Professional Documents
Culture Documents
HYDRAULIC PC130 -8
EXCAVATOR
SERIAL NUMBERS 80001 and up
SEN03765-02
PC130-8
PC130-8 1
SEN03765-02 00 Index and foreword
01 Specification SEN03767-00
Specification and technical data SEN03768-00
40 Troubleshooting SEN03781-00
Failure code table and fuse locations SEN04117-00
General information on troubleshooting SEN04118-00
Troubleshooting by failure code, Part 1 SEN04119-00
Troubleshooting by failure code, Part 2 SEN04120-00
Troubleshooting by failure code, Part 3 SEN04121-00
Troubleshooting by failure code, Part 4 SEN04122-00
Troubleshooting of electrical system (E-mode) SEN04123-00
2 PC130-8
00 Index and foreword SEN03765-02
PC130-8 3
SEN03765-02 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN03765-02
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
01 Specification
Specification and technical data SEN03768-00
Specification dimension drawings ............................................................................................... 2
Working range diagram ............................................................................................................... 3
Specifications .............................................................................................................................. 4
List of weights.............................................................................................................................. 8
List of lubricant and coolant to be filled ....................................................................................... 10
4 PC130-8
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PC130-8 5
SEN03765-02 00 Index and foreword
40 Troubleshooting
Failure code table and fuse locations SEN04117-00
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN04118-00
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information in troubleshooting table ............................................................................................ 6
Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8
Connection table for connector pin numbers............................................................................... 11
T-branch box and T-branch adapter table ................................................................................... 47
Troubleshooting by failure code, Part 1 SEN04119-00
Failure code [989L00] Engine controller lock caution 1............................................................... 3
Failure code [989M00] Engine controller lock caution 2.............................................................. 3
Failure code [989N00] Engine controller lock caution 3 .............................................................. 4
Failure code [AA10NX] Air cleaner clogging ............................................................................... 5
Failure code [AB00KE] Charge voltage low ................................................................................ 6
Failure code [B@BAZG] Eng oil press. low................................................................................. 8
Failure code [B@BAZK] Eng oil level low ................................................................................... 9
Failure code [B@BCNS] Eng coolant overheat........................................................................... 10
Failure code [B@BCZK] Eng water level low .............................................................................. 12
Failure code [B@HANS] Hydr oil overheat ................................................................................. 14
Failure code [CA111] ECM critical internal failure ....................................................................... 16
Failure code [CA115] Eng Ne and Bkup speed sensor error ...................................................... 19
Failure code [CA122] Charge air press sensor high error........................................................... 20
Failure code [CA123] Charge air press sensor low error ............................................................ 22
Failure code [CA131] Throttle sensor high error ......................................................................... 24
Failure code [CA132] Throttle sensor low error........................................................................... 26
Failure code [CA144] Coolant temp. sensor high error ............................................................... 28
Failure code [CA145] Coolant temp. sensor low error ................................................................ 30
Failure code [CA153] Charge air temp. sensor high error........................................................... 32
Failure code [CA154] Charge air temp. sensor low error ............................................................ 34
Failure code [CA155] Chg air temp high speed derate ............................................................... 34
Failure code [CA187] Sensor sup. 2 volt. low error..................................................................... 35
Failure code [CA221] Ambient air press. sensor high error ........................................................ 36
Failure code [CA222] Ambient air press. sensor low error.......................................................... 38
Failure code [CA227] Sensor sup. 2 volt. high error ................................................................... 39
Failure code [CA234] Eng. overspeed ........................................................................................ 40
Failure code [CA238] Ne speed sensor sup. volt. error .............................................................. 42
Failure code [CA271] IMV/PCV1 short error ............................................................................... 44
Failure code [CA272] IMV/PCV1 open error ............................................................................... 45
Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 46
Failure code [CA324] Injector #3 (L #3) system open/short error ............................................... 48
Failure code [CA331] Injector #2 (L #2) system open/short error ............................................... 50
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PC130-8 7
SEN03765-02 00 Index and foreword
8 PC130-8
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PC130-8 9
SEN03765-02 00 Index and foreword
10 PC130-8
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PC130-8 11
SEN03765-02 00 Index and foreword
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
12 PC130-8
SEN03766-00
PC130-8
PC130-8 1
SEN03766-00 00 Index and foreword
2 PC130-8
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3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative () terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
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 those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
PC130-8 3
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4 PC130-8
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard Z twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
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 passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC130-8 5
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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 connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
6 PC130-8
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q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
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.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
PC130-8 7
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC130-8
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Example:
Standard size Tolerance
0.022
120
0.126
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
PC130-8 9
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PC130-8 11
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 PC130-8
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PC130-8 13
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2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this 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 boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 PC130-8
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
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
PC130-8 15
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16 PC130-8
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
PC130-8 17
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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 is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 PC130-8
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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. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC130-8 19
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20 PC130-8
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q 114 engine
q 107 engine
PC130-8 21
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Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC130-8
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- 30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC130-8 23
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6
Cov-
AV Standard 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
24 PC130-8
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & 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
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
PC130-8 25
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3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 PC130-8
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
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.
PC130-8 27
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (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 adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC130-8 29
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Type 2
1. Disconnection
1) 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. 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)
30 PC130-8
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Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (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 portion at the male end. (Fig. 13)
PC130-8 31
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a Fig. A a Fig. B
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PC130-8 33
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5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
34 PC130-8
00 Index and foreword SEN03766-00
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
PC130-8 35
SEN03766-00 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 PC130-8
00 Index and foreword SEN03766-00
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 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
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC130-8 37
SEN03766-00 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
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
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 PC130-8
00 Index and foreword SEN03766-00
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 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 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC130-8 39
SEN03766-00 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 PC130-8
00 Index and foreword SEN03766-00
PC130-8 41
SEN03766-00 00 Index and foreword
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
42 PC130-8
SEN03768-00
PC130-8
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
PC130-8 1
SEN03768-00 01 Specification
a There are net value and gross value for displaying engine rate output. Gross value is measurement of
engine alone, and net value is measurement with close to on-board conditions.
2 PC130-8
01 Specification SEN03768-00
Unit: mm
Working 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
Minimum swing radius of work
F 2,450
equipment
G Maximum reach at ground level 8,170
PC130-8 3
SEN03768-00 01 Specification
Specifications 1
PC130-8
Machine model
Standard specification
Serial No. 80001 and up
Bucket capacity m3 0.50
Operating weight kg 12,700
Max. digging depth mm 5,520
Working ranges
The values are based on the machine with the triple grouser shoe.
4 PC130-8
01 Specification SEN03768-00
PC130-8
Machine model
Standard specification
Serial No. 80001 and up
Model SAA4D95LE-5
4-cycle, water-cooled, in-line, vertical, direct injection, with
Type
turbocharger and air cooled aftercooler
No. of cylinders-bore x stroke mm 95 x 115
Piston displacement l{cc} 3.260{3,260}
Rated horsepower
Net [ISO 9249/SAE J1349] kW{HP}/rpm 68.4{91.7}/2,200
Gross [SAE J1995] 72.1{96.6}/2,200
Performance
PC130-8 5
SEN03768-00 01 Specification
PC130-8
Machine model
Standard specification
Serial No. 80001 and up
Type Reciprocating piston type
Boom cylinder
6 PC130-8
01 Specification SEN03768-00
PC130-8 7
SEN03768-00 01 Specification
List of weights 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
PC130-8
Machine model
Standard specification
Serial No. 80001 and up
Engine assembly (excl. water, oil) 461
Engine (excl. water, oil) 332
Engine mount 21.5
PTO 5.5
Hydraulic pump 102
Filter (for KA specification) (6 x 2)
Cooling assembly (excl. coolant, oil) 96.1
Radiator (excl. coolant) 9.2
Oil cooler (excl. oil) 11.0
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 69 x 2
Carrier roller 16.5 x 2
Track roller 22 x 14
Travel motor (with reduction gear) 145 x 2
Sprocket 33.1 x 2
Track shoe assembly
Triple grouser shoe (500 mm) 755 x 2
Triple grouser shoe (600 mm) 815 x 2
Triple grouser shoe (700 mm) 905 x 2
Road liner (500 mm) 780 x 2
8 PC130-8
01 Specification SEN03768-00
Unit: kg
PC130-8
Machine model
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
PC130-8 9
SEN03768-00 01 Specification
10 PC130-8
01 Specification SEN03768-00
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 247
Cooling system 13.9
PC130-8 11
SEN03768-00 01 Specification
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
12 PC130-8
SEN03770-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03770-00 10 Structure, function and maintenance standard
Engine mount 1
2 PC130-8
10 Structure, function and maintenance standard SEN03770-00
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
PC130-8 3
SEN03770-00 10 Structure, function and maintenance standard
Cooling system 1
4 PC130-8
10 Structure, function and maintenance standard SEN03770-00
Specifications
PC130-8 5
SEN03770-00 10 Structure, function and maintenance standard
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
6 PC130-8
SEN03771-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03771-00 10 Structure, function and maintenance standard
Power train 1
2 PC130-8
10 Structure, function and maintenance standard SEN03771-00
Swing circle 1
Unit: mm
No. Item Criteria Remedy
Basic clearance Clearance limit
1 Bearing clearance Replace
0.5 1.6 2.6
PC130-8 3
SEN03771-00 10 Structure, function and maintenance standard
Swing machinery 1
4 PC130-8
10 Structure, function and maintenance standard SEN03771-00
Unit: mm
No. Item Criteria Remedy
Backlash between swing motor Standard clearance Clearance limit
1
shaft and No. 1 sun gear 0.07 0.18 0.4
Backlash between No. 1 sun
2 0.13 0.31 0.6
gear and No. 1 planetary gear
Backlash between No. 1 plane-
3 0.15 0.34 0.7
tary gear and ring gear
Backlash between No. 1 plane-
4 0.14 0.34 0.7
tary carrier and No. 2 sun gear
Replace
Backlash between No. 2 sun
5 0.13 0.31 0.6
gear and No. 2 planetary gear
Backlash between No. 2 plane-
6 0.15 0.34 0.7
tary gear and ring gear
Backlash between No. 2 plane-
7 0.08 0.19 0.4
tary carrier and swing pinion
Back lash between Swing pin-
8 0.13 1.16 2.3
ion and swing circle
Outside diameter of oil seal Standard size Tolerance Repair limit Repair by hard
9 contacting surface on swing 0 chrome-plating
pinion collar 145 144.8 or replace
-0.100
PC130-8 5
SEN03771-00 10 Structure, function and maintenance standard
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
6 PC130-8
SEN03772-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03772-00 10 Structure, function and maintenance standard
Track frame 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Track Rebuilding
84 89
1 Length at idler guide frame
Idler Rebuilding or
82 77
support replace
Track
185 193 Rebuilding
frame
2 Width at idler guide
Idler Rebuilding or
183 175
support replace
3. Idler 7. Sprocket
4. Track frame 8. Track roller
5. Carrier roller 9. Idler cushion
6. Travel motor (Final drive) 10. Track shoe
2 PC130-8
10 Structure, function and maintenance standard SEN03772-00
Idler cushion 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
1 Recoil spring length load load Replace
84.3 kN 75.0 kN
501.4 390 489
{8,600 kg} {7,650 kg}
2. Idler Specifications
3. Support
Grease G2-LI
4. Rod
5. Recoil spring Grease quantity (cc) 118
6. Cylinder
7. U-packing
8. Pilot
9. Nut
10. Valve
11. Grease fitting
PC130-8 3
SEN03772-00 10 Structure, function and maintenance standard
Idler 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
527
Rebuilding or
2 Outside diameter of tread 489 477
replace
3 Tread depth 19 25
4 Width of projection 52 42
5 Overall width 115 107
Rebuilding or
6 Tread width 31.5 36.5
replace
Standard Tolerance Standard Clearance
Clearance between idler gear size Shaft Hole clearance limit
7
and bushing -0.250 +0.074 0.250
54 1.5
-0.280 0 0.354
Tolerance Standard
Standard Interfer-
interfer- Replace
Interference between bushing size Shaft Hole ence limit
8 ence
and link
+0.117 +0.030 0.057
61
+0.087 0 0.117
Side clearance of idler Standard clearance Clearance limit
9
(each side) 0.18 0.38 1.5
Tread thickness Basic dimension Repair limit Rebuilding or
10
(at tread center) 15 9 replace
Oil capacity 90 cc (engine oil: SAE30CD)
4 PC130-8
10 Structure, function and maintenance standard SEN03772-00
Track roller 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
158 Rebuilding or
2 Outside diameter of tread 130 120 replace
3 Flange width 26.5
4 Overall width 176
Rebuilding or
5 Tread width 35
replace
Standard Tolerance Standard Clearance
Clearance between Shaft and size Shaft Hole clearance limit
6
bushing -0.220 +0.190 0.250
50 1.5
-0.240 +0.030 0.430
Tolerance Standard
Standard Interfer-
interfer- Replace
Interference between roller and size Shaft Hole ence limit
7 ence
bushing
+0.190 0.110
54 0.030
+0.140 0.220
Side clearance of track roller Standard clearance Clearance limit
8
(each side) 0.41 0.90 1.5
Tread thickness Standard size Repair limit Rebuilding or
9
(at tread center) 38 33 replace
Oil capacity 145 155 cc (engine oil: SAE30CD)
PC130-8 5
SEN03772-00 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit Rebuilding or
1 Outside diameter of tread
116 106 replace
2 Tread width 123
Standard Tolerance Standard Clearance
Clearance between shaft and size Shaft Hole clearance limit
3
bushing +0.055 +0.261 0.145
40
+0.035 +0.200 0.226
Tolerance Standard
Standard Interfer-
interfer- Replace
Interference between collar and size Shaft Hole ence limit
4 ence
bushing
+0.061 +0.025 0.011
47
+0.036 0 0.061
Side clearance of carrier roller Standard clearance Clearance limit
5
(each side) 0.363 0.537 1.5
Tread thickness Standard size Repair limit
Rebuilding or
6 (at 10 mm from roller outer
17.7 12.7 replace
edge)
Oil capacity 68 76 cc (engine oil: SAE30CD)
6 PC130-8
10 Structure, function and maintenance standard SEN03772-00
Sprocket 1
Unit: mm
No. Item Criteria Remedy
Standard size Tolerance Repair limit
1 Wear on tooth bottom diameter +1.0
547.4 535
-2.0
2 Wear on tooth tip diameter 607 595 Rebuilding or
3 Wear on tooth tip width 27 22 replace
4 Wear on tooth bottom width 42 1.5 39
+0.465
5 Thickness at tooth bottom 111.7 105.5
-1.160
PC130-8 7
SEN03772-00 10 Structure, function and maintenance standard
Track shoe 1
Triple grouser shoe, road liner
8 PC130-8
10 Structure, function and maintenance standard SEN03772-00
(1/2) Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Link pitch
175.3 178.3
Reverse or
Standard size Reverse
2 Bushing external diameter replace
46.3 42.3
3 Bushing thickness 7.9 3.9
Standard size Repair limit Repair or
4 Link height
86 81 replace
Link thickness (bushing press fit
5 24 19
part)
6 102.4 Replace
7 Shoe bolt pitch 86.4
8 57
9 Internal width 52.4
Repair or
10 Link Overall width 35
replace
11 Tread width 30.1
12 Pin projection 3
13 Regular bushing projection 3.75
14 Pin overall length 168 Adjust or
Bushing overall length (master replace
15 86.7
bushing)
16 Spacer thickness
17 Bushing 39.2 137.3 kN {4 14 ton}
18 Regular pin 78.5 186.3 kN {8 19 ton}
Press-fit force
19
Master pin 39.2 98.1 kN {4 10 ton}
(*)
PC130-8 9
SEN03772-00 10 Structure, function and maintenance standard
(2/2) Unit: mm
No. Item Criteria Remedy
Tightening torque (Nm {kgm}) Retightening angle (degree)
Triple grouser 196 20
a. Regu- 90 10
shoe {20 2}
lar link
147 10
20 Shoe bolt Road liner 50 5 Retighten
{15 1}
Tightening torque Retightening angle Torque lower limit
b. Mas- (Nm {kgm}) (degree) (Nm {kgm})
ter link
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
21
and link +0.387 +0.062
46 0.285 0.387
+0.347 +0.074
Interference between regular +0.150 -0.198
22 30 0.198 0.400
pin and link +0.050 -0.250
Tolerance Standard
Standard size
Clearance between regular pin Shaft Hole clearance
23
and bushing +0.150 +0.830 Adjust or
30 0.180 0.830
+0.050 +0.330 replace
Tolerance Standard
Standard size
24 Interference between master Shaft Hole interference
(*) pin and link +0.020 +0.198
30 0.178 0.270
-0.020 -0.250
Tolerance Standard
Standard size
25 Clearance between master pin Shaft Hole clearance
(*) and bushing -0.200 +0.830
30 0.530 1.130
-0.300 +0.330
26 Grouser height (road liner) 58 21 Replace
10 PC130-8
10 Structure, function and maintenance standard SEN03772-00
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Grouser overall height
20 10
2 Shoe overall height 29.5 19.5
3 Plate thickness 9.5
Rebuilding or
4 20
Grouser bottom length replace
5 20
6 14
7 Grouser tip length 13
8 15
PC130-8 11
SEN03772-00 10 Structure, function and maintenance standard
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
12 PC130-8
SEN03773-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03773-00 10 Structure, function and maintenance standard
2 PC130-8
10 Structure, function and maintenance standard SEN03773-00
PC130-8 3
SEN03773-00 10 Structure, function and maintenance standard
Valve control 1
4 PC130-8
10 Structure, function and maintenance standard SEN03773-00
PC130-8 5
SEN03773-00 10 Structure, function and maintenance standard
6 PC130-8
10 Structure, function and maintenance standard SEN03773-00
Breather
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
PC130-8 7
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Hydraulic pump 1
Type: HPD56+56
8 PC130-8
10 Structure, function and maintenance standard SEN03773-00
Outline
q This pump consists of a variable-displacement
swash plate type piston pump, PC valve, LS
valve and EPC valve.
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
5. Shuttle valve
6. No. 1 check valve
7. No. 2 check valve
PC130-8 9
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PC130-8 11
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Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
12 PC130-8
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Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) via slider (13).
q Being supported by cradle (2) on the cylindrical
surface, 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 pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
PC130-8 13
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LS valve
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 from the con-
trol valve output enters this valve.
14 PC130-8
10 Structure, function and maintenance standard SEN03773-00
Operation
q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is conducted to the larger
pressure (PLS) (LS pressure) from the outlet diameter end from the port (K).
port of the control valve brought to spring q The same pump pressure (PP) is conducted to
chamber (B), and main pump discharge pres- the smaller diameter end from the port (J).
sure (PP) brought to port (H) of sleeve (8). q According to the difference in the areas on
q Magnitude of the force resulting from this LS servo piston (12), the pressure moves in such
pressure (PLS), force of spring (4) and the that the swash plate angle may be minimized.
pump delivery pressure (check valve output
pressure) (PP) determine 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.
PC130-8 15
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PC130-8 17
SEN03773-00 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q Force of spring (4) is adjusted in such that the
the large diameter end of the piston as (A1), position of the balanced stop of this spool (6)
the area receiving the pressure at the small may be determined when (PP) (PLS) = 2.2
diameter end as (A0), and the pressure flowing MPa {22.5 kg/cm2} at the median of the speci-
into the large diameter end of the piston as fied value.
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
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, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 2 : 1.
18 PC130-8
10 Structure, function and maintenance standard SEN03773-00
PC valve
Function
q When the pump discharge pressure (PP1) q If the engine speed goes below the specified
(check valve output pressure) and (PP2) (shut- value because of increased load, the controller
tle valve output pressure) are high, the PC sends a command current to PC-EPC valve
valve controls the pump so that the volume of solenoid in order to reduce the slope angle in
oil beyond the discharge pressure-based spe- proportion to reduction in the engine speed.
cific flowrate may not be conducted however
you may increase the control valve stroke.
Namely it is intended at controlling the horse
power for the pumps so that 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 the relation
is represented as the parameter of the current
value to be given to PC-EPC valve solenoid.
q The controller continues counting the actual
engine speed.
q If the engine speed is slowed down due to
increased load, the controller reduces the
pump delivery to recover the speed.
PC130-8 19
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Operation
1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
20 PC130-8
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PC130-8 21
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Action of spring
q Load of springs (4) and (6) on the PC valve is q Spring load of springs (4) and (6) is also
determined by the swash plate position. affected by the command current (X) to PC-
q As servo piston (9) moves to left, spring (6) is EPC valve solenoid.
retracted. q Port (C) of the PC valve is connected to port
q If the servo piston moves further, it will be con- (E) of the LS valve.
tacted again seat (5) and spring (6) will be q Check valve output pressure (PP1) enters port
fixed. (B) and the small diameter end of servo piston
q After that, spring (4) alone will operate. (9), and shuttle valve output pressure (PP2)
q The spring load is changed by servo piston (9) enters port (A).
as it extends or compresses springs (4) and q When pump pressures (PP1) and (PP2) are
(6). small, spool (3) will be positioned in the right
q If the command current (X) to PC-EPC valve side.
solenoid (1) changes, so does the force push- q Port (C) and (D) are connected, and the pres-
ing piston (2). sure entering the LS valve becomes drain
pressure (PT).
22 PC130-8
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PC130-8 23
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Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the left becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the left, main
(C) to LS valve flows from port (A) to port (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end this flow, to make the pump delivery the minimum.
level of this pressure becomes approximately q When servo piston (9) moves to the left,
half of the main pump pressure (PP). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the right, the opening
of port (C) and port (D) becomes larger.
24 PC130-8
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PC130-8 25
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2. As the emergency pump drive switch is turned on due to failure on the pump
controller
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PC130-8 27
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28 PC130-8
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PC130-8 29
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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
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10 Structure, function and maintenance standard SEN03773-00
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1. When signal current is 0 (coil is de-
tion. energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
controller, it generates the EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the size of the signal, and gized.
outputs it to the PC valve. 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 from the PC valve is
drained to the tank through port (C) and port
(T).
PC130-8 31
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32 PC130-8
10 Structure, function and maintenance standard SEN03773-00
Check valve
Function Operation
q A set of 2 check valves is used to select and 1. When (PA1) > (PA2)
output the higher discharge pressure of the 2 q Discharge pressures (PA1) and (PA2) of the
main pumps. 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).
PC130-8 33
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Shuttle valve
1. Poppet valve
2. Poppet valve
3. Pin
Function Operation
q The shuttle valve selects and outputs the lower q The discharge pressures (PA1) and (PA2) of
discharge pressure of the 2 main pumps. 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 discharge pressure of the 2
main pumps is output.
34 PC130-8
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PC130-8 35
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2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
36 PC130-8
SEN03774-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03774-00 10 Structure, function and maintenance standard
Control valve 1
Outline
The control valves of the following types are set.
q 6-spool valve (Without service valve)
q 7-spool valve (6-spool valve + service valve)
q 8-spool valve (6-spool valve + 2 service valves)
The appearance and section of only the 8-spool valve (6-spool valve + 2 service valves) are shown here.
2 PC130-8
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PC130-8 3
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4 PC130-8
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PC130-8 5
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6 PC130-8
10 Structure, function and maintenance standard SEN03774-00
1. LS selector valve
2. Cooler bypass valve
3. Pressure compensation valve R (Service 2)
4. Pressure compensation valve R (Service 1)
5. Pressure compensation valve R (Bucket)
6. Pressure compensation valve R (Arm)
7. Pressure compensation valve R (Boom)
8. Pressure compensation valve R (Right travel)
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)
19. Pressure compensation valve F (Service 2)
PC130-8 7
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8 PC130-8
10 Structure, function and maintenance standard SEN03774-00
1. LS selector valve
Swing valve
2. Pressure compensation valve F
3. Spool
4. Pressure compensation valve R
5. Swing bleeding valve
PC130-8 9
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10 PC130-8
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1. Unload valve
2. Main relief valve
3. Cooler bypass valve
4. Lift check valve
Boom valve
5. Pressure compensation valve F
6. Suction valve
7. Hydraulic drift prevention valve
8. Suction valve
9. Spool
10. Pressure compensation valve R
Arm valve
11. Pressure compensation valve F
12. Suction valve
13. Suction valve
14. Spool
15. 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 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
PC130-8 11
SEN03774-00 10 Structure, function and maintenance standard
CLSS 1
Outline of CLSS 1
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity
tem, which has the following characteristics: piston pumps, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
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
12 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Basic principle 1
1. Pump swash plate angle control
q The pump swash plate angle (pump delivery) q The pump swash plate angle shifts toward the
is controlled so that LS differential pressure maximum position if LS differential pressure
( P L S ) ( t h e d i ff e r e n c e b e t w e e n p u m p ( PLS) is lower than the set pressure of the
pressure PP and control valve outlet port LS LS valve (when the actuator load pressure is
pressure PLS) (load pressure of actuator) is high).
constant. q If it becomes higher than the set pressure
q [LS differential pressure ( PLS) = Pump (when the actuator load pressure is low), the
discharge pressure (PP) LS pressure (PLS)] pump swash plate angle shifts toward the
minimum position.
PC130-8 13
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14 PC130-8
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PC130-8 15
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16 PC130-8
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1. Swing valve
2. Left travel valve
3. Right travel valve
4. Boom valve
5. Arm valve
6. Bucket valve
7. Service 1 valve
8. Service 2 valve
9. Swing spool
10. Left travel spool
11. Right travel spool
12. Boom spool
13. Arm spool
14. Bucket spool
15. Service 1 spool
16. Service 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 kg/cm}
30. Main relief valve
Set pressure: 31.9 MPa {325 kg/cm}
In one-touch power maximizing mode:
34.5 MPa {352 kg/cm}
31. Unload valve
PC130-8 17
SEN03774-00 10 Structure, function and maintenance standard
Unload valve
1. When control valve is at HOLD
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)]
18 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Function Operation
q When any work equipment valve is operated if q When any work equipment valve is operated
the demand flow for the actuator becomes for a long stroke, LS pressures (LS1) and
greater than the pump discharge from the min- (LS2) are generated and act on the face (SB)
imum swash plate angle, the oil flow to tank cir- of unload spool (1) [(P1) = (P2), (LS1) = (LS2)].
cuit (T) is cut off, and all pump discharge q For this reason, the difference between pump
amount (Q) flows to the actuator circuit. discharge pressure (P1) and (P2) and LS pres-
q Since the pump merge-divider valve is at the sure (LS1) and (LS2) does not reach the load
merge position, pump discharge pressures of spring (2), so spool (1) is pushed to the right
(P1) and (P2) are merged. LS pressures (LS1), by spring (2).
