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Pc128us 2 Sebm018419 PDF
Pc128us 2 Sebm018419 PDF
Pc128us 2 Sebm018419 PDF
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Manual
PC128US-2
PC138US-2
PC138USLC-2E0
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC128US-2 5001 - 7730 avance
PC128US-2 7731 and up GALEO
PC138US-2 4501 and up GALEO
PC138USLC-2E0 1001 and up GALEO
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
No. of page
00-2 PC128US-2
4
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
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10-102 10-132-7 (15) 10-147-7 (15) 20-105 (17) 20-209 (17)
10-103 10-133 (15) 10-148 (15) 20-106 (17) 20-210 (1)
10-104 10-133-1 (15) 10-149 (10) 20-107 (17) 20-211 (1)
10-105 10-134 (10) 10-149-1 (15) 20-108 (17) 20-212 (17)
10-106 10-134-1 (15) 10-150 (18) 20-108-1 (17) 20-214 (10)
10-107 10-135 (10) 10-151 (7) 20-108-2 (17) 20-215 (10)
10-108 10-136 (10) 10-151-1 (15) 20-108-3 (17) 20-216 (10)
10-109 10-136-1 (10) 10-151-2 (15) 20-108-4 (17) 20-217 (7)
10-110 10-136-2 (15) 10-151-3 (11) 20-108-5 (17) 20-218 (7)
10-111 (13) 10-136-3 (11) 10-152 20-108-6 (17) 20-218-2 (17)
10-112 (7) 10-136-4 (15) 10-153 20-108-7 (17) 20-218-3 (7)
10-113 (7) 10-136-5 (15) 20-108-8 (17) 20-218-4 (17)
10-114 10-137 (10) 20-1 (1) 20-108-9 (17) 20-218-5 (7)
10-115 10-138 (7) 20-2 (17) 20-109 (7) 20-218-6 (7)
10-116 (15) 10-138-1 (15) 20-2-1 (17) 20-110 (1) 20-218-8 (17)
10-117 (15) 10-138-2 (18) 20-3 (10) 20-111 (1) 20-218-9 (17)
10-117-1 (15) 10-138-3 (15) 20-4 (14) 20-112 (1) 20-218-10 (17)
10-118 10-138-4 (15) 20-5 (14) 20-113 (9) 20-218-11 (17)
10-119 (15) 10-138-5 (7) 20-6 (7) 20-114 (7) 20-218-12 (17)
10-120 (15) 10-139 (10) 20-7 (18) 20-115 (18) 20-219 (17)
10-121 10-139-1 (15) 20-8 (7) 20-116 (7) 20-220 (17)
10-122 10-140 (10) 20-8-1 (17) 20-117 (18) 20-221 (17)
10-122-1 (13) 10-141 (18) 20-8-2 (17) 20-118 (7) 20-222 (17)
10-122-2 (15) 10-142 (18) q 20-8-3 (19) 20-119 (7) 20-223 (17)
10-122-3 (7) 10-142-1 (15) q 20-8-4 (19) 20-120 (7) 20-224 (17)
10-122-4 (7) 10-142-2 (7) 20-8-5 (18) 20-121 (7) 20-225 (17)
10-122-5 (7) 10-143 (10) 20-8-6 (17) 20-122 (1) 20-226 (17)
10-122-6 (15) 10-143-1 (15) 20-8-7 (17) 20-123 (1) 20-227 (17)
10-122-7 (13) 10-143-2 (15) 20-8-8 (17) 20-124 (7) q 20-228 (19)
10-122-8 (18) 10-143-3 (15) q 20-8-9 (19) 20-125 (10) 20-229 (17)
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10-129 (10) 10-146 (18) 20-17 (7) 20-137 (17) q 20-230-11 (19)
10-130 (10) 10-146-1 (11) 20-18 (7) 20-138 (17) q 20-230-12 (19)
10-131 (10) 10-146-2 (15) 20-19 (17) 20-201 (14) Q 20-230-13 (19)
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20-245 (17) 20-331 (17) 20-552 (17) 20-712 (17) 20-836 (17)
q 20-246 (19) 20-332 (17) 20-554 (7) 20-713 (17) 20-837 (17)
q 20-246-1 (19) 20-334 (17) 20-555 (7) 20-714 (17) 20-838 (17)
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20-308 (17) 20-419 (7) 20-581 (17) 20-813 (17) 20-951 (14)
20-309 (17) 20-420 (7) 20-582 (17) 20-814 (17) 20-952 (14)
20-310 (17) 20-421 (7) 20-583 (17) 20-815 (17) 20-953 (14)
20-311 (17) 20-422 (7) 20-584 (17) 20-816 (17) 20-954 (14)
20-312 (17) 20-423 (7) 20-585 (17) 20-817 (17) 20-955 (14)
20-313 (17) 20-501 (10) 20-586 (17) 20-818 (17) 20-956 (14)
20-314 (17) 20-502 (1) 20-587 (17) 20-819 (17) 20-957 (14)
20-315 (17) 20-503 (1) 20-588 (17) 20-820 (17) 20-958 (14)
20-316 (17) 20-504 (1) 20-589 (17) 20-821 (17) 20-959 (14)
20-317 (17) 20-505 (1) 20-601 (17) 20-822 (17) 20-960 (14)
20-318 (17) 20-506 (1) 20-602 (17) 20-823 (17) 20-961 (14)
20-319 (17) 20-507 (1) 20-603 (17) 20-824 (17) 20-962 (14)
20-320 (17) 20-508 (1) 20-701 (17) 20-825 (17) 20-963 (14)
20-321 (17) 20-509 (1) 20-702 (17) 20-826 (17) 20-964 (14)
20-322 (17) 20-510 (1) 20-703 (7) 20-827 (17) 20-965 (14)
20-323 (17) 20-511 (1) 20-704 (7) 20-828 (17) 20-966 (14)
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20-969 (14) 30-45 (16) 30-97 (16) q 30-148 (19) 40-26-4 (15)
20-970 (14) 30-46 (16) 30-98 (16) q 30-149 (19) 40-26-5 (15)
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20-972 (14) 30-48 (16) 30-100 (16) q 30-151 (19) 40-26-7 (15)
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30-4 (16) 30-55 (16) 30-107 (16) 40-30 (15)
30-5 (16) 30-56 (16) 30-108 (16) 40-1 (15) 40-31
30-6 (16) 30-57 (16) 30-109 (16) 40-2 (15) 40-32 (11)
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q 30-8 (19) 30-59 (16) 30-111 (16) 40-3-1 (15) 40-34 (15)
30-9 (16) 30-60 (16) 30-112 (16) 40-3-2 (15) 40-34-1 (15)
30-10 (16) 30-61 (16) 30-113 (16) 40-4 (14) 40-35 (15)
30-11 (16) 30-62 (16) 30-114 (16) 40-5 (15) 40-35-1 (15)
30-12 (16) 30-63 (16) 30-115 (16) 40-5-1 (10) 40-36 (15)
30-13 (16) 30-64 (16) 30-116 (16) 40-6 (10) 40-37 (13)
30-14 (16) 30-65 (16) 30-117 (16) 40-6-1 (11) 40-37-1 (15)
30-15 (16) 30-66 (16) 30-118 (16) 40-6-2 (15) 40-37-2 (15)
30-16 (16) 30-67 (16) 30-119 (16) 40-7 (11) 40-38 (2)
30-17 (16) 30-68 (16) 30-120 (16) 40-8 (15) 40-39 (15)
30-18 (16) 30-69 (16) 30-121 (16) 40-9 (11) 40-40 (15)
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30-20 (16) 30-71 (16) 30-123 (16) 40-11 (15) 40-42
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30-22 (16) 30-73 (16) 30-125 (16) 40-13 (7) 40-44 (2)
30-23 (16) 30-74 (16) 30-126 (16) 40-14 (15) 40-45 (10)
30-24 (16) 30-75 (16) 30-127 (16) 40-15 (15) 40-45-1 (15)
30-25 (16) 30-76 (16) 30-128 (16) 40-15-1 (15) 40-45-3 (10)
30-26 (16) 30-77 (16) 30-129 (16) 40-15-2 (15) 40-45-4 (10)
30-27 (16) 30-78 (16) 30-130 (16) 40-15-3 (15) 40-45-5 (15)
30-28 (16) 30-79 (16) 30-131 (16) 40-15-4 (15) 40-45-7 (10)
30-29 (16) 30-80 (16) 30-132 (16) 40-16 (15) 40-45-8 (10)
30-30 (16) 30-81 (16) 30-133 (16) 40-17 (15) 40-45-9 (15)
q 30-31 (19) 30-82 (16) 30-134 (16) 40-17-1 (15) 40-46
q 30-32 (19) 30-83 (16) 30-135 (16) 40-17-2 (15) 40-47
30-33 (16) 30-84 (16) q 30-136 (19) 40-18 (15) 40-47-1 (15)
30-34 (16) 30-85 (16) q 30-137 (19) 40-18-1 (15)
30-35 (16) 30-86 (16) q 30-138 (19) 40-19 (15) 90-1 (15)
30-36 (16) 30-87 (16) q 30-139 (19) 40-20 90-2 (15)
30-37 (16) 30-88 (16) q 30-140 (19) 40-21 (15) 90-3
30-38 (16) 30-89 (16) 30-141 (16) 40-22 (15) 90-5
30-39 (16) 30-90 (16) q 30-142 (19) 40-23 (15) 90-5-2 (11)
30-40 (16) 30-91 (16) q 30-143 (19) 40-24 90-7 (10)
30-41 (16) 30-92 (16) q 30-144 (19) 40-25 (15) 90-7-2 (10)
30-42 (16) 30-94 (16) q 30-145 (19) 40-26 (15) 90-9 (10)
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90-9-2 (15)
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90-15 (10)
90-17 (10)
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90-19 (10)
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90-25 (10)
90-27 (15)
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90-35 (15)
PC128US-2 00-2-5
(19)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is 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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤
tank.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
FOREWORD STANDARD TIGHTENING TORQUE
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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 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.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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
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
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
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
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
PC 128US-2 01-l
GENERAL GENERAL ASSEMBLY DRAWING
PC128US-2
Item Unit
7731 and up
Standard specification 12,950
Machine weight kg
Blade specification 13,450
Bucket capacity m3 0.45
Engine type — Komatsu S4D102E-1 Diesel engine
Engine rated output kW{HP}/rpm 64 {85.8}/2,200
A Standard specification mm 7,220
Overall length
A' Blade specification mm 7,955
B Overall height mm 2,850
C Overall width mm 2,515
D Shoe width mm 500
E Trail swing radius mm 1,480
F Crawler overall length mm 3,480
G Distance between tambler center mm 2,750
H Cab height mm 2,810
Minimum ground clearance mm 390
Traveling speed (Low/High) km/h 3.2/5.1
Continuous swing speed rpm 11.0
PC128US-2 01-4-3
(15)
GENERAL GENERAL ASSEMBLY DRAWING
PC138US-2
Item Unit
4501 and up
Standard specification 13,400
Machine weight kg
Blade specification 14,050
Bucket capacity m3 0.50
Engine type — Komatsu SAA4D95LE-3-A Diesel engine
Engine rated output kW{HP}/rpm 66.2 {88.7}/2,200
A Standard specification mm 7,220
Overall length
A' Blade specification mm 7,955
B Overall height mm 2,850
C Overall width mm 2,515
D Shoe width mm 500
E Trail swing radius mm 1,480
F Crawler overall length mm 3,610
G Distance between tambler center mm 2,880
H Cab height mm 2,815
Minimum ground clearance mm 395
Traveling speed (Low/High) km/h 2.9/5.1
Continuous swing speed rpm 11.0
01-4-4 PC128US-2
(15)
GENERAL GENERAL ASSEMBLY DRAWING
PC138USLC-2
Item Unit
1001 – 1500
Standard specification 14,000
Machine weight kg
Blade specification 14,370
Bucket capacity m3 0.50
Engine type — Komatsu S4D102E-1 Diesel engine
Engine rated output kW{HP}/rpm 64 {85.8}/2,200
A Standard specification 7,395
Overall length mm
A' Blade specification 8,035
B Overall height mm 2,850
C Standard specification 2,590
Overall width mm
C' Blade specification 2,515
Standard specification 600
D Shoe width mm
Blade specification 500
E Trail swing radius mm 1,480
F Crawler overall length mm 3,880
G Distance between tambler center mm 3,140
H Cab height mm 2,815
Minimum ground clearance mm 395
Traveling speed (Low/High) km/h 2.9/4.7
Continuous swing speed rpm 11.0
PC128US-2 01-4-5
(15)
GENERAL GENERAL ASSEMBLY DRAWING
PC138USLC-2
Item Unit
1501 and up
Standard specification 14,000
Machine weight kg
Blade specification 14,370
Bucket capacity m3 0.50
Engine type — Komatsu SAA4D95LE-3-E Diesel engine
Engine rated output kW{HP}/rpm 66.2 {88.7}/2,200
A Standard specification 7,390
Overall length mm
A' Blade specification 8,035
B Overall height mm 2,850
C Standard specification 2,590
Overall width mm
C' Blade specification 2,515
Standard specification 600
D Shoe width mm
Blade specification 500
E Trail swing radius mm 1,480
F Crawler overall length mm 3,870
G Distance between tambler center mm 3,140
H Cab height mm 2,815
Minimum ground clearance mm 395
Traveling speed (Low/High) km/h 2.9/5.1
Continuous swing speed rpm 11.0
01-4-6 PC128US-2
(15)
GENERAL GENERAL ASSEMBLY DRAWING
PC128US-2
Working range (mm)
7731 and up
A Maximum digging radius 8,230
B Maximum digging depth 5,405
C Maximum digging height 9,260
D Maximum vertical wall digging depth 4,860
E Maximum dumping height 6,910
F Minimum swing radius of work equipment 1,980
G Maximum reach at ground level 8,110
H Maximum raising distance of blade 470
I Maximum lowering distance of blade 530
PC128US-2 01-4-7
(15)
GENERAL GENERAL ASSEMBLY DRAWING
PC138US-2 PC138USLC-2
Working range (mm)
4501 and up 1001 and up
A Maximum digging radius 8,300
B Maximum digging depth 5,480
C Maximum digging height 9,340
D Maximum vertical wall digging depth 4,900
E Maximum dumping height 6,840
F Minimum swing radius of work equipment 1,980
G Maximum reach at ground level 8,180
H Maximum raising distance of blade 470
I Maximum lowering distance of blade 525 490
01-4-8 PC128US-2
(15)
GENERAL SPECIFICATIONS
SPECIFICATIONS
FOR STD SPEC.
PC128US-2 Serial No.: 5001 – 7730
PC128US-2
Machine model
Without blade With blade
Swing speed
Serial No. 6457 and up rpm 11.0 11.0
Serial No. 5001 – 6456 rpm 12 12
Swing max. slope angle deg. 19 19
Gradeability deg. 35 35
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
PC128US-2 01-5
(15)
GENERAL SPECIFICATIONS
PC128US-2
Machine model
Without blade With blade
Model S4D102E-1
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbochatger
No. of cylinders-bore x stroke mm 4 – 102 x 120
Battery 12V, 64 Ah x 2
GM18VL-J
Travel motor Variable displacement piston type
(with brake valve, holding brake) x 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with shockless safety valve, holding brake) x 1
01-6 PC128US-2
(15)
GENERAL SPECIFICATIONS
PC128US-2
Machine model
STD (without blade) OPT (with blade)
Stroke mm — 181
PC128US-2 01-7
A
GENERAL SPECIFICATIONS
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
01-8 PC128US-2
A
GENERAL SPECIFICATIONS
PC128US-2
Machine model
Without blade With blade
Model S4D102E-1
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbochatger
No. of cylinders-bore x stroke mm 4 – 102 x 120
GM18VL-J
Travel motor Variable displacement piston type
(with brake valve, parking brake) x 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with shockless safety valve, parking brake) x 1
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
PC128US-2 01-9
(15)
GENERAL SPECIFICATIONS
PC128US-2
Machine model
Without blade With blade
Stroke mm — 181
01-10 PC128US-2
(15)
GENERAL SPECIFICATIONS
PC128US-2 01-10-1
(15)
GENERAL SPECIFICATIONS
PC128US-2
Machine model
Without blade With blade
Model S4D102E-1
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbochatger
No. of cylinders-bore x stroke mm 4 – 102 x 120
GM18VL-J
Travel motor Variable displacement piston type
(with brake valve, parking brake) x 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with shockless safety valve, parking brake) x 1
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
01-10-2 PC128US-2
(15)
GENERAL SPECIFICATIONS
PC128US-2
Machine model
STD (without blade) OPT (with blade)
Stroke mm — 181
PC128US-2 01-10-3
A
GENERAL SPECIFICATIONS
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
01-10-4 PC128US-2
A
GENERAL SPECIFICATIONS
PC128US-2
Machine model
Without blade With blade
Model S4D102E-1
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbochatger
GM18VL-J
Hydraulic motor
Travel motor
Variable displacement piston type
(with brake valve, holding brake) x 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with shockless safety valve, holding brake) x 1
PC128US-2 01-10-5
(15)
GENERAL SPECIFICATIONS
PC128US-2
Machine model
Without blade With blade
Stroke mm — 181
01-10-6 PC128US-2
(15)
GENERAL SPECIFICATIONS
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
PC128US-2 01-10-7
(15)
GENERAL SPECIFICATIONS
PC138US-2
Machine model
Without blade With blade
Model SAA4D95LE-3-A
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbochatger, after cooler
GM20VL2-P
Hydraulic motor
Travel motor
Variable displacement piston type
(with brake valve, holding brake) x 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with shockless safety valve, holding brake) x 1
01-10-8 PC128US-2
(15)
GENERAL SPECIFICATIONS
PC138US-2
Machine model
Without blade With blade
Stroke mm — 181
PC128US-2 01-10-9
(15)
GENERAL SPECIFICATIONS
01-10-10 PC128US-2
(15)
GENERAL SPECIFICATIONS
PC138USLC-2
Machine model
Without blade With blade
Model S4D102E-1
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbochatger
GM20VL-P
Hydraulic motor
Travel motor
Variable displacement piston type
(with brake valve, holding brake) x 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with shockless safety valve, holding brake) x 1
PC128US-2 01-10-11
(15)
GENERAL SPECIFICATIONS
PC138USLC-2
Machine model
Without blade With blade
Stroke mm — 181
01-10-12 PC128US-2
(15)
GENERAL SPECIFICATIONS
PC128US-2 01-10-13
(15)
GENERAL SPECIFICATIONS
PC138USLC-2
Machine model
Without blade With blade
Model SAA4D95LE-3-A
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbochatger, after cooler
GM20VL2-P
Hydraulic motor
Travel motor
Variable displacement piston type
(with brake valve, holding brake) x 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with shockless safety valve, holding brake) x 1
01-10-14 PC128US-2
(15)
GENERAL SPECIFICATIONS
PC138USLC-2
Machine model
Without blade With blade
Stroke mm — 181
PC128US-2 01-10-15
(15)
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is a guide for use when transporting or handling component.
FOR STD SPEC.
PC128US-2 Serial No.: 5001 – 7730 Unit: kg
PC128US-2
Machine model
Without blade With blade
• Hydraulic pump 80 80
Control valve 80 96
• Idler assembly 81 x 2 81 x 2
• Carrier roller 11 x 2 11 x 2
• Track roller 21 x 14 21 x 14
PC128US-2 01-11
(15)
GENERAL WEIGHT TABLE
Unit: kg
PC128US-2
Machine model
Without blade With blade
01-12 PC128US-2
(15)
GENERAL WEIGHT TABLE
PC128US-2
Machine model
Without blade With blade
Control valve 80 96
Self pressure reducing valve 4.8 4.8
Swing motor 26 26
• Idler 81 x 2 81 x 2
• Carrier roller 11 x 2 11 x 2
• Track roller 21 x 14 21 x 14
PC128US-2 01-13
(15)
GENERAL WEIGHT TABLE
Unit: kg
PC128US-2
Machine model
Without blade With blade
01-14 PC128US-2
(15)
GENERAL WEIGHT TABLE
PC128US-2
Machine model
Without blade With blade
Operator’s seat 35 35
Swing motor 26 26
• Idler 81 x 2 81 x 2
• Carrier roller 11 x 2 11 x 2
• Track roller 21 x 14 21 x 14
PC128US-2 01-14-1
(15)
GENERAL WEIGHT TABLE
Unit: kg
PC128US-2
Machine model
Without blade With blade
01-14-2 PC128US-2
(15)
GENERAL WEIGHT TABLE
PC128US-2
Machine model
Without blade With blade
• Hydraulic pump 80 80
Control valve 80 96
Swing motor 26 26
• Idler 81 x 2 81 x 2
• Carrier roller 11 x 2 11 x 2
• Track roller 21 x 14 21 x 14
Unit: kg
PC128US-2
Machine model
Without blade With blade
01-14-4 PC128US-2
(15)
GENERAL WEIGHT TABLE
PC138US-2
Machine model
Without blade With blade
• Hydraulic pump 80 80
Control valve 80 96
Swing motor 26 26
• Idler 78 x 2 78 x 2
• Idler cushion 69 x 2 69 x 2
• Carrier roller 11 x 2 11 x 2
• Track roller 21 x 14 21 x 14
PC128US-2 01-14-5
(15)
GENERAL WEIGHT TABLE
Unit: kg
PC138US-2
Machine model
Without blade With blade
01-14-6 PC128US-2
(15)
GENERAL WEIGHT TABLE
PC138USLC-2
Machine model
Without blade With blade
Control valve 80 96
Unit: kg
PC138USLC-2
Machine model
Without blade With blade
01-14-8 PC128US-2
(15)
GENERAL WEIGHT TABLE
PC138USLC-2
Machine model
Without blade With blade
• Hydraulic pump 80 80
Operator’s seat 35 35
Control valve 80 96
Swing motor 26 26
PC128US-2 01-14-9
(15)
GENERAL WEIGHT TABLE
Unit: kg
PC138USLC-2
Machine model
Without blade With blade
01-14-10 PC128US-2
(15)
GENERAL LIST OF LUBRICANTS AND WATER
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
SAE 30
SAE 15W-40
PC128US-2 01-15
(15)
GENERAL LIST OF LUBRICANTS AND WATER
REMARK
• When fuel sulphur content is less than 0.5%,
change oil in the oil pan according to every
periodic maintenance hours described in this
manual.
Change oil according to the following table if
fuel sulphur content is above 0.5%.
01-16 PC128US-2
A
10 STRUCTURE AND FUNCTION
PC128US-2 10-1
(15)
STRUCTURE AND FUNCTION PTO
PTO
10-2 PC128US-2
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
PC128US-2 10-3
(15)
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
9JAOl328
PC128US-2 10-4-1
(15)
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
Specification
10-4-2 PC128US-2
(15)
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
9JA01329
SWING CIRCLE
-
-
.\
A-A
mB-B
m
c-c
9JA01330
SWING MACHINERY
PC128US-2 Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 – 1500
PC128US-2 10-7
(15)
STRUCTURE AND FUNCTION SWING MACHINERY
10-7-1 PC128US-2
(15)
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME
PC128US-2
PC138US-2
1. Idler 5. Sprocket
2. Track frame 6. Track roller
3. Carrier roller 7. Idler cushion
4. Travel motor 8. Track shoe
10-8 PC128US-2
(15)
STRUCTURE AND FUNCTION IDLER CUSHION
IDLER CUSHION
___-__--_--__-__-_--__---~---~~~~--
_____-_--__-__-__ _____-__
_____----__-_--mm
9JA01333
1. Idler Specification
2. support Grease : G2-LI
3. Yoke: Amount of filled grease : 140 cc
4. Cylinder
5. Recoil spring
G.“U-packing
7. Pilot
8. Nut
9. Valve
10. Grease fitting
PC128US-2 1o-9
STRUCTURE AND FUNCTION HYDRAULIC COMPONENT LAYOUT
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Swing motor
6. Hydraulic pump
7. Oil cooler
8. L.H. travel motor
9. L. H. PPC valve
10. Blade PPC valve (Blade specification)
11. R. H. PPC valve
12. Center swivel joint
13. 2-actuator attachment PPC valve
(Option for PC128US-2 KUK only)
(Option for PC138US-2 KUK only)
14. Travel PPC valve
15. 1-actuator attachment PPC valve
(When with attachment)
16. Boom hydraulic anti-burst valve
(For PC128US-2 KUK only)
(For PC138US-2 KUK only)
17. Blade cylinder (Blade specification)
18. Self pressure reducing valve
19. Control valve
20. 4-spool solenoid valve
• PPC lock
• 2-speed travel speed selection
• Swing holding brake
• 2-stage relief
10-10 PC128US-2
(15)
STRUCTURE AND FUNCTION VALVE CONTROL
PC 128US-2 10-13
0
STRUCTURE AND FUNCTION VALVE CONTROL
10-13-1 PC128US-2
(15)
STRUCTURE AND FUNCTION VALVE CONTROL
1. Control valve
2. R.H. work equipment PPC valve
3. R.H. work equipment control lever
(for boom and bucket operation)
4. Blade control lever (Blade specification)
5. 4-spool solenoid valve
6. L.H. work equipment control lever
(for arm, swing operation)
7. Blade PPC valve (Blade specification)
8. L.H. work equipment PPC valve
9. Safety lock lever
10. L.H. travel pedal
11. R.H. travel pedal
12. L.H. travel lever
13. R.H. travel lever
14. Travel PPC valve
15. Attachment PPC valve
(Attachment installable machine)
16. Attachment pedal
(Attachment installable machine)
17. Lock pin (Attachment installable machine)
PC128US-2 10-13-2
A
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
10-14 PC128US-2
(15)
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
PC128US-2 10-14-1
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
10-15-1 PC128US-2
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC128US-2 10-15-2
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
10-16 PC128US-2
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC128US-2 10-16-1
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Function
l This pump converts engine rotation and
torque transmitted to the pump shaft into
hydraulic energy and discharges pressurized
oil according to load.
l This pump can change delivery when the
swash plate angle is changed.
/
B f! \
IO
A-A 9JUOOO77
Structure
l The cylinder block (7) is supported to the shaft
(1) with the spline a, and the shaft (1) is sup-
ported with the front and rear bearings.
l The shoe (5) is punched to the tip of the pis-
ton (6) with a concave ball so that the piston
(6) and the shoe (5) form a spherical bearing.
l The shoe (5) is always pressed to the plane A
of the rocker cam (4) and slides in a circle.
The rocker cam (4) leads highly pressurized
oil together with the cylindrical plane B with
the cradle (2) fixed to the case, forms a static
pressure bearing and slides.
l Thepiston (6) moves in the axial direction rela-
tively in each cylinder of the cylinder block
(7).
l The cylinder block (7) rotates relatively while
sealing pressurized oil against the valve plate
(81, and the plane is designed to balance the
oil pressure properly.
l Oil in each cylinder of the cylinder block (7) is
absorbed and discharged through the valve
plate (8).
PC128U.S2 10-17
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Operation
1. Pump Operation
l The shaft (1) rotates together with the cylin- 1 !i A
der block (7), and the shoe (5) slides on the
plate A. When the rocker arm (4) moves along
the cylindrical plane B, the inclination ato the
centerline X of the rocker cam (4) and the axial
direction of the cylinder block (7) changes.
The inclination a_.is called “swash plate
angle.”
B
SLPOOl63
2. Delivery Control
l When the swash plate angle a increases, the
difference between the capacities E and F be-
comes larger and the delivery Q increases.
The servo piston (12) changes the swash plate
angle a.
- The servo piston moves in the direction of
straight reciprocation according to signal
pressures of the PC and LS valves. This
straight motion 7s transmitted to the rocker
arm (4) through the slider (131, and the rocker
cam (41, which is supported with the cylindri-
cal plane to the cradle (21, slides in the direc-
tion of rotation.
.
9Juoooa2
PC128US-2 10-19
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS AND PC VALVES
LS Valve
PC Valve
9JUOOO85
PO,UT P,’ N
9JUOOO66
1. Plug
2. Plug
Operation
To ma in
va I ve
Direction to
small diameter SVPO7604
1. LS Valve
1) When the control valve is at the center
value position
l The LS valve is a 3-way selector valve, and
the pressure PLS (LS pressure) from the
control valve inlet is being led to the
kpring chamber B and the pump dis-
charge pressure PP is being led to the H
port of the sleeve (8).
l The spool (6) position is determined de-
pending on the force of the LS pressure
PLS + the force of spring (4) Z and the force
ofthe pump discharge pressure (self-pres-
sure) PP.
10-26 PC128US-2
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
10-27-1 PC128US-2
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC128US-2 10-27-2
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
10-27-3 PC128US-2
(18)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Pilot Pressure
To main
LS valve
:
:
.-f ‘:
‘Fixed
throttle
Direction to Direction to
small diameter large diameter
Emergency oumD
PC-EPC valve
Pump ,I _
controller I’ ’ I
SVPO7608
2. PC Valve
1) When the pump controller is normal, the
load to the actuator is small and the pump
discharge pressure PP is low
a. Function of PC-EPC Valve Solenoid (7) sure PP. And the pressure output from
l The pump controller provides a com- the PC valve (the pressure at the C
’ mand current to the PC-EPC valve so- port) varies with the spool position.
lenoid (1). This command current ac- l The value of the command current X
tuates the PC-EPC valve and outputs is determined depending on type of
a signal pressure. When receiving the work (lever control), selection of work-
signal pressure, the PC valve changes ing mode, set point of engine speed
the force given to the piston (2). and actual speed.
l The spool (3) stops where the force to
the piston (2) balances with the com-
bined force of the spring setting force
of the springs (4) and (6) on the oppo-
site side and the force given to the
spool (3) by the pump discharge pres-
Pi lot pressure
To main
;j “I~IIIc-Lel JIUC
.I,,,,,,,,,,,,;;;;;,.,:
c3 -
Direction to
large diameter
Emergency DU~D
drive switch n c c n..__ 1
SVPO7609
Pi lot Pressure
‘0 main
valve
-
Direction to
small diameter
PC-EPC valve
SVPO7610
3) When the pump controller is out of order than the spring set force. So, the spool
and the PC redundant switch is set to ON (3) balances at a position in the left
a. In case of light load to main pump side.
• When the pump controller is out of • At the time, the C port has the same
order, set the PC redundant switch to pressure as the drain pressure at the
ON to change the circuit to the resis- D port, and the drain pressure PT is
tor side. In this case, since the cur- led to the large diameter side of the
rent is too large when the power is di- servo piston (9) through the LS valve.
rectly taken from the battery, the re- Then, the servo piston (9) moves in
sistor is connected to control the cur- the direction where the delivery in-
rent to the PC-EPC valve solenoid. creases because the pressure on the
• At the time, the current becomes con- small diameter side of the piston is
stant and the piston (2) pressing force large.
becomes constant as well.
• When the pump discharge pressure is
low, the combined force of the force
of the PC-EPC valve solenoid (1) and
the discharge pressure PP is smaller
PC128US-2 10-33
(18)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Pi lot Pressure
-
To main
va I ve
31°C
--*I* :
~/,~1,,,,,,,,,,,,,,,,,,
+ -
Direction to
small diameter
Emergency PUTID
-
drive switch
SVPO76 12
CONTROL VALVE
OUTLINE
There are the following 2 types of contral valve.
• 6-spool valve (without service valve)
• 7-spool valve (with service valve)
• 7-spool valve (with blade)
• 8-spool valve (with blade and service valve)
• 8-spool valve (with 2 service valve)
• 9-spool valve (with blade and 2 service valve)
fl Each service valve is a single add-on type, so
it is possible to add or remove the extra valve
at any time.
Extermal oppearance and cross section is given
only for the 7 spool valve.
10-36 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
7 spool valve
(6 spool valve + service valve)
PC128US-2 Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 – 1500
PC128US-2 10-37
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
10-37-1 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
CROSS-SECTIONAL DRAWING
fl Cross-sectional drawing shows 7-spool valve (6-spool + service valve).
(1/8)
10-38 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(2/8)
PC128US-2 10-39
STRUCTURE AND FUNCTION CONTROL VALVE
(3/8)
10-40 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(4/8)
PC128US-2 10-41
STRUCTURE AND FUNCTION CONTROL VALVE
(5/8)
10-42 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(6/8)
PC128US-2 10-43
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(7/8)
10-44 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(8/8)
PC128US-2 10-45
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
9 spool valve
(6-spool valve + Blade valve + Full-flow service valve + Half-flow service valve)
PC128US-2 10-45-2
5
STRUCTURE AND FUNCTION CONTROL VALVE
CROSS-SECTIONAL DRAWING
¡ Cross-sectional drawing shows 9-spool valve (6-spool + service valve).
(1/9)
10-45-3 PC128US-2
5
STRUCTURE AND FUNCTION CONTROL VALVE
(2/9)
PC128US-2 10-45-4
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(3/9)
10-45-5 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(4/9)
PC128US-2 10-45-6
5
STRUCTURE AND FUNCTION CONTROL VALVE
(5/9)
10-45-7 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(6/9)
PC128US-2 10-45-8
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(7/9)
10-45-9 PC128US-2
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(8/9)
PC128US-2 10-45-10
(15)
STRUCTURE AND FUNCTION CONTROL VALVE
(9/9)
10-45-11 PC128US-2
(15)
STRUCTURE AND FUNCTION SUCTION SAFETY VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve
8. Sleeve
9. Adjustment screw
10. Lock nut
Specification
CLSS
OUTLINE OF CLSS
Features
CLSS stands for Closed Center Load Sensing System and is featured as follows :
l Fine controllability without affect of load
l Controllability that allows digging even in the fine control mode.
l Ease of compound operation in which the flow distribution performance depends on spool opening
area duiing compound operation.
l Saving of energy-by variable pump control
Configuration
l The CLSS consists of a variable displacement piston pump, a control valve and actuators.
l The pump body consists of a main pump, a PC valve and an LS valve.
PLS
r________________-------_ Control valve
I
I
I
i
I
I I I
I
I ______(
Servo
valve SDPD2661
PC128US-2 1o-47
STRUCTURE AND FUNCTION CLSS
Basic principle
1. Control of pump swash plate angle
The pump swash plate angle (pump delivery)
l
Actuator
is controlled so that the LS differential pres- I
sure APLS, which is the difference between @
the pump discharge pressure PP and the LS 1
pressure PLS (actuator load pressure) at the
control valve outlet, becomes constant. Control
(LS differential pressure APLS = Pump pres- valve
-_-_-- __
sure PP - LS pressuFe PLS) -----__ I
II
I II
Pump
Passage PLSf I
[I L-l
, L__-------,
I_--_--_---. I
I I
I I
Main DumD
M i n. Max.
-
I 1
Servo
i piston
SEP02562
SOP02563
PC 128US-2
STRUCTURE AND FUNCTION CLSS
Load
1 Actuator 1 Actua
I\ I lcomensationl I II I\ I cobwensa~
SEP02564
Pressure
detect ion
port
PP x
Al
Service
E^-..:^^ I II I 107
T-l .‘.
CYI “.inder
[=1, i!T----_--_-__---
; :---
’ ’ ’ ’ 1’ j+j+
. Left
travel
motor
/ III’ itl /
Swing
motor
9:
I
31.9/34.8HPa
(325/355ko/cm’l
1. Unload valve
Set pressure : 3.38 MPa (34.5 kg/cm?
2. Safety-suction valve
Set pressure : 35.8 MPa (365 kg/cm21
3. Pressure compensation valve
4. Suction valve
5. Main relief valve
Set pressure : normal : 31.9 MPa (325 kg/cm*)
High pressyre : 34.8 MPa (355 kg/cm*}
6. Lift check valve
7. Cooler bypass valve
8. LS selection valve
9. Swing bleeding valve
70. Travel junction valve
11. Boom drift prevention valve
12. Arm regeneration valve
UNLOAD VALVE
1. When the control valve is neutral
Function
l When the control valve is neutral, the delivery Q equivalent to the pump minimum swash plate angle
is released to the tankcircuit. At the time, the pump discharge pressure PP is set to 2.45 MPa {25.Okg/
cm21 with the spring (3) inside the vale. (The LS pressure PLS is 0 MPa {Okg/cm2).)
SDP03735
the pump minimum swash plate angle, the pump discharge pressure PP is set to the LS pressure PLS
+ 2.45 MPa (25.0 kglcm2).
