ...

Page 497: ...40 Troubleshooting SEN04118 02 PC130 8 41 ...

Page 498: ...SEN04118 02 40 Troubleshooting 42 PC130 8 ...

Page 499: ...40 Troubleshooting SEN04118 02 PC130 8 43 ...

Page 500: ...SEN04118 02 40 Troubleshooting 44 PC130 8 ...

Page 501: ...40 Troubleshooting SEN04118 02 PC130 8 45 ...

Page 502: ...SEN04118 02 40 Troubleshooting 46 PC130 8 ...

Page 503: ...10 Adapter for BENDIX MS 14 MS 14P q 799 601 3470 Case q 799 601 2710 Adapter for MIC 5 MIC 5P q q q 799 601 2720 Adapter for MIC 13 MIC 13P q q q 799 601 2730 Adapter for MIC 17 MIC 17P q q q q q q 799 601 2740 Adapter for MIC 21 MIC 21P q q q q q q 799 601 2950 Adapter for MIC 9 MIC 9P q q q q 799 601 2750 Adapter for ECONO 2 ECONO2P q q 799 601 2760 Adapter for ECONO 3 ECONO3P q q 799 601 2770 ...

Page 504: ...pter for DT 2 DT2 q q q q 799 601 9030 Adapter for DT 3 DT3 q q 799 601 9040 Adapter for DT 4 DT4 q q q q 799 601 9050 Adapter for DT 6 DT6 q q 799 601 9060 Adapter for DT Gray 8 DT8GR q q 799 601 9070 Adapter for DT Black 8 DT8B q q 799 601 9080 Adapter for DT Green 8 DT8G q q 799 601 9090 Adapter for DT Brown 8 DT8BR q q 799 601 9110 Adapter for DT Gray 12 DT12GR q q 799 601 9120 Adapter for DT ...

Page 505: ... Oil pressure switch 2 4160 q q 799 601 4180 Adapter for engine CRI T3 PEVA 3 4180 q q 799 601 4190 Socket for engine CRI T3 Commonrail pressure 3 1 2 3L q q 799 601 4230 Socket for engine CRI T3 Air intake pressure temperature 4 1 2 3 4C q q 799 601 4240 Socket for engine CRI T3 PAMB 3 1 2 3A q q 799 601 4250 Socket for engine CRI T3 PIM 3 1 2 3B q q 799 601 4330 Socket for engine CRI T3 G 3 1 2 ...

Page 507: ...ging 5 Failure code AB00KE Charge voltage low 6 Failure code B BAZG Eng oil press low 8 Failure code B BAZK Eng oil level low 9 Failure code B BCNS Eng coolant overheat 10 Failure code B BCZK Eng water level low 12 Failure code B HANS Hydr oil overheat 14 Failure code CA111 ECM critical internal failure 16 Failure code CA115 Eng Ne and Bkup speed sensor error 19 Failure code CA122 Charge air press...

Page 508: ...e CA221 Ambient air press sensor high error 36 Failure code CA222 Ambient air press sensor low error 38 Failure code CA227 Sensor sup 2 volt high error 39 Failure code CA234 Eng overspeed 40 Failure code CA238 Ne speed sensor sup volt error 42 Failure code CA271 IMV PCV1 short error 44 Failure code CA272 IMV PCV1 open error 45 Failure code CA322 Injector 1 L 1 system open short error 46 Failure co...

Page 509: ... machine monitor This trouble may be caused by replacement of machine monitor User code Failure code Trouble Engine controller lock caution 2 Machine monitor system 989M00 Contents of trouble Engine controller lock is detected Factor 2 Action of machine monitor None in particular If cause of failure disappears system resets itself Problem that appears on machine Engine cannot be started Related in...

Page 510: ...tting If cause of failure disappears system resets itself Problem that appears on machine Related information Method of reproducing failure code Failure code is not reproduced since system is reset automati cally Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective engine controller If this failure code is displayed repeatedl...

Page 511: ...is operated as it is engine may be damaged Related information Condition of air cleaner clogging switch signal can be checked with monitoring function Code 04501 Monitor input 2 Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Clogging of air cleaner when system is normal Air cleaner ...

Page 512: ...ormal state Remarks on troubleshooting 1 Defective alternator when system is normal a Prepare with starting switch OFF then start engine and carry out troubleshooting M22 male Engine speed Voltage 1 chassis ground Min medium speed 27 5 29 5 V 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ...

Page 513: ...40 Troubleshooting SEN04119 01 PC130 8 7 Circuit diagram related ...

Page 514: ...ppears on machine If machine is operated as it is engine may be damaged Related information Engine oil pressure switch signal is input to engine controller and then transmitted to machine mon itor Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of engine oil pres sure when s...

Page 515: ...ue in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of engine oil level when system is normal a Check the engine oil level and add new oil If this phenomenon frequently occurs investigate the cause 2 Defective engine oil level switch Internal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON...

Page 516: ...ay be seized Related information Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor Engine coolant temperature can be checked with monitoring function Code 04107 Engine coolant temperature Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troub...

Page 517: ...40 Troubleshooting SEN04119 01 PC130 8 11 ...

Page 518: ...oubleshooting 1 Lowering of radiator coolant level when system is normal a Check the coolant level and add coolant If this phenomenon frequently occurs investigate the cause 2 Defective radiator coolant level switch internal discon nection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON P24 male Radiator coolant level Resistance Between 1 2 Val...

Page 519: ...40 Troubleshooting SEN04119 01 PC130 8 13 Circuit diagram related ...

Page 520: ... information Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine monitor Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraulic oil temperature Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Overheatin...

Page 521: ...40 Troubleshooting SEN04119 01 PC130 8 15 ...

Page 522: ...elay a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE02 female 55 32 Resis tance 185 265 z 3 Disconnection in wiring harness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE02 female ...

Page 523: ...esis tance Min 1 Mz Wiring harness between CE02 female 32 R23 2 and chassis ground Resis tance Min 1 Mz Wiring harness between CE02 female 32 R24 2 and chassis ground Resis tance Min 1 Mz Wiring harness between CE03 female 3 R23 5 and chassis ground Resis tance Min 1 Mz Wiring harness between CE03 female 3 R24 5 and chassis ground Resis tance Min 1 Mz Wiring harness between R23 female 3 battery an...

Page 524: ...SEN04119 01 40 Troubleshooting 18 PC130 8 Circuit diagram related ...

Page 525: ...troubleshooting 1 Defective Ne speed sensor system Carry out troubleshooting for failure code CA689 2 Defective Bkup speed sen sor system Carry out troubleshooting for failure code CA778 3 Defective mount of Ne speed sensor Check mount of Ne speed sensor directly for defect defective installation of sensor indicator ring of crankshaft etc 4 Defective mount of Bkup speed sensor Check mount of Bkup ...

Page 526: ...switch OFF then turn starting switch ON or start engine and carry out troubleshooting PTIM Voltage Between 3 1 Power supply 4 75 5 25 V Sensor voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and con troller too for another cause of trouble and then judge 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in conn...

Page 527: ...ng harness between ENG1 female 19 PTIM female 4 and wiring harness between ENG1 female 36 PTIM female 3 Resis tance Min 1 Mz Wiring harness between ENG1 female 19 PTIM female 4 and wiring harness between ENG1 female 48 PTIM female 1 Resis tance Min 1 Mz Chassis ground between ENG1 female 36 PTIM female 3 and chassis ground between ENG1 female 48 PTIM female 1 Resis tance Min 1 Mz 6 Defective engin...

Page 528: ...xes charge pressure 400 kPa 4 08 kg cm2 and continues operation Problem that appears on machine Acceleration performance of engine drops Related information Signal voltage of charge boost pressure sensor can be checked with monitoring function Code 36501 Boost pressure sensor voltage Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause ...

Page 529: ...40 Troubleshooting SEN04119 01 PC130 8 23 ...

Page 530: ...ut troubleshoot ing without turning starting switch ON P20 male Resistance Between 1 3 4 0 6 0 kz Between 2 1 0 25 5 0 kz Between 2 3 0 25 5 0 kz 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE02 female 27 P20 female 1 Resis t...

Page 531: ...40 Troubleshooting SEN04119 01 PC130 8 25 Circuit diagram related ...

Page 532: ...n fuel control dial signal and continues operation depending on each model Problem that appears on machine Engine speed cannot be controlled with fuel control dial Related information Signal voltage of fuel control dial can be checked with monitoring function Code 03000 Fuel control dial voltage Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal ...

Page 533: ...40 Troubleshooting SEN04119 01 PC130 8 27 ...

Page 534: ... ing without turning starting switch ON TWTR male Coolant temperature Resistance Between A B 0 C 30 37 kz 25 C 9 3 10 7 kz 50 C 3 2 3 8 kz 80 C 1 0 1 3 kz 95 C 700 800 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female...

Page 535: ...40 Troubleshooting SEN04119 01 PC130 8 29 Circuit diagram related ...

Page 536: ...n of controller Fixes coolant temperature 90 C and continues operation Problem that appears on machine Related information Signal voltage of coolant temperature sensor can be checked with monitoring function Code 04105 Engine coolant temperature sensor voltage Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal...

Page 537: ...40 Troubleshooting SEN04119 01 PC130 8 31 ...

Page 538: ...t troubleshoot ing without turning starting switch ON PTIM male Intake air temperature Resistance Between 2 1 0 C 29 36 kz 25 C 9 11 kz 40 C 4 9 5 8 kz 100 C 600 700 z Between 2 chassis ground All range Min 1 Mz 2 Disconnection in wiring harness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting swi...

Page 539: ...40 Troubleshooting SEN04119 01 PC130 8 33 Circuit diagram related ...

Page 540: ...igh speed derate Engine controller system E11 CA155 Contents of trouble Temperature signal of charge boost pressure temperature sensor exceeded control upper temper ature limit Action of controller Limits output and continues operation Problem that appears on machine Engine output lowers Engine stops Related information Charge boost temperature can be checked with monitoring function Code 18500 Bo...

Page 541: ...A187 Contents of trouble Low voltage was detected in sensor power supply 2 5 V circuit Action of controller Problem that appears on machine Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting Carry out troubleshooting for failure code CA227 ...

Page 542: ... then turn starting switch ON and carry out troubleshooting PAMB Voltage Between 3 1 Power supply 4 75 5 25 V Between 2 1 Signal 0 3 4 7 V Sensor voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and con troller too for another cause of trouble and then judge 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in c...

Page 543: ... ENG1 female 36 PAMB female 3 and wiring har ness between ENG1 female 20 PAMB female 2 Resis tance Min 1 Mz Wiring harness between ENG1 female 36 PAMB female 3 and wiring har ness between ENG1 female 48 PAMB female 1 Resis tance Min 1 Mz Wiring harness between ENG1 female 20 PAMB female 2 and wiring har ness between ENG1 female 48 PAMB female 1 Resis tance Min 1 Mz 6 Defective engine controller a ...

Page 544: ...ler Sets oil pressure to default value 52 44 kPa 0 53 kg cm2 and continues operation Problem that appears on machine Output drops Related information Signal voltage of ambient pressure sensor can be checked with monitoring function Code 37401 Ambient pressure sensor voltage Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Causes Standard ...

Page 545: ...tected in sensor power supply 2 5 V circuit Action of controller Problem that appears on machine Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective engine controller a Prepare with starting switch OFF then turn starting switch ON and carry out t...

Page 546: ...peed can be checked with monitoring function Code 01002 Engine speed Method of reproducing failure code Run engine at high idle Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective related system If another failure code is indicated carry out troubleshooting for it 2 Improper way of use Way of use may be improper Teach proper...

Page 547: ...40 Troubleshooting SEN04119 01 PC130 8 41 ...

Page 548: ...has a defect in it Ne speed sensor NE connector 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 26 NE female 3 Resis tance Max 1 z Wiring harness between ENG1 female 44 NE female 2 Resis tance Max 1 z 3 Ground fault i...

Page 549: ...40 Troubleshooting SEN04119 01 PC130 8 43 Circuit diagram related ...

Page 550: ...n 1 2 2 3 5 3 z Between 1 2 chassis ground Min 1 Mz 2 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 10 PREG female 1 Resis tance Min 1 Mz Wiring harness between ENG1 female 14 PREG female 2 Resis tance Min 1 Mz 3 Hot short Short circuit with 24V...

Page 551: ... 1 2 chassis ground Min 1 Mz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 10 PREG female 1 Resis tance Max 1 z Wiring harness between ENG1 female 14 PREG female 2 Resis tance Max 1 z 3 Ground fault in wiring har ne...

Page 552: ... ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 57 CN1 female 2 Resis tance Max 1 z Wiring harness between ENG1 female 53 CN1 female 1 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting s...

Page 553: ...40 Troubleshooting SEN04119 01 PC130 8 47 Circuit diagram related ...

Page 554: ... ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 55 CN3 female 2 Resis tance Max 1 z Wiring harness between ENG1 female 59 CN3 female 1 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting sw...

Page 555: ...40 Troubleshooting SEN04119 01 PC130 8 49 Circuit diagram related ...

Page 556: ... ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 45 CN2 female 2 Resis tance Max 1 z Wiring harness between ENG1 female 58 CN2 female 1 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting sw...

Page 557: ...40 Troubleshooting SEN04119 01 PC130 8 51 Circuit diagram related ...

Page 558: ... ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 56 CN4 female 2 Resis tance Max 1 z Wiring harness between ENG1 female 51 CN4 female 1 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting sw...

Page 559: ...40 Troubleshooting SEN04119 01 PC130 8 53 Circuit diagram related ...

Page 561: ... Abnormality in engine oil pressure switch 10 Failure code CA441 Battery voltage low error 11 Failure code CA442 Battery voltage high error 12 Failure code CA449 Rail press very high error 13 Failure code CA451 Rail press sensor high error 14 Failure code CA452 Rail press sensor low error 16 Failure code CA488 Chg air temp high torque derate 17 Failure code CA553 Rail press high error 18 Failure c...

Page 562: ...2 Failure code CA2249 Rail press very low error 32 Failure code CA2311 Abnormality in IMV solenoid 33 Failure code D110KB Battery relay drive short 34 Failure code D19JKZ Personal code relay abnormality 36 Failure code D862KA GPS antenna discon 38 Failure code DA22KK Pump solenoid power low error 40 Failure code DA25KP 5V sensor 1 power abnormality 42 Failure code DA26KP 5V sensor 2 power abnormal...

Page 563: ...in particular Problem that appears on machine Continues normal operation Engine stops or does not start Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defect in related system If another failure code is displayed carry out troubleshooting for it 2 Defe...

Page 564: ...s turned OFF circuit probably has ground fault 3 Defective power supply cut out relay a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE02 female 55 32 Resis tance 185 265 z 4 Disconnection in wiring harness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubl...

Page 565: ...sis tance Min 1 Mz Wiring harness between CE02 female 32 R23 2 and chassis ground Resis tance Min 1 Mz Wiring harness between CE02 female 32 R24 2 and chassis ground Resis tance Min 1 Mz Wiring harness between CE03 female 3 R23 5 and chassis ground Resis tance Min 1 Mz Wiring harness between CE03 female 3 R24 5 and chassis ground Resis tance Min 1 Mz Wiring harness between R23 female 3 battery and...

Page 566: ...SEN04120 03 40 Troubleshooting 6 PC130 8 Circuit diagram related ...

Page 567: ...d sensor Sets atmospheric pressure sensor to default value 52 44 kPa 0 53 kg cm2 and continues opera tion Fixes charge pressure sensor value 400 kPa 4 08 kg cm2 and continues operation Limits output and continues operation Limits common rail pressure Problem that appears on machine Output drops Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standa...

Page 568: ...vice has a defect in it Bkup speed sensor CAM connector Atmospheric pressure sensor PAMB connector Charge pressure sensor PTIM connector Common rail pressure sensor PFUEL connector 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ...

Page 569: ...40 Troubleshooting SEN04120 03 PC130 8 9 Circuit diagram related ...

Page 570: ... engine oil pressure switch a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON POIL male Resistance Between 1 chassis ground Max 1 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness betwe...

Page 571: ... power supply voltage circuit Action of controller None in particular Problem that appears on machine Engine continues operation normally but it may stop during operation or may not be able to start Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry ou...

Page 572: ...er power supply voltage circuit Action of controller None in particular Problem that appears on machine Engine continues operation normally but it may stop during operation or may not be able to start Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry ...

Page 573: ...sure level 2 Action of controller Limits output and continues operation Limits common rail pressure Problem that appears on machine Output drops Related information Common rail pressure can be checked with monitoring function Code 36400 Common rail pressure Method of reproducing failure code Start engine Possible causes and standard value in normal state Causes Standard value in normal state Remar...

Page 574: ...tch ON or start engine and carry out troubleshooting PFUEL Voltage Between 3 1 Power supply 4 75 5 25 V Between 2 1 Signal 0 25 4 6 V Sensor voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and con troller too for another cause of trouble and then judge 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec...

Page 575: ...ENG1 female 36 PFUEL female 3 and wiring harness between ENG1 female 29 PFUEL female 2 Resis tance Min 1 Mz Wiring harness between ENG1 female 36 PFUEL female 3 and wiring harness between ENG1 female 48 PFUEL female 1 Resis tance Min 1 Mz Wiring harness between ENG1 female 29 PFUEL female 2 and wiring harness between ENG1 female 48 PFUEL female 1 Resis tance Min 1 Mz 6 Defective engine controller ...

Page 576: ...er Limits output and continues operation Limits common rail pressure Problem that appears on machine Output drops Related information Signal voltage of common rail pressure sensor can be checked with monitoring function Code 36401 Common rail pressure sensor voltage Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in...

Page 577: ...Code 18500 Boost temperature Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of cooling perfor mance of aftercooler Cooling performance of aftercooler may be low Check following points directly Looseness and breakage of fan belt Insufficiency of cooling air Clogging of after...

Page 578: ...ses Standard value in normal state Remarks on troubleshooting 1 Defective related system If another failure code is indicated carry out troubleshooting for it 2 Use of improper fuel Check fuel used directly for high viscosity 3 Defective electrical system of common rail pressure sensor Common rail pressure sensor may have electric trouble Carry out troubleshooting for failure code CA451 4 Defectiv...

