Komatsu Pc130 7 Shop Manual

Full download: http://manualplace.com/download/komatsu-pc130-7-shop-manual/

SEBM036301

MACHINE MODEL SERIAL NUMBER

PC130-7 70001 and up

• This shop manual may contain attachiments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.

• PC130-7 mounts the SAA4D95LE-3 engine.

For details of the engine, see the 95-3 Series Engine Shop Manual.

© 2004
All Rights Reserved
Printed in Japan 04-04(02) 00-1
(1)
This is the cut pages sample. Download all 342 page(s) at: ManualPlace.com
 CONTENTS

No. of page
01 GENERAL ................................................................................................................01-1

10 STRUCTURE AND FUNCTION .................................................................10-1

20 TESTING AND ADJUSTING .......................................................................20-1

30 DISASSEMBLY AND ASSEMBLY ............................. To be issued next time

40 MAINTENANCE STANDARD......................................................................40-1

90 OTHERS ....................................................................................................................90-1

00-2 PC130-7
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Q 20-154 (1) Q 20-236 (1) Q 20-330 (1) Q 20-419 (1) Q 20-471 (1)
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Q 20-603 (1) 40-29
Q 20-604 (1) 40-30
Q 20-605 (1) 40-31
Q 20-606 (1) 40-32
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Q 20-608 (1) 40-35
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Q 20-611 (1) 40-38
Q 20-612 (1) 40-39
Q 20-613 (1) 40-40
Q 20-614 (1) 40-41
Q 20-615 (1)
Q 20-616 (1) q 90-1 (1)
Q 20-617 (1) 90-3
Q 20-618 (1) q 90-5 (1)
Q 20-619 (1) q 90-7 (1)
Q 20-620 (1) q 90-9 (1)
Q 20-621 (1) q 90-11 (1)
Q 20-622 (1) Q 90-13 (1)
Q 20-623 (1) Q 90-15 (1)

PC130-7 00-2-3
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 20 TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE.......... 20- 2

STANDARD VALUE TABLE FOR CHASSIS........ 20- 3
TESTING AND ADJUSTING................................ 20-101
TROUBLESHOOTING ......................................... 20-201

Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.

When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.

PC130-7 20-1
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Model name PC130-7

Engine SAA4D95LE-3

Item Measurement condition Unit Standard value Permissible value

High idling 2,350 ± 100 2,350 ± 100

Engine speed Low idling rpm 1,100 ± 50 1,100 ± 50

Rated speed 2,200 —

During sharp acceleration Bosch Max. 4.5 Max. 6.5

Exhaust gas color
During high idling index Max. 1.0 Max. 2.0

Valve clearance Intake valve 0.35 —

mm
(Cooled) Exhaust valve 0.50 —
MPa Min. 2.9 2.0
Oil temperature: 40 – 60 °C
Compression pressure {kg/cm2} {Min. 30} {20}
(Engine speed)
(rpm) (320 – 360) (320 – 360)
Coolant temperature:
kPa Max. 0.49 0.98
Blow-by pressure Within operating range
{mmH2O} {Max. 50} {100}
At rated output
Coolant temperature:
Within operating range
0.34 – 0.59 0.25
At high idling (SAE30)
{3.5 – 6.0} {2.5}
MPa 0.29 – 0.54 0.21
Oil pressure At high idling (SAE10W)
{kg/cm2} {3.0 – 5.5} {2.1}
Min. 0.1 0.07
At low idling (SAE30)
{Min. 1.0} {0.7}
Min. 0.08 0.07
At high idling (SAE10W)
{Min. 0.8} {0.7}

Oil temperature Through speed range (In oil pan) °C 90 – 110 120

Fuel injection timing Before top dead center (BTDC) ° 6 ± 0.75 6 ± 0.75

Deflection under finger pressure of

Fan belt tension mm 6 – 10 6 – 10
58.8 N {6 kg}
Air conditioner compres- Deflection under finger pressure of
mm 6 – 10 6 – 10
sor belt tension 58.8 N {6 kg}

