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SEN03763-05

HYDRAULIC PC130 -8
EXCAVATOR
SERIAL NUMBERS 80001 and up
SEN03765-05

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC130-8

Machine model Serial number


PC130-8 80001 and up

00 Index and foreword 1


Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4

PC130-8 1
SEN03765-05 00 Index and foreword

Composition of shop manual 1


The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN03763-05

00 Index and foreword SEN03764-05


Index SEN03765-05 q
Foreword and general information SEN03766-01

01 Specification SEN03767-01
Specification and technical data SEN03768-01

10 Structure, function and maintenance standard SEN03769-02


Engine and cooling system SEN03770-01
Power train SEN03771-00
Undercarriage and frame SEN03772-01
Hydraulic system, Part 1 SEN03773-00
Hydraulic system, Part 2 SEN03774-01
Hydraulic system, Part 3 SEN03775-02
Work equipment SEN03776-00
Cab and its attachments SEN03777-00
Electrical system SEN03778-01

20 Standard value table SEN03779-02


Standard service value table SEN04113-02

30 Testing and adjusting SEN03780-02


Testing and adjusting, Part 1 SEN04114-02
Testing and adjusting, Part 2 SEN04115-02
Testing and adjusting, Part 3 SEN04116-00

40 Troubleshooting SEN03781-02
Failure code table and fuse locations SEN04117-02
General information on troubleshooting SEN04118-02
Troubleshooting by failure code, Part 1 SEN04119-01
Troubleshooting by failure code, Part 2 SEN04120-01
Troubleshooting by failure code, Part 3 SEN04121-01
Troubleshooting by failure code, Part 4 SEN04122-01
Troubleshooting of electrical system (E-mode) SEN04123-01

2 PC130-8
00 Index and foreword SEN03765-05

Troubleshooting of hydraulic and mechanical system (H-mode) SEN04124-00


Troubleshooting of engine (S-mode) SEN04125-02

50 Disassembly and assembly SEN03782-03


General information on disassembly and assembly SEN04126-02
Engine and cooling system SEN04127-01
Power train SEN04128-01 q
Undercarriage and frame SEN04129-00
Hydraulic system SEN04130-00
Work equipment SEN04131-00
Cab and its attachments SEN04132-00
Electrical system SEN04134-00

90 Diagrams and drawings SEN03783-01


Hydraulic diagrams and drawings SEN03784-00
Electrical diagrams and drawings SEN03785-01

PC130-8 3
SEN03765-05 00 Index and foreword

Table of contents 1
00 Index and foreword
Index SEN03765-05
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4

Foreword and general information SEN03766-01


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

01 Specification
Specification and technical data SEN03768-01
Specification dimension drawings ............................................................................................... 2
Working range diagram ............................................................................................................... 3
Specifications .............................................................................................................................. 4
List of weights.............................................................................................................................. 8
List of lubricant and coolant to be filled ....................................................................................... 10

10 Structure, function and maintenance standard


Engine and cooling system SEN03770-01
Engine mount .............................................................................................................................. 2
PTO ............................................................................................................................................. 3
Cooling system............................................................................................................................ 4
Power train SEN03771-00
Power train .................................................................................................................................. 2
Swing circle ................................................................................................................................. 3
Swing machinery ......................................................................................................................... 4
Undercarriage and frame SEN03772-01
Track frame ................................................................................................................................. 2
Idler cushion ................................................................................................................................ 3
Idler ............................................................................................................................................. 4
Track roller................................................................................................................................... 5
Carrier roller ................................................................................................................................ 6
Sprocket ...................................................................................................................................... 7
Track shoe................................................................................................................................... 8
Hydraulic system, Part 1 SEN03773-00
Hydraulic equipment layout drawing ........................................................................................... 2
Valve control................................................................................................................................ 4
Hydraulic tank and filter ............................................................................................................... 6
Hydraulic pump ........................................................................................................................... 8
Hydraulic system, Part 2 SEN03774-01
Control valve ............................................................................................................................... 2
CLSS ........................................................................................................................................... 12
Functions and operation by valve................................................................................................ 16
Hydraulic system, Part 3 SEN03775-02
PPC valve.................................................................................................................................... 2

4 PC130-8
00 Index and foreword SEN03765-05

Swing motor ................................................................................................................................ 17


Travel motor ................................................................................................................................ 25
Center swivel joint ....................................................................................................................... 34
Solenoid valve............................................................................................................................. 36
Accumulator ................................................................................................................................ 40
Holding valve............................................................................................................................... 42
Hydraulic cylinder........................................................................................................................ 48
Work equipment SEN03776-00
Work equipment .......................................................................................................................... 2
Dimensions of components ......................................................................................................... 4
Cab and its attachments SEN03777-00
Air conditioner ............................................................................................................................. 2
Electrical system SEN03778-01
Electronic control system ............................................................................................................ 2
Machine monitor system ............................................................................................................. 33
KOMTRAX system ...................................................................................................................... 47
Sensor......................................................................................................................................... 49

20 Standard value table


Standard service value table SEN04113-02
Standard value table for engine related parts.............................................................................. 2
Standard value table for chassis related parts ............................................................................ 3

30 Testing and adjusting


Testing and adjusting, Part 1 SEN04114-02
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Sketches of special tools ............................................................................................................ 8
Testing engine speed .................................................................................................................. 9
Testing exhaust temperature....................................................................................................... 10
Checking exhaust gas color ........................................................................................................ 11
Adjusting valve clearance ........................................................................................................... 12
Testing compression pressure .................................................................................................... 14
Testing blow-by pressure ............................................................................................................ 16
Testing engine oil pressure ......................................................................................................... 17
Reduced cylinder mode operation ............................................................................................. 18
No-injection cranking .................................................................................................................. 18
Handling fuel system parts .......................................................................................................... 19
Releasing residual pressure from fuel system ............................................................................ 19
Testing fuel pressure ................................................................................................................... 20
Testing fuel return rate and fuel leakage ..................................................................................... 21
Bleeding air from fuel circuit........................................................................................................ 23
Checking fuel circuit for leakage ................................................................................................. 24
Testing and adjusting alternator belt tension............................................................................... 25
Checking and adjusting air conditioner compressor belt tension ................................................ 26
Testing swing circle bearing clearance........................................................................................ 27
Checking and adjusting track shoe tension................................................................................. 28
Testing and adjusting oil pressure in work equipment, swing, and travel circuits........................ 30
Testing control circuit basic pressure .......................................................................................... 33
Testing and adjusting oil pressure in pump PC control circuit..................................................... 34
Testing and adjusting oil pressure in pump LS control circuit ..................................................... 37
Testing solenoid valve output pressure ....................................................................................... 40
Testing PPC valve output pressure ............................................................................................. 44
Adjusting play of work equipment and swing PPC valves........................................................... 45
Checking parts which cause hydraulic drift of work equipment................................................... 46
Testing and adjusting travel deviation ......................................................................................... 48
Releasing residual pressure from hydraulic circuit...................................................................... 50

PC130-8 5
SEN03765-05 00 Index and foreword

Testing oil leakage....................................................................................................................... 51


Bleeding air from each part ......................................................................................................... 54
Checking cab tipping stopper ...................................................................................................... 56
Installation and adjustment of mirrors and camera ..................................................................... 57
Inspection of air conditioner Recirc/Fresh air filter ...................................................................... 61
Testing and adjusting, Part 2 SEN04115-02
Special functions of machine monitor.......................................................................................... 2
Testing and adjusting, Part 3 SEN04116-00
Handling voltage circuit of engine controller................................................................................ 2
Preparation work for troubleshooting of electrical system ........................................................... 3
Procedure for testing diodes ....................................................................................................... 8
Pm Clinic service......................................................................................................................... 9

40 Troubleshooting
Failure code table and fuse locations SEN04117-02
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN04118-02
Points to remember when troubleshooting .................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information in troubleshooting table ............................................................................................ 6
Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8
Connection table for connector pin numbers............................................................................... 11
T- branch box and T- branch adapter table ................................................................................. 47
Troubleshooting by failure code, Part 1 SEN04119-01
Failure code [989L00] Engine controller lock caution 1............................................................... 3
Failure code [989M00] Engine controller lock caution 2.............................................................. 3
Failure code [989N00] Engine controller lock caution 3 .............................................................. 4
Failure code [AA10NX] Air cleaner clogging ............................................................................... 5
Failure code [AB00KE] Charge voltage low ................................................................................ 6
Failure code [B@BAZG] Eng oil press. low................................................................................. 8
Failure code [B@BAZK] Eng oil level low ................................................................................... 9
Failure code [B@BCNS] Eng coolant overheat........................................................................... 10
Failure code [B@BCZK] Eng water level low .............................................................................. 12
Failure code [B@HANS] Hydr oil overheat ................................................................................. 14
Failure code [CA111] ECM critical internal failure ....................................................................... 16
Failure code [CA115] Eng Ne and Bkup speed sensor error ...................................................... 19
Failure code [CA122] Charge air press sensor high error........................................................... 20
Failure code [CA123] Charge air press sensor low error ............................................................ 22
Failure code [CA131] Throttle sensor high error ......................................................................... 24
Failure code [CA132] Throttle sensor low error........................................................................... 26
Failure code [CA144] Coolant temp. sensor high error ............................................................... 28
Failure code [CA145] Coolant temp. sensor low error ................................................................ 30
Failure code [CA153] Charge air temp. sensor high error........................................................... 32
Failure code [CA154] Charge air temp. sensor low error ............................................................ 34
Failure code [CA155] Chg air temp high speed derate ............................................................... 34
Failure code [CA187] Sensor sup. 2 volt. low error..................................................................... 35
Failure code [CA221] Ambient air press. sensor high error ........................................................ 36
Failure code [CA222] Ambient air press. sensor low error.......................................................... 38
Failure code [CA227] Sensor sup. 2 volt. high error ................................................................... 39
Failure code [CA234] Eng. overspeed ........................................................................................ 40
Failure code [CA238] Ne speed sensor sup. volt. error .............................................................. 42
Failure code [CA271] IMV/PCV1 short error ............................................................................... 44
Failure code [CA272] IMV/PCV1 open error ............................................................................... 45

6 PC130-8
00 Index and foreword SEN03765-05

Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 46


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

PC130-8 7
SEN03765-05 00 Index and foreword

Troubleshooting by failure code, Part 4 SEN04122-01


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

8 PC130-8
00 Index and foreword SEN03765-05

H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE..................... 16
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel .. 17
H-16 Machine deviates during travel........................................................................................... 18
H-17 Travel speed is low............................................................................................................. 19
H-18 Machine cannot be steered easily or steering power is low ............................................... 20
H-19 Travel speed does not change or it is kept low or high ...................................................... 21
H-20 Track does not move (Only either side).............................................................................. 21
H-21 Machine does not swing..................................................................................................... 22
H-22 Swing acceleration or swing speed is low .......................................................................... 23
H-23 Excessive overrun when stopping swing............................................................................ 24
H-24 When upper structure stops swinging, it makes large shock ............................................. 25
H-25 When upper structure stops swinging, it makes large sound ............................................. 25
H-26 Hydraulic drift of swing is large........................................................................................... 26
H-27 Flow rate in attachment circuit cannot be adjusted ............................................................ 27
Troubleshooting of engine (S-mode) SEN04125-02
Method of using troubleshooting chart ........................................................................................ 4
S-1 Starting performance is poor ................................................................................................ 8
S-2 Engine does not start............................................................................................................ 9
S-3 Engine does not pick up smoothly........................................................................................ 12
S-4 Engine stops during operations ............................................................................................ 13
S-5 Engine does not rotate smoothly .......................................................................................... 14
S-6 Engine lacks output (or lacks power).................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 17
S-9 Oil becomes contaminated quickly ....................................................................................... 18
S-10 Fuel consumption is excessive........................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20
S-12 Oil pressure drops .............................................................................................................. 21
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 22
S-14 Coolant temperature becomes too high (overheating) ....................................................... 23
S-15 Abnormal noise is made ..................................................................................................... 24
S-16 Vibration is excessive ......................................................................................................... 25

50 Disassembly and assembly


General information on disassembly and assembly SEN04126-02
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketch of special tool .................................................................................................................. 11
Engine and cooling system SEN04127-01
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 5
Removal and installation of front oil seal..................................................................................... 8
Removal and installation of rear oil seal ..................................................................................... 10
Removal and installation of cylinder head assembly .................................................................. 13
Removal and installation of radiator assembly............................................................................ 23
Removal and installation of aftercooler assembly ....................................................................... 25
Removal and installation of work equipment oil cooler assembly ............................................... 27
Removal and installation of engine and work equipment pump assembly.................................. 29
Removal and installation of fuel tank assembly .......................................................................... 37
Power train SEN04128-01
Removal and installation of travel motor and final drive assembly ............................................. 2
Disassembly and assembly of travel motor and final drive assembly ......................................... 4
Removal and installation of swing motor and swing machinery assembly.................................. 41
Disassembly and assembly of swing machinery assembly......................................................... 43
Removal and installation of swing circle assembly ..................................................................... 49

PC130-8 9
SEN03765-05 00 Index and foreword

Undercarriage and frame SEN04129-00


Disassembly and assembly of track roller ................................................................................... 2
Disassembly and assembly of idler assembly............................................................................. 5
Disassembly and assembly of recoil spring ................................................................................ 8
Spreading and installation of track shoe assembly ..................................................................... 11
Removal and installation of sprocket........................................................................................... 13
Removal and installation of revolving frame assembly ............................................................... 14
Removal and installation of counterweight assembly.................................................................. 16
Hydraulic system SEN04130-00
Removal and installation of center swivel joint assembly............................................................ 2
Disassembly and assembly of center swivel joint assembly ....................................................... 4
Removal and installation of hydraulic tank assembly .................................................................. 5
Removal and installation of work equipment pump assembly..................................................... 8
Removal and installation of control valve assembly .................................................................... 12
Disassembly and assembly of control valve assembly ............................................................... 16
Disassembly and assembly of work equipment PPC valve assembly ........................................ 28
Disassembly and assembly of travel PPC valve assembly ......................................................... 30
Disassembly and assembly of hydraulic cylinder assembly........................................................ 33
Work equipment SEN04131-00
Removal and installation of work equipment assembly............................................................... 2
Cab and its attachments SEN04132-00
Removal and installation of operator's cab assembly ................................................................. 2
Removal and installation of operator cab glass (stuck glass) ..................................................... 5
Removal and installation of front window assembly .................................................................... 15
Removal and installation of floor frame assembly ....................................................................... 22
Electrical system SEN04134-00
Removal and installation of air compressor assembly ................................................................ 2
Removal and installation of air conditioner condenser ................................................................ 3
Removal and installation of air compressor unit assembly ......................................................... 4
Removal and installation of KOMTRAX communication modem assembly ................................ 7
Removal and installation of monitor assembly ............................................................................ 8
Removal and installation of pump controller assembly ............................................................... 10
Removal and installation of engine controller assembly ............................................................. 12

90 Diagrams and drawings


Hydraulic diagrams and drawings SEN03784-00
Hydraulic circuit diagram (1/2)..................................................................................................... 3
Hydraulic circuit diagram (2/2)..................................................................................................... 5
Electrical diagrams and drawings SEN03785-01
Electrical circuit diagram (1/5) ..................................................................................................... 3
Electrical circuit diagram (2/5) ..................................................................................................... 5
Electrical circuit diagram (3/5) ..................................................................................................... 7
Electrical circuit diagram (4/5) ..................................................................................................... 9
Electrical circuit diagram (5/5) ..................................................................................................... 11
Connectors table and arrangement drawing ............................................................................... 13

10 PC130-8
00 Index and foreword SEN03765-05

PC130-8 11
SEN03765-05 00 Index and foreword

PC130-8 Hydraulic excavator


Form No. SEN03765-05

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 03-10

12 PC130-8
SEN03766-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC130-8

Machine model Serial number


PC130-8 80001 and up

00 Index and foreword 1


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

PC130-8 1
SEN03766-01 00 Index and foreword

Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.

1. General precautions 7) If welding repairs are needed, always


k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.

2 PC130-8
00 Index and foreword SEN03766-01

2. Preparations for work 6) When removing a cover which is under


1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. 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
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.

PC130-8 3
SEN03766-01 00 Index and foreword

4. Precautions for sling work and making


signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

4 PC130-8
00 Index and foreword SEN03766-01

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
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
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
SEN03766-01 00 Index and foreword

8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.

2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When 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,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.

6 PC130-8
00 Index and foreword SEN03766-01

How to read the shop manual 1

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.

1. Composition of shop manual


This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.

00. Index and foreword


This section explains the shop manuals list, table of contents, safety, and basic information.

01. Specification
This section explains the specifications of the machine.

10. Structure, function and maintenance standard


This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.

20. Standard value table


This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.

30. Testing and adjusting


This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly


This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.

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.

2. Revision and distribution


Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

PC130-8 7
SEN03766-01 00 Index and foreword

3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.

q Revised edition mark


When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)

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.

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-


a Caution
dards are necessary when performing work.

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.

2 Coat Places to be coated with adhesives, etc. during 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
00 Index and foreword SEN03766-01

Explanation of terms for maintenance standard 1


The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.

1. Standard size and tolerance


q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.

Example:
Standard size Tolerance
–0.022
120
–0.126

a The tolerance may be indicated in the text


and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)

q Usually, the size of a hole and the size of


the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0

PC130-8 9
SEN03766-01 00 Index and foreword

2. Standard clearance and standard value 5. Clearance limit


q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

4. Repair limit and allowable value or allow-


able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.

10 PC130-8
00 Index and foreword SEN03766-01

Handling of electric equipment and hydraulic component 1


To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

Points to remember when handling electric


equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.

2. Main failures occurring in wiring harness


1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.

2) Defective crimping or soldering of connec-


tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

PC130-8 11
SEN03766-01 00 Index and foreword

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.

4) High-pressure water entering connector


The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.

5) Oil or dirt stuck to connector


If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.

12 PC130-8
00 Index and foreword SEN03766-01

3. Removing, installing, and drying connec-


tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.

2] When removing from clips


q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.

q When removing a connector from a


clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.

3] Action to take after removing connec-


tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.

PC130-8 13
SEN03766-01 00 Index and foreword

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
00 Index and foreword SEN03766-01

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
SEN03766-01 00 Index and foreword

4) Drying wiring harness


If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.

16 PC130-8
00 Index and foreword SEN03766-01

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.

5. Points to remember when troubleshooting


electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.

PC130-8 17
SEN03766-01 00 Index and foreword

Points to remember when handling hydraulic equipment


With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.

1. Be careful of the operating environment.


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2. Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there 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.

4. Do not let any dirt or dust get in during


refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

18 PC130-8
00 Index and foreword SEN03766-01

5. Change hydraulic oil when the temperature


is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.

7. 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
SEN03766-01 00 Index and foreword

Handling of connectors newly used for engines 1


a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)

Disconnect connector (1) according to the fol-


lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.

20 PC130-8
00 Index and foreword SEN03766-01

3. Push lock type


q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)

Disconnect connector (3) according to the fol-


lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.

q 114 engine

q 107, 114 engines


Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)

3) While pressing lock (D), pull out connector


(4) in the direction of the arrow.

q 107 engine

a If the lock is on the underside, use


flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

PC130-8 21
SEN03766-01 00 Index and foreword

q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.

Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)

2) Connect the connector according to the


following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.

Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.

22 PC130-8
00 Index and foreword SEN03766-01

How to read electric wire code 1


a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.

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.

Indicates size of wire by nominal No.


Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.


Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)

1. Type, symbol, and material


AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(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
SEN03766-01 00 Index and foreword

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

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

“f” of nominal No. denotes flexible”.

24 PC130-8
00 Index and foreword SEN03766-01

3. Color codes table

(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.

4. Types of circuits and color codes

(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
SEN03766-01 00 Index and foreword

Precautions when carrying out operation 1


[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]

1. Precautions when carrying out removal work


q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234

2) Split flange type hoses and tubes


Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

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
00 Index and foreword SEN03766-01

2. Precautions when carrying out installation work


q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

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.

3. Precautions when completing the operation


1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.

PC130-8 27
SEN03766-01 00 Index and foreword

4) Checking muffler and exhaust pipe for damage and looseness


1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.

28 PC130-8
00 Index and foreword SEN03766-01

Method of disassembling and connecting push-pull type coupler 1


k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.

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
SEN03766-01 00 Index and foreword

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
00 Index and foreword SEN03766-01

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
SEN03766-01 00 Index and foreword

Standard tightening torque table 1


1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.

a The following table applies to the bolts in Fig. A.

Thread diameter of bolt Width across flats Tightening torque


mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370

a The following table applies to the bolts in Fig. B.

Thread diameter of bolt Width across flats Tightening torque


mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2

a Fig. A a Fig. B

Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)

32 PC130-8
00 Index and foreword SEN03766-01

2. Table of tightening torques for split flange bolts


a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt Width across flats Tightening torque


mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5

3. Table of tightening torques for O-ring boss piping joints


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Thread diameter Width across flats Tightening torque Nm {kgm}


Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}

4. Table of tightening torques for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.

Nominal Thread diameter Width across flats Tightening torque Nm {kgm}


No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

PC130-8 33
SEN03766-01 00 Index and foreword

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.

Tightening torque Nm {kgm} Taper seal Face seal


Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –

6. Table of tightening torques for face seal joints


a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).

Outer Width Tightening torque Nm {kgm} Face seal


diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

7. 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 — —

34 PC130-8
00 Index and foreword SEN03766-01

8. 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.

Thread size Tightening torque


mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

9. 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.

Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

PC130-8 35
SEN03766-01 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

1. Convert 55 mm into inches.


1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.


1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches (B)


1 mm = 0.03937 in
0 1 2 3 4 5 6 7 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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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

36 PC130-8
00 Index and foreword SEN03766-01

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

Liters to U.S. Gallons


1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

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
SEN03766-01 00 Index and foreword

Liters to U.K. Gallons


1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

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 SEN03766-01

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
SEN03766-01 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.

1°C = 33.8°F
°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

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

40 PC130-8
00 Index and foreword SEN03766-01

PC130-8 41
SEN03766-01 00 Index and foreword

PC130-8 Hydraulic excavator


Form No. SEN03766-01

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)

42 PC130-8
SEN03768-01

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC130-8

Machine model Serial number


PC130-8 80001 and up

01 Specification
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Working range diagram................................................................................................................................... 3
Specifications .................................................................................................................................................. 4
List of weights ................................................................................................................................................. 8
List of lubricant and coolant to be filled......................................................................................................... 10

PC130-8 1
SEN03768-01 01 Specification

Specification dimension drawings 1

Item Unit PC130-8


Machine weight (Standard specification) kg 12,700
Bucket capacity m 3 0.50
Engine type — Komatsu SAA4D95LE-5 Diesel engine
Net [ISO 9249/SAE J1349] 68.4{91.7}/2,200
Engine rated output kW{HP}/rpm
Gross [SAE J1955] 72.1{96.6}/2,200
A Overall length (Standard specification) mm 7,590
B Overall height mm 2,875
C Overall width mm 2,500
D Shoe width mm 500
E Tail swing radius mm 2,190
F Crawler overall length mm 3,610
G Distance between tambler center mm 2,880
H Cab height mm 2,855
Ground clearance mm 400
Traveling speed (Low/High) km/h 2.9/5.5
Continuous swing speed rpm 11.0

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 SEN03768-01

Working range diagram 1

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
SEN03768-01 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

Max. vertical wall depth mm 4,980


Max. digging reach mm 8,290
Max. reach at ground level mm 8,170
Max. digging height mm 8,650
Performance

Max. dumping height mm 6,210


Maximum digging force (bucket) kN{kg} 93.4{9,520}
Swing speed rpm 11.0
Swing max. slope angle Degree 20.0
Travel speed (Low/High) km/h 2.9/5.5
Gradeability deg. 35
Ground pressure kPa{kg/cm2} 39.9{0.41}
Overall length (for transport) mm 7,590
Overall width mm 2,500
Overall height (for transport) mm 2,875
Overall height (for work) mm 2,855
Ground clearance of counterweight mm 895
Min. ground clearance mm 400
Dimension

Tail swing radius mm 2,190


Min. swing radius of work equipment mm 2,450
Height of work equipment at min.
mm 6,495
swing radius
Crawler overall width mm 2,490
Crawler overall length mm 3,610
Length of track on ground mm 2,880
Track gauge mm 1,990
Overall height of machine cab mm 2,855

The values are based on the machine with the triple grouser shoe.

4 PC130-8
01 Specification SEN03768-01

PC130-8
Machine model
Standard specification
Serial No. 80001 and up
Model SAA4D95LE-5
4-cycle, water-cooled, in-line, vertical, direct injection, with
Type
turbocharger and air cooled aftercooler
No. of cylinders-bore x stroke 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

Max. torque Nm{kgm}/rpm 350{35.7}/1,500


Engine

High idling speed rpm 2,300


Low idling speed rpm 1,100
g/kWh
Min. fuel consumption ratio 224{167}
{g/HPh}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A
Battery (*1) 12 V, 64 Ah x 2
Radiator core type 4-array aluminum mesh core
Aftercooler core type Aluminum mesh core
Carrier roller 1 on each side
Undercarriage

Track roller 7 on each side


Track shoe (iron shoe) Assembly-type triple grouser shoe, 43 on each side
(road liner) Assembly-type road liner, 43 on each side
Hydraulic motor Control valve Hydraulic pump

Type x no. Variable displacement piston type x 1

Discharge l/min 121+121 (at 2,200 rpm)

Set pressure MPa{kg/cm2} 34.8{355}

Type x no. 6-spool type x 1


Hydraulic system

Control method Hydraulic type

Variable displacement piston type


Travel motor
(with brake valve and parking brake) x 2

Fixed displacement piston type


Swing motor
(with safety valve and holding brake) x 1
Hydraulic tank Box-shaped, open
Hydraulic oil filter Tank return side
Hydraulic cooler Air cooled (CF40)

*1. Battery capacity (Ah) is based on 5-hour rate.


a There are net value and gross value for displaying engine rate horsepower. Gross value is measure-
ment of engine alone, and net value is measurement with close to on-board conditions.

PC130-8 5
SEN03768-01 01 Specification

PC130-8
Machine model
Standard specification
Serial No. 80001 and up
Type Reciprocating piston type
Boom cylinder

Cylinder inner diameter mm ø 105


Piston rod diameter mm ø 70
Stroke mm 995
Max. length between pins mm 2,510
Min. length between pins mm 1,515
Work equipment cylinder

Type Reciprocating piston type


Hydraulic system

Cylinder inner diameter mm ø 115


Arm cylinder

Piston rod diameter mm ø 75


Stroke mm 1,175
Max. length between pins mm 2,798
Min. length between pins mm 1,623
Type Reciprocating piston type
Bucket cylinder

Cylinder inner diameter mm ø 95


Piston rod diameter mm ø 65
Stroke mm 885
Max. length between pins mm 2,263
Min. length between pins mm 1,378

6 PC130-8
01 Specification SEN03768-01

PC130-8 7
SEN03768-01 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 SEN03768-01

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

a BOC: Bolt-On Cutting edge


1

PC130-8 9
SEN03768-01 01 Specification

List of lubricant and coolant to be filled 1


a For details of the notes (Note. 1, 2, 3, 4) in the table, see the Operation and Maintenance Manual.
a The details refer to an Operation and Maintenance Manual about Recommended Komatsu fluids again.