When the differential pressure between the discharge pressure PP and the LS pressure PLS comes to
the spring (3) load (2.45 MPa (25.0 kg/cm21), the unload valve will open and the LS differential pres-
sure APLS will come to 2.45 MPa (25.0 kg/cm2}.
SOP03736
Operation
l When the control valve is operated in the fine 1. Unload valve
control mode, the LS pressure PLS will occur 2. Sleeve
and will be applied to the right end face of 3. Spring
the spool (4). At the time the differential pres- 4. Spool
sure between the LS pressure PLS and the
pump discharge pressure PP increases be- PLS : LS circuit (pressure)
cause the opening area of the control valve PP : Pump circuit (pressure)
spool is small. T : Tank circuit
l When the differential pressure between the
pump discharge pressure PP and the LS pres-
sure PLS comes to the spring (3) load (2.45
‘.MPa (25.0 kg/cm2)), the spool (4) will move to
the right side and the pump circuit PP will in-
terconnect to the tank circuit T.
l This means that the pump discharge pressure
PP is set to the spring force (2.45 MPa (25.0
kg/cm2} + LS pressure PLS, and the LS differ-
ential pressure APLS comes to 2.45 MPa (25.0
kg/cm21.
SDP03737
Operation
l When the control valve is operated with large 1. Unload valve
stroke, the LS pressure PLS will occur and will 2. Sleeve
be applied to the right end face of the spool 3. Spring
(4). At the time, the opening areas of the con- 4. Spool
trol valve spool is large and the difference
between the LS pressure PLS and the pump PLS : LS circuit (pressure)
discharge pressure PP is small. PP : Pump circuit (pressure)
l So, the differential pressure between the T :Tankcircuit
pump discharge pressure PP and the LS pres-
sure PLS does not reach the spring (3) load
(2.45 MPa (25.0 kg/cm2)) and the spring (3)
pushes the spool (4) to the left side.
l Then, the pump circuit PP and the tank circuit
Tare interrupted, and the pump delivery Q is
completely flown to the actuator circuit.
LEADING OF LS PRESSURE
Function
l The LS pressure is load pressure to the ac- the LS circuit PLS. Also, the orifice C is
tuator on the outlet side of the control valve. mounted on the piston (5) halfway from the
l In case of a work equipment valve, the pres- pump circuit PP to the pressure reducing valve
sure reducing valve (3) of the pressure com- (31, and the orifice has the damper function.
pensation valve reduces the pump discharge l The travel valves leads the actuator circuit
pressure PP to the same level as the actuator pressure A directly to the LS circuit PLS.
circuit pressure A and leads the pressure to
SOP03738
Operation
l When the spool (1) is operated, the pump dis- l The both end face areas of the pressure re-
charge pressure PP will be led to the actuator ducing valve (3) are the same (SA = SLS), and
circuit A through the bridge passage b from the actuator circuit pressure PA (= A) is ap-
the flow control valve (2) and the spool notch plied to the SA side and the reduced pump
a. discharge pressure PP is applied to the SLS
l Since the pressure reducing valve (3) moves side on the opposite side.
to the right at the same time, the pump dis- l Therefore, the pressure reducing valve bal-
charge pressure PP led from the orifice c is ances at the position where the actuator cir-
reduced due to pressure loss at the notch d cuit pressure PA becomes equal to the pres-
and is led to the LS circuit PLS and to the sure of the spring chamber PLSl. The pump
spring chamber PLSl. discharge pressure PP reduced at the notch d
l At the time, the LS circuit PLS is connected to comes to the actuator circuit pressure A and
the tank circuit T from the LS bypass plug (4). is led to the LS circuit PLS.
PC128US-2 1o-55
STRUCTURE AND FUNCTION CLSS
2. Travel valve
Operation
l When the spool (1) is operated, the pump dis-
charge pressure PP will be led to the actuator
circuit A through the bridge passage b from
the flow control valve (2) and the spool notch
a.
l At the same time, the actuator circuit pres-
sure PA moves the pressure reducing valve
(3) to the right side, and the notches c and d
interconnect to the travel junction circuit e and
the LS circuit PLS respectively.
l So, the actuator circuit pressure PA (= A) is
led from the notch c to the LS circuit PLS
through the notch d.
J, The travel circuit is different from the work
equipment circuit, the actuator circuit pres-
sure PA is directly led to the LS circuit PLS.
LS BYPASS PLUG
Function
l This plug released residual pressure of the LS
pressure PLS.
- This plug slows the rising speed of the LS
pressure PLS, causes pressure losses at the
spool and the throttle of the shuttle valve by
the discarded throttled flow and reduces the
effective LS differential pressure for higher
safety.
PL
SDP03740
PC128US-2 1o-57
STRUCTURE AND FUNCTION CLSS
Aa
\ t
(Comensaed
PP
1 O-58 PC128US-2
STRUCTURE AND FUNCTION CLSS
Operation
l When the load pressure of another actuator
side (the upper side) rises during a compound
operation, the flow in the actuator circuit A
on this side (the lower side) is apt to increase..
l In this case, the LS pressure PLS of another
actuator is applied to the spring chamber PLSl
and pushes the pressure reducing valve (1)
and the flow cont;ol valve (2) to the left side.
l The flow control valve (2) throttles the open-
ing area between the pump circuit PP and the
spool upstream PPA and causes a pressure
loss between PP and PPA.
l 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 reduc-
ing valve (1) and PLS becomes the same as
the pressure loss between PP before and af-
ter the flow control valve and PPA.
l So, the pressure differences between the up-
stream pressures PPA and the downstream
pressures PA of the both spools under com-
pound operation become the same, and the
pump flow is distributed in proportion to the
opening area of each spool notch a.
‘..
T T
9JUOOl26
1. At boom raise
9JUOOl27
Operation
l. When the boom is raised, the main pressure
from the control valve will push the poppet
(5) upward. And the main pressurized oil from
the control valve will flow to the boom cylin-
der bottom through the valve inside.
PC128US-2
lo-61
STRUCTURE AND FUNCTION CLSS
9JUOO128
Operation
0. When the control lever is returned to NEU-
TRAL’while the boom is raised, the holding
pressure on the boom cylinder bottom is con-
fined with the poppet (5). At the same time,
the pressurized oil flown in the inside through
the orifice a is confined with the pilot spool
(3). Then, the boom is held neutral.
3. At boom lower
9JUOOl29
Operation
l When the boom is lowered, the pilot pressure
Pl from the PPC valve will push the pilot spool
(3) and drain pressurized oil from the b cham-
ber inside the poppet.
l The pressurized oil from the boom cylinder
“bottom raises the oil pressure in the Ab port
but reduces the pressurized oil in the b cham-
ber through the orifice a.
l When the pressure in the b chamber drops
below the pressure in the Aa port, the poppet
(5) will open, and the pressurized oil from the
Ab port will be led to the Aa port and flow in
the control valve.
9JUOOl30
9JUOOlJI
Operation
l When the boom is lowered and is in the load l At the time, the head side pressure B and the
process, the head side pressure B of the boom spring (4) close the check valve (3), and the
cylinder (1) rises above the bottom side pres- circuits on the head side and the bottom side
sure A. are interrupted.
PC128US-2 lo-65
STRUCTURE AND FUNCTION CLSS
T PLS
9JUOO132
2. At arm in process
Function
When the bottom pressure B of the cylinder
l
9JUOO133
SJPO7615
Function
l When the L.H. and R.H. travel spool is oper-
ated to compensate flow errors in the L.H. and
R.H. travel circuits during straight travel, the
junction circuit will open.
l Then, the flows to the L.H. and R.H. travel mo-
tors will become the same during the straight
travel, and travel deviation will decrease.
l At the time of steering, load pressure differ-
ence brings back the pressure reducing valve.
of the travel valve inside the steering and
closes the spool notch opening of the travel
junction valve to close the junction circuit for
steering.
Operation
l When the L.H. and R.H. travel spool (1) is op-
erated, the pump delivery will flow from the
pump circuit PP to A through the actuator cir-
cuit PA.
l When traveling straight, the actuator circuit
PA will be equalized and the L.H. and R.H.
pressure reducing valves (2) will be pressed
the same stroke to the right. Then, the notch
a and the junction circuit will open.
* The L.H. travel forward oil pressure P7 and
the R.H. travel forward oil pressure P2 are led
to the spring chamber on the both end of the
travel junction valve spool (4) through the re-
spective shuttle valves (5). So, PI = P2, and
the spool is at the neutral position, and the
notch d is ?open?.
l Then, the L.H. and R.H. travel actuator circuits
are interconnected with the junction circuit.
When any difference occurs in the flows to
the L.H and R.H. travel motors, this valve will
compensate them and will reduce occurrence
of travel deviations.
SJPO7616
Operation
l- When the L.H. travel spool (L.H. 1) is returned
to the neutral side from the straight traveling
state and the steering is operated, there will
occur any difference in the load pressures in
the L.H. and RH. travel actuator circuits PA
(R.H. A > L.H. A).. The LS pressure PLS will
become the same as the R.H. A on the higher
load pressure side.
l Therefore, the flow control valve on the L.H..
travel side is pressed to the left side with the
LS pressure PLS, i.e., the load pressure on the
R.H. travel side, and the notch a closes to in-
terrupt the L.H. and R.H. travel circuits. Also,
since the pressures in the spring chambers
on the both ends of the travel junction valve
spool (4) become different and Pl becomes
higher than P2, the spool (4) moves to the Pl
side and the notch d closes. Then, the steer-
ing can be operated.
- The damper is provided to relax the transi-
tion characteristics of the junction circuit at
the time of abrupt operation.
Function
• When an actuator is operated during travel,
this circuit will increase the discarded throttled
flow of the LS circuit PLS, lessens the pres-
sure compensation accuracy of the travel cir-
cuit and limits reduction of the travel speed
to small extent.
• The bypass circuit is closed in case of inde-
pendent travel or independent operation of
an actuator.
Operation
• When the boom spool (1) is operated, the LS
circuit PLS will come to the same pressure as
the boom circuit pressure A1.
• At the same time, the LS circuit pressure PLS
is led to the spring chamber PLS1 of the pres-
sure reducing valve (2) of the travel valve.
• Since the travel spool is not operated, the
travel actuator circuit PA is closed and the
check valve (4) inside the flow control valve
(3) is also closed.
• Therefore, the travel LS bypass circuit is
closed in case of independent operation of the
boom.
PC128US-2 10-73
(18)
STRUCTURE AND FUNCTION CLSS
9JYOOO2
STRUCTURE AND FUNCTION CLSS
Operation
When the boom spool (1) is operated, the LS
circuit PLS will come to the same pressure as
the boom circuit pressure Al.
Since the actuator circuit pressure is gener-
ally higher at boom RAISE than during travel
(Al > A2), the pressure in the spring chamber
PLSl of the flow control valve (3) on the travel
side is higher than the travel circuit pressure
PA. 4.
So, the pressure reducing valve (2) moves to
the left side, and the LS pressure of the spring
chamber PLSl pushes the check valve (4) from
the orifice a to open it and flows, to the travel
circuit PA through the passages b and c.
Therefore, when the LS circuit pressure PLS,
which has been as high as the boom circuit
pressure Al, flows to the travel circuit AZ, the
pressure will drop.
PR
I:
I:
Pl
kla I--
A-4
9JUOOO62
Pl : From pump
PR : Supply to solenoid valve, PPC valve and EPC
valve, .
T : To hydraulic tank
A-A
9JUOOO63
PC128US-2 1 O-85
STRUCTURE AND FUNCTION SELF PRESSURE REDUCING VALVE
---__-_____-_
Function
MIN3. 66MPa
l The self pressure reducing valves reduces the I-
PI Pork PI Port
discharge pressure of the main pump and -
P, Port
T Port
Hydraulic circuit
SVP07622
Operation
l The spring (6) pushes the poppet (5) t the seat,
and the circuit between the ports PR and T is
closed.
- The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports PI and
PR is open.
l The spring (3) pushes the valve (2) to the left
side, and the circuit between the ports Pl and
P2 is closed.
lo-86 PC 128W2
STRUCTURE AND FUNCTION SELF PRESSURE REDUCING VALVE
SVP07623
2. At neutral and reduction of load pressure P2 (at own weight fall in boom LOWER and arm IN)
Note : When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.
SVP07624
Operation
l The spring (3) and the PR pressure (0 MPa (0 l Therefore, there will occur a differential pres-
kg/cm2} at the time of engine stop) pushes sure around the hold a in the spool (8) and
the valve (2) in the direction to close the cir- the spool will move in the direction to close
cuit between the ports PI and P2. When the the port Pl and the PR opening. Then, the PI
hydraulic oil enters the Pl port, the expres- pressure is reduced and adjusted to a certain
sion (Pl pressure + Spring (7) force + (pld area pressure (set pressure) with the opening and
x PR pressure)) holds, and the self pressure is supplied as the PR pressure.
reducing valve will adjust the openings of the
ports Pl and P2 so that the Pl pressure can
be maintained higher than the PR pressure.
l When the PR pressure rises above the set
pressure, the poppet (5) will open and the hy-
draulic oil flows through the route from the
PR port, the hole a in the spool (81, the pop-
pet (5) opening to the tank port T.
1O-88 F’C128US-2
STRUCTURE AND FUNCTION SELF PRESSURE REDUCING VALVE
-Q Servo
SVPO7626
Operation
l When the load pressure P2 rises due to dig- l When the PR pressure rises above the set
ging*or other operations, the pump delivery pressure, the poppet (5) will open and the hy-
will increase and the Pl pressure will rise. draulic oil will flow through the route from
Then, the expression (PI pressure > Spring the PR port, the hole a in the spool (81, the
(7) force + ($d area x PR pressure)) will hold, poppet (5) opening to the tank port T.
and the valve (2) will move to the right side l Therefore, there will occur a differential pres-
..till the stroke end. As a result, the opening sure around the hold a in the spool (8) and
between the ports Pl and P2 will increase, the the spool will move in the direction to close
passage resistance will become smaller to the port P1 and the PR opening. Then, the Pl
reduce engine loss horsepower. pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and
is supplied as the PR pressure.
f’C128US-2 lo-89
STRUCTURE AND FUNCTION SELF PRESSURE REDUCING VALVE
I” 9
SVP07626
Operation
l When the PR pressure of the self pressure re-
ducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports PR + T so as to reduce the PR
pressure. Then, the equipment (PPC valve,
solenoid valve, etc.), to which the oil pressure
is supplied, is protected from the abnormal
high pressure.
PC128US-2 10-91
A
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
10-92 PC128US-2
A
STRUCTURE AND FUNCTION TRAVEL MOTOR
34
B-B
9JA01339
Specification
OUTLINE
Travel speed selection
PC128US-2 10-95
(18)
STRUCTURE AND FUNCTION TRAVEL MOTOR
OPERATION
Operation of motor
At slow speed (the motor swash plate angle is maximized.)
10-96 PC128US-2
2
STRUCTURE AND FUNCTION TRAVEL MOTOR
PC128US-2 10-97
2
STRUCTURE AND FUNCTION TRAVEL MOTOR
10-98 PC128US-2
(18)
STRUCTURE AND FUNCTION TRAVEL MOTOR
SJP07629
Safety valve
Function
l When stopping a travel (or traveling down-
hill), the counterbalance valve (5) will close
the inlet and outlet circuits of the motor. Since
the motor keeps rotating by inertia, however,
the pressure on the outlet side of the motor
will rise abnormally and the motor and pipes’
may be damaged. Then, the safety valve leads
the abnormally high-pressure to the inlet side
of the motor to prevent the equipment from
being damaged.
Operation
When the pressurized oil being supplied from
the PA port is stopped flowing at the time of
travel stop, the return spring (4) will return
the counterbalance valve (5) from the right
side to the left side (the neutral position).
Though the counterbalance valve (5) closes
the a chamber on th:e outlet side circuit, the
inertia lets the motor rotate and the pressure
in the a chamber rises.
The highly pressurized oil in the a chamber
passes through the throttle b of the safety
valve (6a) and enters in the d chamber from
SJPO7631
the c chamber. The pressurized oil entered
in the d chamber moves the piston (32) to the
left side. Meantime, the safety valve (6a) is
pushed to open by the pressurized oil in the a
chamber, and the pressurized oil in the a
chamber flows in the f chamber through the
e port. Therefore, the pressurized oil in the a
chamber flows in the f chamber at a compara-
tively slow speed to control the pressure in
the a chamber and also to prevent cavitation
in the f chamber at the same time.
When the piston (32) reaches the stroke end,
the pressures in the d and c chambers will
rise, the safety valve (6a) will be closed again
and the pressure in the a chamber will rise
further.
d
Then, the safety valve (6b) will open and the
pressurized oil in the a chamber will flow in
the f chamber from the g chamber. The pres-
sure in the a chamber can be controlled in
two stage as mentioned above, and the hy-
draulic motor can be smoothly braked to stop. 32
SJP07632
10-100 PC128US-2
STRUCTURE AND FUNCTION TRAVEL MOTOR
SJPO7633
5i?
Control valve
M
SJP07634
SWING MOTOR
TYPE : KMF40ABE-3
9JUOOO70
16 17
ii is
c-c 9JUOO102
SWING BRAKE
1. When solenoid valve is demagnetized
Operation
l When the solenoid valve of the swing brake
is demagnetized, the pressurized oil from the
control pump will be interrupted and the B
port will be connected to the tank circuit.
l Then, the’brake piston (7) will be pressed
downward with the_.brake spring (8) and will
push the disc (4) and the plate (5) to work the
brake.
SJP07636
SJPO7636
II
0
--I_-_-
_-J
:____
1 2 3 4 MA Tl
T2 MB
Z 9JUOOO72
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)
MA : Port
MB : Port
Tl : Port
T2 : P&t
PC128US-2 10-105
STRUCTURE AND FUNCTION SWING MOTOR
ME pr essure
Time t
SJPO7637
Function
This function is used for reducing swjng back
l
SOP02036
SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND 2-STAGE
RELIEF SOLENOID VALVE.
Al A4 A3 7i2
A-A to i
B-B
9JA01353
Check valve
11. Plug
12. Spring
13. Plunger
Operation
When solenoid is “demagnetized”
l The coil (6) remains demagnetized as long as
signal current to it is stopped..
l Thus, the spool (8) is pushed leftward by the
spring (IO).
l Since ports P to A are closed by this spool,
#ztiva
flow of. pilot.oil pressure to the actuator is
blocked. At the same time, oil from the ac- t
tuator is lead from A port to T port, then:
drained to the hydraulic oil tank.
SJPO7636
SJPO7639
PPiACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
‘\ 5.
6.
Bladder
Oil port
SBPOO290
Specifications
Gas used : Nitrogen gas
Gas capacity : 0.3 e
Charged gas pressure :
1.18 MPa (12 kg/cm*) at 80°C
Maximum operating pressure :
6.86 MPa (70 kg/cm*)
1. Cap
2. Core
3. Guard rubber
4. Lid
5. Plug
6. Shell
Specification
Type of gas : Nitrogen gas
Gas valume : 0.48 ¬
Sealed gas pressure : 0.1 MPa {1 kg/cm2}(at 80 ºC)
Max. actuating pressure : 6.86 MPa {70 kg/cm2}
1. Cap
2. Gas plug
3. Plug
4. Shell
Specification
Type of gas : Nitrogen gas
Gas valume : 0.5 ¬
Sealed gas pressure :
5.88 MPa {60 kg/cm2}(at 80 ºC)
Max. actuating pressure : 20.6 MPa {210 kg/cm2}
PC128US-2 10-111
C
STRUCTURE AND FUNCTION PPC VALVE
Operation
1. In the neutral mode
l Pl and P2 ports of the operation valves A and
Band the PPCvalve are connected to the drain
room D via the fine control hole on the spool
(1).
10-l 14 PC 128US-2
STRUCTURE AND FUNCTION PPC VALVE
(Fio 41
SEP02572
F’C128US-2 10-115
STRUCTURE AND FUNCTION PPC VALVE
FOR TRAVEL
10-116 PC128US-2
(15)
STRUCTURE AND FUNCTION PPC VALVE
PC128US-2 10-117
(15)
STRUCTURE AND FUNCTION PPC VALVE
10-117-1 PC128US-2
(15)
STRUCTURE AND FUNCTION PPC VALVE
Operation
1. In the neutral mode
• P1 and P2 ports of the operation valves A, B
and PPC valve are connected to the drain
room D via the fine control hole f on the spool
(1).
10-118 PC128US-2
STRUCTURE AND FUNCTION PPC VALVE
PC128US-2 10-119
(15)
STRUCTURE AND FUNCTION PPC VALVE
10-120 PC128US-2
(15)
STRUCTURE AND FUNCTION PPC VALVE
Operation
1. In the neutral mode
l PI and P2 ports of the operation valves A, B
and PPC valve are connected to the drain
room D via the fine control hole f on the spool
(1).
SJPO7648
SJPO7649
PC128US-2 10-122-1
C
STRUCTURE AND FUNCTION BOOM HYDRAULIC DRIFT PREVENTION VALVE
10-122-2 PC128US-2
(15)
STRUCTURE AND FUNCTION ARM HYDRAULIC DRIFT PREVENTION VALVE
10-122-6 PC128US-2
(15)
STRUCTURE AND FUNCTION ARM HYDRAULIC DRIFT PREVENTION VALVE
Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the
oil from flowing back from the work equipment
cylinder to prevent sudden fall of the work equip-
ment.
Operation
1. When work equipment is in neutral
[When piping is normal]
• Check valve (5) is closed by the work equip-
ment cylinder holding prssure applied
through port CY to chamber b.
• When the work equipment is in neutral, no
pilot pressure is applied from the PPC valve
to port Pi. Accordingly, pilot spool (1) is moved
to the left end by the force of springs (2) and
(3), then chambers a and b are shut off from
each other.
• By this operation, oil does not flow between
the main valve and the work equipment cyl-
inder, thus the work equipment cylinder is
held.
• If the pressure in the work equipment cylin-
der rises high abnormally, work equipment
cylinder holding pressure operates safety
valve (4).
PC128US-2 10-122-7
C
STRUCTURE AND FUNCTION ARM HYDRAULIC DRIFT PREVENTION VALVE
10-122-8 PC128US-2
(18)
STRUCTURE AND FUNCTION ARM HYDRAULIC DRIFT PREVENTION VALVE
PC128US-2 10-122-9
C
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING
10-123-1 PC128US-2
(18)
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING
PC128US-2 10-123-2
(18)
STRUCTURE AND FUNCTION ELECTRIC COMPONENT LAYOUT
PC128US-2 10-125
(15)
STRUCTURE AND FUNCTION ELECTRIC COMPONENT LAYOUT
PC128US-2 10-127
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
PC128US-2 10-128-1
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
10-128-2 PC128US-2
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
PC128US-2 10-132-1
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
PC128US-2 10-132-3
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
START OF ENGINE
• When the starting switch comes to the ON po-
sition, the engine stop solenoid (16) drives the
governor stop lever to the "RUN" side. A fail-
safe mechanism has been adopted that stops
the engine when an abnormality occurs in the
electrical system.
• When the safety lock lever (7) comes to the
"LOCK" position and the starting switch (4)
comes to the START position, a start signal
flows to the starting motor and the engine
starts. When the safety lock lever is set to
the "FREE" position, the starting motor cut re-
lay (9) interrupts the start signal to the start-
ing motor (7) and the engine cannot start.
• At the time, the fuel control dial (11) is linked
to the fuel control motor (12), and the engine
speed comes to the speed set with the fuel
control dial (11).
STOP OF ENGINE
• When the starting switch (4) comes to the OFF
position, the engine stop solenoid (18) drive
the governor stop lever to the "STOP" side and
the engine stops.
10-132-4 PC128US-2
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
AUTO-DECELERATOR
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
I/O Signals
a. Controller power supply e. PPC oil pressure switch signal
b. Solenoid power supply f. Throttle signal
c. Monitor panel power supply g. Fuel control motor drive signal
d. S-NET signal h. Potentiometer signal
PC128US-2 10-132-5
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
FUNCTION
• When the all control levers are set to NEU-
TRAL for waiting for a dump track or work,
the engine speed is automatically reduced to
a medium speed, and fuel consumption and
noise are lowered.
• When the control lever is operated, engine
speed returns immediately to the speed that
is set with the fuel control dial (7).
OPERATION
PC128US-2 Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 – 1500
When the control lever is set to NEUTRAL,
• If the all control levers are set to NEUTRAL
while the engine is running at faster speed
than the decelerator operating speed (1,400rpm
approx.), the engine speed lowers immedi-
ately to the 1st deceleration speed, about
200rpm slower than the speed that is set with
the fuel control dial.
• When 4 sec. elapses, the engine speed low-
ers again to the 2nd deceleration speed (about
1,400rpm) and the speed that is kept until the
control lever is operated next time.
10-132-6 PC128US-2
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
PC128US-2 10-132-7
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
SYSTEM COMPONENTS
FUEL ADJUST DIAL
PC128US-2 Serial No.: 5001 – 7730
PC128US-2 10-133
(14)
STRUCTURE AND FUNCTION ENGINE CONTROL
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The potentiometer (5) is installed under the
knob (1) below the monitor panel. When the
knob is turned, the shaft of the potentiometer
(5) rotates.
• When the shaft rotates, the resistance value
of the variable resistor in the potentiometer
(5) changes and any throttle signal is sent to
the controller.
10-133-1 PC128US-2
(15)
STRUCTURE AND FUNCTION ENGINE CONTROL
1. Cable
2. Connector
3. Potentiometer
4. Pulley
5. Gear unit
6. Motor
Input/Output signal
DEUTSCH-6P [CN-M48]
Pin No. Signal name I/O signal
1 Potentiometer input Input
2 Potentiometer output Output
3 Potentiometer GND —
4 NC —
5 Motor (+) Input
6 Motor (–) Input
PC128US-2 10-134-1
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
10-136-2 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Resistor (for driving pump in an emergency)
8. Emergency pump drive switch
9. Swing holding brake release switch
10. Swing lock switch
11. Safety lock lever
12. PPC lock witch
13. Starting motor cut relay
14. Safety relay
15. Fuel control motor relay (for driving)
16. Fuel control motor relay (for acceleration)
17. Fuel control motor relay (for deceleration)
18. Fuel control dial
19. Fuel control motor
20. Monitor panel
21. Hydraulic pump pressure sensor
22. Travel/swing alarm (option)
23. PPC lock solenoid valve
24. Travel speed selector solenoid valve
25. Swing holding brake solenoid valve
26. 2-stage relief solenoid valve
27. LS-EPC valve
28. PC-EPC valve
29. R.H. work equipment PPC valve
30. Travel PPC valve
31. L.H. work equipment PPC valve
32. Blade PPC valve (Blade specification)
33. Boom RAISE PPC oil pressure switch
34. Travel PPC oil pressure switch
35. Arm IN PPC oil pressure switch
36. Swing PPC oil pressure switch
37. Work equipment control lever
PPC oil pressure switch
38. Engine stop solenoid
39. Starting motor
40. Engine speed sensor
41. Coolant temperature sensor
42. Hydraulic pump
42a. Servo piston
42b. LS valve
42c. PC valve
43. Control valve
43a. Self pressure reducing valve
43b. Main relief valve
44. Travel motor
45. Swing motor
PC128US-2 10-136-3
A
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
10-136-4 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Resistor (for driving pump in an emergency)
8. Emergency pump drive switch
9. Swing holding brake release switch
10. Swing lock switch
11. Safety lock lever
12. PPC lock witch
13. Starting motor cut relay
14. Safety relay
15. Engine stop solenoid relay
16. Fuel control motor relay (for acceleration)
17. Fuel control motor relay (for deceleration)
18. Fuel control dial
19. Fuel control motor
20. Monitor panel
21. Hydraulic pump pressure sensor
22. Travel/swing alarm (option)
23. PPC lock solenoid valve
24. Travel speed selector solenoid valve
25. Swing holding brake solenoid valve
26. 2-stage relief solenoid valve
27. LS-EPC valve
28. PC-EPC valve
29. R.H. work equipment PPC valve
30. Travel PPC valve
31. L.H. work equipment PPC valve
32. Blade PPC valve (Blade specification)
33. Boom RAISE PPC oil pressure switch
34. Travel PPC oil pressure switch
35. Arm IN PPC oil pressure switch
36. Swing PPC oil pressure switch
37. Work equipment control lever
PPC oil pressure switch
38. Engine stop solenoid
39. Starting motor
40. Engine speed sensor
41. Coolant temperature sensor
42. Hydraulic pump
42a. Servo piston
42b. LS valve
42c. PC valve
43. Control valve
43a. Self pressure reducing valve
43b. Main relief valve
44. Travel motor
45. Swing motor
46. Heater relay
47. Air heater
PC128US-2 10-136-5
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output signals
a. Controller power supply e. PC-FPC valve drive signal
b. Solenoid power supply f. LS-FPC valve drive signal
c. Monitor panel power supply g. Coolant temperature signal
d. S-NET signal h. Engine speed signal
PC128US-2 10-138-1
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Function
• This function is for selecting any of the three
working modes "A," "B" and "E" with the work-
ing mode selector switch on the monitor
panel. The controller can select optimum
engine torques or pump absorption torques
for works to be expected.
10-138-2 PC128US-2
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Mode A
• Matching point in Mode A
PC128US-2 Serial No.: 5001 and up
66.2 kW/2,200 rpm
PC138USLC-2 Serial No.: 1001 – 1500 Mode A
{88.7 HP/2,200 rpm}
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
• When a load to the pump increases and the
pressure rises and the engine speed lowers.
At the time, the controller reduces the pump
delivery so that the speed lowers to the speed
at the full output point or so. If the pressure
drops on the contrary, the controller increases
the pump delivery so that the speed comes
to the speed at the full output point or so.
The controller repeats these controls so that
the engine can always be used at speeds at
the full output point or so.
PC128US-2 10-138-3
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
10-138-4 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output Signals
a. Controller power supply
b. Solenoid power supply
c. Solenoid valve drive signal
d. Travel PPC oil pressure switch signal
Function
2-stage relief
• The relief pressure in the normal operation is
Condition Relief pressure
31.9 MPa {325 kg/cm2}, and the relief pressure
rises to 34.8 MPa {355 kg/cm2} when the 2-
31.9 MPa {325 kg/cm2}
stage relief function is operated. Therefore, During travel ↓
the oil pressure will rise more.
34.8 MPa {355 kg/cm2}
10-139-1 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
FUNCTION
Swing lock, swing holding brake
• Swing lock holds swing at any position, and
swing holding brake works to prevent swing
drift.
fl Be careful when using the machine in this
condition. When the swing holding brake is
released, the swing is held only by a brake
operated hydraulically by the swing safety
valve, so therre may be hydraulic drift when
the swing is stopped on a slope.
fl Release the swing holding brake also during
arm IN operations.
Swing Swing
lock lock Function Operation
switch lamp
PC128US-2 10-141
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Swing
Swing Swing Swing holding
Swing brake lock lock lock
breake
operates released operates
operates
10-142 PC128US-2
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output Signals
a. Controller power supply e. Solenoid valve drive signal
b. Solenoid power supply f. Swing PPC oil pressure switch signal
c. Monitor panel power supply g. Arm IN PPC oil pressure switch signal
d. S-NET signal h. Alarm operation signal
PC128US-2 10-142-1
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output signals
a. Controller power supply e. Solenoid valve drive signal
b. Solenoid power supply f. Engine speed signal
c. Monitor panel power supply g. Pump pressure signal
d. S-NET signal h. Alarm operation signal
10-143-1 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
FUNCTION
Travel Speed Selection
PC128US-2 10-143-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Travel speed
(km/h) 2.9 5.1
10-143-3 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
PC128US-2 10-143-4
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
10-143-5 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output signals
a. Power supply of controller
b. Power supply of solenoids
c. Solenoid valve driving signals
Function
• PPC lock switch works with safety lock lever.
Setting safety lock lever to "Lock", PPC lock
switch turns to "OFF".
• Turning PPC lock switch to "OFF" shuts off cur-
rent to PPC lock solenoid valve, making op-
eration lever on the work equipment disabled.
PC128US-2 10-144-1
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Function
• If the pressure in the boom cylinder bottom
circuit rises above the set value, the caution
lamp lights up and the buzzer sounds to no-
tify the operator of possibility of tipping over
of the machine by an overload.
10-144-2 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output signals
a. Power supply of controller g. Throttle signal
b. Power supply of solenoids h. Potentiometer signal
c. Power supply of monitor panel i. Fuel control motor driving signal
d. S-NET signal j. Acceleration signal
e. EPC valve driving signal k. Deceleration signal
f. Coolant-temperature signal
PC128US-2 10-144-3
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output signals
a. Power supply of controller h. Engine speed signal
b. Power supply of solenoids i. Throttle signal
c. Power supply of monitor panel j. Potentiometer signal
d. S-NET signal k. Acceleration signal
e. EPC valve driving signal l. Deceleration signal
f. Heater drive signal m. Starting switch C signal
g. Coolant-temperature signal n. Preheating pilot signal
10-144-4 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
PC128US-2 10-144-5
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
10-144-6 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
PC128US-2 10-144-7
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
SYSTEM COMPONENTS
ENGINE SPEED SENSOR
Function 1. Wire
PC128US-2 Serial No.: 5001 – 7730 2. Magnet
• The engine speed sensor is installed on the 3. Terminal
ring gear of the engine flywheel. It electri- 4. Housing
cally counts number of gear teeth that pass 5. Connector
its front side and sends the counting to the
pump controller.
PC128US-2 10-145
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Specification 1. Plug
Contact structre : Normally opened 2. Switch
Operating (ON) pressure : 3. Connector
490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure :
294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function
PC128US-2 Serial No.: 5001 – 7730
• 3 switches installed to control valve sense
operating condetion of each actuator, and
send it to swing holding brake controller.
• 1 switch installed to travel PPC valve sense
travel operating condition, and operates 2-
stage relief solenoid valve.
10-146 PC128US-2
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Specifications
Composition of contacts: Normally open contacts
Operating (ON) pressure:
14.7 ± 0.98 MPa {150 ± 10 kg/cm2}
Function
• One pressure switch is installed to the boom
cylinder bottom circuit to sense the hydraulic
pressure on the boom cylinder bottom side.
PC128US-2 10-146-1
A
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
1. Plug
2. Sensor
3. Connector
Function
• One pressure switch is installed to the boom
cylinder bottom circuit to sense the hydraulic
pressure on the boom cylinder bottom side.
10-146-2 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
CONTROLLER
PC128US-2 Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 – 1500
Slide arm c c ×
Multi changer arm × × ×
c : GND
× : OPEN
10-147-3 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
10-147-5 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Input/Output signals
DEUTSCH-24P [CN-CR1]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 Fuel control motor feedback potentiometer Input 14 Off-set angle (For PC128UU) Input
2 Boom cylinder bottom pressure sensor Input 15 NC —
3 Boom angle Input 16 NC —
4 GND (signal) — 17 C-terminal signal Input
5 Air conditioner compressor signal Input PPC hydraulic pressure switch for boom
18 LOWER Input
6 PPC hydraulic pressure switch for Arm IN Input
7 Fuel control dial Input 19 NC —
8 Swing boom angle sensor Input 20 Arm angle (For arm crame) Input
9 NC — 21 GND (analog) —
10 GND (signal) — 22 Power supply for sensor (+5V) Output
11 Preheating signal Input 23 ACC terminal signal Input
12 PPC hydraulic pressure switch for Arm out Input 24 PPC hydraulic switch for boom RAISE Input
13 Pump pressure sensor Input
PC128US-2 10-147-6
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
1. Sensor
2. Connector
Function
• Mounted on the inlet circuit of control valve,
this sensor changes discharging pressure of
pump into voltage, and send it to automatic
travel speed change controller.
1. Plug
2. Sensor
3. Connector
Function
• Mounted on the inlet circuit of control valve,
this sensor changes discharging pressure of
pump into voltage, and send it to automatic
travel speed change controller.
10-147-7 PC128US-2
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
Monitor panel
fl Refer to the section describing the “Monitor
System”.
PC valve
LS valve
PC-EPC valve
fl Refer to the section describing the “Hydrau-
lic Pump (Piston pump)”.
LS-EPC valve
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
fl Refer to the section describing the “Hydrau-
lic Pump (Piston pump)”.
10-148 PC128US-2
(15)
STRUCTURE AND FUNCTION MONITOR SYSTEM
10-149-1 PC128US-2
(15)
STRUCTURE AND FUNCTION MONITOR SYSTEM
MONITOR PANEL
PC128US-2 Serial No.: 5001 – 7730
Outline
• Monitor panel has monitoring function, gauge • It has LCD display in gauge display position.
display function, service meter function and • It has lamps in monitor display position.
switching function.