(LS2), and (LS3) are also merged. q As a result, pump discharge pressures (P1)
and (P2) and tank circuit (T) are shut off, and
all pump discharge amount (Q) flows to the
actuator circuit.
PC130-8 19
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Function Operation
q When the difference between pump discharge q When fine control is carried out on both travel
pressure (P1) and (P2) and LS pressure (LS1) valves, LS pressures (LS1) and (LS2) are gen-
and (LS2) reaches the load of spring (2), erated and act on the face (SB) of spool (1)
unload spool (1) opens, so excessive oil (maxi- [(P1), (P2), (LS1), and (LS2) are separated].
mum pump discharge mount - demand flow) q When the difference between pump discharge
flows into the tank circuit. pressure (P1) and (P2) and LS pressure (LS1)
q Since the pump merge-divider valve is at the and (LS2) reaches the load of spring (2), spool
separate position, pump discharge pressures (1) moves to the left, and pump discharge
(P1) and (P2) are separated. LS pressures pressures (P1) and (P2) are connected to tank
(LS1) and (LS2) are also separated. circuit (T) and the excessive oil (maximum
q The swash plate angle of the pump becomes pump discharge mount - demand flow) flows.
maximum, so the pump discharge amount q In other words, the excessive oil (maximum
becomes maximum. (For details, see the sec- pump discharge mount - demand flow) above
tions on the pump merge-divider valve.) the strokes of both travel valves flows into tank
circuit (T).
20 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Function Operation
q During operation of both travel valves, when q When both travel valves are operated to the
the demand flow becomes maximum, the oil stroke ends, LS pressures (LS1) and (LS2) are
flow to tank circuit (T) is cut off, and all pump generated and act on the face (SB) of unload
discharge amount (Q) flows to both travel cir- spool (1) [(P1), (P2), (LS1), and (LS2) are sep-
cuits. arated].
q Since the pump merge-divider spool is at the q The area of the openings of both travel valve
separate position, pump discharge pressures spools is large, so LS pressures (LS1) and
(P1) and (P2) are separated. LS pressures (LS2) are not so different from pump discharge
(LS1) and (LS2) are also separated. pressures (P1) and (P2).
q The swash plate angle of the pump becomes q For this reason, the difference between pump
maximum, so the pump discharge amount discharge pressure (P1) and (P2) and LS pres-
becomes maximum. (For details, see the sec- sure (LS1) and (LS2) does not reach the load
tions on the pump merge-divider valve .) of spring (2), so spool (1) is pushed to the right
by spring (2).
q As a result, pump discharge pressures (P1)
and (P2) and tank circuit (T) are shut off, and
all pump discharge amount (Q) flows to the
actuator circuit.
PC130-8 21
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22 PC130-8
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PC130-8 23
SEN03774-00 10 Structure, function and maintenance standard
Merge-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).
24 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Function
q Pump discharge 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.
PC130-8 25
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Introduction of LS pressure
1. Work equipment valve
26 PC130-8
10 Structure, function and maintenance standard SEN03774-00
2. Travel valve
Operation
q When spool (1) is operated, pump discharge
pressure (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).
PC130-8 27
SEN03774-00 10 Structure, function and maintenance standard
LS bypass valve
1. When work equipment valve is operated
(including compound operation of work equipment + travel)
Function Operation
q The LS bypass valve releases the residual q Since pump merge-divider spool (1) is at the
pressure of LS pressure (PLS). merge position, the hydraulic oil in LS circuits
q This lowers the rising speed of LS pressure (PLS1), (PLS2), and (PLS3) flows from tip filter
(PLS). In addition, the discarded throttled flow (a) of LS bypass valve (2) through orifice (b) to
causes a pressure loss in the throttled flow in tank circuit (T).
the reducing valve, and that lowers the effec-
tive LS differential pressure to improve the sta-
bility.
28 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Operation q The hydraulic oil (PLS2) flows from tip filter (c)
q Since pump merge-divider spool (1) is at the of LS bypass valve (3) through orifice (d) to
separate position, LS circuits (PLS1) and tank circuit (T).
(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).
PC130-8 29
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30 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Function
q When the load pressure becomes lower than
another actuator and the flow is going to
increase during a compound operation, this
valve compensates the load pressure. [At the
time, the load pressure of another actuator
under compound operation (the upper side) is
higher than that of the actuator on this side
(the lower side)].
Operation
q When the load pressure (Ab) of another actua-
tor side (the upper side) rises during a com-
pound operation, the flow in the actuator circuit
(Aa) on this side (the lower side) is apt to
increase.
q In this case, the LS pressure (PLS) of 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 difference between (PA) applied
to the both end faces of the pressure reducing
valve (1) and (PLS) becomes the same as the
pressure loss between (PP) before and after
the flow control valve (2) and (PPA).
q So, the pressure differences between the
upstream pressures (PPA) and the down-
stream pressures (PA) of the both spools
under compound operation become the same,
and the pump flow is distributed in proportion
to the opening area of each spool notch (a).
PC130-8 31
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32 PC130-8
10 Structure, function and maintenance standard SEN03774-00
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).
PC130-8 33
SEN03774-00 10 Structure, function and maintenance standard
Function q At the time, the head side pressure (B) and the
q When the head pressure (B) of the cylinder (1) spring (4) close the check valve (3), and the
is higher than the bottom pressure (A) while circuits on the head side and the bottom side
the boom is lowered and the boom is in the are interrupted.
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).
34 PC130-8
10 Structure, function and maintenance standard SEN03774-00
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).
PC130-8 35
SEN03774-00 10 Structure, function and maintenance standard
2. At arm in process
Function
q When the bottom 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-
tom side.
36 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Function Operation
q While the boom lever is not operated, the q If the boom is raised out, the main pressure
hydraulic drift prevention valve prevents pres- from the control valve pushes up poppet (5).
surized oil from leaking from the boom bottom As a result, the main pressure from the control
through spool (1) to prevent the boom from valve flows through the valve into the boom
drifting hydraulically. cylinder bottom.
PC130-8 37
SEN03774-00 10 Structure, function and maintenance standard
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.
38 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Operation
q If the boom is lowered, pilot pressure (P1) from
the PPC valve pushes pilot spool (3) 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.
PC130-8 39
SEN03774-00 10 Structure, function and maintenance standard
40 PC130-8
10 Structure, function and maintenance standard SEN03774-00
LS select valve
1. During normal operation
Function
q At the time of simultaneous operation of swing
+ boom RAISE, this valve prevents high swing
LS pressure from entering the LS circuit (PLS)
and also prevents 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) suitable for the
load pressure, and the pressure is led to the
pump LS valve.
PC130-8 41
SEN03774-00 10 Structure, function and maintenance standard
Operation
q At the simultaneous operation of swing + boom
RAISE, the signal pressure of the PPC circuit
is led to the pilot port (BP).
q When this pilot pressure (BP) is applied to the
piston (2) 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 is
controlled with the boom RAISE LS pressure.
q The pilot pressure (BP) depends on the control
lever stroke.
42 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Function Operation
q This valve connects both travel circuits to each When pilot pressure is turned ON
other so that hydraulic oil will be supplied q If the pilot pressure from the travel junction
evenly to both travel motors and the machine solenoid valve becomes higher than the force
will travel straight. of spring (2), travel junction spool (1) moves to
q When the machine is steered, outside pilot the left stroke end and the junction circuit
pressure (PST) closes the travel junction valve between port (PTL) (Left travel circuit) and
to secure high steering performance. (PTR) (Right travel circuit) is closed.
PC130-8 43
SEN03774-00 10 Structure, function and maintenance standard
44 PC130-8
10 Structure, function and maintenance standard SEN03774-00
Function Function
q The lift check valve generates back pressure in q The cooler bypass valve protects oil cooler (4)
the drain circuit to prevent negative pressure from breakage when the return flow rate from
on each actuator (motor, cylinder, etc.) the control valve increases and oil cooler inlet
pressure (PB) increases.
Operation q The cooler bypass valve returns the return oil
q Drain circuit pressure (PA) of the control valve to the tank directly without passing it through
acts on the left side of piston (2) to move the oil cooler (4).
piston to the right.
q The piston is so balanced that the back pres- Operation
sure will be as follows. q Oil cooler inlet pressure (PB) acts on the
q (PA) (PB) = Force of spring (3) / Area of pis- underside of piston (1) to push up the piston.
ton (2) at diameter (d1) q Piston (1) is so balanced that oil cooler inlet
[(PB) C 0 kg/cm2] pressure (PB) will be as follows.
q (PB) (PT) = Force of spring (5) / Area of pis-
ton (1) at diameter (d2)
[(PT) C 0 kg/cm2]
PC130-8 45
SEN03774-00 10 Structure, function and maintenance standard
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
46 PC130-8
SEN03775-01
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03775-01 10 Structure, function and maintenance standard
PPC valve 1
Work equipment and swing PPC valve 1
2 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 3
SEN03775-01 10 Structure, function and maintenance standard
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Centering spring Free length
10 Outside diameter length load load
(for ports P3 and P4)
17.7 N 14.1 N If damaged or
42.48 15.5 34
{1.8 kg} {1.44 kg} deformed,
Centering spring 29.4 N 23.5 N replace spring.
11 44.45 15.5 34
(for ports P1 and P2) {3 kg} {2.40 kg}
16.7 N 13.3 N
12 Metering spring 26.53 8.15 24.9
{1.7 kg} {1.36 kg}
4 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 5
SEN03775-01 10 Structure, function and maintenance standard
6 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 7
SEN03775-01 10 Structure, function and maintenance standard
8 PC130-8
10 Structure, function and maintenance standard SEN03775-01
1. Plate
2. Body
3. Piston
4. Seal
5. Valve
6. Damper
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
7 Centering spring Outside diameter length load load If damaged or
108 N 86.3 N deformed,
48.57 15.5 32.5
{11 kg} {8.8 kg} replace spring.
16.7 N 13.3 N
8 Metering spring 26.53 8.15 24.9
{1.7 kg} {1.36 kg}
PC130-8 9
SEN03775-01 10 Structure, function and maintenance standard
10 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 11
SEN03775-01 10 Structure, function and maintenance standard
a For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
12 PC130-8
10 Structure, function and maintenance standard SEN03775-01
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
9 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed,
33.88 15.3 28.4
{12.7 kg} {10.2 kg} replace spring.
16.7 N 13.3 N
10 Metering spring 22.73 8.10 22 .0
{1.70 kg} {1.36 kg}
PC130-8 13
SEN03775-01 10 Structure, function and maintenance standard
1. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
If damaged or
Free length Installation Installation Installation
Free length deformed,
8 Return spring Outside diameter length load load
replace EPC
3.1 N 2.6 N valve assembly.
9.5 11.4 8.4
{0.32 kg} {0.26 kg}
14 PC130-8
10 Structure, function and maintenance standard SEN03775-01
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (coil is de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
pump controller, it generates the EPC output the controller to coil (14), coil (14) is de-ener-
pressure in proportion to the size of the signal, gized.
and outputs it to the control valve. 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 from the control valve is
drained to the tank via port (C) and port (T).
PC130-8 15
SEN03775-01 10 Structure, function and maintenance standard
16 PC130-8
10 Structure, function and maintenance standard SEN03775-01
Swing motor 1
Type: KMF45ABE-5
PC130-8 17
SEN03775-01 10 Structure, function and maintenance standard
18 PC130-8
10 Structure, function and maintenance standard SEN03775-01
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake ring
8. Brake piston
9. Housing
10. Piston
11. Cylinder block
12. Valve plate
13. Center shaft
14. Center spring
15. Check valve
16. Shuttle valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
17 Check valve spring Outside diameter length load load If damaged or
8.63 N 6.86 N deformed,
43.3 6 36.5
{0.88 kg} {0.70 kg} replace spring.
1.96 N 1.57 N
18 Shuttle valve spring 13 6.5 9.5
{0.2 kg} {0.16 kg}
PC130-8 19
SEN03775-01 10 Structure, function and maintenance standard
Operation Operation
q As the swing holding brake solenoid valve is q As the swing holding brake solenoid valve is
de-energized, the pressurized oil from the self energized, the valve is switched.
pressure reducing valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (8) is pushed down by brake via port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (8) up.
q Disc (5) is separated from plate (6), releasing
the brake.
20 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 21
SEN03775-01 10 Structure, function and maintenance standard
22 PC130-8
10 Structure, function and maintenance standard SEN03775-01
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)
PC130-8 23
SEN03775-01 10 Structure, function and maintenance standard
24 PC130-8
10 Structure, function and maintenance standard SEN03775-01
Travel motor 1
(With reduction gears)
PC130-8 25
SEN03775-01 10 Structure, function and maintenance standard
26 PC130-8
10 Structure, function and maintenance standard SEN03775-01
Specifications
Type GM21VA-A
Stroke volume Hi 44.2
(cm/rev) Lo 79.1
Rated speed Hi 2,809
(rpm) Lo 1,486
Brake releasing pressure 0.76
(MPa{kg/cm}) {7.71}
Hi-Lo switching pressure 2.94
(MPa{kg/cm}) {30}
Reduction ratio 54.0
Outline
3. Brake valve
Consists of various valves. Provides the follow-
ing functions: stops the hydraulic motor
smoothly, prevents runway of hydraulic motor,
prevents generation of abnormally high pres-
sure when the hydraulic motor is stopped sud-
denly.
PC130-8 27
SEN03775-01 10 Structure, function and maintenance standard
Operation
Operation of motor
At low speed (the motor swash plate angle is maximized.)
1. 2nd travel speed select solenoid valve q Since 2nd travel speed select solenoid valve
2. Regulator valve (1) is de-energized, the pressurized oil from
3. Spring self pressure reduction valve (11) is not fed to
4. Check valve port (P).
5. Regulator piston q Regulator valve (2) is pushed down with spring
6. Swash plate (3) reaction force.
7. Parking brake piston q The main pressurized oil, sent from the control
8. Hydraulic pump valve through check valve (4), is controlled by
9. Travel control valve regulator valve (2) and used to shuts off the cir-
10. Pump merge-divider valve cuit to regular piston (5).
11. Self pressure reducing valve q The pressurized oil in control chamber (C) is
12. Brake valve drained from port (D) through oil passage (e) of
regulator valve (2).
q Swash plate (7) reaches its maximum tilt
angle, and the machine travels at low speed
with the maximum motor capacity.
28 PC130-8
10 Structure, function and maintenance standard SEN03775-01
1. 2nd travel speed select solenoid valve q When 2nd travel speed select solenoid valve
2. Regulator valve (1) is energized, the pressurized oil from self
3. Spring pressure reduction valve (11) is fed to port (P).
4. Check valve q Regulator valve (2) is pushed up with the pres-
5. Regulator piston surized oil that is sent to port (P).
6. Swash plate q The main pressurized oil from the control valve
7. Parking brake piston passes through check valve (4), and passes
8. Hydraulic pump through oil passage (F) in regulator valve (2) to
9. Travel control valve control chamber (C), and is used to push to
10. Pump merge-divider valve regular piston (5) to the left.
11. Self pressure reducing valve q Swash plate (7) reaches its minimum tilt angle,
12. Brake valve and the machine travels at high speed with the
minimum motor capacity.
PC130-8 29
SEN03775-01 10 Structure, function and maintenance standard
Brake valve
Operation when pressure oil is supplied Operation when pressure is shut off
q When the travel lever is operated, the pressur- q When the travel lever is returned to its neutral
ized oil from the control valve is fed to port (A) position, the hydraulic oil circuit from the con-
and check valve (1) is opened. The oil is fur- trol valve is closed. And counterbalance valve
ther sent from port (C) to port (D) through the (2) starts to return to the left by spring (3) reac-
motor. tion force.
q At the same time, when the pressure of the q The hydraulic oil in chamber (G) tends to flow
hydraulic oil that entered in chamber (G) to port (A) through orifice (f). However, the
through orifice (f) exceeds spring (3) reaction back pressure is generated by closing of orifice
force, counterbalance valve (2) moves to the (f), controlling the return speed of counterbal-
right, opening ports (D) and (B), and the motor ance (2) to the right.
becomes ready to rotate. q The motor tends to rotate by inertia even when
q As ports (A) and (E) also open, parking brake the hydraulic oil from the control valve is
piston (4) is pressed down by the hydraulic stopped.During this time, the oil return circuit is
pressure. This releases the parking brake and gradually closed by controlling the movement
the motor starts to rotate. speed of counterbalance valve (2) and by
using its cutout portion. By this, the motor is
smoothly stopped.
30 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 31
SEN03775-01 10 Structure, function and maintenance standard
Relief valve
q The pressurized oil from the control valve is q When the hydraulic oil from the control valve is
fed from port (A) to port (C). As port (C) is con- stopped, ports (A) and (C) are closed. At the
nected to the motor, the pressure drives the same time, ports (D) and (B) are closed, but
motor to rotate. the motor continues to rotate by the inertia.
q When the hydraulic pressure at port (C) q When the hydraulic pressure at port (D)
exceeds the specified value, relief valve (1a) is exceeds the specified value, relief valve (1b) is
pushed up and the hydraulic oil is fed to port pushed up and the hydraulic oil is fed to port
(D).However, relief valve (1b) is kept closed (C).The hydraulic pressure applied to port (D)
independent from the hydraulic pressure at at the outlet side is fed to port (C) at the inlet
port (C). side, and it is used to prevent the oil cavitation.
q The hydraulic oil is fed from port (C) to cham- q The hydraulic oil from port (D) passes through
ber (E) through the oil passages of relief valve the oil passages of relief valve (1b) and sleeve
(1a) and sleeve (2a). By this pressure, piston (2b), and sent to chamber (F). By this pres-
(3) is moved to the right. sure, piston (3) is moved to the left.
q When piston (3) reaches its stroke end posi- q When piston (3) reaches its stroke end posi-
tion, the hydraulic pressure from relief valve tion, the hydraulic pressure from relief valve
(1a) to chamber (E) increases. Therefore, (1b) to chamber (F) increases. Therefore, ports
ports (C) and (D) are closed by relief valve (D) and (C) are closed by relief valve (1b).
(1a). q The hydraulic pressure at port (D) at the inlet
q The hydraulic pressure at port (C) at the inlet side is controlled so that the motor is smoothly
side is controlled so that the motor is smoothly stopped.
started to rotate.
32 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 33
SEN03775-01 10 Structure, function and maintenance standard
A1: From control valve (R.H. travel FORWARD) A2: To R.H. travel motor port B
B1: From control valve (L.H. travel FORWARD) B2: To L.H. travel motor port A
C1: From control valve (R.H. travel REVERSE) C2: To R.H. travel motor port A
D1: From control valve (L.H. travel REVERSE) D2: To L.H. travel motor port B
E1: From 2nd travel speed select solenoid valve E2: To L.H. and R.H. travel motor port P
DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D
1. Cover 4. O-ring
2. Body 5. Shaft
3. Slipper seal
34 PC130-8
10 Structure, function and maintenance standard SEN03775-01
Unit: mm
No. Item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
1 Replace
shaft 80 0.056 0.105 0.111
PC130-8 35
SEN03775-01 10 Structure, function and maintenance standard
Solenoid valve 1
36 PC130-8
10 Structure, function and maintenance standard SEN03775-01
Solenoid valve
7. Coil (ON/OFF type)
8. Push pin
9. Valve spool
10. Sleeve
11. Block
12. Plug
Check valve
13. Plunger
14. Plug
PC130-8 37
SEN03775-01 10 Structure, function and maintenance standard
38 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 39
SEN03775-01 10 Structure, function and maintenance standard
Accumulator 1
For PPC circuit
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
q Mounted on the solenoid valve. If the engine is
stopped 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 80C)
Maximum operating pressure:
6.86 MPa {70 kg/cm}
40 PC130-8
10 Structure, function and maintenance standard SEN03775-01
For breaker
(Machine ready for attachment)
For low pressure For high pressure
1. Cap 1. Cap
2. Core 2. Core
3. Guard rubber 3. Locknut
4. Ring 4. Gas port
5. Lid 5. Bladder
6. Bladder 6. Shell
7. Shell
Outline Outline
q Connected to the attachment piping. When the q Connected to the attachment piping. When the
breaker operates, the oil pulsation is absorbed breaker operates, the oil pulsation is absorbed
by the pressure of compressed nitrogen gas of by the pressure of compressed nitrogen gas of
the accumulator, to protect the hydraulic sys- the accumulator, to protect the hydraulic sys-
tem devices and piping. tem devices and piping.
Specifications Specifications
Gas to be used: Nitrogen gas Gas to be used: Nitrogen gas
Gas capacity: 480 cc Gas capacity: 500 cc
Sealed gas pressure: 0.1 MPa {1 kg/cm} (at 80C) Sealed gas pressure:
Maximum operating pressure: 0.69 MPa {7 kg/cm} 5.88 MPa {60 kg/cm} (at 80C)
Maximum operating pressure:
20.6 MPa {210 kg/cm}
PC130-8 41
SEN03775-01 10 Structure, function and maintenance standard
Holding valve 1
(An immediate fall prevention valve for work equipment)
42 PC130-8
10 Structure, function and maintenance standard SEN03775-01
1. Pilot spool
2. Safety valve
3. Check valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
4 Check valve spring Outside diameter length load load
12.7 N 10.2 N If damaged or
20.8 12.2 13.5
{1.3 kg} {1.04 kg} deformed,
58.8 N 47.1 N replace spring.
5 Spool return spring 41.1 9.6 35.0
{6.0 kg} {4.8 kg}
78.5 N 62.8 N
6 Spool return spring 41.9 25.8 41.0
{8.0 kg} {6.4 kg}
PC130-8 43
SEN03775-01 10 Structure, function and maintenance standard
Function
q Prevents the pressurized oil from reversing
from the work equipment cylinder in order to
prevents sudden drift of the work equipment at
breaking of the piping between the control
valve and the work equipment cylinder.
Operation
1. When the work equipment lever is in neu-
tral
44 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 45
SEN03775-01 10 Structure, function and maintenance standard
46 PC130-8
10 Structure, function and maintenance standard SEN03775-01
PC130-8 47
SEN03775-01 10 Structure, function and maintenance standard
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
48 PC130-8
10 Structure, function and maintenance standard SEN03775-01
Unit: mm
No. Item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
-0.030 +0.259 0.093
Clearance between Boom 70 0.435
-0.076 +0.063 0.335
1 piston rod and bush-
ing -0.030 +0.279 0.095
Arm 75 0.455
-0.076 +0.065 0.355
-0.030 +0.250 0.085
Bucket 65 0.426
-0.076 +0.055 0.326
-0.030 +0.190 0.120
Boom 70 1.0
-0.100 +0.090 0.290 Replace bush-
Clearance between ing
-0.030 +0.190 0.120
2 piston rod support Arm 70 1.0
-0.100 +0.090 0.290
shaft and bushing
-0.030 +0.170 0.100
Bucket 65 1.0
-0.080 +0.070 0.250
-0.030 +0.190 0.120
Boom 70 1.0
Clearance between -0.100 +0.090 0.290
cylinder bottom -0.030 +0.190 0.120
3 Arm 70 1.0
support shaft and -0.100 +0.090 0.290
bushing -0.030 +0.170 0.100
Bucket 65 1.0
-0.080 +0.070 0.250
PC130-8 49
SEN03775-01 10 Structure, function and maintenance standard
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
50 PC130-8
SEN03776-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03776-00 10 Structure, function and maintenance standard
Work equipment 1
Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between mounting size clearance limit
Shaft Hole
1 pin and bushing of boom and
revolving frame -0.030 +0.143 0.093
70 0.8
-0.100 +0.063 0.245
Clearance between mounting
-0.030 +0.145 0.095
2 pin and bushing of boom and 70 0.8
-0.100 +0.065 0.245
arm
Clearance between mounting Replace pin and
-0.030 +0.129 0.104
3 pin and bushing of arm and 60 0.8 bushing
-0.080 +0.074 0.209
bucket
Clearance between mounting -0.030 +0.133 0.105
4 60 0.8
pin and bushing of arm and link -0.080 +0.075 0.213
Clearance between mounting -0.030 +0.132 0.105
5 65 0.8
pin and bushing of link and link -0.080 +0.075 0.212
Clearance between mounting
-0.030 +0.130 0.108
6 pin and bushing of link and 60 0.8
-0.080 +0.078 0.210
bucket
2 PC130-8
10 Structure, function and maintenance standard SEN03776-00
PC130-8 3
SEN03776-00 10 Structure, function and maintenance standard
Dimensions of components 1
Arm
4 PC130-8
10 Structure, function and maintenance standard SEN03776-00
Unit: mm
Tolerance
No. Measurement point Standard size
Shaft Hole
-0.030 +0.100
1 70
-0.100 0
+1.0
Arm side 81.5
2 0
Cylinder head side 80 1.2
+0.5
Boom side 226
0
3
-0.2
Arm side 226
-0.7
-0.030 +0.100
4 70
-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
-0.030 +0.200
15 60
-0.080 0
0
Link side 259
16 -1.0
Bucket side 261 1.0
-0.030 +0.200
17 60
-0.080 0
0
Arm side 226
-0.5
18
+2.0
Bucket side 274
0
Min. 1,378
19
Max. 2,263
PC130-8 5
SEN03776-00 10 Structure, function and maintenance standard
Bucket
6 PC130-8
10 Structure, function and maintenance standard SEN03776-00
Unit: mm
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
+0.2
9 60
0
10 64
+0.25
11 80
0
12 261 1.0
13 50
14 85
+1.0
15 380
0
16 18
17 110
18 130
19 132
20 108
+2.0
21 274
0
22 51
23 34
24 100.5
25 115.3
26 74
27 65
PC130-8 7
SEN03776-00 10 Structure, function and maintenance standard
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
8 PC130-8
SEN03777-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03777-00 10 Structure, function and maintenance standard
Air conditioner 1
Air conditioner piping
2 PC130-8
10 Structure, function and maintenance standard SEN03777-00
PC130-8 3
SEN03777-00 10 Structure, function and maintenance standard
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
4 PC130-8
SEN03778-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN03778-00 10 Structure, function and maintenance standard
2 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 3
SEN03778-00 10 Structure, function and maintenance standard
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Fusible link secure safety when the engine is started.
