Komatsu PC130-7 Service Manual
SEBM036301
MACHINE MODEL SERIAL NUMBER
PC130-7 70001 and up
• This shop manual may co ntain attachiments and optio nal equipment that are not availabl e 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)
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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PC130-7 00-2-3
(1)
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 makin g judgements using the standard value tables for testi ng, adjusting , or troubleshooting.
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 servic e limit value given in the tables is the estimate d value for the shipped machine based on the
results of various tests. It is used for r efer en ce together with the state of repair and the histo ry of op erati on
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
Model name PC130-7
Engine SAA4D95LE-3
Item Measurement condition Unit Standard value Permissible value
STANDARD VALUE TABLE FOR ENGINE
High idling
Engine speed Low idling 1,100 ± 50 1,100 ± 50
Rated speed 2,200 —
Exhaust gas color
Valve clearance
(Cooled)
Compression pressure
Blow-by pressure
Oil pressure
During sharp acceleration
During high idling Max. 1.0 Max. 2.0
Intake valve
Exhaust valve 0.50 —
Oil temperature: 40 – 60 °C
(Engine speed)
Coolant temperature:
Within operating range
At rated output
Coolant temperature:
Within operating range
At high idling (SAE30)
At high idling (SAE10W)
At low idling (SAE30)
At high idling (SAE10W)
rpm
Bosch
index
mm
MPa
{kg/cm
(rpm)
kPa
{mmH
MPa
{kg/cm
2
}
O}
2
2
}
2,350 ± 100 2,350 ± 100
Max. 4.5 Max. 6.5
0.35 —
Min. 2.9
{Min. 30}
(320 – 360)
Max. 0.49
{Max. 50}
0.34 – 0.59
{3.5 – 6.0}
0.29 – 0.54
{3.0 – 5.5}
Min. 0.1
{Min. 1.0}
Min. 0.08
{Min. 0.8}
2.0
{20}
(320 – 360)
0.98
{100}
0.25
{2.5}
0.21
{2.1}
0.07
{0.7}
0.07
{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
Fan belt tension
Air conditioner compres-
sor belt tension
Deflection under finger pressure of
58.8 N {6 kg}
Deflection under finger pressure of
58.8 N {6 kg}
mm 6 – 10 6 – 10
mm 6 – 10 6 – 10
20-2 PC130-7
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
Engine speed
Control val v e spool stroke
Item Measurement condition Unit Standard value Permissible value
• Engine coolant temperature:
Pump relief
Pump relief + Onetouch power maximizing
During auto-deceleration
Boom control valve • Engine: Stopped
Arm control valve
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
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Arm OUT relief
• Engine coolant temperature:
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Arm OUT relief + One-touch power
maximizing switch ON
• Engine speed: High idling
• Auto-decelerator switch: ON
• All control levers in neutral
Within operating range
rpm 2,120 ± 100 2,120 ± 100
Within operating range
rpm 2,180 ± 100 2,180 ± 100
rpm 1,400 ± 100 1,400 ± 100
8.0 ± 0.5 8.0 ± 0.5
IN 9.5 ± 0.5 9.5 ± 0.5
OUT 8.0 ± 0.5 8.0 ± 0.5
mm
Boom control lever
Arm control lever 85 ± 10 85 ± 10
Bucket control lever 85 ± 10 85 ± 10
Swing control lever 85 ± 10 85 ± 10
Travel control lever 112 ± 15 112 ± 15
Control lever stroke
Play of control lever 10 ± 15 10 ± 15
Boom control lever
Arm control lever
Bucket control lever
Swing control lever
Travel control lever
Travel control pedal
Operating effort of control lever
• Engine: Stopped
• Center of lever grip
• Read max. value to stroke end
(Exclude play in neutral position).