20-2 PC130-7
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TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory
• Engine coolant temperature:
Within operating range
• Hydraulic oil temperature: 45 – 55 °C
Pump relief rpm 2,120 ± 100 2,120 ± 100
• Engine speed: High idling
• Working mode: A
Engine speed

• Arm OUT relief

• Engine coolant temperature:
Within operating range
Pump relief + One-
• Hydraulic oil temperature: 45 – 55 °C
touch power maximiz- rpm 2,180 ± 100 2,180 ± 100
• Engine speed: High idling
ing
• Arm OUT relief + One-touch power
maximizing switch ON
• Engine speed: High idling
During auto-decelera-
• Auto-decelerator switch: ON rpm 1,400 ± 100 1,400 ± 100
tion
• All control levers in neutral

Boom control valve • Engine: Stopped 8.0 ± 0.5 8.0 ± 0.5

Control valve spool stroke

IN 9.5 ± 0.5 9.5 ± 0.5

Arm control valve
OUT 8.0 ± 0.5 8.0 ± 0.5
mm
Bucket control valve 8.0 ± 0.5 8.0 ± 0.5

Swing control valve 8.0 ± 0.5 8.0 ± 0.5

Travel control valve 8.0 ± 0.5 8.0 ± 0.5

Boom control lever • Engine: Stopped 85 ± 10 85 ± 10

• Center of lever grip
• Read max. value to stroke end
Control lever stroke

Arm control lever 85 ± 10 85 ± 10

(Exclude play in neutral position).
Bucket control lever 85 ± 10 85 ± 10
mm
Swing control lever 85 ± 10 85 ± 10

Travel control lever 112 ± 15 112 ± 15

Play of control lever 10 ± 15 10 ± 15

• Hydraulic oil temperature: 15.7 ± 3.9 Max. 24.5

Boom control lever
Operating effort of control lever

Within operating range {1.6 ± 0.4} {Max. 2.5}

• Engine speed: High idling 15.7 ± 3.9 Max. 24.5
Arm control lever • Center of lever grip {1.6 ± 0.4} {Max. 2.5}
• Tip of pedal 12.7 ± 2.9 Max. 21.6
Bucket control lever • Read max. value to stroke end
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}
80.4 ± 20.1 Max. 107.9
Travel control pedal
{8.2 ± 2.0} {Max. 11}

PC130-7 20-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
MPa 2.9 ± 0.5 2.9 ± 0.5
Unload pressure • Working mode: A
{kg/cm2} {30 ± 5} {30 ± 5}
• Pump outlet pressure when all levers
are in neutral
• Hydraulic oil tempera- At normal 31.9 + 2.0
0 33.3 – 36.8
ture: 45 – 55 °C relief {325 + 20
0 } {340 – 375}
Boom relief pressure • Engine speed: At power 34.8 ± 1.0 36.3 – 39.2
High idling max. {355 ± 10} {370 – 400}
• Working mode: A
At normal 31.9 + 2.0
0 33.3 – 36.8
• Pump outlet pressure
relief {325 + 20
0 } {340 – 375}
Arm relief pressure when measured circuit is
relieved At power 34.8 ± 1.0 36.3 – 39.2
max. MPa {355 ± 10} {370 – 400}
At normal {kg/cm2} 31.9 + 2.0
0 33.3 – 36.8
relief {325 + 20
0 } {340 – 375}
Oil pressure

Bucket relief pressure

At power 34.8 ± 1.0 36.3 – 39.2
max. {355 ± 10} {370 – 400}
28.9 ± 1.5 28.9 – 32.9
Swing relief pressure
{295 ± 15} {295– 335}
34.8 ± 1.0 36.3 – 39.2
Travel relief pressure
{355 ± 10} {370 – 400}
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
Control circuit basic MPa 3.23 ± 0.2 2.84 – 3.43
• Outlet pressure of self-reducing pres-
pressure {kg/cm2} {33 ± 2} {29 – 35}
sure valve when all levers are in neu-
tral
• Hydraulic oil temperature: When all
45 – 55 °C levers are 2.7 +– 1.0
0.7 2.7 +– 1.0
0.7