10 PC130-8
01 Specification SEN03768-01

Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 11.5 11.0
Swing machinery case 2.5 2.5
Final drive case (each side) 2.1 2.1
PTO case 0.75 —
Hydraulic system 145 90
Fuel tank 246 —
Cooling system 13.9 13.9

PC130-8 11
SEN03768-01 01 Specification

PC130-8 Hydraulic excavator


Form No. SEN03768-01

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)

12 PC130-8
SEN03770-01

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Engine and cooling system
Engine mount.................................................................................................................................................. 2
PTO................................................................................................................................................................. 3
Cooling system ............................................................................................................................................... 4

PC130-8 1
SEN03770-01 10 Structure, function and maintenance standard

Engine mount 1

2 PC130-8
10 Structure, function and maintenance standard SEN03770-01

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
SEN03770-01 10 Structure, function and maintenance standard

Cooling system 1

4 PC130-8
10 Structure, function and maintenance standard SEN03770-01

1. Radiator cap 10. Fuel cooler inlet


2. Shroud 11. Radiator outlet hose
3. Reservoir tank 12. Radiator inlet hose
4. Oil cooler outlet 13. Aftercooler outlet hose
5. Oil cooler 14. Fan guard
6. Aftercooler 15. Oil cooler inlet
7. Radiator 16. Aftercooler inlet hose
8. Fuel cooler 17. Drain cock
9. Fuel cooler outlet

Specifications

Radiator Oil cooler Aftercooler Fuel cooler


4-array aluminum Aluminum mesh
Core type CF40 Drawn cup
mesh core core
Fine pitch (mm) 3.5/2 3.5/2 4.0/2 4.0/2
Total heat dissipation surface 12.96
27.82 8.79 0.59
(m²) (6.48 x 2)
Pressure valve cracking
49.0 ± 14.7
pressure — — —
{0.5 ± 0.15}
(kPa{kg/cm²})
Vacuum valve cracking pressure -4.9 – 0
— — —
(kPa{kg/cm²}) {-0.05 – 0}

PC130-8 5
SEN03770-01 10 Structure, function and maintenance standard

PC130-8 Hydraulic excavator


Form No. SEN03770-01

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)

6 PC130-8
SEN03771-00

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Power train
Power train...................................................................................................................................................... 2
Swing circle..................................................................................................................................................... 3
Swing machinery............................................................................................................................................. 4

PC130-8 1
SEN03771-00 10 Structure, function and maintenance standard

Power train 1

1. Idler 6. Hydraulic pump


2. Control valve 7. Engine
2a. Self pressure reducing valve 8. Swing motor
3. 2nd travel speed select solenoid valve 9. Center swivel joint
4. Swing holding brake solenoid valve 10. Swing machinery
5. Travel motor (Final drive) 11. Swing circle

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

2. Swing circle bearing lubrication a. Inner race soft zone position


3. Swing circle pinion lubrication b. Outer race soft zone position
4. Outer race
5. Ball Specifications
6. Seal
Reduction ratio 90/11=8.182
7. Inner race (Number of teeth: 90)
Grease G2-LI
Grease quantity (l) 9.1

PC130-8 3
SEN03771-00 10 Structure, function and maintenance standard

Swing machinery 1

1. Level gauge Specifications


2. Oil feed pipe
Reduction ratio (14+61) / 14 × (17+61) / 17 = 24.58
3. Swing pinion (Number of teeth: 11)
4. Swing machinery case Swing reduction
24.58 × 8.182 = 201.11
5. No. 2 planetary carrier ratio
6. No. 2 sun gear (Number of teeth: 17) Swing speed
11.0
7. Ring gear (Number of teeth: 61) (rpm)
8. No. 1 planetary carrier
9. No. 1 sun gear (Number of teeth: 14)
10. Swing motor
11. No. 1 planetary gear (Number of teeth: 24)
12. No. 2 planetary gear (Number of teeth: 22)
13. Drain plug

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 ø 145 ø 144.8 or replace
-0.100

PC130-8 5
SEN03771-00 10 Structure, function and maintenance standard

PC130-8 GALEO Hydraulic excavator


Form No. SEN03771-00

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)

6 PC130-8
SEN03772-01

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Undercarriage and frame
Track frame ..................................................................................................................................................... 2
Idler cushion.................................................................................................................................................... 3
Idler ................................................................................................................................................................. 4
Track roller ...................................................................................................................................................... 5
Carrier roller .................................................................................................................................................... 6
Sprocket .......................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8

PC130-8 1
SEN03772-01 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 SEN03772-01

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. Cylinder Grease quantity (cc) 118
6. U-packing
7. Pilot
8. Nut
9. Valve
10. Grease fitting

PC130-8 3
SEN03772-01 10 Structure, function and maintenance standard

Idler 1

Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
ø 527 —
Rebuilding or
2 Outside diameter of tread ø 489 ø 477
replace
3 Tread depth 19 25
4 Width of projection 52 42
5 Overall width 115 107 —
Rebuilding or
6 Tread width (one side) 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 SEN03772-01

Track roller 1

Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
ø 158 — Rebuilding or
2 Outside diameter of tread ø 130 ø 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 –
ø 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 –
ø 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
SEN03772-01 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
ø 116 ø 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 –
ø 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 –
ø 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 SEN03772-01

Sprocket 1

Unit: mm
No. Item Criteria Remedy
Standard size Tolerance Repair limit
1 Wear on tooth bottom diameter +1.0
ø 547.4 ø 535
-2.0
2 Wear on tooth tip diameter ø 607 — ø 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
SEN03772-01 10 Structure, function and maintenance standard

Track shoe 1
Triple grouser shoe, road liner

*1. Triple grouser shoe


*2. Road liner

a P portion shows the link of bushing press fitting end.

8 PC130-8
10 Structure, function and maintenance standard SEN03772-01

(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
ø 46.3 ø 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}
(*)

*: In case of dry type track.

PC130-8 9
SEN03772-01 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
ø 46 0.285 – 0.387
+0.347 +0.074
Interference between regular +0.150 -0.198
22 ø 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
ø 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
ø 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
ø 30 0.530 – 1.130
-0.300 +0.330
26 Grouser height (road liner) 58 21 Replace

*: In case of dry type track.

10 PC130-8
10 Structure, function and maintenance standard SEN03772-01

Triple grouser shoe

Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Grouser height
20 10
2 Shoe 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
SEN03772-01 10 Structure, function and maintenance standard

PC130-8 Hydraulic excavator


Form No. SEN03772-01

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)

12 PC130-8
SEN03773-00

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Hydraulic system, Part 1
Hydraulic equipment layout drawing ............................................................................................................... 2
Valve control ................................................................................................................................................... 4
Hydraulic tank and filter .................................................................................................................................. 6
Hydraulic pump ............................................................................................................................................... 8

PC130-8 1
SEN03773-00 10 Structure, function and maintenance standard

Hydraulic equipment layout


drawing 1
1. Bucket cylinder
2. Arm cylinder
3. Control valve
4. Solenoid valve
5. Accumulator (for PPC circuit)
6. Boom cylinder
7. Hydraulic tank
8. Swing motor
9. Hydraulic pump
10. R.H. travel motor (R.H. Final drive)
11. Oil cooler
12. L.H. travel motor (L.H. Final drive)
13. L.H. work equipment PPC valve
14. R.H. work equipment PPC valve
15. Center swivel joint
16. Travel PPC valve
17. Attachment PPC valve
(Machine ready for attachment)

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

1. Connecting valve 9. R.H. work equipment PPC valve


2. Solenoid valve 10. Travel lever
3. Accumulator (for PPC circuit) 11. Travel pedal
4. Control valve 12. Travel PPC valve
5. R.H. work equipment control lever (for boom 13. Attachment PPC valve
and bucket control) (Machine ready for attachment)
6. L.H. work equipment control lever (for arm and 14. Attachment control pedal
swing control) (Machine ready for attachment)
7. L.H. work equipment PPC valve 15. Lock pin
8. Lock lever

4 PC130-8
10 Structure, function and maintenance standard SEN03773-00

PC130-8 5
SEN03773-00 10 Structure, function and maintenance standard

Hydraulic tank and filter 1

1. Hydraulic tank Specifications


2. Suction strainer
3. Filter element Hydraulic tank capacity (l) 130
4. Bypass valve Oil level in hydraulic tank (l) 90
5. Drain plug Bypass valve set pressure 0.15 ± 0.03
6. Sight gauge (MPa{kg/cm²}) {1.53 ± 0.3}
7. Oil filler cap combined with breather

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

Prevention of negative pressure in tank


q The hydraulic tank is enclosed and pressur-
ized. When the oil level in the hydraulic tank
drops, negative pressure is generated in the
tank.
To prevent this negative pressure generation,
seam valve (4) is opened to draw the atmo-
sphere to the tank.
(Intake valve set pressure:
0 – 0.49 kPa {0 – 0.005 kg/cm²})

Prevention of pressure rise in tank


q When the hydraulic circuit is operating, the
pressure in the hydraulic tank increases as the
hydraulic cylinder operates and the oil level
and temperature increase in the tank.
If the pressure in the tank rises above the set
value, bottom plate (2) is pushed up to release
the pressure in the tank.
(Exhaust valve set pressure:
16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm²})

PC130-8 7
SEN03773-00 10 Structure, function and maintenance standard

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.

Features of double pump system


q The common single pump system makes much
loss in the pressure compensation valve.
Accordingly, the machine travel speed is
reduced much when the machine is steered.
q The double pump system does not make much
loss in the pressure compensation valve, since
the right and left travel circuits are independent
from each other. Accordingly, the machine
travel speed is less reduced when the machine
is steered.
q The double pump has simpler structure than
the tandem pump.

BMP : Breather mounting port


IM : PC mode selector current
OCP : Oil level pick-up port
OFP : Oil filler port
P1T : Travel deviation control orifice
P2T : Travel deviation control orifice
PA1 : Pump discharge port
PA1C : Pump discharge pressure pick-up port
PA2 : Pump discharge port
PA2C : Pump discharge pressure pick-up port
PB : Pump pressure input port
PD1 : Case drain port
PD2 : Drain plug
PEN : Control pressure pick-up port
PEPB : EPC basic pressure pick-up port
PEPC: EPC basic pressure input port
PLS : Load pressure input port
PLSC : Load pressure pickup port
PM : PC mode selector pressure pick-up port
PS : Pump suction port

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
SEN03773-00 10 Structure, function and maintenance standard

1. Shaft 7. Cylinder block


2. Cradle 8. Valve plate
3. Case 9. End cap
4. Rocker cam 10. Servo piston
5. Shoe 11. PC valve
6. Piston

10 PC130-8
10 Structure, function and maintenance standard SEN03773-00

Function q Rocker cam (4) conducts high pressure oil to


q The pump converts the engine rotation and the cylinder surface (B) with cradle (2), which
torque transmitted to its shaft to oil pressure is secured to the case, and forms a static pres-
and delivers pressurized oil corresponding to sure bearing when it slides.
the load. q Piston (6) carries out relative movement in the
q It is possible to change the delivery by chang- axial direction inside each cylinder chamber of
ing the swash plate angle. cylinder block (7).
q Cylinder block (7) seals the pressurized oil to
Structure valve plate (8) and carries out relative rotation.
q Cylinder block (7) is supported to shaft (1) by q This surface is designed so that the oil pres-
spline (10). sure balance is maintained at a suitable level.
q Shaft (1) is supported by front and rear bear- q The oil inside the respective cylinder chambers
ings (11). of cylinder block (7) is suctioned and dis-
q Tip of piston (6) is shaped as a concave ball charged through valve plate (8).
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) constitute the spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.

PC130-8 11
SEN03773-00 10 Structure, function and maintenance standard

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)

q With center line (X) of rocker cam (4) at a


swash plate angle (a) in relation to the axial
direction of cylinder block (7), flat surface (A)
acts as a cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) suctions and discharges the
oil by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.

12 PC130-8
10 Structure, function and maintenance standard SEN03773-00

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
SEN03773-00 10 Structure, function and maintenance standard

LS valve

PA : Pump port 1. Sleeve 7. Plug


PDP : Drain port 2. Piston 8. Locknut
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Sheet
PPL : Control pressure input port 6. Sleeve

Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls main pump delivery (Q)
according to differential pressure ( PLS) [=
(PP) — (PLS)], called the LS differential pres-
sure (the difference between main pump pres-
sure (PP) and control valve outlet port pressure
(PLS)).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output enters this valve.

14 PC130-8
10 Structure, function and maintenance standard SEN03773-00

Operation

1. When the control valve is situated at neutral

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
SEN03773-00 10 Structure, function and maintenance standard

2. Action for the direction of maximizing the pump delivery

q When the difference between the main pump


pressure (PP) and LS pressure (PLS), in other
words, LS differ ential press ure ( P LS)
becomes smaller [for example, when the area
of opening of the control valve becomes larger
and pump pressure (PP) drops], spool (6) is
pushed to the right by the combined force of
LS pressure (PLS) and the force of spring (4).
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the right side. Therefore, the
swash plate is moved in the direction to make
the delivery larger.

16 PC130-8
10 Structure, function and maintenance standard SEN03773-00

3. Action for the direction of minimizing the pump delivery

q When LS differential pressure ( PLS)


becomes larger [for example, when the area of
opening of the control valve becomes smaller
and pump pressure (PP) rises] because of the
leftward move (it reduces delivery) of servo
piston (12), pump pressure (PP) pushes spool
(6) to the left.
q When spool (6) moves, main pump pressure
(PP) flows from port (C) to port (D) and from
port (K), it enters the large diameter end of the
piston.
q Main pump pressure (PP) also enters port (J)
of the small diameter end of the piston, but
because of the difference in area between the
large diameter end and the small diameter end
on servo piston (12), it is pushed to the left. As
the result, the servo piston (12) moves into the
direction of reducing the swash plate angle.

PC130-8 17
SEN03773-00 10 Structure, function and maintenance standard

4. When servo piston is balanced

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

PA : Pump port 1. Plug


PA2 : Pump pressure pilot port 2. Servo piston assembly
PDP : Drain port 3. Pin
PM : Mode selector pressure pilot port 4. Spool
PPL : PC control pressure output port 5. Retainer
PPL2: LC control pressure output port 6. Sheet
7. Cover
8. Wiring

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
SEN03773-00 10 Structure, function and maintenance standard

Operation

1. When pump controller is normal

1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low

Action of PC-EPC valve solenoid (1)


q Command current (X) is being sent to PC-EPC q The pressure [port (C) pressure] output from
valve solenoid (1) from the pump controller. PC valve is changed depending on the above
q This command current acts on PC-EPC valve position.
to output the signal pressure in order to modify q The size of command current (X) is determined
the force pushing piston (2). by the nature of the operation (lever opera-
q Spool (3) stops at a position where the com- tion), the selected working mode, and the set
bined spool-pushing force is balanced by the value and actual value of the engine speed.
setting force of springs (4) and (6) as well as
the pump pressures (PP1) (check valve output
pressure) and (PP2) (shuttle valve output pres-
sure).

20 PC130-8
10 Structure, function and maintenance standard SEN03773-00

PC130-8 21
SEN03773-00 10 Structure, function and maintenance standard

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
10 Structure, function and maintenance standard SEN03773-00

q If port (E) and port (G) of the LS valve are con-


nected, the pressure entering the large diame-
ter end of the piston from port (J) becomes
drain pressure (PT), and servo piston (9)
moves to the right side.
q The pump delivery will be set to the increasing
trend.
q Accompanied with move of servo piston (9),
springs (4) and (6) will be expanded and the
spring force becomes weaker.
q As the spring force is weakened, spool (3)
moves to the left, the connecting between port
(C) and port (D) is shut off and the pump dis-
charge pressure ports (B) and (C) are con-
nected.
q As a result, the pressure on port (C) rises and
the pressure on the large diameter end of the
piston also rises. Thus, the rightward move of
servo piston (9) is stopped.
q Servo piston (9) stop position (= Pump deliv-
ery) is decided by the position where the push-
ing force generated from the pressures (PP1)
and (PP2) applied to spool (3), the pushing
force of the solenoid in PC-EPC valve gener-
ates and the pushing force of springs (4) and
(6) are balanced.

PC130-8 23
SEN03773-00 10 Structure, function and maintenance standard

2) When load on actuator is large and pump discharge pressure is high

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
10 Structure, function and maintenance standard SEN03773-00

q As a result, the pressure on port (C) (= J) is


decreased and the rightward move of servo
piston (9) is stopped.
q The position in which servo piston (9) stops at
this time is further to the left than the position
when pump pressures (PP1) and (PP2) are
low.
q The relationship between the average pump
pressure (PP1 + PP2)/2 and servo piston (9) in
terms of their positions can be represented by
the broken line in the figure because springs
(4) and (6) form the double springs.
q The relationship between the average pump
pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.

q If command current (X) sent to PC-EPC valve


solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the left
because of the pump pressure applied to the
spool (3), so the relationship between the aver-
age pump pressure (PP1 + PP2)/2 and the
pump delivery (Q) moves from (A) to (B) as the
command current (X) is increased.

PC130-8 25
SEN03773-00 10 Structure, function and maintenance standard

2. As the emergency pump drive switch is turned on due to failure on the pump
controller

1) When the main pump is under light load

26 PC130-8
10 Structure, function and maintenance standard SEN03773-00

q If there is a failure in the pump controller, the


emergency pump drive switch is turned on to
hand the control to the resistor side.
q In this case, the power is directly supplied from
the battery. The current, however, is too large
as is, so the resistor is set in between to con-
trol the current flowing to PC-EPC valve sole-
noid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pres-
sure and the PC-EPC valve solenoid (1) is
weaker than the spring set force, so spool (3)
is balanced at a position to the right.
q The port (C) is connected to the drain pressure
of the port (D), and the large diameter end of
the servo piston (9) also becomes the drain
pressure (PT) through the LS valve.
q Since the pressure on the small diameter end
of the piston is large, servo piston (9) moves in
the direction to make the delivery larger.

PC130-8 27
SEN03773-00 10 Structure, function and maintenance standard

2) When the main pump is under heavy load

28 PC130-8
10 Structure, function and maintenance standard SEN03773-00

q If the emergency pump drive switch is turned


on in the same way as in above, the command
current (X) sent to PC-EPC valve solenoid (1)
becomes constant.
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2)
increase, spool (3) moves further to the left
than when the main pump load is light, and is
balanced at the position in the figure above.
q In this case, the pressure from port (A) flows to
port (C), so servo piston (9) moves to the left
(smaller pump delivery) and stops at a position
to the further to the left then when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as
shown with the curve in the figure correspond-
ing to the current sent to the PC-EPC valve
solenoid through the resistor.
q The curve resulting when the emergency pump
drive switch is ON is situated further to the left
(B) than when the pump controller is normal
(A).

PC130-8 29
SEN03773-00 10 Structure, function and maintenance standard

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

30 PC130-8
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
SEN03773-00 10 Structure, function and maintenance standard

2. When signal current is very small 3. When signal current is maximum


(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressure on port (C) increases and the force to q Spool (5) is pushed toward right side by rod
act on spool (5) surface and the spring load on (6).
spring (4) become larger than the propulsion q The maximum volume of pressurized oil is
force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and PC
shut off from port (C). valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be balanced
with pressure of port (C) + spring load of spring
(4).
q The circuit pressure between the EPC valve
and the PC valve is controlled in proportion to
the size of the signal current.

32 PC130-8
10 Structure, function and maintenance standard SEN03773-00

Check valve

PA1: Discharge pressure of main pump 1. Poppet valve


PA2: Discharge pressure of main pump 2. Poppet valve
PP1: Output pressure of 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).

2. When (PA1) < (PA2)


q Reversely to 1., poppet valve (1) is kept closed
and (PA2) is output to (PP1).

PC130-8 33
SEN03773-00 10 Structure, function and maintenance standard

Shuttle valve

PA1: Discharge pressure of main pump


PA2: Discharge pressure of main pump
PP2: Output pressure of 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
10 Structure, function and maintenance standard SEN03773-00

PC130-8 35
SEN03773-00 10 Structure, function and maintenance standard

PC130-8 GALEO Hydraulic excavator


Form No. SEN03773-00

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)

36 PC130-8
SEN03774-01

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Hydraulic system, Part 2
Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 12
Functions and operation by valve ................................................................................................................. 16

PC130-8 1
SEN03774-01 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.

A1 : To swing motor PA6 : From bucket dump PPC valve


A2 : To left travel motor PA7 : From attachment 1 PPC valve
A3 : To right travel motor PA8 : From attachment 2 PPC valve
A4 : To boom cylinder bottom PB1 : From swing left PPC valve
A5 : To arm cylinder head PB2 : From left travel reverse PPC valve
A6 : To bucket cylinder head PB3 : From right travel forward PPC valve
A7 : To attachment 1 PB4 : From boom lower PPC valve
A8 : To attachment 2 PB5 : From arm in PPC valve
B1 : To swing motor PB6 : From bucket curl PPC valve
B2 : To left travel motor PB7 : From attachment 1 PPC valve
B3 : To right travel motor PB8 : From attachment 2 PPC valve
B4 : To boom cylinder head PMAX: Pressure sensor port
B5 : To arm cylinder bottom PP : To main pump
B6 : To bucket cylinder bottom PP1 : PP1 pressure pick-up port
B7 : To attachment 1 PP2 : PP2 pressure pick-up port
B8 : To attachment 2 PPI1 : Pump 1 pressure pick-up port
BP1: From boom raise PPC valve PPI2 : Pump 2 pressure pick-up port
LS : To pump LS valve PR : To solenoid valve and EPC valve
LS1 : LS1 pressure pick-up port PRI : PR pressure pick-up port
LS2 : LS2 pressure pick-up port PS : From solenoid valve of merge-divider valve
LS3 : LS3 pressure pick-up port PS2 : To tank
P1 : From main pump PST : From solenoid valve of travel junction sole-
P2 : From main pump noid valve
PA1: From swing right PPC valve PX : 2-stage relief solenoid valve
PA2: From left travel forward PPC valve TB : To tank
PA3: From right travel reverse PPC valve TC : To oil cooler
PA4: From boom raise PPC valve TS1 : To tank
PA5: From arm dump PPC valve TSW : To swing motor

1. Cover 9. Swing valve


2. Service valve 2 10. Block
3. Service valve 1 11. Swing bleeding valve
4. Bucket valve 12. LS check valve
5. Arm valve 13. Travel junction valve + LS check valve
6. Boom valve 14. Arm regeneration valve
7. Right travel valve 15. Boom hydraulic drift prevention valve
8. Left travel valve 16. Merge-divider valve block

2 PC130-8
10 Structure, function and maintenance standard SEN03774-01

PC130-8 3
SEN03774-01 10 Structure, function and maintenance standard

4 PC130-8
10 Structure, function and maintenance standard SEN03774-01

1. Suction safety valve (Service 2) 15. Suction safety valve (Service 1)


2. Suction safety valve (Service 1) 16. Suction safety valve (Service 2)
3. Suction valve (Bucket) 17. Suction safety valve
4. Suction valve (Arm) 18. Spool (Service 2)
5. Suction valve (Boom) 19. Spool (Service 1)
6. Lift check valve 20. Spool (Bucket)
7. Suction valve (Right travel) 21. Spool (Arm)
8. Suction valve (Left travel) 22. Spool (Boom)
9. Suction valve (Left travel) 23. Spool (Right travel)
10. Suction valve (Right travel) 24. Spool (Left travel)
11. Main relief valve 25. Spool (Swing)
12. Suction valve (Boom) 26. Unload valve
13. Suction valve (Arm) 27. Unload valve
14. Suction valve (Bucket)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installed Installed Installed
Free length
28 Suction valve spring Outside diameter length load load
5.49 N 4.41 N
46.8 × 7.5 40.6 —
{0.56 kg} {0.45 kg}
135 N 108 N
29 Piston return spring 72.7 × 20.6 42.5 —
{13.8 kg} {11.0 kg}
5.1 N 4.12 N
30 Suction valve spring 39.2 × 4.45 33.5 —
{0.52 kg} {0.42 kg}
141 N 113 N
31 Spool return spring 41.8 × 19 38.5 —
{14.4 kg} {11.5 kg}
55.9 N 44.7 N If damaged or
32 Spool return spring 27.14 × 25.8 25.5 —
{5.7 kg} {4.56 kg} deformed,
60.2 N 48.2 N replace spring
33 Spool return spring 32.4 × 11 31.4 —
{6.137 kg} {4.91 kg}
423 N 338 N
34 Spool return spring 76.78 × 20.9 70 —
{43.1 kg} {34.5 kg}
221 N 177 N
35 Spool return spring 45.7 × 28 43 —
{22.55 kg} {18.0 kg}
222 N 178 N
36 Spool return spring 42.4 × 28 39 —
{22.6 kg} {18.1 kg}
230 N 184 N
37 Spool return spring 45.6 × 28 43 —
{23.5 kg} {18.8 kg}
203 N 163 N
38 Spool return spring 45.81 × 28 43 —
{20.7 kg} {16.6 kg}

PC130-8 5
SEN03774-01 10 Structure, function and maintenance standard

6 PC130-8
10 Structure, function and maintenance standard SEN03774-01

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)

F: Flow control valve


R: Pressure reducing valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installed Installed Installed
Free length
20 Check valve spring Outside diameter length load load If damaged or
5.88 N 4.71 N deformed,
41.5 x 8.5 31.5 — replace spring
{0.6 kg} {0.48 kg}
2.94 N 2.35 N
21 Check valve spring 20.3 x 13.7 16 —
{0.3 kg} {0.24 kg}

PC130-8 7
SEN03774-01 10 Structure, function and maintenance standard

8 PC130-8
10 Structure, function and maintenance standard SEN03774-01

1. LS selector valve

Swing valve
2. Pressure compensation valve F
3. Spool
4. Pressure compensation valve R
5. Swing bleeding valve

Left travel valve


6. Pressure compensation valve R
7. Suction valve
8. Suction valve
9. Spool
10. Pressure compensation valve F
11. LS check valve

Right travel valve


12. Pressure compensation valve F
13. Suction valve
14. Suction valve
15. Spool
16. Pressure compensation valve R
17. Travel junction valve + LS check valve

18. Unload valve


19. LS bypass valve
20. Merge-divider valve spool

F: Flow control valve


R: Pressure reducing valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installed Installed Installed
Free length
21 Check valve spring Outside diameter length load load
3.92 N 3.14 N
23.3 × 12.5 23 —
{0.4 kg} {0.32 kg}
1.96 N 1.57 N
22 Check valve spring 21.9 × 5 15.8 —
{0.2 kg} {0.16 kg}
0.98 N 0.78 N
23 Retainer spring 9.1 × 4.2 7.4 —
{0.10 kg} {0.08 kg} If damaged or
15.7 N 12.6 N deformed,
24 Spool return spring 19.26 × 7.5 14 — replace spring
{1.6 kg} {1.28 kg}
1.96 N 1.57 N
25 Check valve spring 21.9 × 5 15.8 —
{0.2 kg} {0.16 kg}
83.4 N 66.7 N
26 Valve return spring 58.9 × 13 53 —
{8.5 kg} {6.8 kg}
98.1 N 78.5 N
27 Spool return spring 49.8 × 18.8 33 —
{10 kg} {8 kg}
13.7 N 11.0 N
28 Check valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.12 kg}

PC130-8 9
SEN03774-01 10 Structure, function and maintenance standard

10 PC130-8
10 Structure, function and maintenance standard SEN03774-01

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

F: Flow control valve


R: Pressure reducing valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installed Installed Installed
Free length
32 Valve return spring Outside diameter length load load
83.4 N 66.7 N If damaged or
58.9 × 13 53 —
{8.5 kg} {6.8 kg} deformed,
168 N 134 N replace spring
33 Spool return valve spring 67.47 × 20.6 42.5 —
{17.1 kg} {13.7 kg}
5.88 N 4.71 N
34 Valve spring 41.5 × 8.5 31.5 —
{0.6 kg} {0.48 kg}

PC130-8 11
SEN03774-01 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 SEN03774-01

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.

LS differential pressure ( PLS) and pump


swash plate angle

a For details of functions, see the "Hydraulic


pump" paragraph.

PC130-8 13
SEN03774-01 10 Structure, function and maintenance standard

2. Pressure compensation control

q A pressure compensation valve is installed to


the outlet port side of the control valve to bal-
ance the load.
q When actuators are operated together, the
p r e s s u r e d i ff e r e n c e ( P ) b e t w e e n t h e
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of opening
(S1) and (S2) of each valve.

14 PC130-8
10 Structure, function and maintenance standard SEN03774-01

PC130-8 15
SEN03774-01 10 Structure, function and maintenance standard

Functions and operation by valve 1


Hydraulic circuit diagram and the name of valves 1

16 PC130-8
10 Structure, function and maintenance standard SEN03774-01

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/cm²}
29. Suction safety valve
Set pressure: 24.5 MPa {250 kg/cm²}
30. Main relief valve
Set pressure: 31.9 MPa {325 kg/cm²}
In one-touch power maximizing mode:
34.5 MPa {352 kg/cm²}
31. Unload valve

PC130-8 17
SEN03774-01 10 Structure, function and maintenance standard

Unload valve
1. When control valve is at HOLD

Function q When the control valve is at HOLD, LS pres-


q When the control valve is at HOLD, pump sures (LS1) and (LS2) are not generated, so
delivery (Q) discharged by the minimum swash only pump discharge pressures (P1) and (P2)
plate angle is released to the tank circuit. At act, and (P1) and (P2) are set by only the load
this time, pump discharge pressure (P1) and of spring (2).
(P2) is set by spring (2) in the valve. [LS pres- q As pump discharge pressure (P1) and (P2)
sure (LS1) and (LS2) = 0 MPa {0 kg/cm²}] rises and reaches the load of spring (2), spool
q Since the pump merge-divider valve is at the (1) is moved to the left. Pump discharge pres-
merge position, pump discharge pressures sures (P1) and (P2) are connected to tank cir-
(P1) and (P2) are merged. LS pressures (LS1), cuit (T) through the notch of spool (1).
(LS2), and (LS3) are also merged.