• Hydraulic oil temperature:
Within operating range
• Engine speed: High idling
• Center of lever grip
• Tip of pedal
• Read max. value to stroke end
mm
N
{kg}
85 ± 10 85 ± 10
15.7 ± 3.9
{1.6 ± 0.4}
15.7 ± 3.9
{1.6 ± 0.4}
12.7 ± 2.9
{1.3 ± 0.3}
12.7 ± 2.9
{1.3 ± 0.3}
24.5 ± 5.9
{2.5 ± 0.6}
80.4 ± 20.1
{8.2 ± 2.0}
Max. 24.5
{Max. 2.5}
Max. 24.5
{Max. 2.5}
Max. 21.6
{Max. 2.2}
Max. 21.6
{Max. 2.2}
Max. 39.2
{Max. 4.0}
Max. 107.9
{Max. 11}
PC130-7 20-3
(1)
TESTING AND ADJUSTING
+2.00+20
0
+2.00+200+2.00+20
0
+1.0
–0.7
+10
– 7
+1.0
–0.7
+10
– 7
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
Oil pressure
Item Measurement condition Unit Standard value Permissible value
Unload pressure
Boom relief pressure
Arm relief pressure
Bucket relief pressure
Swing relief pressure
Travel relief pr essure
Control circuit basic
pressure
LS differential pressure
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Pump outlet pressure when all levers
are in neutral
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed:
High idling
• Working mode: A
• Pump outlet pressure
when measured c ircuit is
relieved
At normal
relief
At power
max.
At normal
relief
At power
max.
At normal
relief
At power
max.
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Outlet pressure of self-reducing pressure valve when all levers are in neutral
• Hydraulic oil temper atur e:
45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Pump pressure - LS pressure
When all
levers are
in neutral
When
travel system runs
idle at Hi
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
2.9 ± 0.5
{30 ± 5}
31.9
{325 }
34.8 ± 1.0
{355 ± 10}
31.9
{325 }
34.8 ± 1.0
{355 ± 10}
31.9
{325 }
34.8 ± 1.0
{355 ± 10}
28.9 ± 1.5
{295 ± 15}
34.8 ± 1.0
{355 ± 10}
3.23 ± 0.2
{33 ± 2}
2.7
{28 }
2.2 ± 0.1
{22.5 ± 1}
2.9 ± 0.5
{30 ± 5}
33.3 – 36.8
{340 – 375}
36.3 – 39.2
{370 – 400}
33.3 – 36.8
{340 – 375}
36.3 – 39.2
{370 – 400}
33.3 – 36.8
{340 – 375}
36.3 – 39.2
{370 – 400}
28.9 – 32.9
{295– 335}
36.3 – 39.2
{370 – 400}
2.84 – 3.43
{29 – 35}
2.7
{28 }
2.2 ± 0.1
{22.5 ± 1}
20-4 PC130-7
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
Item Measurement condition Unit Standard value Permissible value
Overrun of swing
Time taken to start
swinging
• Hydraulic oil temperature: 45 – 55 °C
• 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°
• Hydraulic oil temperature:
• Engine speed: High idling
• Working mode: A
• Time taken to swing 90° and
180° after starting
45 – 55 °C
180° 4.0 ± 0.4 Max. 8.5
deg
(mm)
sec
75 ± 10
{730 ± 100}
2.9 ± 0.3 Max. 3.5
Max. 90
(Max. 870)
Swing
Time taken to swing
Hydraulic drift of 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
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-
gory
Swing
Travel
Item Measurement condition Unit Standard value Permissible value
Leakage from swing
motor
Travel speed (Idle run)
Travel speed
(Actual travel)
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Swing lock switch: LOCK
• Measure leakage for 1 minutes while
swing circuit is relieved.
Lo
• Hydraulic oil temperature:
• Engine speed: High idling
• Working mode: A
• Measure time taken to rotate
track shoe 5 turns after 1 turn.
• Hydraulic oil temperature:
• Engine speed: High idling
• Working mode: A
• Hard and level place
• Measure time taken to travel 20
m after running up 10 m.