• Engine speed: High idling in neutral {28 +– 107 } {28 +– 107 }

LS differential pres- MPa
• Working mode: A
sure When {kg/cm2}
• Pump pressure - LS pres- 2.2 ± 0.1 2.2 ± 0.1
travel sys-
sure tem runs {22.5 ± 1} {22.5 ± 1}
idle at Hi

20-4 PC130-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory

deg 75 ± 10 Max. 90
Overrun of swing
• Hydraulic oil temperature: 45 – 55 °C (mm) {730 ± 100} (Max. 870)
• Engine speed: High idling
• Working mode: A
• Quantity of overrun of swing circle
when it stops after 1 turn
• ( ): Qty of overrun of periphery of
swing circle

90° 2.9 ± 0.3 Max. 3.5

Time taken to start

• Hydraulic oil temperature: sec
swinging
45 – 55 °C
• Engine speed: High idling 180° 4.0 ± 0.4 Max. 8.5
• Working mode: A
• Time taken to swing 90° and
180° after starting
Swing

Time taken to swing sec 28.6 ± 4.8 28.6 ± 5.8

• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Time taken to swing 5 turns after
swinging 1 turn

Hydraulic drift of swing mm 0 0

• Hydraulic oil temperature: 45 – 55 °C
• Engine: Stopped
• Set upper structure at 90° to machine
body on slope of 15°.
• Make match marks on inner race and
outer race of swing circle.
• Measure deviation of match marks in
15 minutes.

PC130-7 20-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
Swing

Leakage from swing

• Swing lock switch: LOCK l/min Max. 3 Max. 6
motor • Measure leakage for 1 minutes while
swing circuit is relieved.

Lo 46.1 ± 9.2 46.1 ± 9.2

Travel speed (Idle run) sec

• Hydraulic oil temperature:

45 – 55 °C
• Engine speed: High idling Hi 21.9 ± 2.2 23.1 ± 3.0
• Working mode: A
• Measure time taken to rotate
track shoe 5 turns after 1 turn.

Lo 27.6 ± 5.1 27.6 ± 7.1

Travel speed
(Actual travel)
• Hydraulic oil temperature:
45 – 55 °C
• Engine speed: High idling
• Working mode: A Hi 13.2 ± 1.2 13.2 ± 1.7
• Hard and level place
Travel

• Measure time taken to travel 20

m after running up 10 m.

• Hydraulic oil temperature: 45 – 55 °C

• Engine speed: High idling
• Working mode: A
Travel deviation • Travel speed: Lo mm Max. 200 Max. 220
• Hard and level place
• Measure travel deviation in travel of
20 m after running up 10 m.

20-6 PC130-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory

Hydraulic drift of travel mm 0 0

Travel

• Hydraulic oil temperature: 45 – 55 °C

• Engine: Stopped
• Stop machine on slope of 12 degrees
with sprocket on upper side.
• Measure hydraulic drift of travel in 5
minutes.
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
Leakage from travel
• Lock sprocket. l/min Max. 5 Max. 10
motor
• Measure leakage for 1 minutes while
travel circuit is relieved.

Whole work
equipment Max. 460 Max. 700
(Hydraulic drift of tooth tip)
Hydraulic drift of work equipment

Boom cylinder
Max. 10 Max. 12
(Retraction of cylinder)
• Hydraulic oil temperature: 45 – 55 °C
• Level and flat place mm
• Bucket: Full of dirt and sand or filled
Arm cylinder with rated load (1,080 kg) Max. 80 Max. 90
(Extension of cylinder) • Level boom top, retract arm cylinder
fully, and extract bucket cylinder fully.
Work equipment

• Engine: Stopped
• Work equipment control lever: Neutral
Bucket cylinder • Start measuring hydraulic drift just Max. 22 Max. 40
(Retraction of cylinder) after setting machine and measure
every 5 minutes for 15 minutes.
Work equipment speed

RAISE 3.7 ± 0.4 Max. 4.3

Boom speed • Hydraulic oil temperature: sec

45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Measure time taken to move LOWER 2.6 ± 0.5 Max. 3.2
bucket between RAISE stroke
end and ground touch point of
bucket.