• CPU (Central Processing Unit) is installed in
it.
10-150 PC128US-2
(18)
STRUCTURE AND FUNCTION MONITOR SYSTEM
Outline
• The monitor panel has the functions to dis- flat type sheet switches. Pressing any of
play a monitor, gauge, service meter and elec- these switches changes the conditions of
tric system. It has also an alarm buzzer built the machine, which are shown by LEDs lo-
in. cated above the switches turned ON.
• A CPU (Central Processing Unit) mounted in- • The monitor does not give correct display if
side processes, displays and outputs infor- any of the monitor panel unit, controller, or
mation. the wiring between monitor-panel and con-
• The monitor's switch section consists of three troller is in abnormal condition.
Input/Output signals
AMP070-12P [CN-P01] AMP040-20P [CN-P02]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 Starting switch (battery) Input 1 Engine coolant temperature Input
2 Starting switch (battery) Input 2 Fuel level Input
3 Window washer motor output Output 3 Radiator coolant level Input
4 Starting switch (C-terminal) Input 4 NC Input
5 Wiper W-contact Input 5 Air cleaner clogging Input
6 GND — 6 NC Input
7 GND — 7 Engine oil pressure Input
8 VB + (24V) Input 8 Engine oil level Input
9 Wiper motor (+) Output 9 S-NET signal Input/Output
10 Wiper motor (–) Output 10 S-NET signal Input/Output
11 Alarm buzzer ON signal Input 11 Battery charge level Input
12 Wiper P-contact Input 12 NC —
13 GND (analog signal) —
14 NC —
15 Pull-up window limit switch Input
16 Alarm buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Lamp switch Input
20 GND (S-NET) —
10-151-1 PC128US-2
(15)
STRUCTURE AND FUNCTION MONITOR SYSTEM
METER DISPLAY
3a Gauge See picture above All the segments of the corresponding level
and lower are turned ON.
Coolant Specified tempera- (Level 8 (102°C or higher):Monitor lamp
3b Caution temperature ture (102°C) or blinks. Level 9: Monitor lamp blinks and Red LED
higher alarm buzzer sounds.)
4a Gauge See picture above All the segments of the corresponding level Blue LCD
Fuel level Specified level and lower are turned on. (Level 1 (42 ¬ or
4b Caution less): Monitor lamp blinks.) Red LED
(42 ¬) or lower
Turned on for about 30 seconds after start-
ing switch was turned to "HEAT". It blinks
Preheating During preheating (for about 10 seconds) after preheating was
5
over to notify it to operator, and then it is
turned off.
• Turned on when the swing lock function is
Swing lock When swing-lock active.
6 Pilot is in operation • Blinks when swing holding brake release Green
switch was turn on.
• Turned ON when specified oil maintenance
periods (125h, 250, and 500h) elapsed.
Oil When specified (Also, elapsed time and telephone No. of
[*2] oil-maintenance Lamp
7 maintenance your dealer are shown on service meter.)
periods elapsed • Not turned on if no oil maintenance pe-
riod has been specified.
PC128US-2 10-151-2
(15)
STRUCTURE AND FUNCTION MONITOR SYSTEM
MONITOR SWITCH
* You can change the default settings which become active when starting switch is turned on. Refer to the "TROUBLE-
SHOOTING" chapter.
fl Signs written in bold fonts in the "Operation" column above represent the positions switches default to when
starting switched is turned on.
10-151-3 PC128US-2
A
STRUCTURE AND FUNCTION MONITOR SYSTEM
SENSORS
l Signal from a sensor is directly entered to the
panel.
l There are two types of sensors, contact type
and resistance type.
l One end of a contacttype sensor is connected
to the ground on the machine body.
0 69 @
Structure of circuit
SBD01537
@=I3
Structure of circuit
SBDOl538
7. Connector
2. Plug
3. Thermistor
fL
F E EMPTY
Y
Structure of circuit
3 4
SEP02590
1. Float
2. Connector
3. Cover
4. Variable resistor
PC128US-2 10-153
20 TESTING AND ADJUSTING
* Note the following.when making judgments using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine 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.
A 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.
A When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
A When checking the water level, always wait for the water to cool down. If the radiator cap is re-
moved when the water is still hot, the water will spurt out and cause burns.
A Be careful not to get caught in the fan, fan belt or other rotating parts.
Engine S4D102E-1
Standard value
Item Measurement conditions Unit for new machine Service limit value
(Water temperature:
Blow-by pressure Operating range) Pa
(SAE 30 oil) {mm H2O} Max. 490 {50} 980 {100}
At high idling
(Water temperature:
Operating range)
At high idling 343 – 588 {3.5 – 6.0} 245 {2.5}
Oil pressure KPa
(SAE 30 oil) At low idling (SAE30) {kg/cm2}
Min. 9.8 {1.0} 69 {0.7}
At low idling (SAE10W) Min. 78 {0.8} 69 {0.7}
20-2 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Engine SAA4D95LE-3-A
Standard value
Item Measurement conditions Unit for new machine Service limit value
(Water temperature:
Blow-by pressure Operating range) Pa
(SAE 30 oil) {mm H2O} Max. 490 {50} 980 {100}
At high idling
(Water temperature:
Operating range)
At high idling 343 – 588 {3.5 – 6.0} 245 {2.5}
Oil pressure KPa
(SAE 30 oil) At low idling (SAE30) {kg/cm2}
Min. 294 {3.0} 196 {2.0}
At low idling (SAE10W) Min. 245 {2.5} 147 {1.5}
PC128US-2 20-2-1
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Blade LOWER
MPa {330 ± 15} {330 ± 25}
{kg/cm}
34.81 ± 0.98 34.81 ± 1.96
Travel
Target {355 ± 10} {355 ± 20}
value
(Range) 3.24 ± 0.20 3.24 ± 0.49
Control
{33 ± 2} {33 ± 5}
• Hydraulic oil
temperature All levers at 2.75 ± 0.98 —
: 45 – 55 ºC HOLD {28 ± 10} {—}
• Engine at full
LS differential throttle
pressure flLS differential
pressure = Travel rotating
pump outlet under no load 2.21 ± 0.1 —
port pressure – Travel lever at {22.5 ± 1} {—}
LS pressure half-way position
20-4 PC128US-2
(14)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. A
5001 – 6462 2.8 ± 0.3 Max. 3.5
• Engine at full throttle (3.4 ± 0.3) (Max. 4.0)
• Hydraulic oil temperature
: 45 – 55°C 90°
• Time taken to swing 90° and 3.2 ± 0.3 Max. 4.0
180° from starting position 6463 and up (3.9 ± 0.3) (Max. 4.6)
• Figure in ( ) shows time when
Time taken to start bucket is at rated load
swing Sec.
fl See Fig. A
Swing
fl See Fig. B
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C
• Bucket at rated load (450 kg) or full
of soil.
• Set machine on 15° slope, and set
upper structure at an uphill angle of
Hydraulic drift of 45°. Deg. 0 0
swing • Make match marks on swing circle (mm) 5001 and up (0) (0)
outer race and track frame.
• Measure distance that match marks
move apart after 15 minutes.
• Figure in ( ) shows at rated load.
PC128US-2 20-5
(14)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
• Engine stopped
Blade • Hydraulic oil temperature: 45 – 55°C
(hydraulic drift • Set blade at maximum lifting height Max. 31 Max. 47
at tip of blade) and measure downward movement
at edge of blade for 15 minutes.
fl See Fig. I
Arm 3.2 ± 0.3 Max. 4.0
IN
Bucket
Cylinder fully • Engine at full throttle 2.9 ± 0.3 Max. 3.7
retracted • Hydraulic oil temperature
: 45 – 55°C
DUMP
fl See Fig. K
RAISE
Blade
Blade in contact • Engine at full throttle 1.3 ± 0.3 Max. 2.5
with ground • Hydraulic oil temperature
: 45 – 55°C
LOWER
PC128US-2 20-7
(18)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
• Center of lever
Boom control lever
knob N → RAISE, LOWER 85 ± 10 Min.75 Max.95
• Tip of pedal
• Read max. value
Arm control lever
to end of travel N → IN, OUT 85 ± 10 Min.75 Max.95
• Engine stopped
Bucket control lever N → CURL, DUMP 85 ± 10 Min.75 Max.95
Travel of control levers
N → FORWARD,
Travel control lever REVERSE 115 ± 12 Min.103 Max.127
(LEFT, RIGHT)
Work equipment,
3–5 5–8
swing
Play of control lever
Travel 10 ± 3 10 ± 5
PC128US-2 20-8-1
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
+ 1.96
31.87 ± 0.49 31.87 – 0.98
Bucket + 20
{325 ± 5} {325 – 10 }
+ 1.47
27.46 ± 0.98 27.46 – 2.45
Swing {280 +– 25
15
{280 ± 10} }
+ 1.96 + 1.96
31.87 0 31.87 – 0.98
Hydraulic pressure
Blade RAISE + 20
{325 +– 10
20
}
{325 0 }
fl See Fig. A
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
Swing
Overrun when • Stop after swinging one turn and Deg. Max. 65 Max. 75
stopping swing measure distance that swing circle (mm) (Max. 610) (Max. 720)
moves
• Figure in ( ) shows movement at
outside of swing circle
20-8-2 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. A
90° 2.9 ± 0.3 Max. 3.6
• Engine at full throttle (3.6 ± 0.3) (Max. 4.2)
• Hydraulic oil temperature
Time taken to : 45 – 55°C
start swing • Time taken to swing 90° and Sec.
180° from starting position
• Figure in ( ) shows time when 4.0 ± 0.4 Max. 6.0
bucket is at rated load 180° (5.0 ± 0.5) (Max. 6.5)
fl See Fig. A
• Engine at full throttle
Time taken to swing • Hydraulic oil temperature: 45 – 55°C Sec. 25 ± 2 25 ± 4
• Swing one turn, and measure time
taken to swing next 5 turns
Swing
fl See Fig. B
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C
• Bucket at rated load (450 kg) or full
of soil.
• Set machine on 15° slope, and set
Hydraulic drift of upper structure at an uphill angle of Deg. 0 0
swing 45°. (mm) (0) (0)
• Make match marks on swing circle
outer race and track frame.
• Measure distance that match marks
move apart after 15 minutes.
• Figure in ( ) shows at rated load.
fl See Fig. C
• Engine at full throttle Lo Max. 41.6 50.6
• Hydraulic oil temperature
: 45 – 55°C
Travel speed (1) • Raise track on one side at a Sec.
time, rotate one turn, then mea-
sure time taken for next 5 turns
with no load. Hi Max. 26.5 32.6
Travel
fl See Fig. D
• Engine at full throttle Lo Max. 25.3 Max. 30.6
• Hydraulic oil temperature
: 45 – 55°C
Travel speed (2) • Run up for at least 10 m, and Sec.
measure time taken to travel
next 20 m on flat ground.
Hi Max. 15.2 Max. 18.3
PC128US-2 20-8-3
(19)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. D
fl See Fig. E
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
Travel deviation • Run up for at least 10 m, and mea- Max. 200 220
sure deviation when traveling next
20 m on flat ground.
fl Use a hard horizontal surface.
mm
fl See Fig. F
Travel
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C
Hydraulic drift of • Stop machine on 12° slope with
sprocket facing straight up the 0 0
travel
slope.
• Measure the distance the machine
moves in 5 minutes.
Max. 15 Max. 23
retraction of • Hydraulic oil temperature: 45 – 55°C
cylinder) • Start measuring immediately after
setting.
• Measure hydraulic drift every 5 min-
Work equipment
Bucket cylinder
(amount of
Max. 40 Max. 60
retraction of
cylinder)
• Engine stopped
Blade • Hydraulic oil temperature: 45 – 55°C
(hydraulic drift • Set blade at maximum lifting height
and measure downward movement Max. 31 Max. 47
at tip of blade) at edge of blade for 15 minutes.
20-8-4 PC128US-2
(19)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. H
Boom 3.8 ± 0.3
RAISE
Max. 4.4
Bucket teeth in • Engine at full throttle (Until touching (Until touching
contact with • Hydraulic oil temperature cushion) cushion)
ground : 45 – 55°C
LOWER
Cylinder fully 3.1 ± 0.3 Max. 4.2
extended
fl See Fig. I
3.2 ± 0.3 Max. 4.0
IN
Arm • Engine at full throttle (Until touching (Until touching
Cylinder fully • Hydraulic oil temperature cushion) cushion)
retracted : 45 – 55°C
Work equipment speed
Sec.
fl See Fig. J
CURL
DUMP
fl See Fig. K
RAISE
fl See Fig. L
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Fully retract arm and bucket
cylinders, then lower boom from
Time lag
PC128US-2 20-8-5
(18)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. M
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Set top surface of boom horizon-
Arm tal, retract bucket cylinder fully, Max. 2 Max. 2
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.
fl See Fig. N
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
Time lag
fl See Fig. O
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Lower blade from maximum Max. 2 Max. 2
Blade height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.
: 45 – 55 ºC
Eachcylinder • Engine full Max. 3.5 Max. 15
• Circuit to be measured is relieved.
cc/
min
Center swivel
joint Max. 10 Max. 50
20-8-6 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
• Center of lever
Boom control lever
knob N → RAISE, LOWER 100 ± 11 100 ± 21
• Tip of pedal
• Read max. value
Arm control lever
to end of travel N → IN, OUT 100 ± 11 100 ± 21
• Engine stopped
Bucket control lever N → CURL, DUMP 100 ± 11 100 ± 21
Travel of control levers
N → FORWARD,
Travel control lever REVERSE 115 ± 12 Min.103 Max.127
(LEFT, RIGHT)
Work equipment,
3–5 5–8
swing
Play of control lever
Travel 10 ± 3 10 ± 5
PC128US-2 20-8-7
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
+ 1.96
31.87 ± 0.49 31.87 – 0.98
Bucket + 20
{325 ± 5} {325 – 10 }
+ 1.47
27.46 ± 0.98 27.46 – 2.45
Swing {280 +– 25
15
{280 ± 10} }
+ 1.96 + 1.96
31.87 0 31.87 – 0.98
Hydraulic pressure
Blade RAISE + 20
{325 +– 10
20
}
{325 0 }
fl See Fig. A
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
Swing
Overrun when • Stop after swinging one turn and Deg. Max. 65 Max. 75
stopping swing measure distance that swing circle (mm) (Max. 610) (Max. 720)
moves
• Figure in ( ) shows movement at
outside of swing circle
20-8-8 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. A
90° 3.3 ± 0.3 Max. 4.1
• Engine at full throttle (4.1 ± 0.3) (Max. 4.8)
• Hydraulic oil temperature
Time taken to : 45 – 55°C
start swing • Time taken to swing 90° and Sec.
180° from starting position
• Figure in ( ) shows time when 4.6 ± 0.5 Max. 6.4
bucket is at rated load 180° (5.8 ± 0.5) (Max. 7.5)
fl See Fig. A
• Engine at full throttle
Time taken to swing • Hydraulic oil temperature: 45 – 55°C Sec. 28.6 ± 2 28.6 ± 4
• Swing one turn, and measure time
taken to swing next 5 turns
Swing
fl See Fig. B
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C
• Bucket at rated load (450 kg) or full
of soil.
• Set machine on 15° slope, and set
Hydraulic drift of upper structure at an uphill angle of Deg. 0 0
swing 45°. (mm) (0) (0)
• Make match marks on swing circle
outer race and track frame.
• Measure distance that match marks
move apart after 15 minutes.
• Figure in ( ) shows at rated load.
fl See Fig. C
• Engine at full throttle Lo Max. 45 54
• Hydraulic oil temperature
: 45 – 55°C
Travel speed (1) • Raise track on one side at a Sec.
time, rotate one turn, then mea-
sure time taken for next 5 turns
with no load. Hi Max. 26.9 32.3
Travel
fl See Fig. D
• Engine at full throttle Lo Max. 26.1 Max. 31.4
• Hydraulic oil temperature
: 45 – 55°C
Travel speed (2) • Run up for at least 10 m, and Sec.
measure time taken to travel
next 20 m on flat ground.
Hi Max. 14.9 Max. 18
PC128US-2 20-8-9
(19)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. D
fl See Fig. E
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
Travel deviation • Run up for at least 10 m, and mea- Max. 200 220
sure deviation when traveling next
20 m on flat ground.
fl Use a hard horizontal surface.
mm
fl See Fig. F
Travel
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C
Hydraulic drift of • Stop machine on 12° slope with
sprocket facing straight up the 0 0
travel
slope.
• Measure the distance the machine
moves in 5 minutes.
Max. 15 Max. 23
retraction of • Hydraulic oil temperature: 45 – 55°C
cylinder) • Start measuring immediately after
setting.
• Measure hydraulic drift every 5 min-
Work equipment
Bucket cylinder
(amount of
Max. 40 Max. 60
retraction of
cylinder)
• Engine stopped
Blade • Hydraulic oil temperature: 45 – 55°C
(hydraulic drift • Set blade at maximum lifting height
and measure downward movement Max. 31 Max. 47
at tip of blade) at edge of blade for 15 minutes.
20-8-10 PC128US-2
(19)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. H
Boom 3.8 ± 0.3
RAISE
Max. 4.4
Bucket teeth in • Engine at full throttle (Untill touching (Untill touching
contact with • Hydraulic oil temperature chshion) chshion)
ground : 45 – 55°C
LOWER
Cylinder fully 3.1 ± 0.3 Max. 4.2
extended
fl See Fig. I
3.2 ± 0.3 Max. 4.0
IN
Arm • Engine at full throttle (Untill touching (Untill touching
Cylinder fully • Hydraulic oil temperature chshion) chshion)
retracted : 45 – 55°C
Work equipment speed
Sec.
fl See Fig. J
CURL
DUMP
fl See Fig. K
RAISE
fl See Fig. L
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Fully retract arm and bucket
cylinders, then lower boom from
Time lag
PC128US-2 20-8-11
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl See Fig. M
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Set top surface of boom horizon-
Arm tal, retract bucket cylinder fully, Max. 2 Max. 2
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.
fl See Fig. N
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
Time lag
fl See Fig. O
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Lower blade from maximum Max. 2 Max. 2
Blade height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.
: 45 – 55 ºC
Eachcylinder • Engine full Max. 3.5 Max. 15
• Circuit to be measured is relieved.
cc/
min
Center swivel
joint Max. 10 Max. 50
20-8-12 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
fl As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average
pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
fl When measuring 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 measurement, and use them as a base for calculating the pump discharge
amount at the specified speed.
PC128US-2 20-11
(18)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
.-?
_s If the condition is as shown in the table 1) Turn starting
below, it is normal switch OFF.
P
2) Disconnect
Between (I I- (2) 500 - 1000 sz
connector.
Between (I), (2) -chassis Min. 1 MQ
-
Inspec-
j
n1
Name of
component l-
Cloyector
I”“.
tion
I method I
Judament table
Measurement
con’ditions
I
the condition is as shown in Table 1 and Table 2, the monitor 1 ) Connect T
mel is normal. adapter.
ble 1 (CHECK, CAUTION section)
ON Max. 1V
.ngin;;if6 ;;pssure Engine started
:HECK, CAUTION OFF 20-30V
ection
Battery charge
Engine started
CN6 (IO)
9.47 - Disconnection
Min. - Max.
(Q)
Right I 0 - 15.7 I
side
Measure
resistance
between fuel T151
level gauge
CN6 (female)
(7) - (3)
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS PARTS
I I I’ I
If the condition is as shown in the table
Coolant temperature
sensor
Measure voltage
Because normal power 2) Insert T-adapter.
supply is used between 3) Turn starting
Power supply voltage CR3 CR3 (1), (21) and chassis, switch ON.
voltage is applied even in 20 – 30 V
starting motor switch
OFF state.
Between CR3 (2), (12),
(22) and chassis
1) Turn starting
below, it is normal switch ON.
At standard 2) Insert T-adapter.
Kerosene mode CR2 Between 4–6V
mode
(6) –
At kerosene chassis 0–1V
mode
20-16 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Measure voltage
supply is used between 3) Turn starting
CR3 [1], [21] and chassis, switch ON.
voltage is applied even in 20 – 30 V
Power supply voltage CR3 starting motor switch
OFF state.
Between CR3 [2], [12],
[22] and chassis
* The voltage can be checked in monitor-
ing mode "1036".
2) Disconnect
At swing brake
Controller
Standard
arm Bit ON Bit OFF Bit OFF
PC128US-2 20-19
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Monitoring
Model/Attachment code
Model selection Standard arm 020
—
Attachment selection
Long arm 021
* The model and attachment codes do not
make difference in performance.
switch ON.
Service
2) Reset safety
Monitoring mode: "1023", bit (5)
Controller
lock lever.
Arm IN pressure switch — 3) Operate work
Arm IN position Bit ON
equipment.
Neutral position Bit OFF
2) Reset safety
Monitoring mode: "1023", bit (4)
lock lever.
Swing pressure switch — 3) Operate work
Swing (Right or left) position Bit ON
equipment.
Neutral position Bit OFF
20-20 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
resistance
Measure
Between (1) – (2) 37 – 60 Ω 2) Disconnect
PPC hydraulic lock
V07 connector.
solenoid Between (1), (2) – chassis Min. 1 MΩ
(male)
PC128US-2 20-21
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
resistance
Measure
Between (1) – (2) 500 – 1,000 Ω 2) Disconnect
connector.
Between (1), (2) – chassis Min. 1 MΩ
2) Insert T-adapter.
Measure
Between (1) – (2) 0.5 – 3.0 V
voltage
20-22 PC128US-2
(17)
TESTING AND ADJUSTING
PC128US-2 20-101
(17)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
07002-11023 O-ring
Oil pressure
C Male, female both 14 x 1.5
• 790-261-1311 (female PT 1/8)
Male, female both 18 x 1.5
• 790-261-1321 (female PT 1/8)
3 Adapter
Male, female both 22 x 1.5
• 790-261-1331 (female PT 1/8)
Male, female both 10 x 1.25
• 790-261-1340 (female PT 1/8)
4 799-401-2320 Hydraulic gauge 1.0 MPa{10kg/cm2}
3 799-601-7050 SW-6P
6 799-601-7320 SW-16P
7 799-601-7340 M-16P
8 799-601-7540 070-18P
20-102 PC128US-2
(19)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
PC128US-2 20-103
(19)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
20-104 PC128US-2
(19)
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
PC128US-2 20-105
(17)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
20-106 PC128US-2
(17)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
PC138US-2 Serial No.: 4501 and up a Adjust the valve clearance according to the
PC138USLC-2 Serial No.: 1501 and up following procedure. Loosen locknut (8) of
adjustment screw (7). Insert filler gauge of
Method of adjusting valve clearance
the specified thickness between valve stem
1. Remove the cylinder head cover.
(6) and rocker arm (5) and adjust the valve
clearance so that the filler gauge will move
2. Turn the crankshaft forward and bring cylinder
lightly.
No. 1 to the compression top dead center and
match the TOP mark line of crank pulley (1) to
pointer (2), watching the movement of the air
intake valve of cylinder No. 4 (4 cylinders).
a The air intake valve of cylinder No. 4 (4 cyl-
inders) moves (opens) when cylinder No. 1
comes near the compression top dead cen-
ter.
PC128US-2 20-107
(17)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
20-108 PC128US-2
(17)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
PC128US-2 20-108-1
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
Adjusting
fl If the timing pin does not mesh with the pointer,
adjust as follows.
20-108-2 PC128US-2
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
PC138US-2 Serial No.: 4501 and up 2. Remove front cover (3) of the fuel injection
PC138USLC-2 Serial No.: 1501 and up pump.
3. Install the fuel injection pump holder and drive
Adjustment by use of match marks
gear as one unit to the engine.
a Apply this method usually.
4. Insert the timing check pin 4.0 – 4.5 mm in diam-
(Then installing the fuel injection pump to the
eter and 80 mm in length on hole a of the front
original engine without repairing it, when check-
gear cover and match it to the hole of the drive
ing only the injection timing, etc.)
gear.
a Check that the timing check pin enters
1. Bring cylinder No. 1 to the compression top dead
straight and the hole of the fuel injection
center.
pump holder is aligned with the mounting
1) Turn the crankshaft forward and match
hole of the front gear cover (in which the
1.4Top line (1) on the crank pulley to pointer
mounting bolt will be inserted).
(2).
a If the holes are deviated from each other,
remove the fuel injection pump and check its
engagement with the drive gear.
PC128US-2 20-108-3
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
Adjustment by delivery valve method 4. Using spring pusher O2, compress the valve
(When installing a repaired or replaced fuel injection spring and remove valve cotter (5).
pump, when checking after disassembling or replac- 5. Loosen spring pusher O2 and remove spring
ing the gear train) seat (6) and valve spring (7).
6. Turn the stem of air intake valve (8) with the fin-
gers while it is in contact with the top of piston
(9) to fit it securely.
20-108-4 PC128US-2
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
PC128US-2 20-108-5
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
20-108-6 PC128US-2
(17)
TESTING AND ADJUSTING BELT TENSION
TESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR
PC128US-2 20-108-7
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
20-108-8 PC128US-2
(17)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
PC128US-2 20-108-9
(17)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID LINKAGE
‘
BEP01424
Testing
1. Turn the starting switch ON, set to the operating
condition, then adjust so that the clearance be-
tween lever (I) and stopper (2) is 1 - 2 mm.
Adjusting
1. Loosen the mounting bolts of solenoid assembly
(31, move solenoid assembly (3) to adjust the clear-
ance between lever (I) and stopper (21, then
tighten the mounting bolts.
* There is an oblong hole at the bracket end.
BLP01317
TXP02405
20-112 PC128US-2
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTlNG AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
Adjusting
1. Adjusting main relief valve
• Disconnect high pressure hose.
1) Adjusting high pressure setting
• Loosen locknut (2) of main relief valve (1),
then turn holder (3) to adjust.
fl Turn the holder to adjust as follows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl After adjusting, use the measurement pro-
cedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
fl When the high pressure setting is ad-
justed, the low pressure setting will also
change, so adjust the low pressure set-
ting also.
2) Adjusting low pressure setting
• Loosen locknut (4) of main relief valve (1),
then turn holder (5) to adjust.
fl Turn the holder to adjust as follows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl After adjusting, use the measurement pro-
cedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
39.2 – 49.0 Nm {4 – 5 kgm}
PC128US-2 20-115
(18)
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
9JFOO253
0
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
[Reference]
If there is any abnormality with problem in the
LS valve or servo piston, the servo piston input
pressure becomes a value close to 0 or the same
pressure as the pump discharge pressure.
PC128US-2 20-117
(18)
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
Adjusting
If the load increases and the engine speed drops,
or if the engine speed is normal but the work
equipment speed is slow, adjust PC valve (6) as
follows if the pump discharge pressure and LS
differential pressure are normal.
1) Loosen iocknut (41, and if the work equipment
speed is slow, turn screw (5) clockwise; if the
engine speed drops, turn the screw counter-
clockwise.
2) Remove pressure measurement plugs (1) and
(2) (Thread dia.= IO mm, Pitch=1.25 mm), and
install oil pressure gauge Cl (39.2 MPa (400
kg/cm*}).
3) Turn the swing lock switch ON.
BKPOIOI5
About same
Neutral pressure
t
PC1 28U.S2
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
-1
conditions in Step 1) - iii), and measure
the pump discharge pressure.
* Stand directly in front of the indicator
and be sure to read it correctly.
v) Run the engine at high idling, set to the
conditions in Step 1) - iii), and measure
the LS pressure.
* Stand directly in front of the indicator
and be sure to read it correctly.
vi) Calculate the LS differential pressure from
the pump discharge pressure and the LS
pressure.
(Differential pressure) = (Pump discharge
pressure) - (LS pressure)
BLP01284
20-120 PC128US-2
0
TESTING AND ADJUSTlNG LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
3. Adjusting LS valve
* If the results show that the LS differential pres-
sure is not within the standard value, adjust
the LS valve as follows.
1) Disconnect hose (8) from LS valve (7).
2) Loosen locknut (9) and turn adjustment screw
(IO) to adjust the differential pressure.
* Turn the adjustment screw to adjust as
follows.
l To INCREASE pressure, turn CLOCK-
WISE
l To DECREASE pressure, turn COUN- BKP01016
TERCLOCKWISE
* Amount of adjustmentfor one turn of ad-
justment screw: 1.30 MPa i13.3 kg/cm*}
(LS differential pressure)
3) After adjusting, tighten locknut (8).
w Locknut : 59 f IO Nm (6 f 1 kgml
* After completion of adjustment, repeat the
procedure above to check the LS differ-
ential pressure again.
Adjusting
* If the pressure in the control circuit is not normal,
adjust the control relief valve as follows.
PPC
BLP01302
Mark
Measure the amount of
distance A at this point
TEP00329
TLP00652
II 9JFOOO95
0
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
Air bleeding procedure
Air bleeding item
1 2 3 4 5 6 7
Bleed air Start Bleed air Bleed air Bleed air Pressurize Start
from engine from from from hydraulic operation
pump cylinder swing travel tank
Nature of work motor motor
• Change hydraulic oil
• Clean strainer → → → → → →
(Note) (Note)
• Replace cylinder
• Remove cylinder piping → → →
Note : Bleed the air from the swing and travel motors only when the oil inside the motor case has been
drained.
PC128US-2 20-129
(17)
TESTING AND ADJUSTING BLEEDING AIR
0
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT,
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC TANK
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
Jr If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as follows.
The travel circuit is an open circuit, so there is no
remaining pressure. In this case, it is enough just
to the oil filler cap.
RELEASING REMAINING
PRESSURE IN HYDRAULIC
TANK
a The hydraulic tank is sealed and pressurized.
When removing the hoses or plugs connected
to the hydraulic tank, do as follows to release
the remaining pressure in the hydraulic tank.
1. Put the red (+) end of the test pin in contact with
the anode (P) of the diode, and the black (-) end in
contact with the cathode (N).
* There is a mark showing the direction of con-
tinuity on the surface of the diode.
* With a normal tester, if it is switched to the
diode range, the voltage of the internal bat-
tery is displayed. The value indicates the fol- Diode included in wiring harness
lowing.
l No change : No continuity
l Changes:
There is continuity (normal) (Note)
I-
0 Value is 0 or near 0:
Short circuit inside diode
Note : In the case of silicon diodes, a value be-
tween 400 and 600 is displayed. Depend-
ing on the type of tester, 0.4 - 0.6 may also
be displayed.
TLP00664
BLPO1357
20-132 PC128US-2
0
TESTING AND ADJUSTING Pm CLINIC INSPECTION TABLE
Good Bad
PC128US-2 20-133
(14)
TESTING AND ADJUSTING Pm CLINIC INSPECTION TABLE
Standard Measure-
value for Service limit ment
Condition Item Unit value Good Bad
Oil
20-134 PC128US-2
(14)
TESTING AND ADJUSTING Pm CLINIC INSPECTION TABLE
Good Bad
PC128US-2 20-135
(17)
TESTING AND ADJUSTING Pm CLINIC INSPECTION TABLE
Standard Measure-
value for Service limit ment
Condition Item Unit value Good Bad
Oil
20-136 PC128US-2
(17)
TESTING AND ADJUSTING Pm CLINIC INSPECTION TABLE
Good Bad
PC128US-2 20-137
(17)
TESTING AND ADJUSTING Pm CLINIC INSPECTION TABLE
Standard Measure-
value for Service limit ment
Condition Item Unit value Good Bad
Oil
20-138 PC128US-2
(17)
TROUBLESHOOTING
PC128US-2 20-201
(14)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
a Stop: the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
g When carrying out the operation with two or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
a If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.,
g Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
a When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
a When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly,
and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure
and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 2) Checkfor any external leakage of oil from
hurry to disassemble the components. the piping or hydraulic equipment.
If components are disassembled immediately 3) Check the travel of the control levers.
any failure occurs: 4) Check the stroke of the control valve
. Parts that have no connection with the fail- spool.
ure or other unnecessary parts will be dis- 5) Other maintenance items can be checked
assembled. externally, so check any item that is con-
. It will become impossible to find the cause sidered to be necessary.
of the failure. 4. Confirming failure
It will also cause a waste of manhours, parts, Confirm the extent of the failure yourself,
or oil or grease, and at the same time, will also and judge whether to handle it as a real fail-
lose the confidence of the user or operator. ure or as a problem with the method of op-
For this reason, when carrying out trouble- eration, etc.
shooting, it is necessary to carry out through * When operating the machine to reenact
prior investigation and to carry out trouble- the troubleshooting symptoms, do not
shooting in accordance with the fixed proce- carry out any investigation or measure-
dure. ment that may make the problem worse.
2. Points to ask user or operator 5. Troubleshooting
1) Have any other problems occured apart Use the results of the investigation and in-
from the problem that had been reported? spection in Items 2 - 4 to narrow down the
2) Was there anything strange about the ma- causes of failure, then use the troubleshoot-
chine before tha failure occurred? ing flowchart to locate the position of the
3) Did the failure occur suddenly, or were failure exactly.
there problems with the machine condition Ir The basic procedure for troubleshooting
before this? is as follows.
4) Under what conditions did the failure oc- 1) Start from the simple points.
cur? 2) Start from the most likely points.
5) Had any repairs been carried out before the 3) Investigate other related parts or in-
failure? formation.
When were these repairs carried out? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred be- Even if the dailure is repaired, if the root
fore? cause of the failure is not repaired, the same
3. Check before troubleshooting failure will occur again.
1) Check the oil level. To prevent this, always investigate why the
problem occureed. Then, remove the root
cause.
TEWOO180 a TEW00181
\
step 1
Examination, confirmation of symptoms
jtep 2
Determining probable location of cause TEWO0183
step 3
Preparation of troubleshooting tools =-
V’
. T-adapter troubleshooting)
- Hydraulic pressure gauge kit, etc. . Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement 1) Before starting troubleshooting, locate and
repair simple failures.
. Check before starting items
- Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEWOO187
Step 4
(Go]
PC128US-2 20-203
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-204 PC128US-2
(17)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00194
PC128US-2 20-205
(17)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
‡ Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con-
nectors apart.
fl Never pull with one hand.
Catches
20-206 PC128US-2
(17)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
‡ Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
fl 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 connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place the connector.