45 – 55 °C
45 – 55 °C
Hi 21.9 ± 2.2 23.1 ± 3.0
Lo 27.6 ± 5.1 27.6 ± 7.1
Hi 13.2 ± 1.2 13.2 ± 1.7
l/min Max. 3 Max. 6
46.1 ± 9.2 46.1 ± 9.2
sec
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
Travel deviation
• Working mode: A
• Travel speed: Lo
• Hard and level place
• Measure travel deviation in travel of
20 m after running up 10 m.
mm Max. 200 Max. 220
20-6 PC130-7
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
Travel
Item Measurement condition Unit Standard value Permissible value
Hydrauli c drift of travel
Leakage from travel
motor
Whole work
equipment
(Hydraulic drift of tooth tip)
• Hydraulic oil temperature: 45 – 55 °C
• Engine: Stopped
• Stop mac hi ne 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
• Lock sprocket.
• Measure leakage for 1 minutes while
travel circuit is relieved.
mm 0 0
l/min Max. 5 Max. 10
Max. 460 Max. 700
Boom cylinder
(Retraction of cylinder)
• Hydraulic oil temperature: 45 – 55 °C
• Level and flat place
Arm cylinder
(Extension of cylinder)
Hydraulic drift of work equipment
Bucket cylinder
(Retraction of cylinder)
Work equipment
Boom speed
Work equipment speed
• Bucket: Full of dirt and sand or filled
with rated load (1,080 kg)
• Level boom top, retract arm cylinder
fully, and extract bucket cylinder fully.
• Engine: Stopped
• Work equipment con trol lev er: Ne utra l
• Start measuring hy draulic drift just
after setting machine and measure
every 5 minutes for 15 minutes.
RAISE
• Hydraulic oil temperature:
• Engine speed: High idling
• Working mode: A
• Measure time taken to move
bucket between RAISE stroke
end and ground touch point of
bucket.
45 – 55 °C
LOWER
mm
sec
Max. 10 Max. 12
Max. 80 Max. 90
Max. 22 Max. 40
3.7 ± 0.4 Max. 4.3
2.6 ± 0.5 Max. 3.2
PC130-7 20-7
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
Work equipment
Item Measurement condition Unit Standard value Permissible value
Arm speed
Work equipment speed
Bucket speed
• Hydraulic oil temperature:
45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Measure time taken to move
arm between OUT stroke end
and IN stroke end (between
starting points of cushion).
• Hydraulic oil temperature:
45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Measure time taken to move
bucket between DUMP stroke
end and CURL stroke end
CURL
sec
DUMP
CURL
sec
DUMP
3.2 ± 0.4 Max. 4.4
3.1 ± 0.3 Max. 3.7
2.9 ± 0.3 Max. 3.7
2.3 ± 0.2 Max. 2.9
Boom time lag
Time lag
• 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 raising front of machine after bucket
touches ground.
sec Max. 3.0 Max. 4.0
20-8 PC130-7
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
Work equipment
Item Measurement condition Unit Standard value Permissible value
Arm time lag
Time lag
Bucket time lag
Cylinder
Center swivel joint Max. 10 Max. 50
Oil leakage
Travel deviation in
compound operation
of work equipment and
travel
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: Low idling
• Working mode: A
• Move IN ar m from OUT stroke end
and measure time taken to start moving arm again after it is stopped.
• For measuring posture, see WORK
EQUIPMENT 6.
• 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 moving bucket again after it is stopped.
• For measuring posture, see WORK
EQUIPMENT 7.
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Relieve cylinder to be measured or
travel circuit and measure leakage in
1 minute.
• Hydraulic oil temperature: 45 – 55 °C
• Engine speed: High idling
• Working mode: A
• Travel speed: Lo
• Hard and level place
• Measure travel deviation in travel of
20 m after running up 10 m.
sec Max. 2.0 Max. 3.0
sec Max. 2.0 Max. 3.0
Max. 3.5 Max. 15
cc/min
mm Max. 500 Max. 500
Compound operation performanc e
PC130-7 20-9
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
PC flow control
Pump
Item Measurement condition Unit Standard value Permissible value
Time taken to swing
90° in compound op eration of raising boom
and starting swinging
characteristics
Hydraulic pump
capacity
performance
• Hydraulic oil temperature: 45 – 55 °C
• Engine: High idling
• Working mode: A
• Bucket: Filled with rated load
• Hard and level place
• Set arm vertically and lower back of
bucket to ground.
• Raise boom and start swinging simultaneously from above posture and
measure time taken to pass 90° point.