Operation
q Pump discharge pressures (P1) and (P2) are
applied to pump pressure receiving (SA) face
of unload spool (1).
q LS pressures (LS1) and (LS2) are applied to
LS pressure receiving (SB) face. [(P1) = (P2),
(LS1) = (LS2)]

18 PC130-8
10 Structure, function and maintenance standard SEN03774-01

2. When work equipment valve is operated

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
SEN03774-01 10 Structure, function and maintenance standard

3. During fine control of both travel valves

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 SEN03774-01

4. When both travel valves are operated

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
SEN03774-01 10 Structure, function and maintenance standard

5. When either travel valve is operated

Function q The area of the openings of left travel valve


q The demand flow decided by the valve stroke spool is large, so LS pressures (LS1) is not so
is sent to the travel circuit on the operated different from pump discharge pressures (P1).
travel valve side and the all pump discharge q For this reason, the difference between pump
amount is sent to the tank circuit on the non- discharge pressure (P1) and LS pressure
operated travel valve side. (LS1) does not reach the load of spring (2), so
q Since the pump merge-divider valve is at the spool (1) is pushed to the right by spring (2).
separate position, pump discharge pressures q As a result, pump discharge pressures (P1)
(P1) and (P2) are separated. LS pressures and tank circuit (T) are shut off, and all pump
(LS1) and (LS2) are also separated. discharge amount (QP1) on the (P1) side flows
q The swash plate angle of the pump becomes to the left travel circuit.
maximum, so the pump discharge amount q Since the right travel valve is at HOLD, LS
becomes maximum. (For details, see the sec- pressure (LS2) is not generated, so only pump
tions on the pump merge-divider valve.) discharge pressure (P2) acts.
q When pump discharge pressure (P2) reaches
Operation the load of spring (2), spool (1) moves to the
left, and all pump discharge amount (QP2) on
When left travel valve is operated to stroke end the (P2) side flows into tank circuit (T).
and right one is at HOLD.
q When the left travel valve is operated to the
stroke end, LS pressure (LS1) is generated
and acts on the face (SB) of unload spool (1).

22 PC130-8
10 Structure, function and maintenance standard SEN03774-01

PC130-8 23
SEN03774-01 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 SEN03774-01

2. When oil is divided: (PS) = 30 kg/cm2

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
SEN03774-01 10 Structure, function and maintenance standard

Introduction of LS pressure
1. Work equipment valve

Function q When this happens, LS circuit (PLS) is con-


q The LS pressure is the actuator load pressure nected to tank circuit (T) from LS bypass valve
at the outlet port end of the control valve. (4) (See the section on the LS bypass valve).
q Actually, pump discharge pressure (PP) is q The areas at both ends of reducing valve (3)
reduced by reducing valve (3) of the pressure are the same [(SA) = (SLS)], and actuator cir-
compensation valve to the same pressure as cuit pressure (PA) acts on the (SA) end. The
actuator circuit pressure (A) and sent to LS cir- reduced pump discharge pressure (PP) acts
cuit (PLS). on (SLS) at the other end.
q In the travel valve, actuator circuit pressure (A) q As a result, reducing valve (3) is balanced at a
is directly introduced to LS circuit (PLS). position where actuator circuit pressure (PA)
and the pressure of spring chamber (PLSS)
Operation are the same. Pump discharge pressure (PP)
q When spool (1) is operated, pump discharge reduced at notch (c) becomes actuator pres-
pressure (PP) flows from flow control valve (2) sure (A) and is introduced into LS circuit (PLS).
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit (A).
q At the same time, reducing valve (3) also
moves to the right, so pump discharge pres-
sure (PP) is reduced by the pressure loss at
notch (c). It goes to LS circuit (PLS), and then
goes to spring chamber (PLSS).

26 PC130-8
10 Structure, function and maintenance standard SEN03774-01

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).

a The travel circuit is different from the work


equipment circuit: actuator circuit pressure
(PA) is directly introduced into LS circuit (PLS).

PC130-8 27
SEN03774-01 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 SEN03774-01

2. When either or both travel valves are operated


(Including operation of only one travel valve)

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
SEN03774-01 10 Structure, function and maintenance standard

Pressure compensation valve

30 PC130-8
10 Structure, function and maintenance standard SEN03774-01

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
SEN03774-01 10 Structure, function and maintenance standard

Area ratio of pressure compensation valve

Function Area ratio (S1) : (S2) and compensation charac-


q The pressure compensation valve slightly teristics
adjusts the ratio (S2) and (S1) of the area (S1) q When the ratio is 1.00 :
on the left side of the flow control valve (2) and The expression [Pump (discharge) pres-
the area (S2) on the right side of the pressure sure (PP) – Spool notch upstream pres-
reducing valve (1) to suite the characteristics sure (PPB)] C [LS circuit pressure (PLS) –
of each actuator and determines the compen- Actuator circuit pressure (PA) (= A)] can
sation characteristics. be held, and the flow is distributed as per
the spool opening area ratio.
S1 : Area of the flow control valve (2) – area of the q When the ratio is more than 1.00:
piston (3) The expression (PP) – (PPB) > (PLS) –
S2 : Area of the pressure reducing valve (1) – (PA) (= A) can be held, and the flow is dis-
area of the piston (3) tributed less than the spool opening area
ratio.
q When the ratio is less than 1.00:
The expression (PP) – (PPB) < (PLS) –
(PA) (= A) can be held, and the flow is dis-
tributed more than the spool opening area
ratio.

32 PC130-8
10 Structure, function and maintenance standard SEN03774-01

Boom regeneration circuit


1. At boom lower and own weight fall

Function q At the time, part of the return flow on the bot-


q When the boom is lowered and falls due to its tom side passes through the regeneration pas-
own weight because the bottom pressure (A) sage (a) of the boom spool (2), pushes the
in the cylinder (1) is higher than the head pres- check valve (3) to open it and flows to the head
sure (B), this circuit brings the return flow on side.
the bottom side to the head side to increase q This increases the boom lower speed.
the cylinder speed.

Operation
q When the boom is lowered and falls due to its
own weight, the bottom side pressure (A) in the
boom cylinder (1) will rise above the head side
pressure (B).

PC130-8 33
SEN03774-01 10 Structure, function and maintenance standard

2. At boom lower load process

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 SEN03774-01

Arm regeneration circuit


1. At arm in and own weight fall

A : Head circuit 1. Arm cylinder


B : Bottom circuit 2. Arm spool
PP : Pump circuit 3. Check valve

Function q At the time, part of the return flow on the head


q When the arm falls due to its own weight side passes through the regeneration passage
because the head pressure (A) in the arm cyl- (a) of the arm spool (2), pushes the check
inder (1) is higher than the bottom pressure (B) valve (3) to open it and flows to the bottom
during arm digging, this circuit brings the return side.
flow on the head side to the bottom side to q This increases the arm digging speed.
increase the cylinder speed.

Operation
q When the arm falls for digging due to its own
weight, the head side pressure (A) in the arm
cylinder (1) will rise above the bottom side
pressure (B).

PC130-8 35
SEN03774-01 10 Structure, function and maintenance standard

2. At arm in process

A : Head circuit 1. Arm cylinder


B : Bottom circuit 2. Arm spool
PP : Pump circuit 3. Check valve

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 SEN03774-01

Hydraulic drift prevention valve


1. When boom is raised

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
SEN03774-01 10 Structure, function and maintenance standard

2. When boom and arm are set in neutral

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 SEN03774-01

3. When boom is lowered

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
SEN03774-01 10 Structure, function and maintenance standard

Swing bleeding valve

Function q Accordingly, the intermediate pressure is set


q When the machine swings, the bleeding valve lower than pump discharge pressure (PP) and
installed to the pressure reducing valve works raised as bleeding spool (3) moves. As a
so that the LS pressure rises gradually and the result, LS pressure (PLS) rises gradually.
machine swings smoothly. q When the lever is in neutral or operated fully,
the bleed-off circuit is closed.
Operation
(In fine control operation)
q The pressure reducing valve moves to the right
and notch (a) connects to the LS circuit. As a
result, pump circuit (PP), bleed-off circuit, and
LS circuit are connected through piston (2).
q Bleeding spool (3) moves to the left in propor-
tion as swing PPC pressure (PA) rises. In the
fine control area, notch (b) chokes the bleed-
off circuit and determines the intermediate
pressure before the lowered pressure is
applied to pump discharge pressure (PP) and
LS pressure (PLS).

40 PC130-8
10 Structure, function and maintenance standard SEN03774-01

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
SEN03774-01 10 Structure, function and maintenance standard

2. At simultaneous operation of swing + boom RAISE

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 SEN03774-01

Travel junction valve

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
SEN03774-01 10 Structure, function and maintenance standard

Self pressure reducing valve

Function When abnormally high pressure is generated


q The self pressure reducing valve lowers the q If the (PR) pressure of the self pressure reduc-
discharge pressure of the main pump and sup- ing valve is raised abnormally, ball (6) sepa-
plies it as the control pressure for the solenoid rates from the seat against the force of spring
valves, PPC valves, etc. (5). As a result, the hydraulic oil flows from
output port (PR) to (TS) and the (PR) pressure
Operation lowers.
q If the (PR) pressure rises higher than the set q Accordingly, the devices receiving the oil pres-
level, poppet (1) opens and the hydraulic oil sure (PPC valves, solenoid valves, etc.) are
flows from port (PR) through orifice (a) in spool protected from abnormally high pressure.
(4) and opening of poppet (1) into seal drain
port (TS).
q Accordingly, differential pressure is generated
over orifice (a) in spool (4) and spool (4)
moves in the direction to close the opening
between ports (P) and (PR). The (P) pressure
is lowered and controlled to a constant pres-
sure (set pressure) by the opening ratio at this
time and supplied as the (PR) pressure.

44 PC130-8
10 Structure, function and maintenance standard SEN03774-01

Lift check valve and cooler bypass valve

Lift check valve Cooler bypass valve

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
SEN03774-01 10 Structure, function and maintenance standard

PC130-8 Hydraulic excavator


Form No. SEN03774-01

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)

46 PC130-8
SEN03775-02

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Hydraulic system, Part 3
PPC valve ....................................................................................................................................................... 2
Swing motor .................................................................................................................................................. 17
Travel motor .................................................................................................................................................. 25
Center swivel joint......................................................................................................................................... 34
Solenoid valve............................................................................................................................................... 36
Accumulator .................................................................................................................................................. 40
Holding valve ................................................................................................................................................ 42
Hydraulic cylinder.......................................................................................................................................... 48

PC130-8 1
SEN03775-02 10 Structure, function and maintenance standard

PPC valve 1
Work equipment and swing PPC valve 1

P : From self-pressure reducing valve


P1 : L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port
P2 : L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port
P3 : L.H. PPC valve: Swing LEFT port/R.H PPC valve: Bucket CURL port
P4 : L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port
T : To tank

2 PC130-8
10 Structure, function and maintenance standard SEN03775-02

PC130-8 3
SEN03775-02 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 SEN03775-02

Operation q The relationship of the position of spool (1) and


body (10) [fine control hole (f) is in the middle
1. When in neutral between drain chamber (D) and pump pres-
q Ports (A) and (B) of the control valve and ports sure chamber (PP)] does not change until
(P1) and (P2) of the PPC valve are connected retainer (9) contacts spool (1).
to drain chamber (D) through fine control hole q Metering spring (2) contracts in proportion to
(f) in spool (1). the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.

2. During fine control


(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).

PC130-8 5
SEN03775-02 10 Structure, function and maintenance standard

3. During fine control 4. At full stroke


(When control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain from port (P2) through fine control hole (f') and
chamber (D), and it is almost simultaneously flows to drain chamber (D).
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.

6 PC130-8
10 Structure, function and maintenance standard SEN03775-02

Travel PPC valve

P : From self-pressure reducing valve


P1 : L.H. REVERSE
P2 : L.H. FORWARD
P3 : R.H. REVERSE
P4 : R.H. FORWARD
T : To hydraulic tank

PC130-8 7
SEN03775-02 10 Structure, function and maintenance standard

8 PC130-8
10 Structure, function and maintenance standard SEN03775-02

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
SEN03775-02 10 Structure, function and maintenance standard

Operation q The relationship of the position of spool (1) and


body (10) [fine control hole (f) is in the middle
1. When in neutral between drain chamber (D) and pump pres-
q Ports (A) and (B) of the control valve and ports sure chamber (PP)] does not change until
(P1) and (P2) of the PPC valve are connected retainer (9) contacts spool (1).
to drain chamber (D) through fine control hole q Metering spring (2) contracts in proportion to
(f) in spool (1). the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.

2. During fine control


(Neutral o fine control)
q When piston (4) is pushed by lever (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).

10 PC130-8
10 Structure, function and maintenance standard SEN03775-02

3. During fine control 4. At full stroke


(When control lever is returned) q Lever (5) pushes down piston (4), and retainer
q When lever (5) starts to be returned, spool (1) (9) pushes down spool (1).
is pushed up by the force of centering spring q Fine control hole (f) is shut off from drain
(3) and pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain from port (P2) through fine control hole (f') and
chamber (D), and it is almost simultaneously flows to drain chamber (D).
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.

PC130-8 11
SEN03775-02 10 Structure, function and maintenance standard

Attachment PPC valve


(with EPC valve) 1

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 SEN03775-02

P : From self-pressure reducing valve


P1 : To service valve
P2 : To service valve
T : To tank

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
SEN03775-02 10 Structure, function and maintenance standard

1. EPC valve

C: To control valve 3. Spool


P: From self-pressure reducing valve 4. Push pin
T: To hydraulic tank 5. Coil
6. Plunger
1. Body 7. Connector
2. Plug

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 SEN03775-02

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
SEN03775-02 10 Structure, function and maintenance standard

2) When signal current is very small 3) When signal current is maximum


(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (5), coil (5) is
(5), coil (5) is energized, and a propulsion force energized.
is generated on the left side of plunger (6). q When this happens, the signal current is at its
q Push pin (4) pushes spool (2) to the left, and maximum, so the propulsion force of plunger
pressurized oil flows from port (P) to port (C). (6) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (2) is pushed to the left by push pin (4).
to act on surface (a) of spool (2) and the spring q The maximum volume of pressurized oil is
load on spring (3) become larger than the pro- conducted from port (P) to port (C), increasing
pulsion force of plunger (6). the circuit pressure across EPC valve and the
q Spool (2) is pushed to the right, port (P) is shut control valve to the maximum level.
off from port (C) and ports (C) and (T) are con- q Since port (T) is closed, pressurized oil does
nected. not flow to the hydraulic tank.
q Spool (2) moves up and down so that the pro-
pulsion force of plunger (6) may be balanced
with pressure of port (C) + spring load of spring
(3).
q The circuit pressure between the EPC valve
and the control valve is controlled in proportion
to the size of the signal current.

16 PC130-8
10 Structure, function and maintenance standard SEN03775-02

Swing motor 1
Type: KMF45ABE-5

B: From swing holding brake solenoid valve Specifications


MA: From control valve Type : KMF45ABE-5
MB: From control valve Theoretical displacement : 143.8 cm³/rev
S: From control valve Safety valve set pressure : 27.1 MPa {276 kg/cm²}
T: To tank Rated speed : 2,111 rpm
Brake release pressure : 1.1 MPa {11 kg/cm²}
1. Reverse prevention valve
2. Safety valve

PC130-8 17
SEN03775-02 10 Structure, function and maintenance standard

18 PC130-8
10 Structure, function and maintenance standard SEN03775-02

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
SEN03775-02 10 Structure, function and maintenance standard

Swing holding brake

1. When solenoid valve is de-energized 2. When solenoid valve is energized

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 SEN03775-02

Relief valve portion

Outline 2. When swing is stopped


q The relief valve portion consists of check q When the swing control lever is returned to
valves (2) and (3), shuttle valves (4) and (5), neutral, the supply of pressurized oil from the
and relief valve (1). pump to port (MA) is stopped.
q The pressurized oil from the motor outlet can't
Function return to the tank since the returning circuit to
q When the machine is in the swing holding the tank is closed from control valve (6). Thus,
mode, control valve (6) closes the motor outlet pressure on port (MB) increases.
circuit, but the motor rotation is continued by q Rotation resistance is generated on the motor
inertial force. and hence the brake starts working.
q The motor output, therefore, is abnormally q Shuttle valve (4) is pressed as pressure on
increased, resulting in damaging the motor. port (MB) goes above port (MA).
q In order to prevent the motor damages, the q The pressure on chamber (C) is increased to
relief valve relieves the abnormally high pres- the se t pr es sure of relief va lv e (1) an d
sure to port (S) from the motor outlet side becomes the same as that of port (MB).
(high-pressure side) of the motor. q A high braking torque works on the motor,
thereby stopping the motor.
Operation q When relief valve (1) is being actuated, the
1. When starting swing relieved pressurized oil and the pressurized oil
q When the swing control lever is operated to the from port (S) are fed to port (MA) via check
right- swing, the pressurized oil from the pump valve (3).
is supplied to port (MA) via control valve (6). q Above prevents cavitation on port (MA).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through the con-
trol valve (6) and returns to the tank.

PC130-8 21
SEN03775-02 10 Structure, function and maintenance standard

Reverse prevention valve

22 PC130-8
10 Structure, function and maintenance standard SEN03775-02

MA: From control valve


MB: From control valve
T1: To tank
T2: To tank

1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)

Explanatory drawing of effects

PC130-8 23
SEN03775-02 10 Structure, function and maintenance standard

Function 2. When motor is stopped temporarily


q This valve reduces the swing back generation q The motor rotation is reversed by the closing
in the swing body by the inertia of the swing pressure generated at port (MB). (1st time:
body, the backlash and rigidity of the machin- reverse rotation)
ery system, and the compression of the q Reversing pressure is generated on port (MA).
hydraulic oil when the swing is stopped. Pressure (MA) is conducted to chamber (a).
q The valve contributes in preventing collapsing q The pressure compresses spring (3) by use of
of load when the swing is stopped and also the difference in areas of circles (øD3 > øD4)
contributes in reducing cycle time (enhances of spool (2) and moves spool (2) to the right
the positioning performance, enabling you to side.
proceed to the next work quicker than ever). q Port (MA) o chamber (b) will be intercon-
nected.
Operation q Ports (b) and (f) will be interconnected through
the drilled hole (h) on spool (5). This intercon-
1. When port (MB) brake pressure is generated nection bypasses the reversing pressure on
q Pressure (MB) is conducted to chamber (d) via port (MA) to port (T), thereby preventing the
notch (g). reverse rotation of the 2nd time.
q The pressure compresses spring (6) by use of
the difference in areas of circles (øD1 > øD2)
of spool (5) and moves spool (5) to the left
side.
q Port (MB) o chamber (e) will be intercon-
nected.
q Since pressure (MA) is lower than the set pres-
sure of spring (3), spool (2) does not move and
the pressurized oil is kept in. Thus the braking
force is ensured.

24 PC130-8
10 Structure, function and maintenance standard SEN03775-02

Travel motor 1
(With reduction gears)

A: From center swivel joint, port B2


(L.H. travel motor)
From center swivel joint, port C2
(R.H. travel motor)
B: From center swivel joint, port D2
(L.H. travel motor)
From center swivel joint, port A2
(R.H. travel motor)
D: To center swivel joint, port DR2
P: From center swivel joint, port E2

1. Oil filler plug


2. Oil level plug
3. Drain plug

PC130-8 25
SEN03775-02 10 Structure, function and maintenance standard

1. Plug 16. Cover


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

26 PC130-8
10 Structure, function and maintenance standard SEN03775-02

Specifications
Type GM21VA-A
Stroke volume Hi 44.2
(cm³/rev) Lo 79.1
Rated speed Hi 2,809
(rpm) Lo 1,486
Brake releasing pressure 0.76
(MPa{kg/cm²}) {7.71}
Hi-Lo switching pressure 2.94
(MPa{kg/cm²}) {30}
Reduction ratio 54.0

Outline

1. Reduction gears (Final drive) 4. 2nd travel speed selector mechanism


Consists of 2-stage planetary gear mecha- Consists of the regulator valve and regulator
nism. Reduces the hydraulic motor speed from piston. Changes the rotation speed in 2 stages
high speed to low speed high torque. by changing the stroke volume of the hydraulic
motor.
2. Hydraulic motor
Swash plate type axial piston motor mecha- 5. Parking brake
nism. Converts oil pressure from the hydraulic Multiple disc type brake mechanism. Forms a
pump into rotary motion. unit with the hydraulic motor.

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
SEN03775-02 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 SEN03775-02

At high speed (the motor swash plate angle is minimized.)

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
SEN03775-02 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 SEN03775-02

Brake operation at travelling downhill

q If the machine is going to run away when trav-


eling downhill, the motor idles and the hydrau-
lic pressure at port (C) drops. The pressure of
hydraulic oil that is sent to chamber (G)
through orifice (f) also drops.
q When the hydraulic oil pressure in chamber
(G) goes below spring (3) reaction force, coun-
terbalance valve (2) starts to return to the left.
q The hydraulic oil in chamber (J) tends to flow
to port (B) through orifice (h). However, the
back pressure is generated by closing of orifice
(h), controlling the return speed of counterbal-
ance (2) to the right.
q When ports (D) and (B) are closed and when
the hydraulic pressure at port (D) increases, a
resistance is generated in motor rotation to
protect the machine from running away.
q Counterbalance valve (2) is moved to the posi-
tion where the hydraulic pressure at port (B) is
well balanced with the pressure by the weight
of machine itself and the pressure at port (A).
The motor speed is controlled according to the
pump delivery by controlling the opening of
hydraulic oil output circuit.

PC130-8 31
SEN03775-02 10 Structure, function and maintenance standard

Relief valve

When starting When stopping

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 SEN03775-02

PC130-8 33
SEN03775-02 10 Structure, function and maintenance standard

Center swivel joint 1


Standard specification

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 SEN03775-02

Unit: mm
No. Item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
1 Replace
shaft ø 80 0.056 – 0.105 0.111

PC130-8 35
SEN03775-02 10 Structure, function and maintenance standard

Solenoid valve 1

36 PC130-8
10 Structure, function and maintenance standard SEN03775-02

P1 : From self pressure reducing valve


A1 : To PPC valve
A2 : To control valve, port PS
A3 : To control valve, port PST
A4 : To center swivel joint, port E1
A5 : To swing motor, port B
A6 : To control valve, port Px
T : To hydraulic tank
ACC : To accumulator (for PPC circuit)

1. PPC lock solenoid valve


2. Merge-flow divider solenoid valve
3. Travel junction solenoid valve
4. 2nd travel speed select solenoid valve
5. Swing holding brake solenoid valve
6. 2-stage relief solenoid valve

Solenoid valve
7. Coil (ON/OFF type)
8. Push pin
9. Valve spool
10. Sleeve
11. Block
12. Plug

Check valve
13. Plunger
14. Plug

PC130-8 37
SEN03775-02 10 Structure, function and maintenance standard

Operation Solenoid valve

Check valve When solenoid valve is “de-energized“ (circuit


is closed)

q Installed between port (P) and PPC solenoid


valve. When the engine is stopped, plunger (1) q Coil (1) is de-energized when no signal current
is pushed back to the left with spring (2) reac- is supplied to coil (1).
tion force, and ports (ACC) and (P) are closed q Spool (2) is pushed back to the left with spring
to maintain the pressure in the accumulator. (3) reaction force.
q When the engine is running, plunger (1) is q As ports (P) and (A) are closed, the pilot pres-
pushed to the right with the pilot pressure that sure is not fed to the actuator through port (A).
is sent to port (P), and ports (P) and (ACC) are At the same time, port (T) is opened, allowing
interconnected. the oil from the actuator to drain to the hydrau-
lic tank.

When solenoid valve is “energized“ (circuit is


connected)

q Coil (1) is energized when signal current is


supplied to coil (1).
q Spool (2) is pushed to the right with push pin
(4).
q As ports (P) and (A) are opened, the pilot pres-
sure is fed to the actuator through port (A).
At the same time, port (T) is closed, shutting off
the oil from the actuator to the hydraulic tank.

38 PC130-8
10 Structure, function and maintenance standard SEN03775-02

PC130-8 39
SEN03775-02 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/cm²} (at 80°C)
Maximum operating pressure:
6.86 MPa {70 kg/cm²}

40 PC130-8
10 Structure, function and maintenance standard SEN03775-02

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/cm²} (at 80°C) Sealed gas pressure:
Maximum operating pressure: 0.69 MPa {7 kg/cm²} 5.88 MPa {60 kg/cm²} (at 80°C)
Maximum operating pressure:
20.6 MPa {210 kg/cm²}

PC130-8 41
SEN03775-02 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 SEN03775-02

CY : To work equipment cylinder


PCY: For pressure pickup port and equalizer circuit
PI : From PPC valve
T : To tank
V : From control valve

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 × ø 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 × ø 9.6 35.0 —
{6.0 kg} {4.8 kg}
78.5 N 62.8 N
6 Spool return spring 41.9 × ø 25.8 41.0 —
{8.0 kg} {6.4 kg}

PC130-8 43
SEN03775-02 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

When the piping is free of breakage If the piping is bursted


q Check valve (5) is closed under the holding q If piping (A) is broken between the control
pressure of the cylinder led from port (CY) to valve and the work equipment cylinder, cham-
chamber (b). bers (a) and (b) are shut off in the same way
q At the neutral, pilot pressure led to port (PI) as the piping is free from damages.
from the PPC valve is 0 MPa {0 kg/cm²}. q Pressure for the work equipment cylinder is
q Spool (1) is pressed to the left by the force of held to prevent a sudden drop of the work
springs (2) and (3). equipment.
q Chambers (a) and (b) are shut off.
q No pressurized oil flows between the control
valve and the work equipment cylinder.
q Accordingly, the work equipment is held in
position.
q If the work equipment cylinder has abnomally
high pressure, safety valve (4) is actuated by
the holding pressure of the work equipment
cylinder.
q Chambers (b) of L.H. and R.H. holding valve
for the boom are interconnected by port (PCY).
q Chambers (b) will have the same pressure if
the L.H. and R.H. holding valves have a differ-
ence in leakage.

44 PC130-8
10 Structure, function and maintenance standard SEN03775-02

2. When pressurized oil flows from the main


valve to the cylinder

When the piping is free of breakage


q Pressurized oil led to chamber (a) from the
control valve becomes higher than the com-
bined force of pressure from work equipment
cylinder circuit chamber (b) and spring (6).
q Check valve (5) opens and chambers (a) and
(b) are interconnected.
q Pressurized oil flows from the control valve to
the work equipment cylinder.

If the piping is bursted


q If piping (A) between the control valve and the
work equipment cylinder is broken, pressur-
ized oil in chamber (a) flows outside from the
damaged portion.
q Pressure force in chamber (a) drops.
q Pressure force in chamber (a) drops lower than
the combined pressure force of chamber (b)
and spring (6).
q Check valve (5) closes and chambers (a) and
(b) are cut off.
q Pressure for the work equipment cylinder is
held to prevent a sudden drop of the work
equipment.

PC130-8 45
SEN03775-02 10 Structure, function and maintenance standard

3. When returning pressurized oil to the main


valve from the work equipment cylinder

When the piping is free of burst If the piping is bursted


q Holding pressure of the work equipment cylin- q If piping (A) bursts between the control valve
der is led to chamber (b) and check valve (5) and the work equipment cylinder.
closes. q Pressurized oil in chamber (a) flows out to the
q Pilot pressure from the PPC valve is led to port bursted portion but resupplied from chamber
(PI) and reaches [Pilot Pressure > Force of (b).
Spring (3)] (area of d). q Since pressurized oil flows via opening (c) of
q Spool (1) moves to the right to the standby spool (1), a sudden drop of the cylinder is pre-
position.(1st stage stroke) vented.
q At this point, chambers (a) and (b) are not
interconnected.
q & Pilot pressure further rises, and reaches
[Pilot pressure > Force of spring (2)] (area of
d).
q Spool (1) moves further to the right, and cham-
bers (a) and (b) are interconnected. (2nd stage
stroke)
q Pressurized oil returns to the control valve
from the work equipment cylinder.