PC128US-2 20-207
(17)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00202
20-208 PC128US-2
(17)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00204
TEW00205
TEW00206
PC128US-2 20-209
(17)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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 en-
tering. 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 leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEWOO208
20-210 PC I 2aus-2
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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 oi I
TEW00710
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3~) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEW00211
PC 128US-2 20-211
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
20-212 PC128US-2
(17)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-218-2 PC128US-2
(17)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
M40 YAZAKI 2 Cigar lighter A-5 S30 X 2 Right swing pressure switch G-4
M40 M 2 Cab work equipment lamp (STD) I-8 S31 X 2 Boom RAISE pressure switch G-5
M41 SWP 6 Arm crane monitor A-7 S32 X 2 Arm dump pressure switch G-5
M41 M 2 Cab work equipment lamp (OPT) J-8 S33 X 2 Boom LOWER pressure switch G-4
M47 090 20 Intermediate connector B-7 S34 X 2 Bucket digging pressure switch G-5
M48 DT 6 Auto decelerator motor L-4 S35 X 2 Bucket dump pressure switch G-5
M83 SUMITOMO 3 Intake duct (Airconditioner) F-6 V04 X 2 Swing holding brake solenoid G-7
Intermediate connector
M84 SWP 14 (Airconditioner unit) E-9 V05 X 2 Travel speed solenoid G-8
Intermediate connector
M85 SWP 16 (Airconditioner unit) E-9 V06 X 2 2-stage relief valve solenoid G-6
M87 S 12 A/C unit C-4 V07 X 2 PPC hydraulic lock solenoid H-8
M88 YAZAKI 10 Airconditioner foot spurting B-5 W03 M 2 Rear limit switch K-8
servo
Boom cylinder bottom
M92 DT 3 pressure sensor — X05 M 4 Swing lock switch D-8
PC128US-2 20-218-3
7
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
20-218-4 PC128US-2
(17)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-218-8 PC128US-2
(17)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
M80 — 20 Air conditioner panel F-4 T02 Terminal 1 Revolving ground L-5
M81 — 16 Air conditioner panel F-5 T03 Terminal 1 Revolving ground L-5
M83 SUMITOMO 3 Intake duct (Air conditioner) F-6 T04 M 1 Radio ground F-5
Intermediate connector
M84 SWP 14 (Air conditioner unit) F-5 T05 Terminal 1 Floor ground C-3
Intermediate connector
M85 SWP 16 (Air conditioner unit) F-7 T06 Terminal 1 Floor frame ground B-3
M87 S 12 Air conditioner unit D-3 T21 Terminal 1 Engine stop solenoid relay I-1
M88 YAZAKI 10 B-3 T22 Terminal 1 Engine stop solenoid relay I-3
PULL Terminal 1 Engine stop solenoid Q-2 V03 SHINAGAWA 6 Starting motor relay B-6
P01 AMP 12 Monitor panel A-5 V4 DT 2 Swing holding brake solenoid valve G-8
P02 AMP 20 Monitor panel A-5 V5 DT 2 Travel speed selector solenoid valve G-9
P03 M 2 Buzzer cancel switch C-7 V6 DT 2 2-stage relief solenoid valve G-8
P06 X 2 Fuel level gauge I-9 V7 DT 2 PPC hydraulic safety lock solenoid H-9
P07 X 2 Engine coolant temperature sensor P-8 V06 X 1 Intermediate connector E-7
Airconditioner outsideair
P09 SWP 2 temperature sensor E-3 V07 X 1 Intermediate connector E-7
R06 SHINAGAWA 6 Starting motor cutout relay B-6 V09 X 1 Intermediate connector E-7
R08 SHINAGAWA 6 Deceleration relay J-3 W03 M 2 Rear limit switch K-9
R09 SHINAGAWA 6 Accelerator relay J-3 X05 M 4 Swing lock switch C-7
PC128US-2 20-218-9
(17)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
20-218-10 PC128US-2
(17)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
PC128US-2 20-218-11
(17)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
20-218-12 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04702
2 799-601-7020
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040
PC128US-2 20-219
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04708
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
20-220 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04715
16 BWP04716 799-601-7320
PC128US-2 20-221
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04718
BWP04717
2 799-601-7090
BWP04719 BWP04720
3 799-601-7110
BWP04721 BWP04722
4 799-601-7120
BWP04723 BWP04724
6 799-601-7130
BWP04725 BWP04726
8 799-601-7340
20-222 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04728
8 BWP04727 799-601-7140
10 BWP04729 BWP04730
799-601-7150
(white)
12 BWP04731 BWP04732
(white) 799-601-7350
16 BWP04733 BWP04734
799-601-7330
(white)
PC128US-2 20-223
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04736
10 BWP04735
(blue) —
— —
12 BWP04737 BWP04738
799-601-7160
(blue)
16 BWP04739 BWP04740
(blue) 799-601-7170
20-224 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04742
BWP04741
5 799-601-2710
BWP04743 BWP04744
9 799-601-2950
BWP04745 BWP04746
13 799-601-2720
PC128US-2 20-225
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04748
BWP04747
17 799-601-2730
BWP04749 BWP04750
21 799-601-2740
20-226 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04752
BWP04751
8 799-601-7180
BWP04753 BWP047544
12 799-601-7190
BWP04755 BWP04756
16 799-601-7210
BWP04757 BWP04758
20 799-601-7220
PC128US-2 20-227
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
BWP04761 BWP04762
12 799-601-7520
BWP04763 BWP04764
14 799-601-7530
BWP04765 BWP04766
18 799-601-7540
BWP04767 BWP04768
20 799-601-7550
20-228 PC128US-2
(19)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04770
2 BWP04769 —
— —
BWP04772
9 BWP04771 —
— —
BWP04774
BWP04773
10 799-601-3460
— —
PC128US-2 20-229
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04776
BWP04775
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
20-230 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04784
BWP04783
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
BWP04786
BWP04785
5 799-601-7360
— —
BWP04788
BWP04787
6 799-601-7370
— —
4 —
— —
PC128US-2 20-230-1
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
20-230-2 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
PC128US-2 20-230-3
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
20-230-4 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
PC128US-2 20-230-5
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
20-230-6 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
PC128US-2 20-230-7
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number
8GR:
799-601-9060
8B:
799-601-9070
8 8G:
799-601-9080
8BR:
799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR:
799-601-9110
12B:
799-601-9120
12 12G:
799-601-9130
12BR:
799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
20-230-8 PC128US-2
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DTM Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number
2 799-601-9010
1 —
Part number:08192-31200 (Contact size #12) Part number:08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC128US-2 20-230-9
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
24 799-601-9360
40
799-601-9350
(A)
40
799-601-9350
(B)
20-230-10 PC128US-2
(19)
TESTING AND ADJUSTING T-ADAPTER TABLE
T-ADAPTER TABLE
a The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring har-
ness checker assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
PC128US-2 20-230-11
(19)
TESTING AND ADJUSTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Cace Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Blown Q Q
799-601-9110 DT 12P-Gray Q Q
20-230-12 PC128US-2
(19)
TESTING AND ADJUSTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Blown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 2-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 For measuring box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
PC128US-2 20-230-13
(19)
TROUBLESHOOTING FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM
Network information
1) Work mode (A, E, B) information (Monitor panel → CR700 controller)
2) Auto-decelerator (ON/OFF) signal (Monitor panel → CR700 controller)
3) Travel Hi/Lo signal (Monitor panel → CR700 controller)
4) Coolant temperature (coolant temperature) information (Monitor panel → CR700 controller)
5) Service code (failure code) information (CR700 controller → Monitor panel)
PC128US-2 20-231
(17)
TROUBLESHOOTING FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM
Network information
1) Work mode (A, E, B) information (Monitor panel → CR700 controller)
2) Auto-decelerator (ON/OFF) signal (Monitor panel → CR700 controller)
3) Travel Hi/Lo signal (Monitor panel → CR700 controller)
4) Coolant temperature (water temperature) information (Monitor panel → CR700 controller)
5) Service code (failure code) information (CR700 controller → Monitor panel)
6) Preheating signal (CR700 controller → Monitor panel)
20-232 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
PC128US-2 20-233
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
20-234 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
PC128US-2 20-235
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
E241 Boom angle potentiometer system error (beyond input value range) —
E242 Arm angle potentiometer system error (beyond input value range) —
20-236 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
PC128US-2 20-237
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
20-238 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
Code No. Item Bit Detailed description (state when a bit comes on)
[1] At ID2 connection
[2] At ID3 connection
[3] At ID4 connection
0008 S-NET connected state
[4] At ID5 connection
[5] At ID6 connection
[6] At ID7 connection
[1] Starting switch “ON” (ON)
[2] Starting switch “Start” (Start) (ON)
[3] Starting switch “Preheat” (ON)
0045 Sensor input 1
[4] Light switch (ON)
[5]
[6]
[1]
[2]
[3] Engine oil pressure (At OPEN time)
0046 Sensor input 2
[4] Engine oil level (At OPEN time)
[5]
[6] Charge level (At decrease time)
[1] Buzzer output (ON)
[2]
[3]
0047 Output state
[4]
[5]
[6]
[1]
[2] Washer output (ON)
[3] Wiper output 1 (ON)
0048 Wiper state
[4] Wiper output 2 (ON)
[5] Wiper output 3 (ON)
[6] Wiper output 4 (ON)
[1] Swing lock switch (ON)
[2] Buzzer cancel switch (ON)
[3] Widow limit switch (ON)
0049 Standby
[4] W contact (ON)
[5] P contact (ON)
[6]
PC128US-2 20-239
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
Code No. Item Bit Detailed description (state when a bit comes on)
[1]
[2] Arm crane mounting (*1)
[3]
1004 Option selection
[4] Arm ground angle warning cancel (*1)
[5]
[6]
[1] ATT selection 2 (At GND connection)
[2] ATT selection 1 (At GND connection)
[3] Model selection 1 (At GND connection)
1020 ON/OFF input 1
[4] ATT selection 3 (At GND connection)
[5] UU/US selection (At GND connection)
[6] Model selection 2 (At GND connection)
[1]
[2]
[3]
1021 ON/OFF input 2
[4] Arm crane mounting (At power supply connection)
[5]
[6] Kerosene mode (At GND connection)
[1] Travel selector switch (Panel)
[2] Working mode selector switch
[3] Back lamp
1022 ON/OFF input 3
[4] SET/CLEAR switch
[5] Mode selector (∆) switch
[6] Mode selector (∇) switch
[1]
[2] Another work equipment mode selector switch (ON)
[3] Travel pressure switch (ON)
1023 ON/OFF input 4
[4] Swing pressure switch (ON)
[5] Arm digging pressure switch (ON)
[6] Boom RAISE pressure switch (ON)
[1]
[2]
ON/OFF input and [3] Motor-driven power supply (*1)
1024
output [4]
[5] Motor relay (–)
[6] Motor relay (+)
[1] Crane mode switch [monitor]
[2] Display selector switch [monitor]
ON/OFF input and [3] Arm ground angle warning cancel switch (At connector connection)
1025
output [4]
[5]
[6] Bucket dump inhibition solenoid + Patlight (At relay output)
[1]
[2] Warning cancel (For EU)
ON/OFF input and [3]
1026
output [4]
[5]
[6]
20-240 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
Code No. Item Bit Detailed description (state when a bit comes on)
[1]
[2]
[3] Preheating signal (*1)
1027 ON/OFF input 5
[4]
[5] C-terminal signal (*1)
[6]
[1] Arm OUT pressure switch (*1)
[2] Service pressure switch (*1)
[3] Bucket digging pressure switch (*1)
1028 ON/OFF input 6
[4] Bucket DUMP pressure switch (*1)
[5]
[6]
[1] Swing holding brake (At brake release)
[2]
[3]
1060 ON/OFF output
[4] Travel 2nd speed (At travel 2nd speed)
[5] Travel or swing alarm (At alarm output)
[6] 2-stage relief (At travel pressure switch ON)
[1]
[2] Heater relay (*1)
[3]
1061 ON/OFF output
[4]
[5]
[6]
PC128US-2 20-241
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
20-242 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
PC128US-2 20-243
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
20-244 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
PC128US-2 20-245
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
20-246 PC128US-2
(19)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
PC128US-2 20-246-1
(19)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
20-246-2 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
PC128US-2 20-246-3
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
Service
meter
2 1) Set the value in the display section to a desired value. When PC138US long arm is selected
Set value Model ATT Remarks
10 PC128US Standard arm Controller default
Display
11 PC128US Long arm
20 PC138US Standard arm
21 PC138US Long arm After switch (5) is pressed, display section
displays "000", and then "---"
(8) + (3): Next code
(8) + (4): Previous code
2) Press switch (5).
Display
20-246-4 PC128US-2
(19)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700
controller (decelerator control) system “E3: ”.
2) When a service code is not displayed on the monitor panel and “ENGINE DOES NOT START”:
When the starting motor rotates:
• Check the rotation
.... Advance to MECHANICAL SYSTEM TROUBLESHOOTING “S-2”.
of a starting motor.
When the starting motor does not rotate:
.... Advance to ELECTRICAL SYSTEM TROUBLESHOOTING “E-8”.
20-252 PC128US-2
(17)
TROUBLESHOOTING HOW TO READ DECISION LIST
2. CR700 Controller (Pump Control System) or Oil Pressure Related Decision Table
• When a service code is displayed on the monitor panel, advance to the troubleshooting
code (C- ) of the lowermost step of the decision table.
(A is marked to the point where a failure mode and a service code match.)
• If a service code is not displayed and a nature of trouble appears in the monitor panel, check the
display of an input signal that matches the failure mode of the decision table (display the location
marked with a circle ( )) and
• When an input signal is displayed normally, advance to the diagnostic code (H- ) at the
right of the decision list.
• When an input signal is not displayed, advance to the diagnostic code (F- ) at the lower-
most step of the decision list.
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700
controller (decelerator control) system “E2: ”.
2) When a service code is not displayed on the monitor panel and “SWING IS NOT PERFORMED”:
• Check a CR700 controller When the signal is provided:
input signal. .... Advance to MECHANICAL SYSTEM TROUBLESHOOTING
(Check it in the monitor- “H-25”.
ing mode.) When the signal is not provided:
.... Advance to the CR700 CONTROLLER INPUT SIGNAL SYS-
TEM TROUBLESHOOTING “F- ”.
PC128US-2 20-253
7
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
C-cc CR700 controller (pump control system) electrical system troubleshooting E2-cc system
20-254 PC128US-2
(17)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
[1] M-12 When the starting switch is set to ON (the engine stopped), precautions and emer-
gency stop items flash.
(But “Battery” and “Engine oil pressure” do not come on.)
[4] fl Inspect both the alternator system and the engine hydraulic system.
[3]
Cause Remedy
1
• Disconnect the terminal R. Is the voltage between the al- NO
• Set the starting switch to ON. ternator R and the machine Defective alternator Replace
• 1V max. body normal?
YES
2
• Disconnect P02. NO
Is the voltage between P02 (11) Hot short-circuit of harness between Repair or
• Set the starting switch to ON.
• 1V max. and the machine body normal? P02 (female) (11) and alternator R replace
YES
Defective monitor panel Replace
PC128US-2 20-255
(17)
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT
TROUBLESHOOTING TROUBLESHOOTING
Besides, the confirmation procedures of the testing items No. 3 and 4 in the following flow are described
on the next page and later pages.
fl Decide the details in accordance with the CR700 controller (decelerator control system) (pump
control system) decision table.
20-256 PC128US-2
(17)
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT
TROUBLESHOOTING TROUBLESHOOTING
For an output signal of the monitor panel, if there is no abnormality display of a communication system
sent by S-NET, it may be decided that the output signal is sent. When there is no abnormality display,
perform testing directly, such as an incorrect operation, according to the following points.Besides, whenan
abnormality occurred in the S-NET system, note diagnosis because the default mode is automatically
switched as shown below.
5 Travel speed Lo —
Table 1
Working mode Operation Engine speed (no load maximum speed) (rpm)
Work equipment About 2,400
A
Travel About 2,400
Work equipment About 2,200
E
Travel About 2,200
Work equipment About 2,000
B
Travel About 2,000
Work equipment About 1,500
Arm crane
Travel About 1,500
PC128US-2 20-257
(17)
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT
TROUBLESHOOTING TROUBLESHOOTING
Note 1: Perform the lever operation slightly in such degree that the machine cannot move.
20-258 PC128US-2
(17)
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT
TROUBLESHOOTING TROUBLESHOOTING
PC128US-2 20-259
(17)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
PC128US-2 20-301
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
20-302 PC128US-2
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
PC128US-2 20-303
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
20-304 PC128US-2
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
PC128US-2 20-305
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
PC-EPC SYSTEM
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-306 PC128US-2
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
PC128US-2 20-307
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
20-308 PC128US-2
(17)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
PC128US-2 20-309
(17)
TROUBLESHOOTING E-1
Items to check on LED display of pump controller when this failure mode occurs
• For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the operator’s compart-
ment, and use a mirror to check.
1. Content of display
1) When normal
• LED lights up.
2) When there is abnormality in power supply voltage
• Output stops, LED goes out.
3) When PC-EPC solenoid output is short circuited [when C01 (13) - PC-EPC solenoid C13 (1) is short
circuited]
• Output stops, LED flashes. (See display pattern a).
4) When there is abnormality in machine model selection
• LED flashes. (See display pattern c).
Note : When kerosene mode selector switch (terminal) is connected, ignore the flashing and carry
out troubleshooting.
5) When there is disconnection in speed sensor [when there is abnormal voltage at C01 (2), (3)]
. Output is made same as when engine speed is minimum, LED flashes. (See display pattern
d).
Note : When engine speed becomes abnormally low, LED does not flash.
6) When there is disconnection in PC-EPC solenoid output [when there is disconnection between
C01 (13) - PC-EPC solenoid C13 (1)]
• LED flashes. (See display pattern b).
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
3) Display pattern c (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5
seconds, then OFF for 2.0 seconds)
4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5
seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
5) If more than one of the above failures occurs at the same time, the above patterns a to d are
repeated.
Note : indicates ON for 0.1 second, indicates OFF for 0.1 second.
20-310 PC128US-2
(17)
TROUBLESHOOTING E-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Speeds of all work equipment, travel, swing are slow or lack power
Cause Remedy
4 YES
To A
Is resistance
YES between C05
3 (female) (4) and
chassis ground Short circuit with chassis
Is resistance normal?
between C13 ground in wiring harness
Repair or replace
YES (female) (1) - (2), NO between C05 (female) (4)
between (1)(2) - and C03 (female) (2)
chassis ground
normal?
2 • Between C13 Defective PC-EPC solenoid Replace
(female) (1) - (2) : NO
Is resistance 500 - 1000 Ω
between C01 • Between C13
YES (female) (3) - (4), (female) (1)(2) - chassis ground :
between (3)(4) - Min. 1 MΩ
chassis ground • Turn starting switch OFF.
normal? Defective contact,
• Disconnect C01.
• Between C01 disconnection, or short
(female) (3) - (4) : 5 YES circuit with chassis ground
Repair or replace
500 - 1000 Ω Is resistance in wiring harness between
• Between C01 between E07 C01 (female) (3) - E07
(female) (3)(4) - (female) (1) - (2), (female) (1) or C01 (4) - E07
chassis ground : NO between (1)(2) - (2)
Min. 1 MΩ chassis ground
1 • Turn starting normal? Defective engine speed
switch OFF. sensor Replace
• Disconnect C01. • Between C01 NO
Does LED of pump (female) (3) - (4) :
500 - 1000 Ω
controller flash? • Between C01 (female)
(3)(4) - chassis ground :
Min. 1 MΩ
• Start engine. • Turn starting switch OFF.
• Disconnect E07.
7 YES
Defective pump controller Replace
Is there continuity
YES between C01 Defective contact,
6 (female) (5) - (10), disconnection, or short
between (6) - (10)? circuit with chassis ground
Does model in wiring harness between Repair or replace
selector connector • Between C01 NO C01 (male) (5) - C09 (male)
(female) (5) - (10) :Continuity (1), C05 (female) (6) - C09
NO match machine • Between C01 (female) (female) (2) or C01 (female)
model? (10) - C09 (male) (3)
(6) - (10) : No continuity
• Turn starting switch OFF.
• Disconnect C01.
Defective machine model Replace
NO selection connector
PC128US-2 20-311
(17)
TROUBLESHOOTING E-1
fl When fuse 2 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit
related to fuse 2.)
Cause Remedy
2 YES
Defective pump controller Replace
Is voltage between
YES C01 (1) and chassis
ground normal? Defective contact or
disconnection in wiring
Repair or replace
• 20 – 30 V NO harness between fuse 2 and
• Turn starting switch C01 (female) (1)
ON.
5 YES
Go to A
1 Is resistance
YES between C05 Defective contact,
4 disconnection, or short circuit
Is pump controller (female) (3) and (4) with chassis ground in wiring
normal? harness between C05 (female)
LED off? Is resistance Repair or replace
(3) and C13 (female) (1), or
YES between C13 • 7 – 14 Ω NO defective contact or
(female) (1) and (2) • Turn starting switch disconnection in wiring
• Turn starting normal? OFF. harness between C05 (female)
switch ON. (4) and C13 (female) (2)
• Disconnect C05.
• 7 – 14 Ω
• Turn starting Defective PC-EPC solenoid Replace
switch OFF. NO
3
• Disconnect C13.
Does pump
controller LED 7 YES Replace
Defective pump controller
NO flash? Is there continuity
YES between C01
• Start engine. (female) (5) - (10), Defective contact or
between (6) - (10)? disconnection in wiring
6 harness between C01 Repair or replace
• Between C01 NO (female) (5) and C09 (male)
Does model (female) (5) - (10) :
Continuity (1), or between C01 (female)
selection (6) and C09 (male) (2)
• Between C01
NO connector match (female) (6) - (10) :
machine model? No continuity
• Turn starting switch
OFF.
• Disconnect C01. Defective machine model
Replace
selection connector
NO
Defective contact,
disconnection, or short circuit
with chassis ground in wiring
harness between C01
YES (female) (7) and C05 (female) Repair or replace
8
(1), or defective contact or
Is there continuity disconnection in wiring
harness between C01
between C05 (female) (13) and C05
A
(female) (1) - (3) (female) (2)
and (2) - (4)?
Defective emergency pump
• Turn starting Replace
NO drive switch
switch OFF.
• Disconnect C05.
20-312 PC128US-2
(17)
TROUBLESHOOTING E-1
PC128US-2 20-313
(17)
TROUBLESHOOTING E-1
Items to check on LED display of pump controller when this failure mode occurs
• For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the operator’s compart-
ment, and use a mirror to check.
1. Content of display
1) When normal
• LED lights up.
2) When there is abnormality in power supply voltage
• Output stops, LED goes out.
3) When PC-EPC solenoid output is short circuited [when CR3 (16) - PC-EPC solenoid C13 (1) is short
circuited]
• Output stops, LED flashes. (See display pattern a).
4) When there is disconnection in speed sensor [when there is abnormal voltage at CR2 (39), (40)]
• Output is made same as when engine speed is minimum, LED flashes. (See display pattern
d).
Note : When engine speed becomes abnormally low, LED does not flash.
5) When there is disconnection in PC-EPC solenoid output [when there is disconnection between
CR3 (16) - PC-EPC solenoid C13 (1)]
• LED flashes. (See display pattern b).
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
3) Display pattern c (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5
seconds, then OFF for 2.0 seconds)
4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5
seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
5) If more than one of the above failures occurs at the same time, the above patterns a to d are
repeated.
Note : indicates ON for 0.1 second, indicates OFF for 0.1 second.
20-314 PC128US-2
(17)
TROUBLESHOOTING E-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Speeds of all work equipment, travel, swing are slow or lack power
4 YES
Go to A
YES Is resistance
between C06
3 (female) (2) - (5) Disconnection or
Is resistance normal? Short circuit with chassis
between C13 ground in wiring harness Repair or replace
YES (female) (1) - (2), • Between C06 NO between C06 (female) (2)
between (1)(2) - (female) (2) - (5): 8 - 15 Ω (5) and C03 (female) (1) (2)
chassis ground • Turn starting switch OFF
normal? • Disconnect C06
2 • Between C13 Replace
Defective PC-EPC solenoid
(male) (1) - (2) : NO
Is resistance 8 - 15 Ω
between CR2 • Between C13
YES (female) (39) - (40), (male) (1)(2) - chassis ground :
between (39)(40) - Min. 1 MΩ
chassis ground • Turn starting switch OFF.
normal? Defective contact,
• Disconnect CR3. disconnection, or short
• Between CR2 circuit with chassis ground
(female) (39) - (40) : 5 YES
in wiring harness between Repair or replace
500 - 1000 Ω Is resistance CR2 (female) (39) - E07
• Between CR2 between E07 (female) (2) or CR2 (40) -
(female) (39) - (40) (female) (2) - (1), E07 (2)
1 chassis ground : NO between (2)(1) -
Min. 1 MΩ chassis ground
• Turn starting normal? Defective engine speed
Does LED of pump switch OFF. sensor Replace
• Disconnect CR2. • Between CR2 NO
controller flash? (female) (39) - (40) :
500 - 1000 Ω
• Between CR2 (female)
• Start engine.
(39)(40) - chassis ground : Min. 1 MΩ
• Turn starting switch OFF.
• Disconnect E07.
6 YES
Defective pump controller Replace
Is machine model
and attachment set
NO up or arm crane 6
set up correct?
Defective machine model Reset up
NO set up or arm crane set up
PC128US-2 20-315
(17)
TROUBLESHOOTING E-1
fl When fuse 1 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit
related to fuse 2.)
Cause Remedy
2 YES
Defective pump controller Replace
Is voltage between
YES CR3 (2) (12) (22)
and chassis
ground normal? Defective contact or
disconnection in wiring Repair or replace
• 20 – 30 V NO harness between fuse 1 and
• Turn starting switch CR3 (female) (2) (12) (22)
ON.
1 5 YES To A
Is resistance Defective contact,
Is pump controller YES between C06 disconnection, or short circuit
LED off? 4 (female) (2) and (5) with chassis ground in wiring
normal? harness between C06
Is resistance (female) (5) and C13 (female) Repair or replace
• Turn starting YES between C13 • 8 – 15 Ω NO (1), or defective contact or
switch ON. (male) (1) and (2) • Turn starting switch disconnection in wiring
normal? harness between C06
OFF. (female) (23) and C13 (female)
• Disconnect C06. (6)
3 • 8 – 15 Ω
• Turn starting Defective PC-EPC solenoid Replace
Does pump NO
switch OFF.
controller LED
• Disconnect C13.
NO flash?
6 YES
• Start engine. Defective pump controller Replace
Is machine model
and attachment set
NO up or arm crane
set up correct?
Defective machine model Reset up
set up or arm crane set up
NO
Defective contact,
disconnection, or short circuit
with chassis ground in wiring
7 YES harness between CR3 (female)
(16) and C06 (female) (3), or Repair or replace
Is there continuity defective contact or
between C06 disconnection in wiring
A harness between CR3 (female)
(female) (2) - (3) (23) and C06 (female) (6)
and (5) - (6)?
Defective emergency pump
drive switch Replace
• Turn starting NO
switch OFF.
• Disconnect C06.
20-316 PC128US-2
(17)
TROUBLESHOOTING E-1
PC128US-2 20-317
(17)
TROUBLESHOOTING E-2
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move
Cause Remedy
Defective contact or
4 YES disconnection in wiring
Repair or replace
Is resistance harness between V07
(female) (2) and S12
YES between S13
(wiring harness
3 end) and chassis Defective contact or
ground normal? disconnection in wiring
Is resistance Repair or replace
YES between S12 and • Max. 1 Ω NO harness between S13 and
S13 (wiring • Turn starting switch OFF. chassis ground
harness end) • Disconnect S13.
2 normal?
Is resistance • Max. 1 Ω
YES between V07 (male) • Turn starting Defective PPC lock switch Replace
(1) - (2), between NO
(1)(2) - chassis switch OFF.
ground normal? • Remove S12 and S13.
1 • Safety lock lever: FREE
Is voltage between • Between V07 (male)
V07 (female) (1) (1) - (2) : Defective PPC lock solenoid Replace
and chassis 500 - 1000 Ω NO
ground normal? • Between V07 (male) (1)(2) -
chassis ground : Min. 1 MΩ
• 20 – 30 V • Turn starting switch OFF.
Defective contact or
• Turn starting switch • Disconnect V07.
disconnection in wiring
Repair or replace
ON. NO harness between fuse 3 and
V07 (female) (1)
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move
Cause Remedy
YES
Defective PPC lock solenoid Replace
1
Is voltage between
V07 (1) and (2) Defective contact or
2 YES disconnection in wiring
normal? Repair or replace
harness between S13 and
Is resistance chassis ground
• Safety lock lever between S12 and
[LOCK] (solenoid NO S13 (switch end)
OFF) : Max. 1 V normal?
• Safety lock lever Defective PPC lock switch Replace
[FREE] (solenoid • Min. 1 MΩ NO
ON) : 20 – 30 V • Turn starting switch OFF.
• Turn starting switch • Disconnect S12 and S13.
ON. • Safety lock lever: [LOCK]
20-318 PC128US-2
(17)
TROUBLESHOOTING E-2
PC128US-2 20-319
(17)
TROUBLESHOOTING E-2
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move
Cause Remedy
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move
Cause Remedy
YES
Defective PPC lock solenoid Replace
1
Is voltage between
V7 (1) and (2) Defective contact in wiring
2 YES
normal? harness between S10 Repair or replace
Is resistance (female) (2) - V7 (female) (2)
• Safety lock lever between S10
[LOCK] (solenoid NO (male) (1) - (2)
OFF) : Max. 1 V normal?
• Safety lock lever Defective PPC lock switch Replace
[FREE] (solenoid • Min. 1 MΩ NO
ON) : 20 – 30 V • Turn starting switch OFF.
• Turn starting switch • Disconnect S10.
ON. • Safety lock lever: [LOCK]
20-320 PC128US-2
(17)
TROUBLESHOOTING E-2
PC128US-2 20-321
(17)
TROUBLESHOOTING E-3
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when swing lock switch is turned OFF, upper structure does not swing
Cause Remedy
4 YES
Go to A —
YES Is resistance
between S08
3 (female) (2), S30
When C03 (female) (female) (2) - chassis Defective contact or
is grounded to ground normal? disconnection in wiring
chassis, is harness between S08 Repair or replace
YES resistance between • Min. 1 Ω NO (female) (2), S30 (female)
S08 (female) (1), • Turn starting switch (2) - chassis ground
2 S30 (female) (1), OFF.
Is resistance S05 (female) (1) -
chassis ground • Disconnect C03, S08, Defective contact or
between S08 and S30. disconnection in wiring Repair or replace
YES (male) (1) - (2), S30 normal?
harness between C03
(male) (1) - (2) or • Min. 1 Ω NO (female) (3) - S08 (female)
1 S05 (male) (1) - (2) (1), S30 (female) (1)
normal? • Turn starting switch OFF.
Is resistance • Disconnect C03, S08, and
between V04 • Min. 1 Ω S30.
Defective swing or arm IN
• Disconnect S08, pressure switch (S08, S30 Replace
(male) (1) and (2) NO or S05)
S30, and S05.
normal? • Start engine.
• Operate swing or arm control
• 20 – 60 Ω lever slightly (but do not move
• Turn starting switch work equipment). Defective swing holding Replace
OFF. brake solenoid valve
• Disconnect V04. NO
8 YES Go to B —
Is resistance
YES between X05
7 (female) (3) and
When V04 (female) chassis ground Defective contact or
is grounded to normal? disconnection in wiring
harness between X05 Repair or replace
YES chassis, is • Min. 1 Ω NO (female) (3) and chassis
resistance between • Turn starting switch
C03 (female) (4) and ground
6 OFF.
chassis ground
Is resistance normal? • Disconnect X05. Defective contact or
disconnection in wiring
YES between C03 • Min. 1 Ω harness between V04 Repair or replace
(female) (2) and NO
chassis ground • Turn starting switch (female) (1) and C03
5 normal? OFF. (female) (4)
Is voltage between • Disconnect C03 and V04.
• Min. 1 Ω Defective contact or
A C03 (female) (1) • Turn starting switch disconnection in wiring
and chassis Repair or replace
OFF. NO harness between C03 (female)
ground normal? • Disconnect C03. (2) and chassis ground
• 20 – 30 V Defective contact or
• Turn starting switch disconnection in wiring
ON. Repair or replace
NO harness between fuse 2 and
C03 (female) (1)
20-322 PC128US-2
(17)
TROUBLESHOOTING E-3
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause Remedy
Is voltage between
Defective contact or
V04 (1) and (2) disconnection in wiring
2 YES
normal? harness between V04 Repair or replace
Is resistance
between X05 (male) (female) (2) and X05
• Swing lock switch (3) and (4), between (female) (4)
[LOCK] (solenoid NO (4) and chassis
OFF) : Max. 1 V ground normal?
• Swing lock switch Defective swing lock switch Replace
[FREE] (solenoid • Min. 1 MΩ NO
ON) : 20 – 30 V • Turn starting switch OFF.
• Turn starting switch • Disconnect X05.
ON. • Swing lock switch: [LOCK]
PC128US-2 20-323
(17)
TROUBLESHOOTING E-3
a) Even when swing lock switch is turned OFF, upper structure does not swing
Cause Remedy
4 YES
Go to A —
YES Is resistance
between S08
3 (female) (2), S30
When CR 1(female) (female) (2) - chassis Defective contact or
(12) is grounded to ground normal? disconnection in wiring
chassis, is harness between S08 Repair or replace
YES resistance between • Min. 1 Ω NO (female) (2), S30 (female)
S08 (female) (1), • Turn starting switch (2) - chassis ground
2 S30 (female) (1), OFF.
Is resistance CR3 (female) (30) -
chassis ground • Disconnect C03, S08, Defective contact or
between S08 and S30. disconnection in wiring
YES (male) (1) - (2), S30 normal?
harness between CR3 Repair or replace
(male) (1) - (2) or • Min. 1 Ω NO (female) (30) - S08 (female)
1 S05 (male) (1) - (2) (1), S30 (female) (1)
normal? • Turn starting switch OFF.
• Disconnect C03, S08, and
Is resistance • Min. 1 Ω S30.
Defective swing or arm IN
between V4 (male) • Disconnect S08, pressure switch (S08, S30 Replace
(1) and (2) normal? S30, and S05. NO or S05)
• Start engine.
• Operate swing or arm control
• 37 – 60 Ω lever slightly (but do not move
• Turn starting switch work equipment). Defective swing holding Replace
OFF. brake solenoid valve
• Disconnect V4. NO
8 YES Go to B —
Is resistance
YES between X05
7 (female) (2) and
When V4 (female) is chassis ground Defective contact or
grounded to normal? disconnection in wiring
harness between X05 Repair or replace
YES chassis, is • Min. 1 Ω NO (female) (3) and chassis
resistance between • Turn starting switch
CR3 (female) (3) ground
6 OFF.
and chassis ground
Is resistance normal? • Disconnect X05. Defective contact or
disconnection in wiring
YES between CR3 • Min. 1 Ω harness between V4 Repair or replace
(female) (7) - X05 NO
(female) (3) • Turn starting switch (female) (1) and CR3
5 normal? OFF. (female) (3)
Is voltage between • Disconnect C03 and V4.
• Min. 1 Ω Defective contact or
A CR3 (female) (2) • Turn starting switch disconnection in wiring
(12) (22) and Repair or replace
chassis ground OFF. NO harness between CR3 (female)
normal? • Disconnect C03. (7) - X05 (female) (3)
• 20 – 30 V Defective contact or
• Turn starting switch disconnection in wiring
ON. Repair or replace
NO harness between fuse 8 and
CR3 (female) (2) (12) (22)
20-324 PC128US-2
(17)
TROUBLESHOOTING E-3
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause Remedy
Is voltage between
Defective contact or
V4 (1) and (2) disconnection in wiring
2 YES
normal? harness between V4 Repair or replace
Is resistance
between X05 (male) (female) (2) and X05
• Swing lock switch (4) and (2), between (female) (4)
[LOCK] (solenoid NO (4) and chassis
OFF) : Max. 1 V ground normal?
• Swing lock switch Defective swing lock switch Replace
[FREE] (solenoid • Min. 1 MΩ NO
ON) : 20 – 30 V • Turn starting switch OFF.
• Turn starting switch • Disconnect X05.
ON. • Swing lock switch: [LOCK]
PC128US-2 20-325
(17)
TROUBLESHOOTING E-4
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when travel speed selector switch is turned to Hi, travel speed does not change to high speed
fl When fuse 2 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit
related to fuse 2.)
Cause Remedy
Defective contact or
4 YES disconnection in wiring
harness between V05 Repair or replace
Is resistance (female) (2) and M39
YES between M39
(female) (1) and
(female) (2)
b) Even when travel speed selector switch is turned to Lo, travel speed does not change to low speed
Cause Remedy
Is voltage between
V05 (1) and (2) Short circuit with chassis
2 YES ground in wiring harness
normal? Repair or replace
Is resistance between V05 (female) (2)
between M39 and M39 (female) (2)
• Travel speed (male) (1) - (2),
selector switch NO between (1)(2) -
[Lo] (solenoid OFF) : chassis ground
Max. 1V normal? Defective travel speed
• Travel speed Replace
selector switch [Hi] • Min. 1 MΩ NO selector switch
(solenoid ON) : • Turn starting switch OFF.
20 – 30 V • Disconnect M39.
• Turn starting switch
ON. • Travel speed selector
switch : [Lo]
20-326 PC128US-2
(17)
TROUBLESHOOTING E-4
PC128US-2 20-327
(17)
TROUBLESHOOTING E-4
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
fl When fuse 1 is normal. (If fuse 1 is blown, check for a short circuit with the ground in the circuit
related to fuse 1.)
fl Befor carrying out troubleshooting check that main pump pressure sensor system is normal.
Cause Remedy
YES
Defective controller Replace
Is resistance
YES between CR3
2 (female) (27) and Defective contact,
(3) normal? 3 disconnect, or short circuit
Is resistance with chassis ground in
Repair or replace
YES between V5 (male)
(2) - (1), between (2)
• Turn starting switch NO wiring harness between
OFF. CR3 (female) (27) (3) - V5
- chassis ground (female) (2) (1)
1 normal? • Disconnect CR3.