• See graph. l/min See graph.
sec
4.0
(Reference value)
20-10 PC130-7
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model name PC130-7
Cate-
gory
Item Measurement condition Unit Standard value Permissible value
Hydraulic pump performance
Pump performance
• PC-EPC current: 400 mA
• Pump speed: 2,000 rpm
Check point
Any point P
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, calc ulate the pump discharge pressure at the specified speed from the
engine speed and pump discharge at the time of measurement.
Test pump discharge
pressure
(MPa{kg/cm2})
Standard discharge
(l/min)
Q
(See graph)
Lower limit of
discharge
(l/min)
Q
(See graph)
PC130-7 20-11
(1)
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
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
....... 20-122
PC130-7 20-101
(1)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Testing and adjusting item
Measuring exhaust gas
color
Adjusting valve clearance
Measuring compression
pressure
Measuring blow-by pressure
Measuring engine oil pressure
Part No. Part name
Symbol
1 799-203-9000
A
Commercially
2
available
Commercially
B
available
795-502-1205 Compres sion gauge 1 0 – 6.9MPa {0 – 70kg/cm2}
C
795-502-1370 Adapter 1
6204-11-3880 Gasket 1
D
799-201-1504 Blow-by checker 1 —
799-101-5002 Hydraulic tester 1
1
790-261-1203
E
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98MPa {10kg/cm
3
799-401-3500 Adapter 1 Size: 06
799-101-5220 Nipple 1
4
07002-11023 O-ring 1
Handy smoke
checker
Smoke meter 1
Feeler gauge 1
Digital hydraulic
tester
Q'ty
1
Pollution level: 0 – 70% (With standard
color)
(Pollution level x 1/10 C Bosch index)
(Air intake side: 0.35 mm, Exhaust side:
0.50 mm)
For 95E-3 engine
Pressure gauge: 2.5,5.9,39.2,58.8MPa
1 Pressure gauge: 58.8MPa {600kg/cm
Size: 10 x 1.25mm
Remarks
{25,60,400,600kg/cm
2
}
2
}
2
}
Measuring fuel injection
timing
Measuring clearanc e of
swing circle bearing
Testing and adjusting oil
pressure in work equipment, swing, and travel circuits
Measuring control circuit
basic pressure
Testing and adjusting oil
pressure in pump PC control circuit
1
795-102-2103 Spring pusher 1
F
Commercially
2
available
Commercially
G
available Dial gauge 1 —
799-101-5002 Hydraulic tester 1
1
790-261-1203
H
799-101-5220 Nipple 1
2
07002-11023 O-ring 1
799-101-5002 Hydraulic tester 1
1
790-261-1203
J
799-101-5230 Nipple 1
2
07002-11423 O-ring 1
799-101-5002 Hydraulic tester 1
1
790-261-1203
K
799-101-5230 Nipple 2
2
07002-11423 O-ring 2
Dial gauge 1
Digital hydraulic
tester
Digital hydraulic
tester
Digital hydraulic
tester
For deliver y valve method
* Same as E1
1
* Same as E4
* Same as E1
1
Size: 14 x 1.5mm
1
* Same as H ( Only quantity is different)
20-102 PC130-7
(1)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Testing and adjusting item
Testing and adjusting oil
pressure in pump LS control circuit
Measuring s olenoid valv e
output pressure
Measuring PPC valve output pressur e
Measuring oil leakage
Measuring water temperature and oil temperature
Part No. Part name
Symbol
799-101-5002 Hydraulic tester 1
1
790-261-1203
L
799-101-5230 Nipple 2
2
07002-11423 O-ring 2
3
799-401-2701
799-101-5002 Hydraulic tester 1
1
M
790-261-1203
2
799-401-3100 Adapter 1 Size: 03
799-101-5002 Hydraulic tester 1
1
N
790-261-1203
2
799-401-3100 Adapter 1 * Same as M2
Commercially
P
available
—
799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
Digital hydraulic
tester
Differential pressure
gauge
Digital hydraulic
tester
Digital hydraulic
tester
Measuring cylinder 1
Q'ty
1
* Same as H (Only quantity is different)
1—
* Same as E1
1
* Same as E1
1
Remarks
Measuring operating effort
and pressing force
Measuring stroke and
hydraulic drift
Measuring work equipment
speed
Measuring voltage and
resistance
79A-264-0021 Push-pull scale 1 0 – 294N {0 – 30kg}
—
79A-264-0091 Push-pull scale 1 0 – 490N {0 – 50kg}
Commercially
—
available
Commercially
—
available
Commercially
—
available
Scale 1 —
Stopwatch 1 —
Circuit tester 1 —
a For the model names and part Nos. of the T-adapters and boxes u sed for troubleshooting for the monitor
panel, controllers, se nso r s, act uators, and wiring h ar nes se s, se e T RO UB LE SHO O TING, Layout of connectors and electric circuit diagram of each system.
