Komatsu PC130-8 Hydraulic Excavator Service Repair Shop Manual (80001 and up) - SEN03763-02

This complete service repair workshop manual PDF download for the PC130-8 Komatsu Hydraulic Excavator (SN: 80001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : PC130-8
Serial Numbers : 80001 and up


TABLE OF CONTENTS :

00. Index and foreword
01. Specification
10. Structure and function
20. Standard value table
30. Testing and adjusting
40. Troubleshooting
50. Disassembly and assembly
90. Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN03763-02
Total Pages : 975


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
Specification and technical data
Specification dimension drawings
Working range diagram
Specifications
List of weights
List of lubricant and coolant to be filled

10 Structure, function and maintenance standard
Engine and cooling system
Engine mount
PTO
Cooling system
Power train
Power train
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe
Hydraulic system, Part 1
Hydraulic equipment layout drawing
Valve control
Hydraulic tank and filter
Hydraulic pump
Hydraulic system, Part 2
Control valve
CLSS
Functions and operation by valve
Hydraulic system, Part 3
PPC valve
Swing motor
Travel motor
Center swivel joint
Solenoid valve
Accumulator
Holding valve
Hydraulic cylinder
Work equipment
Work equipment
Dimensions of components
Cab and its attachments
Air conditioner
Electrical system
Electronic control system
Machine monitor system
KOMTRAX system
Sensor

20 Standard value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts

30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Testing exhaust temperature
Checking exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return rate and fuel leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Testing and adjusting alternator belt tension
Checking and adjusting air conditioner compressor belt tension
Testing swing circle bearing clearance
Checking and adjusting track shoe tension
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing control circuit basic pressure
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Checking parts which cause hydraulic drift of work equipment
Testing and adjusting travel deviation
Releasing residual pressure from hydraulic circuit
Testing oil leakage
Bleeding air from each part
Checking cab tipping stopper
Installation and adjustment of mirrors and camera
Inspection of air conditioner Recirc/Fresh air filter
Testing and adjusting, Part 2
Special functions of machine monitor
Testing and adjusting, Part 3
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service