Page 579: ...proper fuel Check fuel used directly for high viscosity 3 Clogging of fuel filter a If a fuel filter is clogged replace it 4 Defective low pressure cir cuit device a For contents of troubleshooting see Note 1 For check of pres sure in fuel low pressure circuit see Testing and adjusting Testing fuel pressure Pressure in fuel low pressure cir cuit At high idle or rated load 49 0 kPa 0 5 0 kg cm2 5 D...

Page 580: ...ing CA 7 Boost pressure Equivalent to rating kPa 8 Engine coolant temperature Low idle C 9 Fuel temperature Low idle C 5 Check of reduced cylinder mode operation Engine speed Function Reduced cylinder Checking condition Unit Standard value Reference value Measured value Good NG 10 No 1 cylinder Low idle rpm No 2 cylinder Low idle rpm No 3 cylinder Low idle rpm No 4 cylinder Low idle rpm C Check of...

Page 581: ...g Special functions of machine monitor Monitoring items table 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 ...

Page 582: ...Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 26 NE female 3 and chassis ground Resis tance Min 1 Mz Wiring harness between ENG1 female 44 NE female 2 and chassis ground Resis tance Min 1 Mz Wiring harness between ENG1 fema...

Page 583: ...ble causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 7 Defective engine controller If causes 1 6 are not detected engine controller may be defec tive Since trouble is in system troubleshooting cannot be carried out ...

Page 584: ... Running engine stops when Ne speed sensor is also abnormal Stopped engine cannot be started when Ne speed sensor is also abnormal Related information Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective engine Ne speed sensor system Engine Ne speed sensor may be defective Carr...

Page 585: ...controller are lost Action of controller None in particular Problem that appears on machine Engine continues operation normally but it may stop during operation or may not be able to start Related information Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry out trouble...

Page 586: ...t circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 36 CAM female 3 and chassis ground Resis tance Min 1 Mz Wiring harness between ENG1 female 48 CAM female 2 and chassis ground Resis tance Min 1 Mz Wiring harness between ENG1 female 37 CAM female 1 and chassis ground Resis tance Min 1 ...

Page 587: ...40 Troubleshooting SEN04120 03 PC130 8 27 Circuit diagram related ...

Page 588: ...harness between CM02 female 10 CP01 female 64 CE02 female 21 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CM02 female 8 9 CP01 female 45 CE02 female 1 K02 female A N08 male 3 and chassis ground Resis tance Min 1 Mz Wiring ...

Page 589: ...40 Troubleshooting SEN04120 03 PC130 8 29 Circuit diagram related ...

Page 590: ...t in it Fuel control dial P20 connector 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE02 female 27 P20 female 1 Resis tance Max 1 z Wiring harness between CE02 female 28 P20 female 3 Resis tance Max 1 z 3 Ground fault in wiri...

Page 591: ...40 Troubleshooting SEN04120 03 PC130 8 31 Circuit diagram related ...

Page 592: ...of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry out troubleshooting for failure code CA2185 User code Failure code Trouble Rail press very low error Engine controller system E11 CA2249 Contents of trouble Supply pump does not feed fuel level 2 Action of controller Limits com...

Page 593: ... out troubleshoot ing without turning starting switch ON PREG male Resistance Between 1 2 2 3 5 3 z Between 2 chassis ground Min 1 Mz 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ENG1 female 10 PREG female 1 Resis tance Max 1 ...

Page 594: ...e Remarks on troubleshooting 1 Defective battery relay Internal defect a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Battery relay Resistance Between BR terminal BR RE terminal E There is continuity Between BR terminal BR chassis ground Min 1 Mz 2 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting switch O...

Page 595: ...40 Troubleshooting SEN04120 03 PC130 8 35 Circuit diagram related ...

Page 596: ...nternal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Troubleshooting for relay unit R07 male Resistance Between 1 2 300 600 z a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Troubleshooting by replace ment Replace personal code relay R07 with another relay and perfo...

Page 597: ...40 Troubleshooting SEN04120 03 PC130 8 37 Circuit diagram related ...

Page 598: ... particular If cause of failure disappears system resets itself Problem that appears on machine GPS cannot measure position Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective GPS antenna or antenna cable Possible causes are defective GPS antenna ...

Page 599: ...40 Troubleshooting SEN04120 03 PC130 8 39 ...

Page 600: ...en circuit probably has ground fault See Cause 3 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP02 female 116 118 121 F01 2 Resis tance Max 1 z Wiring harness between F01 1A F04 male 2 Resis tance Max 1 z Wiring harness betwee...

Page 601: ...40 Troubleshooting SEN04120 03 PC130 8 41 Circuit diagram related ...

Page 602: ... start ing switch ON and carry out troubleshooting Disconnect sensors at right in order and carry out operation to reproduce trouble If E of fail ure code goes off when a sensor is disconnected that sensor is defective Bucket DIGGING PPC pressure switch P01 Boom DOWN PPC pressure switch P02 Swing RIGHT PPC pressure switch P03 Arm DIGGING PPC pressure switch P04 Bucket DUMP PPC pressure switch P05 ...

Page 603: ...emale 73 P01 female 2 and chassis ground Bucket DIGGING PPC pressure switch sys tem Voltage Max 1 V Wiring harness between CP01 female 14 P02 female 2 and chassis ground Boom DOWN PPC pressure switch system Voltage Max 1 V Wiring harness between CP01 female 16 P03 female 2 and chassis ground Swing RIGHT PPC pressure switch sys tem Voltage Max 1 V Wiring harness between CP01 female 17 P04 female 2 ...

Page 604: ...SEN04120 03 40 Troubleshooting 44 PC130 8 Circuit diagram related ...

Page 605: ...rn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 8 A08 female 7 and chassis ground Resis tance Min 1 Mz 2 Hot s...

Page 606: ...l discon nection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON S30 female Resistance Between 3 4 7 8 Min 1 Mz Between 1 2 8 Max 1 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON...

Page 607: ...40 Troubleshooting SEN04120 03 PC130 8 47 Circuit diagram related ...

Page 609: ...ure code DHPAMA Pump press sensor abnormality 14 Failure code DHSFMA Travel left forward PPC press sensor abnormality 16 Failure code DHSGMA Travel right forward PPC press sensor abnormality 18 Failure code DHSHMA Travel left reverse PPC press sensor abnormality 20 Failure code DHSJMA Travel right reverse PPC press sensor abnormality 22 Failure code DHX1MA Overload sensor abnormality Analog 24 Fai...

Page 610: ...el junction sol discon 32 Failure code DW91KB Travel junction sol short 34 Failure code DWJ0KA Merge divider sol discon 36 Failure code DWJ0KB Merge divider sol short 38 Failure code DWK0KA 2 stage relief sol discon 40 Failure code DWK0KB 2 stage relief sol short 42 ...

Page 611: ...40 Troubleshooting SEN04121 02 PC130 8 3 ...

Page 612: ...emale A Resis tance Max 1 z Wiring harness between CM02 female 10 CP01 female 64 CE02 female 21 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CM02 female 8 9 CP01 female 45 CE02 female 1 K02 female A N08 male 3 and chassis ...

Page 613: ...40 Troubleshooting SEN04121 02 PC130 8 5 Circuit diagram related ...

Page 614: ...starting switch to OFF position 2 Disconnect camera connector and turn starting switch to ON position Disconnect camera and perform failure reproduction operation If failure code disappears at this time camera is defective 2 Defective machine monitor 1 Turn starting switch to OFF position 2 Disconnect connector CM05 and connect T adapter to male side 3 Turn starting switch to ON position Between C...

Page 615: ...40 Troubleshooting SEN04121 02 PC130 8 7 Circuit diagram related to rear view monitor ...

Page 616: ...started Action of machine monitor None in particular If cause of failure disappears system resets itself Problem that appears on machine Related information Method of reproducing failure code Turn starting switch ON At least 50 seconds after starting switch is turned ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective mac...

Page 617: ...40 Troubleshooting SEN04121 02 PC130 8 9 ...

Page 618: ...n CM02 female 10 CP01 female 64 CE02 female 21 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CM02 female 8 9 CP01 female 45 CE02 female 1 K02 female A N08 male 3 and chassis ground Resis tance Min 1 Mz Wiring harness betwee...

Page 619: ...40 Troubleshooting SEN04121 02 PC130 8 11 Circuit diagram related ...

Page 620: ...02 Hydraulic oil temperature sensor voltage Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective hydraulic oil tem perature sensor Internal dis connection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON P22 m...

Page 621: ...40 Troubleshooting SEN04121 02 PC130 8 13 ...

Page 622: ... Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P25 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage is abnormal check failure code If E of failure code goes off at this time pump pressure sensor is defective 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in ...

Page 623: ...40 Troubleshooting SEN04121 02 PC130 8 15 Circuit diagram related ...

Page 624: ...a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P11 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage is abnormal replace travel left forward PPC pressure sensor with another PPC pressure sensor and check failure code If E of failure code goes off at this time travel left forward PPC pressur...

Page 625: ...40 Troubleshooting SEN04121 02 PC130 8 17 Circuit diagram related ...

Page 626: ...ct a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P09 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage is abnormal replace travel right forward PPC pressure sensor with another PPC pressure sensor and check failure code If E of failure code goes off at this time travel right forward PPC pr...

Page 627: ...40 Troubleshooting SEN04121 02 PC130 8 19 Circuit diagram related ...

Page 628: ...a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P12 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage is abnormal replace travel left reverse PPC pressure sensor with another PPC pressure sensor and check failure code If E of failure code goes off at this time travel left reverse PPC pressur...

Page 629: ...40 Troubleshooting SEN04121 02 PC130 8 21 Circuit diagram related ...

Page 630: ...ct a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P10 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage is abnormal replace travel right reverse PPC pressure sensor with another PPC pressure sensor and check failure code If E of failure code goes off at this time travel right reverse PPC pr...

Page 631: ...40 Troubleshooting SEN04121 02 PC130 8 23 Circuit diagram related ...

Page 632: ...nitor is displayed Action of controller None in particular If cause of failure disappears system resets itself Problem that appears on machine Related information Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective pump controller Pump controller may be defective Sin...

Page 633: ... and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Travel alarm defective Internal defect a Turn the engine starting switch OFF for the preparations and keep the engine running during the troubleshooting M14 female Travel lever Voltage Between 1 and 2 Neutral Max 1 V Operated 20 30 V If the above voltage is normal but the travel alarm does not ope...

Page 634: ...1 Method of reproducing failure code Start engine Set travel speed to High Operate travel lever Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel speed shift ing solenoid Internal discon nection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V04 male Resistance ...

Page 635: ... Code 02300 Solenoid 1 Method of reproducing failure code Start engine Set travel speed to High Operate travel lever Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel speed shift ing solenoid Internal discon nection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON...

Page 636: ... brake solenoid Internal dis connection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V05 male Resistance Between 1 2 20 60 z 2 Defective assembled type diode D01 Internal discon nection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON D01 male Digital circuit tester Continuity Between 7 3 ...

Page 637: ...40 Troubleshooting SEN04121 02 PC130 8 29 Circuit diagram related ...

Page 638: ...g brake solenoid can be checked with monitoring function Code 02300 Solenoid 1 Method of reproducing failure code Start engine Swing with left work equipment control lever Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective swing holding brake solenoid Internal short circuit or ground fault a Prepare with starting switch OFF...

Page 639: ...40 Troubleshooting SEN04121 02 PC130 8 31 Circuit diagram related ...

Page 640: ...gine Steer machine with right and left travel levers Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel junction solenoid Internal disconnec tion a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V03 male Resistance Between 1 2 20 60 z 2 Disconnection in wiring har ...

Page 641: ...40 Troubleshooting SEN04121 02 PC130 8 33 Circuit diagram related ...

Page 642: ...e Start engine Steer machine with right and left travel levers Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel junction solenoid Internal short cir cuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V03 male Resistance Between 1 2 20 60 z Betw...

Page 643: ...40 Troubleshooting SEN04121 02 PC130 8 35 Circuit diagram related ...

Page 644: ...nd standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge divider EPC solenoid Internal disconnec tion a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V02 male Resistance Between 1 2 20 60 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a P...

Page 645: ...40 Troubleshooting SEN04121 02 PC130 8 37 Circuit diagram related ...

Page 646: ...blecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge divider EPC solenoid Internal short cir cuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V02 male Resistance Between 1 2 20 60 z Between 2 chassis ground Min 1 Mz 2 Ground fault in wiring har ness Sh...

Page 647: ...40 Troubleshooting SEN04121 02 PC130 8 39 Circuit diagram related ...

Page 648: ...n starting switch ON Set machine in mode other than L Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 2 stage relief sole noid Internal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V06 male Resistance Between 1 2 20 60 z 2 Disconnection in wiring har ...

Page 649: ...40 Troubleshooting SEN04121 02 PC130 8 41 Circuit diagram related ...

Page 650: ...e code Turn starting switch ON Set machine in working mode L Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 2 stage relief sole noid Internal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V06 male Resistance Between 1 2 20 60 z Between...

Page 651: ...40 Troubleshooting SEN04121 02 PC130 8 43 Circuit diagram related ...

Page 653: ... 2 Failure code DXA8KB PC EPC sol short 4 Failure code DXE4KA Service current EPC discon 6 Failure code DXE4KB Service current EPC short 8 Failure code DY20KA Wiper working abnormality 10 Failure code DY20MA Wiper parking abnormality 12 Failure code DY2CKA Washer drive discon 14 Failure code DY2CKB Washer drive short 16 Failure code DY2DKB Wiper drive for short 18 Failure code DY2EKB Wiper drive r...

Page 654: ...ng switch OFF then carry out troubleshoot ing without turning starting switch ON V11 male Resistance Between 1 2 7 14 z 2 Defective emergency pump drive switch Internal discon nection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON S25 male Emergency pump drive switch Resistance Between 3 2 Normal Max 1 z Emergency Min 1 Mz Between 6 5 Normal M...

Page 655: ...40 Troubleshooting SEN04122 01 PC130 8 3 Circuit diagram related ...

Page 656: ...al short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V11 male Resistance Between 1 2 7 14 z Between 1 chassis ground Min 1 Mz 2 Defective emergency pump drive switch Internal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON S25 male Em...

Page 657: ...40 Troubleshooting SEN04122 01 PC130 8 5 Circuit diagram related ...

Page 658: ...itch ON Set in attachment mode ATT Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid Internal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V30 male Resistance Between 1 2 7 14 z 2 Disconnection in wiring har ness Disconnection in w...

Page 659: ...40 Troubleshooting SEN04122 01 PC130 8 7 Circuit diagram related ...

Page 660: ...starting switch ON Set in attachment mode ATT Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid Internal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V30 male Resistance Between 1 2 7 14 z Between 1 chassis ground M...

Page 661: ...40 Troubleshooting SEN04122 01 PC130 8 9 Circuit diagram related ...

Page 662: ... Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M05 female Wiper blade Resistance Between 6 5 Operating range top Max 1 z Other than operating range top Min 1 Mz Between 1 3 All range Max 20 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troublesho...

Page 663: ...40 Troubleshooting SEN04122 01 PC130 8 11 Circuit diagram related ...

Page 664: ...r Inter nal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M05 female Wiper blade Resistance Between 4 5 Storage area Max 1 z Working area Min 1 Mz Between 1 3 All range Max 20 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubles...

Page 665: ...40 Troubleshooting SEN04122 01 PC130 8 13 Circuit diagram related ...

Page 666: ...6A male Resistance Between 1 2 5 20 z Between 1 2 chassis ground Min 1 Mz 3 Defective assembled type diode D02 Internal short cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON D02 female Continuity Resistance Between 3 7 No continuity Min 1 Mz 4 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a...

Page 667: ...40 Troubleshooting SEN04122 01 PC130 8 15 Circuit diagram related ...

Page 668: ...g failure code Turn starting switch ON Turn washer switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective washer motor Internal short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M06A male Resistance Between 1 2 5 20 z 2 Hot short Short circuit with 24V ...

Page 669: ...40 Troubleshooting SEN04122 01 PC130 8 17 Circuit diagram related ...

Page 670: ... ON Set wiper switch to INT or ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M05 female Resistance Between 3 1 There is continuity Between 3 chassis ground Min 1 M...

Page 671: ...40 Troubleshooting SEN04122 01 PC130 8 19 Circuit diagram related ...

Page 672: ...t wiper switch to INT or ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M05 female Continuity Resistance Between 1 3 There is continuity Between 1 chassis ground Mi...

Page 673: ...40 Troubleshooting SEN04122 01 PC130 8 21 Circuit diagram related ...

Page 675: ...hts up 8 E 3 Engine does not start Engine does not turn 11 E 4 Preheater does not operate 14 E 5 Automatic warm up system does not operate in cold season 16 E 6 All work equipment swing and travel mechanism do not move or cannot be locked 18 E 7 Precaution lights up while engine is running 20 E 8 Emergency stop item lights up while engine is running 25 E 9 Engine coolant temperature gauge does not...

Page 676: ...t operate 36 E 20 Power maximizing function does not operate normally 40 E 21 Swing holding brake does not operate normally 42 E 22 Travel alarm does not sound or does not stop sounding 44 E 23 Air conditioner does not operate normally including air conditioner abnormality record 45 E 24 While starting switch is in OFF position service meter is not displayed 57 E 25 Machine monitor cannot be set i...

Page 677: ...ink Fuse No Fuse capacity Destination of power Switch power supply F04 65A 1 10A Pump resistor light switch swing holding brake release switch 2 30A Pump controller 3 10A Starting motor cutout relay PPC oil pressure lock switch 4 10A Windshield washer cigar lighter electrical intake air heater 5 10A Horn Switch power supply F04 65A 6 10A Spare 7 10A Rotary lamp If equipped 8 20A Working lamp relay...

Page 678: ...SEN04123 01 40 Troubleshooting 4 PC130 8 Locations of fusible links Location of fuse box and fuse Nos ...

Page 679: ...ource 24 V circuit is in contact with power source 24 V circuit Short circuit Independent wiring harnesses are in contact with each other abnormally Precautions for troubleshooting 1 Method of indicating connector No and handling of T adapter Insert or connect T adapter as explained below for trouble shooting unless otherwise specified If connector No has no marks of male and female disconnect con...

Page 680: ...fective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between battery chas sis ground Resis tance Max 1 z Wiring harness between battery R04 F05 male 1 Resis tance Max 1 z Wiring harness between F05 male 2 F01 16D Resis tance Max 1 z Wiring harness between F01 17 J06 CM01 female 1 2 Resis tance Max 1 z Wir...