• Safety lock lever: FREE
Is voltage between • Between V5 (male) Defective travel speed
CR3 (female) (2) - (1): 37 - 60 Ω Replace
solenoid
(2),(12),(22) and • Between V5 (male) NO
chassis ground
(1)(2) - chassis ground : Min. 1 MΩ
normal?
• Turn starting switch OFF. Defective contact or
• 20 - 30 V • Disconnect V5. disconnection in wiring
• Turn starting switch Repair or replace
NO harness between fuse 1 and
ON.
CR3 (female) (2) (12) (22)
20-328 PC128US-2
(17)
TROUBLESHOOTING E-5
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl If this failure mode is detected, the travel speed does not change automatically.
Cause Remedy
Cause Remedy
PC128US-2 20-329
(17)
TROUBLESHOOTING E-5
20-330 PC128US-2
(17)
TROUBLESHOOTING E-5
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl If this failure mode is detected, the travel speed does not change automatically.
Cause Remedy
Cause Remedy
PC128US-2 20-331
(17)
TROUBLESHOOTING E-5
20-332 PC128US-2
(17)
TROUBLESHOOTING E-6
7
YES
Is voltage between
safety relay
terminal C and
NO chassis ground 9
normal?
Is voltage between
• 20 – 30 V YES M02 (1) and
• Turn starting switch chassis ground
2 ON. normal?
• 20 – 30 V
YES Is sound heard 8 • Turn starting switch
from battery relay? Is voltage between ON.
safety relay
• Turn starting terminal B and NO
NO chassis ground
switch ON ↔ OFF. normal?
• 20 – 30 V
• Turn starting switch
ON.
NO
14 YES
Is there continuity
YES between battery
relay terminal E and
chassis ground?
1 13
• Turn starting switch NO
Is voltage between OFF.
Is specific gravity battery relay
of battery normal? terminal BR and
NO chassis ground YES
normal?
15
• Min. 1.24 • 20 – 30 V
• Turn starting switch Is voltage
between starting
ON. switch terminal BR YES
NO and chassis 16
ground normal? Is voltage
• 20 – 30 V between starting
• Turn starting switch terminal B
NO and chassis 17 YES
switch ON.
ground normal? Is voltage between
• 20 – 30 V fuse 1 inlet and
• Turn starting NO chassis ground
switch ON. normal?
• 20 – 30 V NO
• Turn starting switch
ON.
20-334 PC128US-2
(17)
TROUBLESHOOTING E-6
Cause Remedy
Defective contact or
disconnection in wiring
harness between battery Repair or replace
relay terminal M and
starting motor terminal B
Defective contact or
disconnection in wiring
harness between battery (+) Repair or replace
terminal and battery relay
terminal B
Defective contact or
disconnection in wiring
harness between safety Repair or replace
relay terminal C and
starting motor terminal S
Defective contact or
disconnection in wiring
Repair or replace
harness between battery
relay E and chassis ground
Defective contact or
disconnection in wiring Repair or replace
harness between starting
switch terminal BR (T7) and
battery relay terminal BR
Defective contact or
disconnection in wiring
harness between fuse 1 Repair or replace
outlet and starting switch
terminal B (T6)
Defective contact or
disconnection in wiring Repair or replace
harness between battery (+)
terminal - M11 (1), (2) - fuse
1 inlet
PC128US-2 20-335
(17)
TROUBLESHOOTING E-6
20-336 PC128US-2
(17)
TROUBLESHOOTING E-6
7 YES
Is voltage between
safety relay
terminal S and
NO chassis ground
normal?
• 20 – 30 V
• Turn starting
8
switch ON.
Is voltage between
safety relay
terminal C and
NO chassis ground
normal?
2
• 20 – 30 V YES
YES Is sound heard • Turn starting
from battery relay? switch ON.
9
• Turn starting
switch ON ↔ OFF. Is voltage between
safety relay
terminal B and
NO chassis ground
normal?
• 20 – 30 V
• Turn starting
switch ON.
NO
24 YES
Is there continuity
YES between battery
1 relay terminal E and
chassis ground?
Is specific gravity 23
• Turn starting switch NO
of battery normal? Is voltage between OFF.
battery relay
terminal BR and
• Min. 1.26 NO chassis ground YES
normal?
25
• 20 – 30 V
• Turn starting switch Is voltage
between starting
ON. switch terminal BR YES
NO and chassis 26
ground normal? Is voltage
• 20 – 30 V between starting
• Turn starting switch terminal B
NO and chassis 27 YES
switch ON.
ground normal? Is voltage between
• 20 – 30 V fuse 20 inlet and
• Turn starting NO chassis ground
switch ON. normal?
• 20 – 30 V NO
• Turn starting switch
ON.
20-338 PC128US-2
(17)
TROUBLESHOOTING E-6
Cause Remedy
Defective contact or
disconnection in wiring
harness between battery Repair or replace
relay terminal M and
starting motor terminal B
Defective contact or
disconnection in wiring
harness between battery (+) Repair or replace
terminal and battery relay
terminal B
Defective contact or
disconnection in wiring
harness between safety Repair or replace
relay terminal C and
starting motor terminal S
YES
Defective safety relay Replace
11
Is voltage between Defective contact,
YES M02 (2) and disconnection, or short
chassis ground
12 YES circuit with power source in Replace
normal? Is voltage between wiring harness between
alternator terminal alternator terminal R and
10 • Max. 13 V M02 (female) (2)
• Turn starting NO R and chassis
Is voltage between ground normal?
M02 (1) and switch ON. Defective alternator Repair or replace
• Max. 13 V NO
chassis ground
• Disconnect terminal R.
normal?
• Turn starting switch ON.
• 20 – 30 V
• Turn starting
switch ON.
• PPC lock switch: Go to A
LOCK NO
Defective contact or
disconnection in wiring
harness between safety Replace
relay terminal B and heater
relay terminal B
Defective contact or
disconnection in wiring
Repair or replace
harness between battery
relay E and chassis ground
Defective contact or
disconnection in wiring Repair or replace
harness between starting
switch terminal BR (T7) and
battery relay terminal BR
PC128US-2 20-339
(17)
TROUBLESHOOTING E-6
Cause Remedy
Disconnection or defective
13 YES contact in wiring harness
Repair or replace
between V03 (female) (6) -
Is voltage between M02 (female) (1)
A V03 (6) and chassis
ground normal? YES Defective V3 relay or Replace relay
malfunction of KOMTRAX
14
• 20 – 30 V
• Starting switch: Is voltage between
START Disconnection or defective
V03 (3) and chassis YES contact in wiring harness
• PPC lock switch: NO ground normal? Repair or replace
LOCK 15 between R06 (female) (3) -
V3 (female) (3)
• 20 – 30 V Is voltage between
• Starting switch: R06 (3) and chassis
START NO ground normal? 16 YES
Go to B
• PPC lock switch:
LOCK Is voltage between
• 20 – 30 V R06 (5) and chassis
• Starting switch: NO ground normal?
START
Go to C
• PPC lock switch: • 20 – 30 V NO
LOCK
• Starting switch:
START
18 YES • PPC lock switch:LOCK
Defective R06 relay Replace
Is resistance
YES between R06
(female) (2) -
chassis ground Disconnection or defective
normal? contact in wiring harness
17 between R06 (female) (2) - Repair or replace
• Max. 1 Ω NO
• Starting switch: OFF chassis ground
Is voltage between
R06 (1) and chassis • Disconnect R06. Disconnection or defective
B
ground normal? YES contact in wiring harness
between S10 (female) (3) - Repair or replace
19 R06 (female) (1)
• 20 – 30 V
• Starting switch: ON Is voltage between
S10 (3) and chassis YES
NO ground normal? 20 Defective PPC lock switch Replace
20-340 PC128US-2
(17)
TROUBLESHOOTING E-6
PC128US-2 20-341
(17)
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
-
T-
l-
-
l. 017tr
\ IVI
- T G
2
Swing motor
- - T- Travel motor
- - -
SOIC aid
-
“2 e
-
$
E
1”
i
5
?
5
u
z z
a,
3
E 2
F
0 s b
t;
$ s E
.-
.P
7 v
> J 8 I
2 t 5
5 4 z
5 2 8 .? s 6 1” B E
27T 2& s
uL
P
-ii
z
7
E
.a
P
h
is 2 z %
Q Y
0
.-E 6 z ;
L
E i;
.s 3 E 2 B
al
2
2 u2 6 2
2 ij
-s
‘m
z z P : J P a A
- - - -
- - - - - - - - - - - -
- - - - - - - - - - -
- - - - - - - - - - 5
- -
- - - - - - - - - - - -
- - - - - - - - - - -
- s
- - - - - - - - - -
- ST
- -
* - - - - - - - -
H-6
- ;5
- - - - - - - - - - -
- - - - - - - - - - - -
- - - - - - - - - - - -
H-7
- - - - - - - - - -
5
- 5
- - - - - - - - - -
H-8
- G
- - - - - - - - - - -
H-9
H-10
- - - - - - - - - - - -
H-l 1
- - - - - - - - - - - -
H-12
- - - - - - - - - - - -
H-13
- - - - - - - - - - -
- -
L
- - - - - - - - - - H-14
- - - - - - i - - - -
- b - - E
- - - H-15
- s
-
E
- - - i- - - -6
F - s
-
H-16
- - - - - - l 6
- - -
H-17
- iz
- - - F
6 - - 0 - - -
H-18
- s
- - r- l c- - - - - 0 - - - - H-19
- - - 0 - - - - - - -
- - - r- l G
- - - - - - - - - H-20
- - - - 0 - - - - - - -
- - - - l Ts
- - - - - - - - - H-21
- - - - DO
8 - - - - - - - -
- - - - - - - - - - - -
H-22
- - - 0 - - - - - - - -
H-23
- - - s- - - - - - - - - H-24
- i00 s- - -
PC128US-2 20-403
0
TROUBLESHOOTING H-l
H-l Speeds of all work equipment, travel, swing are slow or lack power
Jr Check that there is no abnormal noise from the pump before starting troubleshooting. (If there is any
abnormal noise, carry out troubleshooting for H-4.)
Cause Remedy
4 YES
Defective main pump epair or replace
YES
3r
pressure) normal?
GotoA
-See TESTING AND NO
ADJUSTING.
I I
. See TESTING AND Defective PC valve or epair or replace
ADJUSTING. NO PC-EPC valve
YEIS Is main pump
relief pressure
normal?
Defective main relief epair or replace
valve
pressure reducing
(Pressure reducing
6 YES valve, LS circuit) tepair or replace
Defective operation of
main valve
A Is LS differential
pressure normal?
Defective pump LS Ieplace
- 2.2 * 0.1 MPa NO valve
(22.5 * 1 kg/ems)
- Engine at full throttle
f Operate travel on
one side under no
load.
Note :Check the control circuit equipment. For details, see, TESTING AND ADJUSTING, Testing and
adjusting control circuit oil pressure.
Cause Remedy
fiiisz?p
Al reducing valve
- 3.24 f 0.49 MPa
(33 f 5 kg/cm9
- Engine at full
throttle NO
Defective main pump Repair or replace
3 YES
Go to Item 4
YE
pi+JH-
I
Is suction strainer
blocked by
n external object? Defect inside main pump Repair or replace
Is hydraulic tank
% External object:
oil level normal? cloth, etc.
Add hydraulic oi
Fine control
Improper hydraulic oil
N0 ability is poor or
response is poor
Cause Remedy
Is pump servo
orifice clogged? 2 YES Defective LS valve Replace
Does condition
_ become normal _
NO when LS valve is
replaced?
Defective servo piston Replace
NO
5 YES
20-408 PC128US-2
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM
B BRACC C R, Rz
OFF 0
HEAT 0 0 o--o
ON 000
START 0 0 0 O--o
Q
Fuse
Bat terv
308 . . 308 . ,301;
t - t
tterv ’
lay
Fuel level
sensor
Alternator Engine
level
water
sensor
Engine
pressure
switch
oil
h
0
Fusible
I ink
TXP0.2417
20-502 PC128US-2
0
TROUBLESHOOTING M-l
YES
Defective monitor panel Replace
, I
Fusible
I ink
CNll ($WP,l 6)
I I GND
I I
i%’ TXP02418
M-Z Display does not go out after completion of self check (all lamps light
up for 3 seconds) when starting switch is turned ON
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
M-3 Some items do not light up during self check (all lamps light up for 3
seconds) when starting switch is turned ON
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause 1 Remedy
Cause Remedy
I Is there
disconnection in l-l
;o to M-4 -
* Check visually for NO
blown bulb.
M-4 Charge caution lamp does not light up when starting switch is turned
ON (before starting engine) :
* Before carrying out troubleshooting, check that all’the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective monitor panel Replace
1
TXP02419
M-5 Engine oil pressure caution lamp does not light up when starting
switch is turned ON (before starting engine)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on the next step.
P=- Remedy
2 YES
Defective monitor panel Replace
Monitor Panel
I w-2 Engine oil
Pressure switch
a
PO1 (04016) (SWP12)
s17
$iJ
TXP02420
20-506 PC128US-2
0
TROUBLESHOOTING M-6
M-6 Preheating pilot lamp does not light up when starting switch is at
HEAT
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Monitor Panel
TXP0242 1
M-7 Engine oil pressure caution lamp lights up when engine is running
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on the next step.
* Wheri engine oil pressure is normal.
Cause Remedy
-Disconnect S13.
* Start engine.
-
1
-
YES
Is circuit between
_ PO1 (female) (9)
NO and chassis
ground insulated?
_
2 YES
Defective engine oil
pressure sensor
Replace
Repair or replace
wiring harness
- Min. 1 MR NO
and P13
* Disconnect PO1 and P13.
-Turn starting switch OFF.
Monitor Panel
I w-2 E20 Engine oil
Pressure switch
PO1 (04016) (SWP12) (SWP8)
D 3
TXP02.420
0
TROUBLESHOOTING M-8
Cause Remedy
TXP02419
a) After engine is started, temperature remains at bottom level and does not move
RemedY
b) After engine is started, temperature immediately goes up (there is no overheating but gauge enters
red range)
Cause Remedy
2 YES
Defective monitor panel
Is resistance
YES between PO7
1 (male) (1) and (2)
normal? Defective coolant
Is voltage between p - Replace
NO temperature sensor
PO1 (3) and chassis - * Start engine’
* Min. 4 kQ
ground normal? * Disconnect P07. Defective contact or
disconnection in wiring Repair or replace
*Start engine. harness between PO1
* Max. 0.1 V wiring harness
NO (female) (3) and chassis
ground
TXP02419
Cause Remedy
Defective contact or
disconnection in wiring
harness between PO1 Iepair or replace
segments light (female) (7) and PO6
(female) (I), or defective viring harness
Does fuel gauge contact or disconnection in
* Ground PO6 (female) - give full tank wiring harness between
(1) to chassis. fuel level sensor f-end) and
No display?
*Turn startina switch chassis ground
teplace
ON. -
*Wait for approx. 1
-1
* ;;;:3;.ircuit PO1 (7) NO Defective monitor panel
minute.
. Turn starting switch ON.
*Wait for approx. 1 minute.
b) Fuel level has gone down but fuel gauge remains at full tank display
Cause Remedy
3 YES
I II Defective monitor panel ?eplace
YES Do all segments
2 on fuel gauge go
Short circuit with chassis
--out? -1
ground in wiring harness Repair or replace
Is resistance of between PO1 (female) (7) wiring harness
YE . fuel level SenSOr _ * Disconnect P06. NO and PO6 (female) (1)
-Turnstarting switch
normal? ON.
1 p *Wait for approx. 1 minute.
. Remove sensor. Defective fuel level sensor i(eplace
* Move float by hand NO
and measure resistance
PO1 (3) and chassis
behveen PO6 (male) (1)
and chassis ground.
* F position: Max. 10 L2
-Start engine. * E position: Min. 85 Q
. Max. 0.1 V Defective contact or
* Disconnect P4.
disconnection in wiring
harness between PO1 Repair or replace
wiring harness
(female) (3) and chassis
ground
PC128US-2 20-511
0
TROUBLESHOOTING M-10
c) Even when tank is filled, fuel gauge does not give full tank display
I Cause 1 Remedy
- Remove sensor.
Defective fuel level sensor Replace
.zdv;;;;;rV hand NO
TXP02425
Remedy
Replace
when PO1 is
Contact of chassis ground
disconnected? Repair or replace
with wiring harness
between PO1 (female) (15) wiring harness
-Disconnect POl. NO
and PO4 (female) (1)
-Turn starting switch
ON.
Al arm
1 (KESl 2) PO4 (M2)
buzzer Fusible
@. = 3 I ink
a - 3
Monitor Panel I
ry
TXP02426
Remedy
Remedy
Jc Carry out Troubleshooting No. M-9.
Defective generation of
* Start engine. I 3eolace
- Measure voltage electricity by alternator
between alternator No
terminal R and
chassis ground.
-27.5 - 29.5 V
TXP02419
Cause Remedy
Cause Remedy
Lighting switch
’ Battery
relay
,...
Fusible TXP02428
I ink
F
2 YES Go to troubleshooting of
heater
Isthere continuity
:Es between MO6
1
(female) (4) and Defective contact or
Is continuity chassis ground? disconnection in wiring
(between MO6 harness between MO6 Repair or replace
male terminals) of _ * Turn starting NO (female) (4) and chassis
heater switch as switch OFF. ground
shown in table
below?
* Turn starting switch Defective heater switch Replace
OFF. NO
-Disconnect M06.
2 YES Go to troubleshooting of
heater
Is there continuity
YES between Ml 2
1 (female) (2) and Defective contact or
chassis ground? disconnection in wiring
Is there continuity ~ j harness between MO6 Repair or replace
between MO6
_ - DisconnectM12. NO (female) (3) and Ml2
-Turn starting switch OFF. (female) (2)
(male) (3) and (4)? -Turn starting switch to Lo.
- Disconnect M06. Replace
Defective heater switch
- 2;; starting switch NO
Go to troubleshooting of
heater
Defective contact or
I
disconnection in wiring
I I I harness between MO6 3epair or replace
between MO6 *Disconnect M12. NO (female) (3) and Ml2
-Turn starting switch OFF. (female) (2)
(male) (2) and (4)? -Turn starting switch to Hi
4
Preheating switch
Preheating
switch
~06 (KES~ 4) ~12 (KES~ 3) ,____
I TXP0.2429
PC128US-2 20-551
(17)
M-18 The fuel level gauge indicates FULL all the time ............................................................................ 20-580
M-19 The fuel level gauge indicates nothing............................................................................................ 20-580
M-20 Though the swing lock switch is set to ON (lock), (the swing lock monitor) does not come ON..... 20-582
M-21 While the engine is rotating, the service meter does not advance.................................................. 20-582
M-22 The fuel level sensor system is defective ....................................................................................... 20-583
M-23 The coolant temperature sensor system is defective...................................................................... 20-584
M-24 The windshield wiper does not work, or works though the wiper is not switched ON..................... 20-585
a) The windshield wiper does not work........................................................................................... 20-585
b) The windshield wiper works though it is not switched ON .......................................................... 20-585
M-25 The washer motor does not work, or works though the washer is not switched ON ...................... 20-588
a) The washer motor does not work ............................................................................................... 20-588
b) The washer motor works though the washer is not switched ON............................................... 20-588
! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were
inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and
connectors were returned to the original positions, the machine has restored.
! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the
service code "E" is displayed. (When the service code is not displayed, the machine has restored.)
! Before diagnosis, check if related connectors are engaged properly.
! Be sure to return disconnected connectors to the original positions before proceeding to the next step.
20-552 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM
20-556 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM
20-558 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM
PC128US-2 20-559
(17)
TROUBLESHOOTING M-1
" This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13
connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the bat-
tery terminals are disconnected and connected for troubleshooting. This is not an abnormality.
(When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF)
" When the service code is displayed again after the resetting arrangement is made, follow the procedures
below for diagnosis:
Cause Remedy
1
• After making the "Resetting ar- Is the service code displayed NO
rangement," check the situa- —
again after the "Resetting ar- Normal
tions for a while in the normal
operation. (See Note 1.) rangement" is taken?
YES
2
• Set the starting switch to Disconnection, defective contact or
Is the voltage between P01 (8) NO ground fault of harness among the bat- Repair or
OFF. and the machine body normal?
• 20 – 30V tery, M13 (1), (2) and P01 (female) (8) replace
YES
Defective monitor panel Replace
Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)
20-560 PC128US-2
(17)
TROUBLESHOOTING M-1
" This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13
connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the bat-
tery terminals are disconnected and connected for troubleshooting. This is not an abnormality.
(When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF)
" When the service code is displayed again after the resetting arrangement is made, follow the procedures
below for diagnosis:
Cause Remedy
1
• After making the "Resetting ar- Is the service code displayed NO
rangement," check the situa- —
again after the "Resetting ar- Normal
tions for a while in the normal
operation. (See Note 1.) rangement" is taken?
YES
2
• Set the starting switch to Disconnection, defective contact or
Is the voltage between P01 (8) NO ground fault of harness among the bat- Repair or
OFF. and the machine body normal?
• 20 – 30V tery, M13 (1), (2) and P01 (female) (8) replace
YES
Defective monitor panel Replace
Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)
PC128US-2 20-561
(17)
TROUBLESHOOTING M-2, M-3, M-4, M-5, M-6, M-7
Cause Remedy
1
Does the coolant temperature gauge NO
on the monitor indicate a red range
and is the caution lamp flashing?
YES
See M-13-c). —
2
Is "E" shown in front of the serv- NO Failure of engine body system
• Set the starting switch to ON. —
ice code? (See Note 1.)
YES
Defective monitor panel Replace
Note 1 : The monitor panel has returned to normal as far as the display is concerned. Since the coolant tem-
perature sensor detected water temperatures of over 105°C so far, remove the factors in the trouble-
shooting of the engine body.
20-562 PC128US-2
(17)
TROUBLESHOOTING M-8
M-8 When the starting switch is set to ON, the whole monitor panel does
not come ON for 3 sec.
PC128US-2 Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 – 1500
Cause Remedy
1
• Set the starting switch to ON. Are the voltages among P01 (8) – NO
(6), (7), P02 (1), (2) – (6) and (7)
• 20 – 30V
normal?
YES
Defective monitor panel. Replace
2
Disconnection, defective contact or Repair or
• Set the starting switch to ON. Is the voltage between Fuse 13 NO ground fault of harness between Fuse
• 20 – 30V and the machine body normal? replace
13 and battery relay RM.
YES Disconnection, defective contact or Repair or
ground fault of harness between P01
replace
(female) (1) (2) and Fuse 13
3
Disconnection, defective contact or Repair or
• Set the starting switch to ON. Is the voltage between Fuse 18 NO
ground fault of harness between Fuse
• 20 – 30V and the machine body normal? replace
18 and Battery B.
YES Disconnection, defective contact or
ground fault of harness between P02 Repair or
(female) (19) and Fuse 6 replace
Cause Remedy
PC128US-2 20-563
(17)
TROUBLESHOOTING M-8
20-564 PC128US-2
(17)
TROUBLESHOOTING M-8
Cause Remedy
1
• Set the starting switch to ON. Are the voltages among P01 (8) – NO
(6), (7), P02 (1), (2) – (6) and (7)
• 20 – 30V
normal?
YES
Defective monitor panel. Replace
2
Disconnection, defective contact or Repair or
• Set the starting switch to ON. Is the voltage between Fuse 12 NO ground fault of harness between Fuse
• 20 – 30V and the machine body normal? replace
12 and battery relay RM.
YES Disconnection, defective contact or Repair or
ground fault of harness between P01
replace
(female) (1) (2) and Fuse 12
3
Disconnection, defective contact or Repair or
• Set the starting switch to ON. Is the voltage between Fuse 18 NO
ground fault of harness between Fuse
• 20 – 30V and the machine body normal? replace
18 and Battery B.
YES Disconnection, defective contact or
ground fault of harness between P02 Repair or
(female) (19) and Fuse 6 replace
Cause Remedy
PC128US-2 20-565
(17)
TROUBLESHOOTING M-8, M-9
M-9 The starting switch is set to ON, and the whole monitor panel
remains lighted.
Cause Remedy
20-566 PC128US-2
(17)
TROUBLESHOOTING M-10
Cause Remedy
1
• Disconnect the terminal R1. Is the voltage between the starting NO
• Set the starting switch to ON. switch R1 and the machine body Defective starting switch Replace
• Max. 1V normal?
YES
2
• Set the starting switch to Is the voltage between P02 (18) NO Hot short circuit of harness between Repair or
ON. and the machine body normal? starting switch R1 and P02 (female) replace
• Max. 1V (18)
YES
Defective monitor panel Replace
PC128US-2 20-567
(17)
TROUBLESHOOTING M-10
Cause Remedy
1
• Disconnect the terminal R1. Is the voltage between the starting NO
• Set the starting switch to ON. switch R1 and the machine body Defective starting switch Replace
• Max. 1V normal?
YES
2
• Set the starting switch to Is the voltage between CR1 (11) NO Hot short circuit of harness between Repair or
ON. and the machine body normal? starting switch R1 and CR1 (female) replace
• Max. 1V (11)
YES
3
Are the monitoring code [0045] – NO
Defective controller Replace
(3) and [1027] – (3) ON?
YES
4
Is the monitoring code [1061] – NO Replace
Defective controller
(2) ON?
YES
Defective monitor panel Replace
20-568 PC128US-2
(17)
TROUBLESHOOTING M-11
M-11 When the starting switch is set to ON, the engine is started, the
basic check items flash.
a Inspect both the alternator system and the engine oil pressure system.
a) Alternator system
a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is
defective.
Cause Remedy
1
• Engine start, Medium speed Is the voltage between the alter- NO
min. nator R and the machine body Defective alternator Replace
• 20 – 30V normal?
YES
2
• Engine start, Medium speed Is the voltage between P02 (fe- NO Disconnection or defective contact of Repair or
min. male) (11) and the machine body harness between alternator R and P02 replace
• 20 – 30V normal? (female) (11)
YES
Defective monitor panel. Replace
PC128US-2 20-569
(17)
TROUBLESHOOTING M-11
Cause Remedy
1
Does the display disappear when NO
• Engine slow the oil pressure sensor terminal S17
is disconnected at engine slow?
YES
The oil pressure sensor is defective Replace
(at low pressure).
2
• Set the starting switch to OFF. Is there continuity between P02
(female) (7) and the machine
NO
• Disconnect the sensor harness Defective monitor panel Replace
and P02. body?
YES Ground fault of harness between P02 Repair or
(female) (7) and sensor terminal S17 replace
20-570 PC128US-2
(17)
TROUBLESHOOTING M-12
a) Alternator system
a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is
defective.
Cause Remedy
1
• Disconnect the terminal R. Is the voltage between the alter- NO
• Set the starting switch to ON. nator R and the machine body Defective alternator Replace
• Max. 1V normal?
YES
2
• Disconnect P02.
• Set the starting switch to ON. Is the voltage between P02 (11) NO Hot short-circuit of harness between Repair or
and the machine body normal? P02 (female) (11) and alternator R replace
• Max. 1V
YES
Defective monitor panel Replace
PC128US-2 20-571
(17)
TROUBLESHOOTING M-12
Cause Remedy
1
• Set the starting switch to OFF. Is there continuity between the NO
• Disconnect the sensor terminal sensor terminal S17 and the ma- Defective oil pressure sensor Replace
S17. chine body?
YES
2
• Set the starting switch to ON. Is there continuity between P02 NO Disconnection or defective contact of
• Disconnect P02 and sensor (female) (11) and the sensor ter- harness between P02 (female) (7) and Repair or
terminal S17. minal S17? sensor terminal S17 replace
YES
Defective monitor panel Replace
20-572 PC128US-2
(17)
TROUBLESHOOTING M-13
M-13 When the starting switch is set to ON and the engine is started, pre-
cautions and emergency stop items flash. (but when inspection
items before diagnosis and engine are normal)
Cause Remedy
See M-12-b). —
Cause Remedy
See M-12-a). —
PC128US-2 20-573
(17)
TROUBLESHOOTING M-13
Cause Remedy
1
• Engine start Is the coolant temperature gauge NO
Defective monitor panel Replace
• Medium speed min. in the red range?
YES
2
Is only Level 1 (the lowest level)
• Engine start of the gauge displayed after P07 NO
is disconnected?
YES
The coolant temperature sensor —
system is defective. (See M-25.)
3
• Set the starting switch to OFF. Is the resistance value between Disconnection or defective contact of Repair or
• Disconnect P02 and P07. P02 (female) (1) and P07 (fe-
NO harness between P02 (female) (1) and
replace
• Max. 1 Ω male) (1) normal? P07 (female) (1)
20-574 PC128US-2
(17)
TROUBLESHOOTING M-13
Cause Remedy
1
NO Replace
• Engine start Is the fuel gauge in the red range? Defective monitor panel
YES
• Engine start 2
• Wait for 2 minutes approx. Does the gauge indication come
(The display of fuel level is on up to Level 9 (the right end) NO
arranged to be slightly de- when P06 (female) (1) is connect-
layed because the fuel level ed to the machine body ground?
fluctuates.) YES
The fuel level sensor system is
—
defective. (See M-22.)
PC128US-2 20-575
(17)
TROUBLESHOOTING M-14
M-14 When the starting switch is set to ON (the engine stops), the buzzer
does not sound for 1 sec.
Though caution items flash, the buzzer does not sound.
! Even when "BATTERY CHARGE LEVEL" or "FUEL" of the caution items becomes abnormal, the buzzer
does not sound.
! The buzzer is controlled inside the monitor panel. When a buzzer sound is requested or when the voltage
of P01 (11) comes to the range from 20 to 30V, the buzzer will sound.
Cause Remedy
• Set the starting switch to 1
OFF.
• Disconnect P03. Is the resistance value between NO
• Set the buzzer cancel switch Defective buzzer cancel switch Replace
P03 (female) (1) a d (2) normal?
to ON : Max. 1Ω
• Set the buzzer cancel switch
to OFF : Min. 1 M Ω YES
2
• Disconnect P03. Is the voltage between P02 (16) NO Ground fault of harness between P02 Repair or
• Set the starting switch to ON. and the machine body normal? (female) (16) and P03 (female) (2) replace
• 20 – 30V
YES
Defective monitor panel Replace
20-576 PC128US-2
(17)
TROUBLESHOOTING M-15
Cause Remedy
1
• Set the starting switch to ON. NO
Is Bit (4) of Monitoring Code
• Set to Monitoring Code
[0045] OFF?
[0045].
YES
Defective monitor panel Replace
2
• Set the starting switch to ON. Disconnection or defective contact of
Is the voltage between P02 (19) NO Repair or
• Set the lighting switch to ON. harness between P02 (female) (19)
and the machine body normal? replace
• 20 – 30V and M47 (male) (14)
YES
Defective monitor panel Replace
PC128US-2 20-577
(17)
TROUBLESHOOTING M-16, M-17
Cause Remedy
1
When a short connector is connect-
• Disconnect P07. ed to P07 (female), does the gauge NO
• Set the starting switch to ON. level rise step by step and does the
gauge go out finally?
YES
The coolant temperature sensor —
system is defective. (See M-23.)
2
Is there continuity between P02 NO Disconnection or defective contact of
• Set the starting switch to OFF. Repair or
(female) (1) and P07 (female) harness between P02 (female) (1) and
• Disconnect P02 and P07. (1)? replace
P07 (female) (1)
YES
3
Disconnection or defective contact of
Is there continuity between P02
• Set the starting switch to OFF. NO harness between P02 (female) (13) Repair or
(female) (13) (20) and P07
• Disconnect P02 and P07. (female) (2)? (20) and machine body P02 (female) replace
(2) machine body
YES
Defective monitor panel Replace
Cause Remedy
1
• Disconnect P07. Does the gauge indication appear NO
• Set the starting switch to ON. when P07 is disconnected?
YES
The coolant temperature sensor —
system is defective. (See M-23.)
2
• Set the starting switch to ON. Is there continuity between P02 NO
(female) (1) and the machine Defective monitor panel Replace
• Disconnect P02 and P07.
body?
YES Ground fault of harness between P02 Repair or
(female) (1) and P07 (female) (1) replace
20-578 PC128US-2
(17)
TROUBLESHOOTING M-16, M-17
PC128US-2 20-579
(17)
TROUBLESHOOTING M-18, M-19
M-18 The fuel level gauge indicates FULL all the time.
! Before the diagnosis, make sure that the fuel tank is really filled with fuel.
Cause Remedy
2
• Set the starting switch to
Is there continuity between P02 (fe- NO
OFF. Defective monitor panel Replace
male) (2) and the machine body?
• Disconnect P02 and P06.
YES Ground fault of harness between P02 Repair or
(female) (2) and P06 (female) (1) replace
Cause Remedy
1
Does the gauge indicate anything NO
• Disconnect P06. after P06 (female) (1) is connect-
• Set the starting switch to ON. ed to the machine body ground?
YES
The fuel level sensor system is —
defective. (See M-22.)
2
Is there continuity between P02 (fe- Disconnection or defective contact of
• Set the starting switch to OFF. male) (2) and the machine body after NO harness between P02 (female) (2) and Repair or
• Disconnect P02 and P06. P06 (female) (1) is connected to the P06 (female) (1) replace
machine body ground?
YES
Defective monitor panel Replace
20-580 PC128US-2
(17)
TROUBLESHOOTING M-18, M-19
PC128US-2 20-581
(17)
TROUBLESHOOTING M-20, M-21
Cause Remedy
1
Is the voltage between P02 (17) NO Disconnection or defective contact of
Repair or
• Set the starting switch to ON. and the machine body as per the harness between P02 (female) (17)
table? and X05 (male) (1) replace
YES
Table Defective monitor panel Replace
Swing lock switch ON Max. 1V
Swing lock switch OFF 20 – 30V
M-21 While the engine is rotating, the service meter does not advance.
Cause Remedy
1
• Start the engine. Is the battery charge level caution NO
Defective monitor panel Replace
Medium speed min. lamp ON?
YES
See M-12 a). —
20-582 PC128US-2
(17)
TROUBLESHOOTING M-22
Cause Remedy
1
Check by raising and lowering
the float if the resistance valve NO
between the connector (1) and
the flange is as per the table.
YES
Does the arm move smoothly? NO Defective sensor (See Note 2.) Replace
YES
3
Does the float have large crack, NO Clean or
chip or flaw? Defective contact of connector replace the
connector.
YES Replace the
Interference of sensor in tank sensor.
(See Note 2.)
4
Is it found in visual check that the NO Defective sensor Replace
harness is cut?
Table
Upper stopper position About Max. 12Ω
(Full)
Lower stopper position About 85 – 110Ω
(Empty)
PC128US-2 20-583
(17)
TROUBLESHOOTING M-23
Cause Remedy
1
Is the resistance value between the NO
temperature sensor connectors
(male) (1) and (2) as per the table?
YES Clean the
Defective contact of connector connector or
(See Note 1.) replace the
sensor.
2
Is it found in visual check that the NO Defective sensor Replace
harness is cut?
Table
Normal temperature (25°C) About 37 – 50k Ω
100°C About 3.5 – 4.0k Ω
Note 1 : In case of recurrence, the machine side connector (female side) is supposed to be defective. So, check
the machine side connector and harness.
Note 2 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.
20-584 PC128US-2
(17)
TROUBLESHOOTING M-24
M-24 The windshield wiper does not work, or works though the wiper is
not switched ON.
a) The windshield wiper does not work.
! Make sure that the fuse 18 is normal.
! Execute this diagnosis when the service code [E112] [E113], [E115] or [E116] is displayed.
Cause Remedy
1
• Front window : Close position
• Set the starting switch to ON. Does Bit (3) of the monitoring NO
• Set the monitoring code to code [0049] come on?
[0049].
YES
2
• Set the starting switch to ON.
• Set the wiper switch to "ON" When the wiper switch is set to
or "INT." "ON" or "INT," do Bits (4) and (5) NO Defective monitor panel Replace
• Set the monitoring code to of the monitoring code [0049] go
[0049]. out?
YES
3
• Set the starting switch to ON. Are the voltages between pins of NO
M50 as per Table 1?
YES
Defective wiper motor Replace
4
Are the resistance values be- Disconnection, defective contact, short- Repair or
• Set the starting switch to OFF. tween pins from P01 (female) and NO circuit of ground fault of harness of im- replace
• Disconnect P02 and M50. M50 (male) as per Table 2? proper resistance value
YES
Defective monitor panel Replace
5 Check the
• Set the starting switch to OFF. front window,
Is the resistance value between NO The rear limit switch is defective, or the or replace the
• Disconnect Terminals (1)
Terminals (1) and (2) of the rear front window is opened.
and (2) of W03. rear limit
limit switch W03 normal? switch.