PC130-7 20-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory

CURL 3.2 ± 0.4 Max. 4.4

Arm speed sec

• Hydraulic oil temperature:
45 – 55 °C
• Engine speed: High idling
• Working mode: A
Work equipment speed

• Measure time taken to move DUMP 3.1 ± 0.3 Max. 3.7

arm between OUT stroke end
and IN stroke end (between
starting points of cushion).

CURL 2.9 ± 0.3 Max. 3.7

Work equipment

Bucket speed sec

• Hydraulic oil temperature:
45 – 55 °C
• Engine speed: High idling
• Working mode: A DUMP 2.3 ± 0.2 Max. 2.9
• Measure time taken to move
bucket between DUMP stroke
end and CURL stroke end
Time lag

Boom time lag sec Max. 3.0 Max. 4.0

• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: Low idling
• Working mode: A
• Lower boom from RAISE stroke end
and measure time taken to start rais-
ing front of machine after bucket
touches ground.

20-8 PC130-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory

Arm time lag sec Max. 2.0 Max. 3.0

• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: Low idling
• Working mode: A
• Move IN arm from OUT stroke end
and measure time taken to start mov-
ing arm again after it is stopped.
• For measuring posture, see WORK
Time lag

EQUIPMENT 6.
Work equipment

Bucket time lag sec Max. 2.0 Max. 3.0

• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: Low idling
• Working mode: A
• Curl bucket from DUMP stroke end
and measure time taken to start mov-
ing bucket again after it is stopped.
• For measuring posture, see WORK
EQUIPMENT 7.
• Hydraulic oil temperature: 45 – 55 °C
Oil leakage

Cylinder • Engine speed: High idling Max. 3.5 Max. 15

• Relieve cylinder to be measured or cc/min
Center swivel joint travel circuit and measure leakage in Max. 10 Max. 50
1 minute.
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
Compound operation performance

• Working mode: A
• Travel speed: Lo
• Hard and level place
• Measure travel deviation in travel of
20 m after running up 10 m.
Travel deviation in
compound operation
mm Max. 500 Max. 500
of work equipment and
travel

PC130-7 20-9
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TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory
• Hydraulic oil temperature: 45 – 55 °C
• Engine: High idling
PC flow control

• Working mode: A
characteristics

Time taken to swing • Bucket: Filled with rated load

90° in compound oper- • Hard and level place 4.0
sec
ation of raising boom • Set arm vertically and lower back of (Reference value)
and starting swinging bucket to ground.
• Raise boom and start swinging simul-
taneously from above posture and
measure time taken to pass 90° point.
performance
Pump

Hydraulic pump
• See graph. l/min See graph.
capacity

20-10 PC130-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Model name PC130-7

Cate-
Item Measurement condition Unit Standard value Permissible value
gory
Hydraulic pump performance
Pump performance

• PC-EPC current: 400 mA

• Pump speed: 2,000 rpm
Test pump discharge Lower limit of
Check point pressure Standard discharge discharge
(MPa{kg/cm2}) (l/min) (l/min)
Q Q
Any point P
(See graph) (See graph)

a Avoid measuring near a broken point of the graph, since the error becomes large at that point.
a When measuring without removing the pump from the machine, if the engine speed cannot be set to the speci-
fied speed with the fuel control dial, calculate the pump discharge pressure at the specified speed from the
engine speed and pump discharge at the time of measurement.