Page 681: ...40 Troubleshooting SEN04123 01 PC130 8 7 Circuit diagram related ...

Page 682: ...radiator sub tank may be low Check it and add coolant if necessary 2 Defective radiator coolant level switch Internal discon nection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON P24 male Sub tank coolant level Resistance Between 1 2 Between FULL LOW Max 1 z Below LOW Min 1 Mz 3 Disconnection in wiring har ness Disconnection in wiring or defe...

Page 683: ...40 Troubleshooting SEN04123 01 PC130 8 9 Circuit diagram related ...

Page 684: ...witch Internal disconnec tion a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON P44 male Engine oil level Resistance Between 1 chassis ground Between H L Max 1 z Below L Min 1 Mz 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without ...

Page 685: ... troubleshoot ing without turning starting switch ON S14 female Lock lever Resistance Between 1 3 Free Min 1 Mz Lock Max 1 z 5 Defective starting motor cut out relay R06 or R07 Inter nal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON R06 male R07 male Resistance Between 1 2 300 600 z Between 3 4 Max 1 z Between 3...

Page 686: ...le 1 Resis tance Max 1 z Wiring harness between S14 male 3 R06 female 1 Resis tance Max 1 z Wiring harness between R06 female 2 J04 chassis ground T04 Resis tance Max 1 z 10 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between H15 male 4 J01 R06 female 5 circuit br...

Page 687: ...40 Troubleshooting SEN04123 01 PC130 8 13 Circuit diagram related ...

Page 688: ... Starting switch Voltage Between 16 chassis ground OFF Max 1 V HEAT 20 30 V Trouble 2 When starting switch is turned to HEAT position intake air heater mounting part does not become warm Related information Check that engine can be turned with starting motor If engine cannot be turned carry out trouble shooting for E 1 Engine does not start Engine does not turn Possiblecauses and standard value in...

Page 689: ...40 Troubleshooting SEN04123 01 PC130 8 15 Circuit diagram related ...

Page 690: ...s on troubleshooting 1 Defective engine coolant temperature signal system a Turn starting switch ON or start engine and carry out trouble shooting Monitoring code Engine coolant temperature Coolant temperature level 04107 Engine coolant temperature 105 C 6 a Red 102 C 5 a Red 100 C 4 a Blue 85 C 3 a Blue 60 C 2 a Blue 30 C 1 a White If level of coolant temperature gauge is different from actual co...

Page 691: ...40 Troubleshooting SEN04123 01 PC130 8 17 ...

Page 692: ...n 1 2 20 60 z Between 2 chassis ground Min 1 Mz 4 Defective assembled type diode D01 Internal short cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON D01 male Resistance Continuity Between 4 8 Min 1 Mz No continuity 5 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switc...

Page 693: ... Defective lock lever switch Internal short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON S14 female Lock lever Resistance Between 1 2 Lock Min 1 Mz Free Max 1 z 2 Hot short Short circuit with 24V circuit in wiring harness a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Wiring harness betw...

Page 694: ...ound Middle or higher 27 5 29 5 V 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CM01 female 11 J02 M22 female 1 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch...

Page 695: ...40 Troubleshooting SEN04123 01 PC130 8 21 Circuit diagram related ...

Page 696: ...standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Clogging of air cleaner when system is normal Air cleaner may be clogged Check it then clean or replace if nec essary 2 Defective air cleaner clog ging switch Internal discon nection a Prepare with starting switch OFF then start engine and carry out troubleshooting P23 male Air cleaner Resistance Betwe...

Page 697: ...40 Troubleshooting SEN04123 01 PC130 8 23 Circuit diagram related ...

Page 698: ...re gauge sys tem may be defective Carry out troubleshooting for E 9 Engine coolant temperature gauge does not indicate normally Trouble 5 Hydraulic oil temperature monitor lights up white Related infor mation Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system Hydraulic oil temperature can be checked with mon...

Page 699: ...input to pump controller and then transmitted to machine monitor through communication system Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraulic oil temperature Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Overheating of hydraulic oil when system is normal If monitor lights up red hydraulic o...

Page 700: ...re sensor sys tem may be defective Carry out troubleshooting for failure codes CA144 and CA145 2 Defective machine monitor If cause 1 is not detected machine monitor may be defective Since trouble is in system troubleshooting cannot be carried out Trouble 3 Display of coolant temperature gauge is different from actual engine coolant temperature 4 Display of engine coolant temperature gauge is diff...

Page 701: ...ction in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 29 P22 female 2 Resis tance Max 1 z Wiring harness between CP01 female 46 P22 female 1 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepa...

Page 702: ...erature sensor are input to pump controller and then transmitted to machine monitor through communication system Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraulic oil temperature Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor a Turn starting switch ON or start engine ...

Page 703: ... 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CM01 female 9 P21 female 1 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing w...

Page 704: ...n Signal voltage of fuel level sensor can be checked with monitoring function Code 04200 Fuel level sensor voltage Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor a Turn starting switch ON or start engine and carry out trouble shooting Quantity of fuel Reading of fuel level gauge Color of monitor light a ...

Page 705: ...nts 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 Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor LCD panel a Turn starting switch ON and carry out troubleshooting When foll...

Page 706: ...al state Cause Standard value in normal state Remarks on troubleshooting 1 Defective PPC pressure sig nal a Start engine and carry out troubleshooting with monitoring function Monitoring code Item Normal display 01900 Pressure switch 1 Swing When lever is operated ON When lever is in neutral OFF Boom down Boom up Arm digging Arm dump 01901 Pressure switch 2 Bucket digging When lever is operated ON...

Page 707: ...roubleshooting 1 Defective machine monitor Machine monitor may be defective Since trouble is in system troubleshooting cannot be carried out Trouble 2 When working mode is changed setting of engine and hydraulic pump is not changed Related information Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor Machin...

Page 708: ...d is shifted actual travel speed does not change Related information If cause 1 occurs actual travel speed does not lower when travel speed is shifted to Lo Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short Short circuit with 24V circuit in wiring harness a Prepare with starting switch OFF then turn starting switch ON and ...

Page 709: ...gnal of alarm buzzer cancel switch can be checked with monitoring function Code 04504 Monitor 1st 2nd line switches Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor Machine monitor may be defective Since trouble is in system troubleshooting cannot be carried out ...

Page 710: ... 1 Mz When retracted to rear Max 1 z 2 Defective wiper motor Inter nal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M05 female Continuity Between 1 3 There is continuity 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot in...

Page 711: ...40 Troubleshooting SEN04123 01 PC130 8 37 Circuit diagram related ...

Page 712: ... of window washer switch signal can be checked with monitoring function Code 04504 Monitor 1st 2nd line switches Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor Machine monitor may be defective Since trouble is in system troubleshooting cannot be carried out ...

Page 713: ...40 Troubleshooting SEN04123 01 PC130 8 39 ...

Page 714: ...knob switch Resistance Between 1 2 Released Min 1 Mz Pressed Max 1 z 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between F01 9 S11 female 1 Resis tance Max 1 z Wiring harness between S11 female 2 CP01 female 41 Resis tance Max 1 z 4 ...

Page 715: ...Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short Short circuit with 24V circuit in wiring harness a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Wiring harness between CP02 female 109 V06 female 2 Voltage Max 1 V 2 Defective pump controller If cause 1 is not detected pump con...

Page 716: ...ning starting switch ON Wiring harness between CM02 female 5 J02 S04 female 5 CP01 female 19 and chassis ground Resis tance Min 1 Mz 4 Defective machine monitor a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting CM02 Swing lock switch Voltage Between 5 chassis ground OFF 20 30 V ON Max 1 V Trouble 2 When swing lock switch is turned ON swing lock does not ...

Page 717: ...40 Troubleshooting SEN04123 01 PC130 8 43 Circuit diagram related ...

Page 718: ...ontact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP02 female 107 M14 female 1 Resis tance Max 1 z Wiring harness between CP02 female 115 117 120 M14 female 2 Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troublesho...

Page 719: ... 2 Defective fuse in unit If fuse in unit is broken circuit in unit probably has ground fault See cause 4 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between F01 11 fuse in unit ACW wiring side 6 Resis tance Max 1 z Wiring harness be...

Page 720: ...3 Defective blower motor Internal defect a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting MB wiring side Air conditioner switch Voltage Between 1 2 Air blow position 20 30 V If above voltage is normal and blower motor does not revolve blower motor is defective 4 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector ...

Page 721: ...etween R20 female 4 MB wiring side 1 and chassis ground Resis tance Min 1 Mz Wiring harness between MB wiring side 2 PTR wiring side 3 and chassis ground Resis tance Min 1 Mz Wiring harness between PTR wiring side 2 ACW wiring side 8 and chassis ground Resis tance Min 1 Mz 6 Defective air conditioner con troller If causes 1 5 are not detected air conditioner controller may be defective Since troub...

Page 722: ... nal defect Compressor may be defective Check it directly 6 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between F01 11 fuse in unit R21 female 1 Resis tance Max 1 z Wiring harness between R21 female 3 ACW wiring side 35 Resis tance Max...

Page 723: ...then carry out troubleshoot ing without turning starting switch ON Wiring harness between N10 female 1 CM02 female 8 9 CP01 female 45 CE02 female 1 K02 female A N08 male 3 and chassis ground Resis tance Min 1 Mz Wiring harness between N10 female 2 CM02 female 10 CP01 female 64 CE02 female 21 K02 female B N08 male 10 and chassis ground Resis tance Min 1 Mz 3 Hot short Short circuit with 24V circuit...

Page 724: ...switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective internal air sensor Internal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON THI device side Resistance Between 1 2 300 z 430 kz 2 Disconnection in wiring har ness Disconnection i...

Page 725: ...Defective air flow sensor Internal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON THF device side Resistance Between 1 2 100 z 115 kz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning sta...

Page 726: ... P31 female 1 Resis tance Max 1 z Wiring harness between ACW wiring side 15 P31 female 2 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between ACW wiring side 3 P31 female 1 circuit branch end and chassis ground Resis tance Min 1 Mz Wiring harn...

Page 727: ... wiring side 23 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between MV1 wiring side 1 ACW wiring side 3 circuit branch end and chassis ground Resis tance Min 1 Mz Wiring harness between MV1 wiring side 5 ACW wiring side 9 and chassis ground R...

Page 728: ... side 22 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between MAM wiring side 3 ACW wiring side 3 circuit branch end and chassis ground Resis tance Min 1 Mz Wiring harness between MAM wiring side 5 ACW wiring side 2 and chassis ground Resis ta...

Page 729: ... be insufficient Check it directly 2 Defective high and low pres sure switches Internal dis connection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON P17 male Resistance Between 1 2 Max 1 z 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoo...

Page 730: ...SEN04123 01 40 Troubleshooting 56 PC130 8 Circuit diagram related ...

Page 731: ...turned ON if machine monitor displays nothing backup power supply system may be defective In this case carry out troubleshooting for E 1 When starting switch turned ON machine monitor displays nothing 2 Defective machine monitor If cause 1 is not detected machine monitor may be defective Since trouble is in system troubleshooting cannot be carried out Trouble Machine monitor cannot be set in servi...

Page 732: ...ng switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 53 P06 female 2 Resis tance Max 1 z Wiring harness between P06 female 1 chassis ground T10 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring...

Page 733: ...40 Troubleshooting SEN04123 01 PC130 8 59 Circuit diagram related ...

Page 734: ...hoot ing without turning starting switch ON Wiring harness between CP01 female 14 P02 female 2 Resis tance Max 1 z Wiring harness between P02 female 1 chassis ground T10 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 14 P02 f...

Page 735: ...40 Troubleshooting SEN04123 01 PC130 8 61 Circuit diagram related ...

Page 736: ...ot ing without turning starting switch ON Wiring harness between CP01 female 17 P04 female 2 Resis tance Max 1 z Wiring harness between P04 female 1 chassis ground T10 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 17 P04 fem...

Page 737: ...40 Troubleshooting SEN04123 01 PC130 8 63 Circuit diagram related ...

Page 738: ...ot ing without turning starting switch ON Wiring harness between CP01 female 15 P08 female 2 Resis tance Max 1 z Wiring harness between P08 female 1 chassis ground T10 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 15 P08 fem...

Page 739: ...40 Troubleshooting SEN04123 01 PC130 8 65 Circuit diagram related ...

Page 740: ...shoot ing without turning starting switch ON Wiring harness between CP01 female 73 P01 female 2 Resis tance Max 1 z Wiring harness between P01 female 1 chassis ground T10 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 73 P01 ...

Page 741: ...40 Troubleshooting SEN04123 01 PC130 8 67 Circuit diagram related ...

Page 742: ...shoot ing without turning starting switch ON Wiring harness between CP01 female 34 P05 female 2 Resis tance Max 1 z Wiring harness between P05 female 1 chassis ground T10 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 34 P05 ...

Page 743: ...40 Troubleshooting SEN04123 01 PC130 8 69 Circuit diagram related ...

Page 744: ...g switch ON Wiring harness between CP01 female 16 P03 female 2 or P07 female 2 Resis tance Max 1 z Wiring harness between P03 female 1 or P07 female 1 chassis ground T10 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 16 P03 f...

Page 745: ...40 Troubleshooting SEN04123 01 PC130 8 71 Circuit diagram related ...

Page 746: ...tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 52 P14 female 2 P15 female 2 Resis tance Max 1 z Wiring harness between P14 female 1 chassis ground T06 Resis tance Max 1 z Wiring harness between P15 female 1 chassis ground T06 Resis tance Max 1 z 4 Ground fault in wiring har ness Short circuit with GND cir...

Page 747: ...40 Troubleshooting SEN04123 01 PC130 8 73 Circuit diagram related ...

Page 748: ...ing 1 Defective communication 1 a Turn starting switch ON and check Terminal status screen Check item Normal display KOMTRAX communication Open 2 Defective GPS a Turn starting switch ON and check GPS Communication Status screen Check item Normal display Positioning N Latitude E Longitude In positioning If latitude and longitude are not displayed in 5 minutes on open ground notify KOMTRAX service h...

Page 749: ...40 Troubleshooting SEN04123 01 PC130 8 75 ...

Page 751: ...nd travel are low 6 H 2 Engine speed sharply drops or engine stalls 7 H 3 No work equipment travel and swing move 8 H 4 Abnormal noise is heard from around hydraulic pump 8 H 5 Fine control mode does not function 9 H 6 Speed or power of boom is low 10 H 7 Speed or power of arm is low 11 H 8 Speed or power of bucket is low 12 H 9 Work equipment does not move in its single operation 13 H 10 Hydrauli...

Page 752: ...s low 19 H 18 Machine cannot be steered easily or steering power is low 20 H 19 Travel speed does not change or it is kept low or high 21 H 20 Track does not move Only either side 21 H 21 Machine does not swing 22 H 22 Swing acceleration or swing speed is low 23 H 23 Excessive overrun when stopping swing 24 H 24 When upper structure stops swinging it makes large shock 25 H 25 When upper structure ...

Page 753: ...ne Related information Information on occurred failures and troubleshooting Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Cause for presumed failure The attached No for filing and reference purpose only It does not stand for any priority Contents The standard values in normalcy by which to judge good or no good about presumed ca...

Page 754: ...SEN04124 00 40 Troubleshooting 4 PC130 8 System chart for hydraulic and mechanical systems 1 ...

Page 755: ...ooting SEN04124 00 PC130 8 5 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 ...

Page 756: ...ations and keep it running at high idle during the troubleshooting Control levers Control circuit basic pressure All levers in NEUTRAL 3 2 0 5 MPa 33 5 kg cm2 4 Defective adjustment or operation of PC valve a Keep the engine stopped for the preparations and keep it running at high idle during the troubleshooting Measured oil pressure Measurement conditions Oil pressure ratio Pump discharge pressur...

Page 757: ... preparations and keep it running at high idle during the troubleshooting Measured oil pressure Measurement conditions Oil pressure ratio Pump discharge pressure Swing lock ON Arm Relieved in IN direction 1 PC valve output pressure Approx 0 6 Approx 3 5 If the oil pressure cannot be set normally by adjustment the PC valve may be malfunction or may have an internal defect Check the PC valve directl...

Page 758: ... or an internal failure Diagnose it in the following manner Remove the main oil pressure measurement plug and crank the engine If oil flows out it is in normal condition 4 Damper defective It is presumed that the pump shaft does not rotate due to some internal failure of the dumper Check the damper itself Trouble An abnormal noise is heard from around the hydraulic pump Related information Possibl...

Page 759: ... itself 2 Defective adjustment or mal function of LS valve a Stop engine for preparations Start troubleshooting at engine high idle Oil pressure to be measured Oil pressure ratio All control levers in NEUTRAL At bucket CURL Control lever full stroke Pump delivery pressure Nearly equal oil pressure 1 LS valve output pressure Approx 0 6 Approx 3 5 If the oil pressure does not return to normalcy even...

Page 760: ...ntrol valve spool The spool of the boom control valve may have a malfunction Check it directly Including stroke limiting mechanism on RAISE side 5 Malfunction of boom control valve pressure compensa tion valve The pressure compensation valve of the boom control valve may have a malfunction Check it directly 6 Malfunction of boom control valve lock valve The lock valve of the boom control valve may...

Page 761: ...unction of pump merge divider valve The pump merge divider valve of the control valve may have a malfunction Check it directly 4 Malfunction of arm control valve spool The spool of the arm control valve may have a malfunction Check it directly Including stroke limiting mechanisms on IN side and OUT side 5 Malfunction of arm control valve pressure compensa tion valve The pressure compensation valve...

Page 762: ... 43 MPa 29 35 kg cm2 3 Malfunction of pump merge divider valve The pump merge divider valve of the control valve may have a malfunction Check it directly 4 Malfunction of bucket control valve spool The spool of the bucket control valve may have a malfunction Check it directly 5 Malfunction of bucket control valve pressure compensa tion valve The pressure compensation valve of the bucket control va...

Page 763: ...ation Set the working mode at P mode for the troubleshooting Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of PPC valve a Stop engine for preparations Start troubleshooting at engine high idle Work equipment control lever PPC valve output pressure NEUTRAL 0 MPa 0 kg cm2 Operation Above 2 7 MPa Above 28 kg cm2 2 Malfu...

Page 764: ...Arm cylinder Leakage from cylinder Relieved in IN direction 15 cc min 2 Defective sealing of arm con trol valve spool Sealing of the spool of the arm control valve may be defective Check it directly 3 Defective sealing of arm con trol valve suction valve Sealing of the suction valve of the arm control valve on the bottom side may be defective Check it directly 4 Defective sealing of central ized s...