• Max. 1Ω
YES
6
.• Set the starting switch to OFF. Are the resistance values between
• Disconnect P02 and Termi- the rear limit switch W03 terminal NO Disconnection or defective contact of Repair or
nals (1) and (2) of W03. (1) and P02 (female) (15) and be- harness of improper resistance value replace
• Max. 1Ω tween W03 Terminal (2) and the
machine body normal?
YES
Defective monitor panel Replace
Cause Remedy
1
• Front window : Closed position
• Set the starting switch to ON. Does Bit (3) of the monitoring NO
Defective monitor panel Replace
• Set the monitoring code to code [0049] come ON?
[0049]
YES
PC128US-2 20-585
(17)
TROUBLESHOOTING M-24
Table 1
Timing Chart when the windshield wiper is set to ON
When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in the range
of 20 – 30V.
When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in
the range from 20 – 30V.
Table 2
Diagnosis 1 Resistance value
Between P01 (female) (10) and M50 (male) (1)
Between P01 (female) (9) and M50 (male) (3)
Between P01 (female) (12) and M50 (male) (4) Max. 1Ω
Between P01 (female) (6), (7) and M50 (male) (5)
Between P01 (female) (5) and M50 (male) (6)
Between M50 (female) (1), (3), (4), (5), (6) and GND Min. 1MΩ
20-586 PC128US-2
(17)
TROUBLESHOOTING M-24
PC128US-2 20-587
(17)
TROUBLESHOOTING M25
M-25 The washer motor does not work, or works though the washer is not
switched ON.
a) The washer motor does not work.
! Make sure that Fuse 4 is normal.
a-1) When [E114] is displayed.
Cause Remedy
1
• Set the starting switch to ON. Is the voltage among P01 (fe- NO Hot short circuit of harness between
• Disconnect P02 and M28. male) (3), M28 (female) (2) and Replace
P01 (female) (3) and M28 (female) (1).
• Max. 1V the machine body normal?
YES
• Defective monitor panel Repair or
• Defective diode replace
Cause Remedy
1
• Set the starting switch to ON. Is the voltage among Fuse 4, NO Disconnection or defective contact of Repair or
• Disconnect M28. M28 (female) (2) and the ma- harness between Fuse 4 and M28 (fe- replace
• Max. 20 – 30V chine body normal? male) (2).
YES
2
• Set the starting switch to OFF. Is the resistance value between NO Disconnection or defective contact of
• Disconnect P01 and M28. P01 (female) (3), M28 (female) harness between P01 (female) (3) and Repair or
• Max. 1Ω (1) normal? M28 (female) (1). replace
YES
3
• Set the starting switch to ON. Is the voltage between P01 (fe- NO
• Set the washer switch to ON. male) (3) and the machine body Defective washer motor Replace
• Max. 1V normal?
YES
Defective monitor panel Replace
b) The washer motor works though the washer is not switched ON.
Cause Remedy
1
• Set the starting switch to OFF. Is the resistance value between NO Ground fault of harness between P01 Repair or
• Disconnect P02 and M28. M28 (female) (1) and the ma- (female) (3) and M28 (female) (1). replace
• Min. 1M Ω chine body normal?
YES
Defective monitor panel Replace
20-588 PC128US-2
(17)
TROUBLESHOOTING M-25
PC128US-2 20-589
(17)
TROUBLESHOOTING OF COMMUNICATION
SYSTEM (N MODE)
! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were
inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and
connectors were returned to the original positions, the machine has restored.
! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the
service code "E" is displayed. (When the service code is not displayed, the machine has restored.)
! Before diagnosis, check if related connectors are engaged properly.
! Be sure to return disconnected connectors to the original positions before proceeding to the next step.
PC128US-2 20-601
(17)
TROUBLESHOOTING N-1
1 Cause Remedy
Are [128] and "US" intermittently NO
displayed in the monitoring code
1002?
YES
The machine has restored. —
2
• Set the starting switch to ON.
• 7.5V min. Is the voltage between CR2 (21) NO
• Disconnect CR2 and measure and the machine body normal?
the voltage on the harness
side. YES
Defective controller CR700 Replace
3
Is the resistance value among NO Disconnection of harness among P02
P02 (9), (10) and CR2 (21) (9), (10) and CR2 (21) Replace
normal?
YES
Defective monitor panel Replace
• When each controller is not connected to the network, "---" is displayed. When a correct alphanumeric
character is not displayed (when another model is displayed), the model of each controller has not been
selected properly.
20-602 PC128US-2
(17)
TROUBLESHOOTING N-1
1 Cause Remedy
Are model code and attachment NO
code displayed according to
setting in monitoring code 1001?
YES
The machine has restored. —
2
• Set the starting switch to ON.
• 7.5V min. Is the voltage between CR2 (21) NO
• Disconnect CR2 and measure and the machine body normal?
the voltage on the harness
side. YES
Defective controller CR700 Replace
3
Is the resistance value among NO Disconnection of harness among P02
P02 (9), (10) and CR2 (21) (9), (10) and CR2 (21) Replace
normal?
YES
Defective monitor panel Replace
PC128US-2 20-603
(17)
TROUBLESHOOTING OF CONTROLLER CR700
[DECELERATION CONTROL SYSTEM]
(E MODE)
! During troubleshooting after an abnormality occurred, if service code "E" is not displayed when you inserted
a T-adapter after detaching a connector, or when you connected the connector after detaching the T-
adapter, the normal condition has been restored already.
! If you have turned off starting-switch after an abnormality occurred, turn it on and check to see if service
code "E" is displayed. (If it is not displayed, the normal condition has been restored).
! Before starting troubleshooting, check for any faulty engagement of related connectors.
! Before going to next step in the troubleshooting procedure, be sure to connect any connector you have
detached.
PC128US-2 20-701
(17)
CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700
TROUBLESHOOTING [DECELERATION CONTROL SYSTEM]
Any rpm
Engine is forced to be fixed at the rpm for (Follows the throttle
Deceleration-motor warming-up. (Any throttle direction is ignored.) direction.)
potentiometer
(Controls the process.)
2 seconds
The machine does not allow engine to start when coolant is cold (lower than 30° C) when the deceleration
motor was found normal by the check of whether or not the deceleration motor linkage worked.
! To release this control of cold engine start, connect a short-circuit connector to engine-coolant-tempera-
ture sensor (CN-P07) connected to CN-P02 ((1)) on monitor panel and cause short circuit between it
and GND {or between CN-P07 (female) (1) and GND}, or check operation in the deceleration-adjust-
ment mode.
If an abnormality occurred, and it was alarmed in the clock-display section on monitor panel, look up to the
corresponding diagnosis flow of E1 through E10 according to the quick-reference table for troubleshooting.
If no abnormality was alarmed on the display though it existed in the machine body, you have to determine
whether it occurred in "mechanical system or electric system". The problems listed in 1) - 6) above may
also occur due to faulty adjustment of the linkage between deceleration motor and injection pump. If any of
1) - 6) above occurred without no alarm on the display, diagnose it according to the following procedure:
20-702 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
20-708 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
(2/2)
PC128US-2 20-709
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
20-710 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
(2/2)
PC128US-2 20-711
(17)
TROUBLESHOOTING E-1
Cause Remedy
1
• Turn starting switch ON Is voltage normal between CR3 NO
• 20 – 30V (1),(11) – (21), (31), (32), (33)?
YES
Defective controller CR700 Replace
2
• Starting switch ON Is voltage between fuse 18 and NO Disconnection or defective contact of Repair or
• 20 – 30V body normal? harness between fuse 18 and battery. replace
20-712 PC128US-2
(17)
TROUBLESHOOTING E-1
PC128US-2 20-713
(17)
TROUBLESHOOTING E-2
Cause Remedy
1
• Turn starting switch ON;
operate fuel dial. Is current value normal between NO
• 1.2A or less CR3 (female) (18) and (23)?
• Temperature of engine
coolant: 30°C or higher YES
Defective controller Replace
2
• Detach R07 and CR3. Is resistance value normal between NO Defective harness; defective connector Repair or
• Min. 1 MΩ CR3 (female) (18) and body? CN-A09 replace
YES
Defective relay Replace
20-714 PC128US-2
(17)
TROUBLESHOOTING E-3
Cause Remedy
1
• Turn starting switch ON;
operate dial (up). Is current value normal between NO
• 1.2A or less CR3 (female) (25) and (23)?
YES
Defective controller Replace
2
• Detach R09 and CR3. Is resistance value normal between NO Defective harness; defective connector Repair or
• Min. 1 MΩ CR3 (female) (25) and body? CN-A09 replace
YES
Defective relay Replace
PC128US-2 20-715
(17)
TROUBLESHOOTING E-3
20-716 PC128US-2
(17)
TROUBLESHOOTING E-4
Cause Remedy
1
• Turn starting switch ON;
operate dial (down). Is current value normal between NO
• 1.2A or less. CR3 (female) (35) and (23)?
YES
Defective controller Replace
2
• Detach R08 and CR3. Is resistance value normal between NO Repair or
• Min. 1 MΩ CR3 (female) (35) and body? Defective harness
replace
YES
Defective relay Replace
PC128US-2 20-717
(17)
TROUBLESHOOTING E-4
20-718 PC128US-2
(17)
TROUBLESHOOTING E-5
Cause Remedy
• Turn starting switch ON. 1
• 4A or less if normal
When dialed up: Is current value normal between NO
(+) on (5) side, (–) on (6) side M48 (female) (5) (motor (+)) and
When dialed down: (6)(motor (–))?
(–) on (5) side, (+) on (6) side YES
Defective motor (drive system) Replace
motor
• Resistance value between
(1) and (2) of eachrelay:
290 Ω ± 10%
• Operation of each relay
(when starting switch is ON) 2
When neutral: Do relays of R07, R08 and R09 NO
(3) and (6) continue. operate normally? Defective relay Replace
When dialed up:
R07, and R09 (3) and (5)
YES
continue. Repair or
When dialed down: Defective harness; fuse (9) blown
replace
R07, and R08 (3) and (5)
continue.
PC128US-2 20-719
(17)
TROUBLESHOOTING E-5
20-720 PC128US-2
(17)
TROUBLESHOOTING E-6
Cause Remedy
1
• Fuel control dial voltage:
Fuel control dial FULL: 0.7 V Is fuel control dial voltage of NO
monitoring 1034 normal?
–
PC128US-2 20-721
(17)
TROUBLESHOOTING E-7
Cause Remedy
2
• Detach E07 Is resistance value normal bet- NO Replace
Defective engine speed sensor
• 500 – 1,000 Ω ween E07 (male) (1) and (2)?
YES
3
• Detach CR2 Is resistance value normal bet- NO Replace
• 500 – 1,000 Ω ween CR2 (female) (39) and Defective harness motor
(40)?
YES Faulty installation of engine-speed Testing and
sensor adjusting
20-722 PC128US-2
(17)
TROUBLESHOOTING E-8
Cause Remedy
• Reset auto-decelerator.
• Feedback potentiometer 1
voltage:
Fuel control dial FULL: Is feedback potentiometer voltage NO
4.2 V (*1) of monitoring 1035 normal?
4.6 V (*2)
Fuel control dial SLOW: YES
2.1 V (*1)
Defective controller Replace
2.7 V (*2)
• Disconnect M48.
• M48 (male)
Between (1) – (2): 2
0.36 – 3.9 kΩ
Between (2) – (3): Is resistance between M48 (male) NO
Defective decelerator motor Replace
1.4 – 5.5 kΩ (1), (2), and (3) normal?
Between (1) – (3): 5 ± 1 kΩ
• Between M48 (male) (1), (2), YES
(3) – chassis ground: Defective wiring harness Repair or
Min. 1 MΩ replace
PC128US-2 20-723
(17)
TROUBLESHOOTING E-8
20-724 PC128US-2
(17)
TROUBLESHOOTING E-9
1 Cause Remedy
• Disconnect CR1.
• Resistance between CR1 Is resistance between CR1 (female) NO
(female) (22) – chassis (22) and chassis ground normal?
ground: Min. 1 MΩ
YES
Defective controller Replace
2
• Disconnect M48.
• Resistance between CR1 Is resistance between CR1 (female) NO
(female) (22) – chassis (22) and chassis ground normal?
ground: Min. 1 MΩ
YES
Defective deceleration motor Replace
3
• Disconnect M51.
• Resistance between CR1 Is resistance between CR1 (female) NO Defective wiring harness Repair or
(female) (22) – chassis (22) and chassis ground normal? (Short circuit in 5-V line) replace
ground: Min. 1 MΩ
YES
Defective fuel control dial Replace
PC128US-2 20-725
(17)
TROUBLESHOOTING E-9
20-726 PC128US-2
(17)
TROUBLESHOOTING E-10
Cause Remedy
1
• Disconnect CR3.
• Resistance between CR3 Is resistance between CR3 (female) NO
(female) (4) – chassis (4) and chassis ground normal?
ground: 68 Ω ± 10%
YES
Defective controller Replace
• Disconnect M52. 2
• Resistance between M52 Are resistance between stop solenoid
(male) (1) – (2): 68 Ω ± 10% relay M52 (male) (1) and (2) and NO
resistance between each pin and Defective stop solenoid relay Replace
• Resistance between M52
(male) (1), (2) – chassis chassis ground normal?
ground: Min. 1 MΩ YES
• Disconnect D32 3
(with M52 disconnected). NO
Is resistance between CR3 (female) Defective wiring harness Repair or
• Resistance between CR3
(4) and chassis ground normal? (Grounding fault) replace
(female) (4) – chassis
ground: Min. 1 MΩ
YES
Defective diode (D03) Replace
PC128US-2 20-727
(17)
TROUBLESHOOTING E-11
Cause Remedy
1
When auto-decelerator reset
switch is pressed; Is auto-decelerator reset switch NO
Defective monitor panel or controller Replace
• Bit (2): ON (Auto-decelerator of monitoring 1022 normal?
reset)
YES
Monitoring code [1023]
• Bit (1): OFF (Boom LOWER 2
pressure switch)
• Bit (3): OFF (Travel pressure Is each pressure switch signal of
switch) monitoring 1023 and 1028 nor- NO
• Bit (4): OFF (Swing pressure mal?
switch) YES
• Bit (5): OFF (Arm IN Defective controller Replace
pressure switch)
• Bit (6): OFF (Boom RAISE
pressure switch) 3
Monitoring code [1028] When pressure switch connector of
• Bit (1): OFF (Arm OUT abnormal part is disconnected,
NO Defective pressure switch
(Internal seizure) Replace
pressure switch) does bit keep lighting?
• Bit (2): OFF (Att, blade
RAISE/LOWER pressure YES Repair or
Defective wiring harness
switch) (Grounding fault in signal line) replace
• Bit (3): OFF (Bucket CURL
pressure switch)
• Bit (4): OFF (Bucket DUMP
pressure switch)
! The pressure switches for the blade and attachments are not shown in this figure.
20-728 PC128US-2
(17)
TROUBLESHOOTING OF CONTROLLER CR700
[PUMP CONTROL SYSTEM]
(C MODE)
! During troubleshooting after an abnormality occurred, if no service code "E" is displayed when you inserted
a T-adapter after detaching a connector, or when you connected the connector after detaching the T-
adapter, the normal condition has been restored already.
! Before starting troubleshooting, check for any faulty engagement of related connectors.
! Before going to next step in the troubleshooting procedure, be sure to connect the connector you have
detached.
PC128US-2 20-801
(17)
TABLE FOR DETERMINING CONTROLLER
TROUBLESHOOTING CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED
Disconnection in LS-EPC
Disconnection in 2-Stage
Short circuit in PC-EPC
solenoid system
solenoid system
solenoid system
solenoid system
controller
User codes LED E02 E03 —
Failure mode Service codes off 232 233 203 213 206 216 205 215 222 223
Slower speed or reduced power of entire work equipment, traveling,
ment, traveling, and
Entire work-equip-
and swinging
Substantial drop of engine speed, or engine stop
swinging
Boom inoperable
Arm inoperable
Bucket inoperable
Greater hydraulic drift
Greater time lag (engine slow)
Independent relief causes other work equipment's movement.
Full power cannot be attained when pressure is increased.
Worsened or weaker stroke-end cushion of boom RAISE
In the case of compound operation, the greater the load, the longer
Compound
Boom moves slower in the case of the swing + boom (RAISE) oper-
ation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Traveling system
Travel deviation
Deviation is great at the start of traveling
Slower traveling speed
Steering is hard or not powerful.
Traveling speed is unchangeable, or faster than the set speed.
Inoperable (only on one side)
Both R.H. and L.H.
Does not swing.
One side only
Worsened acceleration Both R.H. and L.H.
Swinging system
performance or speed
of swinging One side only
Both R.H. and L.H.
Greater drift when
swinging is stopped
One side only
Greater shock when swinging is stopped (only on one side)
Greater abnormal noise when swinging is stopped
Greater hydraulic drift When swing holding brake is released
during swinging When swing holding brake is operating
Diagnosis codes when service codes are displayed C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
Diagnosis codes when abnormality was found by checking monitoring
— — — — — — — — — — —
codes
Items checked only by monitoring
20-808 PC128US-2
(17)
TABLE FOR DETERMINING CONTROLLER
TROUBLESHOOTING CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED
Model code
Arm IN (5)
Traveling
displayed
— Bit patterns Monitoring codes
224 227 1023 1021 1060 1002 1010 1042 1050 1054
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12
H-13
H-14
—
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
C-12 C-13 — — — — — — — — — — — — — — —
— — F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 — — — — — — — — —
PC128US-2 20-809
(17)
TABLE FOR DETERMINING CONTROLLER
TROUBLESHOOTING CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED
Disconnection in LS-EPC
Disconnection in 2-Stage
Short circuit in PC-EPC
solenoid system
solenoid system
solenoid system
solenoid system
controller
User codes LED E02 E03 —
Failure mode Service codes off 232 233 203 213 206 216 205 215 222 223
Slower speed or reduced power of entire work equipment, traveling,
ment, traveling, and
Entire work-equip-
and swinging
Substantial drop of engine speed, or engine stop
swinging
Boom inoperable
Arm inoperable
Bucket inoperable
Greater hydraulic drift
Greater time lag (engine slow)
Independent relief causes other work equipment's movement.
Full power cannot be attained when pressure is increased.
Worsened or weaker stroke-end cushion of boom RAISE
In the case of compound operation, the greater the load, the longer
Compound
Boom moves slower in the case of the swing + boom (RAISE) oper-
ation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Traveling system
Travel deviation
Deviation is great at the start of traveling
Slower traveling speed
Steering is hard or not powerful.
Traveling speed is unchangeable, or faster than the set speed.
Inoperable (only on one side)
Both R.H. and L.H.
Does not swing.
One side only
Worsened acceleration Both R.H. and L.H.
Swinging system
performance or speed
of swinging One side only
Both R.H. and L.H.
Greater drift when
swinging is stopped
One side only
Greater shock when swinging is stopped (only on one side)
Greater abnormal noise when swinging is stopped
Greater hydraulic drift When swing holding brake is released
during swinging When swing holding brake is operating
Diagnosis codes when service codes are displayed C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
Diagnosis codes when abnormality was found by checking monitoring
— — — — — — — — — — —
codes
Items checked only by monitoring
20-810 PC128US-2
(17)
TABLE FOR DETERMINING CONTROLLER
TROUBLESHOOTING CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED
Model code
Arm IN (5)
Traveling
displayed
— Bit patterns Monitoring codes
224 227 1023 1028 1021 1060 1002 1010 1042 1050 1054
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12
H-13
H-14
—
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
C-12 C-13 — — — — — — — — — — — — — — —
— — F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 — — — — — — — — —
PC128US-2 20-811
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
20-812 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
(2/2)
PC128US-2 20-813
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
20-814 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
(2/2)
PC128US-2 20-815
(17)
TROUBLESHOOTING C-1
Cause Remedy
2 YES
Defective controller Replace
Is voltage normal
YES between CR3 (14),
1 (24) – (21), (31),
Is voltage normal (32), (33)? Disconnection or defective con- Repair or
between CR3 (1), tact of harnesses between CR3 replace
• Turn starting switch NO (14), (24) and CNM47 (3)
(11) and each (21),
(31), (32) and ON
(33)? • 20 – 30 V Disconnection or defective
contact between fuse (18) and
• Attach T-adapter CR3 (1),(11); Disconnection or Replace
• Turn starting switch NO defectivecontact between CR3 motor
OFF: 20 – 30 V (21),(31),(32),(33) and CN-A04
(12),(14)
20-816 PC128US-2
(17)
TROUBLESHOOTING C-1
PC128US-2 20-817
(17)
TROUBLESHOOTING C-2
Cause Remedy
YES
Defective controller CR700 Replace
Table 1
Diagnosis No.2 Diagnosis No.3 Diagnosis No.4 Resistance
C13 (male) (1) – (2) CR3 (female) (16) – (23) C06 (female) (2) – (5) 8 – 15 Ω
C13 (male) (1) – body CR3 (female) (16) – body C06 (female) (2) – 2body Min. 1 M Ω
Table 2
Diagnosis No.5 Resistance
C06 (male) (2) – (3), (5) – (6) Max. 1 Ω
C06 (female) (2), (3), (5), (6) – body Min. 1 M Ω
20-818 PC128US-2
(17)
TROUBLESHOOTING C-2
PC128US-2 20-819
(17)
TROUBLESHOOTING C-3
Cause Remedy
YES
Defective controller CR700 Replace
Table 1
Diagnosis No.2 Diagnosis No.3 Diagnosis No.4 Resistance
C13 (male) (1) –(2) CR3 (female) (16) – (23) C06 (female) (2) – (5) 8 – 15 Ω
C13 (male) (1) – body CR3 (female) (16) – body C06 (female) (2) – 2body Min. 1 M Ω
Table 2
Diagnosis No.5 Resistance
C06 (male) (2) – (3), (5) – (6) Max.1 Ω
C06 (female) (2), (3), (5), (6) – body Min. 1 M Ω
20-820 PC128US-2
(17)
TROUBLESHOOTING C-3
PC128US-2 20-821
(17)
TROUBLESHOOTING C-4
C-4 [E203] "Short circuit in swing holding brake solenoid system" is dis-
played
PC128US-2 Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 – 1500
! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that
service code "E" is displayed. (If it is not displayed, the normal condition has been restored.)
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
Cause Remedy
Table 1
V04 (male)(1) – (2) 37 – 60 Ω
V04 (male)(2) – body Min. 1 M Ω
20-822 PC128US-2
(17)
TROUBLESHOOTING C-4
PC128US-2 20-823
(17)
TROUBLESHOOTING C-4
! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that
service code "E" is displayed. (If it is not displayed, the normal condition has been restored.)
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
Cause Remedy
Table 1
V4 (male)(1) – (2) 37 – 60 Ω
V4 (male)(2) – body Min. 1 M Ω
20-824 PC128US-2
(17)
TROUBLESHOOTING C-4
PC128US-2 20-825
(17)
TROUBLESHOOTING C-5
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
NOTE: [Note] An error [E213] is detected if swing holding brake release switch was turned OFF (swinging
enabled); this is not a failure.
NOTE: [Note] If an error [E213] was detected when swing lock switch was turned ON (swinging locked), do
troubleshooting (F-9) of the swing lock signal input system.
Cause Remedy
Table 1
Diagnosis No. 3 Voltage Measuring conditions
0 – 10 V 4 – 5 seconds after putting all levers to Neutral.
D08(1) – body
20 – 30 V When swing-lever or a lever of work equipment is operated (just for a moment)
20-826 PC128US-2
(17)
TROUBLESHOOTING C-5
PC128US-2 20-827
(17)
TROUBLESHOOTING C-5
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
NOTE: [Note] An error [E213] is detected if swing holding brake release switch was turned OFF (swinging
enabled); this is not a failure.
NOTE: [Note] If an error [E213] was detected when swing lock switch was turned ON (swinging locked), do
troubleshooting (F-9) of the swing lock signal input system.
Cause Remedy
Table 1
Diagnosis No. 3 Voltage Measuring conditions
0 – 10 V 4 – 5 seconds after putting all levers to Neutral.
D02(8) – body
20 – 30 V When swing-lever or a lever of work equipment is operated (just for a moment)
20-828 PC128US-2
(17)
TROUBLESHOOTING C-5
PC128US-2 20-829
(17)
TROUBLESHOOTING C-6
Cause Remedy
Table 1
V05 (male)(1) – (2) 37 – 60 Ω
V05 (male)(2) – body Min. 1 M Ω
20-830 PC128US-2
(17)
TROUBLESHOOTING C-6
Cause Remedy
Table 1
V5 (male)(1) – (2) 37 – 60 Ω
V5 (male)(2) – body Min. 1 M Ω
PC128US-2 20-831
(17)
TROUBLESHOOTING C-7
Cause Remedy
20-832 PC128US-2
(17)
TROUBLESHOOTING C-7
Cause Remedy
PC128US-2 20-833
(17)
TROUBLESHOOTING C-8
Cause Remedy
3 YES
Defective controller CR700 Replace
Is resistance nor-
YES mal between CR3
2 (female) (28) and
Do resistance values body? Ground fault of harness be-
YES between V06 (male) tween CR3 (female) (28) and Repair or
(1) and (2) and be- • Turn starting NO V06 (female) (2) replace
switch OFF.
1 tween (2) and body • Disconnect CR3.
match with Table 1?
Is [E205] displayed • Turn starting switch • 37 – 60 Ω
after replacing the
solenoid and con- OFF.
• Disconnect V06. NO
nector with other
ones?
• Turn starting switch Defective 2-stage relief sole-
OFF. noid (inner short-circuit or Replace
• Replace V06 with NO ground fault)
another one.
• Start engine.
• Turn on swing lock
switch.
Table 1
V06 (male)(1) – (2) 37 – 60 Ω
V06 (male)(2) – body Min. 1 M Ω
20-834 PC128US-2
(17)
TROUBLESHOOTING C-8
Cause Remedy
3 YES
Defective controller CR700 Replace
Is resistance nor-
YES mal between CR3
2 (female) (28) and
Do resistance values body? Ground fault of harness be-
YES between V6 (male) tween CR3 (female) (28) and Repair or
(1) and (2) and be- • Turn starting NO V6 (female) (2) replace
switch OFF.
1 tween (2) and body
• Disconnect CR3.
match with Table 1?
Is [E205] displayed • Turn starting switch • 37 – 60 Ω
after replacing the
solenoid and con- OFF.
• Disconnect V6. NO
nector with other
ones?
• Turn starting switch Defective 2-stage relief sole-
OFF. noid (inner short-circuit or Replace
• Replace V6 with NO ground fault)
another one.
• Start engine.
• Turn on swing lock
switch.
Table 1
V6 (male)(1) – (2) 37 – 60 Ω
V6 (male)(2) – body Min. 1 M Ω
PC128US-2 20-835
(17)
TROUBLESHOOTING C-9
Cause Remedy
3 YES
Defective controller CR700 Replace
Is resistance nor-
YES mal between CR3
2 (female) (28) and
Disconnection, defective con-
tact or hot short circuit of har-
body? ness between CR3 (female) Repair or
YES Is resistance bet- • Turn starting switch NO
(28) and V06 (female) (2), or replace
ween V06 (male) (1) between V06 (female) (1) and
1 and (2) normal? OFF. body.
• Disconnect CR3.
Is [E215] displayed
• Turn starting switch • 37 – 60 Ω
after replacing the
solenoid and con- OFF.
• Disconnect V06. NO
nector with other
ones? • 37 – 60 Ω
• Turn starting switch Defective 2-stage relief sole-
OFF. noid (inner disconnection or Replace
• Replace V06 with NO hot short circuit)
another one.
• Turn starting switch
ON.
20-836 PC128US-2
(17)
TROUBLESHOOTING C-9
Cause Remedy
3 YES
Defective controller CR700 Replace
Is resistance nor-
YES mal between CR3
2 (female) (28) and Disconnection, defective con-
body? tact or hot short circuit of har-
YES Is resistance bet- ness between CR3 (female) Repair or
ween V6 (male) (1) • Turn starting switch NO (28) and V6 (female) (2), or be- replace
OFF. tween V6 (female) (1) and body.
1 and (2) normal?
• Disconnect CR3.
Is [E215] displayed
• Turn starting switch • 37 – 60 Ω
after replacing the
solenoid and con- OFF.
• Disconnect V6. NO
nector with other
ones? • 37 – 60 Ω
• Turn starting switch Defective 2-stage relief sole-
OFF. noid (inner disconnection or Replace
• Replace V6 with NO hot short circuit)
another one.
• Turn starting switch
ON.
PC128US-2 20-837
(17)
TROUBLESHOOTING C-10
Cause Remedy
2 YES
Defective controller CR700 Replace
Do resistance val-
ues between CR3
YES (female) (6) and (13)
and between (6) and Ground fault or hot short cir-
1 body match with Ta- cuit of harnessbetween CR3
Do resistance values ble 1? (female) (6) and C14 (female) Repair or
between C14 (male) (1), or hot short circuit of har- replace
• Turn starting switch NO ness between CR3 (female)
(1) and (2) and be- OFF.
tween (1) and body (13) and C14 (female)(2).
• Disconnect CR3.
match with Table 1?
• Turn starting switch Defective LS-EPC solenoid
OFF. (inner ground fault or hot short Replace
• Disconnect C14. NO circuit)
Table 1
Diagnosis No.1 Diagnosis No.2 Resistance
C14 (male) (1) – (2) CR3 (female) (6) – (13) 8 – 15 Ω
C14 (male) (1) – body CR3 (female) (6) – body Min. 1 M Ω
20-838 PC128US-2
(17)
TROUBLESHOOTING C-11
Cause Remedy
2 YES
Defective controller CR700 Replace
Do resistance val-
ues between CR3
YES (female) (6) and (13)
Disconnection or defective con-
1 and between (13)
tact of harness between CR3
and body match with
Do resistance val- Table 1? (female)(6) and C14 (female) Repair or
ues between C14 (1); or disconnection, defective replace
(male) (1) and (2) • Turn starting switch NO contact, or ground fault of har-
and between (2) and OFF. ness between CR3 (female)
body match with Ta- • Disconnect CR3. (13) and C14 (female) (2).
ble 1?
• Turn starting switch Defective LS-EPC solenoid
OFF. (inner ground fault or hot short Replace
NO circuit)
• Disconnect C14.
Table 1
Diagnosis No.1 Diagnosis No.2 Resistance
C14 (male) (1) – (2) CR3 (female) (6) – (13) 8 – 15 Ω
C14 (male) (1) – body CR3 (female) (13) – body Min. 1 M Ω
PC128US-2 20-839
(17)
TROUBLESHOOTING C-12
Cause Remedy
20-840 PC128US-2
(17)
TROUBLESHOOTING C-13
Cause Remedy
2 YES
Defective controller CR700 Replace
Is resistance be-
YES tween CR2 (female) Disconnection, defective con-
1 (40) and (39) nor- tact or ground fault of harness
mal? between CR2(female)(40) and Repair or
Is resistance be- E07 (female) (1), or between replace
tween E07 (male) • Turn starting switch NO
CR2 (female)(39) and E07 (fe-
(1) and (2) normal? OFF. male)(2).
• Disconnect CR2.
• 500 – 1000 Ω Defective engine speed sensor
• Turn starting switch (inner disconnection, defective Replace
OFF. NO contact or ground fault).
• Disconnect E07.
• 500 – 1000 Ω
PC128US-2 20-841
(17)
TROUBLESHOOTING OF CONTROLLER CR700
[INPUT SIGNAL SYSTEM]
(F MODE)
★ In troubleshooting after an abnormality occurred, if the display in the Monitoring mode is normal after you
attached a T-adapter instead of a connector detached, or after you connected the connector instead of the
T-adapter detached, the normal condition has been restored.
★ Before starting troubleshooting, check for any faulty engagement in related connectors.
★ Before going to next step in troubleshooting process, be sure to connect the connector you have detached.
PC128US-2 20-901
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM
20-902 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM
PC128US-2 20-903
(17)
TROUBLESHOOTING F-1
Turn on swing-lock switch before operating swing lever (even if just for a moment).
★ If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.
Cause Remedy
• Detach S08.
• Start engine. 1
• Put swing lever in Neutral: Is resistance between S08 (male)
(1) and (2) normal? NO
Min. 1 M Ω Defective L.H. swing pressure switch Replace
• Operate swing lever for L.H. Is the connection insulated from
swinging: Max. 1 Ω body?
• Refer to Note. YES
• Detach S30. 2
• Start engine.
• Put swing lever in Neutral: Is resistance between S30 (male)
(1) and (2) normal? NO
Min. 1 M Ω Defective R.H. swing pressure switch Replace
Is the connection insulated from
• Operate swing lever for body?
R.H. swinging: Max.1 Ω
• Refer to Note. YES
3
• Turn starting switch OFF. Are resistance values between Disconnection, defective contact or
• Detach S08 and S30 from CR1 (female) (24) and each of NO ground fault of harness between CR1 Repair or
CR1. S08 and S30 (female) (2) normal?
(female)(24) and S08 (female)(2) or replace
• CR1 – S08/S30: Max.1 Ω Are the connections insulated
S30 (female)(2).
• Harness – body: Min. 1 M Ω from body?
YES
4
• Start engine.
• Put swing-lever in Neutral: Is voltage between CR1(24) and NO Defective controller CR700 Replace
20 – 30 V body normal?
• Operate swing lever:
Max. 1 V YES
5
• Start engine. Is voltage between CR1(24) and NO Disconnection or defective contact of
• Operate swing lever: body normal? harness between S08 (female)(1) or Repair or
S30 (female)(1) and body GND. replace
Max.1 V
YES
Defective controller CR700 Replace
[Note] You may diagnose with a short-circuit connector attached.In step 2 of diagnosis,
• if the voltage between CR1(24) and body is 20 – 30 V, go to YES;
• if it is 1 V or less, go to NO.
20-904 PC128US-2
(17)
TROUBLESHOOTING F-1
Turn on swing-lock switch before operating swing lever (even if just for a moment).
★ If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.
Cause Remedy
• Detach S08.
• Start engine. 1
• Put swing lever in Neutral: Is resistance between S08 (male)
(1) and (2) normal? NO
Min. 1 M Ω Defective L.H. swing pressure switch Replace
• Operate swing lever for L.H. Is the connection insulated from
swinging: Max. 1 Ω body?
• Refer to Note. YES
• Detach S30. 2
• Start engine.
• Put swing lever in Neutral: Is resistance between S30 (male)
(1) and (2) normal? NO
Min. 1 M Ω Defective R.H. swing pressure switch Replace
Is the connection insulated from
• Operate swing lever for body?
R.H. swinging: Max.1 Ω
• Refer to Note. YES
3
• Turn starting switch OFF. Are resistance values between Disconnection, defective contact or
• Detach S08 and S30 from CR3 (female) (30) and each of NO ground fault of harness between CR3 Repair or
CR3. S08 and S30 (female) (2) normal?
(female)(30) and S08 (female)(2) or replace
• CR3 – S08/S30: Max.1 Ω Are the connections insulated
S30 (female)(2).
• Harness – body: Min. 1 M Ω from body?
YES
4
• Start engine.
• Put swing-lever in Neutral: Is voltage between CR3(30) and NO Defective controller CR700 Replace
20 – 30 V body normal?
• Operate swing lever:
Max. 1 V YES
5
• Start engine. Is voltage between CR3(24) and NO Disconnection or defective contact of
• Operate swing lever: body normal? harness between S08 (female)(1) or Repair or
S30 (female)(1) and body GND. replace
Max.1 V
YES
Defective controller CR700 Replace
[Note] You may diagnose with a short-circuit connector attached.In step 2 of diagnosis,
• if the voltage between CR3(30) and body is 20 – 30 V, go to YES;
• if it is 1 V or less, go to NO.
PC128US-2 20-905
(17)
TROUBLESHOOTING F-2
Look around to be sure of safety before operating travel lever (even if just for a moment).
★ If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.
Cause Remedy
• Detach S01. 1
• Start engine.
• Put travel lever in Neutral: Is resistance between S01 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective travel pressure switch Replace
• Operate travel lever: nection insulated from body?
Max. 1 Ω
• Refer to Note.
YES
2
• Turn starting switch OFF.