46 PC130-8
10 Structure, function and maintenance standard SEN03775-02

PC130-8 47
SEN03775-02 10 Structure, function and maintenance standard

Hydraulic cylinder 1
Boom cylinder

Arm cylinder

Bucket cylinder

48 PC130-8
10 Structure, function and maintenance standard SEN03775-02

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 ø 70 0.435
-0.076 +0.063 0.335
1 piston rod and bush-
ing -0.030 +0.279 0.095 –
Arm ø 75 0.455
-0.076 +0.065 0.355
-0.030 +0.250 0.085 –
Bucket ø 65 0.426
-0.076 +0.055 0.326
-0.030 +0.190 0.120 –
Boom ø 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 ø 70 1.0
-0.100 +0.090 0.290
shaft and bushing
-0.030 +0.170 0.100 –
Bucket ø 65 1.0
-0.080 +0.070 0.250
-0.030 +0.190 0.120 –
Boom ø 70 1.0
Clearance between -0.100 +0.090 0.290
cylinder bottom -0.030 +0.190 0.120 –
3 Arm ø 70 1.0
support shaft and -0.100 +0.090 0.290
bushing -0.030 +0.170 0.100 –
Bucket ø 65 1.0
-0.080 +0.070 0.250

PC130-8 49
SEN03775-02 10 Structure, function and maintenance standard

PC130-8 Hydraulic excavator


Form No. SEN03775-02

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)

50 PC130-8
SEN03776-00

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of components............................................................................................................................. 4

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 –
ø 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 ø 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 ø 60 0.8 bushing
-0.080 +0.074 0.209
bucket
Clearance between mounting -0.030 +0.133 0.105 –
4 ø 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 ø 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 ø 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 — ø 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 — ø 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 — ø 60
-0.080 0
0
Link side 259
16 -1.0
Bucket side 261 ±1.0
-0.030 +0.200
17 — ø 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 — ø 60
0
10 — ø 64 —
+0.25
11 — ø 80
0
12 — 261 ±1.0
13 — 50 —
14 — 85 —
+1.0
15 — 380
0
16 — 18 —
17 — ø 110 —
18 — ø 130 —
19 — ø 132 —
20 — ø 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

PC130-8 GALEO Hydraulic excavator


Form No. SEN03776-00

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)

8 PC130-8
SEN03777-00

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Cab and its attachments
Air conditioner ................................................................................................................................................. 2

PC130-8 1
SEN03777-00 10 Structure, function and maintenance standard

Air conditioner 1
Air conditioner piping

1. Air conditioner unit A: Fresh air


2. Hot water pickup piping B: Recirculated air
3. Air conditioner compressor C: Hot air/cold air
4. Refrigerant piping
5. Condenser
6. Hot water return piping
7. Duct

2 PC130-8
10 Structure, function and maintenance standard SEN03777-00

PC130-8 3
SEN03777-00 10 Structure, function and maintenance standard

PC130-8 GALEO Hydraulic excavator


Form No. SEN03777-00

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (02)

4 PC130-8
SEN03778-01

HYDRAULIC EXCAVATOR
PC130-8

Machine model Serial number


PC130-8 80001 and up

10 Structure, function and


maintenance standard 1
Electrical system
Electronic control system ................................................................................................................................ 2
Machine monitor system ............................................................................................................................... 33
KOMTRAX system........................................................................................................................................ 47
Sensor........................................................................................................................................................... 49

PC130-8 1
SEN03778-01 10 Structure, function and maintenance standard

Electronic control system 1


Machine control system diagram

2 PC130-8
10 Structure, function and maintenance standard SEN03778-01

PC130-8 3
SEN03778-01 10 Structure, function and maintenance standard

Engine control function

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 SEN03778-01

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 "prevent the
engine from starting 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,
that is, starting motor cut-out relay (9) cuts off
the starting current to starting motor (13).
However, if lock lever (7) is set in the "FREE"
position at this time, the neutral safety mecha-
nism works so that starting motor cut-out relay
(9) will cut off the starting current to starting
motor (13) to prevent the engine from starting.
q Upon receipt of the engine cut-off command
from the external source, KOMTRAX terminal
(19) sends the signal to machine monitor (18).
Machine monitor (18) causes starting motor
cut-out relay (10) to cut off the starting current
to starting motor (13), therefore the engine
does not start.

Engine speed control


q Upon receipt of a fuel control dial (11) control
signal, engine controller (6) sends a command
current to fuel supply pump (14) to adjust the
fuel injection amount to control the engine
speed.

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
SEN03778-01 10 Structure, function and maintenance standard

Pump and engine mutual control function

1. Battery Input and output signals


2. Battery relay a. Constant power supply
3. Fusible link b. CAN signal (Note.1)
4. Fuse box c. PC-EPC valve drive signal
5. Resistor d. Solenoid valve GND
6. Pump controller e. Oil pressure sensor signal
7. Engine controller f. Oil pressure switch signal
8. Machine monitor g. Throttle signal
9. Emergency pump drive switch h. Fuel supply pump control signal
10. Fuel control dial i. Sensor signals
11. Fuel supply pump
12. Sensors Note.1: CAN is abbreviation of “Controller Area
13. Pump oil pressure sensor Network“ in an in-vehicle standard.
14. Oil pressure sensor
15. Oil pressure switch
16. Hydraulic pump
16a. Servo
16b. LS valve
16c. PC valve
17. Control valve
17a. Pump merge-divider valve
17b. Self pressure reducing valve
18. PC-EPC valve

6 PC130-8
10 Structure, function and maintenance standard SEN03778-01

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
SEN03778-01 10 Structure, function and maintenance standard

Control method in each mode

P mode, E mode, and ATT mode


q Matching point:
Working mode Matching point
68.4 kW/2,200 rpm
Travel
{91.7 HP/2,200 rpm}
P
Working 64.4 kW/2,050 rpm
&
(At arm digging) {86.4 HP/2,050 rpm}
ATT
Working 66.3 kW/2,050 rpm
(Except arm digging) {88.9 HP/2,050 rpm}
60.0 kW/1,980 rpm
E
{80.5 HP/1,980 rpm}

q In P, E, or ATT mode, engine speed is always


controlled so that it is kept around the match-
ing point specified for each mode.
q When a load to the pump increases and the
pressure rises, the engine speed (N) lowers. At
the time, the controller reduces the pump deliv-
ery (Q) to increase the engine speed to the
matching point. If the pressure drops, the con-
troller increases the pump delivery to increase
the engine speed to the matching point.

8 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Modes B and L

Working mode Partial output


B 75%
L 70%

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}

q In B or L mode, engine output is controlled to a


constant level.
q The controller controls the pump absorption
torque to decrease the engine speed while
keeping the engine torque at a constant level
along the equal engine horsepower curve.
q The controller controls pump delivery (Q) so
that the engine torque can be kept at a con-
stant level along the equal engine horsepower
curve.

PC130-8 9
SEN03778-01 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
(Traveling the machine in "Hi" mode increases possible because the hydraulic pump does not
the idle speed, too.) work properly, turning on 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 E Mode.
In this case, a constant current flows from the
battery to the PC-EPC valve, and the valve
detects the oil pressure only.
a. Emergency
b: Normal
a Emergency pump drive switch (1) is of the
alternative type. If the machine is operated
after the switch is set to "Emergency (a)" even
through the machine is normal, user code
"E02" is displayed on the display.

10 PC130-8
10 Structure, function and maintenance standard SEN03778-01

One-touch power maximizing function

1. Pump controller Function


2. Engine controller q The one-touch power maximizing function
3. Machine monitor allows the operator to increases power for a
4. Main relief valve certain time by operating the left knob switch.
5. Fuel control dial q This function is used to increase digging force
6. Fuel supply pump for a certain period of time (e.g., when digging
7. Sensors of the engine up a large rock).
8. 2-stage relief valve switching solenoid q Pressing the L.H. knob switch in P, E, or ATT
9. Hydraulic pump mode increases a hydraulic force by approxi-
9a. Servo mately 8% and horsepower by approximately
9b. LS valve 3%, increasing a digging force.
9c. PC valve At this time, each function is automatically set
10. Oil pressure sensor as shown below.
11. Knob switch
(Work equipment control lever, L.H.) Function Setting
12. Main control valve Engine and pump control
Maching at rated output
12a. Pump merge-divider valve point
12b. Self pressure reducing valve Normal
2-stage relief 31.9 MPa {325 kg/cm²}
13. PC-EPC valve mode
function of
the main One-touch
Input signals
relief valve power max. 34.5 MPa {352 kg/cm²}
a. CAN signal (Note.1) mode
b. PC-EPC valve drive signal Software cut-off function Cancel
c. Solenoid valve change signal
d. Oil pressure sensor signal q These setting are automatically reset after 8.5
e. Throttle signal seconds when the switch is pressed.
f. Fuel supply pump control signal
g. Sensor signals
h. Knob switch signal

Note.1: CAN is cf. 6 page.

PC130-8 11
SEN03778-01 10 Structure, function and maintenance standard

Auto-decelerator function

1. Pump controller Input and output signals


2. Engine controller a. CAN signal (Note.1)
3. Machine monitor b. Oil pressure sensor signal
4. Fuel control dial c. Oil pressure switch signal
5. Fuel supply pump d. Throttle signal
6. Sensors e. Fuel supply pump control signal
7. Oil pressure sensor f. Sensor signals
8. Oil pressure switch
9. Hydraulic pump Note.1: CAN is cf. 6 page.
10. Control valve
10a. Pump merge-divider valve
10b. Self pressure reducing valve
11. PPC lock solenoid valve

12 PC130-8
10 Structure, function and maintenance standard SEN03778-01

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.

When any control lever is operated


q With the engine speed at the control speed
(approx. 1,400 rpm), when any control lever is
operated, the engine speed increases immedi-
ately to the speed that is set with the fuel con-
trol dial.

A : All work equipment control levers in “NATU-


RAL“
B : All work equipment control levers “OPER-
ATED“
C: Fuel control dial set speed
D: Engine control speed (approx. 1,400 rpm)
E : 4 sec.
F : Max. 2 sec.
G: Max. 0.2 sec.

PC130-8 13
SEN03778-01 10 Structure, function and maintenance standard

Engine automatic warm-up function

1. Battery Input and output signals


2. Battery relay a. CAN signal (Note.1)
3. Fusible link b. PC-EPC valve drive signal
4. Fuse box c. Solenoid valve GND
5. Resistor d. Hydraulic oil temperature signal
6. Pump controller e. Throttle signal
7. Engine controller f . Fuel supply pump control signal
8. Machine monitor g. Sensor signals
9. Emergency pump drive switch
10. Fuel control dial Note.1: CAN is cf. 6 page.
11. Fuel supply pump
12. Sensors
13. Hydraulic oil temperature sensor
14. Hydraulic pump
14a. Servo
14b. LS valve
14c. PC valve
15. Control valve
15a. Pump merge-divider valve
15b. Self pressure reducing valve
16. PC-EPC valve

14 PC130-8
10 Structure, function and maintenance standard SEN03778-01

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

Release conditions (either one required) Release


Coolant temperature: Min. 55 °C and All control lever position: Neutral o
Engine speed: Any
Fuel control dial: Min. 1,300 rpm and All control lever position: Neutral

Overheat prevention function


a See “Engine automatic warm-up function“ for system circuit diagram.

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. 95°C
Working mode: P, ATT Engine speed: Remains same
Coolant temperature: Min. 95°C o • Sends torque control signal to o Hydraulic oil temperature: Max. 95°C
• The original conditions are restored if
Hydraulic oil temperature: Min. 95°C lower the pump absorption torque
above requirements are met (auto-
Traveling status check: OFF and reduce the engine load. matic restoration).

Operational conditions Operation and actions taken Release conditions


Coolant temperature: Max. 98°C
Working mode: P, ATT
Coolant temperature: Min. 98°C o • Engine speed: Remains same o Hydraulic oil temperature: Max. 98°C
• The original conditions are restored if
Hydraulic oil temperature: Min. 98°C • Travel speed: Down
above requirements are met (auto-
Traveling status check: ON
matic restoration).

Operational conditions Operation and actions taken Release conditions

Working mode: P, ATT Engine speed: Remains same Coolant temperature: Max. 100°C
Coolant temperature: Min. 100°C o • Sends torque control signal to o Hydraulic oil temperature: Max. 100°C
• The original conditions are restored if
Hydraulic oil temperature: Min. 100°C lower the pump absorption torque
above requirements are met (auto-
Traveling status check: Any and reduce the engine load. matic restoration).

Operational conditions Operation and actions taken Release conditions


Engine speed: Remains same Coolant temperature: Max. 102°C
Working mode: P, ATT, E, B
Coolant temperature: Min. 102°C o Alarm monitor: ON o Hydraulic oil temperature: Max. 102°C
Hydraulic oil temperature: Min. 102°C
• Sends torque control signal to • The original conditions are restored if
lower the pump absorption torque above requirements are met (auto-
Traveling status check: Any
and reduce the engine load. matic restoration).

Operational conditions Operation and actions taken Release conditions


Coolant temperature: Max. 105°C
Hydraulic oil temperature: Max. 105°C
Working mode: Any
Coolant temperature: Min. 105°C o Engine speed: Low idle o Fuel control dial: Returns to low idle
Alarm monitor: ON (MIN) position.
Hydraulic oil temperature: Min. 105°C
Alarm monitor: Sounds • The original conditions are restored if
Traveling status check: Any
above requirements are met (man-
ual restoration).

PC130-8 15
SEN03778-01 10 Structure, function and maintenance standard

Turbocharger protection function


a See “Engine automatic warm-up function“ for system circuit diagram.

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 The duration of turbocharger protection 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)

*1. Working mode: Mode P


Fuel control dial: Full rotation position
Travel lever operated

16 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Swing control function

1. Battery Input and output signals


2. Battery relay a. Swing holding brake release signal
3. Fusible link b. Swing holding brake solenoid valve drive sig-
4. Fuse box nal
5. Swing holding brake release switch c. CAN signal (Note.1)
6. Swing lock switch d. Solenoid valve GND
7. Pump controller e. Oil pressure switch signal
8. Machine monitor
9. Oil pressure switch Note.1: CAN is cf. 6 page.
10. Hydraulic pump
11. Control valve
11a. Pump merge-divider valve
11b. Self pressure reducing valve
12. Swing motor
13. Swing holding brake solenoid valve

PC130-8 17
SEN03778-01 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.

A: L.H. work equipment control lever “SWING“


(Swing holding brake “RELEASE“)
B: L.H. work equipment control lever “NEUTRAL“
C: Swing holding brake “OPERATED“
D: 5 sec

18 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Swing holding brake release function


q If the controller gets out of order and no swing
is possible because the swing holding brake
does not work properly, operating swing hold-
ing brake release switch (2) releases the swing
holding brake and allows swing operation.
a: Release (Emergency)
b: Normal
Swing
holding Release Normal
brake (when the controller (when the controller
release is out of order) is in order)
switch
Swing
lock ON OFF ON OFF
switch
Swing
Swing
Swing holding Swing
Swing holding
lock brake is lock
brake brake
works. released. works.
works.
(*1)

*1: Hydraulic brake by the safety valve.

a Even if the swing holding brake release switch


is set to “RELEASE“, the swing holding brake
is not be released while the swing lock switch
is set to “ON“.
a When the swing holding brake is released,
only the hydraulic brake with the safety valve is
effective for swing. So, note that, when the
swing stops on a slope, a hydraulic drift may
occur.
a Swing holding brake release switch (2) is of the
alternator type. When the switch is turned to
“RELEASE (a)“ position, the swing lock moni-
tor in the machine monitor will blink.

PC130-8 19
SEN03778-01 10 Structure, function and maintenance standard

Travel control function

1. Pump controller Input and output signals


2. Engine controller a. Oil pressure sensor signal
3. Machine monitor b. CAN signal (Note.1)
4. Fuel control dial c. Pump merge-divider solenoid valve drive sig-
5. Fuel supply pump nal
6. Sensors d. Travel junction solenoid valve drive signal
7. Pump oil pressure sensor e. 2nd travel speed select solenoid valve drive
8. Oil pressure sensor signal
9. Travel alarm buzzer f . Oil pressure sensor signal
10. Hydraulic pump g. Travel alarm buzzer operation signal
11. Control valve h. Throttle signal
11a. Pump merge-divider valve i . Fuel supply pump control signal
11b. Self pressure reducing valve j . Sensor signals
11c. Travel junction valve
11d. Pump merge-divider valve Note.1: CAN is cf. 6 page.
12. Travel motor
13. 2nd travel speed select solenoid valve
14. Travel junction solenoid valve
15. Pump merge-divider solenoid valve

20 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Function

Travel speed select function


1. Travel speed “Manual“ change
q Turning the travel speed selector switch
“Hi“ and “Lo“ changes the motor capacity
and allows the machine to select travel
speed.
Lo (low Hi (high
Travel speed selector switch
speed) speed)
Motor capacity (cc/rev.) 79.1 44.2
Travel speed (km/h) 2.9 5.5
Travel motor swash plate angle Max. Min. A: 17.7 MPa {180 kg/cm²}
B: 32.4 MPa {330 kg/cm²}
2. Travel speed “Automatic“ change C: Min. 0.1 sec.
1) Automatic selection corresponding to D: Min. 0.02 sec.
engine speed
q When the engine speed is lowered to Pump control function during travel
below 1,500 rpm with the fuel control a See “Pump and engine mutual control func-
dial, the travel speed changes to “Lo“ tion“ for details.
automatically.
Travel junction function
2) Automatic selection corresponding to q When the travel lever is operated, detects the
pump discharge pressure pilot pressure and judges whether it is for
q If the travel pressure increases on an straight-travel or for steering.
uphill with the travel speed selector q For straight-travel, a signal is sent to the travel
switch in “Hi“, and the travel hydraulic junction solenoid valve, controlling the pump
pressure exceeding 32.4 MPa {330 flow between the right and left to be equal, to
kg/cm²} continues for 0.02 seconds or prevent travel deviation and improve straight
more, the travel motor capacity is line stability.
switched to low speed (corresponds q When steering, the signal to the travel junction
to “Lo“) automatically (the travel solenoid valve is cut-off, separating the pump
speed switch position is remain “Hi“). flow between the right and left, to improve
q If the travel pressure decreases on a steering stability.
flat or downhill with low speed
(caused by the automatic gear shift- Pump merge-divider function
ing due to high pressure), and the q When the travel lever is operated, detects the
travel hydraulic pressure below 17.7 pilot pressure and judges if it is for straight-
MPa {180 kg/cm²} continues for 0.1 travel.
seconds or more, the travel motor q For straight-travel, a signal is sent to the pump
capacity is switched back to the set merge-divider solenoid valve, dividing the
speed of “Hi“ automatically. pump delivery, to improve travel performance.

PC130-8 21
SEN03778-01 10 Structure, function and maintenance standard

PPC lock function

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 SEN03778-01

Oil flow adjuster function for attachment


(Machine ready for attachment)

1. Pump controller Input and output signals


2. Engine controller a. Oil flow adjuster EPC valve drive signal for
3. Machine monitor attachment
4. Fuel control dial b. Oil pressure switch signal
5. Fuel supply pump c. CAN signal (Note.1)
6. Sensors d. PC-EPC valve drive signal
7. Emergency pump drive switch e. Solenoid valve GND
8. Oil pressure switch f . Throttle signal
9. Hydraulic pump g. Fuel supply pump control signal
9a. Servo h. Sensor signals
9b. LS valve
9c. PC valve Note.1: CAN is cf. 6 page.
10. Control valve
10a. Pump merge-divider valve Function
10b. Self pressure reducing valve q Setting of the working mode and oil flow rate
11. PPC lock solenoid valve on the machine monitor controls the oil flow to
12. Oil flow adjuster EPC valve for attachment the attachment when the attachment control
13. PC-EPC valve pedal is depressed all the way.
14. Attachment circuit selector valve
15. Attachment

PC130-8 23
SEN03778-01 10 Structure, function and maintenance standard

System components
Engine controller

Input and output signals


q The following is the list of the symbols used for
signal classification in the input/output signal
chart.
A: Power supply
B: Input
C: Ground/shield/return
D: Output
E: Communication

DTP-4P [CN-CE03]
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 SEN03778-01

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]
Signal Signal
Pin No. Signal name classification Pin No. Signal name classification
1 CAN(+) E 31 NC —
2 NC — 32 Engine controller power cut-off relay 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
SEN03778-01 10 Structure, function and maintenance standard

Pump controller

26 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Input and output signals


AMP-81P [CN-C01]
Pin No. Signal name Input/output Pin No. Signal name Input/output
signal signal
1 Constant power supply (24 V) Input 41 Knob switch Input
2 GND Input 42 NC —
3 Window washer Output 43 Starting switch ACC signal Input
4 Constant power supply (24 V) Input 44 GND (pulse signal) Input
5 GND Input 45 CAN_H Input/output
6 NC — 46 GND (analog signal) Input
7 NC — 47 NC —
8 Potentiometer power supply (5 V) Output 48 NC —
9 Potentiometer power supply (5 V) Output 49 Pump oil pressure sensor Input
10 NC — 50 NC —
11 Arm angle sensor Input 51 Blade LOWER oil pressure sensor Input
12 Boom cylinder head oil pressure sensor Input 52 Attachment oil pressure switch Input
13 L.H. travel REVERSE oil pressure sensor Input 53 Boom RAISE oil pressure switch Input
14 Boom LOWER oil pressure switch Input 54 NC —
15 Arm OUT pressure switch Input 55 R.H. travel FORWARD oil pressure sensor Input
16 Swing oil pressure switch Input 56 Wiper motor reverse (W) Input
17 Arm IN pressure switch Input 57 Cab front window open limit switch Input
18 GND (analog signal) Input 58 Model select 4 Input
19 Swing lock switch Input 59 NC —
20 NC — 60 Starting switch C signal Input
21 Model select 2 Input 61 NC —
22 NC — 62 External start signal Input
23 NC — 63 NC —
24 Starting switch ACC signal Input 64 CAN_L Input/output
25 NC — 65 NC —
26 NC — 66 NC —
27 NC — 67 Boom angle sensor Input
28 NC — 68 NC —
29 Hydraulic oil temperature sensor Input 69 L.H. travel FORWARD oil pressure sensor Input
30 NC — 70 GND (analog signal) Input
31 Boom cylinder bottom oil pressure sensor Input 71 NC —
32 Blade RAISE oil pressure sensor Input 72 NC —
33 NC — 73 Bucket CURL oil pressure switch Input
34 Bucket DUMP oil pressure switch Input 74 NC —
35 NC — 75 Wiper motor stop (P) Input
36 R.H. travel REVERSE oil pressure sensor Input 76 Blade specification signal Input
37 GND (digital signal) Input 77 Model select 3 Input
38 Swing holding brake cancel switch Input 78 Overload alarm enable signal Input
39 Model select 5 Input 79 Starting switch ACC signal Input
40 Model select 1 Input 80 NC —
81 NC —
AMP-40P [CN-C02]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
82 NC — 102 NC —
83 NC — 103 NC —
84 NC — 104 NC —
85 NC — 105 NC —
86 NC — 106 NC —
87 2nd travel speed select solenoid Output 107 Travel and swing alarm buzzer Output
88 NC — 108 Battery relay drive Output
89 NC — 109 NC —
90 NC — 110 Travel junction solenoid Output
91 NC — 111 NC —
92 NC — 112 Pump merge-divider solenoid Output
93 NC — 113 NC —
94 Bucket DUMP operation lock solenoid Output 114 Wiper motor (–) Output
95 NC — 115 GND (solenoid) Input
96 PC-EPC Output 116 Solenoid power supply Input
97 Oil flow adjuster EPC for attachment Output 117 GND (solenoid) Input
98 NC — 118 Solenoid power supply Input
99 NC — 119 Wiper motor (+) Output
100 NC — 120 GND (solenoid) Input
101 Swing holding brake solenoid Output 121 Solenoid power supply Input

PC130-8 27
SEN03778-01 10 Structure, function and maintenance standard

Fuel control dial

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 SEN03778-01

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
SEN03778-01 10 Structure, function and maintenance standard

Engine oil pressure switch

1. Connector
2. Sensor
3. O-ring

Specifications
Contact type: Normal close

Function
q Installed in the cylinder block. Detects engine
oil pressure, and turns the switch “ON“ when
the pressure goes below the specified value.

30 PC130-8
10 Structure, function and maintenance standard SEN03778-01

PPC oil pressure switch

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
SEN03778-01 10 Structure, function and maintenance standard

32 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Machine monitor system 1

1. Machine monitor Outline


2. Battery q The monitor system keeps the operator
3. Pump controller informed of all machine functions, by monitor-
4. Engine controller ing the machine conditions using the sensors
5. Air conditioner controller and switches installed in various parts of the
6. KOMTRAX terminal machine and processing them instantly to dis-
7. Sensors, switches play on the machine monitor.
8. Wiper motor, window washer motor The information displayed on the machine
monitor falls into the following types:
Input and output signals 1. Alarm when an error occurs
a. Power supply 2. Machine status display (coolant tempera-
b. CAN signal (Note.1) ture, hydraulic oil temperature and fuel
c. Sensor and switch signals level)
d. Drive signal q The switches on the machine monitor controls
the machine.
Note.1: CAN is cf. 6 page.

PC130-8 33
SEN03778-01 10 Structure, function and maintenance standard

Machine monitor

Outline Precautions on the machine monitor display


q The machine monitor provides monitor display q The LCD panel may has black points (points
function, mode selection function and switch which are not lighted) and bright points (points
function of the electrical equipment etc. Also it which do not go off) for the reason of its char-
provides an alarm buzzer. acteristics. If the number of the bright points
q The monitor panel has a CPU (Central Pro- and black points does not exceed 10, it does
cessing Unit) in it to process, display, and out- not indicate a failure or a defect.
put the information. q When the engine is started, the battery voltage
q The machine monitor consists of display and may drop suddenly depending on ambient
switches: the display is of LCD type, and the temperatures and battery conditions. In this
switches are of flat sheet switch. case, the machine monitor may go off for a
q If an error occurs in the machine monitor itself, moment. However, this phenomenon is not a
controller or wiring circuit between monitor and failure.
controller, the monitor does not display prop- q After the machine monitor is used continu-
erly. ously, blue points (points which do not go off)
may be seen on the black background. This
phenomenon does not indicate a failure or a
defect.
Blue points can never be a problem as the
screen has usually blue or white background.
(White in the LCD is made up of red, green and
blue.)

34 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Input and output signals


070-18P(1) [CN-CM01]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
1 Constant power supply (24 V) Input 10 Engine coolant temperature Input
2 Constant power supply (24 V) Input 11 Battery level Input
3 GND (constant power supply) — 12 GND (machine analog signal) —
4 GND (constant power supply) — 13 Lamp switch Input
5 Wake-up Input/output 14 Starting switch ACC signal Input
Starting motor cut-out relay (for per-
6 Output 15 Starting switch C signal Input
sonal code)
7 GND (machine signal) — 16 Preheat Input
8 Hydraulic oil temperature Input 17 USB power supply (5 V) Output
9 Fuel level Input 18 GND (USB power supply) —

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
SEN03778-01 10 Structure, function and maintenance standard

Display

A: Normal operation screen


B: All indicators light-up screen
q When monitor items (14) to (18) are faulty after starting the engine, monitor items are displayed on
the screen in chronological order from the upper left.
q If the hydraulic oil temperature goes High or Low while the hydraulic oil temperature gauge is dis-
played at the center of the screen, the screen displays only hydraulic oil temperature monitor (2b).
C: Screen with maintenance interval reminder

36 PC130-8
10 Structure, function and maintenance standard SEN03778-01

No. Classification Display item Description Remarks


Display Tempera- Background
location ture (°C) color
W1 105 Red • Indicates corresponding temperature
W2 102 Red range.
1a Gauge (*1)
W3 100 Blue • Alarm buzzer sounds when the temper-
Coolant tem-
perature ature exceeds 105°C.
W4 85 Blue
• If the monitor background appears
W5 60 Blue
white, warm-up the engine.
W6 30 White
1b Caution See the column “Gauge“.
Display Tempera- Background
location ture (°C) color
• Indicates corresponding temperature
H1 105 Red
range.
H2 102 Red • Alarm buzzer sounds when the temper-
2a Gauge (*1)
Hydraulic oil H3 100 Blue ature exceeds 105°C.
temperature H4 85 Blue • If the monitor background appears
H5 40 Blue white, warm-up the hydraulic compo-
H6 20 White nents.
2b Caution See the column “Gauge“.
Display Background
Quantity (l)
location color
F1 198 Blue
F2 148 Blue
3a Gauge (*1) F3 123 Blue • Indicates corresponding fuel level.
Fuel level
F4 84 Blue
F5 66 Blue
F6 36 Red
3b Caution See the column “Gauge“.
Segment Load level • Indicates average load per minute on a
Light to scale of 1 to 10.
4 ECO gauge Green 1–8
medium (Indicates when “Default (ECO display
Orange 9,10 Heavy setting)“ of the service mode is “ON“.)
• Indicates accumulated engine operat-
Service meter 00000 h – 99999 h ing hours (the alternator is generating).
5 (F4 switch changes for clock display.)
• 12-hour display (AM/PM) • Displays time.
Clock
• 24-hour display (F4 switch changes for service meter.)
Background
Status (If KOMTRAX is equipped.)
color
6 Message • Displays message status.
Green There is unread message.
(OFF when no message is available.)
Blue There is unsent message.
Light ON: ON • Indicates air conditioner and air blower
7 Air conditioner
Light OFF: OFF operating status.
INT: Intermittent
• Indicates front glass wiper operating
8 Wiper ON: Continuous
Pilot Light OFF: Stop status.