4. Fuse box q The engine does not start until the lock
5. Starting switch lever is set in the LOCK position.
6. Engine controller
7. Lock lever 2. The KOMTRAX engine cut circuit is employed
8. PPC lock switch to disable the engine from starting when the
9. Starting motor cut-out relay (for PPC lock) KOMTRAX terminal receives an engine cut
10. Starting motor cut-out relay (for personal code) command issued through external operation.
11. Fuel control dial
12. Safety relay
13. Starting motor
14. Fuel supply pump
15. Sensors
16. Engine controller power cut-off relay A
17. Engine controller power cut-off relay B
18. Machine monitor
19. KOMTRAX terminal
4 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Starting engine
q When starting switch (5) is turned ON, engine
controller (6) sends command current to fuel
supply pump (14).
For this reason, a fail-safe mechanism is pro-
vided with the electrical system to stop the
engine when an electrical failure occurs.
q When starting switch (5) is turned to START
with lock lever (7) set in the LOCK position, a
starting current is supplied to starting motor
(13) causing the engine to start.
However, as the neutral safety mechanism is
provided, the engine will not start if lock lever
(7) is set in the FREE position at this time;
starting motor cut-out relay (9) cuts off the
starting current to starting motor (13).
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 current
to starting motor (13), therefore the engine
does not start.
Stopping engine
q When starting switch (5) is turned OFF, the
current from the ACC terminal of starting
switch (5) to engine controller (6) is cut off, and
consequently the command current to fuel sup-
ply pump (14) is cut off.
Fuel supply pump (14) stops fuel feed, causing
the engine speed to go down and the engine
stops.
PC130-8 5
SEN03778-00 10 Structure, function and maintenance standard
6 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Function
q A function that selects working mode with the
working mode selector switch in the machine
monitor. 5 modes (P, E, L, ATT, B) are avail-
able, allowing the operator to select appropri-
ate engine torque (T) and pump absorption
torque depending 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 speed is lowered, the con-
troller prevents the engine from stopping by
throttling the pump absorption torque.
PC130-8 7
SEN03778-00 10 Structure, function and maintenance standard
8 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Modes B and L
q Matching point:
Working mode Matching point
50.9 kW/1,870 rpm
B
{68.2 HP/1,870 rpm}
47.8 kW/1,640 rpm
L
{64.1 HP/1,640 rpm}
PC130-8 9
SEN03778-00 10 Structure, function and maintenance standard
Control function during travel Control function with emergency pump drive
q Traveling the machine in P or ATT mode switch ON
increases engine speed (N). q If the controller gets out of order and no work is
(At the time of Hi ran, the idle number of revo- possible because the hydraulic pump does not
lution rises, too.) work properly, operating emergency pump
q Traveling the machine in E, L or B mode does drive switch (1) temporarily enables to main-
not change engine speed (N) or pump absorp- tain functions of the machine with absorption
tion torque. torques quite similar to those in the Mode E.
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 Emergency pump drive switch (1) is of the
alternative type. If the machine is operated
after the switch is set to Emergency (a) even
though the machine is normal, the user code
E02 will be shown on the display.
10 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 11
SEN03778-00 10 Structure, function and maintenance standard
Auto-decelerator function
12 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Function
q When all the control levers are set to NEU-
TRAL for waiting for a dump track or work, the
engine speed is automatically reduced to a
control speed, and fuel consumption and noise
are lowered.
q When any control lever is operated, the engine
speed returns immediately to the speed that is
set with the fuel control dial.
Operation
When control levers are set in neutral
q If all 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.
PC130-8 13
SEN03778-00 10 Structure, function and maintenance standard
14 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Function
q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after
start-up of the engine.
Operational conditions (all required) Operation
Coolant temperature: Max. 55 C o
Fuel control dial: Max. 1,300 rpm Engine speed: 1,300 rpm
All control lever position: Neutral
q Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil tem-
perature becomes too high.
Operational conditions Operation and actions taken Release conditions
Coolant temperature: Max. 95C
Working mode: P, ATT Engine speed: Remains same
Coolant temperature: Min. 95C o Sends torque control signal to o Hydraulic oil temperature: Max. 95C
The original conditions are restored if
Hydraulic oil temperature: Min. 95C lower the pump absorption torque
above requirements are met (auto-
Traveling status check: OFF and reduce the engine load. matic restoration).
Working mode: P, ATT Engine speed: Remains same Coolant temperature: Max. 100C
Coolant temperature: Min. 100C o Sends torque control signal to o Hydraulic oil temperature: Max. 100C
The original conditions are restored if
Hydraulic oil temperature: Min. 100C lower the pump absorption torque
above requirements are met (auto-
Traveling status check: Any and reduce the engine load. matic restoration).
PC130-8 15
SEN03778-00 10 Structure, function and maintenance standard
q When the engine is started at low temperatures and the engine speed is increased sharply, the turbo-
charger may be seized. Controlling the engine speed prevents this problem.
q Duration of engine speed control depends on the coolant temperature.
Operational conditions Operating
o Turbocharger protection
Engine oil pressure: Max. 50 kPa {0.51 kg/cm2}
(See the following figure)
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)
16 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 17
SEN03778-00 10 Structure, function and maintenance standard
Function
Swing lock
OFF ON
switch
Swing lock and swing holding brake functions
Swing lock
q Turning swing lock switch (1) to ON locks the OFF ON
monitor
swing lock (manual lock) at any position.
Function Swing holding brake Swing lock
q Interlocked with the swing operation, the swing
holding brake (auto lock) prevents hydraulic When the L.H. work The swing hold-
drift from occurring after the swing stops. equipment control ing brake works to
q Interlocked with the arm retract operation, the lever is set to NEU- lock the swing.
TRAL, the swing Even if the L.H.
swing holding brake is released to reduce the holding brake works work equipment
load on the swing equipment during excavation in 5 sec. control lever is
work. When the L.H. work operated for
Operation equipment control swing, the swing
lever is operated for holding brake
swing or the arm cannot be
lever is operated for released, and no
retract, the swing swing is possible.
holding brake is
released allowing
free swing opera-
tion.
18 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 19
SEN03778-00 10 Structure, function and maintenance standard
20 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Function
PC130-8 21
SEN03778-00 10 Structure, function and maintenance standard
1. Battery Function
2. Battery relay q Interlocked with the lock lever, the PPC lock
3. Fusible link switch is turned OFF when operating the lock
4. Fuse box lever to LOCK position.
5. Starting switch q When the PPC lock switch is turned OFF, the
6. Lock lever current to the PPC lock solenoid valve is cut-
7. PPC lock switch off, causing neither the work equipment nor
8. Hydraulic pump machine moves even if levers or pedal is oper-
9. Control valve ated.
9a. Pump merge-divider valve
9b. Self pressure reducing valve
10. PPC lock solenoid valve
22 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 23
SEN03778-00 10 Structure, function and maintenance standard
System components
Engine controller
DTP-4P [CN-CE03]
Signal
Pin No. Signal name
classification
1 GND C
2 NC
3 Constant power supply (24 V) A
4 NC
24 PC130-8
10 Structure, function and maintenance standard SEN03778-00
DRC-60P(1) [CN-CE01]
Signal Signal
Pin No. Signal name Pin No. Signal name
classification classification
1 NC 31 NC
2 NC 32 Engine oil pressure switch B
3 NC 33 NC
4 NC 34 NC
5 NC 35 NC
6 NC 36 Sensor power supply (5 V) A
7 NC 37 Camshaft speed sensor B
8 NC 38 NC
9 NC 39 NC
10 Fuel supply pump regulator (+) B 40 NC
11 Boost temperature sensor B 41 NC
12 NC 42 Crankshaft speed sensor B
13 NC 43 NC
14 Fuel supply pump regulator () C 44 Crankshaft speed sensor GND C
15 NC 45 Injector #2 (+) D
16 NC 46 NC
17 NC 47 Coolant temperature sensor GND C
18 NC 48 Sensor GND C
19 Boost pressure sensor B 49 Coolant temperature sensor D
20 Ambient 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 Pin No. Signal name Signal
classification classification
1 CAN(+) E 31 NC
Engine controller power cut-off relay
2 NC 32 C
GND
3 NC 33 NC
4 NC 34 NC
5 NC 35 Fuel control dial (+) B
6 NC 36 NC
7 NC 37 NC
8 NC 38 NC
9 NC 39 NC
10 NC 40 NC
11 NC 41 NC
12 NC 42 NC
13 NC 43 NC
14 NC 44 NC
15 NC 45 Starting switch ACC signal B
16 NC 46 NC
17 NC 47 NC
18 NC 48 NC
19 NC 49 NC
20 NC 50 NC
21 CAN () E 51 NC
22 NC 52 NC
23 NC 53 NC
24 NC 54 NC
25 NC 55 Engine controller power cut-off relay D
26 NC 56 NC
27 Fuel control dial (5 V) A 57 NC
28 Fuel control dial () C 58 NC
29 NC 59 NC
30 NC 60 NC
PC130-8 25
SEN03778-00 10 Structure, function and maintenance standard
Pump controller
26 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 27
SEN03778-00 10 Structure, function and maintenance standard
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
q Installed in the right 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.
28 PC130-8
10 Structure, function and maintenance standard SEN03778-00
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.
PC130-8 29
SEN03778-00 10 Structure, function and maintenance standard
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.
30 PC130-8
10 Structure, function and maintenance standard SEN03778-00
1. Plug
2. Switch
3. Connector
Specifications
Contact 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.
PC130-8 31
SEN03778-00 10 Structure, function and maintenance standard
32 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 33
SEN03778-00 10 Structure, function and maintenance standard
Machine monitor
34 PC130-8
10 Structure, function and maintenance standard SEN03778-00
070-12P(1) [CN-CM02]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
1 Engine oil pressure sensor Input 7 GND (machine signal)
2 Engine oil level sensor Input 8 CAN terminal signal
3 Radiator coolant level sensor Input 9 CAN_H Input/output
4 Air cleaner clogging sensor Input 10 CAN_L Input/output
5 Swing lock switch Input 11 USB data () Input/output
6 Spare Input 12 USB data (+) Input/output
070-18P(2) [CN-CM03]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
For communication terminal, RS232C For communication terminal, RS232C
1 Input 10 Input
CD CTS
For communication terminal, RS232C For communication terminal, RS232C
2 Input 11 Input
RXD RI
For communication terminal, RS232C GND (communication terminal power
3 12
SG supply)
GND (communication terminal con- Communication terminal status signal
4 13 Input
trol signal) CH1
Communication terminal selection Communication terminal power sup-
5 Input 14 Output
signal ply control signal
For communication terminal, RS232C Communication terminal control sig-
6 Output 15 Output
RTS nal CH1
For communication terminal, RS232C Communication terminal control sig-
7 Output 16 Output
TXD nal CH2
For communication terminal, RS232C Communication terminal status signal
8 Output 17 Input
DTR CH2
For communication terminal, RS232C Communication terminal power sup-
9 Input 18 Output
DSR ply (12 V)
070-12P(2) [CN-CM04]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
GND (peripheral equipment power
1 7 Reserved
supply)
2 Peripheral equipment control signal Output 8 Reserved
GND (for peripheral equipment,
3 9 Reserved
RS232C)
4 For peripheral equipment, RS232C TXD Output 10 Reserved
For peripheral equipment, RS232C
5 Input 11 Reserved
RXD
Peripheral equipment power supply
6 Reserved 12 Output
(12 V)
B60-8P [CN-CM05]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply)
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1)
3 Camera NTSC signal 2 Input 7 GND (Camera signal 2)
4 Camera NTSC signal 3 Input 8 GND (Camera signal 3)
PC130-8 35
SEN03778-00 10 Structure, function and maintenance standard
Display
36 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 37
SEN03778-00 10 Structure, function and maintenance standard
*2: Included in the star-up check. After the staring switch is turned ON, the monitor turns ON for 2 sec-
onds, and changes to a normal operation screen if no error is found.
38 PC130-8
10 Structure, function and maintenance standard SEN03778-00
PC130-8 39
SEN03778-00 10 Structure, function and maintenance standard
Switches
*1: When the working mode is changed, the auto-decelerator function turns ON.
40 PC130-8
10 Structure, function and maintenance standard SEN03778-00
*2: When the temperature is set at 18.0C or 32.0C, the fan speed is kept at High. Even if the set tem-
perature is reached, the fan speed remains the same.
*3: When the fan is set at Stop, the air conditioner does not start even if the switch is pressed.
PC130-8 41
SEN03778-00 10 Structure, function and maintenance standard
Guidance
Function switch Item Function
icon
1 Clear Clears selected/displayed item.
Moves selection down one page.
2 Move selection
(To the top page from the bottom page.)
3 Set Sets function.
F1 Starts function.
4 Start (Used for starting measurement of spilt fuel consump-
tion.)
Stops function.
5 Stop (Used for stopping measurement of spilt fuel con-
sumption.)
Sets selected item back to default.
1 Default
(Used for screen adjustment.)
F2 Moves selection up one page.
2 Move selection
(To the bottom page from the top page.)
3 Clear Clears selected/displayed item.
1 Camera image Switches to camera image.
Moves selection down one item.
2 Move selection (To the top item from the bottom item.) Releases hold-
F3
ing of the monitor.
Moves selection to the left.
3 Move selection
(To the rightmost item from the leftmost item.)
1 Switching clock/service meter Switches clock/service meter display.
Moves selection up one item.
2 Move selection (To the bottom item from the top item.) Holds the mon-
F4
itor.
Moves selection to the right.
3 Move selection
(To the leftmost item from the rightmost item.)
42 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Guidance
Function switch Item Function
icon
1 Selecting maintenance screen Selects maintenance screen.
F5
2 Return Returns to the previous screen or condition.
1 Selecting user mode screen Selects user mode screen.
F6
2 Fix Fixes selected/displayed item.
PC130-8 43
SEN03778-00 10 Structure, function and maintenance standard
*1: The items available in the operator mode fall into the following categories.
A: Display from the time starting switch is turned ON until the ordinary screen appears. Display after
the starting switch is turned OFF.
B: Display when the switch of machine monitor is operated.
C: Display when a certain condition is satisfied
D: Display when special switch operation is necessary.
*2: For the category A, the order in which items are displayed varies depending on the setting and condi-
tions of the machine as follows:
W: When the engine start lock is set on
X: When the engine start lock is set off
Y: When an error is detected during start-up check.
Z: When a maintenance overdue is detected.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or Spe-
cial functions of machine monitor in Testing and adjusting.
a For how to set the engine start lock on/off, see Password setting/cancel manual.
44 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Oil flow setting for breaker Oil flow setting for attachment
q Oil flow for the breaker can be changed in the q Oil flow for the compound attachment can be
Breaker/attachment setting of the user mode. changed in the Breaker/attachment setting of
q Oil flow level can be set as follows: the user mode.
q Oil flow level can be set as follows:
Oil flow level Quantity (l/min) Remarks
1 60 Oil flow level Quantity (l/min) Remarks
2 70 1 30
3 80 2 85
4 90 3 105
5 100 4 130
6 110 5 155
7 120 6 175
10 150
11 160 Language setting
12 170
13 180
14 190
15 200
PC130-8 45
SEN03778-00 10 Structure, function and maintenance standard
a For how to operate the service mode functions, see Special functions of machine monitor in Testing
and adjusting.
46 PC130-8
10 Structure, function and maintenance standard SEN03778-00
KOMTRAX system 1
PC130-8 47
SEN03778-00 10 Structure, function and maintenance standard
KOMTRAX terminal
TH300
AMP-10P [CN-CK02]
Input/output
Pin No. Signal name
signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 NC
B8 NC
B9 NC
B10 NC
48 PC130-8
10 Structure, function and maintenance standard SEN03778-00
Sensor 1
Atmospheric pressure sensor
1. Connector
2. Pressure inlet port
Function
q Installed in the bracket on the side face of the cylinder block. Detects the ambient pressure and outputs
variable voltage.
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.
PC130-8 49
SEN03778-00 10 Structure, function and maintenance standard
1. Connector
2. Sensor
3. O-ring
Function
q Installed in the water pump. Detects the temperature change and outputs signal as a resistance change.
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.
50 PC130-8
10 Structure, function and maintenance standard SEN03778-00
1. Common rail
2. Sensor
3. Connector
Function
q Installed in the common rail. Detects the fuel pressure and outputs variable voltage.
1. Connector 3. Float
2. Bracket 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.
PC130-8 51
SEN03778-00 10 Structure, function and maintenance standard
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
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 operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
52 PC130-8
10 Structure, function and maintenance standard SEN03778-00
1. Reserve tank
2. Float
3. Sensor
4. Connector
PC130-8 53
SEN03778-00 10 Structure, function and maintenance standard
1. Connector
2. Plug
3. Thermistor
Function
q Installed in the suction pipe of the hydraulic pump. Detects the temperature change and outputs signal
as a resistance change of the thermistor.
Function
q The pump oil pressure sensor is installed in the
control valve. Detects the pump discharge
pressure and outputs variable voltage.
54 PC130-8
10 Structure, function and maintenance standard SEN03778-00
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.
PC130-8 55
SEN03778-00 10 Structure, function and maintenance standard
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
56 PC130-8
SEN04113-00
PC130-8
PC130-8 1
SEN04113-00 20 Standard value table
Engine SAA4D95LE-5
Arm IN relief
0.34 0.59 0.25
SAE30 Oil
At sudden {3.5 6.0} {2.5}
Oil pressure acceleration 0.29 0.49 0.2
SAE10W Oil
(Hydraulic oil MPa {3.0 5.0} {2.1}
temperature: {kg/cm2} Min. 0.18 0.15
Min. 80C) SAE30 Oil
{Min. 1.8} {1.5}
Low idle
Min. 0.15 0.13
SAE10W Oil
{Min. 1.5} {1.3}
Whole speed range
Oil temperature C 80 115 120
(inside oil pan)
Between fan pulley and
alternator pulley
Fan belt tension Deflection when pressed with mm 6 10
finger force of approx.
60 N {6.1 kg}
Between fan pulley and
Air conditioner compressor pulley
compressor belt Deflection when pressed with mm 12 15 12 15
tension finger force of approx.
60 N {6.1 kg}
2 PC130-8
20 Standard value table SEN04113-00
45 55C
Engine oil pressure:
At 1-pump relief rpm 2,050 100
Within operating range
Engine water temperature:
Within operating range
Center of No
Boom control lever 85 10 85 10
lever knob RAISE, LOWER
Tip of pedal
Arm control lever Read max. N o IN, OUT 85 10 85 10
value to end
Travel of control levers
of travel No
Bucket control lever Engine 85 10 85 10
CURL, DUMP
stopped
No
Swing control lever 85 10 85 10
LEFT, RIGHT mm
N o FORWARD,
Travel control lever REVERSE 115 12 115 12
(LEFT, RIGHT)
Work equipment,
Max. 1.5 Max. 20
swing
Play of control lever
Travel Max. 20 Max. 25
PC130-8 3
SEN04113-00 20 Standard value table
4 PC130-8
20 Standard value table SEN04113-00
PC130-8 5
SEN04113-00 20 Standard value table
cylinder)
Boom For testing posture, see 3.7 0.3 Max. 4.3
RAISE
O
Cylinder fully 2.6 0.3 Max. 3.2
Work equipment speed
extended
For testing posture, see 3.2 0.3 Max. 4.0
Arm
Work equipment 3 (Until touching (Until touching
IN
Cylinder fully
Engine at high idle sec. cushion) cushion)
retracted
Hydraulic oil temperature:
I 2.7 0.3 Max. 3.7
O 45 55C
OUT
+0.4
Cylinder fully Work equipment 4 2.5 0.1 Max. 3.4
retracted Engine at high idle
I Hydraulic oil temperature:
DUMP
O 45 55C 2.0
+0.3
Max. 2.6
0.1
Fully extended
6 PC130-8
20 Standard value table SEN04113-00
45 55C
Arm Set top surface of boom sec. Max. 2 Max. 2
horizontal, retract bucket
Work equipment
PC130-8 7
SEN04113-00 20 Standard value table
P1 + P2
As desired P1 P2 See graph See graph
2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pres-
sure when testing.
The error is large near the point where the graph curves, so avoid testing at this point.
a When testing with the pump mounted 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.
8 PC130-8
20 Standard value table SEN04113-00
Posture of machine for testing performance and Travel 2: Travel speed (actual run), travel deviation
test procedure
Swing 1: Swing brake angle, time taken to start
swing, time taken to swing
PC130-8 9
SEN04113-00 20 Standard value table
10 PC130-8
20 Standard value table SEN04113-00
PC130-8 11
SEN04113-00 20 Standard value table
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
12 PC130-8
SEN04114-00
PC130-8
PC130-8 1
SEN04114-00 30 Testing and adjusting
2 PC130-8
30 Testing and adjusting SEN04114-00
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Exhaust temperatures R 799-101-1502 Digital thermometer 1 -99.9 1,299C
1 799-201-9001 Handy smoke checker 1 Bosch index: 0 9
Checking exhaust gas
A Commercially
color 2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance B Commercially Intake: 0.35 mm
2 Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 6.9 MPa {0 70 kg/cm2}
Testing compression pres-
C 795-502-1370 Adapter 1
sure 2 For 95E-5 engine
6261-11-3880 Gasket 1
Testing blow-by pressure D 1 799-201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:60 MPa
799-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Testing engine oil pres- Pressure gauge:1.0 MPa
E 2 799-401-2320 Gauge 1
sure {10 kg/cm2}
799-401-3500 Adapter 1 Size: 06
3
02896-11018 O-ring 1
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
4
07002-11023 O-ring 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:60 MPa
Testing fuel pressure F 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
795-471-1450 Adapter 1 Size: 8 x 1.25 mm
2
07005-00812 Washer 1
3 799-401-2320 Boost gauge kit 1
1 6151-51-8490 Spacer 1 14
2 6164-81-5750 Joint 1 14
3 07042-20108 Plug 1
Commercially
4 Hose 1 Internal dimensions: Approx. 12 mm
available
Testing fuel return rate
G Commercially
and leakage 5 Hose 1 Internal dimensions: Approx. 9 mm
available
Commercially
6 Measuring cylinder 1
available
Commercially
7 Stopwatch 1
available
Testing swing circle bear- Commercially
H Dial gauge 1
ing clearance available
PC130-8 3
SEN04114-00 30 Testing and adjusting
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Testing and adjusting oil 1 {25, 60, 400, 600 kg/cm2}
pressure in work equip- Pressure gauge: 60 MPa
J
ment, swing, and travel 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
circuits
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
2
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing basic pressure of Pressure gauge: 60 MPa
K
control circuit 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
2
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting oil
pressure in pump PC con- L Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
trol circuit {600 kg/cm2}
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
2
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting oil Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
pressure in pump LS con- M {600 kg/cm2}
trol circuit Differential pressure
2 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
3
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing solenoid valve out- Pressure gauge: 60 MPa
N 790-261-1204 Digital hydraulic tester 1
put pressure {600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
3
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing PPC valve output Pressure gauge: 60 MPa
P 790-261-1204 Digital hydraulic tester 1
pressure {600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
3
07002-11023 O-ring 2
Commercially
Testing oil leakage Q Measuring cylinder 1
available
4 PC130-8
30 Testing and adjusting SEN04114-00
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
799-601-4101
or T-adapter assembly 1
799-601-4201
For DRC60, Econo (Does not
799-601-4350 Measuremen box 1
include 799-601-4201)
799-601-4130 T-adapter 1 CAM
Troubleshooting for 799-601-4160 T-adapter 1 Ne sensor
engine controller/sensors/ S 799-601-4220 T-adapter 1 Engine controller
actuators
799-601-4240 Socket 1 For ambient pressure sensor
799-601-4190 Socket 1 Common rall pressure sensor
799-601-4340 Socket 1 Injector
795-799-5530 Socket 1 Engine water temprature sensor
799-601-4380 Socket 1 Boost pressure sensor
799-601-4260 Socket 1 Engine controller
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 is not supplied any
799-601-2900 T-adapter assembly 1
more.
or
799-601-7100
or
799-601-7400
or
799-601-8000
For Econo (Does not include 799-
799-601-2600 Measuremen box 1
601-2700)
799-601-4101
or
799-601-4201
Troubleshooting for chas- or T-adapter assembly 1
sis sensors/wiring har- T 799-601-9000
nesses or
799-601-9200
For DRC60 and Econo (excluding
799-601-4350 Measuremen box 1 799-601-4201, 799-601-9000 and
799-601-9200 for DT6P)
For DT, HD (Does not include 799-
799-601-9320 Measuremen box 1
601-4100 and 799-601-4201)
799-601-9020 Adapter for DT 1 For DT2P
For DT3P (Does not include 799-601-
799-601-9030 Adapter for DT 1
4100 and 799-601-4201)
799-601-9040 Adapter for DT 1
For DT6P (Does not include 799-601-
799-601-9050 Adapter for DT 1
4100 and 799-601-4201)
For DT12P (Does not include 799-
799-601-9110 Adapter for DT (Gray) 1
601-4100 and 799-601-4201)
For AMP3P (Does not include 799-
799-601-9420 Adapter for AMP 1
601-9000 and 799-601-9200)
PC130-8 5
SEN04114-00 30 Testing and adjusting
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
For X1P (Does not include 799-601-
799-601-7010 Adapter for X 1
7000 and 799-601-7100)
799-601-7020 Adapter for X 1 For X2P
For SW6P (Does not include 799-
799-601-7050 Adapter for SWP 1
601-8000)
For SW6P (Does not include 799-
799-601-7060 Adapter for SWP 1
601-8000)
For M1P (Does not include 799-601-
799-601-7080 Adapter for M 1
7000 and 799-601-7100)
Troubleshooting for chas- 799-601-7090 Adapter for M 1 For M2P
sis sensors/wiring har- T 799-601-7110 Adapter for M 1 For M3P
nesses 799-601-7120 Adapter for M 1 For M4P
799-601-7130 Adapter for M For M6P
799-601-7140 Adapter for S 1 For S8P
799-601-7500 T-adapter assembly 1
799-601-7510 Adapter for 070 1 For 070-10P
799-601-7520 Adapter for 070 1 For 070-12P
799-601-7530 Adapter for 070 1 For 070-14P
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
Socket for engine (CRI-
799-601-9410 1
T2)
Testing coolant tempera-
799-101-1502 Digital thermometer 1 -99.9 1,299C
ture and oil temperature
Testing operating effort 79A-264-0021 Push-pull scale 1
and depressing force 79A-264-0091 Push-pull scale 1
Testing stroke and hydrau- Commercially
Ruler 1
lic drift available
Testing work equipment Commercially
Stopwatch 1
speed available
Testing voltage and resis- Commercially
Circuit tester 1
tance available
Removal and installation 27 mm deep socket (hexagonal),
Commercially
of engine oil pressure Deep socket 1 Inside diameter: 24.5 (Equivalent to
available
switch TONE 4A-27L)
Removal and installation
of coolant temperature 795T-981-1010 Deep socket 1 27 mm deep socket
sensor
a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the
machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Trou-
bleshooting (General information on troubleshooting), List of T-boxes and T-adapters".