PC130-7 20-103
(1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING ENGINE SPEED
TESTING AND ADJUSTING
ENGINE SPEED
MEASURING
1. Preparation work
1) Turn the starting switch ON and set the monitor panel in the "Monitoring func tion [02]" to
prepare for measurement of the engine
speed.
a For the operating method, see "Special
functions of monitor panel".
• Monitoring code: 010 (Engine speed)
a The engine speed is displayed in rpm.
2) Warm up the engine to the following o perating condition.
• Engine coolant temperature: Within oper-
ating range
• Hydraulic oil temperature: 45 – 55°C
a Measure the engine speed with the work-
ing mode switch in the A-mode position.
4. Measuring pump relief and one-touch power
maximizing speed
1) Set the fuel control dial in the high idling
(MAX) position.
2) Relieve the arm circuit by moving the arm IN,
keeping pressing the one-touc h power max imizing switch, and measure the engine
speed.
a The one-touch power maximizing func-
tion is reset automatically in about 8.5
seconds even if the switch is kept held.
Accordingly, measure the engine speed
in that period.
5. Measuring auto-deceleration speed
1) Start the engine and set the fuel contr ol dial
in the high idling position (MAX).
2) Set the work equip ment control, swing con-
trol, and travel levers in n eutr a l an d me as ure
the engine speed.
a The engine speed lowers to a certain
level about 5 seconds after all the levers
are set in neutral. This level is the autodeceleration speed.
1. Measuring low idling speed
1) Set the fuel contr ol dial in t he low idli ng (M IN)
position.
2) Set the work equipment control, swing control, and travel levers in neu tr al a nd m eas ure
the engine speed.
2. Measuring high idling speed
1) Turn the auto-decelerator switch OFF.
2) Set the fuel control dial in the high idling
(MAX) position.
3) Set the wo rk equipment control, swing control, and travel levers in neu tr al a nd m eas ure
the engine speed.
ADJUSTING
Adjusting governor spring
a If the high idling speed is out of the standard
range or the engine speed is unstable (the
engine hunts), adjust the governor spring with
"Governor adjustment function [03]" of the monitor panel.
a For the adjustment procedure, see SPECIAL
FUNCTIONS OF MONITOR PANEL.
3. Measuring pump relief speed
1) Set the fuel control dial in the high idling
(MAX) position.
2) Relieve the arm circui t by mo ving the a rm IN
and measure the engine speed.
20-104 PC130-7
(1)
TESTING AND ADJUSTING
MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS
COLOR
a Measuring instruments for exhaust gas color
Symbol Part No. Part name
1 799-201-9000 Handy Smoke Checker
A
k When installing and removing the measuring
a If an air source and an el ec tric p ower source are
not available in the field, use handy smo ke
checker A1. When recording official data, use
smoke meter A2.
1. Measuring with handy smoke checker A1
1) Stick a sheet of filter paper to smoke checker
2) Insert the exhaust gas intake pipe in exhaust
3) Run the engine.
4) Accelerate the engine suddenly or run it at
Commercially
2
instruments, take care not to touch a hot part.
available
A1.
pipe (1).
high idling and operate the han dle of smoke
checker A1 so that the filter paper will absorb
the exhaust gas.
Smoke Meter
2. Measuring with smoke meter A2
1) Insert probe [1] of smoke meter A2 in the
outlet of exhaust pipe (1) and fix it to the
exhaust pipe with a clip.