Swing lock Swing hold-


ing brake Monitor
switch
release display
switch
9 Swing lock OFF OFF OFF • Indicates swing lock operating status.
ON OFF ON
OFF ON Blink
ON ON Blink
*1: If the gauge signal is not available due to disconnection of CAN communication line, the gauge pointer
goes off.

PC130-8 37
SEN03778-01 10 Structure, function and maintenance standard

No. Classification Display item Description Remarks


Elapsed time after turning
Monitor
the starting switch to
display
“HEAT (preheat)“.
Preheat 0 – 30 sec. ON • Indicates preheat operating status.
30 – 40 sec. Blink
10
40 sec. or more OFF
One-touch power max. Monitor
One-touch switch display Goes off after about 8.5 seconds if switch
power max. While pressed ON is kept pressed.
Pilot While released OFF
Auto-decelera- Light ON: ON • Indicates auto-decelerator operating
11
tor Light OFF: OFF status.
P: Heavy-duty operation
E: Low-fuel consumption operation
12 Working mode L: Fine operation • Displays working mode.
B: Breaker operation
ATT: Compound attachment operation
Lo: Low speed
13 Travel speed • Displays travel speed setting.
Hi: High speed
• When an error is detected with the
Light ON: Abnormal range (below the
(*2) engine running, the monitor lights up on
14 specified value)
Engine oil level the screen and the alarm buzzer
Light OFF: Normal range
sounds at the same time.
(*2) Light ON: Abnormal range (below the • When an error is detected with the
15 Engine oil specified value) engine stopped, the monitor lights up
pressure Light OFF: Normal range on the screen.
Light ON: Defective battery charge • When an error is detected with the
(*2)
16 (Charge voltage < Battery voltage) engine running, the monitor lights up on
Battery level
Light OFF: Normal range the screen.
• When an error is detected with the
(*2) Light ON: Abnormal range (below the
engine running, the monitor lights up on
17 Caution Radiator cool- specified value)
ant level Light OFF: Normal range the screen and the alarm buzzer
sounds at the same time.
(*2) • When an error is detected with the
Light ON: Abnormal range
18 Air cleaner engine running, the monitor lights up on
Light OFF: Normal range
clogging the screen.
Background
Status
color • The display changes depending on the
There is a maintenance time to/after the maintenance.
Maintenance item which is 30 hours or • After the starting switch is turned “ON“,
19 Yellow
interval less left before next main- the monitor turns ON if the monitor
tenance. light-up conditions are met, and then
There is a maintenance turns OFF in 30 seconds.
Red
overdue item.

*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 SEN03778-01

PC130-8 39
SEN03778-01 10 Structure, function and maintenance standard

Switches

No. Name Function Operation


Turns the auto-decelerator function ON/ • When the working mode is in “L“, the auto-
Auto-decelerator
OFF. decelerator does not work.
1 switch
Light ON: ON
[Numeric keypad: 1] OFF io ON
Light OFF: OFF
P: Heavy-duty operation
(*1) Working mode E: Low-fuel consumption operation
Displays the working mode selector
2 selector switch L: Fine operation
screen.
[Numeric keypad: 2] B: Breaker operation
ATT: Compound attachment operation
Travel speed selec- Changes the travel speed.
3 tor switch Lo light ON: Low speed Lo (low speed) io Hi (high speed)
[Numeric keypad: 3] Hi light ON: High speed
Stops the alarm buzzer. • Stops the alarm buzzer.
Buzzer cancel switch
4 (Some alarm buzzer does not stop even if • The alarm buzzer resumes when another
[Numeric keypad: 4]
the switch is pressed.) error is detected.
Operates the front glass wiper.
o INT o ON o OFF o
Wiper switch INT: Intermittent
5 I (Intermittent) (Continuous) (Stop) O
[Numeric keypad: 5] ON: Continuous
i i i
Light OFF: Stop
ON: Washer fluid is sprayed and wiper
works continuously.
[When wiper is not working]
Window washer OFF: Wiper works twice and stops after the
6 switch Sprays washer fluid onto the front glass. switch is released.
[Numeric keypad: 6] [When wiper is working intermittently]
OFF: Wiper works twice continuously and
returns to intermittent operation after
the switch is released.

*1: When the working mode is changed, the auto-decelerator function turns “ON“.

40 PC130-8
10 Structure, function and maintenance standard SEN03778-01

No. Name Function Operation


• The air flow increases immediately after
Fan switch (Up)
7 Controls the fan speed of the air condi- the air conditioner adjustment screen
[Numeric keypad: 7]
tioner in 6 levels. appears.
(Low, Medium 1, Medium 2, Medium 3, • The air flow decreases immediately after
7a Fan switch (Down) Medium 4, High)
the air conditioner adjustment screen
appears.
Temperature control • The temperature control increases immedi-
8 switch (Up) ately after the air conditioner adjustment
[Numeric keypad: 8] Controls the temperature inside the cab. screen appears.
Temperature control (18.0°C – 32.0°C: Aailable at every 0.5°C) • The temperature control decreases imme-
8a switch (Down) diately after the air conditioner adjustment
[Numeric keypad: 0] screen appears.
• Automatically controls the fan speed, air
outlet port, internal/external air flow accord-
(*2) Auto switch Auto-runs the air conditioner and air
9 ing to the temperature setting, immediately
[Numeric keypad: 9] blower. AUTO light ON: Auto run
after the air conditioner adjustment screen
appears.
• Switches to the air conditioner adjustment
Turns the air conditioner ON/OFF. screen, and pressing it again switches ON/
(*3) Air conditioner
10 AC ON lights-up: Manual operation OFF.
switch
Light OFF: Stop
OFF io ON
• Switches to the air conditioner adjustment
FRESH/RECIRC screen, and pressing it again switches
11 Changes the FRESH/RECIRC. internal/external air flow.
selector switch
RECIRC io FRESH
• Switches to the air conditioner adjustment
Selects the air vent mode from 6 modes. screen, and pressing it again switches air
1. Front outlet mode.
2. Front and rear
• Mode 1, 5 and 6 are not available with auto
12 Vent selector switch 3. Front and rear-foot
4. Foot mode.
5. Foot and defroster o 1 o 2 o 3 o 4 o 5o 6 o
6. Defroster I O
i i i i i i i
Turns the fan and air conditioner OFF.
13 OFF switch • Turns the fan and air conditioner OFF.
Light OFF: OFF
14a Guidance icon
a See “Guidance icon and function switch.“
14b Function switch

*2: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at “High“. Even if the set 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
SEN03778-01 10 Structure, function and maintenance standard

Guidance icon and function switch


q Functions available with the function switch depend on the guidance icon displayed above the switch.
q No function is available if no guidance icon appears above the function switch.
q The following is the list of guidance icons and the functions displayed above the function switches.

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 SEN03778-01

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
SEN03778-01 10 Structure, function and maintenance standard

Operator mode function


q The functions in this mode are displayed in normal operation. Display and setting of these functions are
available from the operator's switch operations.
Display and setting of some functions require special operation of the switch.
q Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) W X Y Z
Display of KOMATSU logo 1 1 1 1
Display of inputting password 2 — — —
Display of start-up check 3 2 2 2
Display of warning after start-up check — — 3 —
A
Display of overdue maintenance — — — 3
Display of check of working mode and travel speed 4 3 4 4
Display of normal operation screen 5 4 5 5
Display of end screen
Selection of auto-decelerator
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner
Operation to display camera mode
B Operation to display clock/service meter
Check of maintenance information
Setting and display of user mode
• Breaker/attachment setting
• Display of message (including KOMTRAX messages for user)
• Screen adjustment
• Clock adjustment
• Language setting
• Economy mode adjustment
Display of energy-saving guidance
C Display of caution monitor
Display of user code and failure code
Function of checking display of LCD (Liquid Crystal Display)
D Function of checking service meter
Function of changing attachment/maintenance password

*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 SEN03778-01

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

8 130 Default 7 200

9 140 8 225 Default

10 150
11 160 Language setting
12 170
13 180
14 190
15 200

q The language used in the machine monitor can


be changed in the “Language setting“ of the
user mode.
q The available languages are as follows:
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, Turkish,
Indonesian and Thai

PC130-8 45
SEN03778-01 10 Structure, function and maintenance standard

Service mode function


q The functions in this mode are not accessible from the normal operation screen. Display and setting of
these functions are available by the serviceman's special operations of the switch.
This mode is used for special setting, testing, adjusting or troubleshooting.
q Items available in the service mode are as follows:
Monitoring
Mechanical systems
Abnormality record Electrical systems
Air conditioner system
Maintenance record
Change of maintenance mode
Setting of telephone No.
Working mode with key ON
Selection of units of measure
With/Without attachment
Default
Setting of attachment/maintenance password
Setting of camera
Setting of ECO display
Adjustment Pump absorption torque
Cylinder cut-out operation
No injection cranking
Display of fuel consumption
Setting condition of KOMTRAX terminal
Display of KOMTRAX
Condition of positioning and communication
system setting
KOMTRAX terminal serial number (Model TH300)
Display of KOMTRAX message

a For how to operate the service mode functions, see “Special functions of machine monitor“ in Testing
and adjusting.

46 PC130-8
10 Structure, function and maintenance standard SEN03778-01

KOMTRAX system 1

q The KOMTRAX system uses satellite commu-


nication technology.
q This system consists of the KOMTRAX termi-
nal, communication antenna, machine monitor
and GPS antenna.
q This system sends various information of the
machine via wireless communication. It allows
operators of the KOMTRAX to obtain the
machine information from the office and to pro-
vide various services with the customers.
q The information available from the KOMTRAX
system are as follows:
1. Operation map
2. Service meter
3. Machine location
4. Error record
a To provide the services, you need to make an
arrangement for starting the KOMTRAX sys-
tem service separately.

PC130-8 47
SEN03778-01 10 Structure, function and maintenance standard

KOMTRAX terminal
TH300

1. Communication antenna connection Input and output signals


2. Machine harness connection (AMP-14P)
3. Machine harness connection (AMP-10P) AMP-14P [CN-CK01]
Input/output
Pin No. Signal name
Outline signal
q The KOMTRAX terminal sends various A1 Power supply (5 V) Input
machine information based on the network sig- A2 NC —
nals and input signals obtained through the
A3 NC —
machine monitor, as well as GPS position
d ata , v i a wi r e l e s s c o mm u n i c at i o n. T h e A4 Selection of power supply voltage Output
KOMTRAX terminal can sends information via A5 NC —
communication antenna. A6 NC —
q Conditions of the KOMTRAX terminal can be
A7 GND Input
checked with the “Display of KOMTRAX sys-
tem s etting“ in the ser vic e mode of the A8 GND Input
machine monitor. A9 NC —
q Use of KOMTRAX terminal must be limited for A10 NC —
the countries in which such communication is
A11 NC —
allowed.
A12 NC —
A13 NC —
A14 NC —

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 SEN03778-01

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.

Boost pressure, temperature sensor

1. Connector
2. Sensor
3. O-ring

Function
q Installed in the intake manifold. Detects the boost pressure and boost temperature, and outputs signal
as a variable voltage for pressure, and a resistance change for temperature.

PC130-8 49
SEN03778-01 10 Structure, function and maintenance standard

Coolant temperature sensor

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.

Crankshaft speed sensor


Camshaft speed sensor

1. Connector
2. Sensor
3. O-ring

Function
q The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is
installed in the gear of the camshaft. Each of the sensors outputs a pulse voltage according to the gear
rotation.

50 PC130-8
10 Structure, function and maintenance standard SEN03778-01

Common rail pressure sensor

1. Common rail
2. Sensor
3. Connector

Function
q Installed in the common rail. Detects the fuel pressure and outputs variable voltage.

Engine oil level sensor

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
SEN03778-01 10 Structure, function and maintenance standard

Fuel level sensor

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 fuel
level and a 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 SEN03778-01

Air cleaner clogging sensor

Coolant level sensor

1. Reserve tank
2. Float
3. Sensor
4. Connector

PC130-8 53
SEN03778-01 10 Structure, function and maintenance standard

Hydraulic oil temperature sensor

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.

Pump oil pressure sensor

1. O-ring Output characteristics


2. Sensor
3. Connector

Function
q The pump oil pressure sensor is installed in the
control valve. Detects the pump discharge
pressure and outputs variable voltage.

54 PC130-8
10 Structure, function and maintenance standard SEN03778-01

PPC oil pressure sensor


(For travel operation)

1. O-ring Output characteristics


2. Sensor
3. Connector

Function
q The PPC oil pressure sensor is installed in the
control valve connecting part of the pilot circuit
for travel operation. Detects the pilot pressure
and outputs variable voltage.

PC130-8 55
SEN03778-01 10 Structure, function and maintenance standard

PC130-8 Hydraulic excavator


Form No. SEN03778-01

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)

56 PC130-8
SEN04113-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC130-8

Machine model Serial number


PC130-8 80001 and up

20 Standard value table 1


Standard service value table
Standard value table for engine related parts ................................................................................................. 2
Standard value table for chassis related parts ................................................................................................ 3

PC130-8 1
SEN04113-02 20 Standard value table

Standard value table for engine related parts 1

Applicable model PC130-8

Engine SAA4D95LE-5

Cate- Standard value for


Item Test conditions Unit Service limit value
gory new machine

High idle rpm 2,150 ± 60 —


• Coolant
Engine speed temperature: Low idle rpm 1,100 ± 50 —
operating range
Rated
rpm 2,200 —
speed
At sudden
• Coolant % Max. 30 30
acceleration
Exhaust gas color temperature:
operating range At high idle % Max. 10 20

Intake valve mm 0.35 —


• Normal
Valve clearance
temperature Exhaust
mm 0.50 —
valve
• Oil temperature: 40 – 60°C
Compression MPa Min. 2.9 2.0
• Engine speed: 320 – 360 rpm
pressure {kg/cm2} {Min. 30} {20}
• SAE0W30E0S
• Coolant temperature: operating
kPa Max. 0.98 1.47
Blow-by pressure range
{mmH2O} {Max. 100} {150}
Engine

• 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. 80°C) 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 SEN04113-02

Standard value table for chassis related parts 1

Applicable model PC130-8

Cate- Standard value for


Item Test conditions Unit Service limit value
gory new machine
• Hydraulic oil temperature:
Engine speed

45 – 55°C
• 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

• Engine at high idle 15.7 ± 3.9 Max. 24.5


Boom control lever
Operating effort of control lever

• Oil temperature: 45 – 55°C {1.6 ± 0.4} {Max. 2.5}


• Fit push-pull scale to center of
15.7 ± 3.9 Max. 24.5
Arm control lever control lever knob to test
{1.6 ± 0.4} {Max. 2.5}
• Fit push-pull scale to tip of
control pedal to test 12.7 ± 2.9 Max. 21.6
Bucket control lever • Test max. value to end of travel N {1.3 ± 0.3} {Max. 2.2}
{kg} 12.7 ± 2.9 Max. 21.6
Swing control lever
{1.3 ± 0.3} {Max. 2.2}
24.5 ± 5.9 Max. 39.2
Travel control lever
{2.5 ± 0.6} {Max. 4.0}
74.5 ± 18.6 Max. 107.6
Travel pedal
{7.6 ± 1.9} {Max. 11}
• Hydraulic oil temperature:
45 – 55°C
• Engine at high idle
MPa 5.9 5.9
Unload pressure • Working mode: P mode
{kg/cm2} {Max. 60} {Max. 60}
• Hydraulic pump output pressure
with all control levers in
NEUTRAL position
Hydraulic pressure

+2.0
• Hydraulic oil In power-max. 34.8 ± 1.0 34.8 –1.0
temperature: mode {355 ± 10} {355 +20
–10 }
Boom relief 45 – 55°C +2.0
31.9 ± 1.0 31.9 –1.0
• Engine at In normal mode
{325 ± 10} {325 +20
–10 }
high idle MPa +2.0
• Pump In power-max. {kg/cm2} 34.8 ± 1.0 34.8 –1.0
discharge mode {355 ± 10} {355 +20
–10 }
Arm relief pressure Target 31.9 ± 1.0
+2.0
31.9 –1.0
• Relieve only In normal mode value
circuit to be {325 ± 10} {325 +20
–10 }
(Range) +2.0
tested In power-max. 34.8 ± 1.0 34.8 –1.0
mode {355 ± 10} {355 +20
–10 }
Bucket relief +2.0
31.9 ± 1.0 31.9 –1.0
In normal mode
{325 ± 10} {325 +20
–10 }

PC130-8 3
SEN04113-02 20 Standard value table

Applicable model PC130-8

Cate- Standard value for


gory Item Test conditions Unit Service limit value
new machine
+1.5
• Hydraulic oil temperature: 29.2 ± 1.0 29.2 –2.5
Swing relief
45 – 55°C {298 ± 10} {298 +15
–25 }
• Engine at high idle +2.0
34.8 +0
+2.0
34.8 –1.0
Blade RAISE • Pump discharge pressure {355 +20
+0 } {355 +20
–10 }
• Relieve only circuit to be tested
34.8 ± 1.5 34.8 ± 2.5
Blade LOWER
{355 ± 15} {355 ± 25}
34.8 ± 1.0 34.8 ± 2.0
Travel relief
{355 ± 10} {355 ± 20}
Control circuit source 3.2 ± 0.2 3.2 ± 0.5
Hydraulic pressure

pressure MPa {33 ± 2} {33 ± 5}


2
• Hydraulic oil Control levers at {kg/cm } 3.4 ± 1.0 3.4 ± 1.0
temperature: HOLD {35 ± 10} {35 ± 10}
Servo piston input Target
45 – 55°C
pressure At pump relief value 16.0 ± 1.5 16.0 ± 2.5
• Engine at
high idle (normal actuation) (Range) {163 ± 15} {163 ± 25}
• Hydraulic oil
temperature:
All levers at 2.75 ± 0.98 —
45 – 55°C
HOLD {28 ± 10} {—}
• Engine at
LS differential high idle
pressure a LS differential
pressure = Travel rotating
pump outlet under no load 2.2 ± 0.1 —
port pressure Travel lever at {22.5 ± 1} {—}
– LS pressure half-way position

• For testing posture, see Swing


1
• Engine at high idle
• Hydraulic oil temperature:
Overrun when 45 – 55°C Deg. 75 ± 10 Max. 90
stopping swing • Stop after swinging one turn (mm) (730 ± 100) (Max. 870)
and test distance that swing
circle moves
• Figure in ( ) shows movement
at outside of swing circle
• For testing posture, see
Swing 1
• Engine at high idle 2.9 ± 0.3 Max. 3.5
90°
{3.5 ± 0.4} (Max. 4.0)
Swing

• Hydraulic oil temperature:


45 – 55°C
Time taken to start
• Time taken to swing 90° sec.
swing
and 180° from starting
position 4.3 ± 0.4 Max. 6.2
• Figure in ( ) shows time 180°
{5.1 ± 0.5} (Max. 6.4)
when bucket is at rated
load
• For testing posture, see Swing
1
• Engine at high idle
Time taken to swing • Hydraulic oil temperature: sec. 27.3 ± 2 27.3 ± 4
45 – 55°C
• Swing one turn, and test time
taken to swing next 5 turns

4 PC130-8
20 Standard value table SEN04113-02

Applicable model PC130-8

Cate- Standard value for


gory Item Test conditions Unit Service limit value
new machine
• For testing posture, see Swing
2
• Engine stopped
• Hydraulic oil temperature:
45 – 55°C
• Bucket at rated load
Hydraulic drift of • Set machine on 15° slope, and Deg. 0 0
swing set upper structure at an uphill (mm) (0) (0)
Swing

angle of 45°.
• Make match marks on swing
circle outer race and track
frame.
• Test distance that match marks
move apart after 15 minutes.
• Engine at high idle
Leakage from travel • Hydraulic oil temperature:
l/min Max. 3 Max. 6
motor 45 – 55°C
• Relieve swing circuit.
• For testing posture, see
Travel 1
• Engine at high idle Lo Max. 39.6 Max. 45
• Hydraulic oil temperature:
Travel speed
45 – 55°C sec.
(without load)
• Raise track on one side at a
time, rotate one turn, then Hi Max. 22.0 Max. 25
test time taken for next 5
turns with no load.
• For testing posture, see
Travel 2
• Engine at high idle Lo Max. 31.0 Max. 35
• Hydraulic oil temperature:
Travel speed
45 – 55°C sec.
(actual run)
• Run up for at least 10 m,
and test time taken to travel Hi Max. 14.5 Max. 17
next 20 m on flat ground.
Travel

• For testing posture, see Travel


2 and 3
• Engine at high idle
• Hydraulic oil temperature:
Travel deviation 45 – 55°C mm Max. 150 Max. 220
• Run up for at least 10 m, and
test deviation when traveling
next 20 m on flat ground.
a Use a hard horizontal surface.
• For testing posture, see Travel
4
• Engine stopped
• Hydraulic oil temperature:
Hydraulic drift of 45 – 55°C
mm 0 0
travel • Stop machine on 12° slope with
sprocket facing straight up the
slope.
• Test the distance the machine
moves in 5 minutes.

PC130-8 5
SEN04113-02 20 Standard value table

Applicable model PC130-8

Cate- Standard value for


gory Item Test conditions Unit Service limit value
new machine
• Engine at high idle
• Hydraulic oil temperature:
Travel

Leakage from travel


45 – 55°C l/min Max. 1.1 Max. 1.7
motor
• Lock shoes and relieve travel
circuit.
Total work • For testing posture, see Work
equipment equipment 1
(hydraulic drift at • Place in above posture and test Max. 460 Max. 700
Hydraulic drift of work equipment

tip of bucket extension or retraction of each


teeth) cylinder and downward
Boom cylinder movement at tip of bucket teeth.
(amount of • Horizontal, flat ground
• Bucket: Rated load (450 kg) Max. 10 Max. 12
retraction of
cylinder) • Levers at HOLD
mm
• Engine stopped
Arm cylinder • Hydraulic oil temperature:
(amount of 45 – 55°C Max. 80 Max. 90
extension of • Start testing immediately after
cylinder) setting.
Bucket cylinder • Test hydraulic drift every 5
(amount of minutes, and judge from results
for 15 minutes. Max. 22 Max. 40
retraction of
Work equipment

cylinder)
Boom • For testing posture, see 3.7 ± 0.3 Max. 4.3
RAISE

Bucket teeth in Work equipment 2 (Until touching (Until touching


contact with • Engine at high idle cushion) cushion)
ground • Hydraulic oil temperature:
I 45 – 55°C
LOWER

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
IN

Cylinder fully Work equipment 3 (Until touching (Until touching


• Engine at high idle sec. cushion) cushion)
retracted
• Hydraulic oil temperature:
I 2.7 ± 0.3 Max. 3.7
O
OUT

45 – 55°C (Until touching (Until touching


Fully extended
cushion) cushion)
• For testing posture, see
CURL

Bucket +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 – 55°C 2.0
+0.3
Max. 2.6
–0.1
Fully extended

6 PC130-8
20 Standard value table SEN04113-02

Applicable model PC130-8

Cate- Standard value for


gory Item Test conditions Unit Service limit value
new machine
• For testing posture, see Work
equipment 5
• Engine at low idle
• Hydraulic oil temperature:
45 – 55°C
Boom • Fully retract arm and bucket Max. 3 Max. 3
cylinders, then lower boom from
maximum height and test time
taken from point where bucket
contacts ground to point where
chassis rises from ground.
• For testing posture, see Work
equipment 6
• Engine at low idle
• Hydraulic oil temperature:
Time lag

45 – 55°C
Arm • Set top surface of boom sec. Max. 2 Max. 2
horizontal, retract bucket
Work equipment

cylinder fully, then extend arm


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

• Hydraulic oil temperature:


Each cylinder 45 – 55°C Max. 3.5 Max. 15
• Engine at high idle
• Circuit to be tested is relieved.
cc/min
Center swivel
Max. 10 Max. 50
joint

PC130-8 7
SEN04113-02 20 Standard value table

Pump performance curve

q TVC current: 0.4 A


q Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)
Test pump Discharge Average Standard value for Judgement
Check point discharge pressure of pressure discharge amount standard lower
pressure other pump Q (l/min) limit Q (l/min)
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2})

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 SEN04113-02

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

Travel 3: Travel deviation

Swing 2: Hydraulic drift of swing

Travel 4: Hydraulic drift of travel

Travel 1: Travel speed (without load)

PC130-8 9
SEN04113-02 20 Standard value table

Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed


equipment

Work equipment 5: Boom time lag


Work equipment 2: Boom speed

Work equipment 6: Arm time lag


Work equipment 3: Arm speed

10 PC130-8
20 Standard value table SEN04113-02

Work equipment 7: Bucket time lag

PC130-8 11
SEN04113-02 20 Standard value table

PC130-8 Hydraulic excavator


Form No. SEN04113-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09

12 PC130-8
SEN04114-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC130-8

Machine model Serial number


PC130-8 80001 and up

30 Testing and adjusting 1


Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketches of special tools ................................................................................................................................ 8
Testing engine speed ...................................................................................................................................... 9
Testing exhaust temperature......................................................................................................................... 10
Checking exhaust gas color...........................................................................................................................11
Adjusting valve clearance ............................................................................................................................. 12
Testing compression pressure ...................................................................................................................... 14
Testing blow-by pressure .............................................................................................................................. 16
Testing engine oil pressure ........................................................................................................................... 17
Reduced cylinder mode operation ................................................................................................................ 18
No-injection cranking .................................................................................................................................... 18
Handling fuel system parts............................................................................................................................ 19
Releasing residual pressure from fuel system .............................................................................................. 19
Testing fuel pressure..................................................................................................................................... 20
Testing fuel return rate and fuel leakage....................................................................................................... 21
Bleeding air from fuel circuit.......................................................................................................................... 23

PC130-8 1
SEN04114-02 30 Testing and adjusting

Checking fuel circuit for leakage ................................................................................................................... 24


Testing and adjusting alternator belt tension................................................................................................. 25
Checking and adjusting air conditioner compressor belt tension .................................................................. 26
Testing swing circle bearing clearance.......................................................................................................... 27
Checking and adjusting track shoe tension................................................................................................... 28
Testing and adjusting oil pressure in work equipment, swing, and travel circuits ......................................... 30
Testing control circuit basic pressure ............................................................................................................ 33
Testing and adjusting oil pressure in pump PC control circuit....................................................................... 34
Testing and adjusting oil pressure in pump LS control circuit ....................................................................... 37
Testing solenoid valve output pressure ......................................................................................................... 40
Testing PPC valve output pressure ............................................................................................................... 44
Adjusting play of work equipment and swing PPC valves............................................................................. 45
Checking parts which cause hydraulic drift of work equipment..................................................................... 46
Testing and adjusting travel deviation ........................................................................................................... 48
Releasing residual pressure from hydraulic circuit........................................................................................ 50
Testing oil leakage......................................................................................................................................... 51
Bleeding air from each part ........................................................................................................................... 54
Checking cab tipping stopper........................................................................................................................ 56
Installation and adjustment of mirrors and camera ....................................................................................... 57
Inspection of air conditioner Recirc/Fresh air filter ........................................................................................ 61

2 PC130-8
30 Testing and adjusting SEN04114-02

Tools for testing, adjusting, and troubleshooting 1


Sym-

Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Exhaust temperatures R 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
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 ø14
2 6164-81-5750 Joint 1 ø14
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
SEN04114-02 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 SEN04114-02

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
SEN04114-02 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 – 1,299°C
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),
of engine oil pressure — 795-799-6210 Deep socket 1
Inside diameter: 24.5 mm
switch
21mm deep socket
Removal and installation
Commercially (MITOLOY 4ML-21 or equivalent)
of engine coolant temper- — Socket 1
available Applicable engine serial No.:
ature sensor
500001 - 502653

6 PC130-8
30 Testing and adjusting SEN04114-02

Sym-

Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
19mm deep socket
Removal and installation
(MITOLOY 4ML-19 or equivalent)
of engine coolant temper- — 795T-981-1010 Socket 1
Applicable engine serial No.:
ature sensor
502654 and up

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".

PC130-8 7
SEN04114-02 30 Testing and adjusting

Sketches of special tools 1


Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

Socket

8 PC130-8
30 Testing and adjusting SEN04114-02

Testing engine speed 1 4. Testing pump relief speed


1) Start the engine and operate the arm cyl-
a Test the engine speed with the monitoring inder to the IN stroke end.
function of the machine monitor. 2) Set the fuel control dial in the high idle
a Test the engine speed under the following con- (MAX) position and set the working mode
dition. in the power mode (P).
q Engine coolant temperature: Within oper- 3) Operate the left work equipment control
ating range lever to relieve the arm circuit at the IN
q Hydraulic oil temperature: Within operat- stroke end and test the engine speed.
ing range
5. Testing auto-deceleration speed
1. Preparation work 1) Start the engine, set the fuel control dial in
Operate the machine monitor so that the the high idle position (MAX), and turn the
engine speed can be monitored. auto-decelerator ON.
a For the operating method of the machine 2) Set all the levers and pedals for work
monitor, see Special functions of machine equipment control, swing control, and
monitor. travel in neutral and test the engine speed
a Monitoring code: 01002 Engine speed when the auto-decelerator operates.
a The engine speed lowers to a certain level
about 5 seconds after all the levers and
pedals are set in neutral. This level is the
auto-deceleration speed.