Page 765: ...ion of control valve suction valve The suction valve of the control valve on the head side may have a malfunction Check it directly Trouble Power maximizing function does not operate normally Related information Carry out all troubleshooting in power mode P of working mode Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunctio...

Page 766: ...less may have a malfunction Check it directly Compound operation More loaded side Less loaded side Boom RAISE Arm IN Boom Arm Boom RAISE Arm OUT Arm Boom Boom RAISE Bucket CURL Boom Bucket Arm IN Bucket CURL Arm Bucket Boom LOWER Arm OUT Arm Boom Trouble Boom RAISE speed is low in compound operation of swing boom RAISE Related information If the speed of single operation of the boom RAISE speed is...

Page 767: ...levers Solenoid output pressure All levers in NEUTRAL 0 MPa 0 kg cm2 Position for travel only On either or both sides 2 84 3 43 MPa 29 35 kg cm2 2 Malfunction of pump merge divider valve The pump merge divider valve may have a malfunction Check it directly 3 Malfunction of work equip ment control valve pressure compensation valve The pressure compensation valve of the work equipment control valve ...

Page 768: ... junction solenoid valve a Keep the engine stopped for the preparations and keep it running at high idle during the troubleshooting Travel lever Solenoid valve output pressure All levers in NEUTRAL 0 MPa 0 kg cm2 Position for travel only on either side 2 84 3 43 MPa 29 35 kg cm2 5 Malfunction of unload valve a Keep the engine stopped for the preparations and keep it running at high idle during the...

Page 769: ...rs in NEUTRAL 0 MPa 0 kg cm2 Position for travel only On either or both sides 2 84 3 43 MPa 29 35 kg cm2 4 Malfunction of unload valve a Keep the engine stopped for the preparations and keep it running at high idle during the troubleshooting Control levers Unload pressure All levers in NEUTRAL 2 8 1 0 MPa 28 10 kg cm2 5 Malfunction of pump merge divider valve The pump merge divider valve may have ...

Page 770: ...ll levers in NEUTRAL 0 MPa 0 kg cm2 Position for travel only on either side 2 84 3 43 MPa 29 35 kg cm2 4 Malfunction of hydraulic pump check valve The check valve of the hydraulic pump may have a malfunction or its sealing may be defective Check it directly 5 Malfunction of hydraulic pump shuttle valve The shuttle valve of the hydraulic pump may have a malfunction or its sealing may be defective C...

Page 771: ... does not move only either side Related information Conduct the troubleshooting in working mode P Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective seat of travel con trol valve suction valve The suction valve seat of the travel control lever may be defective Check it directly 2 Defective seat of travel con trol valve safe...

Page 772: ...ect in it Check it directly It may be checked by abnormal sound abnormal heating metal chips in drain oil etc Trouble Machine does not swing 2 Machine does not swing in only one direction Related information Conduct the troubleshooting in working mode P Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of swing PPC valve...

Page 773: ...on or swing speed is low 2 Swing acceleration or swing speed is low in only one direction Related information Conduct the troubleshooting in working mode P Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of swing PPC valve a Keep the engine stopped for the preparations and keep it running at high idle during the troubl...

Page 774: ...reparations and keep it running at high idle during the troubleshooting Left work equipment control lever PPC valve output pressure In NEUTRAL 0 MPa 0 kg cm2 Operated for swing Above 2 7 MPa Above 28 kg cm2 2 Clogging of swing PPC slow return valves The swing PPC slow return valves may be clogged Check them directly They may be checked by exchanging with each other and checking change of the pheno...

Page 775: ...nging with each other and checking change of the phenomenon 3 Malfunction of swing motor safety valve The safety valve of the swing motor may have malfunction Check it directly Trouble When upper structure stops swinging it makes large sound Related information Conduct the troubleshooting in working mode P Possiblecauses and standard value in normal state Cause Standard value in normal state Remar...

Page 776: ...rouble Hydraulic drift of swing is large 2 When swing holding brake is released Related information If the swing holding brake release is in the emergency position the swing holding brake is released and the upper structure is held with only hydraulic pressure Conduct the troubleshooting in working mode P Possiblecauses and standard value in normal state Cause Standard value in normal state Remark...

Page 777: ...Operation manual Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of attachment flow rate adjustment EPC valve The attachment flow rate adjustment EPC valve may have a mal function Check it directly 2 Malfunction of service PPC valve a Keep the engine stopped for the preparations and keep it running at high idle during ...

Page 779: ...Engine stops during operations 13 S 5 Engine does not rotate smoothly 14 S 6 Engine lacks output or lacks power 15 S 7 Exhaust smoke is black incomplete combustion 16 S 8 Oil consumption is excessive or exhaust smoke is blue 17 S 9 Oil becomes contaminated quickly 18 S 10 Fuel consumption is excessive 19 S 11 Oil is in coolant or coolant spurts back or coolant level goes down 20 S 12 Oil pressure ...

Page 780: ...SEN04125 02 40 Troubleshooting 2 PC130 8 S 15 Abnormal noise is made 24 S 16 Vibration is excessive 25 ...

Page 781: ...40 Troubleshooting SEN04125 02 PC130 8 3 ...

Page 782: ...eir level Check items Simple check items used by the serviceman to narrow the causes They correspond to C in the chart on the right Causes Items to be narrowed from the questions and check items The serviceman narrows down the probable causes from A B and C Troubleshooting Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applying...

Page 783: ...40 Troubleshooting SEN04125 02 PC130 8 5 ...

Page 784: ...st gas is black 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 ...

Page 785: ...l 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 ...

Page 786: ...r when temperature is low preheating monitor does not indicate normally w During operation charge level monitor indicates abnormal charge w w Dust indicator is red w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Q When priming pump is operated it makes no reaction or it is heavy w Q Starting motor cranks engine slowly w Check items While engine is cranked with ...

Page 787: ...Q w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion moves out but Speed of rotation is low w Makes grating noise w w Soon disengages again w Makes rattling noise and does not turn Q Q Q Q Troubleshooting Inspect flywheel ring gear directly q Carry out troubleshooting on E mode Carry out troubleshoot...

Page 788: ... Replacement of filters has not been carried out according to Operation and Maintenance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained Q E E E Check items When fuel filter is removed there is not fuel in it w w Fuel is leaking from fuel piping w When priming pump is operated it ma...

Page 789: ... w Dust indicator is red w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w When fuel filter is removed there is not fuel in it w Fuel is leaking from fuel piping w When priming pump is operated it makes no reaction or it is heavy w Q Starting motor cranks engine slowly w Check items When engine is cranked abnormal sound is generated around cylin...

Page 790: ...ust indicator is red w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from fuel piping w When priming pump is operated it makes no reaction or it is heavy w Q Check items When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low Q w Color of exhaust gas is Blue under light load w Bla...

Page 791: ...Q Q Non specified fuel is being used Q Q Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w w Fuel level monitor indicates low level w When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Check items Rust and water are found when fuel tank is drained w w Metal partic...

Page 792: ...Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carried out according to Operation and Maintenance Manual w When fuel tank is inspected it is found to be empty w Check items Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained Q Fuel is leaking from fuel piping w When primin...

Page 793: ... must be added more frequently Q Q Dust indicator is red w w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Output becomes insufficient after short stop of operation w Check items Color of exhaust gas is Black w w Blue under light load w When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low w w When engine is cra...

Page 794: ... Q Q Q Gradually Q Q Q Q Dust indicator is red w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operated in low temperature mode at normal temperature Q Q Q When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low Q w When engine is cranked interference sound is generated around turbocha...

Page 795: ...Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in intake system w Check items Inside of turbocharger intake outlet pipe is dirty with oil w Inside of turbocharger exhaust outlet pipe is dirty with oil Q w There is oil in coolant w Oil level in clutch cham...

Page 796: ...story Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Oil must be added more frequently w Metal particles are found when oil filter is drained Q Q w Inside of exhaust pipe is dirty with oil w Engine oil temperature rises quickly w Check items Color of exhaust gas is Blue under light load w Black w Amount of blow by gas Excessive Q Q w Q None w Troublesh...

Page 797: ...model Q Q Q Q Gradually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check items When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low w Low idle speed is high Q Torque converter stall speed or pump relief speed is high Q Color...

Page 798: ...oler core O ring Questions Confirm recent repair history Degree of use of machine Operated for long period E E Oil level Suddenly rose Q Q Gradually rose Q Q Hard water is being used as coolant Q Q Oil level has risen and oil is milky Q Q w Check items There are excessive air bubbles in radiator coolant spurts back w Trouble shooting Pressure tightness test of cylinder head shows there is leakage ...

Page 799: ...eing used Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w Oil pressure monitor if installed Indicates pressure drop at low idle w Indicates pressure drop at low high idle Q w w w Q Indicates pressure drop on slopes w Sometimes indicates pressure drop w Q Oil level monitor indicates oil level drop w w Oil level in oil pan is low w Check items Exte...

Page 800: ...equently w w Coolant must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Check items When radiator cap is removed and engine is run at low idle an abnormal number of bubbles appears or coolant spurts back w Q Exhaust smoke is white Q Oil level in damper chamber is low w Oil leve...

Page 801: ... fan pulley is turned it has play w Milky oil is floating on coolant w There are excessive air bubbles in radiator coolant spurts back w When light bulb is held behind radiator core no light passes through w Radiator shroud inside of underguard side are clogged with dirt or mud w w Coolant is leaking because of cracks in hose or loose clamps w Coolant flows out from radiator overflow hose w Fan be...

Page 802: ...use of machine Operated for long period E Condition of abnormal noise Gradually occurred Q Q Suddenly occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles are found when oil filter is drained w w Air leaks between turbocharger and cylinder head w Check items When engine is cranked interference sound is generated around turbocharger w When engine is ...

Page 803: ...mper Questions Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specified oil is being used Q Q Metal particles are found when oil filter is drained w w Metal particles are found when oil pan is drained w w Check items Oil pressure is low at low idle Q Q Vibration occurs at mid range sp...

Page 805: ...AVATOR 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: ...ins procedures and precautions for implementing the work know how and the amount of oil or coolant to be drained q The common tools necessary for the removal work are indicated 1 2 and their part Nos part names and quantity are not described q Various symbols used in the Removal Section are explained and listed below k This mark indicates safety related precau tions that must be followed when impl...

Page 807: ...able from Komatsu in Japan i e must be made locally Disassembly q In Disassembly section the work procedures precautions and know how for carrying out those procedures and quantity of the oil and coolant drained are described q The common tools necessary for the disas sembly work are indicated 1 2 and their part Nos part names and quantity are not described q The meanings of the symbols used in Di...

Page 808: ...5 790 129 9120 75 g Tube Heat resistant seal used to repair engines ThreeBond 1735 790 129 9140 50 g Polyethylene container Quick setting adhesive Setting time Within 5 sec to 3 min Used mainly to stick metals rubbers plastics and woods Aron alpha 201 790 129 9130 2 g Polyethylene container Quick setting adhesive Quick setting type max strength is obtained after 30 minutes Used mainly to stick rub...

Page 809: ...e prevention compound LC G NEVER SEEZ Can Feature Seizure and scuffing prevention com pound with metallic super fine grain etc Used for the mounting bolt in the high tempera ture area of the exhaust manifold and the turbo charger etc Grease G2 LI G0 LI For cold district SYG2 400LI SYG2 350LI SYG2 400LI A SYG2 160LI SYGA 160CNLI SYG0 400LI A SYG0 160CNLI Various Various Feature Lithium grease with ...

Page 810: ...onate coated surface Using limit 4 months after date of manu facture SUNSTAR SASH PRIMER GP 402 22M 54 27250 20 ml Glass container Used as primer for sash Almite Using limit 4 months after date of manu facture Adhesive SUNSTAR PENGUINE SEAL 580 SUPER S or W 417 926 3910 320 ml Polyethylene container Adhesive for cab glass S is used for high temperature season and W for low temperature season as ad...

Page 811: ...ation front oil seal 795T 221 1010 Plate 1 790 101 5221 Grip 1 01010 51225 Bolt 1 Engine rear oil seal 2 795 931 1100 Seal puller assembly q 1 Removal rear oil seal Engine rear oil seal 3 790 101 5401 Push tool Kit t 1 Instllation rear oil seal 795T 221 1020 Plate 1 790 101 5421 Grip 1 01010 51240 Bolt 1 Hydraulic oil tank D 796 460 1210 Oil stopper q 1 Stop oil supply from hydraulic tank 795 799 ...

Page 812: ...stallation of floating seal ø88 2 796T 430 1220 Installer t 1 N Q Filling oil and checking of air leak 3 791 601 1000 Oil pump q 1 Expansion installation of track shoe R 791 620 3000 Remover and installer t 1 Removal and pressfit of mas ter pin 791 635 3110 Frame 1 791 635 3120 Support 1 791 635 3130 Nut 1 791 635 3140 Screw 1 791 635 3150 Hook 1 791 635 3160 Extention 1 791 635 3170 Nut 1 791 635...

Page 813: ... Press fit of bucket cylinder roll bushings 790 201 1791 Push tool 1 790 101 5021 Grip 1 01010 50816 Bolt 1 790 201 1702 Push tool Kit t 1 Press fit of boom cylinder roll bushings 790 201 1811 Push tool 1 790 101 5021 Grip 1 01010 50816 Bolt 1 790 201 1702 Push tool Kit t 1 Press fit of arm and blade cyl inder roll bushings 790 201 1821 Push tool 1 790 101 5021 Grip 1 01010 50816 Bolt 1 4 790 201 ...

Page 814: ...1100 Remover t 1 Removal of boom foot pin 792 785 1110 Sleeve 1 792 785 1120 Plate 1 792 900 1530 Screw 1 01803 13034 Nut 1 01643 33080 Washer 1 796 270 1110 Adapter 1 790 101 4000 Puller 490 kN 50 ton t 1 790 101 1102 Pump t 1 Operator s cab glass stuck glass X 1 793 498 1210 Lifter Suction cup t 2 Removal and installation of operator s cab glass stuck glass 2 20Y 54 13180 Adapter t 2 Component S...

Page 815: ...C130 8 11 Sketch of special tool 1 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 M1 Push tool ...

Page 816: ... and assembly 12 PC130 8 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 ...

Page 817: ...EN04126 02 PC130 8 13 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 ...

Page 818: ...SEN04126 02 50 Disassembly and assembly 14 PC130 8 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches T4 Push tool ...

Page 819: ...50 Disassembly and assembly SEN04126 02 PC130 8 15 ...

Page 821: ...ctor assembly 5 Removal and installation of front oil seal 8 Removal and installation of rear oil seal 10 Removal and installation of cylinder head assembly 13 Removal and installation of radiator assembly 23 Removal and installation of aftercooler assembly 25 Removal and installation of work equipment oil cooler assembly 27 Removal and installation of engine and work equipment pump assembly 29 Re...

Page 822: ... tank 247 l 2 Open and lock engine hood 2 3 Remove bracket 3 4 Disconnect connector PREG 4 5 Disconnect wiring clamps 5 6 and 7 6 Disconnect fuel hose 8 from the supply pump 7 Remove 2 boots 9 from the common rail and supply pump 1 8 Loosen sleeve nuts 10 and 11 and remove high pressure pipe 12 2 9 Remove the pin and disconnect spill hose 13 10 Remove joint bolts 14 15 and 16 and fuel tubes 17 and...

Page 823: ...time 3 Remove supply pump and pump holder assembly 21 a The following figure shows locations a of mounting bolts 19 12 Remove the supply pump assembly from the pump holder according to the following proce dure 1 Loosen nut 22 and pull out supply pump gear 23 with gear puller 1 5 a Fully loosen the nut and keep it installed to the shaft until the supply pump gear is pulled out 2 Remove 3 nuts 24 an...

Page 824: ...er installing the high pressure pipe a Before installing a high pressure pipe confirm the following points If any abnormality was found replace it with new one Otherwise leakage of fuel can result q No visible striations b or patchy dents c in the taper seal portion of the connection a portion area 2 mm inside the tip q No deformation in portion d at the end of the taper seal portion 2 mm inside t...

Page 825: ...ood 2 3 Removal of the high pressure pipe a The following indicates the removal of injector assembly of cylinder No 1 for example 1 Remove clamp 3 from the high pressure pipe 2 Remove boot 4 from the injector and common rail sides 1 3 Remove injector wiring connector 5 Connector No Cylinder No 1 CN1 Cylinder No 2 CN2 Cylinder No 3 CN3 Cylinder No 4 CN4 4 Remove pin 6 and disconnect spill hose 7 5 ...

Page 826: ...lamp used for fixing a high pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque k Be sure to install the boot to the sleeve nut after installing the high pressure hose a Before Installing a high pressure pipe confirm the following points If any abnormality was found replace it with new one Otherwise leakage of fuel can result q No visible striations b or p...

Page 827: ...50 Disassembly and assembly SEN04127 02 PC130 8 7 4 q When reusing injector always replace Oring 13 and gasket 14 with new ones ...

Page 828: ...unting bolt 1 3 Loosen fan belt adjust bolt 2 and remove fan belt 3 1 4 Remove engine speed sensor connector 4 5 Remove speed sensor mounting bolt 5 and remove speed sensor 6 2 6 Remove crankshaft pulley mounting bolt 7 and remove crankshaft pulley 8 3 7 Remove front oil seal 9 Sym bol Part No Part name Necessity Q ty New Remodel A 1 790 101 5201 Push tool kit t 1 795T 221 1010 Plate 1 790 101 522...

Page 829: ...oil seal 2 Fill about 2 cc of grease to between the oil seal lips 2 Front oil seal Grease G2 LI 2 Install the crankshaft pulley a Align key a of crankshaft 11 with key groove b of crankshaft pulley 8 and install the pulley 3 For the rest of the installation work carry out the installation in the reverse order of removal 1 Confirm the direction of the fan 2 2 Speed sensor mounting bolt 5 7 0 11 Nm ...

Page 830: ...ily lift flywheel 3 3 Remove 5 flywheel mounting bolts 4 except one 2 4 Loosen flywheel mounting bolt 4 k Leave 3 threads or 4 engaged to prevent the flywheel from suddenly shooting out in the following pro cedure 5 Pull out the flywheel by prying with a bar etc 6 Checking that flywheel 3 is manually removable remove the flywheel mounting bolt 4 7 Lift flywheel 3 and remove it 4 Flywheel 25 kg Sym...