2) Connect the probe hose, receptacle of the
accelerator switch, and air hose to smoke
meter A2.
a Limit the supplied air pressure to 1.5
MPa {15 kg/cm
3) Connect the p ower cable to a receptacle of
AC 100 V.
a Before connecting the cable, chec k that
the power switch of the smoke meter is
turned OFF.
4) Loosen the cap nut of the sucti on pump and
fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
A2.
2
}.
5) Remove the filter paper and compare it with
the attached scale.
6) After finishing measurement, remove the
measuring instrument and return the
removed parts.
6) Start the engine and heighten the engine
coolant temperature to the operating range.
PC130-7 20-105
(1)
TESTING AND ADJUSTING
7) Accelerate the engine suddenly or run it at
high idling and press the accelerator pedal of
smoke meter A2 and co llect the exhau st ga s
into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
9) After finishing measurement, remove the
measuring instrument and return the
removed parts.
MEASURING EXHAUST GAS COLOR
20-106 PC130-7
(1)
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
a Adjusting instrument for valve clearance
Symbol Part No. Part name
B
1. Open the engine hood and remove all cylinder
head covers (1).
2. Remove the engine unde rcover (on the radiator
side).
3. Rotate the crankshaft forward to bring the
stamped "1.4TOP" line (a) of the crank p ulley to
pointer (2) and set the N o. 1 c yli nde r to the compression top dead center.
a Crank the crankshaft with the crank pulley
a There are 2 stamped "1.4TOP" lines on the
a When the No. 1 cylinder is at the c ompres-
Commercially
available
mounting bolt.
crank pulley. Use the one at the diagonal
position of "2.3TOP".
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 cyl in der is not at
the compression top dead center. In th is
case, rotate the crankshaft one more turn.
Feeler gauger
4. While the No. 1 cylinder is at the compression
top dead center, adjust the valve clearances
marked with q in the valve arran gem ent dr awi ng
according to the following procedure.
1) Insert feeler gauge B in clearance (b)
between rocker arm (3) and valve stem (4)
and adjust the clearance with adjustment
screw (5).
a With the feeler gauge inserted, turn the
adjustment screw to a degree that you
can move the filler gauge lightly.
2) Secure adjustment screw (5) and tighten
locknut (6).
3 Locknut: 39.2 – 49 Nm {4 – 5 kgm}
a After tightening the locknut, check the
valve clearance again.
a After adjusting all of the valves marked
with q, go to the next procedure.
5. Rotate the crankshaft forward to bring the
stamped "1.4TOP" line (a) of t he crank pulley to
pointer (2) and set the No . 4 c ylin der to t he c ompression top dead center.
PC130-7 20-107
(1)
TESTING AND ADJUSTING
6. While the No. 4 cylinder is at the compression
top dead center, adjust the valve clearances
marked with Q in the valve arrangement drawing.
a Adjust the valve clearance acc ording to st ep
4 above.
7. After finishing adjustment, return the removed
parts.
3 Cylinder head cover mounting bolt:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
ADJUSTING VALVE CLEARANCE
20-108 PC130-7
(1)
TESTING AND ADJUSTING
MEASURING COMPRESSION
PRESSURE
a Measuring instruments for compression pressure
Symbol Part No. Part name
795-502-1205 Compression gauge
C
a When measuring the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rota ting
part.
1. Adjust the valve clearance.
a See Adjusting valve clearance.
2. Warm up the engine until the engine oil temperature is 40 – 60°C.
795-502-1370 Adapter
6204-11-3880 Gasket
MEASURING COMPRESSION PRESSURE
6. Remove governor spring (2).
7. Put governor l ever (3) of the fuel injection pump
to the STOP side stopper and fix it.
3. Prepare for measuring the engine speed.
a See Testing and adjusting engine speed.
4. Open the engine hood and remove nozzle holder
(1) of the cylinder to measure the compression
pressure.
5. Install adapter [1] of compression gauge C to the
mounting part of the nozzle ho lder and connect
gauge [2].
a Install the gasket to the end of the adapter.
a Secure the adapter with the clamping holder
and mounting bolt for the nozzle holder.