40 Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Information in troubleshooting table
Phenomena looking like troubles and troubleshooting Nos.
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Troubleshooting by failure code, Part 1
Failure code [989L00] Engine controller lock caution 1
Failure code [989M00] Engine controller lock caution 2
Failure code [989N00] Engine controller lock caution 3
Failure code [AA10NX] Air cleaner clogging
Failure code [AB00KE] Charge voltage low
Failure code [B@BAZG] Eng oil press. low
Failure code [B@BAZK] Eng oil level low
Failure code [B@BCNS] Eng coolant overheat
Failure code [B@BCZK] Eng water level low
Failure code [B@HANS] Hydr oil overheat
Failure code [CA111] ECM critical internal failure
Failure code [CA115] Eng Ne and Bkup speed sensor error
Failure code [CA122] Charge air press sensor high error
Failure code [CA123] Charge air press sensor low error
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA144] Coolant temp. sensor high error
Failure code [CA145] Coolant temp. sensor low error
Failure code [CA153] Charge air temp. sensor high error
Failure code [CA154] Charge air temp. sensor low error
Failure code [CA155] Chg air temp high speed derate
Failure code [CA187] Sensor sup. 2 volt. low error
Failure code [CA221] Ambient air press. sensor high error
Failure code [CA222] Ambient air press. sensor low error
Failure code [CA227] Sensor sup. 2 volt. high error
Failure code [CA234] Eng. overspeed
Failure code [CA238] Ne speed sensor sup. volt. error
Failure code [CA271] IMV/PCV1 short error
Failure code [CA272] IMV/PCV1 open error
Failure code [CA322] Injector #1 (L #1) system open/short error
Failure code [CA324] Injector #3 (L #3) system open/short error
Failure code [CA331] Injector #2 (L #2) system open/short error
Failure code [CA332] Injector #4 (L #4) system open/short error
Troubleshooting by failure code, Part 2
Failure code [CA342] Calibration code incompatibility
Failure code [CA351] Inj. drive circuit error
Failure code [CA352] Sensor sup. 1 volt. low error
Failure code [CA386] Sensor sup. 1 volt. high error
Failure code [CA435] Abnormality in engine oil pressure switch
Failure code [CA441] Battery voltage low error
Failure code [CA442] Battery voltage high error
Failure code [CA449] Rail press. very high error
Failure code [CA451] Rail press. sensor high error
Failure code [CA452] Rail press. sensor low error
Failure code [CA488] Chg air temp high torque derate
Failure code [CA553] Rail press. high error
Failure code [CA559] Rail press. low error
Failure code [CA689] Eng. Ne speed sensor error
Failure code [CA731] Eng. Bkup speed sensor phase error
Failure code [CA757] All persistent data lost error
Failure code [CA778] Eng. Bkup speed sensor error
Failure code [CA1633] KOMNET datalink timeout error
Failure code [CA2185] Throttle sens. sup. volt. high error
Failure code [CA2186] Throttle sens. sup. volt. low error
Failure code [CA2249] Rail press. very low error
Failure code [CA2311] Abnormality in IMV solenoid
Failure code [D110KB] Battery relay drive short
Failure code [D19JKZ] Personal code relay abnormality
Failure code [D862KA] GPS antenna discon
Failure code [DA22KK] Pump solenoid power low error
Failure code [DA25KP] 5V sensor 1 power abnormality
Failure code [DA26KP] 5V sensor 2 power abnormality
Failure code [DA29KQ] Model selection abnormality
Troubleshooting by failure code, Part 3
Failure code [DA2RMC] CAN discon (Pump controller detected)
Failure code [DAF8KB] Short circuit in camera power supply
Failure code [DAFGMC] GPS module error
Failure code [DAFRMC] CAN discon (Monitor detected)
Failure code [DGH2KB] Hydr oil sensor short
Failure code [DHPAMA] Pump press sensor abnormality
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality
Failure code [DHX1MA] Overload sensor abnormality (Analog)
Failure code [DV20KB] Travel alarm short circuit
Failure code [DW43KA] Travel speed sol discon
Failure code [DW43KB] Travel speed sol short
Failure code [DW45KA] Swing brake sol discon
Failure code [DW45KB] Swing brake sol short
Failure code [DW91KA] Travel junction sol discon
Failure code [DW91KB] Travel junction sol short
Failure code [DWJ0KA] Merge-divider sol discon
Failure code [DWJ0KB] Merge-divider sol short
Failure code [DWK0KA] 2-stage relief sol discon
Failure code [DWK0KB] 2-stage relief sol short
Troubleshooting by failure code, Part 4
Failure code [DXA8KA] PC-EPC sol discon
Failure code [DXA8KB] PC-EPC sol short
Failure code [DXE4KA] Service current EPC discon
Failure code [DXE4KB] Service current EPC short
Failure code [DY20KA] Wiper working abnormality
Failure code [DY20MA] Wiper parking abnormality
Failure code [DY2CKA] Washer drive discon
Failure code [DY2CKB] Washer drive short
Failure code [DY2DKB] Wiper drive (for) short
Failure code [DY2EKB] Wiper drive (rev) short
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information in troubleshooting table
E-1 When starting switch turned ON, machine monitor displays nothing
E-2 When starting switch turned ON (before starting engine), basic check item lights up
E-3 Engine does not start (Engine does not turn)
E-4 Preheater does not operate
E-5 Automatic warm-up system does not operate (in cold season)
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked
E-7 Precaution lights up while engine is running
E-8 Emergency stop item lights up while engine is running
E-9 Engine coolant temperature gauge does not indicate normally
E-10 Hydraulic oil temperature gauge does not indicate normally
E-11 Fuel level gauge does not indicate normally
E-12 Contents of display by machine monitor are different from applicable machine
E-13 Machine monitor does not display some items
E-14 Function switch does not work
E-15 Auto-decelerator does not operate normally
E-16 Working mode does not change
E-17 Travel speed does not change
E-18 Alarm buzzer cannot be stopped
E-19 Windshield wiper and window washer do not operate
E-20 Power maximizing function does not operate normally
E-21 Swing holding brake does not operate normally
E-22 Travel alarm does not sound or does not stop sounding
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)
E-24 While starting switch is in OFF position, service meter is not displayed
E-25 Machine monitor cannot be set in service mode
E-26 Monitoring function does not display lever control signal normally
E-27 KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Information contained in troubleshooting table
System chart for hydraulic and mechanical systems
H-1 Speed or power of all work equipment, swing, and travel are low
H-2 Engine speed sharply drops or engine stalls
H-3 No work equipment, travel and swing move
H-4 Abnormal noise is heard from around hydraulic pump
H-5 Fine control mode does not function
H-6 Speed or power of boom is low
H-7 Speed or power of arm is low
H-8 Speed or power of bucket is low
H-9 Work equipment does not move in its single operation
H-10 Hydraulic drift of work equipment is large
H-11 Time lag of work equipment is large
H-12 Power maximizing function does not operate normally
H-13 Work equipment loaded more is slower during compound operation
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel
H-16 Machine deviates during travel
H-17 Travel speed is low
H-18 Machine cannot be steered easily or steering power is low
H-19 Travel speed does not change or it is kept low or high
H-20 Track does not move (Only either side)
H-21 Machine does not swing
H-22 Swing acceleration or swing speed is low
H-23 Excessive overrun when stopping swing
H-24 When upper structure stops swinging, it makes large shock
H-25 When upper structure stops swinging, it makes large sound
H-26 Hydraulic drift of swing is large
H-27 Flow rate in attachment circuit cannot be adjusted
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketch of special tool
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of front oil seal
Removal and installation of rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of work equipment oil cooler assembly
Removal and installation of engine and work equipment pump assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of travel motor and final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Disassembly and assembly of track roller
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring
Spreading and installation of track shoe assembly
Removal and installation of sprocket
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of work equipment pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Electrical system
Removal and installation of air compressor assembly
Removal and installation of air conditioner condenser
Removal and installation of air compressor unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly

90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (2/2)
Electrical diagrams and drawings
Electrical circuit diagram (1/5)
Electrical circuit diagram (2/5)
Electrical circuit diagram (3/5)
Electrical circuit diagram (4/5)
Electrical circuit diagram (5/5)
Connectors table and arrangement drawing

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