Page 831: ... oil seal to flywheel housing a Fill about 3 cc of grease to between the rear oil seal lips 2 Rear oil seal Grease G2 LI 2 For the following installation work carry out the installation in the reverse order of removal 1 3 Coupling mounting bolt 98 122 6 Nm 10 12 5 kgm 2 q Tighten the flywheel mounting bolts according to the following procedure 1 Apply engine oil EO 30 to the bolt threads 2 Mountin...

Page 832: ...le a Check that the position of needle remains in its original position after the flywheel is rotated one full turn Radial runout Max 0 15 mm q Measuring face runout of flywheel 1 As with the measurement of radial runout set the probe of the dial gauge at right angles to end face b close to the outer periphery of the flywheel a For measurement move the crank shaft forward or backward to prevent er...

Page 833: ...sor accord ing to the following procedure 1 Disconnect air conditioner hose clamp 6 2 Disconnect wiring connector AC02 7 3 Remove air conditioner compressor drive belt protective cover 8 4 Loosen air conditioner compressor mount ing bolt 9 and drive belt adjustment bolt 10 and remove drive belt 11 1 5 Remove air conditioner compressor mount ing bolt 9 and air conditioner compressor belt tension ad...

Page 834: ...Remove mounting bolt 19a of side cover 19 too 5 Remove partition plate 21 6 Remove clamp 22a between the turbo charger and muffler 2 7 Remove 4 muffler assembly bracket mounting bolts 22 8 Lift off muffler assembly 23 and bracket together 6 Disconnect heater hose clamps 24 and 25 a Disconnect clamp 25 and bracket 26 together 7 Disconnect air hose 27 from air intake con nector 28 3 a Make marks at ...

Page 835: ...arger and air cleaner from the tur bocharger 5 5 Remove 3 mounting bolts 37 and discon nect air connector 38 from the turbo charger 6 6 Disconnect turbocharger lubrication inlet tube 39 from the turbocharger 7 7 Disconnect turbocharger lubrication return tube 40 from the turbocharger 8 Remove 6 inside mounting bolts leaving 2 exhaust manifold mounting bolts 41 on the right and left sides 8 9 Sling...

Page 836: ...l not be an obstacle a Ground cable 50 is also tightened with bolt 45 3 Remove electrical intake air heater assembly 51 11 Disconnect injector wiring connectors CN1 CN4 52 and boost pressure sensor connector PTIM 53 12 Disconnect 3 wiring clamps 54 13 Remove the high pressure pipe according to the following procedure 1 Disconnect coolant temperature sensor wiring clamp 55 2 Remove spill hose mount...

Page 837: ... the alternator belt tension adjustment bolt and fully loosen alternator belt tension adjustment bolt 71 until the alternator belt can be removed 3 Remove alternator belt 72 14 a Bolt a is tightening the water pump Remove it when removing the water pump See 9 4 Disconnect coolant temperature sensor TWTR 73 5 Disconnect radiator upper hose 74 heater hoses 75 and 76 and radiator lower hose 77 from t...

Page 838: ...ng procedure 1 Loosen locknut 84 and fully loosen adjustment screw 85 17 a Loosen the intake and exhaust adjustment screws of all the cylin ders 2 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 18 Remove the cylinder head assembly according to the following procedure 1 Pull out 8 push rods 89 2 Remove 17 cylinder ...

Page 839: ... 6 122 5 Nm 7 12 5 kgm 3 a Use a new MIKALOR clamp a Align the hose to the original position marking position a Reference Depth of insertion 80 mm aftercooler side a Set the bridge BR under the clamp bolt and lap it over band BD at least b reaches 5 mm a Do not use an impact wrench when tightening the clamp 2 Clamp bolt BC Lubricanting oil THREE BOND PANDO 18B q When reusing the hose a Install the...

Page 840: ... set the gasket a Set the gasket with the side of stamp of 6205 on the manifold side 2 Install the exhaust manifold and tighten the mounting bolts 3 Exhaust manifold mounting bolt 34 3 53 9 Nm 3 5 5 5 kgm 9 q When installing air intake connector 48 and electrical intake air heater assembly 45 observe the following precautions a When installing air intake connector 48 and electrical intake air heat...

Page 841: ...an feel 3 Sleeve nut 25 5 29 4 Nm 2 6 3 0 kgm 12 a Before installing the air intake manifold apply gasket sealant to it Apply gasket sealant in a string of about 1 mm in diameter 2 Mounting face Gasket sealant LG 7 13 q Installation procedure for injector 1 Install seal 94 to injector 67 2 Install copper gasket 95 to injector 67 3 Insert injector 67 in the cylinder head 4 Install holder 66 to inje...

Page 842: ...g bolts Apply molybdenum disulfide lubricant LM P to the threaded parts of the cylinder head mounting bolts and tighten the bolts in the order shown in the figure according to the fol lowing procedure 3 Cylinder head mounting bolt 1st time 68 6 9 8 Nm 7 0 1 0 kgm 2nd time 107 8 4 9 Nm 11 0 0 5 kgm 3rd time Make marks on bolt head and cylinder head and tighten 90 degrees 30 0 degrees a After tighte...

Page 843: ...nnect the negative terminal of the battery beforehand 1 Remove lower cover 1 2 Open the coolant drain valve 2 to drain 1 6 Coolant 13 9 l 3 Remove 2 mounting bolts 4 of plate 3 and remove the cover 4 Disconnect radiator lower hose 5 2 5 Open engine hood 6 and lock it 6 Disconnect radiator overflow hose 7 7 Disconnect radiator upper hose 8 3 8 Remove 3 plate mounting bolts 9 and remove plate 10 9 R...

Page 844: ... out the installation in the reverse order of removal 1 5 Coolant 13 9 l 2 3 3 Radiator hose clamp bolt Both upper and lower hoses 8 8 0 5 Nm 0 9 0 05 kgm 4 3 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 ...

Page 845: ...er cover 1 2 Remove 2 mounting bolts 2 and disconnect the air aftercooler lower hose 3 3 Remove 2 mounting bolts 4 and remove plate 5 4 Loosen 2 clamps 6 and disconnect the air aftercooler upper hose 7 1 2 5 Remove 3 mounting bolts 8 and remove plate 9 6 Remove 2 air aftercooler mounting bolts 10 7 Pull out air aftercooler 11 3 a Take care not to damage sponge around the aftercooler ...

Page 846: ... its clamp install the MIKALOR clamp according to the following procedure a Use a new clamp a Align the hose to the original position marking position a Reference Depth of insertion 85 mm a Set the bridge BR under the clamp bolt and lap it over band BD at least b reaches 5 mm a Do not use an impact wrench when tightening the clamp 2 Clamp bolt BC Lubricanting oil THREE BOND PANDO 18B q When reusin...

Page 847: ...lly to release the pressure in the hydraulic tank a Put tags to the pipings to prevent a mistake in re connecting them 1 Remove undercover 1 2 Loosen drain plug 2 of the oil cooler outlet tube and drain the oil in the piping 1 3 Open the rear left inspection window and remove 2 mounting bolts 3 4 Disconnect tube 4 under the oil cooler 5 Remove 2 tube mounting bolts 5 above the oil cooler and disco...

Page 848: ...g bolts 11 2 2 upper mounting bolts 12 of oil cooler side bracket on each side 4 3 2 lower oil cooler piping mounting bolts 13 5 4 2 lower mounting bolts 14 of oil cooler side bracket on each side 6 Installation q Carry out installation in the reverse order to removal 1 3 Hydraulic oil drain plug 58 8 78 5 Nm 6 0 8 0 kgm 5 Hydraulic tank 69 l 2 6 3 Mounting bolt 44 9 8 Nm 4 5 1 0 kgm ...

Page 849: ... hydraulic tank cap gradually to release the pressure in the hydraulic tank a Put tags to the pipings to prevent a mistake in re connecting them 1 Remove hydraulic tank undercover 1 radia tor undercover 2 engine undercover 3 and work equipment undercover 4 2 Loosen hydraulic oil drain plug 5 and drain the hydraulic oil 1 6 Hydraulic tank 90 l Specified quantity of oil 145 l 1 Open fuel drain valve...

Page 850: ... and bracket 16 together 8 Remove side covers 17 and 18 a Remove mounting bolt 17a of side cover 17 too 9 Remove partition plate 19 10 Remove brackets 20 and 20a and partition plates 21 and 22 11 Disconnect the air conditioner compressor according to the following procedure 1 Disconnect air conditioner hose clamp 23 2 Disconnect wiring connector AC02 24 3 Remove air conditioner compressor belt pro...

Page 851: ...ill not be an obstacle 12 Disconnect the hoses according to the follow ing procedure 1 Disconnect radiator upper hose 30 from the radiator 4 2 Disconnect aftercooler upper hose 31 from the aftercooler 5 3 Disconnect 2 heater hose clamps 32 and 33 and disconnect heater hose 34 from water pump 35 4 Disconnect hose 36 between the turbo charger and air cleaner from the turbo charger 6 5 Disconnect con...

Page 852: ... is tightened with wiring clamp mounting bracket 45 a The wiring clamp of connector CE02 41 and CE03 42 and controller mounting bracket 44 are tightened with wiring clamp bracket 45 4 Disconnect electrical intake air heater wir ing M23 46 5 Disconnect starting motor wirings M20 47 and M17 48 9 6 Disconnect starting motor wiring clamp 49 a Starting motor wiring M20 47 is a pair of wire tightened to...

Page 853: ...mp 56 15 Disconnect fuel hose clamp 57 16 Remove the fan assembly according to the fol lowing procedure 1 Loosen alternator mounting bolts 58 and 59 2 Fully loosen alternator belt tension adjust ment bolt 61 until the alternator belt can be removed a Do not loosen double nut 60 3 Remove alternator belt 62 11 4 Remove fan guard 63 5 Remove fan pulley mounting bolt 64 and remove fan and pulley assem...

Page 854: ...e damper case oil supply hose bracket is tightened with 2 mounting bolts 69a too 5 Disconnect connectors V11 71 and P22 72 6 Disconnect fuel filter 73 from bracket 74 7 Disconnect fuel prefilter 75 and bracket 74 together from the frame 8 Disconnect engine oil filter 76 and bracket together from the frame 9 Disconnect 5 hydraulic hoses 77 81 10 Disconnect suction hose 82 and elbow 82a together fro...

Page 855: ... 8 3 Radiator hose clamping bolt Both upper and lower hoses 8 8 0 5 Nm 0 9 0 05 kgm 5 If air hose was disconnected from air connector of air intake manifold install the MIKALOR clamp according to the following procedure a Use a new clamp a Align the hose to the original position marking position a Reference Depth of insertion 85 mm a Set the bridge BR under the clamp bolt and lap it over band BD a...

Page 856: ... 6 6 6 Nm 0 27 0 68 kgm M20 17 7 24 5 Nm 1 8 2 5 kgm 10 3 Alternator wiring terminal mounting bolt M21 5 9 9 9 Nm 0 6 1 0 kgm 11 a For adjustment of the alternator belt tension see Testing and adjusting alternator belt ten sion 12 a If hose 82 was disconnected from elbow 82a install the MIKALOR clamp according to the following procedure q Tighten the clamp on the inside of the hose first and then ...

Page 857: ...om the negative terminal of the battery 1 Open the rear right inspection cover and open drain valve 1 to drain the fuel 1 6 Fuel When tank is full 247 l 2 Remove handrail mounting bolts 2 3 and 4 2 pieces each and remove handrail 5 a To remove mounting bolts 4 open cover 6 3 Remove 2 cover upper mounting bolts 7 and 2 cover lower mounting bolts 9 and remove cover 8 4 Remove fuel level sensor conne...

Page 858: ...ustment shims 16 are installed to the 2 bolts on the hydraulic tank side 10 Lift off fuel tank assembly 17 4 Fuel tank assembly 120 kg Installation q Carry out installation in the reverse order to removal 1 5 Fuel tank 247 l 2 a When installing the 2 bolts on the hydraulic tank side install the height adjustment shims too 3 Fuel tank mounting bolt 235 285 Nm 23 5 29 5 kgm ...

Page 859: ...50 Disassembly and assembly SEN04127 02 PC130 8 39 ...

Page 861: ...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 41 Disassembly and assembly of swing machinery assembly 43 Removal and installation of swing circle assembly 49 ...

Page 862: ...oil filler cap slowly to release the pressure inside the hydraulic tank 2 Disconnect 4 mounting bolts 1 and remove travel motor cover 2 3 Disconnect 4 travel motor hoses 2 4 Remove all travel motor and final mounting bolts 4 except 1 5 Sling the travel motor and final drive assembly 5 and remove mounting bolt 6 Lift off travel motor and final drive assembly 1 a Be extremely careful not to damage t...

Page 863: ... Thread tightener LT 2 3 Travel motor and final drive assembly mounting bolt 235 285 Nm 23 5 29 5 kgm a Bleed the air from the travel motor For details see Testing and adjusting Bleeding air from travel motor q 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 ...

Page 864: ...SEN04128 01 50 Disassembly and assembly 4 PC130 8 Disassembly and assembly of travel motor and final drive assembly 1 Component parts ...

Page 865: ...50 Disassembly and assembly SEN04128 01 PC130 8 5 ...

Page 866: ...SEN04128 01 50 Disassembly and assembly 6 PC130 8 ...

Page 867: ...ring retainer 29 Floating seal 326 Plug 30 Plug 327 Valve 31 O ring 328 Spring 32 O ring 329 Orifice 33 O ring 330 Spring 34 Dowel pin 331 O ring 35 Hexagonal socket head bolt 336 O ring 36 Ring 341 Dowel pin 102 Shaft 343 Hexagonal socket head bolt 103 Swash plate 352 Plug 104 Cylinder block 353 Seal ball 105 Piston 354 Hexagonal socket head plug 106 Shoe 357 Plug 107 Retainer plate 358 O ring 10...

Page 868: ... ring pliers For shaft and hole 1 each 11 Pliers 200 mm 1 12 Sling Lifting load Min 2 940 N 300 kg Eyebolt M16 Eyebolt M12 Eyebolt PF 1 2 Wire with hook 1 set 2 3 2 1 13 Container Common vat W450 x D300 x H120 mm 2 14 Leather gloves 1 pair No Part name Model Dimension Q ty 1 Hexagonal socket head bolt M12 P1 5 x 40 mm 2 Use Part No Part name Model Dimension Q ty Disassembly and assembly Common wor...

Page 869: ...d to install spring 114 washer 110 and snap ring 145 to cylinder block 104 q Used to remove spring 114 from cyl inder block 104 No 2 holder 3 q Used to remove ball bearing 149 from shaft 102 Push tool 4 q Used to press fit oil seal 132 to spin dle 2 Jig 5 q Used to install lock washer 22 to the groove of spindle 2 Push tool 6 q Used to press fit ball bearing 24 to hub 1 ...

Page 870: ...ndle 2 and hub 1 Spatula 9 q Used to remove timing plate 109 from rear flange 301 No 1 mounting jig 10 q Used to install floating seal 29 to hub 1 No 2 mounting jig 11 q Used to install floating seal 29 to hub 1 and spindle 2 No 3 mounting jig 12 q Used to install floating seal 29 to spindle 2 Use Dimension A Hub M16 Hub M10 Spindle M16 Travel motor M16 ...

Page 871: ...50 Disassembly and assembly SEN04128 01 PC130 8 11 Pin punch 13 q Used to remove the outer race from ball bearing 24 ...

Page 872: ...0 0 5 324 Plug M36 P1 5 41 Socket 2 441 39 2 45 0 4 0 343 Hexagonal socket head bolt M12 P1 75 10 10 102 15 7 10 4 1 6 352 Plug PF 1 8 5 3 12 3 2 45 1 25 0 25 354 Hexagonal socket head bolt NPTF 1 16 4 5 9 81 1 96 1 0 0 2 380 Plug PF 3 8 8 2 58 8 9 81 6 0 1 0 396 Hexagonal socket head bolt PT 1 4 6 2 29 4 4 90 3 0 0 5 398 Hexagonal socket head bolt PT 1 8 5 5 12 3 2 45 1 25 0 25 Part No Part name ...

Page 873: ...bly or prying them If you do so the parts may have burrs and may be broken and that can make assembly impossible and lower the performance 4 If the parts are left as disassembled they may be rusted by moisture and dirt When leaving them disassembled be sure to take measures to protect them from rusting and dirt 5 When disassembling put match marks on the matching portions of the parts 6 During the...

Page 874: ...he case and then tighten it lightly See Compo nent parts a If the case is pressurized oil may spout out when the drain plug is loos ened 3 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 6 Final drive case 2 1 l 4 Removal of cover 1 Turn over t...

Page 875: ...netary gear A 5 See Component parts 6 Removal of coupling 1 Remove coupling 15 from shaft 102 See Component parts 7 Removal of sun gear B 1 Install eyebolts 8 to the lifting taps 3 places of carrier B 7 and remove the carrier assembly 4 Carrier assembly 25 kg a Set the center axes of the hub and carrier assembly vertically and lift up the carrier assembly slowly so that the internal teeth of the h...

Page 876: ...forcibly but sling it by using a press etc 10 Removal of floating seal 1 Hold the inside of floating seal 29 with your fingers and remove it up a When removing the floating seal put on gloves to protect your fingers from the edge of the floating seal a If the floating seal is stuck with mud etc pry it up with a flat head screw driver etc 11 Removal of ball bearing 1 To remove ball bearing 24 apply...

Page 877: ...e spring 328 is still compressed after plugs 324 are loosened the plugs and spring may jump out Take care See Component parts 3 Loosen two plugs 380 two plugs 352 and plug 357 4 Remove two relief valve assemblys 18 a Do not reuse removed O rings 207 209 and 212 and rings 208 and 210 See Component parts 5 Remove ten hexagonal socket head bolts 343 from rear flange 301 6 Remove rear flange 301 from ...

Page 878: ...iming plate 109 from rear flange 301 a If timing plate 109 is stuck because of the oil put spatula 9 in the groove on the rear flange 301 to remove See Tools 4 Tools to be manufac tured a If you use a sharp tool such as a flat head screwdriver you may scratch mating face a Accordingly do not use such a tool 3 Remove ball bearing 150 from rear flange 301 4 Remove dowel pin 341 from rear flange 301 ...