6 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 7
SEN04114-00 30 Testing and adjusting
Testing exhaust temperature 1 4. Run the engine and test the exhaust tempera-
ture over the speed range.
a Testing tools for exhaust temperature
Symbol Part No. Part name
R 799-101-1502 Digital thermometer
8 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 9
SEN04114-00 30 Testing and adjusting
Adjusting valve clearance 1 3. Remove plate (5) on the starting motor and
insert gear B1.
a Adjusting tools for valve clearance
Symbol Part No. Part name
1 795-799-1131 Gear
B Commercially
2 Thickness gauge
available
10 PC130-8
30 Testing and adjusting SEN04114-00
5. Adjust the valve clearances marked with q in 7. After finishing adjustment, remove the adjust-
the valve arrangement drawing according to ing tools and return the removed parts.
the following procedure. k Take care not to forget remove gear B1.
3 Cylinder head cover mounting nut:
8.82 0.98 Nm {0.9 0.1 kgm}
PC130-8 11
SEN04114-00 30 Testing and adjusting
12 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 13
SEN04114-00 30 Testing and adjusting
14 PC130-8
30 Testing and adjusting SEN04114-00
Testing engine oil pressure 1 5. Test the oil pressure during low idle and high
idle.
a Testing tools for engine oil pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge
E 799-401-3500 Adapter (Size: 06)
3
02896-11018 O-ring
799-101-5220 Nipple (10 x 1.25 mm)
4
07002-11023 O-ring
PC130-8 15
SEN04114-00 30 Testing and adjusting
16 PC130-8
30 Testing and adjusting SEN04114-00
Testing fuel pressure 1 3) Run the engine at high idle and test the
pressure in the fuel low-pressure circuit.
a Testing tools for fuel pressure a If the pressure in the fuel low-pres-
Symbol Part No. Part name sure circuit is in the following range, it
is normal.
799-101-5002 Hydraulic tester
1 Reference: Negative pressure is indi-
790-261-1204 Digital hydraulic tester cated.
F 795-471-1450 Adapter (8 x 1.25 mm)
2 Engine speed Fuel pressure
07005-00812 O-ring
-49 0 kPa
3 799-201-2202 Boost gauge kit At high idle
{-0.5 0 kg/cm2}
PC130-8 17
SEN04114-00 30 Testing and adjusting
Testing fuel return rate and fuel a Lay test hose G4 so that it will not
leakage 1 slacken and put its end in the oil pan.
1. Preparation work
1) Remove tube (3) and spill hose (4)
between common rail (1) and return block
(2).
18 PC130-8
30 Testing and adjusting SEN04114-00
2. Testing leakage from pressure limiter 3. Testing return rate from injector
1) Lay test hose G4 so that it will not slacken a While testing the return rate from the
and put its end in the oil pan. injector, keep the test hose on the pres-
2) Start the engine and keep its speed at sure limiter side connected and keep its
1,600 rpm with no load. end in the oil pan.
3) After the engine speed is stabilized, test 1) Run the engine at the rated output.
the leakage in 1 minute with measuring 2) After the engine speed is stabilized, test
cylinder G6. the return rate in 1 minute with measuring
a You may test for 20 seconds and cylinder G6.
judge by multiplying the result by 3. a You may test for 20 seconds and
a If the leakage from the pressure lim- judge by multiplying the result by 3.
iter is in the following standard range, a If the supply pump pressure is low,
it is normal. the engine speed may not rise. In this
case, record the engine speed, too,
Engine speed Leakage during the test.
(rpm) (cc/min)
a If the return rate (spill) from the injec-
At rated output Max. 20 tor is in the following standard range,
it is normal.
Rated output Limit of return rate
speed (rpm) (spill) (cc/min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230
PC130-8 19
SEN04114-00 30 Testing and adjusting
20 PC130-8
30 Testing and adjusting SEN04114-00
1. Fuel tank
2. Priming pump
3. Pre-filter with water separator
4. Main filter
5. Feed pump
6. IMV (Inlet Metering Valve)
7. Overflow valve
8. Rail
9. Injector
10. Safety valve
11. High pressure pump
PC130-8 21
SEN04114-00 30 Testing and adjusting
Checking fuel circuit for leakage 1 9. Check the fuel piping and devices for fuel leak-
age.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After checking the fuel system or removing and check again from step 2.
its parts, check it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure. completed.
k Stop the machine on a level ground and
lower the work equipment to the ground.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
22 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 23
SEN04114-00 30 Testing and adjusting
k Stop the machine on a level ground and 1. Loosen bolts (1) and (2).
lower the work equipment to the ground.
2. Move compressor (3) and bracket (4) together
Checking to adjust the belt tension.
1. Open the engine hood and remove fan guard
(1). 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 a crack, replace it.
a If the belt is replaced, adjust their tension
again after operating the machine for 1
hour.
a After tightening the bolts, check the belt
tension again according the above proce-
dure.
24 PC130-8
30 Testing and adjusting SEN04114-00
Testing swing circle bearing 4. Set the arm almost perpendicular to the
clearance 1 ground and lower the boom until the front track
shoe floats.
a Testing tools for swing circle bearing clearance a At this time the front of the upper structure
Symbol Part No. Part name rises and the rear lowers.
Commercially
H Dial gauge 5. Under this condition, read dial gauge H.
available
a The value indicated by dial gauge H is the
clearance of the bearing.
a When testing the swing circle bearing clear-
a For the standard value, see Structure,
ance installed to the machine, perform the fol-
function and maintenance standard,
lowing procedure.
k
"Swing circle".
Stop the machine on a level ground and
lower the work equipment to the ground.
k Do not put your hands or feet under the
undercarriage during test.
PC130-8 25
SEN04114-00 30 Testing and adjusting
26 PC130-8
30 Testing and adjusting SEN04114-00
2. Decreasing tension
1) Loosen valve (1) to discharge grease, and
then tighten it.
k Do not loosen 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.
PC130-8 27
SEN04114-00 30 Testing and adjusting
Testing
a The oil pressure in the work equipment, swing,
and travel circuits (pump discharge pressure)
can be checked with monitoring function of the
machine monitor, too (For details, see "Special
functions of machine monitor").
q Monitoring code: 01100 pump pressure
a Test the oil pressure in the work equipment,
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
28 PC130-8
30 Testing and adjusting SEN04114-00
3. Testing work equipment relief pressure 2) Set the working mode in the power mode
1) Start the engine and move the cylinder to (P).
be tested to the stroke end. 3) Run the engine at high idle, operate the
2) Set the working mode in the power mode travel lever and pedal to relieve the travel
(P). motor, and test the oil pressure.
3) Run the engine at high idle, operate the k Before operating the travel lever
right and left work equipment control and pedal, check the position and
levers to relieve the cylinder, and test the locking direction of the locked
oil pressure. sprocket again.
a The pressure tested when the main a The pressure tested when the main
relief valve is relieved is indicated (If relief valve of the control valve is
t he boo m is l owe r ed si ng ly, th e relieved is indicated. The travel circuit
safety-suction valve of the control is always relieved at high pressure.
valve for lowering the boom is
relieved). 6. Work after finishing test
After finishing test, remove the testing tools
4. Testing swing relief pressure and return the removed parts.
1) Start the engine, set the working mode in 3 Oil pressure pickup plug:
the power mode (P), and turn the swing 20 27 Nm {2.0 2.8 kgm}
lock switch ON.
2) Run the engine at high idle, operate the
left work equipment control lever to relieve
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.
PC130-8 29
SEN04114-00 30 Testing and adjusting
1. Adjusting work equipment and travel relief 2. Adjusting swing relief pressure
pressure a If the swing relief pressure is abnormal,
a If the relief pressure of the work equip- adjust safety valve (7) of the swing motor
ment circuit and travel circuit is abnormal, according to the following procedure.
adjust main relief valves (3) according to
the following procedure.
q (3): Main relief valve
a Adjust only the low relief pressure of the
main relief valve. If the low relief pressure
is adjusted, the high relief pressure is set
automatically.
a The low relief pressure is the pressure
applied when the 2-stage relief solenoid
valve is turned OFF and the pilot pressure
is not applied to the selector port.
30 PC130-8
30 Testing and adjusting SEN04114-00
Testing control circuit basic 2. Install nipple K2 and connect oil pressure
pressure 1 gauge [1] of hydraulic tester K1.
a Use the oil pressure gauge of 5.9 MPa {60
a Testing tools for control circuit basic pressure kg/cm2}.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
K
799-101-5220 Nipple (10 1.25 mm)
2
07002-11023 O-ring
PC130-8 31
SEN04114-00 30 Testing and adjusting
Testing
a Before testing the oil pressure in the PC con-
trol circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the basic pressure of the control circuit are nor-
mal.
a Test the oil pressure in the pump PC control
circuit under the following condition.
q Hydraulic oil temperature: Within operating
range
1. Testing PC valve output pressure (servo a Install nipple L2 to the inspection part
piston inlet pressure) of plug (2) and connect it to oil pres-
a Test the PC valve output pressure (servo sure gauge [1] by hose [2] of hydrau-
piston inlet pressure) and pump discharge lic tester L1.
pressure simultaneously and compare a Use the oil pressure gauges of 58.8
them. MPa {600 kg/cm2}.
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
32 PC130-8
30 Testing and adjusting SEN04114-00
5) Run the engine at high idle, operate the 2) Install nipples L2 and connect them to oil
left work equipment control lever to relieve pressure gauges [1].
the arm circuit at the IN stroke end, and a Use the oil pressure gauges of 5.9
test the oil pressure. MPa {60 kg/cm2}.
a Testing condition and method of judg- 3) Start the engine and set the working mode
ment: If the pressures are in the fol- in the power mode (P).
lowing ratio, the PC valve is normal. 4) Run the engine at high idle and low idle,
set all the levers and pedals for work
Tested oil Operation of Ratio of oil
pressure lever pressures equipment control, swing control, and
travel in neutral, and test the oil pressure
Pump discharge
1 at each speed.
pressure
Arm IN relief
PC valve output Approx. 0.6
pressure (Approx. 3/5)
PC130-8 33
SEN04114-00 30 Testing and adjusting
Adjusting
Adjusting pump PC valve
a If the following phenomenon occurs and PC
valve (4) seems to be defective, adjust PC
valve (4) according to the following procedure.
q As the working load increases, the engine
speed lowers remarkably.
q The engine speed is normal but the work
equipment speed is low.
a The width across flats of the PC valve locknut
is 13 mm and that of the adjustment screw
(inside width) is 4 mm.
Do not turn any other locknuts or adjustment
screws since they affects the hydraulic pump
performance. 4. After finishing adjustment, check again that the
PC valve output pressure (servo piston inlet
pressure) is normal according to the above
described test procedure.
34 PC130-8
30 Testing and adjusting SEN04114-00
Testing
a Before testing the oil pressure in the LS control
circuit, check that the oil pressure in the work
equipment, swing, and travel circuits and the
basic pressure of the control circuit are normal.
a Test the oil pressure in the pump LS control cir-
cuit under the following condition.
q Hydraulic oil temperature: Within operating
range
1. Testing LS valve output pressure (servo a Install nipple M3 to the inspection part
piston inlet pressure) of plug (2) and connect it to oil pres-
a Test the LS valve output pressure (servo sure gauge [1] by hose [2] of hydrau-
piston inlet pressure) and pump discharge lic tester M1.
pressure simultaneously and compare a Use the oil pressure gauges of 58.8
them. MPa {600 kg/cm2}.
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
PC130-8 35
SEN04114-00 30 Testing and adjusting
36 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 37
SEN04114-00 30 Testing and adjusting
Testing solenoid valve output a Since hoses (2) (6) are installed under
pressure 1 the control valve, remove the control valve
undercover.
a Testing tools for solenoid valve output pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
799-401-3100 Adapter (Size: 02)
N 2
799-401-3200 Adapter (Size: 03)
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
38 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 39
SEN04114-00 30 Testing and adjusting
40 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 41
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42 PC130-8
30 Testing and adjusting SEN04114-00
4. Test the pressure when the engine is running Adjusting play of work equipment
at high idle and the control lever of the circuit to and swing PPC valves 1
be tested is kept in the NEUTRAL position and
at the full stroke. a If the right and left work equipment levers have
a If PPC valve output pressure is at the level large play, adjust them according to the follow-
shown below, it is judged normal. ing procedure.
a The play of the lever terminal must be 0.5 3
Lever control Hydraulic pressure mm at a position of 200 mm from the center of
In NEUTRAL 0 MPa {0 kg/cm2} lever rotation.
Nearly equal to control
At full stroke original pressure 1. Remove the work equipment and swing PPC
(See standard value table) valve assembly.
5. Detach all the test tools, and make sure that 2. Remove bellows (1).
the machine is back to normal condition.
3. Loosen locknut (2) and tighten disc (3) until it
touches the heads of 4 pistons (4).
PC130-8 43
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44 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 45
SEN04114-00 30 Testing and adjusting
Inspection
1. Run the engine and heighten the hydraulic oil
temperature to the operating range and set the
machine in the travel posture.
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.
46 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 47
SEN04114-00 30 Testing and adjusting
48 PC130-8
30 Testing and adjusting SEN04114-00
1. Testing oil leakage from boom cylinder hose on the cylinder bottom side.
1) Move the boom cylinder to the RAISE a Use the following part to block the
stroke end and stop the engine. hose side.
k Release the residual pressure from
07376-70522 (Plug #05)
the piping on the boom cylinder
head side. For details, see "Releas-
ing residual pressure from hydrau-
lic circuit" (Operate the lever in the
boom RAISE direction only, how-
ever).
2) Disconnect hose (1) on the cylinder head
side and block it with a plug.
k Take care not to disconnect the
hose on the cylinder bottom side.
a Use the following part to block the
hose side.
07379-00640 (Flange #06)
PC130-8 49
SEN04114-00 30 Testing and adjusting
3. Testing oil leakage from bucket cylinder 4. Testing oil leakage from swing motor
1) Move the bucket cylinder to the CURL 1) Disconnect 2 drain hoses (4) and block
stroke end and stop the engine. the hose side with plugs.
k Release the residual pressure from a Use the following parts to block the
the piping on the bucket cylinder hose side.
head side. For details, see Releas- 07376-70315 (Plug #03)
ing residual pressure from hydrau-
lic circuit (Operate the lever in the
bucket CURL direction only, how-
ever).
2) Disconnect hose (3) on the cylinder head
side and block it with a plug.
k Take care not to disconnect the
hose on the cylinder bottom side.
a Use the following part to block the
hose side.
07376-70422 (Plug #04)
50 PC130-8
30 Testing and adjusting SEN04114-00
5. Testing oil leakage from travel motor 5) After finishing test, return the removed
1) Remove the travel motor cover. parts.
2) Run the engine, lock the travel mecha-
nism, and stop the engine.
k Put pin [1] between the sprocket
and track frame to lock the travel
mechanism securely.
PC130-8 51
SEN04114-00 30 Testing and adjusting
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
52 PC130-8
30 Testing and adjusting SEN04114-00
4. Bleeding air from swing motor 6. Checking oil level and starting work
1) Turn the swing lock switch "ON" and run 1) Run the engine, retract the arm cylinder
the engine at low idle for 5 minutes. and bucket cylinder to the stroke ends,
a Bleed air from the swing motor by lower the work equipment to the ground,
applying the S-port pressure. and stop the engine.
2) Remove the swing motor top cover, dis-
connect hose (1) from the swing motor,
and block the hose with a plug.
a Use the following plug to block the
hose.
07379-70628 (Plug #06)
PC130-8 53
SEN04114-00 30 Testing and adjusting
[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}
54 PC130-8
30 Testing and adjusting SEN04114-00
Installation and adjustment of Retract the mirror into position (C) when
mirrors and camera 1 transporting the machine.
Tightening torque of mirror bolt (2): Retract the mirror into position (C) when
4.0 5.4 Nm {0.41 0.55 kgm} transporting the machine.
Tightening torque of mirror stay bolt (3):
15 Nm {1.52 kgm}
PC130-8 55
SEN04114-00 30 Testing and adjusting
56 PC130-8
30 Testing and adjusting SEN04114-00
If the image projected on the monitor deviates, 3) Loosen camera mounting bolt (5) and
remove cover (4) and adjust installed angle (A) adjust the installed angle of the camera so
of the rear view monitor camera. that the center of mounting bolt (5) will be
set to 4th scale mark (B) from the bottom.
PC130-8 57
SEN04114-00 30 Testing and adjusting
58 PC130-8
30 Testing and adjusting SEN04114-00
PC130-8 59
SEN04114-00 30 Testing and adjusting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
60 PC130-8
SEN04115-00
PC130-8
PC130-8 1
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2 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 3
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Page Page
t Operator mode (Outline) Service mode
6p 19p
A Display of KOMATSU logo 6p Monitoring 20p
A Display of inputting password 7p Mechanical Systems 25p
Abnormality
A Display of check of breaker mode 7p Electrical Systems 26p
Record
A Display of check before starting 7p Air-conditioning System 31p
A Display of warning after check before starting 7p Maintenance Record 32p
A Display of ending of maintenance interval 8p Maintenance Mode Change 33p
A Display of check of working mode and travel speed 8p Phone Number Entry 35p
A Display of ordinary screen 8p Key-on Mode 36p
A Display of end screen 8p Unit 37p
O (Special operation)
4 PC130-8
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PC130-8 5
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6 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 7
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8 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 9
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10 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 11
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12 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 13
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14 PC130-8
30 Testing and adjusting SEN04115-00
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried
E11
Output reduced to protect engine out immediately.
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Operations are possible, but have inspection carried out
E20 Abnormality in travel system
immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error
out immediately.
PC130-8 15
SEN04115-00 30 Testing and adjusting
16 PC130-8
30 Testing and adjusting SEN04115-00
Function of changing attachment/maintenance 3. After the New password input screen is dis-
password played, input a new password with the numeral
When changing the attachment/maintenance pass- input switches and confirm it with the function
word used for the attachment setting function and switch.
maintenance setting function, follow these proce- a Set a new password of 4 6 digits (If it
dures. has only 3 or less digits or has 7 or more
1. While the ordinary screen is displayed, perform digits, it is not accepted).
the following operation with the numeral input q [F5]: Reset input numeral/Return to ordi-
switches. nary screen
q Operation of switches (While pressing [4], q [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
PC130-8 17
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18 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 19
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Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select "Monitoring" on the service menu
screen.
20 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 21
SEN04115-00 30 Testing and adjusting
22 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 23
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24 PC130-8
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PC130-8 25
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26 PC130-8
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PC130-8 27
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28 PC130-8
30 Testing and adjusting SEN04115-00
User Component
Failure code Trouble (Displayed on screen) Category of record
code in charge
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 phase error ENG Electrical system
E10 CA757 All persistent data lost error ENG Electrical system
E15 CA778 Eng. Bkup speed sensor error ENG Electrical system
E0E CA1633 KOMNET datalink timeout error ENG Electrical system
E14 CA2185 Throttle sens. sup. volt. high error ENG Electrical system
E14 CA2186 Throttle sens. sup. volt. low error ENG Electrical system
E11 CA2249 Rail press. very low error ENG Electrical system
E11 CA2311 Abnormality in IMV solenoid ENG Electrical system
D110KB Battery relay drive short PUMP Electrical system
E01 D19JKZ Personal code relay abnormality KOM Electrical system
D862KA GPS antenna discon KOM Electrical system
E0E DA22KK Pump solenoid power low error PUMP Electrical system
DA25KP 5V sensor 1 power abnormality PUMP Electrical system
DA26KP 5V sensor 2 power abnormality PUMP Electrical system
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 Electrical system
E20 DHSFMA Travel left forward PPC press sensor abnormality PUMP Electrical system
E20 DHSGMA Travel right forward PPC press sensor abnormality PUMP Electrical system
E20 DHSHMA Travel left reverse PPC press sensor abnormality 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 DW45KB Swing brake sol short PUMP Electrical system
DW91KA Travel junction sol discon PUMP Electrical system
DW91KB Travel junction sol short PUMP Electrical system
DWJ0KA Merge-divider sol discon PUMP Electrical system
DWJ0KB Merge-divider sol short PUMP Electrical system
DWK0KA 2-stage relief sol discon PUMP Electrical system
PC130-8 29
SEN04115-00 30 Testing and adjusting
User Component
Failure code Trouble (Displayed on screen) Category of record
code in charge
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 Electrical system
DXE4KA Service current EPC discon PUMP Electrical system
DXE4KB Service current EPC short PUMP Electrical system
DY20KA Wiper working abnormality PUMP Electrical system
DY20MA Wiper parking abnormality PUMP Electrical system
DY2CKA Washer drive discon PUMP Electrical system
DY2CKB Washer drive short PUMP Electrical system
DY2DKB Wiper drive (for) short PUMP Electrical system
DY2EKB Wiper drive (rev) short PUMP Electrical system
30 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 31
SEN04115-00 30 Testing and adjusting
32 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 33
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34 PC130-8
30 Testing and adjusting SEN04115-00
1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
PC130-8 35
SEN04115-00 30 Testing and adjusting
3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set with the function
switches.
q 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
36 PC130-8
30 Testing and adjusting SEN04115-00
1. Selecting menu
Select "Default" 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]: Confirm selection and return to
"Default" screen
PC130-8 37
SEN04115-00 30 Testing and adjusting
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 selection and return to
Default screen
38 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 39
SEN04115-00 30 Testing and adjusting
40 PC130-8
30 Testing and adjusting SEN04115-00
1. Selecting menu
Select "Default" on the "Service Menu" screen.
PC130-8 41
SEN04115-00 30 Testing and adjusting
42 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 43
SEN04115-00 30 Testing and adjusting
Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" oper-
ation with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1. Selecting menu
Select "Cylinder Cut-Out" on the "Service
Menu" screen.
44 PC130-8
30 Testing and adjusting SEN04115-00
[Reference] No Injection
q If a normally operating cylinder is Cut-Out, If the engine is operated after long storage of the
the following phenomena occur. machine, it may be worn or damaged because of
1) Lowering of engine speed insufficient lubrication with oil. To prevent this, the
2) Increase of final injection rate com- function to lubricate the engine before starting it by
mand (quantity) cranking it without injecting fuel is installed.
q If the engine is running near the high idle, Set the no-injection cranking while the engine is
however, the engine speed may not lower stopped.
for the reason of engine control.
q In this case, lower the engine speed with 1. Selecting menu
the fuel control dial and judge by increase Select "No Injection" on the "Service Menu"
of the injection rate command. screen.
PC130-8 45
SEN04115-00 30 Testing and adjusting
46 PC130-8
30 Testing and adjusting SEN04115-00
2. Starting test
After the screen of "Fuel Consumption" is dis-
played, start test with the function switches.
q [F1]: Start
q [F2]: Clear 4. Finishing test
q [F5]: Return to Service menu screen Press [F1], and test is finished and the data
a When the screen of Fuel consumption is are displayed on the finishing date and time
displayed, if a data is indicated, it is the side.
data of the previous test. This data is not
an obstacle to new test and can be reset 5. Displaying fuel consumption
by pressing [F2]. If the test is finished, the hourly fuel consump-
a If [F1] is pressed, the data is displayed on tion calculated from the fuel consumption cal-
the starting date and time side and test culated by the engine controller and the
starts. elapsed time are displayed.
PC130-8 47
SEN04115-00 30 Testing and adjusting
48 PC130-8
30 Testing and adjusting SEN04115-00
KOMTRAX Settings (GPS & Communication Status) 3. Contents of display of GPS & communication
The setting condition and operating condition of status
KOMTRAX can be checked with "KOMTRAX Set- On the screen of "GPS & Communication Sta-
tings". tus", the following items are displayed.