3 Mounting bolt: 39.2 – 49 Nm {4 – 5 kgm}
8. Crank the engine with the starting motor and
measure the compression pressure.
a Read the compression gauge when its
pointer is stabilized.
a When measuring the compression pr essure,
measure the engine speed, too, and check
that it is in the measurement condition range.
9. After finishing measurement, remove the measuring instruments and return the removed parts.
a Check that the fulcrum of the clamping
holder for the nozzle holder is seated on the
cylinder head, and then ti ghten th e mounti ng
bolt.
3 Mounting bolt: 39.2 – 49 Nm {4 – 5 kgm}
PC130-7 20-109
(1)
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
a Measuring instruments for blow-by pressure
Symbol Part No. Part name
D 799-201-1504 Blow-by checker
1. Remove the engine und ercover (on the flywhee l
side).
2. Install nozzle [1] of blow- by che ck er C to the end
of blow-by hose (1) and connect it to gauge [2].
5. Run the engine at high idling and measure the
blow-by pressure .
• Working mode: A
• Work equipment, swing, and travel circuit:
Relieve the travel circuit.
6. After finishing measurement, remove the measuring instruments and return the removed parts.
3. Start the engine and lock the travel mechanism.
k Put pin [3] between the sprocket and track
frame to lock the travel mechanism
securely.
4. Start the engine and warm it up to t he operating
range.
• Engine coolant temperature: Within operat-
ing range
• Hydraulic oil temperature: 45 – 55°C
20-110 PC130-7
(1)
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL
PRESSURE
a Measuring instruments for engine oil pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
E
3 799-401-3500 Adapter (Size: 06)
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.
5. Measure the oil pressure during low idling and
high idling.
6. After finishing measurement, remove the measuring instruments and return the removed parts.
2. Install adapter E3 and conne ct the di sconnec ted
hose again.
3. Install nipple E4 and connect it to hydraulic tester
E2.
4. Start the engine and heighten the engine coolant
temperature to the operating range.
PC130-7 20-111
(1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING FOR FUEL INJECTION TIMING
TESTING AND ADJUSTING
FOR FUEL INJECTION TIMING
a Testing and adju sting instruments for fuel injec-
tion timing (for delivery valve method)
Symbol Part No. Part name
1 795-102-2103 Spring pusher
F
TESTING AND ADJUSTING BY MATCH MARK
METHOD
a After removing and installing the fuel injection
pump without repairing it or when only checking
the injection timing, test and adjust the injection
timing according to the following procedure.
2
Commercially
available
Dial gauge
4. Remove cover (3) of the fuel injection pump
drive shaft.
TESTING
1. Open the engine hood and remove all cylinder
head covers (1).
2. Remove the engine under cover (on the radiator
side).
3. Rotate the crankshaft forward to bring the
stamped "1.4TOP" line (a) of the crank pulley to
pointer (2) and set the No. 1 cyl inder to th e c ompression top dead center.
a Crank the crankshaft with the crank pulley
mounting bolt.
a There are 2 stamped "1.4TOP" lines on t he
crank pulley. Use the one at the diagonal
position of "2.3TOP".
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 han d. If the rocker arm
cannot be moved, the No. 1 cy li nde r is no t at
the compression top dead center. In this
case, rotate the crankshaft one more turn.
5. Insert pin [1] in the mounting bolt hole of the front
cover (on the outside of the engi ne) to chec k the
fuel injection timing.
a Use a pin 4.0 – 4.5 mm in diameter and
about 80 mm in length.
a If the pin enters smoothly to inside of the
drive gear of the fuel injection pump, the fuel
injection timing is normal. In this case, return
the removed parts.
a If the pin touches the drive gear of the fuel
pump, the fuel injection timing is abnormal.
In this case, adjust the fuel injection timing.
ADJUSTING
a If the fuel injection timing is abnormal, adjust it
according to the following procedure.
1. Remove the fuel pump, holder, and drive gear
together.
a See DISASSEMBLY AND ASSEMBLY,
Removal, installation of fuel pump assembly.
20-112 PC130-7
(1)
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