2. Testing low idle speed


1) Start the engine and set the fuel control
dial in the low idle (MIN) position.
2) Set all the levers and pedals for work
equipment control, swing control, and
travel in neutral and test the engine
speed.

3. Testing high idle speed


1) Start the engine and set the fuel control
dial in the high idle (MAX) position.
2) Set the working mode in the power mode
(P) and turn the auto-decelerator OFF.
3) Set all the levers and pedals for work
equipment control, swing control, and
travel in neutral and test the engine
speed.

PC130-8 9
SEN04114-02 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

k Install or remove the testing instrument


after the exhaust manifold temperature has
lowered.

1. Remove the engine compartment side cover


and exhaust manifold cover.

2. Remove exhaust temperature pickup plug (1)


from the side of the center of the exhaust man-
ifold.
5. After finishing test, remove the testing instru-
ment and return the removed parts.

3. Install sensor [1] of digital thermometer R and


connect it to thermometer [2].

10 PC130-8
30 Testing and adjusting SEN04114-02

Checking exhaust gas color 1


a Checking tools for exhaust gas color
Symbol Part No. Part name
1 799-210-9001 Handy smoke checker
A Commercially
2 Smoke meter
available

k Stop the machine on a level ground and


lower the work equipment to the ground.
k Be careful not to touch any hot part when
removing or installing the checking tools.
a Check the exhaust gas color under the follow-
ing condition.
q Engine coolant temperature: Within oper- 2) Connect the probe hose, receptacle of the
ating range accelerator switch, and air hose to smoke
a If an air source and an electric power source meter A2.
are not available in the field, use handy smoke a Limit the supplied air pressure to 1.5
checker A1. When recording official data, use MPa {15 kg/cm2}.
smoke meter A2. 3) Connect the power cable to an AC recep-
tacle.
1. Testing with handy smoke checker A1 a Before connecting the cable, check
1) Stick a sheet of filter paper to smoke that the power switch of the smoke
checker A1. meter is turned OFF.
2) Insert the exhaust gas intake pipe in 4) Loosen the cap nut of the suction pump
exhaust pipe (1). and fit the filter paper.
3) Start the engine and accelerate it sud- a Fit the filter paper securely so that the
denly or run it at high idle and operate the exhaust gas will not leak.
handle of smoke checker A1 so that the 5) Turn on the power switch of smoke meter
filter paper will absorb the exhaust gas. A2.
a Absorbing time: 1.4 ± 0.2 sec

6) Start the engine and accelerate it sud-


4) Remove the filter paper and compare it denly or run it at high idle and depress the
with the attached scale. accelerator pedal of smoke meter A2 and
5) After finishing checking, remove the test- collect the exhaust gas into the filter
ing tools and return the removed parts. paper.
7) Place the contaminated filter paper on the
2. Checking with smoke meter A2 clean filter paper (at least 10 sheets) in the
1) Insert probe [1] of smoke meter A2 in the filter paper holder and read the indicated
outlet of the exhaust pipe and fix it to the value.
exhaust pipe with a clip. 8) After finishing checking, remove the
checking tools and return the removed
parts.

PC130-8 11
SEN04114-02 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

k Stop the machine on a level ground and


lower the work equipment to the ground.
a Adjust the valve clearance under the following
condition.
q Engine coolant temperature: Normal tem-
perature

1. Open the engine hood and remove mainte-


nance step (1) and air supply hose (2) on the 4. Remove compression top dead center TDC
engine. check plug (6) from the flywheel housing.
Rotate the crankshaft forward with gear B1
and set it so that you can see the white mark of
the flywheel.

2. Remove cylinder head cover (4).

a When the No. 1 cylinder is at the compres-


sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not
at the compression top dead center. In
this case, rotate the crankshaft one more
turn.

12 PC130-8
30 Testing and adjusting SEN04114-02

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}

1) While fixing adjustment screw (1), loosen


locknut (2).
2) Insert thickness gauge B2 in the clearance
between rocker arm (3) and valve stem (4)
and adjust the valve clearance with
adjustment screw (1).
a With the thickness gauge inserted,
turn the adjustment screw to a degree
that you can move the thickness
gauge lightly.
3) While fixing adjustment screw (1), tighten
locknut (2).
3 Locknut: 39.2 – 49 Nm {4 – 5 kgm}
a After tightening the locknut, check the
valve clearance again.

6. Rotate the crankshaft forward 1 turn according


to step 4 to set the No. 4 cylinder to the com-
pression top dead center and adjust the valve
c l ea r a nc e s m a r k ed w i t h Q i n t he va l v e
arrangement drawing similarly to those marked
with q.

PC130-8 13
SEN04114-02 30 Testing and adjusting

Testing compression pressure 1


a Testing tools for compression pressure
Symbol Part No. Part name
1 795-502-1590 Compression gauge
C 795-502-1370 Adapter
2
6261-11-3880 Gasket

k When testing the compression pressure,


take care n ot to burn you rself on t he
exhaust manifold or muffler or get caught
in a rotating part.
a Test the compression pressure after the engine
is warmed up. 2. Install adapter C2 to the injector mounting part
(Engine oil temperature: 40 – 60°C) with holder (7) and connect compression
gauge C1.
1. Remove the injector of the cylinder to be tested a Fit the gasket to the adapter end without
according to the following procedure. fail.
a Test of the No. 1 cylinder is explained
3
below as an example. Holder mounting bolt:
1) Remove wiring harness connector (2) 27 – 30 Nm {2.8 – 3.1 kgm}
from injector (1). a Tighten the mounting bolt after the fulcrum
2) Move fuel scatter prevention cover (3) of the holder is seated perfectly.
from the joint.
3) Remove clamp (4) and high-pressure pipe
(5).
4) Pull spill hose connector (6) out of injector
(1).

5) Remove holder (7) and injector (1).


a If the injector is stuck and is not
removed easily, pass a wire under the
fuel inlet and pull it up to remove the
injector.
a Do not apply an external force to the
terminal at the injector top.

14 PC130-8
30 Testing and adjusting SEN04114-02

3. Set the engine in the no-injection cranking


mode with the machine monitor.
q Instead of the above work, you may dis-
connect the wiring harness connectors
from all the injectors so that fuel will not be
injected at all.
k Since starting of engine is dangerous,
be sure to set the injectors so that they
will not inject fuel before starting the
check.

4. Rotate the engine with the starting motor and


test the compression pressure.
a Test the compression pressure when the
gauge pointer is stabilized.

5. After finishing test, remove the testing instru-


ments and return the removed parts.
a Install the injector and spill hose connector
according to the following procedure.
1) Fit O-ring (8) and gasket (9) to injector (1).
a Do not fit O-ring (8) to groove (a).

PC130-8 15
SEN04114-02 30 Testing and adjusting

Testing blow-by pressure 1


a Testing tools for blow-by pressure
Symbol Part No. Part name
D 1 799-201-1504 Blow-by checker

k Stop the machine on a level ground and


lower the work equipment to the ground.
a Test the blow-by pressure under the following
condition.
q Engine coolant temperature: Within oper-
ating range
q Hydraulic oil temperature: Within operat-
ing range
5. After finishing test, remove the testing tools
1. Remove the undercover of the hydraulic pump. and return the removed parts.

2. Install tool and adapter [1] of blow-by checker


D1 to breather hose (1) and connect gauge [2].

3. Start the engine, set the working mode in the


power mode (P), and turn the swing lock
switch ON.
a If the swing lock switch is turned ON, the
main relief valve is set for high-pressure
relief.

4. While running the engine at high idle, relieve


the arm circuit and test the blow-by pressure.
a Read the gauge when the pointer is stabi-
lized.

16 PC130-8
30 Testing and adjusting SEN04114-02

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

1. Open the pump room cover and disconnect


outlet hose (1) of the engine oil filter.
6. After finishing test, remove the Testing tools
and return the removed parts.

2. Install adapter E3 and connect the discon-


nected hose again.

3. Install nipple E4 and connect it to hydraulic


tester E2.

4. Start the engine and heighten the engine cool-


ant temperature to the operating range.

PC130-8 17
SEN04114-02 30 Testing and adjusting

Reduced cylinder mode No-injection cranking 1


operation 1 a No-injection cranking means to crank the
a Reduced cylinder mode operation means to engine with the starting motor while all the
run the engine with the fuel injectors of 1 or injections are stopped electrically. The pur-
more cylinders disabled electrically to reduce pose and effect of this operation are as follows.
the number of effective cylinders. The pur- q Before the engine is started after it or the
poses and effects of this operation are as fol- engine unit has been stored for a long period,
lows. the no-injection cranking is performed to lubri-
1. This operation is used to find out a cylinder cate the engine parts and protect them from
which does not output power normally (or, seizure.
combustion in it is abnormal).
2. When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q Compression leakage through cylinder
head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.

18 PC130-8
30 Testing and adjusting SEN04114-02

Handling fuel system parts 1 Releasing residual pressure from


a Precautions for checking and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel main filter – Supply pump
trouble. High-pressure circuit:
When checking and maintaining the fuel sys- Supply pump – Common rail – Injector
tem, take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is checked and its parts
cartridge. are removed, the residual pressure in the fuel
Since the common rail fuel injection system circuit must be released completely. Accord-
(CRI) consists of more precise parts than the ingly, observe the following.
conventional fuel injection pump and nozzle, it k Before checking the fuel system or remov-
employs a high-efficiency special filter to pre- ing its parts, wait at least 30 seconds after
vent foreign matter from entering it. If a filter stopping the engine until the residual pres-
other than the genuine one is used, the fuel sure in the fuel circuit is released. (Do not
system may have a trouble. Accordingly, never start the work just after stopping the engine
use such a filter. since there is residual pressure.)

PC130-8 19
SEN04114-02 30 Testing and adjusting

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}

k Stop the machine on a level ground and


lower the work equipment to the ground.
a Test only the fuel pressure in the low-pressure
circuit from the priming pump through the fuel
main filter to the supply pump and the return
circuit from the supply pump/common rail/
injector to fuel tank.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be tested.

1. Testing pressure in fuel low-pressure cir-


cuit
1) Open the engine hood and remove fuel
pressure pickup plug (1) from the fuel
4) After finishing test, remove the testing
main filter.
tools and return the removed parts.
3 Fuel pressure pickup plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}

2) Install adapter F2 and nipple [1] of the


hydraulic tester F1 and connect them to
gauge of boost gauge kit F3.

20 PC130-8
30 Testing and adjusting SEN04114-02

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.

a Testing tools for fuel return rate and fuel leak-


age
Symbol Part No. Part name
1 6151-51-8490 Spacer
2 6164-81-5750 Joint
3 07042-20108 Plug
Commercially
4 Hose
available
G Commercially
5 Hose
available
Commercially
6 Measuring cylinder
available
6) Remove spill hose connector joint (5) and
Commercially
7 Stopwatch install plug G3.
available

a Prepare an oil pan of about 20 l to receive the


fuel flowing out during the test.

1. Preparation work
1) Remove tube (3) and spill hose (4)
between common rail (1) and return block
(2).

a The above is the preparation work for


test of the leakage from the pressure
limiter and return rate from the injec-
tor.

2) Insert spacer G1 on return block (2) side


and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the spacer.
3) Insert joint G2 on common rail (1) side and
tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect test hose G4 to the end of joint
G2.
5) Connect test hose G5 to connector (6)
side of spill hose (4).
a Bind the connecting part of the test
hose with a wire etc. to prevent it from
coming off.

PC130-8 21
SEN04114-02 30 Testing and adjusting

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

4) After finishing test, stop the engine.

3) After finishing test, stop the engine.

4. After finishing test, remove the testing tools


and return the removed parts.
3 Joint bolt: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}

22 PC130-8
30 Testing and adjusting SEN04114-02

Bleeding air from fuel circuit 1


a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
k Stop the machine on a level ground and
lower the work equipment to the ground.

1. Fill the fuel tank with fuel.


a Add oil until the oil filler float reaches the
maximum rising position.

2. Open the side cover of the pump room.

3. Loosen knob (1) of the feed pump and pull it


out, and then operate it forward and backward.
a Move the knob until it becomes heavy.
a The plug at the top of the fuel main filter
does not need to be removed.

4. After bleeding air, push in and tighten knob (1).

PC130-8 23
SEN04114-02 30 Testing and adjusting

Checking fuel circuit for leakage 1 9. Check the fuel piping and devices for fuel leak-

k
age.
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.
k
completed.
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.

1. Spray color checker (developer) over the fuel


supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2. Run the engine at speed below 1,000 rpm and


stop it after its speed is stabilized.

3. Check the fuel piping and devices for fuel leak-


age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and check again from step 2.

4. Run the engine at low idle.

5. Check the fuel piping and devices for fuel leak-


age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and check again from step 2.

6. Run the engine at high idle.

7. Check the fuel piping and devices for fuel leak-


age.
a Check around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
a If any fuel leakage is detected, repair it
and check again from step 2.

8. Run the engine at high idle and load it.


a Relieve the arm circuit at the IN stroke
end.

24 PC130-8
30 Testing and adjusting SEN04114-02

Testing and adjusting alternator Adjusting


belt tension 1 a If the deflection is out of the standard range,
adjust the belt tension according to the follow-
Testing ing procedure.
1. Open the engine hood and remove belt guard
(1). 1. Loosen alternator fixing bolts (1) and (2).
a Loosen fixing bolt (2) from the rear side of
the engine.

Press the intermediate point of the belt


between the alternator pulley and fan pulley
with a finger and test deflection (a) of the belt. 2. Adjust the tension of alternator belt (4) by turn-
a Pressing force: Approx. 60 Nm {Approx. ing adjustment bolt (3).
6.1 kg} a Do not loosen double nut (5) at the adjust-
a Deflection (a): 6 – 10 mm ment bolt end. (If you have loosened it,
apply LOCTITE (LT-2) to it when tighten-
ing.)
Reference: If adjustment bolt (3) is tightened
(turned to the right), the alternator
belt (4) is loosened. If the former
is turned to the left, the latter is
tightened.

3. After adjusting the belt tension, tighten alterna-


tor fixing bolts (1) and (2).

4. Check again that the tension of alternator belt


(4) is in the standard range.

PC130-8 25
SEN04114-02 30 Testing and adjusting

Checking and adjusting air Adjusting


conditioner compressor belt a If the belt deflection is abnormal, adjust it
tension 1 according to the following procedure.

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.

2. Press the intermediate point of the belt


between fan pulley and compressor pulley with
a finger and measure deflection (a) of the belt.
q Belt pressing force: 58.8 N {6 kg}

4. After finishing test, return the removed parts.

26 PC130-8
30 Testing and adjusting SEN04114-02

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.

1. Fix dial gauge H to the track frame and apply


the probe to the lower end of the outer race.

6. Return the machine to the condition of step 2


and check that dial gauge H indicates 0.
a If the dial gauge does not indicate 0,
repeat steps 2 through 5.

2. Set the work equipment to the maximum reach


position and set the bucket tip to the height of
the under side of the revolving frame.
a At this time the front of the upper structure
lowers and the rear rises.

3. Set dial gauge H to the 0 point.

PC130-8 27
SEN04114-02 30 Testing and adjusting

Checking and adjusting track Adjusting


shoe tension 1 a If the track shoe tension is abnormal, adjust it
according to the following procedure.
Checking
1. Run the engine at low idle and drive the 1. Increasing tension
machine forward by the length of track on 1) Add grease through grease fitting (2) with
ground, and then stop slowly. a grease gun.
2) To check that the tension is normal, run
2. Place square bar [3] longer than the distance the engine at low idle and move the
between idler (1) and carrier roller (2) on the machine forward by the length of track on
track shoe. ground, then stop slowly.
a As the steel bar, use an angle steel, etc. 3) After adjusting, check the track shoe ten-
which will be deflected less. sion again according to the above proce-
dure.
3. Test maximum clearance (a) between steel bar
[3] and track shoe.
q Standard maximum clearance (a):
10 – 30 mm

a You may add grease until dimension (b)


between the idler guide and track frame
end becomes 0 mm. If the tension is still
low, the pins and bushings are worn
much. In this case, reverse or replace the
pins and bushings.

28 PC130-8
30 Testing and adjusting SEN04114-02

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 29
SEN04114-02 30 Testing and adjusting

Testing and adjusting oil pressure


in work equipment, swing, and
travel circuits 1
a Testing and adjusting tools for oil pressure in
work equipment, swing, and travel circuits
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
J
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

k Stop the machine on a level ground and


lower the work equipment to the ground. 2) Install nipples J2 and connect oil pressure
Then, release the residual pressure from the gauges [1] of hydraulic tester J1.
hydraulic circuit. For details, see "Releasing a Use the oil pressure gauges of 58.8
residual pressure from hydraulic circuit". MPa {600 kg/cm2}.

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

2. Testing unload pressure


1) Start the engine, set the working mode in
the power mode (P), and turn the auto-
decelerator OFF.
2) Run the engine at high idle, set all the
levers and pedals for work equipment con-
trol, swing control, and travel in neutral,
and test the oil pressure.
a The pressure tested when the unload
valve is unloaded is indicated.

30 PC130-8
30 Testing and adjusting SEN04114-02

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.

5. Testing travel relief pressure


1) Run the engine and lock the travel mecha-
nism.
k Put pin [2] between the sprocket
and track frame to lock the travel
mechanism securely.

PC130-8 31
SEN04114-02 30 Testing and adjusting

Adjusting 5) After finishing adjustment, check again


a The unload valve and safety-suction valve for that the oil pressure is normal according to
lowering the boom cannot be adjusted. the above described test procedure.

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.

1) While fixing adjustment screw (8), loosen


locknut (9).
2) Turn adjustment screw (8) to adjust the
pressure.
a If the adjustment screw is
q Turned to the right, the set pres-
sure is increased.
q Turned to the left, the set pres-
sure is decreased.
a Quantity of adjustment per turn of
adjustment screw:
1) Disconnect pilot hose (4). Approx. 6.7 MPa {Approx. 68.4 kg/cm2}
2) While fixing holder (5), loosen locknut (6). 3) While fixing adjustment screw (8), tighten
3) Turn holder (7) to adjust the set pressure. locknut (9).
a If the holder is 3 Locknut:
q Turned to the right, the set pres- 78 – 103 Nm {8 – 10.5 kgm}
sure is increased.
q Turned to the left, the set pres-
sure is decreased.
a Quantity of adjustment per turn of
holder:
Approx. 20.5 MPa {Approx. 209 kg/cm2}
4) While fixing holder (5), tighten locknut (6).
3 Locknut: 49 – 58.8 Nm {5 – 6 kgm}

4) After finishing adjustment, check again


that the oil pressure is normal according to
the above described test procedure.

32 PC130-8
30 Testing and adjusting SEN04114-02

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

k Stop the machine on a level ground and


lower the work equipment to the ground.
Then, release the residual pressure from
the hydraulic circuit. For details, see
"Releasing residual pressure from hydrau-
lic circuit".
a Test the control circuit basic pressure under
the following condition.
q Hydraulic oil temperature: Within operating
range

1. Open the pump room side cover and remove


oil pressure pickup plug (1).

3. Start the engine, set the working mode in the


power mode (P), and turn the auto-decelerator
OFF.

4. Run the engine at high idle, set all the levers


and pedals for work equipment control, swing
control, and travel in neutral, and test the oil
pressure.

5. After finishing test, remove the testing tools


and return the removed parts.

a The control circuit basic pressure may be


tested with oil pressure pickup plug (2) on the
hydraulic pump side.
a Do not adjust the relief valve for control circuit
basic pressure.

PC130-8 33
SEN04114-02 30 Testing and adjusting

Testing and adjusting oil pressure


in pump PC control circuit 1
a Testing and adjusting tools for oil pressure in
pump PC control circuit
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

k Stop the machine on a level ground and


lower the work equipment to the ground.
Then, release the residual pressure from 2) Install nipple L2 and connect it to oil pres-
the hydraulic circuit. For details, see sure gauge [1] of hydraulic tester L1.
"Releasing residual pressure from hydrau-
lic circuit".

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

3) Start the engine and move the arm cylin-


der to the IN stroke end.
4) Set the working mode in the power mode
(P).

34 PC130-8
30 Testing and adjusting SEN04114-02

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)

a If the PC valve or the servo piston is


abnormal, the PC valve output pres-
sure (servo piston inlet pressure) is
"the same as the pump discharge
pressure" or "almost 0".
6) After finishing test, remove the testing
tools and return the removed parts.

2. Testing PC-EPC valve output pressure


1) Open the side cover of the pump room
and remove oil pressure pickup plugs (3).
(3): PC-EPC valve output pressure pickup a Testing condition and method of judg-
plug ment: If the output pressures are in
the following ratio, the PC-EPC valve
is normal.
Operation of
Engine Output pressure
lever

All control Approx. 2.9 MPa


Low idle
levers and {Approx. 30 kg/cm2}
pedals in Approx. 0 MPa
High idle neutral {Approx. 0 kg/cm2}

5) After finishing test, remove the testing


tools and return the removed parts.

PC130-8 35
SEN04114-02 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.

1. Loosen locknut (5).


a Before loosening the locknut, make
counter mark at the adjustment screw end
so that you can see the position of the
locknut before the adjustment (and you
can return the locknut to its original posi-
tion after turning it in reverse).

2. Turn adjustment screw (6) clockwise or coun-


terclockwise to adjust.
a Turn the adjustment screw
q Clockwise when the work equipment
s pee d i s low ( to i nc re ase pu mp
absorption torque) and
q Counterclockwise when the engine
speed lowers (to decrease pump
absorption torque).

3. Tighten locknut (5).


3 Locknut: 27 – 34 Nm {2.8 – 3.5 kgm}

36 PC130-8
30 Testing and adjusting SEN04114-02

Testing and adjusting oil pressure


in pump LS control circuit 1
a Testing and adjusting tools for oil pressure in
pump LS control circuit
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
M 2 799-401-2701 Differential pressure gauge
799-101-5220 Nipple (10 × 1.25 mm)
3
07002-11023 O-ring

k Stop the machine on a level ground and


lower the work equipment to the ground. 2) Install nipple M3 and connect it to oil pres-
Then, release the residual pressure from sure gauge [1] of hydraulic tester M1.
the hydraulic circuit. For details, see
"Releasing residual pressure from hydrau-
lic circuit".

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

3) Start the engine and push up the track


shoe on the side to be tested with the
work equipment and prepare for running
the track shoe idle.
k Since the raised track shoe will be
run idle during test, secure a suffi-
cient working area.

PC130-8 37
SEN04114-02 30 Testing and adjusting

4) Set the working mode in the power mode q (2): LS pressure pickup plug
(P) and set the travel speed in the High
position.
5) Run the engine at high idle, set all the
levers and pedals for work equipment con-
trol, swing control, and travel in neutral,
and test the oil pressure at each speed.
Then, operate the travel lever to run the
track shoe idle and test the oil pressure.
k While checking the safety around
the machine extremely, run the
track shoe pushed up idle.
a Do not operate the travel lever to the
stroke end (but stop it halfway).

2) Install nipples M3 and connect it to differ-


ential pressure gauge M2 or the oil pres-
sure gauge [1] of hydraulic tester M1.
a When using differential pressure gauge
M2:
Connect the pump discharge pres-
sure to the high pressure side (back
side) and connect the LS pressure to
the low pressure side (lower side).
Since the differential pressure gauge
needs a 12V power source, connect it
to a battery.
a When using oil pressure gauge (in M1):
a Testing condition and method of judg- Use the oil pressure gauge of 58.8
ment: If the pressures are in the fol- MPa {600 kg/cm2} having the unit of
lowing ratio, the LS valve is normal. 0.98 MPa {10 kg/cm2}. Since the dif-
ferential pressure is about 3.9 MPa
Lever
{40 kg/cm 2 } at maximum, test it by
operating Travel lever
condition All levers and half stroke installing the same gauge to the
pedals in neu- position pickup plugs alternately.
tral (Travel with q The figure shows the pump discharge
Tested no load) pressure side.
oil pressure
Set mea-
Pump discharge
sured value
pressure
Almost same as 1
pressure Approx. 3/5
LS valve output
of above
pressure
pressure

6) After finishing test, remove the testing


tools and return the removed parts.

2. Testing LS differential pressure


a Test the pump discharge pressure and LS
pressure (actuator load pressure) simulta-
neously and calculate the difference
between them.
1) Open the side cover of the pump room
and remove oil pressure pickup plugs (1)
and (2).
q (1): Pump discharge pressure pickup
plug

38 PC130-8
30 Testing and adjusting SEN04114-02

3) Run the engine, push up the track shoe on Adjusting


the side to be tested with the work equip- Adjusting LS valve
ment, and prepare for running track shoe a If the LS differential pressure is abnormal,
idle. adjust the LS valve according to the following
q When testing P1 circuit: Right track procedure.
shoe q (3): Pump LS valve
q When testing P2 circuit: Left track
shoe
k Since the raised track shoe will be
run idle during test, secure a suffi-
cient working area.
4) Set the working mode in the power mode
(P) and set the travel speed in the High
position.
5) Run the engine at high idle, set all the
levers and pedals for work equipment con-
trol, swing control, and travel in neutral,
and test the oil pressure at each speed.
Then, operate the travel lever to run the
track shoe idle and test the oil pressure.
k While checking the safety around
the machine extremely, run the 1. While fixing adjustment screw (4), loosen lock-
track shoe pushed up idle. nut (5).
a Do not operate the travel lever to the
stroke end (but stop it halfway). 2. Turn adjustment screw (4) to adjust the differ-
ential pressure.
a If the adjustment screw is
q Turned to the right, the differential
pressure is increased.
q Turned to the left, the differential
pressure is decreased.
a Quantity of adjustment (LS differential
pressure) per turn of adjustment screw:
Approx. 1.1 MPa {Approx. 10.8 kg/cm2}

3. While fixing adjustment screw (4), tighten lock-


nut (5).
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}

a Testing condition and method of judg-


ment: If the pressures are in the fol-
lowing ratio, the LS valve is normal.
LS differential
Operation of levers
pressure
All control levers and pedals 2.8 ± 1.0 MPa
in neutral {28 ± 10 kg/cm2}
Travel lever moved halfway 2.2 ± 0.1 MPa
(No-load travel operation of
one side) {22.5 ± 1 kg/cm2}

6) After finishing test, remove the testing


tools and return the removed parts. 4. After finishing adjustment, check again that the
Insert the removed connector V5 of the LS differential pressure is normal according to
solenoid valve in its original position. the above described test procedure.

PC130-8 39
SEN04114-02 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

a Before testing the solenoid valve output pres-


sure, check that the control circuit basic pres-
sure is normal.
k Lower the work equipment to the ground
2. Install adapter N2 and connect the discon-
and stop the engine. Operate the control
nected hoses again.
lever several times to release the residual
pressure from the piping, and then loosen
3. Install nipple N3 and connect it to pressure
the oil filler cap of the hydraulic tank slowly
gauge [1] of hydraulic tester N1.
to release the residual pressure from the
a Use the oil pressure gauge of 5.9 MPa {60
tank.
kg/cm2}.
a The testing tools installed to the outlet
1. Disconnect hoses (1) – (6) of the solenoid
hose of the PPC lock solenoid valve are
valves to be tested.
shown in the figure.
No. Solenoid valve to be tested
1 PPC lock solenoid valve
2 Pump merge-divider solenoid valve
3 Travel junction solenoid valve
4 Travel speed selector solenoid valve
5 Swing holding brake solenoid valve
6 2-stage relief solenoid valve

a Since hose (1) is installed under the cab,


remove the cab undercover (rear one).

4. Run the engine and heighten the hydraulic oil


temperature to the operating range.

40 PC130-8
30 Testing and adjusting SEN04114-02

5. Run the engine at high idle and operate the


control levers and switches and test the pres-
sure when each solenoid valve is turned ON or
OFF.
a For the conditions for turning each sole-
noid valve ON and OFF, see the table for
functioning conditions of each solenoid
valve.
a The operating conditions of the solenoid
valves can be checked with the monitoring
function of the machine monitor (special
function of the machine monitor).
a If the output pressure of a solenoid valve
is as follows, that solenoid valve is normal.
Solenoid valve Output pressure
OFF (Demagnetized) 0 MPa {0 kg/cm2}
Almost same as control
ON (Magnetized) basic pressure
(See standard values table)

6. After finishing test, remove the testing tools


and return the removed parts.