GPS & communication status is used to check the q Positioning: Positioning condition of GPS
condition of positioning and communication of the q Communication: Communication environ-
KOMTRAX terminal. ment of communication MODEM and con-
necting condi tion of c ommunication
1. Selecting menu MODEM
Select "KOMTRAX Settings" on the "Service q Number of message not yet sent: Number
Menu" screen. of mails which are saved in machine mon-
itor and not transmitted yet
q [F5]: Return to KOMTRAX settings screen
PC130-8 49
SEN04115-00 30 Testing and adjusting
1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
50 PC130-8
30 Testing and adjusting SEN04115-00
PC130-8 51
SEN04115-00 30 Testing and adjusting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
52 PC130-8
SEN04116-00
PC130-8
PC130-8 1
SEN04116-00 30 Testing and adjusting
2 PC130-8
30 Testing and adjusting SEN04116-00
1. Machine monitor
1) Remove 2 mounting bolts and cover (1).
a One of the mounting bolts is installed
in the cover on the right of the day-
light sensor.
a While removing the mounting bolts,
disconnect connector P31 of the day-
light sensor.
a The following figure shows the model 2. Engine controller
of the arm crane specification 1) Open the engine hood.
equipped with a level. If the machine a The engine controller is mounted on
which you are working on has the arm the cooling frame (on the counter-
crane specification, remove level (2). weight side).
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors CE01, CE02, and
CE03 of engine controller (5).
a Connectors CE01 and CE02 are fixed
with screws. When disconnecting
them, loosen the screws.
a When returning connectors CE01 and
CE02, tighten the screws to the spec-
ified torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}
PC130-8 3
SEN04116-00 30 Testing and adjusting
4 PC130-8
30 Testing and adjusting SEN04116-00
PC130-8 5
SEN04116-00 30 Testing and adjusting
7. Supply pump IMV solenoid (Fuel regulator) a Precautions for connecting connector
a Disconnection and connection of con- Take care not to connect the connector
nector reversely.
The connector of the supply pump IMV Engage lock (e) on the wiring harness side
solenoid has a special locking mecha- with triangular notch (f) on the sensor side
nism. Disconnect it according to steps (a) (Do not engage lock (e) with square guide
(b) and connect it according to steps (c) (g) on the opposite side of triangular notch
(d) as shown below. (f)).
Disconnection: (a) Unlock (b) Discon-
nect connector.
Connection: (c) Connect connector (d)
Lock.
6 PC130-8
30 Testing and adjusting SEN04116-00
PC130-8 7
SEN04116-00 30 Testing and adjusting
8 PC130-8
30 Testing and adjusting SEN04116-00
Pm Clinic service 1
Model name Serial No. Service meter
T PC130-8 h
User's name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 500 mm T( )
Arm T Standard T ( ) T( ) T 600 mm
Bucket T Standard T ( ) T( ) T 700 mm
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
C m
Operator's opinion
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/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
PC130-8 9
SEN04116-00 30 Testing and adjusting
Check sheet
Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Checking condition
Standard Mea-
Service limit
Good
Fuel Work- Auto-
Bad
No. Check item Operation of work Unit value for new sured
control ing decel- value
equipment machine value
dial mode eration
1 Engine speed rpm 2,090 2,210 2,090 2,210
Engine oil MAX All levers in neutral MPa 0.34 0.59 0.25
2
pressure {kg/cm2} {3.47 6.02} {2.5}
P OFF
3 Engine speed rpm 1,050 1,150 1,050 1,150
Engine oil MIN All levers in neutral MPa Min. 0.10 0.07
4
pressure {kg/cm2} {Min. 1.0} {0.7}
Good
Fuel Work-
Bad
No. Check item Unit value for new sured
control ing Checking posture, etc. value
machine value
dial mode
1 Boom RAISE Work equipment extended fully sec 3.4 4.1 Max. 4.3
2 Arm IN sec 2.9 3.5 Max. 4.0
Boom top horizontal
3 Arm OUT sec 2.4 3.0 Max. 3.7
Boom top horizontal
4 Bucket CURL sec 2.4 2.9 Max. 3.4
MAX P Arm cylinder retracted fully
Work equipment extended fully Max. 23.3
5 Swing (5 turns) sec 25.3 29.3
Swing right and left Min. 31.3
One side of track LO STD sec Max. 39.6 Max. 45
Travel
6 pushed up and turned
(5 idle turns) HI STD sec Max. 22.0 Max. 25
forward and backward
Fuel Work-
Bad
10 PC130-8
30 Testing and adjusting SEN04116-00
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Checking condition
600K 600K 600K 600K 60K
Good
Bad
No. Checked part Fuel Work-
Pump Pump Pump Pump
control ing Operation of work equipment Control
main 1 main 2 LS 1 LS 2
dial mode
Self pressure A
1 All lever in neutral
reducing valve
B B
2 Main relief valve Arm out relief
C1 C1 C2 C2
3 Unload valve All levers in neutral
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 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}
Standard value
C (Unload pressure) 1.8 3.8 {18 38} 1.8 3.8 {18 38}
D (LS differential pressure when MPa
travel lever is operated half with no {kg/cm2} 2.1 2.3 {21.5 23.5} 2.1 2.3 {21.5 23.5}
load)
E (Swing relief pressure) 28.2 30.2 {288 308} 26.7 30.7 {273 313}
F (Travel relief pressure) 33.8 35.8 {345 365} 32.8 36.8 {335 375}
Checked oil pressure Unit Standard value for new machine Service limit value
Standard value
H1 : H2 = 1 : 0.6
H (Servo control pressure)
(Oil pressure ratio)
PC130-8 11
SEN04116-00 30 Testing and adjusting
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Checking condition
600K 600K 60K 60K 60K
Good
Bad
No. Check item Fuel Work-
F pump R pump F pump R pump
control ing Operation of work equipment LS-EPC
main main (F) (R)
dial mode
J1 J1
MIN
P
J2 J2
J3 J3
8 PC-EPC valve E All levers in neutral
MAX
J4 J4
L
J5 J5
B
Checked oil pressure Unit Standard value for new machine Service limit value
Standard value
12 PC130-8
30 Testing and adjusting SEN04116-00
PC130-8 13
SEN04116-00 30 Testing and adjusting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
14 PC130-8
SEN04117-00
PC130-8
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Fuse locations................................................................................................................................................. 6
PC130-8 1
SEN04117-00 40 Troubleshooting
2 PC130-8
40 Troubleshooting SEN04117-00
PC130-8 3
SEN04117-00 40 Troubleshooting
4 PC130-8
40 Troubleshooting SEN04117-00
PC130-8 5
SEN04117-00 40 Troubleshooting
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
Pump resistor, light switch, swing holding brake release
1 10A
switch
2 30A Pump controller
F04
Switch power supply 3 10A Starting motor cutout relay, PPC oil pressure lock switch
(65A)
Windshield washer, cigar lighter, electrical intake air
4 10A
heater
5 10A Horn
6 10A (Spare)
7 10A Rotary lamp (If equipped)
F04
Switch power supply 8 20A Working lamp relay
(65A)
9 10A Radio, speaker, one-touch power max. switch
10 10A (Spare)
11 20A Air conditioner unit
F04 12 10A (Spare)
Switch power supply
(65A) 13 10A Relay for cab light
14 10A Optional power supply (1)
15 10A Optional power supply (2)
F05 16 10A Radio backup, room lamp
Constant power supply
(30A) 17 20A Machine monitor, pump controller, starting switch (B)
18 10A (Spare)
Starting switch 19 30A Engine controller
Switch power supply
ACC 20 5A Engine controller
6 PC130-8
40 Troubleshooting SEN04117-00
PC130-8 7
SEN04117-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
8 PC130-8
SEN04118-00
PC130-8
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Information in troubleshooting table................................................................................................................ 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
PC130-8 1
SEN04118-00 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting Use the results of the investigation and inspec-
in accordance with the fixed procedure. tion in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is
2) Was there anything strange about the as follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were 2] Start from the most likely points.
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure
occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before Even if the failure is repaired, if the root cause
the failure? When were these repairs car- of the failure is not repaired, the same failure
ried out? will occur again.To prevent this, always investi-
6) Has the same kind of failure occurred gate why the problem occurred. Then, remove
before? the root cause.
2 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 3
SEN04118-00 40 Troubleshooting
4 PC130-8
40 Troubleshooting SEN04118-00
1. Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding "Display of code" according to the displayed failure code.
2. When electrical system error code or mechanical system error code is recorded in abnormality
record:
If a user code and a failure code are not displayed on the machine monitor, check a mechanical system
failure code and an electrical system failure code with the abnormality record function of the machine
monitor.
If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according 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 in E-mode.
3. When user code and failure code is not displayed and no failure code is recorded in abnormality
record:
If a user code and failure code are not displayed on the machine monitor and no failure code is recorded
in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the
electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode".
PC130-8 5
SEN04118-00 40 Troubleshooting
6 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 7
SEN04118-00 40 Troubleshooting
8 PC130-8
40 Troubleshooting SEN04118-00
Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
34 Hydraulic drift of work equipment is large H-10
35 Time lag of work equipment is large H-11
36 Power maximizing function does not operate normally E-20 H-12
Flow rate in attachment circuit cannot be adjusted (when attachment is
37 H-27
installed)
Phenomena related to compound operation
38 Work equipment loaded more is slower during compound operation H-13
Boom RAISE speed is low in compound operation of swing + boom
39 H-14
RAISE
Travel speed lowers largely during compound operation of work
40 H-15
equipment/swing + travel
Phenomena related to travel
41 Machine deviates during travel H-16
42 Travel speed is low H-17
43 Machine cannot be steered easily or steering power is low H-18
44 Travel speed does not change or it is kept low or high E-17 H-19
45 Track does not move (Only either side) H-20
46 Travel alarm does not sound or does not stop sounding E-22
Phenomena related to swing
47 Machine does not swing H-21
48 Swing acceleration or swing speed is low H-22
49 Excessive overrun when stopping swing H-23
50 When upper structure stops swinging, it makes large shock H-24
51 When upper structure stops swinging, it makes large sound H-25
Swing holding brake does not operate normally
52 E-21 H-26
Hydraulic drift of swing is large
Phenomena related to machine monitor
53 When starting switch turned ON, machine monitor displays nothing E-1
When starting switch turned ON (before starting engine), basic check
54 E-2
item lights up
55 Precaution lights up while engine is running E-7
56 Emergency stop item lights up while engine is running E-8
57 Engine coolant temperature gauge does not indicate normally E-9
58 Hydraulic oil temperature gauge does not indicate normally E-10
59 Fuel level gauge does not indicate normally E-11
Contents of display by machine monitor are different from applicable
60 E-12
machine
61 Machine monitor does not display some items E-13
62 Function switch does not work E-14
63 Alarm buzzer cannot be stopped E-18
64 Windshield wiper and window washer do not operate E-19
Air conditioner does not operate normally (including air conditioner
65 E-23
abnormality record)
66 While starting switch is in OFF position, service meter is not displayed E-24
67 Machine monitor cannot be set in service mode E-25
PC130-8 9
SEN04118-00 40 Troubleshooting
Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
68 Monitoring function does not display lever control signal normally E-26
Other phenomena
69 KOMTRAX system does not operate normally E-27
10 PC130-8
40 Troubleshooting SEN04118-00
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
PC130-8 11
SEN04118-00 40 Troubleshooting
12 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 13
SEN04118-00 40 Troubleshooting
14 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 15
SEN04118-00 40 Troubleshooting
16 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 17
SEN04118-00 40 Troubleshooting
18 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 19
SEN04118-00 40 Troubleshooting
20 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 21
SEN04118-00 40 Troubleshooting
22 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 23
SEN04118-00 40 Troubleshooting
24 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 25
SEN04118-00 40 Troubleshooting
26 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 27
SEN04118-00 40 Troubleshooting
28 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 29
SEN04118-00 40 Troubleshooting
30 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 31
SEN04118-00 40 Troubleshooting
32 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 33
SEN04118-00 40 Troubleshooting
34 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 35
SEN04118-00 40 Troubleshooting
36 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 37
SEN04118-00 40 Troubleshooting
38 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 39
SEN04118-00 40 Troubleshooting
40 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 41
SEN04118-00 40 Troubleshooting
42 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 43
SEN04118-00 40 Troubleshooting
44 PC130-8
40 Troubleshooting SEN04118-00
PC130-8 45
SEN04118-00 40 Troubleshooting
46 PC130-8
40 Troubleshooting SEN04118-00
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
PC130-8 47
SEN04118-00 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
48 PC130-8
40 Troubleshooting SEN04118-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
PC130-8 49
SEN04118-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
50 PC130-8
SEN04119-00
PC130-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 1
Failure code [989L00] Engine controller lock caution 1 .................................................................................. 3
Failure code [989M00] Engine controller lock caution 2 ................................................................................. 3
Failure code [989N00] Engine controller lock caution 3.................................................................................. 4
Failure code [AA10NX] Air cleaner clogging................................................................................................... 5
Failure code [AB00KE] Charge voltage low.................................................................................................... 6
Failure code [B@BAZG] Eng oil press. low .................................................................................................... 8
Failure code [B@BAZK] Eng oil level low ....................................................................................................... 9
Failure code [B@BCNS] Eng coolant overheat ............................................................................................ 10
Failure code [B@BCZK] Eng water level low................................................................................................ 12
Failure code [B@HANS] Hydr oil overheat ................................................................................................... 14
Failure code [CA111] ECM critical internal failure ......................................................................................... 16
Failure code [CA115] Eng Ne and Bkup speed sensor error ........................................................................ 19
Failure code [CA122] Charge air press sensor high error ............................................................................ 20
Failure code [CA123] Charge air press sensor low error.............................................................................. 22
Failure code [CA131] Throttle sensor high error........................................................................................... 24
Failure code [CA132] Throttle sensor low error ............................................................................................ 26
PC130-8 1
SEN04119-00 40 Troubleshooting
2 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 3
SEN04119-00 40 Troubleshooting
4 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 5
SEN04119-00 40 Troubleshooting
6 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 7
SEN04119-00 40 Troubleshooting
8 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 9
SEN04119-00 40 Troubleshooting
10 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 11
SEN04119-00 40 Troubleshooting
12 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 13
SEN04119-00 40 Troubleshooting
14 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 15
SEN04119-00 40 Troubleshooting
16 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 17
SEN04119-00 40 Troubleshooting
18 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 19
SEN04119-00 40 Troubleshooting
20 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 21
SEN04119-00 40 Troubleshooting
22 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 23
SEN04119-00 40 Troubleshooting
24 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 25
SEN04119-00 40 Troubleshooting
26 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 27
SEN04119-00 40 Troubleshooting
28 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 29
SEN04119-00 40 Troubleshooting
30 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 31
SEN04119-00 40 Troubleshooting
32 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 33
SEN04119-00 40 Troubleshooting
34 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 35
SEN04119-00 40 Troubleshooting
36 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 37
SEN04119-00 40 Troubleshooting
38 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 39
SEN04119-00 40 Troubleshooting
40 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 41
SEN04119-00 40 Troubleshooting
42 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 43
SEN04119-00 40 Troubleshooting
44 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 45
SEN04119-00 40 Troubleshooting
46 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 47
SEN04119-00 40 Troubleshooting
48 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 49
SEN04119-00 40 Troubleshooting
50 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 51
SEN04119-00 40 Troubleshooting
52 PC130-8
40 Troubleshooting SEN04119-00
PC130-8 53
SEN04119-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
54 PC130-8
SEN04120-00
PC130-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 2
Failure code [CA342] Calibration code incompatibility.................................................................................... 3
Failure code [CA351] Inj. drive circuit error..................................................................................................... 4
Failure code [CA352] Sensor sup. 1 volt. low error ........................................................................................ 7
Failure code [CA386] Sensor sup. 1 volt. high error ....................................................................................... 8
Failure code [CA435] Abnormality in engine oil pressure switch .................................................................. 10
Failure code [CA441] Battery voltage low error .............................................................................................11
Failure code [CA442] Battery voltage high error ........................................................................................... 12
Failure code [CA449] Rail press. very high error .......................................................................................... 13
Failure code [CA451] Rail press. sensor high error ...................................................................................... 14
Failure code [CA452] Rail press. sensor low error ....................................................................................... 16
Failure code [CA488] Chg air temp high torque derate ................................................................................ 17
Failure code [CA553] Rail press. high error.................................................................................................. 18
Failure code [CA559] Rail press. low error ................................................................................................... 19
Failure code [CA689] Eng. Ne speed sensor error ....................................................................................... 22
Failure code [CA731] Eng. Bkup speed sensor phase error......................................................................... 24
Failure code [CA757] All persistent data lost error ....................................................................................... 25
PC130-8 1
SEN04120-00 40 Troubleshooting
2 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 3
SEN04120-00 40 Troubleshooting
4 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 5
SEN04120-00 40 Troubleshooting
6 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 7
SEN04120-00 40 Troubleshooting
8 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 9
SEN04120-00 40 Troubleshooting
10 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 11
SEN04120-00 40 Troubleshooting
12 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 13
SEN04120-00 40 Troubleshooting
14 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 15
SEN04120-00 40 Troubleshooting
16 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 17
SEN04120-00 40 Troubleshooting
18 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 19
SEN04120-00 40 Troubleshooting
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm 1,100 50
*1 Engine speed High idle rpm 2,300 60
Equivalent to rating rpm 2,200
Low idle % 0
*2 Throttle opening degree
High idle % 100
*3 Fuel injection command Equivalent to rating mm3
20 PC130-8
40 Troubleshooting SEN04120-00
*1 *10:
See Testing and adjusting, "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
PC130-8 21
SEN04120-00 40 Troubleshooting
Related
Method of reproducing failure code: Start engine.
information
22 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 23
SEN04120-00 40 Troubleshooting
Related
Method of reproducing failure code: Start engine.
information
24 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 25
SEN04120-00 40 Troubleshooting
Related
Method of reproducing failure code: Start engine.
information
26 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 27
SEN04120-00 40 Troubleshooting
28 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 29
SEN04120-00 40 Troubleshooting
30 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 31
SEN04120-00 40 Troubleshooting
32 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 33
SEN04120-00 40 Troubleshooting
34 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 35
SEN04120-00 40 Troubleshooting
36 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 37
SEN04120-00 40 Troubleshooting
Configuration drawing
38 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 39
SEN04120-00 40 Troubleshooting
40 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 41
SEN04120-00 40 Troubleshooting
42 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 43
SEN04120-00 40 Troubleshooting
44 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 45
SEN04120-00 40 Troubleshooting
46 PC130-8
40 Troubleshooting SEN04120-00
PC130-8 47
SEN04120-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
48 PC130-8
SEN04121-00
PC130-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 3
Failure code [DA2RMC] CAN discon (Pump controller detected)................................................................... 4
Failure code [DAF8KB] Short circuit in camera power supply ........................................................................ 6
Failure code [DAFGMC] GPS module error.................................................................................................... 8
Failure code [DAFRMC] CAN discon (Monitor detected).............................................................................. 10
Failure code [DGH2KB] Hydr oil sensor short .............................................................................................. 12
Failure code [DHPAMA] Pump press sensor abnormality............................................................................. 14
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality ................................................. 16
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality .............................................. 18
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality ................................................ 20
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................................... 22
Failure code [DHX1MA] Overload sensor abnormality (Analog)................................................................... 24
Failure code [DV20KB] Travel alarm short circuit ......................................................................................... 25
Failure code [DW43KA] Travel speed sol discon.......................................................................................... 26
Failure code [DW43KB] Travel speed sol short ............................................................................................ 27
Failure code [DW45KA] Swing brake sol discon........................................................................................... 28
Failure code [DW45KB] Swing brake sol short ............................................................................................. 30
PC130-8 1
SEN04121-00 40 Troubleshooting
2 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 3
SEN04121-00 40 Troubleshooting
4 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 5
SEN04121-00 40 Troubleshooting
6 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 7
SEN04121-00 40 Troubleshooting
8 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 9
SEN04121-00 40 Troubleshooting
10 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 11
SEN04121-00 40 Troubleshooting
12 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 13
SEN04121-00 40 Troubleshooting
14 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 15
SEN04121-00 40 Troubleshooting
16 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 17
SEN04121-00 40 Troubleshooting
18 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 19
SEN04121-00 40 Troubleshooting
20 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 21
SEN04121-00 40 Troubleshooting
22 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 23
SEN04121-00 40 Troubleshooting
24 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 25
SEN04121-00 40 Troubleshooting
26 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 27
SEN04121-00 40 Troubleshooting
28 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 29
SEN04121-00 40 Troubleshooting
30 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 31
SEN04121-00 40 Troubleshooting
32 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 33
SEN04121-00 40 Troubleshooting
34 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 35
SEN04121-00 40 Troubleshooting
36 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 37
SEN04121-00 40 Troubleshooting
38 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 39
SEN04121-00 40 Troubleshooting
40 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 41
SEN04121-00 40 Troubleshooting
42 PC130-8
40 Troubleshooting SEN04121-00
PC130-8 43
SEN04121-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
44 PC130-8
SEN04122-00
PC130-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 4
Failure code [DXA8KA] PC-EPC sol discon ................................................................................................... 2
Failure code [DXA8KB] PC-EPC sol short...................................................................................................... 4
Failure code [DXE4KA] Service current EPC discon ...................................................................................... 6
Failure code [DXE4KB] Service current EPC short ........................................................................................ 8
Failure code [DY20KA] Wiper working abnormality ...................................................................................... 10
Failure code [DY20MA] Wiper parking abnormality ...................................................................................... 12
Failure code [DY2CKA] Washer drive discon ............................................................................................... 14
Failure code [DY2CKB] Washer drive short.................................................................................................. 16
Failure code [DY2DKB] Wiper drive (for) short ............................................................................................. 18
Failure code [DY2EKB] Wiper drive (rev) short ............................................................................................ 20
PC130-8 1
SEN04122-00 40 Troubleshooting
2 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 3
SEN04122-00 40 Troubleshooting
4 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 5
SEN04122-00 40 Troubleshooting
6 PC130-8
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PC130-8 7
SEN04122-00 40 Troubleshooting
8 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 9
SEN04122-00 40 Troubleshooting
10 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 11
SEN04122-00 40 Troubleshooting
12 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 13
SEN04122-00 40 Troubleshooting
14 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 15
SEN04122-00 40 Troubleshooting
16 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 17
SEN04122-00 40 Troubleshooting
18 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 19
SEN04122-00 40 Troubleshooting
20 PC130-8
40 Troubleshooting SEN04122-00
PC130-8 21
SEN04122-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
22 PC130-8
SEN04123-00
PC130-8
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 3
Information in troubleshooting table................................................................................................................ 5
E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 6
E-2 When starting switch turned ON (before starting engine), basic check item lights up.............................. 8
E-3 Engine does not start (Engine does not turn) ..........................................................................................11
E-4 Preheater does not operate.................................................................................................................... 14
E-5 Automatic warm-up system does not operate (in cold season).............................................................. 16
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ........................... 18
E-7 Precaution lights up while engine is running .......................................................................................... 20
E-8 Emergency stop item lights up while engine is running.......................................................................... 25
E-9 Engine coolant temperature gauge does not indicate normally ............................................................. 26
E-10 Hydraulic oil temperature gauge does not indicate normally................................................................ 27
E-11 Fuel level gauge does not indicate normally ........................................................................................ 29
E-12 Contents of display by machine monitor are different from applicable machine .................................. 31
PC130-8 1
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2 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 3
SEN04123-00 40 Troubleshooting
4 PC130-8
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PC130-8 5
SEN04123-00 40 Troubleshooting
E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble When starting switch turned ON, machine monitor displays nothing.
When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen to check breaker mode (if set), screen of check before starting, screen to check
Related infor-
working mode and travel speed, and ordinary screen in order.
mation
When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery.
6 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 7
SEN04123-00 40 Troubleshooting
8 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 9
SEN04123-00 40 Troubleshooting
10 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 11
SEN04123-00 40 Troubleshooting
12 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 13
SEN04123-00 40 Troubleshooting
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related Check that engine can be turned with starting motor (If engine cannot be turned, carry out trouble-
information shooting for E-1 Engine does not start (Engine does not turn)).
14 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 15
SEN04123-00 40 Troubleshooting
E-5 Automatic warm-up system does not operate (in cold season) 1
Trouble Automatic warm-up system does not operate (in cold season).
Related When engine coolant temperature is below 50C automatic warm-up system raises engine low idle
information speed to 1,300 rpm.
16 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 17
SEN04123-00 40 Troubleshooting
E-6 All work equipment, swing, and travel mechanism do not move or
cannot be locked 1
Trouble (1) All work equipment, swing, and travel mechanism do not move.
Related
information
18 PC130-8
40 Troubleshooting SEN04123-00
Trouble (2) All work equipment, swing, and travel mechanism cannot be locked.
Related
information
PC130-8 19
SEN04123-00 40 Troubleshooting
20 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 21
SEN04123-00 40 Troubleshooting
22 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 23
SEN04123-00 40 Troubleshooting
24 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 25
SEN04123-00 40 Troubleshooting
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.
Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
26 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 27
SEN04123-00 40 Troubleshooting
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to
Related machine monitor through communication system.
information Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)
28 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 29
SEN04123-00 40 Troubleshooting
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel level sensor voltage)
30 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 31
SEN04123-00 40 Troubleshooting
32 PC130-8
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Trouble (2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related
information
PC130-8 33
SEN04123-00 40 Troubleshooting
Trouble (2) When travel speed is shifted, actual travel speed does not change.
Related
If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo.
information
34 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 35
SEN04123-00 40 Troubleshooting
Trouble (2) When wiper switch is operated, wiper does not operate.
Related Condition of window rear limit switch signal can be checked with monitoring function.
information (Code: 02204 Switch input 5)
36 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 37
SEN04123-00 40 Troubleshooting
Trouble (3) When window washer switch is operated, window washer does not operate.
Related Condition of window washer switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
38 PC130-8
40 Troubleshooting SEN04123-00
PC130-8 39
SEN04123-00 40 Troubleshooting
40 PC130-8
40 Troubleshooting SEN04123-00
Trouble (3) When left knob switch is released, work equipment power does not return to normal level.
Related infor- Condition of left knob switch signal can be checked with monitoring function.
mation (Code: 02200 Switch input 1)
PC130-8 41
SEN04123-00 40 Troubleshooting
(2) When swing lock switch is turned ON, swing lock does not operate. (Hydraulic drift of swing occurs
Trouble
on slope.)