• Detach S01 from CR1. Is resistance between CR1 (fe-
male)(18) and S01 (female)(2) NO Disconnection, defective contact or
• Between CR1 and S01: ground fault of harness between CR1 Repair or
Max. 1 Ω normal? Is the connection insulat- replace
ed from body? (female) (18) and S01 (female) (2)
• Between harness and body:
Min. 1 M Ω YES
3
• Start engine. Is voltage between CR1(18) and NO
• Put swing lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
4
• Start engine. Disconnection or defective contact of
• Operate travel lever: Is voltage between CR1(18) and NO harness between S01 (female) (1) and Repair or
body normal? body GND. replace
Max. 1 V
YES
Defective controller CR700 Replace
[Note] You may diagnose with a short-circuit connector attached.In step 1 of diagnosis,
• if the voltage between CR1(18) and body is 20 – 30 V, go to YES;
• if it is 1 V or less, go to NO.
20-906 PC128US-2
(17)
TROUBLESHOOTING F-2
Look around to be sure of safety before operating travel lever (even if just for a moment).
★ If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.
Cause Remedy
• Detach S01. 1
• Start engine.
• Put travel lever in Neutral: Is resistance between S01 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective travel pressure switch Replace
• Operate travel lever: nection insulated from body?
Max. 1 Ω
• Refer to Note.
YES
2
• Turn starting switch OFF.
• Detach S01 from CR3. Is resistance between CR3 (fe-
male)(40) and S01 (female)(2) NO Disconnection, defective contact or
• Between CR3 and S01: ground fault of harness between CR3 Repair or
Max. 1 Ω normal? Is the connection insulat- replace
ed from body? (female) (40) and S01 (female) (2)
• Between harness and body:
Min. 1 M Ω YES
3
• Start engine. Is voltage between CR3(40) and NO
• Put swing lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
4
• Start engine. Disconnection or defective contact of
• Operate travel lever: Is voltage between CR3(40) and NO harness between S01 (female) (1) and Repair or
body normal? body GND. replace
Max. 1 V
YES
Defective controller CR700 Replace
[Note] You may diagnose with a short-circuit connector attached.In step 1 of diagnosis,
• if the voltage between CR3(40) and body is 20 – 30 V, go to YES;
• if it is 1 V or less, go to NO.
PC128US-2 20-907
(17)
TROUBLESHOOTING F-3
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
Is resistance between CR1 (5) NO
• Put boom lever in Neutral: Defective controller CR700 Replace
and body normal?
20 – 30 V
YES
2
• Start engine.
• Put boom lever in LOWER: Is resistance between CR1 (5) NO
Max. 1 V and body normal?
YES
Defective controller CR700 Replace
• Disconnect S33. 3
• Start engine.
• Put boom lever in Neutral: Is resistance between S33 (male) NO
Defective boom LOWER pressure
Min. 1 M Ω (1) and (2) normal? Is the con-
switch
Replace
• Put boom lever in LOWER: nection insulated from body?
Max. 1 Ω YES
• Refer to Note.
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(5) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
20-908 PC128US-2
(17)
TROUBLESHOOTING F-3
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
Is resistance between CR1 (18) NO
• Put boom lever in Neutral: Defective controller CR700 Replace
and body normal?
20 – 30 V
YES
2
• Start engine.
• Put boom lever in LOWER: Is resistance between CR1 (18) NO
Max. 1 V and body normal?
YES
Defective controller CR700 Replace
• Disconnect S33. 3
• Start engine.
• Put boom lever in Neutral: Is resistance between S33 (male) NO
Defective boom LOWER pressure
Min. 1 M Ω (18) and (2) normal? Is the con-
switch
Replace
• Put boom lever in LOWER: nection insulated from body?
Max. 1 Ω YES
• Refer to Note.
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(18) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
PC128US-2 20-909
(17)
TROUBLESHOOTING F-4
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
• Put boom lever in Neutral: Is resistance between CR1 (12) NO Defective controller CR700 Replace
20 – 30 V and body normal?
YES
2
• Start engine.
Is resistance between CR1 (12) NO
• Put boom lever in RAISE:
and body normal?
Max. 1 V
YES
Defective controller CR700 Replace
• Disconnect S31. 3
• Start engine.
• Put boom lever in Neutral: Is resistance between S31 (male) NO
Min. 1 M Ω Defective boom RAISE pressure
(1) and (2) normal? Is the connec- Replace
• Put boom lever in RAISE: switch
tion insulated from body?
Max. 1 Ω
YES
• Refer to Note.
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(12) and body is 20 – 30 V, go to YES;
• if it is Max.1 V, go to NO.
20-910 PC128US-2
(17)
TROUBLESHOOTING F-4
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
• Put boom lever in Neutral: Is resistance between CR1 (24) NO Defective controller CR700 Replace
20 – 30 V and body normal?
YES
2
• Start engine.
Is resistance between CR1 (24) NO
• Put boom lever in RAISE:
and body normal?
Max. 1 V
YES
Defective controller CR700 Replace
• Disconnect S31. 3
• Start engine.
• Put boom lever in Neutral: Is resistance between S31 (male) NO
Min. 1 M Ω Defective boom RAISE pressure
(1) and (2) normal? Is the connec- Replace
• Put boom lever in RAISE: switch
tion insulated from body?
Max. 1 Ω
YES
• Refer to Note.
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(24) and body is 20 – 30 V, go to YES;
• if it is Max.1 V, go to NO.
PC128US-2 20-911
(17)
TROUBLESHOOTING F-5
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
• Put arm lever in Neutral: Is resistance between CR1 (6) NO
Defective controller CR700 Replace
20 – 30 V and body normal?
YES
2
• Start engine.
• Put arm lever in IN: Is resistance between CR1 (6) NO
Max. 1 V and body normal?
YES
Defective controller CR700 Replace
• Disconnect S05.
• Start engine.
3
• Put arm lever in Neutral: Is resistance between S05 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm IN pressure switch Replace
• Put arm lever in IN: nection insulated from body?
Max. 1 Ω
• Refer to Note. YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(6) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
20-912 PC128US-2
(17)
TROUBLESHOOTING F-5
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
• Put arm lever in Neutral: Is resistance between CR1 (12) NO
Defective controller CR700 Replace
20 – 30 V and body normal?
YES
2
• Start engine.
• Put arm lever in IN: Is resistance between CR1 (12) NO
Max. 1 V and body normal?
YES
Defective controller CR700 Replace
• Disconnect S05.
• Start engine.
3
• Put arm lever in Neutral: Is resistance between S05 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm IN pressure switch Replace
• Put arm lever in IN: nection insulated from body?
Max. 1 Ω
• Refer to Note. YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(12) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
PC128US-2 20-913
(17)
TROUBLESHOOTING F-6
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine. Is resistance between CR1 (5) NO
• Put arm-lever in Neutral: and body normal? Defective controller CR700 Replace
20 – 30 V
YES
2
• Start engine.
• Put arm lever in OUT: Is resistance between CR1 (5) NO
Max. 1 V and body normal?
YES
Defective controller CR700 Replace
• Disconnect S32.
• Start engine.
3
• Put arm lever in Neutral: Is resistance between S32 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm OUT pressure switch Replace
• Put arm lever in OUT: nection insulated from body?
Max. 1 Ω
• Refer to Note. YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(5) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
20-914 PC128US-2
(17)
TROUBLESHOOTING F-6
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine. Is resistance between CR1 (6) NO
• Put arm-lever in Neutral: and body normal? Defective controller CR700 Replace
20 – 30 V
YES
2
• Start engine.
• Put arm lever in OUT: Is resistance between CR1 (6) NO
Max. 1 V and body normal?
YES
Defective controller CR700 Replace
• Disconnect S32.
• Start engine.
3
• Put arm lever in Neutral: Is resistance between S32 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm OUT pressure switch Replace
• Put arm lever in OUT: nection insulated from body?
Max. 1 Ω
• Refer to Note. YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(6) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
PC128US-2 20-915
(17)
TROUBLESHOOTING F-7
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine. Is voltage between CR1 (5) and NO
• Put bucket lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in CURL: Is voltage between CR1 (5) and NO
Max. 1 V body normal?
YES
Defective controller CR700 Replace
• Disconnect S34. 3
• Start engine. Is resistance between S34 (male)
• Put bucket lever in Neutral: (1) and (2) normal? NO
Min.1 Mz Defective bucket CURL pressure
Is the connection insulated from Replace
• Put bucket lever in CURL: switch
body?
Max. 1 z
• Refer to Note. YES
4
• Turn starting switch OFF. Is resistance between CR1 (fe-
• Disconnect S34 from CR1. male) (5) and S34 (female) (2) NO Disconnection, defective contact or Repair or
• Between CR1 and S34: normal? ground fault of harness between CR1 replace
Max. 1 z Is the connection insulated from (female) (5) and S34 (female) (2).
• Between harness and body: body?
Min. 1 Mz
YES Disconnection or defective contact of
harness between S34 (female)(1) and Repair or
body GND. replace
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(5) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
20-916 PC128US-2
(17)
TROUBLESHOOTING F-7
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine. Is voltage between CR3 (10) and NO
• Put bucket lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in CURL: Is voltage between CR3 (10) and NO
Max. 1 V body normal?
YES
Defective controller CR700 Replace
• Disconnect S34. 3
• Start engine. Is resistance between S34 (male)
• Put bucket lever in Neutral: (1) and (2) normal? NO
Min.1 Mz Defective bucket CURL pressure
Is the connection insulated from Replace
• Put bucket lever in CURL: switch
body?
Max. 1 z
• Refer to Note. YES
4
• Turn starting switch OFF. Is resistance between CR3 (fe-
• Disconnect S34 from CR3. male) (10) and S34 (female) (2) NO Disconnection, defective contact or Repair or
• Between CR3 and S34: normal? ground fault of harness between CR3 replace
Max. 1 z Is the connection insulated from (female) (10) and S34 (female) (2).
• Between harness and body: body?
Min. 1 Mz
YES Disconnection or defective contact of
harness between S34 (female)(1) and Repair or
body GND. replace
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR3(10) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
PC128US-2 20-917
(17)
TROUBLESHOOTING F-8
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
Is voltage between CR1 (5) and NO Defective controller CR700
• Put bucket lever in Neutral: Replace
body?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in Dump: Is voltage between CR1 (5) and NO
Max. 1 V body normal?
YES
Defective controller CR700 Replace
• Disconnect S35. 3
• Start engine. Is resistance between S35 (male)
• Put bucket lever in Neutral: (1) and (2) normal? NO
Min.1 Mz Defective bucket Dump pressure Replace
Is the connection insulated from switch
• Put bucket lever in Dump: body?
Max. 1 z
• Refer to Note. YES
4
• Turn starting switch OFF. Is resistance between CR1 (fe-
• Disconnect S35 from CR1. male) (5) and S35 (female) (2) NO Disconnection, defective contact or
• Between CR1 and S35: normal? ground fault of harness between CR1 Replace
Max. 1 z Is the connection insulated from (female) (5) and S35 (female) (2). motor
• Between harness and body: body?
Min. 1 Mz
YES Disconnection or defective contact of
harness between S35 (female) (2) and Repair or
body GND. replace
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR1(5) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
20-918 PC128US-2
(17)
TROUBLESHOOTING F-8
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
Is voltage between CR3 (20) and NO Defective controller CR700 Replace
• Put bucket lever in Neutral:
body?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in Dump: Is voltage between CR3 (20) and NO
Max. 1 V body normal?
YES
Defective controller CR700 Replace
• Disconnect S35. 3
• Start engine. Is resistance between S35 (male)
• Put bucket lever in Neutral: (1) and (2) normal? NO
Min.1 Mz Defective bucket Dump pressure Replace
Is the connection insulated from switch
• Put bucket lever in Dump: body?
Max. 1 z
• Refer to Note. YES
4
• Turn starting switch OFF. Is resistance between CR3 (fe-
• Disconnect S35 from CR3. male) (20) and S35 (female) (2) NO Disconnection, defective contact or
• Between CR3 and S35: normal? ground fault of harness between CR3 Replace
Max. 1 z Is the connection insulated from (female) (20) and S35 (female) (2). motor
• Between harness and body: body?
Min. 1 Mz
YES Disconnection or defective contact of
harness between S35 (female) (2) and Repair or
body GND. replace
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
• if the voltage between CR3(20) and body is 20 – 30 V, go to YES;
• if it is Max. 1 V, go to NO.
PC128US-2 20-919
(17)
TROUBLESHOOTING F-9
If you take some measurement with engine started, operate a lever to such an extent that no movement of
ATT is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
• Put swing lever in Neutral: Is voltage between CR1 (5) and NO
20 – 30 V body?
• Operate swing lever: Max. 1 V
YES
Defective controller CR700 Replace
• Disconnect S40. 2
• Start engine.
• Put ATT-pedal in Neutral: Is resistance between S40 (male)
Min.1 MΩ (1) and (2) normal? NO
Is the connection insulated from Defective service (front) pressure switch Replace
• Operate ATT pedal service
(front) pressure switch: body?
Max. 1 Ω YES
• Refer to Note.
• Disconnect S41. 3
• Start engine.
Is resistance between S41 (male)
• Put ATT-pedal in Neutral:
(1) and (2) normal? NO
Max.1 MΩ Defective service (rear) pressure switch Replace
Is the connection insulated from
• Operate ATT pedal service
body?
(front) pressure switch:
Max. 1 Ω YES
• Refer to Note.
4
• Turn starting switch OFF. Are resistance values between CR1 Disconnection, defective contact or Replace
• Disconnect S40 and S41 (female) (5) and each of S40 and NO ground fault of harness between CR1 motor
from CR1. S41 (female) (2) normal? (female) (5) and S40(female)(2) or S41
• Between CR1 and S40, S41: Are the connections insulated from (female)(2).
Max. 1 Ω body?
• Harness body: Min. 1 MΩ
YES Disconnection or defective contact of
Repair or
harness between S40 (female) (1) or
replace
S41 (female) (1) and body GND.
[Note] You may diagnose with a short-circuit connector attached.In this case,
• if the voltage between CR1(5) and body is 20 – 30 V, go to YES;
• f it is Max. 1 V, go to NO.
20-920 PC128US-2
(17)
TROUBLESHOOTING F-9
If you take some measurement with engine started, operate a lever to such an extent that no movement of
blade is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause Remedy
1
• Start engine.
• Put swing lever in Neutral: Is voltage between CR3 (9) and NO
20 – 30 V body?
• Operate swing lever: Max. 1 V
YES
Defective controller CR700 Replace
• Disconnect S38. 2
• Start engine.
• Put blade lever in Neutral: Is resistance between S38 (male)
Min.1 MΩ (1) and (2) normal? NO
Is the connection insulated from Defective blade LOWER pressure switch Replace
• Operate blade LOWER
pressure switch: body?
Max. 1 Ω YES
• Refer to Note.
• Disconnect S39. 3
• Start engine.
Is resistance between S41 (male)
• Put blade lever in Neutral:
(1) and (2) normal? NO
Max.1 MΩ Defective blade RAISE pressure switch Replace
Is the connection insulated from
• Operate blade RAISE (front)
body?
pressure switch:
Max. 1 Ω YES
• Refer to Note.
4
• Turn starting switch OFF. Are resistance values between CR3 Disconnection, defective contact or Replace
• Disconnect S38 and S39 (female) (9) and each of S38 and NO ground fault of harness between CR3 motor
from CR3. S39 (female) (2) normal? (female) (9) and S38(female)(2) or S39
• Between CR3 and S40, S41: Are the connections insulated from (female)(2).
Max. 1 Ω body?
• Harness body: Min. 1 MΩ
YES Disconnection or defective contact of
Repair or
harness between S38 (female) (1) or
replace
S39 (female) (1) and body GND.
[Note] You may diagnose with a short-circuit connector attached.In this case,
• if the voltage between CR3(9) and body is 20 – 30 V, go to YES;
• f it is Max. 1 V, go to NO.
PC128US-2 20-921
(17)
TROUBLESHOOTING F-10
Cause Remedy
1
• Turn starting switch ON. Disconnection or defective contact of
• S Harness for Kerosene mode:
IIs voltage between CR2 (6) and NO harness between CR2 (female) (6) and Repair or
Connected: 20 – 30 V
Open: Max. 1 V
body normal? (Max. 1V ) fuse (1) in the harness for kerosene replace
mode.
• Max. 1
YES (20 – 30 V)
Defective controller CR700 Replace
20-922 PC128US-2
(17)
TROUBLESHOOTING OF ENGINE
(S MODE)
PC128US-2 20-951
(14)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections A + B in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from Causes
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and (b) (2) (3)
[Check items].
(a) w
Questions
A (b) w
(c) w
(d) c
(e) c
Check items
B
C
i b
shooting
Trouble-
ii b
iii b
20-952 PC128US-2
(14)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
n)
for locating the cause of the failure. How-
ctio
ever, do not use this when making calcula-
inje
tions to narrow down the causes.
sive
e
ª2. Use the # in the Cause column as reference
renc
xces
zzle
for [Degree of use (Operated for long pe-
n no
erfe
p (e
e
ing
inde
lem
riod)] in the [Questions] section as reference.
, int
ctio
pum
n tim
er e
As a rule, do not use it when calculating the
, cyl
rger
inje
ion
lean
points for locating the cause, but it can be
ctio
ring
cha
zed
ject
e
included if necessary to determine the order
air c
urbo
, sei
ston
r inj
e in
for troubleshooting.
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
ª1 Confirm recent repair history
ª2 Degree of use Operatred for long period
PC128US-2 20-953
(14)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
d )
ead
n)
eize
• Excessive injection of fuel
ctio
nd h
er s
inje
er a
lung
at
sive
e se
harg
ck, p
elem rence
xces
n tim nozzle
valv
boc
p (ra
ent
terfe
p (e
r
lve,
r
n tu
ing
fler
ce
nde
tion
pum
pum
r, in
aran
f va
muf
e
, cyli
e
rope ized inje
etw
n pis cleaner
arge
ion
ct o
le
rope jection
d
ctio
ring
c
e
ject
air b
a
lve
logg
Clog urboch
t
inje
con
Legend
e in
ton
r va
, se
in
air
e of
: Possible causes (judging from Questions and check items)
d, c
r
e
e
ectiv
ged
ged
ctiv
ctiv
ed t
: Most probable causes (judging from Questions and Check items)
she
kag
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Wor
Seiz
Deff
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
on reduced cylinders
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-954 PC128US-2
(14)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
PC128US-2 20-955
(14)
TROUBLESHOOTING S-1
t
elem alve sea
fl Battery charging rate
lter
Ambient Charging rate
100 % 90 % 80 % 75 % 70 %
ve, v
ze fi
ent
temperature
r
r
r
e
inde
eate
20°C 1.28 1.26 1.24 1.23 1.22
rain
gau
f val
0°C 1.29 1.27 1.25 1.24 1.23
, cyl
air h
r, st
ump
–10°C 1.30 1.28 1.26 1.25 1.24
ner
act o
filte
ring
clea
ake
• The specific gravity should exceed the value for the
p
cont
feed
fuel
l int
ston
charging rate of 70% in the above table.
a i r
ctive
trica
ged
ged
ged
• In cold areas the specific gravity must exceed the
n pi
Defe
Clog
value for the charging rate of 75% in the above table.
Clog
Clog
Elec
Wor
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Replace
Correct
Clean
Clean
Clean
Remedy
PC128US-2
Defe or d
ctive eter
iora
ªAdjust Defe injec ted
tion batt
tive nozz ery
Replace Defe
injec
tion le
tive timi
Correct Leak injec ng
tion
age, p ump
Clean
TROUBLESHOOTING
(14)
S-1
20-957
TROUBLESHOOTING S-2
n
witc
ctio
fl If internal parts of the engine are seized, carry
it
nne
ery
ircu
ty s
out troubleshooting for "Engine stops during
batt
al co
safe
ng c
operations".
id
ated
itch
leno
tarti
rmin
or
y or
lay
ot
g sw
• Defective electrical system
rior
of s
t so
rela
gm
e
e
t
r
• Failure in power train
ttery
dete
ttery
el cu
ar
artin
iring
artin
fety
g ge
e ba
e ba
e sa
e or
e fu
e st
e st
ew
r in
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ken
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Bro
Confirm recent repair history
Questions
move out
Remedy —
20-958 PC128US-2
(14)
TROUBLESHOOTING S-2
d)
• Supply of fuel is extremely small
eize
• Improper selection of fuel (particularly in winter)
er s
key
lung
nk
el ta
aft,
★ Standards for use of fuel
ck, p
on
e sh
in fu
pist
AMBIENT TEMPRATURE
p (ra
ng
iner
driv
noid
KIND
ump
hole
pipi
-4 14 32 50 68ºF
rain
stra
OF FLUID
pum
nk
mp
-20 -10 0 10 20ºC
sole
p
fuel
r, st
her
in ta
mp
eed
n pu
ed
ion
cut
reat
filte
king
l us
u
en f
fuel
ject
p
ctio
ASTM D975 No.2
fuel
air b
feed
r fue
fuel
, lea
brok
Diesel fuel
e in
inje
ent
e
ged
rope
ged
ged
ASTM D975 No.1
ged
ctiv
ctiv
ffici
ed,
ken
Clog
Defe
Clog
Defe
Clog
Clog
Insu
Seiz
Imp
Bro
Confirm recent repair history
Questions
Remedy
PC128US-2 20-959
(14)
TROUBLESHOOTING S-2
.)
r, etc
k)
stuc
le v e
ap
General causes why exhaust smoke comes out but
y
spra
r
cke r
nk c
e
engine not start
lung
em
ater
e , ro
el t a
e
syst
ctiv
ck, p
ttery
r he
(valv
ner
in fu
• Lack of rotating force due to defective electri-
defe
fuel
p (ra
t
iner
a
i
i
men
ke a
l
tem
b
cal system
iner
r
ole
inde
ated
,
ir in
zzle
stra
pum
e sy s
inta
• Insufficient supply of fuel
r ele
a
er h
r
, cyl
n no
g, a
rior
er, s
mp
• Insufficient intake of air
v a lv
ed
ical
eat h
ane
ion
dete
n
ring
l us
d pu
ctio
• Improper selection of fuel and oil
i
ectr
ject
l
ke n
ogg
e
i
r br
f
l
air c
r fue
fuel
inje
ston
e or
e
, bro
e in
e el
e, cl
e
a i
f
rope
ged
ged
ged
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly failed to start
Questions
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-960 PC128US-2
(14)
TROUBLESHOOTING S-3
ap
y
seat
spra
nk c
• Insufficient supply of fuel
lve
el t a
ive
• Improper condition of fuel injction
nce
d va
fect
er
• Improper fuel used
er
in fu
fere
r lin
ung
e an
ent
ng
, de
er
er
nter
rain
pipi
e
hole
e
lem
p pl
rain
valv
zzle
ranc
d
cylin
er, i
p st
er e
fuel
pum
r, st
n no
her
clea
t of
pum
harg
lean
reat
filte
king
ring
ntac
ctio
tion
lve
c
air b
feed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
f
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Engine pick-up suddenly became poor
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Noise of interference is heard from around turbocharger
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Check items
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
PC128US-2 20-961
(14)
TROUBLESHOOTING S-4
c.)
r, et
fl If there is overheating and the engine stops,
k)
leve
stuc
carry out troubleshooting for overheating.
cker
ger
• Failure in power train
ro d
nk
e, ro
plun
el ta
ent
key
ring
ting
ston
fl If the engine stops because of a failure in
valv
,
ipm
in fu
k
aft,
a
nec
c
the power train, carry out troubleshooting
p pi
ft be
m (
p (r a
ng
er
equ
er
e sh
rain
co n
hole
pipi
for the chassis.
yste
pum
rain
in
ksha
pum
nk
r tra
ary
driv
p st
in
on,
lve s
fuel
r, st
ther
in ta
r tra
eed
i
cran
l
gea
ion
pist
pum
i
p
x
c va
filte
king
pum
a
p au
ed f
owe
e
fuel
ject
zed
zed
r
zed
air b
feed
ynam
fuel
, lea
pum
e in
in p
fuel
, sei
ent
, sei
, sei
, sei
ged
ged
ged
ged
ctiv
en d
ffici
ken
ure
ken
ken
ken
ken
ken
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy —
Add
20-962 PC128US-2
(14)
TROUBLESHOOTING S-5
p
zzle
pum
• Defective governor mechanism
d no
• Defective electric governor mechanism
feed
p an
(engine with electric governor)
and
pum
nk
tank
el t a
fl If hunting stops when electric governor rod is
k
r
l rac
erno
feed
rn o r
fuel
disconnected, carry out troubleshooting for the
in fu
o
er
gov
een
ontr
ove
een
chassis.
in ta low
iner
rain
hole
w
betw
of g
t of
of c
t
o
stra
nk
it be
p st
is to
her
men
ion
ion
rcuit
pum
circu
ilter
reat
eed
erat
erat
just
fuel
c i
f
air in
air b
feed
g sp
air in
fuel
e ad
e op
e op
ent
idlin
ged
ged
ged
ged,
ctiv
ged,
ctiv
ctiv
ffici
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low
Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Questions
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
PC128US-2 20-963
(14)
TROUBLESHOOTING S-6
ent
• Improper condition of fuel injection
stm
m
ray
seat
• Improper fuel used
hrag
e sp
adju
nk
(if non-specified fuel is used, output drops)
lve
el ta
diap or diap
ctiv
e
d va
tive
• Lack of output due to overtaking
renc
m
in fu
r
defe
nge
efec
e an
hrag
ng
ent
iner
erfe
t
ump iner
nsa
u
r
hole
pipi
e
fl If there is overheating and lack of output,
inde
zle,
d
lem
p pl
valv
ranc
stra
, int
mpe
ge,
a
noz
carry out troubleshooting for overheating.
fuel
er e
pum
, cyl
ther
rger
nka
clea
t of
ate
t co
r ,
tion
lean
filte
ing
ring
brea
ntac
er li
estg
cha
tion
lve
ed p
o s
c
k
air c
inje
l lev
fuel
urbo
, lea
e bo
r va
e co
ston
njec
ew
i r
e
a
f
t fue
rope
ged
ged
ged
ctiv
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
Defe
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly
Power was lost
Gradually
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-964 PC128US-2
(14)
TROUBLESHOOTING S-7
d)
d
n)
hea
eize
ctio
• Excessive injection of fuel
and
er s
at
pray
inje
e se
lung
rger
ve s
sive
valv
e
ck, p
cha
renc
n tim defecti
xces
and
urbo
p (ra
ent
erfe
( e
r
alve
ing
fler
e
nde
p
lem
zle,
en t
ranc
, int
pum
f
u
of v
noz
u
i
er e
, cyl
t we
on p
ed m
rger
clea
ion
lean
tion
tact
o
e
ring
i
cha
air b
ecti
ject
ject
e
logg
v
con
njec
air c
l
urbo
r inj
a
ston
e in
e in
v
e of
d, c
e
i
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
PC128US-2 20-965
(14)
TROUBLESHOOTING S-8
r
arge
e)
General causes why oil consumption is excessive
och
ngin
Turb
ss e
al
d
• Abnormal combustion of oil
hea
n se
ace
m
ose
oler
er le
• External leakage of oil
surf
yste
der
oke
h
il co
r (lin
• Wear of lubrication system
cylin
her
), br
ke s
seal
plug
o
reat
inde
d
nd
uide
r
inta
n or
ter o
ping
eal,
n
ain
e
er e
or b
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
il fil
ing
low
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
mo
on r
at b
brea
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
al
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Oil consumption suddenly increased
Engine oil must be added more frequently
Questions
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-966 PC128US-2
(14)
TROUBLESHOOTING S-9
end
• Improper oil used
• Operation under excessive load
ine
be
turb
n tu
se
er
r ho
r
drai
e
r lin
harg
athe
r oil
inde
ide
boc
lack
, b re
arge
e gu
, cyl
t tur
is b
r
ther
oole
och
ring
valv
er
al a
oke
l filt
brea
turb
oil c
ston
e se
lve,
t sm
oi
ged
n va
ged
ged
ged
ctiv
n pi
aus
Clog
Defe
Clog
Clog
Clog
Wor
Wor
Exh
Confirm recent repair history
Questions
None
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
PC128US-2 20-967
(14)
TROUBLESHOOTING S-10
• Leakage of fuel
• Improper condition of fuel injection
• Excessive injection of fuel
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
er
ger
cess
l con
pipin
d pu
o v
n
ng
y
c
p plu
p (ex
spra
f fue
ead
timi
e fee
fuel
pum
h
pum
lder
nt o
tion
insid
from
side
le ho
stme
injec
tion
ction
el in
l
age
e a
injec
nozz
adju
oil s
fuel
e
of fu
leak
i n j
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Confirm recent repair history
Questions
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-968 PC128US-2
(14)
TROUBLESHOOTING S-11
et
gask
k
bloc
ing
ler
d
l coo
, O-r
der
e
ad, h
g
cylin
ittin
core
in oi
e
by p
er h
r tra
oler
s in
ylind
rack
used
owe
il co
nal c
en o
en p
en c
s ca
Brok
Brok
Hole
Brok
Inter
Confirm recent repair history
Questions
Remedy
PC128US-2 20-969
(14)
TROUBLESHOOTING S-12
SAE30CD
g
SAE10WCD
ipin
Engine oil
n
pan
l pa
sor
lic p
ing
SAE10W-30CD
n
e oi
sor
alve
drau
o
braz
e se
side
l
l sen
d
urna
e
tor v
ssur
insi
d hy
an
pipe
SAE15W-40CD
valv
mp
e in
oil p
leve
g, jo
il
ilter
iner
l pre
gula
she
l pu
in o
l pip
lief
ion
l in
oil f
stra
l
arin
, cru
e re
e re
e oi
e oi
e oi
suct
uel
o i
i
of o
n be
ctiv
ctiv
ged
ged
ctiv
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy —
Add
20-970 PC128US-2
(14)
TROUBLESHOOTING S-13
ver
d co
seal
• Water in oil (milky white)
hea
ent
ump
• Fuel in oil (diluted, and smells of diesel fuel)
ket
side
ipm
ace
• Entry of oil from other component
on p
gas
e
g in
surf
-ring
equ
leev
k
ead
ecti
bloc
n
seal
pipi
iary
er s
re, O
d, h
n j
g
i
der
hold
l
from
ittin
t
rear
e
osta
aux
hea
r co
cylin
s i
by p
rt in
zzle
oole
ged
erm
mp
der
fuel
side
e no
e pu
cylin
e pa
ama
ade
oil c
e th
e of
ks in
sm
ctiv
ctiv
ctiv
ctiv
n, d
kag
ken
ken
Defe
Hole
Defe
Defe
Defe
Crac
Wor
Lea
Bro
Bro
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC128US-2 20-971
(14)
TROUBLESHOOTING S-14
re
ratu
en)
• Defective cooling circulation system
sket
mpe
t op
aug
lley
• Rise in oil temperature in power train
d ga
g
ns
s no
n pu
il te
ture
or fi
hea
er o
doe
oole
fl Carry out troubleshooting for chassis.
rn fa
lve
pera
diat
tat (
vert
g
,
core
e va
r
ead
oil c
, wo
ittin
e
d ra
ump
tem
a t
mos
con
h
w
r
ator
by p
essu
ping
ken
she
der
ater
er p
rque
ther
, bro
radi
, cru
ooli
cylin
p
e pr
ade
ew
wat
s li
in to
e
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
20-972 PC128US-2
(14)
TROUBLESHOOTING S-15
ead
etc.)
gine
General causes why abnormal noise is made
)
ition
d)
d er h
ion)
ss en
ver,
eize
f pos
ject
cylin
er le
er s
er le
• Abnormality due to defective parts
ce
n
out o
rock
aran
lung
• Abnormal combustion
i
r (lin
r an d
ive
nce
• Air sucked in from intake system
oard
e cle
cess
linde
alve
ck, p
enc
arg e
pum ozzle
fere
m (v
ing b
ash
x
rfer
g, cy
valv
p (ra
b o ch
r
p (e
e
on n
ackl
e
yste
lt in
divid
n rin
t
g
t of
pum
n tu r
n
n
i
er, i
ject
b
lve s
i
n be
ush
men
pisto
fler (
train
wee
ion
ion
harg
ic va
ed b
n, fa
i
just
muf
r bet
ized
r of
ject
ject
a r
c
ynam
z
wea
urbo
r ge
d fa
e ad
e in
of ai
side
, sei
e in
, s e
rme
rope
ssive
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
age
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Leak
Seiz
Imp
Exce
Mis
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC128US-2 20-973
(14)
TROUBLESHOOTING S-16
)
n)
stuck
ctio
normal noise is made”.
ion
, etc.
ned
inje
ush
lever
General causes why vibration is excessive
alig
per)
fuel
en c
mis
cker
(dam
sive
ring
brok
• Defective parts (abnormal wear, breakage)
e, ro
n
xces
bea
i
r tra
t
• Improper alignment
(valv
lts,
a
ash
h
ain
p (e
s
owe
g bo
• Abnormal combustion
ystem
t
ackl
utpu
d, m
pum
nd p
ntin
b
lve s
de o
g ro
train
hing
mou
ion
a
ic va
gine
ctin
insi
ject
bus
a r
nam
e
r ge
nne
ngin
f en
e in
part
m
d y
n co
rope
ter o
n ca
ctiv
se e
ctive
ken
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Replace
Correct
Correct
Adjust
Remedy
20-974 PC128US-2
(14)
30 DISASSEMBLY AND ASSEMBLY
PC128US-2 30-1
(16)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
(Example)
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
30-2 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PC128US-2 30-3
(16)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
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 idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 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.
30-4 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Neces-
Sketch
New/
Q’ty
sity
Component Symbol Part No. Part Name Nature of work, remarks
• 790-101-2510 • Block 1
• 790-101-2550 • Leg 1
• 790-101-2560 • Nut 2
1 Removal of bearing
• 790-101-2570 • Plate 4
790-101-4200 Puller q 1
(294 kN {30 ton})
790-101-1102 Hydraulic oil pump q 1
1 790-201-2850 Spacer t 1
3 Press fit of bearing inner
race
2 790-201-2750 Spacer t 1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
• 790-101-5461 • Plate 1
Press fitting of main bearing
7
outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
• 790-101-5471 • Plate 1
8 Press fitting of sub bearing
outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
PC128US-2 30-5
(16)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Neces-
Sketch
New/
Q’ty
sity
Component Symbol Part No. Part Name Nature of work, remarks
791-635-3160 Extension t 1
2 Compression of spring
• 790-201-2770 • Spacer t 1
Cylinder
790-101-1600 (686 kN {70 ton}) t 1
Disassembly, assembly of L
idler recoil spring
790-101-1102 Pump t 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
Application of floating seal
1 790-434-1650 Installer t 1
Disassembly, assembly of 88
M
track roller Sealing of oil and checking of
2 791-601-1000 Oil pump q 1 air leak
791-616-1040 Remover & installer t 1
Removal,
Cylinder PC128US-2 pressfit of
790-105-1100 (297 kN {30 ton}) t 1
master pin
791-101-1102 Pump t 1
791-616-1110 Frame t 1
791-616-1121 Plate t 1
791-616-1131 Plate t 1
791-616-1150 Guide t 1
791-616-1160 Adapter t 1
791T-616-1280 Adapter t 1 N Q
Expansion, installation of
R
track shoe
791-620-3530 Push t 1
Removal,
PC138USLC-
791-620-3260 Push t 1 pressfit of
2
master pin
791-620-3270 Guide t 1
01011-62260 Bolt t 2
01643-62260 Washer t 2
01011-61455 Bolt t 3
01643-31445 Washer t 3
790-105-1100 Cylinder t 1
(297 kN {30 ton})
790-101-1102 Pump t 1
30-6 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Neces-
Sketch
New/
Q’ty
sity
Nature of work Symbol Part No. Part Name Nature of work, remarks
• 790-101-2520 • Screw 1
• 790-101-2540 • Washer 1
• 791-112-1180 • Nut 1
Disassembly of center T Disconnection of rotor from
• 790-101-2630 • Leg 2
swivel joint shaft
• 790-101-2570 • Washer 4
• 790-101-2560 • Nut 2
• 791-112-2650 • Adapter 2
• 01010-50816 • Bolt 1
• 01010-50816 • Bolt 1
• 01010-50816 • Bolt 1
• 01010-50816 • Bolt 1
• 01010-50816 • Bolt 1
• 01010-50816 • Bolt 1
PC128US-2 30-7
(16)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
remodel
Neces-
Sketch
New/
Q’ty
sity
Nature of work Symbol Part No. Part Name Nature of work, remarks
• 796-270-1110 • Adapter t 1
Removal, installation, of V 1 Removal of boom foot pin
work equipment and boom Puller
790-101-4000 t 1
(490 kN {50 ton})
790-101-1102 Pump t 1
30-8 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOL
F6 Wrench
PC128US-2 30-9
(16)
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOL
R Adapter
30-10 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
PC128US-2 30-11
(16)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
30-12 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
PC128US-2 30-13
(16)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
INSTALLATION
• Carry out installation in the reverse order to [*4]
3 Fuel injection pipe sleeve nut:
removal.