Table for functioning conditions - PPC lock


solenoid valve
Operating condition Functioning
Work equipment lock LOCK OFF
lever RESET ON

PC130-8 41
SEN04114-02 30 Testing and adjusting

Table for functioning conditions - 2-stage relief solenoid valve


Functioning condition Functioning
When overheat setting of the 1st stage is ON
When overheat setting of the 2nd stage is ON OFF
When all the signals for work equipment, swing and travel are OFF
When swing lock switch is ON
When travel signal is ON
ON
When working mode is L mode
When left knob switch is If signals other than swing operation only is ON
In P/ATT mode/E mode
ON If swing operation only is ON
OFF
In conditions other than above

Table for functioning conditions - travel speed shifting solenoid valve


Functioning condition Functioning
When overheat setting of the 2nd stage is ON
When the fuel dial indicates less than 1500 rpm
When the travel speed switch is at Lo
OFF
The travel signal is OFF
If front or rear pump pressure is
When the travel speed
32.3 MPa {330 kg/cm2}
switch is at Hi The travel signal is ON
If front or rear pump pressure is
17.6 MPa {180 kg/cm2} ON
In conditions other than above

Table for functioning conditions - swing holding brake solenoid


Functioning condition Functioning
Swing signal
When any of them is ON ON
Arm in signal
Elapsed time after failure of above condition < 5 sec ON
Other than above OFF

Table for functioning conditions - travel junction solenoid valve


Functioning condition Functioning
Steering judgment ON ON
Other than above OFF

42 PC130-8
30 Testing and adjusting SEN04114-02

Functioning conditions - merge/divide solenoid valve

PC130-8 43
SEN04114-02 30 Testing and adjusting

Testing PPC valve output a Install nipple P3 to adapter P2 and mea-


pressure 1 sure the travel PPC pressure at the valve
box elbow.
a Testing tools for PPC valve output pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
P 2 799-401-3100 Adapter (Size: 02)
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring

a Test PPC valve output pressure after confirm-


ing that control circuit original pressure is nor-
mal.

1. Remove PPC oil pressure switches (1) through


(10) in the hydraulic circuits to be tested. Con- 2. Fit fitting [2] of hydraulic tester P and connect
nector numbers are shown in brackets ( ). oil pressure gauge [1].
a Use an oil pressure gauge with the capacity
No. Circuit to be tested No. Circuit to be tested of 5.9 MPa {60 kg/cm2}.
1 Boom, RAISE (P06) 5 Bucket, CURL (P01) a The testing tools installed to the mounting
2 Boom, LOWER (P02) 6 Bucket, DUMP (P05) part of the boom RAISE PPC oil pressure
switch are shown in the figure.
3 Arm, IN (P04) 7 Swing, left (P07)
4 Arm, OUT (P08) 8 Swing, right (P03)

a (1) – (8) are installed to the PPC junction


block in the rear of the cab.

3. Start the engine and keep it running until the


hydraulic oil temperature rises to the operating
range.
a Turn OFF the auto-decelerator switch.

44 PC130-8
30 Testing and adjusting SEN04114-02

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).

4. Fix disc (3) and tighten locknut (2) to the speci-


fied torque.
3 Locknut: 69 – 88 Nm {7 – 9 kgm}

5. Install bellows (1).

6. Install the work equipment and swing PPC


valve assembly.

PC130-8 45
SEN04114-02 30 Testing and adjusting

Checking parts which cause 2. Checking arm cylinder


hydraulic drift of work 1) Stop the arm cylinder about 100 mm before
the IN stroke end and stop the engine.
equipment 1
a If the work equipment (cylinder) drifts hydrauli-
cally, check to see if the cause is on the cylin-
d e r pa c k i n g s i d e o r c o n t r o l v a l v e s i d e
according to the following procedure.

1. Checking boom cylinder and bucket cylinder


1) Set the machine in the position for testing
hydraulic drift and stop the engine.
a Fill the bucket with a rated load or
with dirt and sand.

2) Operate the arm control lever in the IN


position.
q If the lowering speed is increased at
this time, the cylinder packing is
defective.
q If the lowering speed does not change
at this time, the control valve is defec-
tive.
a Operate the control lever while the
starting switch is in the ON position.
a If the pressure in the accumulator is
2) When checking the boom cylinder, set the lost, run the engine for about 5 sec-
boom control lever in the RAISE position. onds to heighten the pressure in the
When checking the bucket cylinder, set the accumulator.
bucket control lever in the CURL position. [Reference]
q If the lowering speed is increased at this Reason why the lowering speed is increased
time, the cylinder packing is defective. by the above operation when the cylinder
q If the lowering speed does not change at packing is the cause of the hydraulic drift:
this time, the control valve is defective. 1) If the machine is set in the above position
a Operate the control lever while the (where the holding pressure is applied to
starting switch is in the ON position. the bottom side), the oil leaks from the
a If the pressure in the accumulator is bottom side to the head side. Since the
lost, run the engine for about 5 sec- volume on the head side is less than that
onds to heighten the pressure in the on the bottom side by the volume of the
accumulator. rod, the pressure in the head side is
increased by the oil flowing in from the
bottom side.
2) As the pressure in the head side is
increased, it is balanced at a certain level
(which depends on the leakage), and then
the lowering speed is lowered.
3) If the circuit on the head side is opened to
the drain circuit by the above operation of
the lever (the bottom side is closed by the
check valve at this time), the oil on the
head side flows in the drain circuit. As a
result, the pressure is unbalanced and the
lowering speed is increased.

46 PC130-8
30 Testing and adjusting SEN04114-02

3. Checking PPC valve


While the pressure in the accumulator is high,
set the lock lever in the LOCK/FREE position
and test the lowering distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for about 5 seconds to
heighten the pressure in the accumulator.
a If there is a difference in the lowering dis-
tance between the LOCK position and
FREE position, the PPC valve is defective
(it has an internal defect).

PC130-8 47
SEN04114-02 30 Testing and adjusting

Testing and adjusting travel deviation 1

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°.

2. Set the working mode to P and travel speed to


Lo.

3. Run up for 10 m with the engine speed at high


idle and continue travel under the same condi-
tion for 20 m and test the deviation (a).
a Install an oil pressure gauge and check
that the P1 and P2 discharge pressures of
the hydraulic pump are even.

48 PC130-8
30 Testing and adjusting SEN04114-02

Adjustment 2. Fixing plug (3) with a hexagonal wrench (Width


a If the machine deviates, it can be corrected by across flats: 4 mm), loosen locknut (4).
partially draining the oil discharged more from a If the locknut is sealed with a vinyl tape,
the pump through the travel deviation adjusting remove that tape.
plug. (If the travel deviation is corrected by this a Before loosening the locknut, make match
method, however, the pump discharge is marks on it and pump case.
reduced. As a result, the travel speed, work q Loosening angle of locknut: Approx. 90 –
equipment speed in compound operation, and 180°
relief pressure may lower.)
a If the machine deviates in the same direction
regardless of the travel direction, correct it
according to the following procedure. (If the
deviating direction of the machine depends on
the travel direction, the cause of deviation may
not be in the hydraulic pump. In this case,
carry out troubleshooting.)
a Only when the travel deviation is 200 mm or
less, it can be corrected by the following
method.
k If the adjusting plug is loosened more than
the adjustment limit, high-pressure oil will
spout out. Take care extremely.
k Lower the work equipment to the ground
3. Loosen plug (3) to adjust the travel deviation.
and stop the engine. Operate the control q Quantity of adjustment of deviation per
lever several times to release the residual turn of plug: 150 mm (Reference)
pressure from the piping, and then loosen a The plug is fully tightened when shipped.
the oil filler cap of the hydraulic tank slowly Adjust the deviation by the loosening
to release the residual pressure from the angle of the plug from the fully tightened
tank. position.
a If the plug is turned together with the lock-
1. Check the deviating direction and the locations nut, tighten it fully again, then start adjust-
of travel deviation adjusting plugs (1) and (2). ment.
q (1): Right deviation adjusting plug (P1 a The plug can be loosened by 2 turns
pump) (720°) from the fully tightened position.
q (2): Left deviation adjusting plug (P2
pump) 4. Fixing plug (3) with a hexagonal wrench,
a Loosen only the plug on either side for tighten locknut (4).
3 Locknut: 2.9 – 4.9 Nm {0.3 – 0.5 kgm}
adjustment. Do not loosen the plugs on
both sides. a After tightening the locknut, seal its hole
with a vinyl tape.

5. After finishing adjustment, check travel devia-


tion again according to the procedure for
inspection described above.

PC130-8 49
SEN04114-02 30 Testing and adjusting

Releasing residual pressure from 4) Repeat steps 2) and 3) above 2 – 3 times,


hydraulic circuit 1 and the residual pressure in the piping is
released completely.
1. Releasing residual pressure from hydraulic
tank 3. Releasing residual pressure from swing
k Since the hydraulic tank is enclosed motor circuit
and pressurized, release the residual The residual pressure in the swing motor cir-
pressure from it when removing a hose cuit can be released by performing the opera-
or a plug connected to it. tion for "Releasing residual pressure from
1) Lower the work equipment to the ground hydraulic cylinder circuit" (Operate the lever in
in a stable position and stop the engine. the swing direction only, however).
2) Loosen oil filler cap (1) of the hydraulic
tank gradually to release the air in the 4. Releasing residual pressure from travel
tank. motor circuit
Since the control valve spool of the travel
motor circuit is open, the pressure in this circuit
can be released by performing "Releasing
residual pressure from hydraulic tank".

2. Releasing residual pressure from hydraulic


cylinder circuit
k When disconnecting a pipe between a
hydraulic cylinder and the control
valve, release the residual pressure
from the piping according to the follow-
ing procedure.
1) Lower the work equipment and release the
residual pressure from the hydraulic tank.
For details, see "Releasing residual pres-
sure from hydraulic tank".
a Keep the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch ON and set the
lock lever in the FREE position, and then
operate the right and left work equipment
control levers forward, backward, to the
right, and to the left.
a The control valve is operated by the
pressure in the accumulator. The
pressure in the accumulator is used
up, however, after the control valve is
operated 2 – 3 times.
3) Run the engine at low idle for 5 seconds to
heighten the pressure in the accumulator.
a The engine does not start until the
lock lever is set in the LOCK position
once.

50 PC130-8
30 Testing and adjusting SEN04114-02

Testing oil leakage 1 2. Testing oil leakage from arm cylinder


1) Move the arm cylinder to the IN stroke end
a Testing tools for oil leakage and stop the engine.
Symbol Part No. Part name k Release the residual pressure from
the piping on the arm cylinder
Commercially
Q Measuring cylinder head side. For details, see Releas-
available
ing residual pressure from hydrau-
a Test the oil leakage under the following condi- lic circuit (Operate the lever in the
tion. arm IN direction only, however).
q Hydraulic oil temperature: Within operating 2) Disconnect hose (2) on the cylinder head
side and block it with a plug.
k Take care not to disconnect the
range

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)

3) Run the engine at high idle and relieve the


arm circuit by moving the arm IN.
k Take care not to "move the arm
OUT".
4) Start testing the oil leakage 30 seconds
after relieving is started and test for 1
minute.
5) After finishing test, return the removed
parts.

3) Run the engine at high idle and relieve the


boom circuit by raising the boom.
k Take care not to "lower the boom".
4) Start testing the oil leakage 30 seconds
after relieving is started and test for 1
minute.
5) After finishing test, return the removed
parts.

PC130-8 51
SEN04114-02 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)

2) Turn the swing lock switch ON.


3) Run the engine at high idle and relieve the
swing circuit by swinging.
a Start testing the oil leakage 30 sec-
onds after relieving is started and test
for 1 minute.
a After testing 1 time, swing 180°, and
then test again.
4) After finishing test, return the removed
parts.

3) Run the engine at high idle and relieve the


bucket circuit by curling the bucket.
k Take care not to "dump the bucket".
4) Start testing the oil leakage 30 seconds
after relieving is started and test for 1
minute.
5) After finishing test, return the removed
parts.

52 PC130-8
30 Testing and adjusting SEN04114-02

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.

3) Disconnect drain hose (5) of the travel


motor and block the hose side with a plug.
a Use the following part to block the
hose side.
07376-70422 (Plug #04)

4) Run the engine at high idle, relieve the


travel circuit, and test the oil leakage.
k Before operating the travel lever,
check the position and locking
direction of the locked sprocket
again.
k Wrong operation of the lever can
cause an accident. Accordingly,
make signs and checks securely.
a Start testing the oil leakage 30 sec-
onds after relieving is started and test
for 1 minute.
a Test several times, moving the motor
a little (changing the position of the
valve plate and cylinder and that of
the cylinder and piston) each time.

PC130-8 53
SEN04114-02 30 Testing and adjusting

Bleeding air from each part 1


Air bleeding procedure
Air bleeding item
1 2 3 4 5 6
Bleeding air Checking oil
Bleeding air Bleeding air
from Starting Bleeding air level and
from swing from travel
Contents of work hydraulic engine from cylinder starting
motor motor
pump operation
• Replacing hydraulic oil q q
q q q q
• Cleaning strainer (See note) (See note)
• Replacing return filter element q o o o q
• Replacing and repairing hydraulic
pump q q q o o q
• Removing suction piping
• Replacing and repairing control
valve q q o o q
• Removing control valve piping
• Replacing and repairing cylinder
q q o o q
• Removing cylinder piping
• Replacing and repairing swing
motor q o q o q
• Removing swing motor piping
• Replacing and repairing travel
motor q o o q q
• Removing travel motor piping
• Replacing and repairing swivel joint
q o o o q
• Removing swivel joint piping

Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.

1. Bleeding air from hydraulic pump 2. Starting engine


1) Loosen air bleeder (1) and check that oil When running the engine after performing step
oozes out through the air bleeder. 1, keep its speed at low idle for 10 minutes.
2) After the oil oozes out, tighten air bleeder
(1). 3. Bleeding air from cylinder
3 Air bleeder: a If a cylinder is replaced, bleed air from it
7.8 – 9.8 Nm {0.8 – 1.0 kgm} before connecting the work equipment. In
a Do not use an impact wrench to particular, the boom cylinder does not
tighten the air bleeder. move to the lowering stroke end, if it is
installed to the work equipment.
1) Run the engine at low idle for about 5 min-
utes.
2) While running the engine at low idle, raise
and lower the boom 4 – 5 times.
a Stop the piston rod about 100 mm
b efo re e ac h s tr ok e en d. Do no t
relieve the oil.
3) While running the engine at high idle, per-
form step 2).
4) While running the engine at low idle, move
the piston rod to the stroke end and
relieve the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).

54 PC130-8
30 Testing and adjusting SEN04114-02

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)

2) Check the oil level by sight gauge (4) on


the rear side of the hydraulic tank.
a If the oil level is below line L, it is
insufficient. Add oil.
a The oil level changes according to the
oil temperature. Add oil when the oil
3) Run the engine at low idle and check that level is out of the following standard
oil flows out of elbow (2). ranges.
a If no oil flows out of the elbow, per- q When oil temperature is 10 – 30°C:
form step 1) again. Between line H and line L
4) Connect hose (1) under its normal condi- q When oil temperature is 50 – 80°C:
tion. Near line H

5. Bleeding air from travel motor


1) Remove the travel motor cover and dis-
connect motor drain hose (2).
2) Run the engine at low idle and check that
oil flows out of nipple (3).

PC130-8 55
SEN04114-02 30 Testing and adjusting

Checking cab tipping stopper 1

a Check the cab tipping stopper according to the


following procedure.

1. Remove the additional undercover from the


rear of the operator's cab.

2. Check the tightening torque of the mounting


bolt (2) of the lock plate (1).
3 Bolt (2): 98 – 123 Nm {10 – 12.5 kgm}

[Reference]
q The tightening torque of mounting bolt (4) of
cab tipping stopper (3) is different from that of
a common bolt 30 mm in diameter. Take care.
3 Bolt (4): 245 – 309 Nm {25 – 31.5 kgm}

56 PC130-8
30 Testing and adjusting SEN04114-02

Installation and adjustment of Tightening torque of mirror bolt (2):


mirrors and camera 1 4.0 – 5.4 Nm {0.41 – 0.55 kgm}
Tightening torque of mirror stay bolt (3):
15 Nm {1.52 kgm}
a If the tightening torque is low, the bolts
may be dragged. If the former is too high,
the body may be broken.

1. Installation of retractable mirrors


Install retractable mirrors (a1) and (b1) as
shown in the figure.
q Retractable mirror (a1): Install at 20 mm
(from the bottom of the intermediate stay). Retract the mirror into position (C) when
Install mirror stay (1) so that the mirror will transporting the machine.
be fixed at (A) of the 3 stopping positions
where the mirror is extracted most and at q Retractable mirror (b1): Install at 65 mm
an angle of about 73° to the intermediate (from the top of the stay). Install mirror
stay. stay (4) so that the mirror will be fixed at
a If the mirrors are not installed to the cor- (A) of the 3 stopping positions where the
rect positions, they may interfere with the mirror is extracted most and at an angle of
exterior parts. about 19° to the side of the machine body.
a If the mirrors are not installed to the cor-
rect positions, they may interfere with the
exterior parts.

PC130-8 57
SEN04114-02 30 Testing and adjusting

Tightening torque of mirror bolt (5):


4.0 – 5.4 Nm {0.41 – 0.55 kgm}
Tightening torque of mirror stay bolt (6):
15 Nm {1.52 kgm}
a If the tightening torque is low, the bolts
may be dragged. If the former is too high,
the body may be broken.

Retract the mirror into position (C) when


transporting the machine.

2. Installation of fixed mirror


Install fixed mirror (c1) as shown in the figure.

Tightening torque of mirror bolt (7):


4.0 – 5.4 Nm {0.41 – 0.55 kgm}

3. Adjustment of retractable mirrors


1) Adjust the retractable mirrors at position
A.
2) With retractable mirrors (a1) and (b1)
open, loosen mirror bolts (1) and (2) and
stay mounting bolts (3) and (4) and adjust
the mirrors so that the operator can see
the right and left rear views best which are
blind corners from the operator's seat.
a Adjust the mirror so that the operator can
see persons (or things 1 m high and about
30 cm in diameter) at the right and left rear
ends of the machine.
a Take care not to tighten stay mounting
bolts (3) and (4) (If they are tightened to
strongly, the stay may be broken since it is
made by die-casting).

58 PC130-8
30 Testing and adjusting SEN04114-02

3) Tighten the stay mounting bolts so that the If the image projected on the monitor deviates,
clearance to the stay mating face will be remove cover (4) and adjust installed angle (A)
even. of the rear view monitor camera.

4. Adjustment of fixed mirror


Loosen mirror bolt (3) and adjust the mirror so
that the operator can see a person at the right
front end from the operator's seat.

1) To remove cover (1), insert a flat-head


screwdriver etc. in hole (3) at the top of
cover (2) to push the inside claw and
remove the cover.
2) Remove 2 bolts (4) and remove cover (1).
5. Adjustment of rear view monitor camera
angle
Adjust the rear view monitor camera so that
the operator can see persons on the ground at
1 m around the machine from the operator's
seat.

PC130-8 59
SEN04114-02 30 Testing and adjusting

3) Loosen camera mounting bolt (5) and


adjust the installed angle of the camera so
that the center of mounting bolt (5) will be
set to 4th scale mark (B) from the bottom.

a A part of the machine is projected on the


monitor.
4) After adjusting, tighten bolt (5).

60 PC130-8
30 Testing and adjusting SEN04114-02

Inspection of air conditioner 2. Cleaning of fresh air filter


Recirc/Fresh air filter 1 1) Unlock (2) at the left rear of the operator's
cab with the key (starting switch key).
If the filters are clogged, the air flow decreases and While holding cover (2) open with your
a muffled hum of the air conditioner unit is heard. hand, take filter (3) out of the cover.
2) Clean the filter with compressed air. If it is
Cleaning of air conditioner Recirc/Fresh
stained with oil or very dirty, wash it in
air filters water and neutral detergent. After wash-

k
ing, dry sufficiently and then install.
When using compressed air, put on protec- If the dirt clogging the filter cannot be
tive glasses, dust mask and other protec- removed with compressed air or water,
tive gears since dirt will scatter and it can replace the filter.
cause serious injury or death.
3) After filter (3), return it and close the cover.
Then, lock the cover with the key (starting
1. Cleaning of recirculated air filter
switch key). Take care not to forget to pull
1) Remove wing bolt (1) of the inspection out the key (starting switch key).
hole at the inside left rear bottom of the
operator's cab and remove the recircu-
lated air filter.
2) Clean the filter with compressed air. If it is
stained with oil or very dirty, wash it in
water and neutral detergent. After wash-
ing, dry sufficiently and then install.
If the dirt clogging the filter cannot be
removed with compressed air or water,
replace the filter with new one.
a Since the recirculated air filter has
directional properties, install it with
the projection side toward the front of
the machine.
a Since fresh air filter (3) has directional
properties, insert it with longer side
(L) ahead. If it is inserted with shorter
side (S) ahead, cover (2) cannot be
closed.

PC130-8 61
SEN04114-02 30 Testing and adjusting

PC130-8 Hydraulic excavator


Form No. SEN04114-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09

62 PC130-8
SEN04115-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC130-8

Machine model Serial number


PC130-8 80001 and up

30 Testing and adjusting 1


Testing and adjusting, Part 2
Special functions of machine monitor ............................................................................................................. 2

PC130-8 1
SEN04115-02 30 Testing and adjusting

Special functions of machine monitor 1


Air conditioner specification

2 PC130-8
30 Testing and adjusting SEN04115-02

Upper section of machine monitor (Display sec-


tion)
(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.

Upper section of machine monitor (Switch sec-


tion)
[F1]: F1 function switch
[F2]: F2 function switch
[F3]: F3 function switch
[F4]: F4 function switch
[F5]: F5 function switch
[F6]: F6 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.

Lower section of machine monitor (Switch sec-


tion)
[1]: Numeral 1 input switch/Auto-decelerator
switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed shifting
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner or
heater switch
[8]: Numeral 8 input switch/Air conditioner or
heater switch
[9]: Numeral 9 input switch/Air conditioner or
heater switch
[0]: Numeral 0 input switch/Air conditioner or
heater switch
Switch having no numerals: Air conditioner or
heater switch
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display.

PC130-8 3
SEN04115-02 30 Testing and adjusting

t Ordinary functions and special functions of machine monitor


The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.

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)

B Selection of auto-deceleration 9p With/Without Attachment 38p


Default
B Selection of working mode 9p Attachment/Maintenance Password 39p
B Selection of travel speed 10p Camera 40p
B Operation to stop alarm buzzer 10p ECO Display 41p
B Operation of windshield wiper 10p Pump Absorption Torque 42p
Adjustment
B Operation of window washer 10p Attachment Flow Adjustment 43p
B Operation of air conditioner/heater 11p Cylinder Cut-Out 44p
B Operation to display camera mode 11p No Injection 45p
B Operation to display clock and service meter 12p Fuel Consumption 47p
B Check of maintenance information 12p Terminal Status 48p
KOMTRAX
Setting and display of user mode GPS & Communication Status 49p
B 13p Settings
(Including KOMTRAX messages for user)
MODEM S/N (TH300) 50p
C Display of energy-saving guidance 14p
Display of KOMTRAX message 51p
C Display of caution monitor 14p
C Display of user code and failure code 14p
O (Special operation)
Function of checking display of LCD
D 16p
(Liquid Crystal Display)
D Function of checking service meter 16p
Function of changing attachment/maintenance
D 17p
password

4 PC130-8
30 Testing and adjusting SEN04115-02

a Classification of operator mode


A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch

PC130-8 5
SEN04115-02 30 Testing and adjusting

t Operator mode (Outline) a Display pattern of operator mode


a Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/opera- starting switch is turned ON to time when
tion of each function/display, see the Structure, screen changes to ordinary screen depends on
function and maintenance standard, or Opera- the setting and condition of the machine.
tion and Maintenance Manual. A : When engine start lock is set effective
a The following are the displays or functions of B : When engine start lock is set ineffective
the operator mode explained in this section C : When working mode at start is set to
(including some items which need special breaker mode (B)
operations). D : When there is abnormal item in check-
before-starting items
Display pattern E : When there is maintenance item which is
A B C D E not maintained after specified interval
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 — — — —
Display of check before starting 3 2 3 2 2
Display of KOMATSU logo
Display of warning after check
— — — 3 — When the s tarting switch is turned ON, the
before starting
Display of ending of maintenance KOMATSU logo is displayed for 2 seconds.
interval
— — — — 3 a After the KOMATSU logo is displayed for 2
Display of check of working mode seconds, the screen changes to "Display of
4 3 4 4 4 inputting password", or "Display of check
and travel speed
Display of ordinary screen 5 4 5 5 5 before starting".
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner
Operation to display camera mode
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode (including a The following screen may be displayed instead
KOMTRAX messages for user) of the above Display of inputting password
Display of energy-saving guidance screen.
Display of caution monitor a If this screen is displayed, call the person
Display of user code and failure code responsible to operation of KOMTRAX in your
O (Special operation) Komatsu distributor and ask for remedy.
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing attachment/maintenance pass-
word

6 PC130-8
30 Testing and adjusting SEN04115-02

Display of inputting password Display of check before starting


After the KOMATSU logo is displayed, the screen When the screen changes to the check-before-
to input the engine start lock password is displayed. starting screen, the check before starting is carried
a This screen is displayed only when the engine out for 2 seconds.
start lock function is set effective. a If any abnormality is detected by the check
a If the password is input normally, the screen before starting, the screen changes to "Display
changes to "Display of check before starting". of warning after check before starting" or "Dis-
a The machine monitor has some password play of ending of maintenance interval".
functions other than the engine start lock. a If no abnormality is detected by the check
Those functions are independent from one before starting, the screen changes to "Display
another. of check of working mode and travel speed".
a The monitors (3 pieces) displayed on the screen
are the items under the check before starting.

Display of check of breaker mode


When the starting switch is turned ON, if the work-
ing mode is set to the breaker mode [B], a message Display of warning after check before starting
to inform the operator of starting in the breaker If any abnormality is detected by the check before
mode is displayed on the screen. starting, the warning monitor is displayed on the
k If an attachment other than the breaker is screen.
used while the working mode is set to the a The following figure shows that the engine oil
breaker mode [B], the machine may move level monitor (a) is warning of low of engine oil
unexpectedly or may not operate normally level.
or the hydraulic components may be dam-
aged.
a After operation to check of the breaker mode is
finished, the screen changes to "Display of check
before starting".
If No is selected: Working mode is set to econ-
omy mode [E]
If Yes is selected: Working mode is set to breaker
mode [B]

PC130-8 7
SEN04115-02 30 Testing and adjusting

Display of ending of maintenance interval Display of ordinary screen


When the check before starting is carried out, if a If the machine monitor starts normally, the ordinary
maintenance item is near or after the end of the set screen is displayed.
interval, the maintenance monitor is displayed for a Service meter (a) or a clock is displayed at the
30 seconds to urge the operator to maintenance. center upper section of the screen (The ser-
a This screen is displayed only when the mainte- vice meter or clock is selected with [F4]).
nance function is effective. The color of the a ECO gauge (b) is displayed at the right end of
maintenance monitor (yellow or red) indicates the screen (It is turned ON and OFF in the ser-
the length of the time after the maintenance vice mode).
interval.
a Set or change the maintenance function in the
service mode.
a After display of this screen is finished, the
screen changes to "Display of check of work-
ing mode and travel speed".

Display of end screen


When the starting switch is turned OFF, the end
screen is displayed for 5 seconds.
a Another message may be displayed on the
end screen, depending on the message dis-
play function of KOMTRAX.
Display of check of working mode and travel
speed
If the check before starting is finished normally, the
screen to check the working mode and travel speed
is displayed for 2 seconds.
a After display of check of the working mode and
travel speed is finished, the screen changes to
"Display of ordinary screen".

8 PC130-8
30 Testing and adjusting SEN04115-02

Selection of auto-deceleration q [F4]: Move to upper working mode


While the ordinary screen is displayed, if the auto- q [F5]: Cancel selection and return to ordi-
deceleration switch is pressed, large auto-deceler- nary screen
ation monitor (a) is displayed for 2 seconds and the q [F6]: Confirm selection and return to ordi-
setting of the auto-deceleration is changed. nary screen
a Each time the auto-deceleration switch is Working mode selector switch
pressed, the auto-deceleration is turned ON q Press: Move to lower working mode
and OFF alternately. q Hold down:Confirm selection and return to
a If the auto-deceleration is turned ON, large ordinary screen
monitor (a) and auto-deceleration monitor (b) a If you do not touch any of the function
are displayed simultaneously. switches and working mode selector
a If the auto-deceleration is turned OFF, auto- switch for 5 seconds, the selection is con-
deceleration monitor (b) goes off. firmed and the screen changes to the ordi-
nary screen.