Related
information
42 PC130-8
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PC130-8 43
SEN04123-00 40 Troubleshooting
E-22 Travel alarm does not sound or does not stop sounding 1
Alarm does not sound during travel.
Trouble
Alarm does not stop sounding while machine is stopped.
Related
information
44 PC130-8
40 Troubleshooting SEN04123-00
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information
PC130-8 45
SEN04123-00 40 Troubleshooting
Trouble (3) Air does not come out (Air flow is insufficient).
Related
information
46 PC130-8
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PC130-8 47
SEN04123-00 40 Troubleshooting
48 PC130-8
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(5) Air conditioner abnormality record: Communication condition CAN disconnection, Communica-
Trouble
tion condition Abnormal
While abnormality in communication is being detected, CAN disconnection is displayed.
If abnormality in communication has been detected and reset, Abnormality is displayed.
Related
If CAN disconnection is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, condition of other items is not displayed.
Method of reproducing abnormality record: Turn starting switch ON.
PC130-8 49
SEN04123-00 40 Troubleshooting
Trouble (7) Air conditioner abnormality record: Internal air sensor Abnormality
If CAN disconnection is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
50 PC130-8
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Trouble (8) Air conditioner abnormality record: External air sensor Unused
External air sensor is not used in air conditioner system of this machine.
Related
If CAN disconnection is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, this condition is not displayed.
Trouble (9) Air conditioner abnormality record: Air flow sensor Abnormality
If CAN disconnection is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
PC130-8 51
SEN04123-00 40 Troubleshooting
52 PC130-8
40 Troubleshooting SEN04123-00
Trouble (11) Air conditioner abnormality record: Air outlet damper Abnormality
If CAN disconnection is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
PC130-8 53
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54 PC130-8
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PC130-8 55
SEN04123-00 40 Troubleshooting
56 PC130-8
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PC130-8 57
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E-26 Monitoring function does not display lever control signal normally 1
Trouble (1) Boom raise operation is not displayed normally by monitoring function.
Related
Monitoring code: 01900 Pressure switch 1
information
58 PC130-8
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PC130-8 59
SEN04123-00 40 Troubleshooting
Trouble (2) Boom lower operation is not displayed normally by monitoring function.
Related
Monitoring code: 01900 Pressure switch 1
information
60 PC130-8
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PC130-8 61
SEN04123-00 40 Troubleshooting
Trouble (3) Arm curl operation is not displayed normally by monitoring function.
Related
Monitoring code: 01900 Pressure switch 1
information
62 PC130-8
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PC130-8 63
SEN04123-00 40 Troubleshooting
Trouble (4) Arm out operation is not displayed normally by monitoring function.
Related
Monitoring code: 01900 Pressure switch 1
information
64 PC130-8
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PC130-8 65
SEN04123-00 40 Troubleshooting
Trouble (5) Bucket curl operation is not displayed normally by monitoring function.
Related
Monitoring code: 01901 Pressure switch 2
information
66 PC130-8
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PC130-8 67
SEN04123-00 40 Troubleshooting
Trouble (6) Bucket dump operation is not displayed normally by monitoring function.
Related
Monitoring code: 01901 Pressure switch 2
information
68 PC130-8
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PC130-8 69
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70 PC130-8
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PC130-8 71
SEN04123-00 40 Troubleshooting
72 PC130-8
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PC130-8 73
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a Select Terminal Status from 12 Display of a Select GPS & Communication Status from
KOMTRAX setting in the service menu of the 12 Display of KOMTRAX setting in the ser-
machine monitor. vice menu of the machine monitor.
74 PC130-8
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PC130-8 75
SEN04123-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
76 PC130-8
SEN04124-00
PC130-8
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Information contained in troubleshooting table ............................................................................................... 3
System chart for hydraulic and mechanical systems ...................................................................................... 4
H-1 Speed or power of all work equipment, swing, and travel are low ........................................................... 6
H-2 Engine speed sharply drops or engine stalls............................................................................................ 7
H-3 No work equipment, travel and swing move ............................................................................................ 8
H-4 Abnormal noise is heard from around hydraulic pump............................................................................. 8
H-5 Fine control mode does not function ........................................................................................................ 9
H-6 Speed or power of boom is low .............................................................................................................. 10
H-7 Speed or power of arm is low..................................................................................................................11
H-8 Speed or power of bucket is low ............................................................................................................ 12
H-9 Work equipment does not move in its single operation.......................................................................... 13
H-10 Hydraulic drift of work equipment is large ............................................................................................ 14
H-11 Time lag of work equipment is large..................................................................................................... 15
H-12 Power maximizing function does not operate normally........................................................................ 15
PC130-8 1
SEN04124-00 40 Troubleshooting
H-13 Work equipment loaded more is slower during compound operation .................................................. 16
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE....................................... 16
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel ............... 17
H-16 Machine deviates during travel............................................................................................................. 18
H-17 Travel speed is low............................................................................................................................... 19
H-18 Machine cannot be steered easily or steering power is low ................................................................. 20
H-19 Travel speed does not change or it is kept low or high ........................................................................ 21
H-20 Track does not move (Only either side)................................................................................................ 21
H-21 Machine does not swing....................................................................................................................... 22
H-22 Swing acceleration or swing speed is low ............................................................................................ 23
H-23 Excessive overrun when stopping swing.............................................................................................. 24
H-24 When upper structure stops swinging, it makes large shock ............................................................... 25
H-25 When upper structure stops swinging, it makes large sound ............................................................... 25
H-26 Hydraulic drift of swing is large............................................................................................................. 26
H-27 Flow rate in attachment circuit cannot be adjusted .............................................................................. 27
2 PC130-8
40 Troubleshooting SEN04124-00
2
Possible causes Cause for presumed
and standard failure <Contents>
value in normal (The attached No. for The standard values in normalcy by which to judge "good"
3
state filing and reference or "no good" about presumed causes.
purpose only. It does not References for making judgement of "good" or "no good"
stand for any priority)
4
PC130-8 3
SEN04124-00 40 Troubleshooting
4 PC130-8
40 Troubleshooting SEN04124-00
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as
a reference material when troubleshooting the hydraulic and mechanical systems.
PC130-8 5
SEN04124-00 40 Troubleshooting
H-1 Speed or power of all work equipment, swing, and travel are low 1
Trouble Speed or power of all work equipment, swing, and travel are low.
Related
Conduct the troubleshooting in working mode P.
information
6 PC130-8
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PC130-8 7
SEN04124-00 40 Troubleshooting
8 PC130-8
40 Troubleshooting SEN04124-00
PC130-8 9
SEN04124-00 40 Troubleshooting
10 PC130-8
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PC130-8 11
SEN04124-00 40 Troubleshooting
12 PC130-8
40 Troubleshooting SEN04124-00
PC130-8 13
SEN04124-00 40 Troubleshooting
Trouble Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large.
Related
Conduct the troubleshooting in working mode P.
information
Trouble Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large.
Related
Conduct the troubleshooting in working mode P.
information
14 PC130-8
40 Troubleshooting SEN04124-00
PC130-8 15
SEN04124-00 40 Troubleshooting
16 PC130-8
40 Troubleshooting SEN04124-00
PC130-8 17
SEN04124-00 40 Troubleshooting
18 PC130-8
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PC130-8 19
SEN04124-00 40 Troubleshooting
20 PC130-8
40 Troubleshooting SEN04124-00
PC130-8 21
SEN04124-00 40 Troubleshooting
Trouble Machine does not swing. (2) Machine does not swing in only one direction.
Related
Conduct the troubleshooting in working mode P.
information
22 PC130-8
40 Troubleshooting SEN04124-00
Defective sealing of swing Sealing of the suction valve of the swing motor may be defective.
4
motor (suction valve) Check it directly.
Malfunction of swing motor Sealing of the reverse prevention valve of the swing motor may be
5
(reverse prevention valve) defective. Check it directly.
PC130-8 23
SEN04124-00 40 Troubleshooting
Defective sealing of swing Sealing of the suction valve of the swing motor may be defective.
5
motor (suction valve) Check it directly.
Malfunction of swing motor Sealing of the reverse prevention valve of the swing motor may be
6
(reverse prevention valve) defective. Check it directly.
24 PC130-8
40 Troubleshooting SEN04124-00
PC130-8 25
SEN04124-00 40 Troubleshooting
Trouble Hydraulic drift of swing is large. (2) When swing holding brake is released
If the swing holding brake release is in the emergency position, the swing holding brake is released
Related
and the upper structure is held with only hydraulic pressure.
information
Conduct the troubleshooting in working mode P.
26 PC130-8
40 Troubleshooting SEN04124-00
PC130-8 27
SEN04124-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
28 PC130-8
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PC130-8
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 4
S-1 Starting performance is poor .................................................................................................................... 8
S-2 Engine does not start ............................................................................................................................... 9
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operations .............................................................................................................. 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17
S-9 Oil becomes contaminated quickly ......................................................................................................... 18
S-10 Fuel consumption is excessive............................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20
S-12 Oil pressure drops ................................................................................................................................ 21
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 23
PC130-8 1
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2 PC130-8
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PC130-8 3
SEN04125-00 40 Troubleshooting
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 PC130-8
40 Troubleshooting SEN04125-00
PC130-8 5
SEN04125-00 40 Troubleshooting
6 PC130-8
40 Troubleshooting SEN04125-00
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in
the [Causes] section.
The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is
explained according to Step 1 Step 3 shown below.
PC130-8 7
SEN04125-00 40 Troubleshooting
Defective injector
nomenon does not indicate a trouble, however.
Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated q
by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
8 PC130-8
40 Troubleshooting SEN04125-00
on E-mode
When terminal B and terminal C of starting switch are connected, q
engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are
connect cord, and carry out q
connected, engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are
connected, engine does not start q
Replace
Replace
Replace
Replace
Correct
Remedy
PC130-8 9
SEN04125-00 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
10 PC130-8
40 Troubleshooting SEN04125-00
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
PC130-8 11
SEN04125-00 40 Troubleshooting
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
12 PC130-8
40 Troubleshooting SEN04125-00
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Add
Remedy
PC130-8 13
SEN04125-00 40 Troubleshooting
Remedy
14 PC130-8
40 Troubleshooting SEN04125-00
(air leakage)
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Suddenly Q w Q Q Q Q
Questions
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy
PC130-8 15
SEN04125-00 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
16 PC130-8
40 Troubleshooting SEN04125-00
Turbocharger
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC130-8 17
SEN04125-00 40 Troubleshooting
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
18 PC130-8
40 Troubleshooting SEN04125-00
Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) indicated
q
by code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
PC130-8 19
SEN04125-00 40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Suddenly rose Q Q
Oil level
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
Replace
Replace
Replace
Replace
Remedy
20 PC130-8
40 Troubleshooting SEN04125-00
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Add
Remedy
PC130-8 21
SEN04125-00 40 Troubleshooting
Remedy
22 PC130-8
40 Troubleshooting SEN04125-00
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q w w Q
Rises quickly Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When 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
Check items
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 belt whines under sudden acceleration w
Hydraulic oil temperature enters red range faster than engine coolant
temperature w
on H-mode
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
PC130-8 23
SEN04125-00 40 Troubleshooting
Gradually occurred Q Q
Condition of abnormal noise
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
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
When exhaust manifold is touched immediately after starting engine, temperature of
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
24 PC130-8
40 Troubleshooting SEN04125-00
Suddenly increased Q Q
Condition of vibration
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
Oil pressure is low at low idle Q Q
Check items
Replace
Replace
Replace
Remedy
PC130-8 25
SEN04125-00 40 Troubleshooting
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
26 PC130-8
SEN04126-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04126-00 50 Disassembly and assembly
1) Necessity of work.
t : Special tools that cannot be substi- a: This mark gives guidance or precautions when
tuted and should always be used doing the procedure.
(installed). [*1] : This mark shows that there are instructions or
q : Special tools that will be useful if avail- precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a Installation
new part number. q Except where otherwise instructed, installation
R: Tools with upgraded part numbers. of parts is done in the reverse order of removal.
They are remodeled from already q Instructions and precautions for installing parts
available tools for other models. are shown with [*1] mark in the "Removal" sec-
Blank: Tools already available for other tion, identifying which step the instructions are
models. They can be used without intended for.
any modification. q Marks shown in the "Installation" section stand
3) Circle mark Q in sketch column: for the following.
q The sketch of the special tool is pre- k : Precautions related to safety in execution
sented in the section of "Sketches of of work.
special tools". a: This mark gives guidance or precautions when
q Part No. of special tools starting with doing the procedure.
2 : Type of coating material
* *** ****
79 T- - :
means that they can not be supplied 3 : Tightening torque
5
from Komatsu in Japan (i.e. locally : Quantity of oil or coolant to be added
made parts ).
Sketches of special tools
a General tools that are necessary for
q Various special tools are illustrated for the con-
removal or installation are described as
venience of local manufacture.
[1], [2]etc. and their part names, part
numbers and quantities are not described.
2 PC130-8
50 Disassembly and assembly SEN04126-00
PC130-8 3
SEN04126-00 50 Disassembly and assembly
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube Heat-resistant seal used to repair engines.
Quick-setting adhesive.
ThreeBond Polyethylene Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
Used mainly to stick rubbers, plastics, and
metals.
Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc Used for fitted portions used at high tempera-
648-50 container
tures.
Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
Used to seal transfer case, etc.
4 PC130-8
50 Disassembly and assembly SEN04126-00
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
Can be coated with paint.
Gasket sealant
LC-G
Can Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
PC130-8 5
SEN04126-00 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
facture)
SUNSTAR Ecocart Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 PC130-8
50 Disassembly and assembly SEN04126-00
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Qty
790-101-5201 Push tool (Kit) t 1
790-101-5271 Plate 1
Engine front oil seal 1 Instllation front oil seal
790-101-5221 Grip 1
01010-51225 Bolt 1
Engine rear oil seal A 2 795-931-1100 Seal puller assembly q 1 Removal rear oil seal
790-101-5401 Push tool (Kit) t 1
790-101-5431 Plate 1
Engine rear oil seal 3 Instllation rear oil seal
790-101-5421 Grip 1
01010-51240 Bolt 1
796-460-1210 Oil stopper q 1 Stop oil supply from hydraulic
Hydraulic oil tank D
795-799-1131 Adapter q 1 tank
790-101-4200 Puller q 1
(294 kN {30 ton})
Swing machinery F 790-101-1102 Hydraulic oil pump q 1
790-101-5401 Push tool (Kit) (C) q 1 Instllation Bearing outer race
790-101-5461 Plate 1 For main bearing
3 790-101-5441 Plate 1 For sub bearing
790-101-5421 Grip 1
01010-51240 Bolt 1
4 790-201-2850 Spacer t 1
Instllation Bearing inner race
5 790-201-2750 Spacer t 1
796T-426-1140 Push tool t 1 Q
6 Instllation oil seal
790-201-2680 Plate q 1
PC130-8 7
SEN04126-00 50 Disassembly and assembly
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Qty
1 791-675-1510 Installer t 1 Application of floating seal
791-600-2001 Compressor (A) 1
or t
791-685-8006 Compressor (B) 1
791-635-3160 Extension t 1
2 790-201-2770 t 1 Compression of spring
Spacer
Cylinder
790-101-1600 (686 kN {70 ton}) t 1
790-101-1102 Pump t 1
Disassembly, assembly 790-201-1500 Push tool (Kit) q 1
of idler recoil spring L
790-201-1590 Plate 1
3 (Periphery 74) Press fit of piston dust seal
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1702 Push tool kit t 1
790-201-1781 Push tool 1
4 Press fit of bushing
790-101-5021 Grip 1
01010-50816 Bolt 1
1 796T-430-1210 Push tool t 1 N Q Installation of floating seal 88
Disassembly, assembly M 2 796T-430-1220 Installer t 1 N Q Filling oil and checking of air
of track roller
3 791-601-1000 Oil pump q 1 leak
Remover and
791-620-3000 installer t 1
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
Expansion, installation
of track shoe R Removal and pressfit of mas-
791-635-3180 Screw 1 ter pin
791-635-3190 Screw (for fixation) 1
791-635-3210 Pilot 1
791-630-3220 Adapter 1
791-620-3260 Pin pusher 1
796T-432-1010 Guide t 1 N Q
790-101-1300 Cylinder
or (980 kN {100 ton}) t 1
Cylinder
790-101-1600 (686 kN {70 ton})
790-101-1102 Pump t 1
790-101-2501 Push puller q 1
Disassembly of center 790-101-2510 1 Disconnection of rotor from
swivel joint T 1 Block shaft
790-101-2520 Screw 1
8 PC130-8
50 Disassembly and assembly SEN04126-00
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Qty
790-101-2540 Washer 1
791-112-1180 Nut 1
790-101-2630 Leg 2 Disconnection of rotor from
1 shaft
790-101-2570 Washer 4
790-101-2560 Nut 2
Disassembly of center
swivel joint T 791-112-2650 2
Adapter
Installation of bushing (inside)
2 796T-416-1010 Push tool t 1 N Q of travel PPC valve
01010-50816 Bolt 1
790-201-1702 Push tool (Kit) t 1
790-201-1811 Push tool 1 Press fit of boom cylinder roll
3 bushings
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1702 Push tool (Kit) t 1
790-201-1821 Push tool 1 Press fit of arm and blade cyl-
Disassembly, assembly 790-101-5021 Grip 1 inder roll bushings
of hydraulic cylinder U
01010-50816 Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1610 Push tool 1 Press fit of bucket cylinder
790-101-5021 Grip 1 dust seal
01010-50816 Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1620 Push tool 1 Application of boom cylinder
4
790-101-5021 Grip 1 dust seal
01010-50816 Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1630 Push tool 1 Application of arm and blade
790-101-5021 Grip 1 cylinder bushing
01010-50816 Bolt 1
5 790-720-1000 Expander t 1 Extension of piston ring
PC130-8 9
SEN04126-00 50 Disassembly and assembly
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Qty
796-720-1660 Ring t 1 Bucket cylin-
Disassembly, assembly der Removal,
of hydraulic cylinder U 6 Arm, boom, installation of
07281-01159 Clamp t 1 blade cylinder piston ring
792-785-1100 Remover t 1
792-785-1110 Sleeve 1
792-785-1120 Plate 1
792-900-1530 Screw 1
Removal, installation,
of work equipment and V 1 01803-13034 Nut 1 Removal of boom foot pin
boom 01643-33080 Washer 1
796-270-1110 Adapter 1
Puller
790-101-4000 (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
1 793-498-1210 Lifter (Suction cup) t 2 Removal and installation of
Operators cab glass X operator's cab glass (stuck
(stuck glass) 2 20Y-54-13180 Adapter t 2 glass)
10 PC130-8
50 Disassembly and assembly SEN04126-00
F6 Push tool
M1 Push tool
PC130-8 11
SEN04126-00 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
M2 Installer
R Guide
12 PC130-8
50 Disassembly and assembly SEN04126-00
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
T2 Push tool
T3 Push tool
PC130-8 13
SEN04126-00 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
T4 Push tool
14 PC130-8
50 Disassembly and assembly SEN04126-00
PC130-8 15
SEN04126-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
16 PC130-8
SEN04127-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04127-00 50 Disassembly and assembly
10. Remove joint bolts (14), (15) and (16) and fuel
tubes (17) and (18). [*3]
a Joint bolt (16) is fixing fuel tube (18) to
under supply pump (25).
2 PC130-8
50 Disassembly and assembly SEN04127-00
11. Removal of supply pump and pump holder 12. Remove the supply pump assembly from the
assembly pump holder according to the following proce-
1) Remove 4 mounting bolts (19) from the dure.
gear case side. 1) Loosen nut (22) and pull out supply pump
2) Fully loosen mounting bolts (20) on the gear (23) with gear puller [1] [*5]
pump holder side. [*4] a Fully loosen the nut and keep it
a Mounting bolts (20) cannot be installed to the shaft until the supply
removed from between the supply pump gear is pulled out.
pump and pump holder at this time.
3) Remove supply pump and pump holder
assembly (21).
PC130-8 3
SEN04127-00 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
a Set the boot slit facing outward and downward.
a The boot is designed with fire safety to prevent
fuel from splashing onto the hot engine if fuel
leaks.
[*2]
k Never bend a high-pressure pipe for the
convenience sake.
k The clamp 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 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 the tip).
[*3]
3 Joint bolts (14) and (15):
24.5 34.3 Nm {2.5 3.51 kgm}
[*4]
a For mounting bolt (20), install M6 bolt with LT-
2A.
[*5]
3 Pump gear mount nut:
65 75 Nm {6.6 7.6 kgm}
4 PC130-8
50 Disassembly and assembly SEN04127-00
PC130-8 5
SEN04127-00 50 Disassembly and assembly
[*2]
k Never bend a high-pressure pipe for the
convenience sake.
k The clamp 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 patchy dents (c) in
the taper seal portion of the connection ( (a)
portion: area 2mm inside the tip).
q No deformation in portion (d) (at the end of the
taper seal portion: 2 mm inside the tip).
[*3]
3 Holder mounting bolt (10):
27 30 Nm {2.8 3.1 kgm}
6 PC130-8
50 Disassembly and assembly SEN04127-00
[*4]
q When reusing injector, always replace Oring
(13) and gasket (14) with new ones.
PC130-8 7
SEN04127-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
790-101-5201 Push tool (kit) t 1
790-101-5271 Plate 1
A 1
790-101-5221 Grip 1
01010-51225 Bolt 1
Removal
1. Remove the engine assembly, referring to
"Removal and installation of engine assembly."
8 PC130-8
50 Disassembly and assembly SEN04127-00
Installation
1. Use tool A1 (outside diameter of 80 mm) to
press front oil seal (9) in gear case (10).
1) Check the crankshaft end corner and the
oil seal lip sliding surface for flaws, burrs,
scars, or rust, before installing the oil seal.
2) Fill about 2 cc of grease to between the oil
seal lips.
2 Front oil seal: grease (G2-LI)
[*1]
Confirm the direction of the fan.
[*2]
2 Speed sensor mounting bolt (5):
7.0 11 Nm {0.7 1.1 kgm}
[*3]
2 Crankshaft pulley mounting bolt (7):
343 402 Nm {35 41 kgm}
PC130-8 9
SEN04127-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
Seal puller assem-
2 795-931-1100 q 1
bly
790-101-5401 Push tool (kit) t 1
A
790-101-5431 Plate 1
3
790-101-5421 Grip 1
01010-51240 Bolt 1
4) Loosen flywheel mounting bolt (4).
k Leave 3 threads or 4 engaged to
prevent the flywheel from suddenly
Removal
k
shooting out in the following pro-
Disconnect the negative () terminal of the
cedure.
battery beforehand.
5) Pull out the flywheel by prying with a bar,
etc.
1. Remove the work equipment pump assembly,
6) Checking that flywheel (3) is manually
referring to "Removal and Installation of Work
removable, remove the flywheel mounting
Equipment Pump Assembly."
bolt (4).
7) Lift flywheel (3) and remove it.
2. Removal of the flywheel
4 Flywheel: 25 kg
1) Remove coupling mounting bolt (1) and
remove coupling (2). [*1]
10 PC130-8
50 Disassembly and assembly SEN04127-00
[*2]
q Tighten the flywheel mounting bolts according
to the following procedure:
1) Apply engine oil EO#30 to the bolt threads.
2 Mounting bolt threads:
Engine oil (EO30)
2) Tighten the bolts in the order of 1 to 6 as
shown in the diagram (CPP14824).
3) Tighten the bolts each in two actions by
applying torque as specified in the order of
item 2) above.
3 Mounting bolt:
Unit: Nm{kgm}
procedure target range
1st time 88.2 {9.0} 58.7 117.7 {6.0 12.0}
2nd time 191.3 {19.5} 186.4 196.2 {19.0 20.0}
PC130-8 11
SEN04127-00 50 Disassembly and assembly
[*3]
q Measuring radial runout of flywheel
1) Install dial gauge [2] to the flywheel hous-
ing.
2) Set the probe of the dial gauge at right
angles to the spigot joint (a) or the outer
periphery of the flywheel.
3) Rotate the crank shaft one full turn and
measure the difference of the maximum
values of runout of the needle.
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
12 PC130-8
50 Disassembly and assembly SEN04127-00
PC130-8 13
SEN04127-00 50 Disassembly and assembly
5. Remove the muffler assembly according to the 8) Lift off muffler assembly (23) and bracket
following procedure. together.
1) Remove bracket assembly (13).
2) Remove bracket (14).
3) Remove 4 upper mounting bolts (15) and
2 partition plate mounting bolts (16) and
remove frame (17) and bracket (18)
together.
4) Remove side covers (19) and (20).
a 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]
14 PC130-8
50 Disassembly and assembly SEN04127-00
PC130-8 15
SEN04127-00 50 Disassembly and assembly
10. Remove the air intake connector and electrical 11. Disconnect injector wiring connectors CN1
intake air heater according to the following pro- CN4 (52) and boost pressure sensor connector
cedure. [*9] PTIM (53).
1) Disconnect electrical intake air heater
cable (43). 12. Disconnect 3 wiring clamps (54).
2) Remove 4 mounting bolts (44) (47) and
air intake connector (48).
a Since oil level gauge (49) is also tight-
ened with bolt (44), bind the discon-
nected oil level gauge with a string,
etc. so that it will not be an obstacle.
a Ground cable (50) is also tightened
with bolt (45).
16 PC130-8
50 Disassembly and assembly SEN04127-00
14. Remove 8 air intake manifold mounting bolts 3) Remove alternator belt (72). [*14]
(63) and air intake manifold (64). [*12] a Bolt (a) is tightening the water pump.
Remove it when removing the water
pump. (See 9).)
PC130-8 17
SEN04127-00 50 Disassembly and assembly
9) Remove 4 water pump mounting bolts 18. Remove the cylinder head assembly according
(82). to the following procedure.
a Among mounting bolts (82), one (a) is 1) Pull out 8 push rods (89).
tightening the alternator mounting 2) Remove 17 cylinder head mounting bolts
bracket, too. (See the figure in step (90). [*19]
3.) [*16]
10) Remove water pump (83).