PC130-7 20-11
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 TESTING AND ADJUSTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ......................................................... 20-102

TESTING AND ADJUSTING ENGINE SPEED .......................................................................................... 20-104
MEASURING EXHAUST GAS COLOR ..................................................................................................... 20-105
ADJUSTING VALVE CLEARANCE ........................................................................................................... 20-107
MEASURING COMPRESSION PRESSURE ............................................................................................. 20-109
MEASURING BLOW-BY PRESSURE ....................................................................................................... 20-110
MEASURING ENGINE OIL PRESSURE ................................................................................................... 20-111
TESTING AND ADJUSTING FOR FUEL INJECTION TIMING ................................................................ 20-112
ADJUSTING ENGINE SPEED SENSOR .................................................................................................. 20-116
TESTING AND ADJUSTING FAN BELT TENSION .................................................................................. 20-117
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION .............................. 20-118
MEASURING CLEARANCE OF SWING CIRCLE BEARING .................................................................... 20-119
TESTING AND ADJUSTING TRACK SHOE TENSION ............................................................................ 20-120
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....... 20-122
MEASURING CONTROL CIRCUIT BASIC PRESSURE ........................................................................... 20-125
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT .................................. 20-126
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT .................................. 20-129
MEASURING SOLENOID VALVE OUTPUT PRESSURE ......................................................................... 20-133
MEASURING PPC VALVE OUTPUT PRESSURE .................................................................................... 20-135
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES ............................................... 20-136
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT .................................. 20-137
MEASURING OIL LEAKAGE ..................................................................................................................... 20-139
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT ............................................................. 20-142
BLEEDING AIR FROM EACH PART ......................................................................................................... 20-143
TESTING PROCEDURE FOR DIODE ...................................................................................................... 20-146
SPECIAL FUNCTIONS OF MONITOR PANEL ......................................................................................... 20-147
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM .................................... 20-166
PM-CLINIC SERVICE ................................................................................................................................. 20-167

PC130-7 20-101
(1)
Komatsu Pc130 7 Shop Manual
Full download: http://manualplace.com/download/komatsu-pc130-7-shop-manual/
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Symbol

Q'ty
Testing and adjusting item Part No. Part name Remarks

Handy smoke
1 799-203-9000 checker 1 Pollution level: 0 – 70% (With standard
Measuring exhaust gas A color)
color Commercially (Pollution level x 1/10 C Bosch index)
2 available Smoke meter 1

B Commercially (Air intake side: 0.35 mm, Exhaust side:

Adjusting valve clearance available Feeler gauge 1 0.50 mm)
795-502-1205 Compression gauge 1 0 – 6.9MPa {0 – 70kg/cm2}
Measuring compression C
pressure 795-502-1370 Adapter 1
For 95E-3 engine
6204-11-3880 Gasket 1

Measuring blow-by pres- D

sure 799-201-1504 Blow-by checker 1 —

Pressure gauge: 2.5,5.9,39.2,58.8MPa

799-101-5002 Hydraulic tester 1 {25,60,400,600kg/cm2}
1
Digital hydraulic
790-261-1203 tester 1 Pressure gauge: 58.8MPa {600kg/cm2}
Measuring engine oil pres- E 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98MPa {10kg/cm2}
sure
3 799-401-3500 Adapter 1 Size: 06

799-101-5220 Nipple 1
4 Size: 10 x 1.25mm
07002-11023 O-ring 1
1 795-102-2103 Spring pusher 1
Measuring fuel injection F For delivery valve method
timing 2 Commercially
available Dial gauge 1

Commercially
Measuring clearance of G available Dial gauge 1 —
swing circle bearing

799-101-5002 Hydraulic tester 1

1 * Same as E1
Testing and adjusting oil Digital hydraulic
pressure in work equip- 790-261-1203 tester 1
H
ment, swing, and travel cir-
cuits 799-101-5220 Nipple 1
2 * Same as E4
07002-11023 O-ring 1

799-101-5002 Hydraulic tester 1

1 * Same as E1
Digital hydraulic
Measuring control circuit 790-261-1203 tester 1
basic pressure J
799-101-5230 Nipple 1
2 Size: 14 x 1.5mm
07002-11423 O-ring 1

799-101-5002 Hydraulic tester 1

1
Testing and adjusting oil 790-261-1203 Digital hydraulic 1
pressure in pump PC con- K tester * Same as H (Only quantity is different)
trol circuit
799-101-5230 Nipple 2
2
07002-11423 O-ring 2

20-102 PC130-7
(1)
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