Page 879: ...24 a Do not reuse removed O rings 336 15 Disassembly of 2nd travel speed selector spool 1 Remove plug 357 from rear flange 301 2 Remove O ring 359 from plug 357 a Do not reuse removed O ring 359 See Component parts 3 Remove spring 366 and spool 363 from rear flange 301 See Component parts 16 Disassembly of piston 1 Remove two plugs 380 from rear flange 301 2 Remove two O rings 383 from two plugs 3...

Page 880: ...ough parking brake oil passage b of spindle 2 to take out piston 112 k If compressed air is blown sud denly piston 112 jumps out and that is dangerous Accordingly blow compressed air gradually Place protective cover 19 for safety in advance 2 Remove O rings 135 and 139 from pis ton 112 a Do not reuse removed O rings 135 and 139 19 Disassembly of travel motor 1 Turn spindle 2 90 degrees to set it i...

Page 881: ...h plate 103 and shoe 106 See Component parts 6 Remove piston assemblies pistons 105 and shoes 106 and retainer plate 107 together from cylinder block 104 a Hold and remove retainer plate 107 with both hands a Since piston 105 and shoe 106 are joined by drawing the shoe over the spherical portion of the piston a Replace piston 105 and shoe 109 together always Hereinafter this assembly is referred t...

Page 882: ...d suddenly spring 114 jumps out and that is dangerous Accordingly release the press gradually 4 Remove THS snap ring 145 washer 110 spring 114 and washer 110 from cylinder block 104 See Component parts 21 Removal of swash plate 1 Turn spindle 2 90 degrees to set it in the horizontal position and remove swash plate 103 from shaft 102 a When removing swash plate 103 pivot 167 may stick to it Take ca...

Page 883: ...e ball bearing only when replacing it 1 Set No 2 holder 3 on the press stand and set shaft 102 in it 2 Push out shaft 102 from ball bearing 149 with the press a Do not reuse ball bearing 149 23 Removal of spindle component parts 1 Remove shim 23 from spindle 2 2 Remove floating seal 29 from spindle 2 3 Remove oil seal 132 from spindle 2 a Do not reuse removed floating seal 29 and oil seal 132 See ...

Page 884: ...ed to wash the parts Since it is highly inflammable and can cause a fire or a burn handle it with extreme care a If you wash the parts immediately after putting them in the oil they may be scratched Leave them in the oil until the dirt oil grease etc are sep arated and then wash 25 Finish washing 1 Put each part in the finish washing tank containing kerosene and wash them to their inside while rot...

Page 885: ...ce is pitted Rolling surface of bearing is flaked 24 Ball bearing There is impression Rolling surface of ball bearing is flaked Worn unevenly 301 Rear flange There are scratches on sliding surface of spools 323 and 363 and piston 381 102 Shaft Contact surface against oil seal 132 is worn Spline portion is worn 103 Swash plate Parts are seized 104 Cylinder block Spline portion is worn Inside wall o...

Page 886: ...ing There is impression Rolling surface of bearing is flaked Parts are worn 161 162 2nd speed selec tion piston assembly Piston Shoe Outside surface is worn abnormally Shoe is worn abnormally and unevenly 323 363 Spool Outside surface is worn unevenly There is scratch on outside surfaces 381 Piston There is scratch on outside surfaces ...

Page 887: ...y a little amount of grease to them and then install them carefully so that they are not damaged 6 Be sure to apply power train oil TO30 to the moving parts and sliding parts of the travel motor before assembly 7 When assembling do not put on cloth gloves Prevent malfunction caused by entry of a fiber of cloth gloves 8 Tighten the bolts and plugs according to Tightening torque table 9 Immediately ...

Page 888: ...ace of floating seal 29 is 1 mm or below 2 Assembly of spindle assembly 1 Apply grease to the O ring of floating seal 29 and install it to spindle 2 2 O ring Grease G2 LI a Remove the O ring and apply grease thinly all over its surface 2 Set No 3 mounting jig 12 and No 2 mounting jig 11 to spindle 2 in order and push in No 2 mounting jig 11 until it touches No 3 mounting jig 12 a Remove No 3 mount...

Page 889: ... and ball bearing 24 to prevent them from floating 3 Select shim 23 from the following table so that clearance e will be 0 13 to 0 17 mm q Clearance e Dimension c d 4 Install shim 23 to spindle 2 4 Installation of hub 1 Sling and lower hub 1 while aligning it with spindle 2 and press fit it into ball bearing 24 See Component parts 4 Hub 1 50 kg 2 Fix hub 1 to work stand 1 by using hex agonal socke...

Page 890: ...arts 8 Turn over the work stand to set the travel motor side up 5 Assembly of parts inside spindle 1 Use push tool 4 to press fit oil seal 132 to spindle 2 2 Lip of oil seal 132 Grease G2 LI a When installing oil seal 132 check the direction it faces 2 Install two dowel pins 171 to the holes of spindle 2 See Component parts 3 Install two pivots 167 to dowel pins 171 See Component parts 2 Hemispher...

Page 891: ...h 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 7 Assembly of cylinder block 1 Install washer 110 spring 114 washer 110 and THS snap ring 145 to cylinder block 104 in order a Face the acute angle side of washer 110 on the THS snap ring 145 side upward a Face the acute angle side of THS snap ring 145 upward See...

Page 892: ...ston assemblies pistons 105 and shoes 106 to retainer plate 107 a After installing soak all the parts in power train oil TO30 4 Install piston assemblies pistons 105 and shoes 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 ...

Page 893: ...Assembly of parking brake 1 Turn the travel motor assembly 90 degrees to set the travel motor side up 2 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 3 Install O rings 135 and 139 to piston 112 2 O rings 135 and 139 Grease G2 LI 4 Install piston 112 to spindle 2 a If piston 112 does not enter easily hit ...

Page 894: ...lugs 380 See Component parts 2 O ring 383 Grease G2 LI 2 Install piston 381 to rear flange 301 3 Install two plugs 380 to rear flange 301 13 Assembly of brake valve portion 1 Install the spool 323 to rear flange 301 2 Spool 323 Power train oil TO30 a Insert spool 323 carefully in the spool hole of rear flange 301 a When spool 323 is inserted if spool 323 or spool hole of rear flange 301 is scratch...

Page 895: ... Ball bearing 150 Grease G2 LI 2 Install dowel pin 341 to the pin hole of rear flange 301 3 Install timing plate 109 to rear flange 301 by using the dowel pin as a guide 2 Mating faces of rear flange 301 and timing plate 109 Grease G2 LI a Check that timing plate 109 and rear flange 301 are stuck with the grease a Perform this step to prevent timing plate 109 from falling when rear flange 301 is i...

Page 896: ...ut through the mating faces of rear flange 301 and spindle 2 dur ing operation and you may mistake it for oil leakage See Component parts 2 Supply oil to spindle 2 5 In spindle 2 Power train oil 1 0 l TO30 3 Install two dowel pins 34 to spindle 2 4 Install rear flange 301 to spindle 2 a Install rear flange 301 while match ing installation hole on rear flange to dowel pins 34 See Component parts 5 ...

Page 897: ...rse work stand to set the final drive side up 2 Install sun gear B 8 to carrier B 7 See Component parts 3 Install eyebolts 8 to the lifting taps 3 places of carrier B 7 and sling and install the carrier assembly 4 Carrier assembly 25 kg a Set the center axes of the hub and carrier assembly vertically and lift down the carrier assembly slowly so that the internal teeth of the hub will not be damage...

Page 898: ...ill not be damaged by the end of plane tary gear A 5 2 Install sun gear A 4 while matching it with the spline of coupling 15 See Component parts a If sun gear A 4 cannot be installed because of interference with the tooth tips of planetary gear A 5 lift up car rier assembly slowly until sun gear B 8 is disconnected from the gear cou pling and then install sun gear A 4 See Component parts 3 Install...

Page 899: ...92 Nm 6 8 0 4 kgm 21 Adding oil 1 Add oil through oil filler port j 5 Final drive case 2 1 l 2 Tighten three plugs 30 3 Plug 30 98 1 19 6 Nm 10 0 2 0 kgm 22 Removal of travel motor 1 Turn over the travel motor assembly to set the travel motor side up 2 Remove the mounting bolts of the travel motor from work stand 1 See Compo nent parts 3 Install eyebolts 8 to the threaded holes of spindle 2 and li...

Page 900: ...ate from the hydraulic motor aDo not install the travel motor by hitting it with a hammer etc but install it carefully by using the bolt holes 2 Running in of travel motor Selection Travel motor speed Pressure Rotation direction Operating time Low speed 10 rpm No load Left Right Min 1 minute in each direction High speed 20 rpm 3 Performance check test of travel motor 1 Running in before test Perfo...

Page 901: ...ic circuit referring to Bleeding residual pressure from hydraulic circuit in Testing and adjusting k Disconnect the negative terminal of the battery beforehand a Put tags to the disconnected hoses to pre vent a mistake in re connecting them 1 Remove lower cover 1 2 Loosen hydraulic oil drain plug 2 and drain the hydraulic oil 6 Hydraulic tank 90 l Specified quantity of oil 145 l 3 Disconnect hoses...

Page 902: ...swing machinery assembly 95 kg Installation q Carry out the installation in the reverse order of removal q Refilling oil Hydraulic tank a Fill oil up to the specified level start the engine to circulate oil in the pipe and check the oil level again q Bleeding air a Bleed air from the piping referring to Bleeding air from each part in Testing and adjusting 1 3 Wing machinery mounting bolt 303 8 362...

Page 903: ... 1 and Sun gear No 2 assembly 1 Remove sun gear No 1 4 2 Remove carrier No 1 and sun gear No 2 assembly 5 Sym bol Part No Part name Necessity Q ty New Remodel Sketch F 1 790 201 2750 Spacer t 1 2 790 101 5201 Push puller Kit q 1 790 101 2510 Block 1 790 101 2550 Leg 1 790 101 2560 Nut 2 790 101 2570 Plate 4 790 101 3101 Bearing puller q 1 790 101 4200 Puller 294 kN 30 ton q 1 790 101 1102 Hydrauli...

Page 904: ... No 2 14 from carrier 15 4 Ring gear Remove ring gear 16 5 Carrier No 2 assembly 1 Remove spacer 17 2 Remove carrier No 2 assembly 18 3 Sub disassembly of carrier No 2 assem bly 1 Press pin 19 in and punch out shaft 20 from carrier 21 a Remove the shaft then remove pin 19 2 Remove thrust washer 22 gear 23 bearing 24 and thrust washer 25 6 Retainer and collar 1 Remove retainer 26 2 Set the shaft an...

Page 905: ...mbly 29 to block 2 and remove shaft assembly 30 with the press using push tool 3 2 Remove bearing 28 3 Use tool F2 to remove bearing 31 and collar 32 from shaft 33 8 Oil seal and bearing outer race 1 Remove oil seal 34 from case 35 2 Use puller 4 to remove bearing outer races 36 and 37 from case 35 ...

Page 906: ...n be entered a Press fit force 11 760 N 1 200kg a Press the bearing gradually by rotat ing the case 5 Install 2 piece collar 27 6 Screw in bolt 12 mm P 1 75 to the case Using push pull scale 5 to measure the tangential force in the direction of rota tion a Tangential force Max 176 4 N 18kg a Tangential force refers to a maximum value at the start of rotation 3 Oil seal Using tool F6 to press oil s...

Page 907: ...nsert the pin then caulk the pin of the carrier 2 Install carrier No 2 assembly 18 to the shaft and case assembly 3 Install spacer 17 6 Ring gear Install O ring 39 to the shaft and case assem bly and install ring gear 16 7 Carrier No 1 and sun gear No 2 assembly 1 Sub disassembly of carrier No 1 and sun gear No 2 assembly 1 Install carrier No 1 15 to sun gear No 2 14 and Install snap ring 13 2 Ali...

Page 908: ...g a After installation check that the snap ring is firmly in place 2 Install carrier No 1 and sun gear No 2 assembly 5 to the shaft case assembly 3 Install sun gear No 1 4 8 Swing motor assembly 1 Install swing motor assembly 4 2 Install 15 swing motor mounting bolts 3 3 Swing motor mounting bolt 98 122 5 Nm 10 12 5 kgm 3 Install hose 2 4 Install oil level pipe 1 9 Refilling with oil Tighten the d...

Page 909: ...embly 2 Temporarily lift swing circle assembly 1 to remove the 38 mounting bolts 1 3 Remove swing circle assembly 1 2 4 Swing circle assembly 155 kg Installation q Installation is performed in the opposite way to removal 1 2 Swing circle mounting bolt Liquefied adhesive LT 2 3 Swing circle mounting bolt 245 308 9 Nm 25 31 5 kgm 2 a Lift swing circle assembly 1 and install it on the track frame wit...

Page 911: ...nd 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 Removal and installation of sprocket 13 Removal and installation of revolving frame assembly 14 Removal and installation of counterweight assembly 16 ...

Page 912: ...om shaft 5 a It is filled with 75 85 cc of oil so drain the oil at this point or lay a cloth to prevent the area from becoming dirty 4 Remove floating seal 6 on opposite side from roller 4 and shaft 5 5 Remove collar 8 from shaft 5 6 Remove bushings 9 and 10 from roller 4 Sym bol Part No Part name Necessity Q ty New Remodel Sketch M 1 796T 430 1210 Push tool t 1 N Q 2 796T 430 1220 Installer t 1 N...

Page 913: ...4 a For details of the precautions when install ing floating seals 6b and 6d and 3b and 3d see the precautions marked a for Step 3 5 Assemble shaft 5 to roller 4 6 Turn over roller 4 and shaft 5 assembly 7 Using tool M2 install floating seal 3 to collar 2 a For details of the precautions when install ing floating seals 3a and 3c see the precautions marked a for Step 3 8 Assemble collar 2 to shaft ...

Page 914: ...129 02 50 Disassembly and assembly 4 PC130 8 10 Using tool M3 fill track roller assembly with oil then tighten plug 11 5 Track roller oil 145 155 cc EO30 DH 3 Plug 15 5 Nm 1 5 0 5 kgm P To oil pump T To tank ...

Page 915: ...and support assembly 7 a 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 4 Remove floating seal 6 on opposite side from idler 4 and shaft 5 and support assem bly 7 5 Remove dowel pin 8 then remove support 7 from shaft 5 6 Remove bushings 9 and 10 from idler 4 Sym bol Part No Part name Necessity Q ty New Remodel L 1 791 675...

Page 916: ...ing seal with oil and be careful not to let any dirt or dust get stuck to it a Remove all grease and oil from the con tact surface of the O ring and the floating seal 4 Assemble shaft 5 and support assembly 7 to idler 4 5 Using tool L1 install floating seal 3 to idler 4 and support 2 a Coat the sliding surface of the floating seal with oil and be careful not to let any dirt or dust get stuck to it...

Page 917: ... oil filler port and check air leakage a 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 down 8 Using tool M3 fill track roller assembly with oil then tighten plug 11 5 Track roller oil 90 cc EO30 DH 3 Plug 15 5 Nm 1 5 0 5 kgm P To oil pump T To tank ...

Page 918: ...ring is under large installed load so be sure to set the tool properly Failure to do this is dangerous a Installed load of spring 84 300 N 8 600 kg Sym bol Part No Part name Necessity Q ty New Remodel Sketch L 2 791 600 2001 or 791 685 8006 Compressor A Compressor B t 1 1 791 635 3160 Extension t 1 790 201 2770 Spacer t 1 790 101 1600 Cylinder 686 kN 70 ton t 1 790 101 1102 Pump t 1 3 790 201 1500...

Page 919: ... spring to a point where the nut becomes loose a Release the hydraulic pressure slowly to remove the spring tension 3 Remove pilot 8 and spring 7 4 Remove snap ring 10 dust seal 11 and bush 12 from cylinder 9 4 Disassembly of yoke piston 5 assembly 1 Remove snap ring 14 then remove U packing 15 2 Remove wear ring 16 from yoke piston 13 ...

Page 920: ...ng 7 and set to tool L2 4 Apply hydraulic pressure slowly to com press spring and tighten nut 6 so that installed length of spring is dimension a a Installed length a of spring 390 mm 5 Remove recoil spring assembly 4 from tool L2 3 Assemble yoke piston assembly 5 to recoil spring assembly 4 2 Yoke piston sliding portion wear ring Grease G2 LI 4 Fit valve 3 and seat 2 and secure with lock plate 1 ...

Page 921: ...and in reverse 3 Remove 2 shoes 4 above and in front of the master pin 1 4 Using tool R pull out the master pin 2 5 Using tool R pull out the temporary pin and remove the dust seal Move the machine in reverse to spread track shoe assembly 5 3 Sym bol Part No Part name Necessity Q ty New Remodel Sketch R 791 620 3000 Remover and installer t 1 791 635 3110 Frame 1 791 635 3160 Extension 1 791 635 31...

Page 922: ...that its projection will be dimension a Projection a of master pin 3 2 mm 3 a When installing the dust seal apply grease G2 LI 1 to its contact face to the bushing a When press fitting the master pin apply grease G2 LI 1 to the inside of the master bushing a 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 wit...

Page 923: ...mbly 2 Swing the work equipment by 90 and push up 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 4 Sprocket 35 kg Installation q Carry out installation in the reverse order to removal 1 2 Threads of sprocket mounting bolt Adhesive LT 2 3 Sprocket mounting bolt 323 6 362 8 Nm 33 37 kgm ...

Page 924: ...and position of the shims mounted 1 4 Lift boom cylinder assembly 4 to remove it 4 Boom cylinder assembly 110 kg 5 Remove operator cab assembly 5 by refer ring to Removal of operator cab assembly 6 Disconnect hoses 6 12 from center swivel joint 7 Disconnect plate 13 from revolving frame 8 Remove mounting bolts 14 leaving one each at front and rear 2 9 Lift revolving frame assembly 16 to loosen rem...

Page 925: ...ount on the boom cylinder bottom and the frame using the shims so that it becomes 1mm or less 2 2 Swing circle contacting face Liquefied gasket LG 1 2 Revolving frame mounting bolt screw Liquefied adhesive LT 2 3 Revolving frame mounting bolt 245 308 9 Nm 25 31 5 kgm Tuget 279 3 Nm 28 5 kg q Supplying oil hydraulic oil tank Supply oil from the oil filler port to the specified level start the engin...