18 PC130-8
50 Disassembly and assembly SEN04127-00
Installation [*5]
q Carry out installation in the reverse order to 3 Air hose clamp bolt:
removal. 10.5 0.5 Nm {107 5 kgm}
[*1] [*6]
a For adjustment of the air conditioner compres- a If air hose (92) was disconnected from air con-
sor belt tension, see "Testing and adjusting air nector (38), install the MIKALOR clamp
conditioner compressor belt tension". according to the following procedure.
a Use a new MIKALOR clamp.
[*2] a Align the hose to the original position
q Install the clamp mounting bolts between the
(marking position).
turbocharger and muffler according to the fol-
lowing procedure. a Reference
3 Clamp mounting bolt: Depth of insertion: 65 mm (aftercooler side)
1st time: 39.2 49 Nm {4 5 kgm} a Set the bridge (BR) under the clamp bolt
2nd time: and lap it over band (BD) at least (b)
68.6 122.5 Nm {7 12.5 kgm} reaches 5 mm.
[*3] a Do not use an impact wrench, when
a Use a new MIKALOR clamp. tighten the clamp.
a Align the hose to the original position (marking 2 Clamp bolt (BC): Lubricanting oil
position). (THREE-BOND PANDO 18B)
a Reference
Depth of insertion: 80 mm (aftercooler side) q When reusing the hose
a Set the bridge (BR) under the clamp bolt and a Install the clamp to the clamp mark
lap it over band (BD) at least (b) reaches 5 made on the hose.
mm. 3 Tighten to torque of at least 6
a Do not use an impact wrench, when tighten the Nm {0.6kgm}
clamp.
2 Clamp bolt (BC): Lubricanting oil (THREE-
q When using a new hose
a Tighten until dimention (BDG) is 0 3
BOND PANDO 18B)
mm.
q When reusing the hose
a Install the clamp to the clamp mark made
on the hose.
3 Tighten to torque of at least 6 Nm
{0.6kgm}
q When using a new hose
a Tighten until dimention (BDG) is 0 3
mm.
[*4]
q When installing the head cover, observe the
following precautions.
a Fit the O-ring to the head cover.
a When installing the head cover mounting
nuts and washers, check that the packing
is fitted to the head cover.
a Check that the packing is free of damage.
3 Cylinder head cover mounting nut:
7.84 9.8 Nm {0.8 1.0 kgm}
PC130-8 19
SEN04127-00 50 Disassembly and assembly
[*7] [*11]
3 Lubrication inlet hose mounting nut: q Precautions for installing high-pressure pipe
9.8 12.7 Nm {1.0 1.3 kgm} k Do not bend the high-pressure pipe to col-
lect before installing.
[*8] k Be sure to use the genuine high-pressure
q Installation procedure for exhaust manifold pipe clamps and observe the tightening
1) Install the guide bolts to the cylinder head torque.
and set the gasket. a Before installing the high-pressure pipe, check
a Set the gasket with the side of stamp it for the following defects. If there is any of
of "6205" on the manifold side. these defects, it can cause fuel leakage.
2) Install the exhaust manifold and tighten Accordingly, replace the high-pressure pipe.
the mounting bolts. q Check the taper seal of the connecting
3 Exhaust manifold mounting bolt: part (Part (j): Part of 2 mm from the end)
34.3 53.9 Nm {3.5 5.5 kgm} for visible lengthwise slit (k) and dent (l).
[*9] q Check part (m) (End of the taper seal: Part
q When installing air intake connector (48) and at 2 mm from the end) for stepped-type
electrical intake air heater assembly (45), wear (fatigue) which your nail can feel.
observe the following precautions.
a When installing air intake connector (48)
and electrical intake air heater (51),
replace the gasket with new one.
a When installing air intake connector
mounting bolt (44), tighten oil level gauge
(49), too.
a When installing air intake connector
mounting bolt (45), tighten ground cable
(50), too.
a If ground cable (50) was removed from
electrical intake air heater (51), install it to
electrical intake air heater (51) by tighten-
3
ing ground cable mounting bolt (93) to the
Sleeve nut:
following torque.
3 Ground cable mounting bolt:
25.5 29.4 Nm {2.6 3.0 kgm}
4.9 5.9 Nm {0.5 0.6 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)
[*10]
k After installing the high-pressure pipe, be
sure to install the boot to the sleeve nut.
k Direct the slits of the boot out and down.
a The boot is installed so that fuel will not spout
over the hot parts of the engine and catch fire
when it leaks for some reason.
20 PC130-8
50 Disassembly and assembly SEN04127-00
[*14]
a For adjustment of the alternator belt tension,
see "Testing and adjusting alternator belt ten-
sion".
[*15]
3 Radiator hose clamp bolt:
(Both upper and lower hoses)
8.8 0.5 Nm {0.9 0.05 kgm}
[*16]
q Tighten water pump mounting bolt (a) to install
alternator mounting bracket (96), too.
PC130-8 21
SEN04127-00 50 Disassembly and assembly
[*19]
q Tightening procedure for cylinder head mount-
ing 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 tightening, make 1 punch mark (n) on
each bolt head to indicate the number of tight-
ening time.
a If there are 5 punch marks on a bolt, do not
reuse that bolt but replace it.
22 PC130-8
50 Disassembly and assembly SEN04127-00
Removal and installation of 5. Open engine hood (6) and lock it.
radiator assembly 1
Removal
k Stop the machine on a level place and
lower it to the ground. Stop the engine and
set the lock lever to locked position.
k Disconnect the negative () terminal of the
battery beforehand.
PC130-8 23
SEN04127-00 50 Disassembly and assembly
10. Lift radiator assembly (12) and remove it. [*5] Installation
4 Radiator assembly: 12 kg q Carry 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.
24 PC130-8
50 Disassembly and assembly SEN04127-00
Removal and installation of 4. Loosen 2 clamps (6) and disconnect the air
aftercooler upper hose (7). [*1] [*2]
aftercooler assembly 1
5. Remove 3 mounting bolts (8) and remove plate
Removal
k
(9).
Disconnect the negative () terminal of the
battery beforehand.
PC130-8 25
SEN04127-00 50 Disassembly and assembly
Installation [*2]
q Carry out the installation in the reverse order of If air aftercooler upper hose was disconnected by
removal. losening its clamp. Install the MIKALOR clamp
according to the following procedure.
[*1] a Use a new clamp.
a Take care not to damage sponge on the sides a Align the hose to the original position (marking
when installing the aftercooler. position).
a Reference
a When installing the radiator assembly, align Depth of insertion: 85 mm
the convex portion (a) on the bottom of the air a Set the bridge (BR) under the clamp bolt and
aftercooler with the concave portion (b) on the lap it over band (BD) at least (b) reaches 5
machine. 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 hose
a Install the clamp to the clamp mark made
on the hose.
3 Tighten to torque of at least 6 Nm
{0.6kgm}
q When using a new hose
a Tighten until dimention (BDG) is 7 10
mm.
[*3]
3 Mounting bolt: 44 9.8 Nm {4.5 1.0 kgm}
26 PC130-8
50 Disassembly and assembly SEN04127-00
Removal and installation of work 3. Open the rear left inspection window and
remove 2 mounting bolts (3).
equipment oil cooler assembly 1
4. Disconnect tube (4) under the oil cooler.
Removal
k Stop the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Disconnect the cable from the negative ()
terminal of the battery.
k Loosen the 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.
PC130-8 27
SEN04127-00 50 Disassembly and assembly
[*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}
28 PC130-8
50 Disassembly and assembly SEN04127-00
Removal and installation of 2. Loosen hydraulic oil drain plug (5) and drain
engine and work equipment pump the hydraulic oil. [*1]
6 Hydraulic tank: 90 l
assembly 1 (Specified quantity of oil): 145 l
Removal
k Stop the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Disconnect the cable from the negative ()
terminal of the battery.
k Loosen the 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.
PC130-8 29
SEN04127-00 50 Disassembly and assembly
4. Remove covers (8) (10). 10. Remove brackets (20) and (20a) and partition
plates (21) and (22).
30 PC130-8
50 Disassembly and assembly SEN04127-00
4) Loosen air conditioner compressor mount- 6) Disconnect radiator lower hose (38) from
ing bolt (26) and drive belt adjustment bolt the water pump. [*8]
(27) and remove drive belt (28). [*3] a Since heater hose (39) is connected
5) Remove air conditioner compressor to radiator lower hose (38), discon-
mounting bolt (26) and air conditioner nect them together.
compressor belt tension adjustment bolt
(27) and disconnect air conditioner com-
pressor assembly (29).
a Move the air conditioner compressor
assembly aside and bind it with a
rope, etc. so that it will not be an
obstacle.
PC130-8 31
SEN04127-00 50 Disassembly and assembly
13. Disconnect wirings according to the following 4) Disconnect electrical intake air heater wir-
procedure. ing M23 (46).
1) Disconnect engine controller wiring con-
nectors ENG1 (40), CE02 (41) and CE03
(42).
2) Disconnect ground cable (43) from engine
controller mounting bracket (44).
3) Disconnect ENG1 connector wiring clamp
mounting bracket (45) and ENG1 connec-
tor wiring clamp together from engine con-
troller mounting bracket (43).
a The wiring of connector ENG1 (40) is
tightened with wiring clamp mounting
bracket (45).
a The wiring clamp of connector CE02
(41) and CE03 (42) and controller
5) Disconnect starting motor wirings M20
mounting bracket (44) are tightened
(47) and M17 (48). [*9]
with wiring clamp bracket (45). 6) Disconnect starting motor wiring clamp
(49).
a Starting motor wiring M20 (47) is a
pair of wire tightened together.
a Starting motor wiring M17 (48) can be
disconnected more easily from under-
side of the engine.
7) Disconnect engine oil pan oil temperature
sensor connector (50).
a Disconnect oil temperature sensor
connector (50) from underside of the
engine.
32 PC130-8
50 Disassembly and assembly SEN04127-00
8) Disconnect alternator wirings M21 (51) 16. Remove the fan assembly according to the fol-
and M22 (52). [*10] lowing procedure.
a Alternator wiring M22 (52) is a pair of 1) Loosen alternator mounting bolts (58) and
wire tightened together. (59).
9) Disconnect 2 wiring clamps (53). 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]
PC130-8 33
SEN04127-00 50 Disassembly and assembly
17. Remove the piping and wiring around the work 6) Disconnect fuel filter (73) from bracket
equipment pump according to the following (74).
procedure. 7) Disconnect fuel prefilter (75) and bracket
1) Disconnect hoses (66) and (67). (74) together from the frame.
2) Disconnect attachment filter (68) and 8) Disconnect engine oil filter (76) and
bracket together. bracket together from the frame.
3) Disconnect damper case oil supply hose
(69).
4) Disconnect hydraulic oil filter (70).
a The damper case oil supply hose
bracket is tightened with 2 mounting
bolts (69a), too.
34 PC130-8
50 Disassembly and assembly SEN04127-00
[*1]
5 Hydraulic tank: 90 l
(Specified quantity of oil): 145 l
a Start the engine, check the oil level, and add
new oil if necessary.
[*2]
5 Fuel tank: 247 l
[*3]
a For adjustment of the air conditioner compres-
sor belt tension, see "Testing and adjusting air
conditioner compressor belt tension".
[*4] [*8]
3 Radiator hose clamping bolt:
(Both upper and lower hoses)
8.8 0.5 Nm {0.9 0.05 kgm}
PC130-8 35
SEN04127-00 50 Disassembly and assembly
[*5] [*7]
If air hose was disconnected from air connector of a If air hose (84) was disconnected from air con-
air intake manifold, install the MIKALOR clamp nector (35), install the MIKALOR clamp
according to the following procedure. according to "[*5] Installation procedure for
a Use a new clamp. MIKALOR clamp".
a Align the hose to the original position (marking Depth of insertion: 65 mm
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 tighten the
clamp.
2 Clamp bolt (BC): Lubricanting oil (THREE-
BOND PANDO 18B)
q When reusing the hose
a Install the clamp to the clamp mark made
on the hose.
3 Tighten to torque of at least 6 Nm
{0.6kgm}
[*9]
q When using a new hose 3 Starting motor wiring terminal mounting bolt:
a Tighten until dimention (BDG) is 7 10 (M17) 2.6 6.6 Nm {0.27 0.68 kgm}
mm. (aftercooler side) 0 3 mm. (turbo- (M20) 17.7 24.5 Nm {1.8 2.5 kgm}
charger side)
[*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
[*6] hose first and then tighten the clamp on
3 Air hose clamping bolt: the hose side (elbow side).
10.5 0.5 Nm {107 5 kgm} q Then, referring to "[*5] Installation proce-
dure for MIKALOR clamp", tighten the
hose clamp.
[*13]
3 Engine mounting bolt: LT2
Engine mounting bolt:
235 285 Nm {23.5 29.5 kgm}
Target: 279.6 Nm {28.5 kgm}
36 PC130-8
50 Disassembly and assembly SEN04127-00
PC130-8 37
SEN04127-00 50 Disassembly and assembly
[*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}
38 PC130-8
50 Disassembly and assembly SEN04127-00
PC130-8 39
SEN04127-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
40 PC130-8
SEN04128-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04128-00 50 Disassembly and assembly
Removal and installation of travel 4. Remove all travel motor and final mounting
bolts (4), except 1.
motor and final drive assembly 1
Removal
1. Remove sprocket.
For details, see "Removal and installation of
sprocket".
2 PC130-8
50 Disassembly and assembly SEN04128-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Thread of travel motor and final drive
assembly mounting bolt :
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".
PC130-8 3
SEN04128-00 50 Disassembly and assembly
4 PC130-8
50 Disassembly and assembly SEN04128-00
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:
303.8 362.6 Nm {31 37 kgm}
PC130-8 5
SEN04128-00 50 Disassembly and assembly
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
1 790-201-2750 Spacer t 1
790-101-5201 Push puller (Kit) q 1
790-101-2510 Block 1
4) Disconnect swing motor assembly (3)
790-101-2550 Leg 1
using forcing screw [1].
790-101-2560 Nut 2 5) Lift and remove swing motor assembly (3).
2 790-101-2570 Plate 4
790-101-3101 Bearing puller q 1
Puller
790-101-4200 q 1
(294 kN {30 ton})
Hydraulic oil
F 790-101-1102 q 1
pump
790-101-5401 Push tool (Kit) (C) q 1
790-101-5461 Plate 1
3 790-101-5441 Plate 1
790-101-5421 Grip 1
01010-51240 Bolt 1
4 790-201-2850 Spacer t 1 3. Carrier No. 1 and Sun gear No. 2 assembly
1) Remove sun gear No. 1 (4).
5 790-201-2750 Spacer t 1
2) Remove carrier No. 1 and sun gear No. 2
796T-426-1140 Push tool t 1 Q assembly (5).
6
790-201-2680 Plate q 1
Disassembly
1. Oil drain
Remove the drain plug and drain oil from the
swing machinery.
6 Swing machinery case: 2.5 l
6 PC130-8
50 Disassembly and assembly SEN04128-00
4. Ring gear
Remove ring gear (16).
PC130-8 7
SEN04128-00 50 Disassembly and assembly
8 PC130-8
50 Disassembly and assembly SEN04128-00
2. Shaft assembly
1) Install O-ring to inside collar (32) and
install to shaft (33).
2) Use push tool F4 to press bearing (31)
with the press. 3. Oil seal
Using tool F6 to press oil seal (34).
a Replace the oil seal with a new one.
2 Circumference of oil seal: LG-6
a Be careful not to allow LG-6 to attach to
the lip and shaft.
2 Oil seal lip portion: Grease (G2-LI)
PC130-8 9
SEN04128-00 50 Disassembly and assembly
6. Ring gear
Install O-ring (39) to the shaft and case assem-
bly, and install ring gear (16).
10 PC130-8
50 Disassembly and assembly SEN04128-00
PC130-8 11
SEN04128-00 50 Disassembly and assembly
12 PC130-8
50 Disassembly and assembly SEN04128-00
PC130-8 13
SEN04128-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
14 PC130-8
SEN04129-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04129-00 50 Disassembly and assembly
Disassembly and assembly of 3. Pull out roller (4) from shaft (5).
a It is filled with 75 85 cc of oil, so drain the
track roller 1 oil at this point or lay a cloth to prevent the
area from becoming dirty.
Special tools
4. Remove floating seal (6) (on opposite side)
New/Remodel
from roller (4) and shaft (5).
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 796T-430-1210 Push tool t 1 N Q
M 2 796T-430-1220 Installer t 1 N Q
3 791-601-1000 Oil pump Q 1
Disassembly
1. Remove pin (1), then remove collar (2).
2 PC130-8
50 Disassembly and assembly SEN04129-00
PC130-8 3
SEN04129-00 50 Disassembly and assembly
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)
4 PC130-8
50 Disassembly and assembly SEN04129-00
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
L 1 791-675-1510 Installer t 1
M 3 791-601-1000 Oil pump q 1
PC130-8 5
SEN04129-00 50 Disassembly and assembly
2. Fit O-ring and install support (7) to shaft (5) 5. Using tool L1, install floating seal (3) to idler (4)
with dowel pin (8). and support (2).
a Coat the sliding surface of the floating seal
3. Using tool L1, install floating seal (6) to idler (4) with oil, and be careful not to let any dirt or
and shaft (5) and support assembly (7). dust get stuck to it.
a Coat the sliding surface of the floating seal a Remove all grease and oil from the con-
with oil, and be careful not to let any dirt or tact surface of the O-ring and the floating
dust get stuck to it. seal.
a Remove all grease and oil from the con-
tact surface of the O-ring and the floating
seal.
6 PC130-8
50 Disassembly and assembly SEN04129-00
6. Install O-ring, then install support (2) with 8. Using tool M3 fill track roller assembly with oil,
dowel pin (1). 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)
PC130-8 7
SEN04129-00 50 Disassembly and assembly
Special tools
Disassembly
New/Remodel
bol
a Do not remove grease fitting (17) from the
Q'ty
valve (3).
791-600-2001 Compressor (A) 1
or t 2. Remove yoke piston assembly (5) from recoil
791-685-8006 Compressor (B) 1 spring assembly (4).
791-635-3160 Extension t 1
2 3. Disassembly of recoil spring assembly (4)
790-201-2770 Spacer t 1
1) Set recoil spring assembly (4) to tool L2.
790-101-1600
Cylinder
t 1 k The recoil spring is under large
(686 kN {70 ton}) installed load, so be sure to set the
790-101-1102 Pump t 1 tool properly. Failure to do this is
790-201-1500 Push tool kit q 1 dangerous.
L a Installed load of spring:
Plate
790-201-1590 1 84,300 N {8,600 kg}
3 (outside: 75)
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1702 Push tool kit t 1
780-201-1780 Push tool 1
4
790-101-5021 Grip 1
01010-50816 Bolt 1
8 PC130-8
50 Disassembly and assembly SEN04129-00
PC130-8 9
SEN04129-00 50 Disassembly and assembly
Assembly
4. Fit valve (3) and seat (2), and secure with lock
plate (1).
a Install the valve so that the direction of the
3) Assemble cylinder (9) and pilot (8) to fitting (17) is to the outside.
spring (7), and set to tool L2.
4) Apply hydraulic pressure slowly to com- 5. Fill inside of cylinder with a approximately 120
press spring, and tighten nut (6) so that cc of grease.
installed length of spring is dimension 2 Inside cylinder: Grease (G2-LI)
(a).
a Installed length (a) of spring: 390 mm
10 PC130-8
50 Disassembly and assembly SEN04129-00
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Remover and
791-620-3000 t 1
installer
791-635-3110 Frame 1
791-635-3160 Extension 1 3. Remove 2 shoes (4) above and in front of the
791-635-3170 Nut 1 master pin. [*1]
791-635-3180 Screw 1
Screw
791-635-3190 1
(for fixing)
R 791-635-3210 Pilot 1
791-630-3220 Adapter 1
791-620-3260 Pin pusher 1
796T-432-1010 Guide t 1 N Q
Cylinder
790-101-1300
(980kN {100ton})
or t 1
Cylinder
790-101-1600
(686kN {70ton})
791-101-1102 Pump t 1
4. Using tool R, pull out the master pin. [*2]
PC130-8 11
SEN04129-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Adjust the track shoe tension. For detail, see
Testing and adjusting, "Testing and adjusting
track shoe tension".
[*2]
a Using tool R, press fit the master pin so 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
with new one immediately. If the bolt heads
are crushed, the bolts cannot be removed.
12 PC130-8
50 Disassembly and assembly SEN04129-00
PC130-8 13
SEN04129-00 50 Disassembly and assembly
Removal and installation of 6. Disconnect hoses (6) (12) from center swivel
joint.
revolving frame assembly 1
7. Disconnect plate (13) from revolving frame.
Removal
k Disconnect the negative () terminal of the
battery.
14 PC130-8
50 Disassembly and assembly SEN04129-00
Installation
q Installation is performed in the opposite way to
removal.
[*1]
2 Surface inside bushing during pin assembly:
Hyper white grease (G2-T)
2 Greasing after pin assembly:
Hyper white grease (G2-T)
[*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 Bleeding air
Bleed the air. For details , see Testing and
adjusting, "Bleeding air from each part".
PC130-8 15
SEN04129-00 50 Disassembly and assembly
16 PC130-8
50 Disassembly and assembly SEN04129-00
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}
PC130-8 17
SEN04129-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
18 PC130-8
SEN04130-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04130-00 50 Disassembly and assembly
Removal and installation of center 3. Disconnect hoses (3) (8) between travel
motor and swivel joint.
swivel joint assembly 1
4. Remove elbow (9).
Removal
k Stop the machine on a level ground, lower
5. Disconnect drain hose (10), (11).
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
6. Disconnect hoses (12) (15) between control
position.
k
valve and swivel joint.
Disconnect the cable from the negative ()
terminal of the battery.
k
7. Disconnect hose (16) from solenoid valve.
Loosen the hydraulic tank cap gradually to
release the pressure in the hydraulic tank.
8. Remove plate (17).
a Put tags to the pipings to prevent a mistake in
re-connecting them.
2 PC130-8
50 Disassembly and assembly SEN04130-00
q Bleeding air
Bleed air from the swing motor. For details,
see Testing and adjusting, "Bleeding air from
each part".
PC130-8 3
SEN04130-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-2501 Push puller q 1
790-101-2510 Block 1
790-101-2520 Screw 1
790-101-2540 Washer 1
Assembly
T1 791-112-1180 Nut 1 1. Fit slipper seals (7) and O-rings (6) to swivel
790-101-2630 Leg 2 rotor.
790-101-2570 Washer 4
2. Set swivel shaft (5) to block, then fit it by using
790-101-2560 Nut 2 push tool and hitting swivel rotor (4) lightly with
791-112-2650 Adapter 2 plastic hammer.
2 Contact surfaces of rotor and shaft
: Grease (G2-LI)
Disassembly a When installing the rotor, take care not to
1. Remove cover (1). damage the slipper seals and O-rings.
2. Remove snap ring (2). 3. Install ring (3) and secure with snap ring (2).
3. Using tool T1, pull out swivel rotor (4) and ring 4. Fit O-ring and install cover (1).
(3) from swivel shaft (5). 3 Swivel joint mounting bolt :
31.3 2.9 Nm {3.2 0.3 kgm}
4. Remove O-rings (6) and slipper seals (7) from
swivel shaft (5).
4 PC130-8
50 Disassembly and assembly SEN04130-00
Removal and installation of 3. Remove the exterior parts according to the fol-
lowing procedure.
hydraulic tank assembly 1 1) Remove handrail mounting bolts (3), (4)
and (5), 2 pieces each, and remove
Removal
k
handrail (6).
Stop the machine on a level ground, lower
a To remove mounting bolts (5), open
the work equipment to the ground, stop the
cover (7).
engine, and set the lock lever in the lock
2) Remove 2 cover upper mounting bolts (8)
position.
k
and 2 cover lower mounting bolts (9) and
Disconnect the cable from the negative ()
remove cover (10).
terminal of the battery.
k
3) Remove tool box mounting bolt (11) and
Loosen the hydraulic tank cap gradually to
move tool box (12) forward.
release the pressure in the hydraulic tank.
4) Remove fuel tank side cover (13).
5) Open and lock engine hood (14).
1. Remove undercover (1).
PC130-8 5
SEN04130-00 50 Disassembly and assembly
6 PC130-8
50 Disassembly and assembly SEN04130-00
[*1]
3 Drain plug (1): 58.8 78.4 Nm {6 8kgm}
Target: 68.6 Nm {7 kgm}
5 Hydraulic oil tank: 90 l
(Capacity: 145 l)
[*2]
a Use a new MIKALOR clamp.
a Align the hose to the original position (marking
position).
a Reference
8. Lift off hydraulic tank assembly (39). 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 hose
a Install the clamp to the clamp mark made
on the hose.
3 Tighten to torque of at least 6 Nm
{0.6kgm}
a Sling the hydraulic tank assembly, pull it to
q When using a new hose
this side, and remove it by swinging it
a Tighten until dimention (BDG) is 14 17
diagonally.
mm.
4 Hydraulic tank assembly : 100 kg
[*3]
PC130-8 7
SEN04130-00 50 Disassembly and assembly
8 PC130-8
50 Disassembly and assembly SEN04130-00
11. Remove the filters according to the following 13. Disconnect hoses (29) (33).
procedure.
1) Disconnect hoses (17) and (18) from the 14. Disconnect suction hose (34) and elbow (35)
work equipment pump. together from the work equipment pump. [*3]
2) Disconnect attachment filter assembly
(19) and bracket together.
3) Disconnect damper case oil supply hose
(20).
4) Disconnect hydraulic oil filter assembly
(21).
a The damper case oil supply hose
bracket is tightened with 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.
15. Remove all work equipment pump mounting
6) Disconnect fuel filter assembly (24) from
bolts (36), except 1 or 2.
bracket (25).
7) Disconnect fuel prefilter assembly (26)
and bracket (25) together.
PC130-8 9
SEN04130-00 50 Disassembly and assembly
10 PC130-8
50 Disassembly and assembly SEN04130-00
[*1]
5 Hydraulic tank: 90 l
(Specified quantity of oil): 145 l
a Start the engine, check the oil level, and add
new oil if necessary.