3. When the ordinary screen is displayed again,


Selection of working mode large working mode monitor (a) is displayed for
Select a working mode according to the following 2 seconds, and then the setting of the working
procedure. mode is changed.
1. While the ordinary screen is displayed, press a When large monitor (a) is displayed, the
the working mode selector switch, and the display of working mode monitor (b) is
working mode selection screen is displayed. changed, too.
a The following figure is the working mode
selection screen displayed when "With
attachment" is set (If "With attachment" is
not set in the service mode, the attach-
ment mode [ATT] is not displayed).

<Precautions for selecting breaker mode [B]>


q If breaker mode [B] is selected, both of the
control of the hydraulic pump and the setting of
the hydraulic circuit are changed.
2. Operate the function switches or working mode q If an attachment other than the breaker is
selector switch to select and confirm the work- used, the machine may move unexpectedly or
ing mode which you will use. may not operate normally or the hydraulic
Function switches components may be damaged.
q [F3]: Move to lower working mode

PC130-8 9
SEN04115-02 30 Testing and adjusting

Selection of travel speed Operation of windshield wiper


While the ordinary screen is displayed, if the travel While the ordinary screen is displayed, if the wiper
speed shifting switch is pressed, large travel speed switch is pressed, large wiper monitor (a) is dis-
monitor (a) is displayed for 2 seconds and the set- played for 2 seconds and the windshield wiper
ting of the travel speed is changed. starts or stops.
a Each time the travel speed shifting switch is a Each time the wiper switch is pressed, the
pressed, the travel speed is changed to Lo, Hi, windshield wiper setting is changed to INT,
and Lo again in order. ON, OFF, and INT again in order.
a When large monitor (a) is displayed, the dis- a When large monitor (a) is displayed, the dis-
play of travel speed monitor (b) is changed, play of wiper monitor (b) is changed or turned
too. OFF, too.
a If the windshield wiper is turned OFF, large
monitor (a) is not displayed.

Operation to stop alarm buzzer


While the alarm buzzer is sounding, if the alarm
buzzer cancel switch is pressed, the alarm buzzer Operation of window washer
stops. While the ordinary screen is displayed, if the win-
a Even if the alarm buzzer cancel switch is dow washer switch is pressed, the washing liquid is
pressed, the screen does not change. splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen does not change.

10 PC130-8
30 Testing and adjusting SEN04115-02

Operation of air conditioner/heater Operation to display camera mode


While the ordinary screen is displayed, press the air When a camera is installed, if [F3] is pressed, the
conditioner switch and the air conditioner adjust- multi-display changes to the camera image (Set the
ment screen is displayed. connection of the camera in the service mode).
a While the air conditioner adjustment screen is
displayed, if you do not touch any switch for 5
seconds, the screen changes to the ordinary
screen.
a Air conditioner specification

a If a caution is generated in the camera mode,


the caution monitor is displayed at the left
upper of the screen (The low hydraulic oil tem-
perature caution is not displayed there, how-
ever).

a When an error that there is a user code occurs


in the camera mode, if you do not touch any
control lever for 10 seconds, the screen
changes to the ordinary screen and displays
the error information.

PC130-8 11
SEN04115-02 30 Testing and adjusting

Operation to display clock and service meter Check of maintenance information


While the ordinary screen is displayed, press [F4], While the maintenance monitor or ordinary screen
and section (a) changes to the service meter and is displayed, press [F5], and the maintenance table
clock alternately. screen is displayed.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the sum-
mer time with the user mode function.

a To reset the time left after finishing mainte-


nance, more operations are necessary.

12 PC130-8
30 Testing and adjusting SEN04115-02

Setting and display of user mode [KOMTRAX message]


(Including KOMTRAX messages for user) q There are 2 types of KOMTRAX message; 1 is
While the ordinary screen is displayed, press [F6], for the user and the other is for the service.
and the user menu screen is displayed. q For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message,
operate "User Message" in the above user
menu.
q For service:
A message transmitted from the KOMTRAX
base station for the service. Even if it is
received, nothing is displayed on the ordinary
screen. To see the contents of the message,
operate "KOMTRAX message" display in the
service menu.

a There are following items in the user menu.


Breaker/Attachment Settings
User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment

a The breaker/attachment setting menu is dis-


played only when "With attachment" is set in
the service mode.

PC130-8 13
SEN04115-02 30 Testing and adjusting

Display of energy-saving guidance Display of user code and failure code


When the machine is set in a certain operating con- If an abnormality which displays a user code and a
dition, the energy-saving guidance screen is dis- failure code occurs on the ordinary screen or cam-
played automatically to urge the operator to the era mode screen, all the information of the abnor-
energy-saving operation. mality is displayed.
a The energy-saving guidance is displayed when (a): User code (3 digits)
the following condition is satisfied while the (b): Failure code (5 or 6 digits)
display setting is set effective in the service (c): Telephone mark
mode. (d): Telephone No.
a Condition for display: a This screen is displayed only when an abnor-
Engine is running + All levers have been in mality (failure code) for which a user code is
neutral for 5 minutes + Caution (Note) or user set occurs.
code is not generated (Note) a The telephone mark and telephone No. are
Note: Excluding hydraulic oil low temperature displayed only when the telephone No. is reg-
caution istered in the service mode.
a If any lever or pedal is operated, or [F5] is a If multiple abnormalities occur simultaneously,
pressed, the screen returns to the ordinary all the codes are displayed repeatedly in order.
screen. a Since the information of the displayed failure
code is recorded in the abnormality record in
the service mode, check the details in the ser-
vice mode.

Display of caution monitor


If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode a When the caution monitor is also displayed,
screen, the caution monitor is displayed large for a the telephone mark is not displayed.
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution mon-
itor flashes at the left upper of the screen when
the caution is generated.

14 PC130-8
30 Testing and adjusting SEN04115-02

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
SEN04115-02 30 Testing and adjusting

Function of checking display of LCD (Liquid Function of checking service meter


Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the
a When finishing the operation of the switches, LCD, hold down the switches until the LCD dis-
release [F2] first. plays normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continu-
part is indicated in black. ously, blue points (points which do not go off)
a The LCD panel sometimes has black points may be seen on this screen. This phenomenon
(points which are not lighted) and bright points does not indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.

16 PC130-8
30 Testing and adjusting SEN04115-02

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.

4. After the New password input screen is dis-


played again, input a new password again with
the numeral input switches and confirm it with
the function switch.
q [F5]: Reset input numeral/Return to ordi-
2. After the Attachment/Maintenance PASS- nary screen
WORD screen is displayed, input the current q [F6]: Confirm input numeral
password with the numeral input switches and a If a password different from the password
confirm it with the function switch. input before is input, the message to input
q [F5]: Reset input numeral/Return to ordi- again is displayed.
nary screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.

PC130-8 17
SEN04115-02 30 Testing and adjusting

5. If the screen to notify completion of setting is


displayed and then the ordinary screen is dis-
played, the password is changed successfully.

18 PC130-8
30 Testing and adjusting SEN04115-02

t Service mode a The items which can be selected in the


To change the operator mode to the service mode, service menu are as follows (including
perform the following operation. some items which need special opera-
This operation is always required when you use the tions).
service mode. 01 Monitoring
Mechanical Systems
1. Check of display of screen and operation of
02 Abnormality
switches Electrical Systems
Record
While the ordinary screen is displayed, perform Air-conditioning System
the following operation with the numeral input 03 Maintenance Record
switches.
04 Maintenance Mode Change
q Operation of switches (While pressing [4],
perform the operation in order): 05 Phone Number Entry
[4] + [1] o [2] o [3] Key-on Mode
a This operation of the switches is accepted Unit
only while the ordinary screen is displayed.
With/Without Attachment
06 Default Attachment/Maintenance
Password
Camera
ECO Display
Pump Absorption Torque
07 Adjustment
Attachment Flow Adjustment
08 Cylinder Cut-Out
09 No Injection
10 Fuel Consumption
Terminal Status
11 KOMTRAX
GPS & Communication Status
Settings
2. Selection of service menu MODEM S/N (TH300)
When the Service menu screen is displayed, 12 Display of service message
the service mode is selected. Select a service
menu you use with the function switches or
numeral input switches.
q [F3]: Move to lower menu
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].

PC130-8 19
SEN04115-02 30 Testing and adjusting

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.

3. Deciding monitoring items


After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Double-
click or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
2. Selecting monitoring items monitoring is executed.
After the "Monitoring selection menu screen" is a If monitoring items are selected up to the
displayed, select items to be monitored with limit number, monitoring is executed auto-
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t matically.
switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Reset input numeral/Return to ser-
vice menu screen
q [F6]: Confirm selection
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
a Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that item
with [F6].
a If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
a Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.

20 PC130-8
30 Testing and adjusting SEN04115-02

4. Executing monitoring 6. Changing machine setting mode


After the "Executing monitoring screen" is dis- To change the setting of the working mode,
played, perform the necessary operation of the travel speed, or auto-deceleration during moni-
machine and check the monitoring information. toring, operate the corresponding switch under
a Monitoring information is indicated by the current condition, and the mode setting
value, ON/OFF, or special display. screen is displayed.
a The unit of display can be set to SI unit, While this screen is displayed, if the corre-
metric unit, or inch unit with the Initializa- sponding switch is operated further, the corre-
tion function in the service mode. sponding mode is changed.
a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the
screen returns to the ordinary screen after
monitoring is finished.

5. Holding monitoring information


The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold information (displayed data)
q [F5]: Return to monitoring selection menu
screen

PC130-8 21
SEN04115-02 30 Testing and adjusting

Monitoring items table


Unit (Initial setting: ISO) Com-
Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
00200 Controller model select — PUMP
00201 Machine ID — ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd eng. speed command r/min rpm rpm PUMP
01100 Pump pressure MPa kg/cm2 psi PUMP
07102 Travel FW L PPC pressure MPa kg/cm2 psi PUMP
07103 Travel FW R PPC pressure MPa kg/cm2 psi PUMP
07104 Travel BW L PPC pressure MPa kg/cm2 psi PUMP
07105 Travel BW R PPC pressure MPa kg/cm2 psi PUMP
07106 Blade raise PPC pressure MPa kg/cm2 psi PUMP
07107 Blade lower PPC pressure MPa kg/cm2 psi PUMP
04107 Coolant temperature °C °C °F ENG
04401 Hyd oil temperature °C °C °F PUMP
01300 PC-EPC sol current mA mA mA PUMP
01700 Attachment sol current mA mA mA PUMP
Measured ATT PPC pressure reducing EPC
01701 mA mA mA PUMP
current value 2
Measured ATT PPC pressure reducing EPC
01702 mA mA mA PUMP
current value 3
Measured ATT PPC pressure reducing EPC
01703 mA mA mA PUMP
current value 4
Measured ATT PPC pressure reducing EPC
01704 mA mA mA PUMP
current value 5
Lever potentiometer 1 voltage (main) for
42008 V V V PUMP
service flow control
Lever potentiometer 1 voltage (sub) for
42009 V V V PUMP
service flow control
Lever potentiometer 2 voltage (main) for
42010 V V V PUMP
service flow control
Lever potentiometer 2 voltage (sub) for
42011 V V V PUMP
service flow control
Operation amount of lever potentiometer 1 for
42012 % % % PUMP
service flow control
Operation amount of lever potentiometer 2 for
42013 % % % PUMP
service flow control
03200 Battery voltage V V V PUMP
03203 Battery power supply V V V ENG
04300 Battery charge vol. V V V MON
36400 Rail pressure MPa kg/cm2 psi ENG
37400 Ambient pressure kPa kg/cm2 psi ENG
18500 Charge temperature °C °C °F ENG
All items (including the
ambient pressure) are
36500 Charge pressure-abs kPa kg/cm2 psi ENG indicated by absolute val-
ues.
36700 Engine torque ratio % % % ENG
18700 Engine output torque Nm kgm lbft ENG
03000 Fuel dial pos sens volt V V V ENG
04200 Fuel level sensor volt V V V MON
04105 Coolant temp sens volt V V V ENG
04402 Hyd temp sens volt V V V PUMP

22 PC130-8
30 Testing and adjusting SEN04115-02

Unit (Initial setting: ISO) Com-


Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
37401 Ambient press sens volt V V V ENG
18501 Charge temp sens volt V V V ENG
36501 Charge press sens volt V V V ENG
36401 Rail pressure sens volt V V V ENG
17500 Engine power mode — ENG
31701 Throttle position % % % ENG
31706 Final throttle position % % % ENG
18600 Inject fueling command mg/st mg/st mg/st ENG
36200 Rail press command MPa kg/cm2 psi ENG
36300 Injection timing command CA CA CA ENG
37300 Fuel rate (Note 1) l/h l/h gal/h ENG
01602 2nd eng. speed command % % % PUMP
13113 Main pump absorb torque Nm kgm lbft PUMP
15900 Boom bottom pressure MPa kg/cm2 psi PUMP
Swing ON•OFF PUMP
Boom lower ON•OFF PUMP
01900 Pressure switch 1 Boom raise ON•OFF PUMP
Arm curl ON•OFF PUMP
Arm dump ON•OFF PUMP
Bucket curl ON•OFF PUMP
01901 Pressure switch 2 Bucket dump ON•OFF PUMP
Attachment ON•OFF PUMP
Travel junction ON•OFF PUMP
Swing brake ON•OFF PUMP
02300 Solenoid valve 1 Merge-divide ON•OFF PUMP
2-stage relief ON•OFF PUMP
Travel speed ON•OFF PUMP
Lever switch ON•OFF PUMP
02200 Switch input 1 Swing release sw ON•OFF PUMP
Swing brake sw ON•OFF PUMP
Blade spec ON•OFF PUMP
02201 Switch input 2
Overload alarm ON•OFF PUMP
02202 Switch input 3 Key switch ON•OFF PUMP
Breaker ON•OFF PUMP
02203 Switch input 4
Quick coupler ON•OFF PUMP
Window limit sw. ON•OFF PUMP
02204 Switch input 5 P limit sw. ON•OFF PUMP
W limit sw. ON•OFF PUMP
Model select 1 ON•OFF PUMP
Model select 2 ON•OFF PUMP
02209 Switch input 6 Model select 3 ON•OFF PUMP
Model select 4 ON•OFF PUMP
Model select 5 ON•OFF PUMP
03701 Controller output 2 Travel alarm ON•OFF PUMP
Key switch ON•OFF MON
Start ON•OFF MON
04500 Monitor input 1 Preheat ON•OFF MON
Light ON•OFF MON
Rad. lever ON•OFF MON

PC130-8 23
SEN04115-02 30 Testing and adjusting

Unit (Initial setting: ISO) Com-


Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
Air cleaner ON•OFF MON
04501 Monitor input 2 Eng. oil level ON•OFF MON
Battery charge ON•OFF MON
04502 Monitor input 3 Swing brake sw. ON•OFF MON
F1 ON•OFF MON
F2 ON•OFF MON
Monitor function F3 ON•OFF MON
04503
switches F4 ON•OFF MON
F5 ON•OFF MON
F6 ON•OFF MON
SW1 ON•OFF MON
SW2 ON•OFF MON
Monitor 1st & 2nd SW3 ON•OFF MON
04504
row switches SW4 ON•OFF MON
SW5 ON•OFF MON
SW6 ON•OFF MON
SW7 ON•OFF MON
SW8 ON•OFF MON
Monitor 3rd & 4th SW9 ON•OFF MON
04505
row switches SW10 ON•OFF MON
SW11 ON•OFF MON
SW12 ON•OFF MON
SW13 ON•OFF MON
Monitor 5th row
04506 SW14 ON•OFF MON
switches
SW15 ON•OFF MON
20216 ECM build version — ENG
20217 ECM calibration data ver — ENG
18900 ECM internal temp °C °C °F ENG
20400 ECM serial No — ENG
20227 Monitor ass'y P/N — MON
20402 Monitor serial No — MON
20228 Monitor prog. P/N — MON
20229 Pump con ass'y P/N — PUMP
20403 Pump con serial No — PUMP
20230 Pump con. prog P/N — PUMP

a Entry order of items in table


The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in Initialization of the
service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
Note 1: The momentary fuel consumption (Code No.: 37300) means the theoretical fuel consumption (Since
it is a theoretical value, it is a little different from the actual fuel consumption).

24 PC130-8
30 Testing and adjusting SEN04115-02

Abnormality Record (Mechanical Systems) 3. Information displayed on "abnormality record"


The machine monitor classifies and records the screen
abnormalities which occurred in the past or which On the "Mechanical Systems" screen, the fol-
are occurring at present into the mechanical sys- lowing information is displayed.
tems, electrical systems, and air-conditioning sys- (a) : Occurrence order of abnormalities from
tem or heater system. latest one/Total number of records
To check the mechanical system abnormality (b) : Failure code
record, perform the following procedures. (c) : Contents of trouble
(d) : Number of occurrence time (Displayable
1. Selecting menu range: 0 – 65,535 times)
Select "Abnormality Record" on the "Service (e) : Service meter reading at first occurrence
Menu" screen. (f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if
displayed)
q [F5]: Return to abnormality record screen
a If no abnormality record is recorded, "No
abnormality record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
a For all the failure codes that the machine
2. Selecting sub menu monitor can record, see the failure codes
After the "Abnormality Record" screen is dis- table in "Abnormality Record (Electrical
played, select "Mechanical Systems" with the Systems)".
function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the record
of that code and confirm it with [F6].
a The following figure shows the display of
the air conditioner specification. The
heater specification and heaterless speci-
fication are different from each other in the
display of "03 Air-conditioning System",
which may not be displayed in the heater-
less specification.

PC130-8 25
SEN04115-02 30 Testing and adjusting

4. Resetting abnormality record


The contents of the mechanical system abnor-
mality record cannot be reset.

Abnormality Record (Electrical Systems)


The machine monitor classifies and records the
abnormalities which occurred in the past or which
are occurring at present into the mechanical sys-
tems, electrical systems, and air-conditioning
system.
To check the electrical system abnormality record,
perform the following procedures.
3. Information displayed on "abnormality record"
1. Selecting menu screen
Select "Abnormality Record" on the "Service On the "Electrical Systems" screen, the follow-
Menu" Screen. ing information is displayed.
(a) : Occurrence order of abnormalities from
latest one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if
displayed)
q [F3]: Move to lower item
q [F4]: Move to upper item
2. Selecting sub menu q [F5]: Return to "abnormality record" screen
After the "Abnormality Record" screen is dis- a If no abnormality record is recorded, "No
played, select "Electrical Systems" with the abnormality record" is displayed.
function switches or numeral input switches. a If the number of occurrence time is 1 (first
q [F3]: Move to lower item occurrence), the service meter reading at
q [F4]: Move to upper item the first occurrence and that at the last
q [F5]: Return to service menu screen occurrence are the same.
q [F6]: Confirm selection a If [E] is displayed on the left of a failure
a You may enter a 2-digit code with the code, the abnormality is still occurring or
numeral input switches to select the resetting of it has not been confirmed.
record of that code and confirm it with a For all the failure codes that the machine
[F6]. monitor can record, see the failure codes
a The following figure shows the display of table.
the air conditioner specification. The
heater specification and heaterless speci-
fication are different from each other in the
display of "03 Air-conditioning System",
which may not be displayed in the heater-
less specification.

26 PC130-8
30 Testing and adjusting SEN04115-02

4. Resetting abnormality record 3) After the "Electrical Sys. Error Reset"


1) While the "Electrical Systems" screen is screen is displayed, operate the function
displayed, perform the following operation switches.
with the numeral input switches. q [F5]: Return to "Electrical systems"
q Operation of switches (While pressing screen (Reset mode)
[4], perform the operation in order): q [F6]: Execute reset
[4] + [1] o [2] o [3] a The following figure shows the screen
displayed when the items are reset
one by one (which is a little different
from the screen displayed when all
the items are reset together).

2) Check that the screen is set in the reset


mode, and then reset the items one by
one or together with the function switches.
a If the screen is set in the reset mode,
[CLEAR] graphic mark is indicated at 4) After the selected information or all the
[F2]. information is deleted, “Reset!” or “All
q [F2]: Reset all items Reset!” is displayed for a while, and then
q [F3]: Move to lower item “No Error” is displayed.
q [F4]: Move to upper item
q [F5]: Return to abnormality record
screen
q [F6]: Reset selected item
a To reset items one by one: Select the
item to be reset with [F3] or [F4] and
press [F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless
of selection of the items.
a If [E] is displayed on the left of a fail-
ure code, the resetting operation is
accepted but the information is not
reset.

PC130-8 27
SEN04115-02 30 Testing and adjusting

Failure codes table


User Component
Failure code Trouble (Displayed on screen) Category of record
code in charge
989L00 Engine controller lock caution 1 MON Electrical system
989M00 Engine controller lock caution 2 MON Electrical system
989N00 Engine controller lock caution 3 MON Electrical system
AA10NX Air cleaner clogging MON Mechanical system
AB00KE Charge voltage low MON Mechanical system
B@BAZG Eng oil press. low ENG Mechanical system
B@BAZK Eng oil level low MON Mechanical system
B@BCNS Eng coolant overheat ENG Mechanical system
B@BCZK Eng water level low MON Mechanical system
B@HANS Hydr oil overheat PUMP Mechanical system
E10 CA111 ECM critical internal failure ENG Electrical system
E10 CA115 Eng Ne and Bkup speed sensor error ENG Electrical system
E11 CA122 Charge air press sensor high error ENG Electrical system
E11 CA123 Charge air press sensor low error ENG Electrical system
E14 CA131 Throttle sensor high error ENG Electrical system
E14 CA132 Throttle sensor low error ENG Electrical system
E15 CA144 Coolant temp. sensor high error ENG Electrical system
E15 CA145 Coolant temp. sensor low error ENG Electrical system
E15 CA153 Charge air temp. sensor high error ENG Electrical system
E15 CA154 Charge air temp. sensor low error ENG Electrical system
E11 CA155 Chg air temp high speed derate ENG Electrical system
E15 CA187 Sensor sup. 2 volt. low error ENG Electrical system
E11 CA221 Ambient air press. sensor high error ENG Electrical system
E11 CA222 Ambient air press. sensor low error ENG Electrical system
E15 CA227 Sensor sup. 2 volt. high error ENG Electrical system
CA234 Eng. overspeed ENG Mechanical system
E15 CA238 Ne speed sensor sup. volt. error ENG Electrical system
E10 CA271 IMV/PCV1 short error ENG Electrical system
E10 CA272 IMV/PCV1 open error ENG Electrical system
E11 CA322 Injector #1 (L #1) system open/short error ENG Electrical system
E11 CA324 Injector #3 (L #3) system open/short error ENG Electrical system
E11 CA331 Injector #2 (L #2) system open/short error ENG Electrical system
E11 CA332 Injector #4 (L #4) system open/short error ENG Electrical system
E10 CA342 Calibration code incompatibility ENG Electrical system
E10 CA351 Inj. drive circuit error ENG Electrical system
E15 CA352 Sensor sup. 1 volt. low error ENG Electrical system
E15 CA386 Sensor sup. 1 volt. high error ENG Electrical system
E15 CA435 Abnormality in engine oil pressure switch ENG Electrical system
E10 CA441 Battery voltage low error ENG Electrical system
E10 CA442 Battery voltage high error ENG Electrical system
E11 CA449 Rail press. very high error ENG Electrical system

28 PC130-8
30 Testing and adjusting SEN04115-02

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
SEN04115-02 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

a Entry order of items in table


The items are entered in the order of their failure codes (incremental order).
a User code
Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
a Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
a Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.

30 PC130-8
30 Testing and adjusting SEN04115-02

Abnormality Record (Air-conditioning System) 3. Information displayed on "abnormality record"


The machine monitor classifies and records the screen
abnormalities which occurred in the past or which On the "Air-conditioning System" screen, the
are occurring at present into the mechanical sys- following information is displayed.
tems, electrical systems, and air-conditioning (a): System/Component name
abnormalities. (b): Number of occurrence time
To check the air-conditioning abnormality record or (c): Condition (Normal or abnormal)
heater abnormality record, perform the following q [F2]: Reset abnormality record
procedures. q [F5]: Return to abnormality record screen
If [E] is displayed on the left of a condition,
1. Selecting menu the abnormality is still occurring or reset-
Select "Abnormality Record" on the "Service ting of it has not been confirmed.
Menu" screen. If CAN disconnection is displayed in Com-
munication condition, communication can-
not be carried out normally. Accordingly,
the conditions of other items are turned
OFF.

2. Selecting sub menu


After the "Abnormality Record" screen is dis-
played, select "Air-conditioning System" with
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t
switches. 4. Resetting abnormality record
q [F3]: Move to lower item While the "abnormality record" screen is dis-
q [F4]: Move to upper item played, press [F2], and the number of occur-
q [F5]: Return to service menu screen rence time of abnormality is reset. If it is
q [F6]: Confirm selection confirmed at this time that the abnormality has
a You may enter a 2-digit code with the been reset, the display changes to Normal.
numeral input switches to select the
record of that code and confirm it with
[F6].

PC130-8 31
SEN04115-02 30 Testing and adjusting

Maintenance Record a The following items can be selected in the


The machine monitor records the maintenance maintenance record.
information of the filters, oils, etc., which the opera- 01 Engine oil change
tor can display and check by the following opera- 02 Engine oil filter change
tions. When maintenance is carried out, if the data
03 Fuel main filter change
are reset in the operator mode, the number of the
41 Fuel pre-filter change
times of maintenance is recorded in this section.
04 Hydraulic oil filter change
05 Hydraulic tank breather change
1. Selecting menu 06 Corrosion resistor change
Select "Maintenance Record" on the "Service 07 Damper case service
Menu" screen. 08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change

3. Items displayed on maintenance record screen


The following items are displayed.
(a) : Maintenance items
(b) : Number of times of replacement up to now
(c) : Service meter reading (SMR) at previous
replacement

2. Selecting maintenance record item


After the "Maintenance Record" screen is dis-
played, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the
numeral input switches to select the item
of that code.

32 PC130-8
30 Testing and adjusting SEN04115-02

Maintenance Mode Change a The following items can be selected on


The operating condition for maintenance function in the Change of maintenance mode screen.
the operation mode can be set and changed with 00 Maintenance mode on/off
this menu. 01 Engine oil change int.
q Set function effective or ineffective
02 Engine oil filter change int.
q Change set replacement interval (by items)
03 Fuel main filter change int.
q Initialize all set replacement intervals
41 Fuel pre filter change int.
1. Selecting menu 04 Hyd oil filter change int.
Select of "Maintenance Mode Change" on the 05 Hyd tank breather change int.
"Service Menu" screen. 06 Corrosion resistor change int.
07 Damper case service int.
08 Final drive case oil change int.
09 Machinery case change int.
10 Hydraulic oil change int.
99 Initialize all items

3. Contents of setting of Maintenance mode on/


off
After selecting "Maintenance Mode On/Off", if
the screen is displayed, set ON or OFF with
the function switches.
q ON: Functions of all maintenance items
are set effective in operator mode
2. Selecting sub menu q OFF: Functions of all maintenance items
After the "Maintenance Mode Change" screen are set ineffective in operator mode
is displayed, select an item to change the set- q [F3]: Move to lower item
ting with the function switches or numeral input q [F4]: Move to upper item
switches. q [F5]: Cancel selection and return to Main-
q [F1]: Move to next page (screen) tenance mode change screen
q [F2]: Move to previous page (screen) q [F6]: Confirm selection and return to
q [F3]: Move to lower item Maintenance mode change screen
q [F4]: Move to upper item a Even if ON/OFF of each item has been
q [F5]: Return to service menu screen set, if the above setting is changed, it is
a You may enter a 2-digit code with the applied.
numeral input switches to select the item
of that code and confirm it with [F6].

PC130-8 33
SEN04115-02 30 Testing and adjusting

4. Contents of setting of each maintenance item since the start of setting, the change is
After selecting each maintenance item, if the recognized as a resetting operation.
screen is displayed, set the item with the func-
tion switches.

5. Function of initializing all items


q Initial value: Maintenance interval set in After selecting "99 Use Default Value", if the
machine monitor (Recommended by man- screen is displayed, set with the function
ufacturer and not changeable). switches.
q Set value: Maintenance interval which can
be set freely. Maintenance functions in
operator mode operate on basis of this set
time (which is increased or decreased by
50 hours).
q ON: Maintenance function of this item is
set effective in operator mode.
q OFF: Maintenance function of this item is
set ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
q If this operation is executed, the set val-
and return to Maintenance mode
ues of all the maintenance items are ini-
change screen.
tialized.
q [F6]: Confirm setting of upper or lower line.
q [F5]: Return to Maintenance mode change
a After the setting of the upper and lower
screen
lines is confirmed with [F6] and the screen
q [F6]: Execute initialization
changes to the Maintenance mode
a A while after [F6] is pressed, the initializa-
change screen with [F5], the setting is
tion completion screen is displayed. Then,
effective.
if the "Maintenance Mode Change" screen
a If the set value of an item set to "ON" is
is displayed, initialization is completed.
changed after 1 or more operating hours

34 PC130-8
30 Testing and adjusting