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Komatsu 80001 Shop Manual
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Komatsu 80001 Shop Manual

Komatsu 80001 Shop Manual

Hydraulic excavator
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SEN03763-00TH
SEN03763-03
HYDRAULIC
PC130
-8
EXCAVATOR
C30001
80001
SERIAL NUMBERS
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Summary of Contents for Komatsu 80001

  • Page 1 SEN03763-00TH SEN03763-03 HYDRAULIC PC130 EXCAVATOR C30001 80001 SERIAL NUMBERS and up...
  • Page 2 SEN03765-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 00 Index and foreword Index Composition of shop manual .......................... 2 Table of contents ............................. 4 PC130-8 Find manuals at https://best-manuals.com...
  • Page 3 SEN03765-03 00 Index and foreword Composition of shop manual 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.
  • Page 4 00 Index and foreword SEN03765-03 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04124-00 SEN04125-01 q Troubleshooting of engine (S-mode) 50 Disassembly and assembly SEN03782-01 SEN04126-01 q General information on disassembly and assembly SEN04127-01 q Engine and cooling system Power train SEN04128-00 Undercarriage and frame SEN04129-00...
  • Page 5 SEN03765-03 00 Index and foreword Table of contents 00 Index and foreword Index SEN03765-03 Composition of shop manual....................... Table of contents ......................... Foreword and general information SEN03766-01 Safety notice..........................How to read the shop manual ..................... Explanation of terms for maintenance standard................Handling of electric equipment and hydraulic component............
  • Page 6 00 Index and foreword SEN03765-03 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 .......................... Dimensions of components ......................Cab and its attachments SEN03777-00 Air conditioner ..........................
  • Page 7 SEN03765-03 00 Index and foreword Installation and adjustment of mirrors and camera ..............55 Inspection of air conditioner Recirc/Fresh air filter ..............59 Testing and adjusting, Part 2 SEN04115-01 Special functions of machine monitor..................Testing and adjusting, Part 3 SEN04116-00 Handling voltage circuit of engine controller................
  • Page 8 00 Index and foreword SEN03765-03 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 ..............Failure code [CA351] Inj. drive circuit error ................. Failure code [CA352] Sensor sup. 1 volt. low error..............Failure code [CA386] Sensor sup.
  • Page 9 SEN03765-03 00 Index and foreword Failure code [DXE4KA] Service current EPC discon ..............Failure code [DXE4KB] Service current EPC short..............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 ................
  • Page 10 00 Index and foreword SEN03765-03 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.....................
  • Page 11 SEN03765-03 00 Index and foreword 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............Disassembly and assembly of center swivel joint assembly ............
  • Page 12 00 Index and foreword SEN03765-03 PC130-8...
  • Page 13 SEN03765-03 00 Index and foreword PC130-8 Hydraulic excavator Form No. SEN03765-03 © 2008 KOMATSU All Rights Reserved Printed in Japan 12-08 (02) PC130-8...

  • Page 14: Table Of Contents

    HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 00 Index and foreword 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...

  • Page 15: 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.
  • Page 16 00 Index and foreword SEN03766-01 Preparations for work When removing a cover which is under 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.
  • Page 17 SEN03766-01 00 Index and foreword Precautions for sling work and making signs 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.
  • Page 18 00 Index and foreword SEN03766-01 13) If the hoist stops because of a power fail- If the load is unstable or the wire rope 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 Do not lift up the load slantingly.
  • Page 19 SEN03766-01 00 Index and foreword a Example of O-ring (Fitted to every joint of Precautions for disconnecting and con- necting hoses and tubes in air conditioner hoses and tubes) circuit Disconnection 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.

  • Page 20: How To Read The Shop Manual

    Engine volume This section explains the method of reproducing, repairing, and replacing parts. 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...
  • Page 21 SEN03766-01 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark q q q q When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.

  • Page 22: Explanation Of Terms For Maintenance Standard

    00 Index and foreword SEN03766-01 Explanation of terms for maintenance standard 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. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
  • Page 23 SEN03766-01 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are 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.

  • Page 24: Handling Of Electric Equipment And Hydraulic Component

    00 Index and foreword SEN03766-01 Handling of electric equipment and hydraulic component 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.
  • Page 25 SEN03766-01 00 Index and foreword 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.
  • Page 26 00 Index and foreword SEN03766-01 Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors 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.
  • Page 27 SEN03766-01 00 Index and foreword Connecting connectors 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.
  • Page 28 00 Index and foreword SEN03766-01 Heavy duty wire connector (DT 8-pole, 12- Disconnection 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) Push in female connector (2) horizon- tally until the lock clicks.
  • Page 29 SEN03766-01 00 Index and foreword 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.
  • Page 30 00 Index and foreword SEN03766-01 Handling controller 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. Do not place objects on top of the control- ler.
  • Page 31 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.
  • Page 32 00 Index and foreword SEN03766-01 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.

  • Page 33: Handling Of Connectors Newly Used For Engines

    SEN03766-01 00 Index and foreword Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example) 114E-3 Intake air temperature sensor in 125E-5 intake manifold: TIM 140E-5...
  • Page 34 00 Index and foreword SEN03766-01 Push lock type 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engines Example)
  • Page 35 SEN03766-01 00 Index and foreword Turn-housing type (Round green connector) 95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, 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.

  • Page 36: How To Read Electric Wire Code

    00 Index and foreword SEN03766-01 How to read electric wire code 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.
  • Page 37 SEN03766-01 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 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...
  • Page 38 00 Index and foreword SEN03766-01 Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...

  • Page 39: Precautions When Carrying Out Operation

    SEN03766-01 00 Index and foreword Precautions when carrying out operation [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.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.
  • Page 40 00 Index and foreword SEN03766-01 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
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Pc130-8