Page 926: ...tive terminal of the battery 1 Open and lock engine hood 1 2 Remove cover 2 3 Disconnect monitor camera wiring connector A40 3 4 Using 2 sling bolts M 36 x 3 mm sling the counterweight and remove 4 mounting bolts 4 1 5 Lift off counterweight assembly 5 a Move the counterweight backward at first so that it will not interfere with the machine and then lift it up 4 Counterweight assembly PC120 8 2 30...

Page 927: ...mbly SEN04129 02 PC130 8 17 Installation q Carry out installation in the reverse order to removal 1 2 Counterweight mounting bolt Adhesive LT 2 3 Counterweight mounting bolt 1 177 1 470 Nm 120 150 kgm Target 1 324 Nm 135 kgm ...

Page 929: ... and installation of work equipment pump assembly 8 Removal and installation of control valve assembly 12 Disassembly and assembly of control valve assembly 16 Disassembly and assembly of work equipment PPC valve assembly 28 Disassembly and assembly of travel PPC valve assembly 30 Removal and installation of anti drop valve for boom assembly 33 Removal and installation of anti drop valve for arm a...

Page 930: ...the pressure in the hydraulic tank a Put tags to the pipings to prevent a mistake in re connecting them 1 Remove undercover 1 2 Loosen hydraulic oil drain plug 2 and drain the hydraulic oil 1 6 Hydraulic tank 90 l Specified quantity of oil 145 l 3 Disconnect hoses 3 8 between travel motor and swivel joint 4 Remove elbow 9 5 Disconnect drain hose 10 11 6 Disconnect hoses 12 15 between control valve...

Page 931: ...he bolts 4 Center swivel joint assembly 30 kg Installation q Installation is performed in the opposite way to removal 1 5 Hydraulic tank 90 l Specified quantity of oil 145 l 2 Mounting bolt screw Liquefied adhesive LT 2 3 Mounting bolt 98 1 123 0 Nm 10 0 12 5 kgm q Bleeding air Bleed air from the swing motor For details see Testing and adjusting Bleeding air from each part ...

Page 932: ...it it by using push tool and hitting swivel rotor 4 lightly with plastic hammer 2 Contact surfaces of rotor and shaft Grease G2 LI a When installing the rotor take care not to damage the slipper seals and O rings 3 Install ring 3 and secure with snap ring 2 4 Fit O ring and install cover 1 3 Swivel joint mounting bolt 31 3 2 9 Nm 3 2 0 3 kgm Sym bol Part No Part name Necessity Q ty New Remodel Ske...

Page 933: ...ure in the hydraulic tank 1 Remove undercover 1 2 Loosen hydraulic oil drain plug 2 and drain the hydraulic oil 1 6 Hydraulic tank 90 l Specified quantity of oil 145 l 3 Remove the exterior parts according to the fol lowing procedure 1 Remove handrail mounting bolts 3 4 and 5 2 pieces each and remove handrail 6 a To remove mounting bolts 5 open cover 7 2 Remove 2 cover upper mounting bolts 8 and 2...

Page 934: ...move 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 4 Disconnect return hose 30 5 Remove work equipment pump suction hose 31 a Disconnect elbow 31a from the pump 2 a Make marks at the hose end and tube so that it can be reconnected correctly 6 Disconnect 6 hoses 32 37 ...

Page 935: ... l 2 a Use a new MIKALOR clamp a Align the hose to the original position marking position a Reference Depth of insertion q Hydraulic oil tank side 92 mm q Work equipment pump side 85 mm a Set the bridge BR under the clamp bolt and lap it over band BD at least b reaches 5 mm a Do not use an impact wrench when tighten the clamp 2 Clamp bolt BC Lubricanting oil THREE BOND PANDO 18B q When reusing the...

Page 936: ...raulic tank a Prepare an oil receiving pan under the work equipment pump a Put tags to the pipings to prevent a mistake in re connecting them 1 Remove undercover 2 2 Loosen the damper case drain plug and drain the damper case oil 1 6 Damper case 0 75 l 3 Open and lock engine hood 3 4 Remove covers 4 and 5 5 Remove bracket assembly 6 6 Remove frame 7 7 Remove bracket 8 8 Remove 5 upper mounting bol...

Page 937: ... 2 mounting bolts 22 too 5 Disconnect engine oil filter assembly 23 and bracket together a Fix the engine oil filter assembly with a rope etc so that it will not be an obstacle 6 Disconnect fuel filter assembly 24 from bracket 25 7 Disconnect fuel prefilter assembly 26 and bracket 25 together 12 Disconnect connectors V11 27 and P22 28 13 Disconnect hoses 29 33 14 Disconnect suction hose 34 and elb...

Page 938: ... Disassembly and assembly 10 PC130 8 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 ...

Page 939: ... parts C and tighten the clamps 2 Lubricating oil THREEBOND PANDO 18B q Adjust bridge A so that it will be under band B q Tighten until dimensions L and M are set to the specified dimensions 3 a Use a new MIKALOR clamp a Align the hose to the original position marking position a Reference Depth of insertion q Hydraulic oil tank side 92 mm q Work equipment pump side 85 mm a Set the bridge BR under ...

Page 940: ...rcover 1 2 Loosen hydraulic oil drain plug 2 and drain the hydraulic oil 1 6 Hydraulic tank 90 l Specified quantity of oil 145 l 3 Open and lock engine hood 3 4 Remove cover 4 5 Remove brackets 5 and 6 and covers 7 and 8 6 Remove clamps 9 and 10 7 Disconnect front upper hoses 11 16 Port Nos and connection points 11 Control valve A7 To attachment 1 12 Control valve B7 To attachment 1 13 Control val...

Page 941: ...nts 27 Control valve PB7 From attachment 1 PPC valve 28 Control valve PB6 From bucket digging PPC valve 29 Control valve PB5 From arm in PPC valve 30 Control valve PB4 From boom lower PPC valve 31 Control valve TC From attachment 1 32 Control valve TC To oil cooler 33 Control valve PS From merge divider valve solenoid valve 34 Control valve PST From travel junction valve solenoid valve 35 Control ...

Page 942: ...Control valve PA2 From left travel for ward PPC valve 51 Control valve PA1 From swing right PPC valve 52 Control valve TSW To swing motor a Control valve BP1 port is installed to the bottom block of the rear of the control valve a Disconnect hose 46 from port PA4 since it will be an obstacle to disconnection of hoses 49 51 a Hose 49 is connected to the rear of con nector 53 and hose 50 is connecte...

Page 943: ...y and assembly SEN04130 01 PC130 8 15 14 Remove the 4 bolts on the underside of the control valve mount 59 15 Lift off control valve assembly 60 Installation q Carry out installation in the reverse order to removal ...

Page 944: ...tions for each part are as follows Random order q Installation of cover 1 Tighten nuts 17 in the order of 1 4 in 3 times 3 1st time 58 8 68 6 Nm 6 7 kgm 2nd time 78 5 88 3 Nm 8 9 kgm 3rd time 98 1 113 Nm 10 11 5 kgm a Projection of stud end from nut end 0 5 3 mm q Assembly of block 10 Tighten bolts 18 in the order of 1 4 in 3 times 3 1st time 19 6 29 4 Nm 2 3 kgm 2nd time 39 2 49 0 Nm 4 5 kgm 3rd ...

Page 945: ...50 Disassembly and assembly SEN04130 01 PC130 8 17 ...

Page 946: ... PPC valve q PA6 From bucket dump PPC valve q PA7 From attachment 1 PPC valve q PA8 From attachment 2 PPC valve q PB1 From swing left PPC valve q PB2 From left travel reverse PPC valve q PB3 From right travel forward PPC valve q PB4 From boom lower PPC valve q PB5 From arm in PPC valve q PB6 From bucket digging PPC valve q PB7 From attachment 1 PPC valve q PB8 From attachment 2 PPC valve q PMAX Pr...

Page 947: ...50 Disassembly and assembly SEN04130 01 PC130 8 19 ...

Page 948: ...lve Boom 13 Suction valve Arm 14 Suction valve Bucket 15 Suction safety valve Service 1 16 Suction safety valve Service 2 17 Suction safety valve 18 Spool Service 2 19 Spool Service 1 20 Spool Bucket 21 Spool Arm 22 Spool Boom 23 Spool Right travel 24 Spool Left travel 25 Spool Swing 26 Unload valve 27 Unload valve 28 Suction valve spring 29 Piston return spring 30 Suction valve spring 31 Spool re...

Page 949: ...50 Disassembly and assembly SEN04130 01 PC130 8 21 ...

Page 950: ...9 Pressure compensation valve R Left travel 10 Pressure compensation valve R Swing 11 Pressure compensation valve F Swing 12 Pressure compensation valve F Left travel 13 Pressure compensation valve F Right travel 14 Merge divider valve spool 15 Pressure compensation valve F Boom 16 Pressure compensation valve F Arm 17 Pressure compensation valve F Bucket 18 Pressure compensation valve F Service 1 ...

Page 951: ...50 Disassembly and assembly SEN04130 01 PC130 8 23 ...

Page 952: ...ation valve F 11 LS check valve Right travel valve 12 Pressure compensation valve F 13 Suction valve 14 Suction valve 15 Spool 16 Pressure compensation valve R 17 Travel junction valve LS check valve 18 Unload valve 19 LS bypass valve 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 Spoo...

Page 953: ...50 Disassembly and assembly SEN04130 01 PC130 8 25 ...

Page 954: ... Pressure compensation valve R 16 Regeneration valve Bucket valve 17 Pressure compensation valve F 18 Suction valve 19 Suction valve 20 Spool 21 Pressure compensation valve R Service 1 valve 22 Pressure compensation valve F 23 Suction safety valve 24 Suction safety valve 25 Spool 26 Pressure compensation valve R Service 2 valve 27 Pressure compensation valve F 28 Suction safety valve 29 Suction sa...

Page 955: ...50 Disassembly and assembly SEN04130 01 PC130 8 27 ...

Page 956: ...ssembling clean and inspect the parts closely and take care fully so that dirt rust flaw etc will not cause a trouble a When installing plug 2 to body 1 take care that its tip will not enter the hole of the body 20 mm in diameter 3 Plug 2 4 9 Nm 0 4 0 9 kgm a The head of plug 3 must not be projected from the body 1 surface 3 Plug 3 6 11 Nm 0 6 1 1 kgm a When installing piston 8 apply grease G2 LI ...

Page 957: ...0 02 g of LOCTITE No 262 each to 2 places of the female screw A of the body Before installing the joint thoroughly degrease and dry its male screw and the female screw of the body with DRYSOL 2 Drop LOCTITE to the following positions 2 Female screw A of body LOCTITE No 262 3 Joint 10 39 49 Nm 4 5 kgm a Apply grease G2 LI to the rocking part of joint 12 and the contact surfaces of disc 13 and pisto...

Page 958: ...se 5 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 6 Remove seal 9 and collar 8 7 Remove piston 7 to remove retainer 6 springs 5 and 4 and shim 3 a Store shim 3 after checking the thickness and the number of shims at each mount ing position 8 Remove valve 2 from body 1 Sym bol Part No Part name Necessity Q ty New...

Page 959: ...g from 10 chamfered side a Installing dimension B of the bush ing 14a should be as follows End surface of bushing will tightly fit to the end surface of case q B 0 mm a Do not apply shock load to the bush ing directly 3 Install lever 13 4 Install shaft 16 5 Using tool T4 insatll pin 17 a Installing dimension C of the pin 17 should be as follows q C 0 0 5 mm a Do not apply shock load to the pin dir...

Page 960: ...ly and assembly 32 PC130 8 a Tighten each part to the following torque q Plug 26 6 11 Nm 0 6 1 1 kgm q Plug 25 4 9 Nm 0 4 0 9 kgm q Screw 22 7 8 9 8 Nm 0 8 1 0 kgm q Bolt 19 25 30 Nm 2 5 3 2 kgm q Bolt 11 27 34 Nm 2 8 3 5 kgm ...

Page 961: ...t DUMP position and hold the work equipment at the height a off from the ground a a 1 5 m 2 Keep the arm cylinder and bucket cylinder at the most retracted position Turn the starting switch to OFF position to stop the engine 3 Turn the starting switch to ON position 4 Set the work equipment lock lever in FREE position 5 Check that the work equipment is lowered to the ground by slowly operating the...

Page 962: ...ontainer under the anti drop valve assembly 7 to receive oil k Place an oil mat as well in case the oil leaks 2 Disconnect the hoses 3 4 and 5 k Slowly loosen the fitting of the hose so that the remaining pres sure in the circuit between the anti drop valve and the cylinder is released The remaining pressure may damage the O ring and the oil may be splashed Use a waste cloth to protect the fitting...

Page 963: ...rcuit accumu lator 1 Set the arm cylinder and bucket cylinder to the most retracted position maximum arm OUT bucket DUMP position and hold the work equipment at the height a off from the ground a a 1 5 m 2 Keep the arm cylinder and bucket cylinder at the most retracted position Turn the starting switch to OFF position to stop the engine 3 Turn the starting switch to ON position 4 Set the work equi...

Page 964: ...sembly 1 Place an oil container under the anti drop valve assembly 6 to receive oil k Place an oil mat as well in case the oil leaks 2 Disconnect the hoses 3 and 4 k Slowly loosen the fitting of the hose so that the remaining pres sure in the circuit between the anti drop valve and the cylinder is released The remaining pressure may dam age the O ring and the oil may be splashed Use a waste cloth ...

Page 965: ...t k Do not stand in a direction where the inside part may jump out when performing disas sembly otherwise the inside part that will jump out may hit your body k Insert a wooden piece or a thick cloth to fix the anti drop valve to the vise when per forming the disassembly k Wash the parts thoroughly with clean hydraulic oil when performing assembly Replace the O ring with the new one Disassembly 1 ...

Page 966: ... tool U1 Sym bol Part No Part name Necessity Q ty New Remodel Sketch U 1 790 502 1003 Repair stand t 1 790 101 1102 Pump t 1 2 790 102 4300 Wrench assembly t 1 790 201 4310 Pin t 1 3 790 201 1702 Push tool Kit t 1 790 201 1791 Push tool 1 790 101 5021 Grip 1 01010 50816 Bolt 1 790 201 1702 Push tool Kit t 1 790 201 1811 Push tool 1 790 101 5021 Grip 1 01010 50816 Bolt 1 790 201 1702 Push tool Kit ...

Page 967: ... not used use the four drill holes diameter 10 to loosen the piston assembly 4 Remove plunger 5 q Arm cylinder and boom cylinder 5 Remove collar 6 q Arm cylinder and boom cylinder 6 Remove the head assembly 7 7 Remove cap 8 to remove eleven balls 9 and cushion plunger 10 q For the arm cylinder only a Since cap 8 is made of nylon tighten a screw into it and pull it out with pliers 2 Sub disassembly...

Page 968: ...ove bushing 20 Assembly a Be careful not to damage the packing the dust seal the O ring or the like a Do not forcibly insert the backup ring but make it warm with hot water 50 to 60 C before insertion 1 Sub assembly of cylinder head assembly 1 Press fit bushing 20 using tool U3 2 Engage buffer ring 19 3 Engage rod packing 18 4 Mount dust seal 17 using tool U4 and fix it with snap ring 16 5 Mount t...

Page 969: ... backup ring to collar 6 and assemble q Arm cylinder and boom cylinder 4 Assemble plunger 5 q Arm cylinder and boom cylinder a Check that there is a small amount of play at the tip of the plunger 5 Set cushion plunger 10 on the piston rod and engage 11 balls 9 and fix them using cap 8 q For the arm cylinder only 6 Assemble piston assembly 4 in the fol lowing procedure q When the rod and piston ass...

Page 970: ...After tightening the piston make sure that there is some play with plunger q For the boom and arm cylinders only 2 Drill a hole for mounting screw 3 a Engage the drill with the screw V shaped grooves of piston 4 and rod 2 for horizontal processing a Process the bottom cushion equipped cylinder arm cylinder on other part than the cap hole 8 3 Clear it of cut powder and dust and com pletely wash it ...

Page 971: ...of the piston rod assembly and the cylinder tube to insert them a After insertion make sure that the ring is not damaged or dropped and completely push the piston rod 9 Mount head assembly 1 and tighten it with the mounting bolt 3 Mounting bolt 10 Mount the piping Cylinder Tightening torque Bucket 172 25 Nm 17 5 2 5 kgm Arm 270 39 Nm 27 5 4 0 kgm Boom 172 25 Nm 17 5 2 5 kgm Blade 270 39 Nm 27 5 4 ...

Page 973: ...PC130 8 1 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 ...

Page 974: ...e tube 7 5 Remove 2 lock bolts 8 and plate 9 6 Sling the cylinder and push out pin 10 to the opposite side until it comes off the cylinder head 1 a When driving out the pin do not hit its end face directly since the threads of the lock bolt hole may be damaged a Check the quantity and locations of the installed shims 7 Sling boom cylinder 11 and lower it onto the block a Connect the negative batte...

Page 975: ...13 of boom foot pin 12 10 Remove mounting bolts 14 and lock plate 15 11 Remove toolbox cover 19 12 Set tool V to boom foot pin 12 13 Sling work equipment assembly 16 and oper ate tool V to pull out boom foot pin 12 2 a Operate the crane to disconnect the work equipment assembly from the revolving frame and lift it off slowly 4 Work equipment assembly 1 960 kg ...

Page 976: ...rs in them 2 2 Inside of bushing when inserting pin Molybdenum disulfide lubricant LM P 2 Lubrication after insertion of pin Grease LM G k When aligning the pin holes never insert your fingers in them a Adjust clearance c between boom 23 and bracket 24 to 0 5 mm or less with shims a Standard shim thickness 0 5 1 0 2 0 mm q q q q Bleeding air a Bleed air For details see Testing and adjusting Bleedi...

Page 977: ...50 Disassembly and assembly SEN04131 00 PC130 8 5 ...

Page 979: ...bly 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 15 Removal and installation of floor frame assembly 22 Removal and installation of front wiper assembly 26 ...

Page 980: ...at 3 4 Refer to Removal and installation of monitor assembly and remove monitor assembly 4 5 Remove covers 5 and 6 6 Remove cover duct assembly 7 7 Insert key 8 turn it right and open the out side air filter cover 8 Remove outside air filter 9 9 Remove rear covers 10 to 13 10 Remove duct 14 11 Remove cover 15 a Disconnect connector H15 fixed on the back from the clip 12 Remove plate 16 13 Remove p...