[*2]
5 Damper case: 0.75 l
a If the suction hose was disconnected from the
elbow, install the MIKALOR clamp according to
the following procedure.
q Tighten the clamp on the inside of the
hose first and then tighten the clamp on
the hose side (elbow side).
q Apply the following lubricating oil or equiv-
alent to threaded 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 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 hose
a Install the clamp to the clamp mark made
on the hose.
3 Tighten to torque of at least 6 Nm
{0.6kgm}
PC130-8 11
SEN04130-00 50 Disassembly and assembly
1. Remove undercover (1). 5. Remove brackets (5) and (6) and covers (7)
and (8).
12 PC130-8
50 Disassembly and assembly SEN04130-00
8. Disconnect 8 front lower hoses (17) (24). 9. Disconnect 11 hoses (27) (37) on the left side
(Port Nos. and connection points) (operator cab side).
(17) Control valve (A4) To boom bottom side (Port Nos. and connection points)
(18) Control valve (B4) To boom head side (27) Control valve (PB7) From attachment 1
(19) Control valve (TS2) To hydraulic tank PPC valve
(20) Control valve (LS) To work equipment (28) Control valve (PB6) From bucket digging
pump (LS valve) PPC valve
(21) Control valve (A3) To right travel motor (29) Control valve (PB5) From arm in PPC
(reverse side) valve
(22) Control valve (B3) To right travel motor (30) Control valve (PB4) From boom lower
(forward side) PPC valve
(23) Control valve (A2) To left travel motor (31) Control valve (TC) From attachment 1
(forward side) (32) Control valve (TC) To oil cooler
(24) Control valve (B2) To left travel motor (33) Control valve (PS) From merge-divider
(reverse side) valve solenoid valve
(25) Control valve (A1) To swing motor (right (34) Control valve (PST) From travel junction
swing side) valve solenoid valve
(26) Control valve (B1) To swing motor (left (35) Control valve (PB3) From right travel for-
swing side) ward PPC valve
a Disconnect hoses (25) and (26) between (36) Control valve (PB2) From left travel
the control valve and swing motor from the reverse PPC valve
swing motor. (37) Control valve (PB1) From swing left
PPC valve
a Hose (31) is the return hose from the
direction selector valve of attachment 1,
which is connected to the top of block
(31a).
a Hose (32) is the return hose to the oil
cooler, which is connected to the rear of
block (31a).
a Hose (34) (Port PST) is located at the rear
of hose (35) (Port PB3).
a Hose (35) is connected to the opposite
side to connector (39).
a Hose (36) is connected to the opposite
side to connector (40).
PC130-8 13
SEN04130-00 50 Disassembly and assembly
14 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 15
SEN04130-00 50 Disassembly and assembly
16 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 17
SEN04130-00 50 Disassembly and assembly
18 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 19
SEN04130-00 50 Disassembly and assembly
20 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 21
SEN04130-00 50 Disassembly and assembly
1. LS select valve
2. Cooler bypass valve
3. Pressure compensation valve R (Service 2)
4. Pressure compensation valve R (Service 1)
5. Pressure compensation valve R (Bucket)
6. Pressure compensation valve R (Arm)
7. Pressure compensation valve R (Boom)
8. Pressure compensation valve R (Right travel)
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)
19. Pressure compensation valve F (Service 2)
20. Check valve spring
21. Check valve spring
22 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 23
SEN04130-00 50 Disassembly and assembly
1. LS select valve
Swing valve
2. Pressure compensation valve F
3. Spool
4. Pressure compensation valve R
5. Swing bleed valve
24 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 25
SEN04130-00 50 Disassembly and assembly
Bucket valve
17. Pressure compensation valve F
18. Suction valve
19. Suction valve
20. Spool
21. Pressure compensation valve R
26 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 27
SEN04130-00 50 Disassembly and assembly
28 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 29
SEN04130-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
2 796T-416-1010 Push tool t 1 N Q
T 3 796T-416-1030 Push tool t 1 N Q
4 796T-416-1020 Push tool t 1 N Q
Disassembly
1. Remove screw (22) to remove lever (21). 6. Remove seal (9) and collar (8).
2. Remove mounting bolt (19) to remove case 7. Remove piston (7) to remove retainer (6),
(18), shaft (16) and lever (13) assembly. springs (5) and (4) and shim (3).
a Store shim (3) after checking the thickness
3. Remove pin (17). and the number of shims at each mount-
ing position.
4. Remove shaft (16) bushing (14) (14a) and
lever (13) from the case. 8. Remove valve (2) from body (1).
30 PC130-8
50 Disassembly and assembly SEN04130-00
Assembly
Only the precautions for assembling the travel PPC
valve assembly are discribed.
PC130-8 31
SEN04130-00 50 Disassembly and assembly
32 PC130-8
50 Disassembly and assembly SEN04130-00
New/Remodel
and assembly of offset cylinder assembly".
Necessity
Sym-
Part No. Part name
1. Piston rod assembly
Sketch
bol
1) Remove the piping from the cylinder
Q'ty
assembly.
790-502-1003 Repair stand t 1
1 2) Remove the mounting bolt to disconnect
790-101-1102 Pump t 1 head assembly (1).
790-102-4300 Wrench assembly t 1 3) Remove piston rode assembly (2).
2 a Place an oil pan or the like under the
790-201-4310 Pin t 1
cylinder to receive oil.
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
3
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1702 Push tool (Kit) t 1
790-201-1821 Push tool 1
790-101-5021 Grip 1
4) Disassemble the piston rod assembly with
01010-50816 Bolt 1 the following procedure.
U 790-201-1500 Push tool (Kit) q 1 1] Set piston rod assembly (2) on tool
790-201-1610 Push tool 1 U1.
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1620 Push tool 1
4
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1630 Push tool 1
790-101-5021 Grip 1
01010-50816 Bolt 1
5 790-720-1000 Expander t 1
796-120-1650 Ring t 1
07281-01159 Clamp t 1
6
796-720-1660 Ring t 1
07281-01159 Clamp t 1
PC130-8 33
SEN04130-00 50 Disassembly and assembly
2] Remove piston assembly lock screw 6] Remove the head assembly (7).
(3).
Screw size
M12 x 1.75 pitch:
Boom, arm and blade
M10 x 1.5 pitch: Bucket
34 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 35
SEN04130-00 50 Disassembly and assembly
36 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 37
SEN04130-00 50 Disassembly and assembly
7) Set piston rod assembly (2) on tool U1. 10) Mount the piping.
8) Engage piston rod assembly (2)
2 Seal: Grease (G2-LI)
a Set the ring abutment joint horizon-
tally and align the axes 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.
38 PC130-8
50 Disassembly and assembly SEN04130-00
PC130-8 39
SEN04130-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
40 PC130-8
SEN04131-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04131-00 50 Disassembly and assembly
Removal and installation of work 3. Disconnect working lamp wiring connector (6).
equipment assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792-785-1100 Remover t 1
796-270-1110 Adapter t 1
V Puller
790-101-4000 t 1
(490 kN {50 ton})
790-101-1102 Pump t 1 4. Disconnect grease tube (7).
2 PC130-8
50 Disassembly and assembly SEN04131-00
PC130-8 3
SEN04131-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*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.
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.
[*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 Bleeding air
a Bleed air. For details, see Testing and
adjusting, "Bleeding air from hydraulic cyl-
inder".
4 PC130-8
50 Disassembly and assembly SEN04131-00
PC130-8 5
SEN04131-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
6 PC130-8
SEN04132-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04132-00 50 Disassembly and assembly
2 PC130-8
50 Disassembly and assembly SEN04132-00
15. Remove duct (20). 23. Remove ducts (32) and (33).
16. Disconnect connector L03 (21). a Cut tie-wrap.
17. Remove plates (22) and (23) from the operator 24. Disconnect wiper motor connector M05 (34).
cab. 25. Remove harness (35) and antenna (36) from
the cab wall.
a Cut 2 points of tie-wrap.
PC130-8 3
SEN04132-00 50 Disassembly and assembly
31. Detach harness clamp (41) from the right back 35. Lift off and remove operator's cab assembly
side of cab. (47).
4 Operator's cab assembly: 470 kg
[*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}
4 PC130-8
50 Disassembly and assembly SEN04132-00
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 5 panes (1) to (4) (2) : Left side rear window glass
and (18) are stuck. (3) : Door lower window glass
a In this section, the procedure for replacing the (4) : Front window glass
stuck glasses is explained. (5) : Front window assembly
a When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5) . (It is impossible to (6) : Dam rubber
replace only the front window glass while the (17) : Center trim seal
front window assembly is installed to the opera- (18) : Rear glass
tor's cab.)
a For the procedure for replacing the front win-
dow assembly, see Removal and installation of
front window assembly.
PC130-8 5
SEN04132-00 50 Disassembly and assembly
Necessity
Symbol
Sketch
Part number Part name
Qty
N/R
2 793-498-1210 Lifter (Suction cup) t 2
X
3 20Y-54-13180 Stopper rubber t 2
Removal
a Remove the window glass to be replaced
according to the following procedure.
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet)(8).
6 PC130-8
50 Disassembly and assembly SEN04132-00
PC130-8 7
SEN04132-00 50 Disassembly and assembly
a Parts to be coated with primer; Apply the prim- a Never apply the wrong primer.
er all over dimension (a). If the glass primer, etc. is applied by mistake,
q Dimension to apply primer (a): 25 mm wipe it off with white gasoline.
8 PC130-8
50 Disassembly and assembly SEN04132-00
PC130-8 9
SEN04132-00 50 Disassembly and assembly
3) Stick dam rubber (6) for door lower win- a Stick dam rubber (6c) of the lower
dow glass (3) to the position as shown in side of the front window glass along
the figure. the outside edge of the lower line, dif-
ferently from other dam rubbers (6).
(If it is stuck along the inside, it will be
seen through the transparent part of
the glass.)
10 PC130-8
50 Disassembly and assembly SEN04132-00
PC130-8 11
SEN04132-00 50 Disassembly and assembly
12 PC130-8
50 Disassembly and assembly SEN04132-00
PC130-8 13
SEN04132-00 50 Disassembly and assembly
8. Fix the window glass. 9. After installing the window glass, remove any
1) After installing right window glass (1) to excess of the primer and adhesive from the
the operator's cab, insert stopper rubbers operator's cab and window glass.
X3 to 2 places (v) at the bottom of the a By using the white gasoline, wipe off the
glass to fix the glass. adhesive before it is dried up.
a When cleaning the glass, do not give an
impact on it.
14 PC130-8
50 Disassembly and assembly SEN04132-00
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks ( on both sides).
PC130-8 15
SEN04132-00 50 Disassembly and assembly
16 PC130-8
50 Disassembly and assembly SEN04132-00
PC130-8 17
SEN04132-00 50 Disassembly and assembly
18 PC130-8
50 Disassembly and assembly SEN04132-00
8. Adjust the Open position of the front window 3) Close front window assembly (10).
assembly lock. 4) Loosen locknut (20) of right and left side of
1) After adjusting the Close position of the rubber stoppers (18), and then pull back
front window assembly lock in steps 6 and both rubber stoppers (18) so that they
7, raise the front window assembly to the won't contact with the front window
ceiling. assembly when it is in Open position.
2) Set the front window assembly locks at
the both sides of rear of the operator's cab
to the Open position, and then check the
following items.
q Check the working condition of right
a nd left l ock s ( 16) and ( 17) ( as
explained above).
q Front window assembly must be in
contact with the right and left rubber
stoppers (18) and furthermore, must
be pushing them backward for 1.5
3.0 mm.
q The front window assembly must be
pushing the limit switch backward for
4 7 mm. 5) Loosen both sides of locknuts (22), and
a The position of limit switch (19) can- adjust the position of striker bolt (21).
n ot be ad ju st ed. T he re for e , th e a Striker bolt (21): M10
Open position of the front window Inner diameter of plate (23): 14.5
assembly is decided within the range mm
where this switch works.
a Limit switch (19) is used to prevent
the windshield wiper from moving
when turning the wiper switch on by
m i s ta k e w h e n t h e f r o n t w i n d o w
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
turned on, the wiper does not operate
when the front window assembly is in
Open position.
1] Front window assembly (10) must be
pushing the limit switch backward for
4 7 mm (at Open position).
2] Working condition of lock (17).
PC130-8 19
SEN04132-00 50 Disassembly and assembly
6) Adjustment of right and left rubber stop- 4] Tighten locknuts (20) of the both
pers (18). sides of rubber stopper (18).
1] Bring front window assembly (10) (the
lock should be in Open position) into
contact with right and left rubber stop-
pers (18).
20 PC130-8
50 Disassembly and assembly SEN04132-00
[*2]
3 Left lower pin:
27 34 Nm {2.75 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC130-8 21
SEN04132-00 50 Disassembly and assembly
22 PC130-8
50 Disassembly and assembly SEN04132-00
q Step 7 9 is optional (for breaker specifi- 19. Remove clamps (24) and (25). [*2]
cation). 20. Disconnect clamp (26). (If equipped)
7. Disconnect the following PPC hoses from the
PPC valve. The color of the band is;
q (7): Yellow
q (8): No color
a Plug the hose to stop oil flow-out.
8. Disconnect connectors P14 (9) and P15 (10).
9. Disconnect connectors V30 (11) and V13 (12).
PC130-8 23
SEN04132-00 50 Disassembly and assembly
27. Disconnect the clamp of wiring harness (35). 30. Sling floor frame assembly (42) and remove it.
28. Move plates (36) and (37) together with wiring a Make sure that the hoses, connectors,
harness (35) to the boom side. clamps, and so on are disconnected with-
out fail.
4 Floor frame assembly: 250 kg
24 PC130-8
50 Disassembly and assembly SEN04132-00
Installation
q Installation is done in the reverse order of
removal.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-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.
PC130-8 25
SEN04132-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
26 PC130-8
SEN04134-00
HYDRAULIC EXCAVATOR
PC130-8
PC130-8 1
SEN04134-00 50 Disassembly and assembly
2 PC130-8
50 Disassembly and assembly SEN04134-00
Removal and installation of air 6. Remove bolts (7) (2 pieces each on the right
and left sides) and remove condenser assem-
conditioner condenser 1 bly (8). [*1]
Removal
k Disconnect the negative terminal () of the
battery before starting the work.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Mounting bolt: Adhesive (LT-2)
2. Remove radiator reservoir tank (3). 3 Mounting bolt:
10.0 15.0 Nm {1.0 1.5 kgm}
3. Remove air cleaner assembly (4). q Charging air conditioner with refrigerant
Charge the air conditioner circuit with refriger-
4. Remove bracket (5). ant (air conditioner gas R134a).
a Filling quantity: 850 50 g
5. Disconnect 2 hoses (6).
a Stop the hoses and condenser with blind
plugs to prevent water etc. will not enter
them.
PC130-8 3
SEN04134-00 50 Disassembly and assembly
Removal and installation of air 7. Pull fresh air filter cover opening lever (8).
compressor unit assembly 1 8. Remove fresh air filter (9).
Removal
k Disconnect the negative terminal () of the
battery before starting the work.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a). 9. Remove rear covers (10) (13).
a Never release the refrigerant (R134a) to the
atmosphere.
4 PC130-8
50 Disassembly and assembly SEN04134-00
13. Remove plate (17). 16. Remove ducts (22) and (23).
a Cut the cable tie.
14. Remove lock pin (18) and duct (19).
17. Remove upper and lower ducts (24).
PC130-8 5
SEN04134-00 50 Disassembly and assembly
[*1]
a When installing the air conditioner circuit
hoses, take care that dirt, dust, water, etc. will
not enter them.
a When installing 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
24. Remove mounting bolt (33) and disconnect air 100 PG (equivalent to PAG 46).
3 Mounting bolt: 8 12 Nm {0.8 1.2 kgm}
conditioner tubes (34). [*1]
25. Disconnect heater hoses (35). q Charging air conditioner with refrigerant
a Record the connection point. Charge the air conditioner circuit with refriger-
ant (R134a).
a Filling quantity: 850 50 g
6 PC130-8
50 Disassembly and assembly SEN04134-00
Installation
q Installation is done in the reverse order of
removal.
PC130-8 7
SEN04134-00 50 Disassembly and assembly
8 PC130-8
50 Disassembly and assembly SEN04134-00
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.
PC130-8 9
SEN04134-00 50 Disassembly and assembly
Installation
q Installation is done in the reverse order of re-
moval.
a Reference
1. Procedure for removing connector cover (1).
2. Disconnect relay R08 (4) from the clip. 1) Cut and remove cable tie (2).
3. Disconnect bracket (5) and put it to the right 2) Move lever (3) up.
side.
4. 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).
10 PC130-8
50 Disassembly and assembly SEN04134-00
a Connector without connector cover 3) Set claw (C) to the connector and place
(1). connector cover (1).
a Take care that wiring harness (5) will
not be caught.
PC130-8 11
SEN04134-00 50 Disassembly and assembly
a Reference
1. Open the engine hood.
q How to replace the seal of O-ring of power
source connector (4).
2. Referring to "Removal and installation of air
Seal of O-ring:
compressor assembly," disconnect air condi-
1010-074-0406 (NIHON-DEUTSCH Ltd.)
tioner compressor (1).
or equivalent
a Do not disconnect the air conditioner
hoses from the air conditioner compres-
1) Remove cover (7) by nipping the tab with twee-
sor.
zers [1].
12 PC130-8
50 Disassembly and assembly SEN04134-00
PC130-8 13
SEN04134-00 50 Disassembly and assembly
2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (02)
14 PC130-8
SEN03784-00
PC130-8
PC130-8 1
SEN03784-00 90 Diagrams and drawings
2 PC130-8
Hydraulic circuit diagram (1/2) Hydraulic circuit diagram (1/2)
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SEN03784-00
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Hydraulic circuit diagram (2/2) Hydraulic circuit diagram (2/2)
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SEN03784-00
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90 Diagrams and drawings SEN03784-00
PC130-8 7
SEN03784-00 90 Diagrams and drawings
2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)
8 PC130-8
SEN03785-01
PC130-8
PC130-8 1
SEN03785-01 90 Diagrams and drawings
2 PC130-8
Electrical circuit diagram (1/5) Electrical circuit diagram (1/5)
PC130-8
PC130-8
SEN03785-01
PC130-8 3
Electrical circuit diagram (2/5) Electrical circuit diagram (2/5)
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Electrical circuit diagram (3/5) Electrical circuit diagram (3/5)
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Electrical circuit diagram (4/5) Electrical circuit diagram (4/5)
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Electrical circuit diagram (5/5) Electrical circuit diagram (5/5)
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PC130-8 11
Connectors table and arrangement drawing
Connectors table and arrangement drawing PC130-8 PC130-8
A08 SWP 12 Intermediate connector J-1 PFUEL BOSCH 3 Common rall pressure sensor AL-5
A13 DT 2 Intermediate connector (Working lamp) F-1 POIL - 1 Engine oil prresure switch (Low pressure) AJ-6
A22 DT 2 Intermediate connector (Working lamp) H-9 PREG - 2 Supply pump solenoid (IMV) AJ-7
A40 DT 4 Back camera I-9 PTIM BOSCH 4 Boost pressure/temp. sensor AJ-7
A41 DT 4 Back camera (If equipped) I-1 R01 Terminal 1 Battery relay (Terminal E) N-5
A43 S 8 Intermediate connector V-1 R02 Terminal 1 Battery relay (Terminal BR) N-6
AC01 - 8 Air conditioner unit Y-3 R03A Terminal 1 Battery relay (Terminal M) M-9
CAM FRAMETONE 2 CAM sensor AL-1 R03B Terminal 1 Battery relay (Terminal M) M-8
CE02 DRC 60 Engine controller L-8 R04 Terminal 1 Battery relay (Terminal B) M-9
CE03 DTP 4 Engine controller L-8 R05 RELAY 5 Relay for light U-9
CK01 070 14 KOMTRAX Communication module Z-7 R06 RELAY 5 Relay for Starter cut (PPC lock) P-9
CK02 070 10 KOMTRAX Communication module Z-7 R07 RELAY 5 Relay for Starter cut (Personal code) P-9
CM01 070 18 Machine monitor P-5 R10 RELAY 5 Relay for rear working lamp (If equipped) U-9
CM02 070 12 Machine monitor P-4 R12 RELAY 5 Relay for cab light U-9
CM03 070 18 Machine monitor P-3 R15 Terminal 1 Ribbon heater relay M-7
CM04 070 12 Machine monitor P-4 R16 Terminal 1 Ribbon heater relay M-7
CM05 B60 8 Machine monitor Q-6 R17 Terminal 1 Ribbon heater relay N-7
CN1 DT 2 Injector#1 AL-9 R19 X 2 Starting motor safety relay N-5
CN2 DT 2 Injector#2 AL-9 R20 RELAY 5 Blower relay T-8
CN3 DT 2 Injector#3 AM-9 R21 RELAY 4 Compressor relay T-8
CN4 DT 2 Injector#4 AN-9 R23 RELAY 6 Engine controller relay (1) W-9
CP01 AMP 81 Pump controller U-8 R24 RELAY 6 Engine controller relay (2) W-9
CP02 AMP 40 Pump controller U-8 R28 Terminal 1 Starting motor safety relay (Terminal C) M-8
D01 SWP 8 Diode O-8 R29 Terminal 1 Starting motor safety relay (Terminal B) M-8
D02 SWP 8 Diode O-9 S02 SWP 6 Light switch S-7
D03 SWP 8 Diode P-9 S04 SWP 6 Swing lock switch S-7
D10 M 2 Diode X-8 S07 SWP 6 Beacon switch (If equipped) S-7
D11 M 2 Diode Y-8 S10 YAZAKI 2 Switch horne R-6
NEG 1 DRC 60 Engine controller K-8,AK-9 S11 YAZAKI 2 Left knob switch W-1
F01 Fuse 20 Fuse V-9 S14 M 3 PPC hydraulic lock switch W-1
F04 L 2 Fusible link (65A) N-6 S21 - 11 Emergency pump drive switch P-9
F05 L 2 Fusible link (30A) N-6 S22 - 6 Emergency swing parking brake release P-9
H08 M 4 Intermediate connector Z-3,AH-4 S25 SUMITOMO 16 Intermediate connector Q-8
H09 S 8 Intermediate connector AA-4,AH-4 S30 S 8 Model selection T-8
H15 SUMITOMO 22 Intermediate connector (Starter switch) U-1 SSW Terminal 5 Starting switch R-6
H16 S (Blue) 12 Intermediate connector (Radio) Z-3 T01 Terminal 1 Floor frame Y-3
H31 DT 6 Intermediate connector (Blade up sensor) D-9 T02 Terminal 1 Cab GND AH-3
J06 SUMITOMO 20 Junction connector Y-8 T10 Terminal 1 Revolving frame G-1
(Orange)
T13 Terminal 1 Revolving frame K-9
K01 M 2 Pump resistor P-6
T14 Terminal 1 Revolving frame I-9
K02 DT 3 CAN terminal resistance K-8
T15 Terminal 1 Revolving frame H-9
L01 DT 2 Working lamp (Boom) A-7
TWTR PACKARD 2 Engine water temperature sensor AK-9
L02 DT 2 Working lamp (Right) A-5
V01 DT 2 PPC lock solenoid valve C-9
L03 M 2 Cab light AE-8
V02 DT 2 Confluence solenoid valve C-9
L05 SWP 2 Intermediate connector (Beacon) AG-9
V03 DT 2 Travel junction solenoid valve C-8
L15 DT 2 Beacon (If equipped) AF-9
V04 DT 2 Travel speed shifting solenoid valve C-8
M01 PA 9 Radio X-2
V05 DT 2 Swing holding brake solenoid valve C-8
M02 M 2 Speaker (left) AH-8
V06 DT 2 2 step relief solenoid valve C-8
M03 M 2 Speaker (Right) AG-9
V11 DT 2 PC-EPC valve H-9
M04 2 Cigar lighter R-6
V30 DT 2 Attachment current F-1
M05 M 6 Wiper motor P-3,AC-5
W03 X 2 Rear limit switch AG-9
M06 X 2 Intermediate connector A-6
M06A KES0 2 Window washer motor A-4
M07 090 2 Horn (High tone) E-1
M11 M 4 DC/DC converter (If equipped) AA-5
M12 M 2 Spare AA-4
M13 M 2 12V power supply connector (If equipped) AA-5
M14 DT 2 Travel alarm L-2
M17 Terminal 1 Starter (Terminal C) J-9
M20 Terminal 1 Starter (Terminal B) J-9
M21 Terminal 1 Alternator (Terminal B) I-9
M22 SUMITOMO 3 Alternator J-9
M23 Terminal 1 Ribbon heater I-9
M34 X 1 Air conditioner compressor electromagnetic clutch J-9
M40 X 2 Head light (left) AD-8
M41 X 2 Head light (right) AC-7
N01 - 4 Air conditioner unit T-7
N08 DT (Gray) 12 Service connector V-9
NE FRAMETONE 3 NE sensor AL-1
P01 X 2 Pressure switch (Bucket digging) N-2
P02 X 2 Pressure switch (Boom down) N-1
P03 X 2 Pressure switch (Right swing) N-2
P04 X 2 Pressure switch (Arm digging) N-2
P05 X 2 Pressure switch (Bucket dump) N-2
P06 X 2 Pressure switch (Boom up) N-1
P07 X 2 Pressure switch (Left swing) 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 oil temperature sensor G-9
P23 DT 2 Air cleaner clogging sensor L-5
P24 X 2 Radiator coolant level sensor L-4
P25 AMP 3 Pump pressure sensor G-9
P31 050 2 Sunshine sensor P-5
P44 DT 2 Engine oil level sensor K-8
PAMB AMP 3 Ambient pressure sensor AK-5
SEN03785-01
PC130-8 13
90 Diagrams and drawings SEN03785-01
PC130-8 15
SEN03785-01 90 Diagrams and drawings
2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (02)
16 PC130-8