Page 981: ...first an error is recorded in KOMTRAX 20 Disconnect connector M10 27 from the opera tor s cab If equipped 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 23 Remove ducts 32 and 33 a Cut tie wrap 24 Disconnect wiper motor connector M05 34 25 Remove harness 35 and antenna 36 from the cab wall a Cut 2 points...

Page 982: ...te 43 1 33 Remove bolt 44 2 34 Dismount 6 mounting bolts 45 and 4 mount ing nuts 46 a Check the bolt length beforehand 35 Lift off and remove operator s cab assembly 47 4 Operator s cab assembly 470 kg Installation q Installation is done in the reverse order of removal 1 3 Mounting bolt of lock plate 43 98 123 Nm 10 12 5 kgm 2 3 Bolt 44 245 309 Nm 25 31 5 kgm ...

Page 983: ...acing front window glass 4 remove front window assembly 5 It is impossible to replace only the front window glass while the front window assembly is installed to the opera tor s cab a For the procedure for replacing the front win dow assembly see Removal and installation of front window assembly 1 Right side window glass 2 Left side rear window glass 3 Door lower window glass 4 Front window glass ...

Page 984: ...tc or hold them by winding them onto some thing and move the wire to the right and left to cut the adhesive and dam rubber Since the wire may be broken by the fric tional heat apply lubricant to the wire The figure shows the operator s cab of a wheel loader a If the window glass is broken finely it may be removed with a knife 4 and a screw driver a Widening the cut with a flat blade screw driver c...

Page 985: ...ure Do not use the primer after this limit a Use the primer within 2 hours after un packing it a Even if the primer is packed again just after it is unpacked use it within 24 hours after it is unpacked for the first time Discard the primer 24 hours after it is unpacked 1 Stir the primers for both of paint and glass sufficiently before using them a If the primer has been stored in a refrig erator l...

Page 986: ...plied by mistake wipe it off with white gasoline 4 Apply the glass primer to the sticking sur faces of window glass 9 2 Glass primer Sunstar primer for glass 580 super or equivalent a Do not apply the primer more than 2 times If it is applied more than 2 times its performance will be lowered a Parts to be coated with primer Apply the primer to all around of sticking surface d of window glass 9 for...

Page 987: ... taken not to float the dam rubber of each sticking corner a When sticking dam rubber 6 around a frame do not lap its finishing end over the starting end Or make clearance of about 5 mm between them e 1 Stick dam rubber 6 for right side window glass 1 to the position as shown in the figure a Stick dam rubber 6a additionally to right side window glass 1 q Positions to stick additional dam rub ber t...

Page 988: ...ide it will be seen through the transparent part of the glass 5 Position the new window glass 1 Check the clearance between the window glass and the operator s cab on the right left upper and lower sides and then posi tion the window glass to be the clearances evenly 2 Stick tapes 6 between window glass 9 and operator s cab 8 and draw position ing line n a Stick tapes 6 for positioning to 3 points...

Page 989: ...seal 580 super W or equivalent a The using limit of the adhesive is 4 months after the date of manufacture Do not use the adhesive after this limit a Keep the adhesive in a dark place where the temperature is below 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 1 Break aluminum seal 13 of the outlet of adhesive cartridge...

Page 990: ...nly with same height level a Apply adhesive 15 additionally to additional dam rubber 6a of right side window glass and additional dam rubber 6b of door lower window glass 7 Install the window glass 1 Install window class 9 matching it to the lines of the positioning tapes drawn in step 5 a Since the window glass cannot be removed and stuck again stick it with utmost caution a Stick the glass withi...

Page 991: ...ith caulking mate rial in range s with dimensions t and u After applying the primer to glass 4 of section A A apply the adhesive as caulking material q Caulking dimension t 2 mm q Caulking dimension u 5 mm a When caulking mask the glass side and form the adhesive with a rubber spatula as shown in the figure a Wipe off the projected adhesive 2 Glass primer Sunstar primer for glass 580 super or equi...

Page 992: ... window glass remove any excess of the primer and adhesive from the operator s cab and window glass a By using the white gasoline wipe off the adhesive before it is dried up a When cleaning the glass do not give an impact on it 10 Protect the stuck window glass 1 Keep the stopper rubbers styrene foam blocks and rubber bands installed for 10 hours at temperature of 20 C and humidity of 60 2 After r...

Page 993: ... corner block are used to hang the pull up assist cable in the following step 6 3 Release the rear lock of the cab 4 Lower the front window assembly carefully a little Put out rollers 5 and 6 under the both sides of the front window through the portion from which the corner blocks were removed in the above step 2 the portion where the rail is open and hold them 5 Remove rollers 5 and 6 under the b...

Page 994: ...ough the rail opening portion and lower it gradually 8 Lower front window assembly 10 completely a Do not let the front window assembly touch the monitor 9 Twist front window assembly 10 to the right and left to remove both upper rollers 11 and 12 from the rails and then remove front win dow assembly 10 ...

Page 995: ... the front window assembly and fix it with the rear locks on both sides a Check that the locks in the rear of the operator s cab are securely fastened 4 Install right corner block 2 a Fully tighten the block after adjusting the Close position in the following step 6 a Install the right corner block so that clear ance a between the rail and right corner block 2 becomes 0 2 0 mm a Install the right ...

Page 996: ...t and left locks 16 and 17 do not work normally 1 Loosen lock fitting bolt 18 move lock 16 forward and then tighten the bolt again a The same applies to the right side 2 After moving the lock recheck the fit ness of front window glass 14 and cab side trim seal 15 which was checked in step 1 3 Repeat the work in 1 and 2 until the fitness of the front window glass and the working condition of locks ...

Page 997: ...tch works a Limit switch 19 is used to prevent the windshield wiper from moving when turning the wiper switch on by mistake when the front window assembly is in Open position If the wiper operates when there is no glass in the front the wiper falls down inside the cab and causes trouble To check whether limit switch 19 is working turn the key switch on and see that even if the wiper switch is turn...

Page 998: ...turn of rubber stopper 18 to the left is equivalent to squashing the rubber for approxi mately 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 4 Tighten locknuts 20 of the both sides of rubber stopper 18 9 Adjust stopper 24 of the front window assem bly 1 Adjust and lock both sides of stopper 24...

Page 999: ... After finishing the adjustment of steps 6 9 check that latching efforts of both right and left locks 16 and 17 are even a 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 3 Left lower pin 27 34 Nm 2 75 3 47 kgm 2 Mounting bolt Adhesive LT 2 ...

Page 1000: ...d fill ing operation of refrigerant R134a a Never release the refrigerant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accordingly put on protective goggles while you are collect ing the refrigerant R134a or filling the air conditioner circuit with the refrigerant R134a Collecting and filling work must be conducted by a qualified person 1 Turn the up...

Page 1001: ... a Disconnect the work equipment PPC hose P at joint box side See procedure 30 14 Disconnect connector P17 18 from the air conditioner tube 15 Remove the clamp and disconnect spacer 19 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 1...

Page 1002: ...o the boom side 29 Disconnect PPC hose 40 of the work equip ment From the top the color of the band is Red None Black White Yellow Blue Brown Green a Prepare an oil sump a Disconnect hose dump 30 Sling floor frame assembly 42 and remove it a Make sure that the hoses connectors clamps and so on are disconnected with out fail 4 Floor frame assembly 250 kg ...

Page 1003: ...ring a When connecting the refrigerant piping coat the O ring with compressor oil for new refrig erant R134a Denso ND OIL8 Zexcel ZXL100PG PAG 46 or equivalent 3 Mounting bolt 8 12 Nm 0 8 1 2 kgm 2 a Make sure that the hoses do not lap over q Filling air conditioner circuit with refriger ant R134a Fill the air conditioner circuit with refrigerant R134a a Filling quantity 850 50 g q Refilling with ...

Page 1004: ...work equipment lock lever in LOCK position k Turn the battery disconnect switch to OFF position and remove the key Removal 1 Check that wiper arm 1 is stowed in the right stay 2 While holding grips 2 on the right and left of the front window pull lever 3 forward to release the lock 3 Pull up lower grip 4 by left hand and upper grip 5 by right hand and push them to lock catch 6 at the rear of the c...

Page 1005: ...and pull up knob 8 to remove lower win dow 9 6 Remove cover 10 and floor mat 11 7 Remove cover 12 a 1 out of the mounting screws 4 pieces is covered with cap 13 8 Disconnect connector P31 14 inside of cover 12 9 Remove covers 15 and 16 10 Remove cover 17 a Insert a flat head screwdriver to slit 18 at the lower left and pull it up to remove the cover while avoiding protrusion 19 ...

Page 1006: ...olt of bracket 21 and move it backward together with machine moni tor 22 a The connector of the machine monitor needs not to be disconnect 13 Move harness 23 and disconnect connector M05 24 14 Open cap 25 and remove nut 26 to remove wiper arm 27 15 Remove cap 28 nut 29 washer 30 and packing 31 ...

Page 1007: ...ing washer 30 direct the chamfered side toward the front of the cab 3 Nut 29 10 8 to 12 7 Nm 1 10 to 1 30 kgm 3 Install cap 28 and wiper arm 27 a Install the wiper arm 27 so that the clear ance a between the washer nozzle 34 and wiper blade 35 and overlap d between the end surface c of the stopper 41 and end surface b of the slider 43 are the following dimensions q Dimension a 22 mm q Dimension b ...

Page 1008: ... is as the following drawing when storing the wiper arm wiper switch to OFF position 5 To check the wiper arm operation preform the following works 1 Connect connectors M05 24 and P31 14 2 Hold knob 8 and install lower window 9 3 While holding grips 2 on the right and left of the front window set to the ceiling pull down lever 3 to release the lock ...

Page 1009: ... window to front lock catches 36 and engage the lock 6 Check that lever 3 is securely at LOCK position a Check that the arrow on lock case 7 is aligned with that of lever 3 7 Turn battery disconnect switch to ON posi tion 8 Check that the work equipment lock lever is in LOCK position and start the engine 9 Check the operation of the wiper arm with the front window dried 1 Press the wiper switch 37...

Page 1010: ...Hold down window washer switch 39 for a few seconds to wet the front window sufficiently and then release the switch 2 Check that wiper arm 27 swings 2 round trips and then is stowed in the right stay 3 Perform step 1 again 4 Check that wiper arm 27 swings odd number of round trips and then is stowed in the right stay 5 Hold down window washer switch 39 to operate the wiper and check the following...

Page 1011: ...d assembly SEN04132 01 PC130 8 33 11 In case of abnormality as results of the above checks adjust the wiper arm instal lation as described in step 3 6 Perform the subsequent installation in the reverse order to removal ...

Page 1013: ...of air compressor assembly 2 Removal and installation of air conditioner condenser 3 Removal and installation of air compressor unit assembly 4 Removal and installation of KOMTRAX communication modem assembly 7 Removal and installation of monitor assembly 8 Removal and installation of pump controller assembly 10 Removal and installation of engine controller assembly 12 ...

Page 1014: ...n 1 Remove drive belt protective cover 1 2 Disconnect wiring connector M34 2 3 Disconnect air conditioner pipings 3 and 4 1 4 Loosen drive belt tension adjustment bolt 5 and lock bolt 6 5 Remove drive belt 7 6 Remove drive belt tension adjustment bolt 5 and lock bolt 6 7 Remove air conditioner compressor assembly 8 2 Installation q Carry out installation in the reverse order to removal 1 q Precaut...

Page 1015: ...nt R134a or filling the air conditioner circuit with the refrigerant R134a Collecting and filling work must be conducted by a qualified person 1 Disconnect wiring connectors 1 and 2 2 Remove radiator reservoir tank 3 3 Remove air cleaner assembly 4 4 Remove bracket 5 5 Disconnect 2 hoses 6 a Stop the hoses and condenser with blind plugs to prevent water etc will not enter them 6 Remove bolts 7 2 p...

Page 1016: ...rant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accordingly put on protective goggles while you are collect ing the refrigerant R134a or filling the air conditioner circuit with the refrigerant R134a Collecting and filling work must be conducted by a qualified person k If the radiator coolant temperature is high wait until it lowers to avoid scaldi...

Page 1017: ...le tie 16 Remove ducts 22 and 23 a Cut the cable tie 17 Remove upper and lower ducts 24 18 Remove upper and lower ducts 25 19 Disconnect plate 26 from the cab wall 20 Disconnect connectors N10 27 and AC01 28 21 Disconnect connectors ECU10 and ECU11 29 from air conditioner controller ACCONT 22 Loosen cable tie 30 and draw in wiring har ness 31 ...

Page 1018: ...ng each air conditioner hose check that the O ring is fitted to the joint a Check each O ring for a flaw and deterioration a When connecting the refrigerant piping coat the O rings with compressor oil for new refrig erant R134a DENSO ND OIL 8 ZEXEL ZXL 100 PG equivalent to PAG 46 3 Mounting bolt 8 12 Nm 0 8 1 2 kgm q Charging air conditioner with refrigerant Charge the air conditioner circuit with...

Page 1019: ... battery before starting the work 1 Remove covers 1 4 2 Disconnect connectors CK01 5 and CK02 6 3 Twist antenna wire 7 and disconnect it If con nectors CK01 and CK02 are not disconnected first an error is recorded in KOMTRAX 4 Remove the 4 mounting bolts and KOMTRAX communication modem assembly 8 Installation q Installation is done in the reverse order of removal ...

Page 1020: ...er 5 as follows 1 1 Insert flat head screwdriver inside slit SL and push it upward 2 Release lock L and remove the cover 3 Disconnect wiring connector M04 of the cigarette lighter from the back of cover 5 5 Remove the 4 mounting bolts and lift monitor assembly 6 2 6 Disconnect connectors CM01 7 CM02 8 and CM03 9 a Since CM02 8 and CM03 9 can be installed reversely be careful not to mis take CM03 9...

Page 1021: ... 9 Installation 1 2 1 Temporarily install monitor assembly 6 with 4 mounting bolts and then install cover 5 2 With cover 5 installed tighten the mounting bolts of monitor assembly q Carry out the rest of installation in the reverse order to removal ...

Page 1022: ... Disconnect wiring connectors C01 6 and C02 7 as follows q Tilt lock L12 inside while pressing lock L1 a Bar B comes out and the lock is re leased 5 Remove the 4 mounting bolts and pump con troller assembly 8 Installation q Installation is done in the reverse order of re moval a Reference 1 Procedure for removing connector cover 1 1 Cut and remove cable tie 2 2 Move lever 3 up 3 Lightly push part ...

Page 1023: ...rom the upper position to the left position lock position in the figure a B C Claws a If the sliders and lever are not set as shown in the following figure the con nector is not disconnected or locked securely with the lever Accordingly check their positions again 3 Set claw C to the connector and place connector cover 1 a Take care that wiring harness 5 will not be caught 4 Set claw B and install...

Page 1024: ... disconnect the air conditioner hoses from the air conditioner compres sor 3 Remove wiring connectors CE01 2 CE02 3 and CE03 4 1 4 Remove mounting bolts 5 and remove engine controller 6 Installation q Carry out the installation in the reverse order of removal 1 3 Screw 3 1 Nm 0 3 0 1 kgm a a a a Reference q How to replace the seal of O ring of power source connector 4 Seal of O ring 1010 074 0406 ...

Page 1025: ...50 Disassembly and assembly SEN04134 00 PC130 8 13 ...

Page 1027: ...84 00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130 8 Machine model Serial number PC130 8 80001 and up 90 Diagrams and drawings 1 Hydraulic diagrams and drawings Hydraulic circuit diagram 1 2 3 Hydraulic circuit diagram 2 2 5 ...

Page 1028: ...SEN03784 00 90 Diagrams and drawings 2 PC130 8 ...

Page 1029: ...3 SEN03784 00 PC130 8 Hydraulic circuit diagram 1 2 PC130 8 Hydraulic circuit diagram 1 2 PC130 8 ...

Page 1030: ...5 SEN03784 00 PC130 8 Hydraulic circuit diagram 2 2 PC130 8 Hydraulic circuit diagram 2 2 PC130 8 ...

Page 1031: ...90 Diagrams and drawings SEN03784 00 PC130 8 7 ...

Page 1033: ...d up 90 Diagrams and drawings 1 Electrical diagrams and drawings Electrical circuit diagram 1 6 3 Electrical circuit diagram 2 6 5 Electrical circuit diagram 3 6 7 Electrical circuit diagram 4 6 9 Electrical circuit diagram 5 6 11 Electrical circuit diagram 6 6 13 Connectors table and arrangement drawing 15 ...

Page 1034: ...SEN03785 02 90 Diagrams and drawings 2 PC130 8 ...

Page 1035: ...3 SEN03785 02 PC130 8 Electrical circuit diagram 1 6 PC130 8 Electrical circuit diagram 1 6 PC130 8 ...

Page 1036: ...5 SEN03785 02 PC130 8 Electrical circuit diagram 2 6 PC130 8 Electrical circuit diagram 2 6 PC130 8 ...

Page 1037: ...7 SEN03785 02 PC130 8 Electrical circuit diagram 3 6 PC130 8 Electrical circuit diagram 3 6 PC130 8 ...

Page 1038: ...9 SEN03785 02 PC130 8 Electrical circuit diagram 4 6 PC130 8 Electrical circuit diagram 4 6 PC130 8 ...

Page 1039: ...11 SEN03785 02 PC130 8 Electrical circuit diagram 5 6 PC130 8 Electrical circuit diagram 5 6 PC130 8 ...

Page 1040: ...13 SEN03785 02 PC130 8 Electrical circuit diagram 6 6 PC130 8 Electrical circuit diagram 6 6 PC130 8 ...

Page 1041: ...g N 2 P08 X 2 Pressure switch Arm dump N 2 P09 AMP 3 Pressure sensor Right travel forward J 9 P10 AMP 3 Pressure sensor Right travel backward F 9 P11 AMP 3 Pressure sensor Left travel forward E 9 P12 AMP 3 Pressure sensor Left travel backward F 9 P13 X 2 Service pressure switch G 1 P17 SUMITOMO 2 A C HI LO pressure switch K 1 P20 M 3 Fuel dial R 7 P21 X 2 Fuel level sensor C 8 P22 DT 2 Hydraulic o...

Page 1042: ...90 Diagrams and drawings SEN03785 02 PC130 8 17 ...

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Komatsu PC130-8, Shop Manual

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