19.6 – 24.5 Nm {2 – 2.5 kgm}
[*1]
3 Air hose clamp [*5]
3 Mounting bolt of exhaust manihold and
After cooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
turbocharger:
34.3 – 53.9 Nm {3.5 – 5.5 kgm}
[*2]
2 Apply gasket sealant (ThreeBond [*6]
TB1208E) to the range of 30 mm from a Insert the cylinder head cover O-ring in the
each end of radiator hose adapters (of O-ring groove, taking care not to expand or
the radiator and water pump) and con- contact it, and fit it to the cylinder head.
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 7.84 – 9.8 Nm {0.8 – 1.0 kgm}
[*3] [*7]
3 Mounting bolt of clamp between turbo- 3 Rock nut: 39.2 – 49 Nm {4 – 5 kgm}
charger and muffler:
1st time: 39.2 – 49 Nm {4 – 5 kgm} [*8]
3 Rocker arm shaft mounting bolt and nut:
2nd time:
68.6 – 122.5 Nm {7 – 12.5 kgm}
19.6 – 29.4 Nm {2 – 3 kgm}
[*9]
1. Tighten the cylinder head mounting bolts in the
following order.
1) Apply molybdenum disulphide LM-P all over
the threads and seating face of each bolt and
the seats of the cylinder head holes.
2) Turn the bolts with the fingers until they are
screwed in the threaded holes of the cylinder
head by 2 – 3 threads in the order of [1] –
[17] shown in the figure.
3) Tighten the bolts to 68.6 ± 9.8 Nm {7 ± 1
kgm} in the order of [1] – [17] shown in the
figure.
4) Tighten the bolts to 107.8 ± 4.9 Nm {11 ± 0.5
kgm} in the order of [1] – [17] shown in the
figure.
a (1): Exhaust side, (2): Air intake side, (3):
Front, (4): Rear
30-14 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
Reference
3 U-clamp nut:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
• Supplying coolant
Supply coolant from the cooloant filter port to the
specified level, start the engine to circulate cool-
ant and recheck the level.
5 Coolant: 13.2 l
• Bleeding air
Bleed air from the fuel system. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC128US-2 30-15
(16)
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
REMOVAL
k Disconnect the wiring harness from the nega-
tive terminal of the battery.
30-16 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
PC128US-2 30-17
(16)
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
INSTALLATION
1. Before installing fuel injection pump (24), remove
the bolt from part E and secure the gear with M6
bolt [3] 35 mm or longer.
[*1]
3 Fuel injection pipe sleeve nut:
19.6 – 24.5 Nm {2 – 3.5 kgm}
30-18 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
REMOVAL
k Completely ground the work equipment.
k Disconnect the negative (-) terminal of the bat-
tery.
PC128US-2 30-19
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
a Adjust the cable length by referring to
"ADJUSTMENT OF FUEL CONTROL
CABLE".
[*2]
a Install the engine main pump assembly by
placing the engine mounting rubber as
shown in the figure below.
3 Engine mounting tightening bolt :
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
• Supplying coolant
a Supply coolant from the water filler port to
the specified level, start the engine to circu-
late coolant and recheck the level.
• Bleeding air
a Bleed air from the main pump. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
30-20 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
k Disconnect the negative (-) terminal of the bat-
tery.
PC128US-2 30-21
(19)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
30-22 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
PC128US-2 30-23
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1] [*2]
2 Apply gasket sealant (ThreeBond
TB1208E) to the range of 30 mm from
each end of radiator hose adapters (of
the radiator and water pump) and con-
nect the radiator hose.
3 Air hose clamp:
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
3 Radiator hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Aftercooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*3]
Adjust the cable length. For details, see TEST-
ING AND ADJUSTING, Adjustment of fuel con-
trol cable.
[*4]
a Install the engine main pump assembly by
placing the engine mounting rubber as
shown in the figure below.
3 Engine mounting tightening bolt:
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
• Supplying coolant
Supply coolant from the coolant filler port to the
specified level, start the engine to circulate cool-
ant and recheck the level.
5 Coolant: 17.2 l
• Bleeding air
Bleed air from the pump. For details, see TEST-
ING AND ADJUSTING, Bleeding air from each
part.
30-24 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
REMOVAL
PC128US-2 30-25
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
30-26 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
PC128US-2 30-27
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
30-28 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
3 Air hose clamp and aftercooler hose
clamp: 10.8 ± 0.5 Nm {1.1 ± 0.5 kgm}
[*2]
2 Apply gasket sealant (ThreeBond
TB1208E) to the range of 30 mm from
each end of radiator hose adapters (of
the radiator and water pump) and con-
nect the radiator hose.
3 Radiator hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
Adjustment to fuel control cable. For details, see
TESTING AND ADJUSTING, testing and adjust-
ing of an accelerator pedal.
[*4]
3 Starting motor terminal E13 (21) (M10):
15.7 – 19.6 Nm {1.6 – 2 kgm}
3 Starting motor terminal E54 (22) (M5):
2.5 – 3 Nm {0.25 – 0.31 kgm}
[*5]
Note that washer B on the inside of the chassis
(INSIDE) and that on the outside of the chassis
(OUTSIDE) to support bottom rubber A of the
engine mount on the chassis are different from
each other.
3 Engine mount mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
PC128US-2 30-29
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
• Supply coolant
Supply coolant from the coolant filler port to the
specified level, start the engine to circulate cool-
ant and recheck the level.
5 Coolant: 13.2 l
• Bleeding air
Bleed air from the pump and fuel system. For
details, see TESTING AND ADJUSTING, Bleed-
ing air from each part.
30-30 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC OIL COOLER
REMOVAL
kGradually loosen the hydraulic oil tank cap to
bleed the internal air after completely grounding
the work equipment and stopping the engine.
PC128US-2 30-31
(19)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC OIL COOLER
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a Check that the O-ring is not damaged or
deteriorated, then connect the hoses.
5 Hydraulic oil: 69 l
5 Coolant: 18.2 l
30-32 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR ASSEMBLY
PC128US-2 Serial No. : 8101 and up
PC138US-2 Serial No. : 3201 and up
REMOVAL
1. Drain cooling water.
6 Coolant : 17.2 l [*3]
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1] [*2]
3 Radiator hose clamp:
8.8 ± 0.5 Nm {0.9 – 0.05 kgm}
[*3]
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
Coolant : 13.2 l
PC128US-2 30-33
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL
k Gradually loosen the hydraulic oil tank cap to
bleed the internal air after completely grounding
the work equipment and stopping the engine.
30-34 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
INSTALLATION
• Carry out installation in the reverse order to
removal.
5 Hydraulic oil :
69 l (Oil level in hydraulic tank)
100 l (Capacity)
PC128US-2 30-35
(16)
DISASSEMBLY AND ASSEMBLY AFTER COOLER
REMOVAL
k Completely grounding the work equipment.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1] [*2]
3 After cooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
30-36 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY AFTER COOLER
REMOVAL
k Completely grounding the work equipment.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3 After cooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
PC128US-2 30-37
(16)
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
REMOVAL
k Completely ground the work equipment.
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
2 Fuel tank mounting bolt screw :
Liquefied adhesive (LT-2)
30-38 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
2 Mounting bolt screw :
Liquefied adhesive (LT-2)
3 Mounting bolt :
98.1 – 123.0 Nm {10.0 – 12.5 kgm}
• Bleeding air
Bleed air from the swing motor. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC128US-2 30-39
(16)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
3. Using tool T, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
ASSEMBLY
1. Fit slipper seals (7) and O-rings (6) to swivel
rotor.
30-40 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY
SWING MOTOR,
SWING MACHINERY
REMOVAL
k Gradually loosen the hydraulic oil tank cap to
bleed the internal air after completely grounding
the work equipment and stopping the engine.
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
2 Swing machinery fitting surface :
Gasket sealant (LG-4 or LG-6)
3 Mounting bolt :
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
• Bleeding air
Bleed air from the swing motor. For details , see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC128US-2 30-41
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
SWING MACHINERY
PC128US-2 Serial No. : 5001 and up
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
DISASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery.
6 Swing machinery case : Approx. 2.5 l
2. Swing motor
Remove swing motor assembly (1).
4 Swing motor assembly : 30 kg
30-42 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
4. Ring gear
Remove ring gear (14).
6. Retainer, collar
1) Remove retainer (24).
2) Set shaft and case assembly to press, push
split collar (25) with push tool F5, and press
fit bearing (26).
a Operate the press gradually and press fit
the bearing to a point where the split col-
lar can be removed.
3) Remove split collar (25).
7. Shaft assembly
1) Set shaft and case assembly (27) to block
[2], then using push tool [3], remove shaft
assembly (28) with press.
2) Remove bearing (26).
PC128US-2 30-43
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
30-44 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
2. Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
shaft (31).
PC128US-2 30-45
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
3. Oil seal
Using push tool F2, press fit oil seal (32).
4. Retainer
Install retainer (24).
30-46 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
6. Ring gear
Assemble O-ring (37) to shaft and case assem-
bly, and install ring gear (14).
PC128US-2 30-47
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
30-48 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
SWING MACHINERY
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
6 Swing machinery case: 2.5 l
4. Ring gear
Remove ring gear (14).
PC128US-2 30-49
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
6. Shaft assembly
Using push tool F1, remove bearing (29) and col-
lar (30) from shaft (31).
30-50 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
PC128US-2 30-51
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
2. Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
shaft (31).
30-52 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
3. Oil seal
Using push tool F2, press fit oil seal (32).
5. Ring gear
Install ring gear (14).
PC128US-2 30-53
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
3 Mounting bolt:
Install swing motor assembly (1).
30-54 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REVOLVING FRAME
REMOVAL
k Disconnect the negative (-) terminal of the bat-
tery.
PC128US-2 30-55
(16)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
2 Surface inside bushing during pin
assembly : Hyper white grease (G2-T)
2 Greasing after pin assembly :
Hyper white grease (G2-T)
[*2]
2 Swing circle contacting face :
Liquefied gasket (LG-1)
2 Revolving frame mounting bolt screw :
Liquefied adhesive (LT-2)
3 Revolving frame mounting bolt :
277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}
• Bleeding air
Bleed the air. For details , see TESTING AND
ADJUSTING, Bleeding air from each part.
30-56 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
SWING CIRCLE
REMOVAL
k Gradually loosen the hydraulic oil tank cap to
bleed the air from the tank after grounding the
work equipment and stopping the engine and
lock the safety lock lever.
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
2 Swing circle mounting bolt :
Liquefied adhesive (LT-2)
3 Swing circle mounting bolt :
245 – 308.9 Nm {25 – 31.5 kgm}
[*2]
a Lift swing circle assembly (1) and install it on
the track frame with the inner wheel soft
zone S symbol of the inner race facing the
right side of the body as shown in the figure.
2 Amount of circle grease sealed :
9.1 l (G2-LI grease)
PC128US-2 30-57
(16)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
2 Thread of travel motor mounting bolt :
Thread tightener (LT-2)
3 Sprocket mounting bolt :
323.6 – 362.8 Nm {33 – 37 kgm}
[*2]
2 Thread of travel motor and final drive
assembly mounting bolt :
Thread tightener (LT-2)
3 Travel motor and final drive assembly
mounting bolt :
235 – 285 Nm {23.5 – 29.5 kgm}
a Bleed the air from the travel motor.
For details, see TESTING AND ADJUSTING,
Bleeding air from travel motor.
30-58 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
RECOIL SPRING
PC128US-2 Serial No. : 5001 and up
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001– 1500
DISASSEMBLY
PC128US-2 30-59
(16)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY
1. Assembly of yoke piston assembly
1) Assemble wear ring (14) to yoke piston (11).
2) Assemble U-packing (13) and secure with
snap ring (14).
4. Fit valve (3) and seat (2), and secure with lock
plate (1).
a Install the valve so that the direction of the fit-
ting (15) is to the outside.
30-60 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
RECOIL SPRING
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
DISASSEMBLY
PC128US-2 30-61
(16)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY
1. Assembly of yoke piston assembly
1) Assemble wear ring (16) to yoke piston (13).
2) Assemble U-packing (15) and secure with
snap ring (14).
4. Fit valve (3) and seat (2), and secure with lock
plate (1).
a Install the valve so that the direction of the fit-
ting (17) is to the outside.
30-62 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY IDLER
IDLER
DISASSEMBLY
1. Remove dowel pin (1), then remove support (2).
PC128US-2 30-63
(16)
DISASSEMBLY AND ASSEMBLY IDLER
ASSEMBLY
1. Press fit bushings (9) and (10) to idler (4).
30-64 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY IDLER
PC128US-2 30-65
(16)
DISASSEMBLY AND ASSEMBLY IDLER
30-66 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
TRACK ROLLER
DISASSEMBLY
1. Remove pin (1), then remove collar (2).
8 5
6
10
4
9
3
2
11
CLP00790
PC128US-2 30-67
(16)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
CLP00791
ASSEMBLY
1. Using push tool [1], press fit bushings (9) and
(10) to roller (4).
CLP00793
CLP00866
30-68 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
CLP00867
10. Using tool M2, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil : 75 – 85 cc (EO30-CD)
PC128US-2 30-69
(16)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
TRACK SHOE
REMOVAL
1. Lower work equipment to ground, then loosen
lubricator (1), and relieve track tension. [*1]
kThe adjustment cylinder is under extremely
high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards and
forwards.
INSTALLATION
[*1]
a Adjust the track tension.
For details, see TESTING AND ADJUSTING,
Testing and adjusting track tension.
[*2]
a Use tool R and press fit the master pin so
that the protrusion of the master pin is
dimension "a".
Protrusion "a" of master pin : 5.5 ± 2 mm
[*3]
a When assembling the dust seal, coat the
bushing contact surface with grease (G2-LI).
30-70 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL
k Gradually loosen the hydraulic tank cap to
bleed the internal air after completely grounding
the work equipment and stopping the engine.
PC128US-2 30-71
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
2 Thread of hydraulic tank mounting bolt :
Thread tightener (LT-2)
3 Hydraulic tank mounting bolt :
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
• Bleeding air
Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air from each part.
30-72 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY MAIN PUMP
MAIN PUMP
PC128US-2 Serial No. : 5001 and up
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
k Completely ground the work equipment.
PC128US-2 30-73
(16)
DISASSEMBLY AND ASSEMBLY MAIN PUMP
MAIN PUMP
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
REMOVAL
k Completely grounding the work equipment.
k Disconnect the negative (-) terminal of the bat-
tery.
30-74 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY MAIN PUMP
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
2 Mating surface of pump case :
Gasket sealant (LG-6)
• Bleeding air
a Bleed the air from main pump.
For details, see TESTING AND ADJUSTING,
Bleeding air from each part.
PC128US-2 30-75
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Turn on the main switch and
operate the work equipment control levers on
both sides freely to release the PPC pressure,
then turn off the main switch.
30-76 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
INSTALLATION
• Carry out installation in the reverse order to
removal.
• Bleeding air.
Bleed the air from the circuit between the valve
and the hydraulic cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from each part.
PC128US-2 30-77
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
PC128US-2 Serial No. : 5001 and up
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
DISASSEMBLY
30-78 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
PC128US-2 30-79
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-80 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
PC128US-2 30-81
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-82 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
ASSEMBLY
PC128US-2 30-83
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-84 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
PC128US-2 30-85
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
a Before assembling the parts, apply engine oil to 2) Install spring (87) and valve (86), then install
their sliding surfaces. plug (85).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
1. Studs for combination (Addition of service
valve)
5. Boom pressure compensation valve
a When adding a service valve, assemble
1) Install valve (84), piston (83), and spring
according to the following procedure.
(82), then install plug (81).
3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}
1) Tighten 4 studs temporarily.
2) Install service valve assembly.
3) Install cover (106).
2) Install spring (80) and valve (79), then install
4) Install 4 washers and tighten nuts (105).
plug (78).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
a Tighten the nuts in the diagonal order
according to the following procedure.
3 Nut :
6. Right travel pressure compensation valve
1st time : 64 ± 4.9 Nm
and left travel pressure compensation valve
{6.5 ± 0.5 kgm}
1) Install valve (77) and spring (76), then install
At this time, check that the
plug (75).
3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}
height of the stud top is
0.5 – 3 mm above the nut
top. If it is out of this
2) Install valve (74) and plug (73) as one unit.
3 Plug : 107.8 ± 9.8 Nm {11 ± 1 kgm}
range, loosen the nut and
adjust the height of the
stud with a flat-head
screwdriver. 7. Swing pressure compensation valve
2nd time : 83.36 ± 4.9 Nm 1) Install valve (72), piston (71), and spring
{8.5 ± 0.5 kgm} (70), then install plug (69).
3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}
3rd time : 105.42 ± 7.4 Nm
{10.75 ± 0.75 kgm}
Check again that the 2) Install spring (68) and valve (67), then install
height of the stud top is plug (66).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
0.5 – 3 mm above the nut
top.
8. Service control valve
2. Service pressure compensation valve
1) Install spool assembly (65).
1) Install valve (104) and spring (103), then
2) Install 2 retainers (64) and 2 springs (63),
install valve (102).
3 Valve : 215.6 ± 19.6 Nm {22 ± 2 kgm}
then install 2 cases (62).
3 Mounting bolt :
2) Install spring (101) and valve (100), then 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
install plug (99).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
9. Bucket control valve
1) Install spool assembly (61).
2) Install 2 retainers (60) and 2 springs (59),
3. Bucket pressure compensation valve
then install 2 cases (58).
3 Mounting bolt :
1) Install valve (98), piston (97), and spring
(96), then install plug (95).
3 Plug : 166.6 ± 19.6Nm {17 ± 2 kgm}
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
2) Install spring (94) and valve (93), then install 10. Arm regeneration valve
plug (92). Install valve (57) and spring (56), then install plug
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
(55).
30-86 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12. Boom hydraulic drift prevention valve 18. Cooler bypass valve and lift check valve
1) Install sleeve (50), then install plug (49). 1) Install sleeve (14), piston (13), and spring
2) Install piston (48), then install spring (47). (12), then install case (11).
3 Mounting bolt :
3) Install valve (46), spring (45), piston (44),
and spring (43), then install plate (42).
3 Mounting bolts (39), (40) :
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
2) Install sleeve (10), piston (9), and spring (8),
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
then install case (7).
3 Mounting bolt :
Mounting bolt (41) :
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
13. Boom control valve
1) Install spool assembly (38). 19. Valve assembly
2) Install 2 retainers (37) and 2 springs (36), 1) Install unload valve assembly (6).
3 Unload valve assembly :
then install 2 cases (35).
3 Mounting bolt : 166.6 ± 19.6 Nm {17 ± 2 kgm}
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
2) Install 10 suction valve assemblies (5).
14. Travel interconnection valve 3 Suction valve assembly :
1) Install 2 balls (34), then install 2 plugs (33). 147 ± 9.8 Nm {15 ± 1 kgm}
3 Plug : 7.4 ± 1.5 Nm {0.75 ± 0.15 kgm} 3) Install LS select valve assembly (4).
2) Install 2 spools (32), 2 retainers (31), and 2 3 LS select valve assembly:
springs (30), then install 2 plugs (29). 127.4 ± 19.6 Nm {13 ± 2 kgm}
3 Plug : 55.9 ± 6.9 Nm {5.7 ± 0.7 kgm} 4) Install safety-suction valve assembly (3).
3 Safety-suction valve assembly :
15. Right travel control valve and left travel con-
186.2 ± 9.8 Nm {19 ± 1 kgm}
trol valve
1) Install spool (28). 5) Install main relief valve assembly (2).
3 Main relief valve assembly :
2) Install 2 retainers (27), 2 springs (26), then
install 2 cases (25).
3 Mounting bolt :
98 ± 9.8 Nm {10 ± 1 kgm}
PC128US-2 30-87
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
ASSEMBLY
30-88 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
a In this section, only the precautions for assem- a When loosening and tightening plug T1-5L, be
bling the control valve assembly are described. sure to keep the spool in the valve chamber.
3 T1-5L:14.7 – 19.6 Nm {1.5 – 2 kgm}
• Before assembling the parts, apply engine oil to
See LOCTITE shown below.
3 T1-2L: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
their sliding surfaces.
2 Mating face:
See LOCTITE shown below.
2 T1-2L, T1-5L:
Liquid sealant (Sealend 242 or equivalent)
a The tightening torque of the parts and the pre- Apply 1 drop (about 0.02 g) of
cautions are shown below (in random order). LOCTITE No. 638 to each of the
points shown below.
• T (Install cover (1)):
Tighten the nuts in the diagonal order according a Degrease and dry up the threads of the plugs
to the following procedure. and female screws in advance. Do not apply
pressure for 2 hours after tightening them.
3 T6 : 59 – 78 Nm {6 – 8 kgm}
PC128US-2 30-89
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-90 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
PC128US-2 30-91
(16)
DISASSEMBLY AND ASSEMBLY LS SELECTION VALVE
LS SELECTION VALVE
DISASSEMBLY
ASSEMBLY
a Before assembling coat the sliding surface with
engine oil.
30-92 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
30-94 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
1. A (Bucket)
1) Remove plug (1), then remove spring (2),
piston (3), and valve (4).
2) Remove plug (5), then pull out valve (6) and
remove spring (7) from it.
2. B (Arm)
1) Remove plug (8), then remove spring (9),
piston (10), and valve (11).
2) Remove plug (12), then pull out valve (13)
and remove spring (14) from it.
3. C (Boom)
1) Remove plug (15), then remove spring (16),
piston (17), and valve (18).
2) Remove plug (19), then pull out valve (20)
and remove spring (21) from it.
4. D (Travel)
1) Remove plug (22), then remove spring (23)
and valve (24).
2) Remove plug (25), then remove bolt (26) and
washer together.
3) Remove sleeve (27), then remove spring
(28) and valve (29).
5. E (Swing)
1) Remove plug (30), then spring (31), piston
(32), and valve (33).
2) Remove plug (34), then pull out valve (35)
and remove spring (36) from it.
PC128US-2 30-95
(16)
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
ASSEMBLY
30-96 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
1. A (Bucket)
1) Fit spring (7) to valve (6) and insert them in
valve body, then install O-ring and plug (5).
2) Install piston (3) and spring (2) to valve (4)
and insert them in valve body, then install O-
ring and plug (1).
2. B (Arm)
1) Fit spring (14) to valve (13) and insert them
in valve body, then install O-ring and plug
(12).
2) Install piston (10) and spring (9) to valve (11)
and insert them in valve body, then install O-
ring and plug (8).
3. C (Boom)
1) Fit spring (21) to valve (20) and insert them
in valve body, then install O-ring and plug
(19).
2) Install piston (17) and spring (16) to valve
(18) and insert them in valve body, then
install O-ring and plug (15).
4. D (Travel)
1) Install spring (28) and valve (29) to sleeve
(27) and insert them in valve body and fix
them with washer and bolt (26), then install
O-ring and plug (25) to sleeve (27).
2) Fit spring (23) to valve (24) and insert them
in valve body, then install O-ring and plug
(22).
PC128US-2 30-97
(16)
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
30-98 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
ASSEMBLY
a Before assembling the parts, apply engine oil to
their sliding surfaces.
PC128US-2 30-99
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(4).
30-100 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
ASSEMBLY
1. Assemble valve (13) to body (14).
P1, P2 44.4mm
P3, P4 42.4mm
PC128US-2 30-101
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
ASSEMBLY
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
etc. will not cause a trouble.
30-102 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
PC128US-2 30-103
(16)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY
4
1. Remove screw (1) to remove lever (2).
2
2. Remove mounting bolt (3) to remove case shaft
assembly (4).
5
3. Remove mounting bolt (5) to remove plate (6)
together with damper assembly (7). 18
a Check the thickness and the mounting posi-
tion of washer (18). 1
6
4. Remove mounting bolt (8) to remove damper
assembly (7) from plate (6). 9
16
17
CEP00533
30-104 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
ASSEMBLY
1
1. Engage valve (16) with body (17). 2
3
2. Engage shim (15) and spring (14) with valve
(16).
a Mount shim (15) on the position which has 4
been checked at the time of disassembly
with the proper thickness and number. 2
Standard shim thickness : 0.3mm
a Since spring (14) is not symmetric vertically ,
engage it with the smaller diameter side fac- 5
ing the shim.
18
3. Mount spring (13), retainer (12) and piston (11).
2 Piston outside perimeter and body hole :
1
6
Grease (G2-LI)
9
4. Place the O-ring on collar (10) to engage them
with body (17) and mount seal (9) on them.
10
5. Mount damper assembly (7) on plate (6) and
tighten mounting bolt (8). 11
2 Mounting bolt : Adhesive (LT-2) 7
3 Mounting bolt :
12
8
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm} 13
0.39°.
3 Mounting bolt :
31.0 ± 3.4 Nm {3.15 ± 0.35 kgm}
3 Mounting bolt :
contacting part : Grease (G2-LI)
PC128US-2 30-105
(16)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
ASSEMBLY
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
etc. will not cause a trouble.
4. Use the insertion jig to insert pin (5). (Do not drive
in the pin with impact loads of a hammer, etc.)
30-106 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
DISASSEMBLY
a This section explains how to disassemble and
assemble the boom, arm, bucket and blade cyl-
inders. For how to disassemble and assemble
the offset cylinder, refer to "DISASSEMBLY AND
ASSEMBLY OF OFFSET CYLINDER ASSEM-
BLY".
PC128US-2 30-107
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
30-108 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
PC128US-2 30-109
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY
a Be careful not to damage the packing, the dust
seal, the O-ring or the like
a Do not forcibly insert the backup ring but make it
warm with hot water (50 to 60°C) before inser-
tion.
30-110 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
PC128US-2 30-111
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
3 Screw (3) :
LOCTITE No. 262
30-112 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
PC128US-2 30-113
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL
k Fully extend the work equipment and set a
block at the arm end and lower the bucket tip to
30-114 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a When tightening the locknut, tighten so that
the clearance a between the plate and nut is
0.5 – 1.5 mm.
[*2]
2 Inside surface of bushing when assem-
bling pin :
Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :
Grease (LM-G)
kWhen aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust the shim thickness so that clearance
b between cylinder rod (21) and plate (22) is
less than 1 mm.
a Standard shim thickness : 1.0 mm
[*3]
2 Inside surface of bushing when assem-
bling pin :
Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :
Grease (LM-G)
kWhen aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust the shim thickness so that clearance c
between boom (23) and bracket (24) is less
than 0.5 mm.
a Standard shim thickness : 0.5, 1.0, 2.0 mm
• Bleeding air
Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
PC128US-2 30-115
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
OPERATOR’S CAB
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599
PC138USLC-2 Serial No. :
REMOVAL
k Completely ground the work equipment.
k Disconnect the negative (-) terminal of the bat-
tery.
30-116 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
INSTALLATION
• Installation is performed in the opposite way to
removal.
PC128US-2 30-117
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
OPERATOR’S CAB
PC128US-2 Serial No. : 7301 and up
PC138US-2 Serial No. : 2601 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
k When removing the floor frame together, swing
to the left by 135 degrees. (See REMOVAL OF
30-118 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
PC128US-2 30-119
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
INSTALLATION
• Carry out installation in reverse oder to removal.
30-120 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
OPERATOR’S CAB
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
REMOVAL
a When removing the floor frame together, swing
to the left by 135 degrees. (See REMOVAL OF
FLOOR FRAME ASSEMBLY.)
k Remove the negative (-) terminal from the bat-
tery before setting to work.
PC128US-2 30-121
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
22. Take out grommet (35) from the right front of the
cab and disconnect windshield washer hose
from (36).
INSTALLATION
• Carry out installation in reverse order to
removed.
30-122 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
Amoung the panes of window glass on the 4 (1): Right side window glass
sides of the operator’s cab, 5 panes (1) – (5) are (2): Left side rear window glass
stuck. (3): Door upper window glass
In this section, the procedure for replacing the (4): Door lower window glass
stuck glass is explained. (5): Front window glass
When replacing front window glass (5), remove (6): Front window assembly
front window assembly (6). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the ( 7 ) : Both-sided adhesive tape
front window assembly is installed to the opera- (16) : Center trim seal
tor’s cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
PC128US-2 30-123
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
SPECIAL TOOLS
New/Removal
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
REMOVAL
a Remove the window glass to be replaced accor-
ing to the following procedure.
30-124 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
INSTALLATION
1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking sur-
faces) of the operator’s cab.
a Remove the adhesive and both-sided adhe-
sive tape to a degree that they will not affect
adhesion of the new adhesive. Take care not
to scratch the painted surfaces. (If the
painted surfaces are scratched, adhesion will
be lowered.)
(The figure shows the operator’s cab of a wheel
loader.)
PC128US-2 30-125
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
30-126 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
PC128US-2 30-127
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
30-128 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
PC128US-2 30-129
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
6. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
2 Adhesive (Winter):
SEAL 580 SUPER "S"
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where the
temperaure is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
30-130 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
PC128US-2 30-131
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
30-132 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
PC128US-2 30-133
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
30-134 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
REMOVAL
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides). [*1]
INSTALLATION
• Carry out installation in the reverse order to
removal.
PC128US-2 30-135
(16)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
FLOOR FRAME
PC128US-2 Serial No. : 5001 – 7300
PC138US-2 Serial No. : 1001 – 2600
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
30-136 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
INSTALLATION
• Carry out installation in the reverse order to
removal.
PC128US-2 30-137
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
FLOOR FRAME
PC128US-2 Serial No. : 7301 and up
PC138US-2 Serial No. : 2601 – 4500
REMOVAL
k Remove the negative (-) terminal from the bat-
tery before setting to work.
1. Drain coolant
6 Coolant: 17.2 l
30-138 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
11. Remove the cover from under the seat and dis-
connect air conditioner tubes (18) and (19) from
the air conditioner unit. [*1]
INSTALLATION
• Carry out installation in reverse oder to removal.
[*1]
3 Air conditioner tube nut:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
PC128US-2 30-139
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
FLOOR FRAME
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1001 and up
REMOVAL
k Remove the negative (-) terminal from the bat-
tery before setting to work.
1. Drain coolant
6 Coolant: 13.2 l
30-140 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
PC128US-2 30-141
(16)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
13. Remove the cover from under the seat and dis-
connect air conditioner tubes (18) and (19) from
the air conditioner unit. [*1]
INSTALLATION
• Carry out installation in reverse order to removal.
[*1]
3 Air conditioner tube nut:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
30-142 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
AIR CONDITIONER
COMPRESSOR
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599
REMOVAL
k Completely ground the work equipment.
INSTALLATION
• Installation is performed in the opposite way to
removal.
PC128US-2 30-143
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
AIR CONDITIONER
COMPRESSOR
PC128US-2 Serial No. : 7301 and up
PC138US-2 Serial No. : 2601 and up
PC138USLC-2 Serial No. : 1001 and up
REMOVAL
k Lower the work equipment to the ground com-
pletely.
INSTALLATION
• Carry out installation in reverse oder to reomval.
30-144 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
AIR CONDITIONER
CONDENSER
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599
REMOVAL
k Completely ground the work equipment.
INSTALLATION
• Installation is performed in the opposite way to
removal.
PC128US-2 30-145
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
AIR CONDITIONER
CONDENSER
PC128US-2 Serial No. : 7301 and up
PC138US-2 Serial No. : 2601 and up
REMOVAL
k Lower the work equipment to the ground com-
pletely.
INSTALLATION
• Carry out installation in reverse oder to remaval.
30-146 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL
k Completely ground the work equipment.
PC128US-2 30-147
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION
• Installation is performed in the opposite way to
removal.
30-148 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL
k Remove the negative (-) terminal from the bat-
tery before setting to work.
1. Drain coolant.
6 Coolant: 17.2 l
PC128US-2 30-149
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
30-150 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION
• Carry out installation in reverse oder to removal.
PC128US-2 30-151
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL
k Disconnect negative (-) terminal of the battery.
30-152 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
PC128US-2 30-153
(19)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION
• Carry out installation in reverse order to removal.
[*1]
3 Air conditioner tube nut:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
• Supplying coolant
Add coolant through the coolant filler to the spec-
ified level. Run the engine to circulate the cool-
ant through the system. Then, check the coolant
level again.
5 Coolant: 13.2 l
30-154 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL
k Completely ground the work equipment.
PC138USLC-2)
: 3,450 kg (Standard specification)
: 3,050 kg (Blade specification)
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
3 Mounting bolt :
3,850 – 4,710 Nm (393 – 480 kgm)
PC128US-2 30-155
(16)
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
INSTALLATION
• Carry out installation in the reverse order to
removal.
30-156 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROLLER
CONTROLLER ASSEMBLY
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
REMOVAL
k Disconnect the cable from the negative (-) ter-
minal of the battery.
INSTALLATION
• Carry out installation in the reverse order to
removal.
PC128US-2 30-157
(16)
40 MAINTENANCE STANDARD
PC128US-2 40-1
(15)
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
PC128US-2 Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 – 1500
40-2 PC128US-2
(15)
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
PC128US-2 40-3
(14)
MAINTENANCE STANDARD SWING MACHINERY
40-3-1 PC128US-2
(15)
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
PC128US-2 40-3-2
(15)
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
40-4 PC128US-2
(14)
MAINTENANCE STANDARD TRACK FRAME, IDLER CUSHION
Unit: mm
Track Rebuild
frame 185 193
2 Idler guide left
and right width Idler Rebuild or
support 183 175 replace
Standard size Repair limit
84.3 kN 75.0 kN
ª2 502 390 {8,600 kg} 490 {7,650 kg}
Unit: mm
PC128US-2 40-6-1
A
MAINTENANCE STANDARD IDLER
40-6-2 PC128US-2
(15)
MAINTENANCE STANDARD IDLER
Unit: mm
PC128US-2 40-7
A
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm
TRACK ROLLER
PC128US-2 Serial No.: 5001 – 5362
Unit: mm
Rebuild or
5 Width of tread 35 — replace
PC128US-2 40-9
A
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm
Rebuild or
5 Width of tread 35 — replace
40-10 PC128US-2
(15)
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm
Rebuild or
5 Width of tread 35 — replace
PC128US-2 40-11
(15)
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
+0.465
Tooth bottom PC128US-2 111.7
– 1.160
105.5
5 wall thick-
ness +0.465
PC138USLC-2 109.4 103
– 1.160
40-12 PC128US-2
0
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
TRIPLE SHOE, ROAD LINER, CITY PAD SHOE
PC128US-2 40-13
7
MAINTENANCE STANDARD TRACK SHOE
PC128US-2
(1/2) Unit: mm
5 102.4
Replace
6 Shoe bolt pitch 86.4
7 57
16 Spacer thickness —
Press fitting —
18 force Regular pin 78.5 – 186.3 kN {8 – 19 ton}
ª
19 Master pin 39.2 – 98.1 kN {4 – 10 ton}
40-14 PC128US-2
(15)
MAINTENANCE STANDARD TRACK SHOE
PC128US-2
(2/2) Unit: mm
• Triple 196 ± 20 90 ± 10
a. Regular link • City pad {20 ± 2}
Number of shoes ª2 42
—
(on one side) ª3 43
Tolerance Standard
Standard size interference
Interference between Shaft Hole
21
bushing and link
+0.387 +0.062
46 0.285 –0.387
+0.347 0
Tolerance Standard
Standard size clearance
Clearance between regular Shaft Hole
23 pin and bushing
+0.150 +0.830
30 0.180 – 0.830 Adjust or
0 +0.330 replace
Tolerance Standard
Standard size interference
ª 1 Interference between Shaft Hole
24 master pin and link
+0.020 –0.198
30 –0.250 0.178 – 0.270
–0.020
Tolerance Standard
Standard size clearance
ª 1 Clearance between master Shaft Hole
25 pin and bushing
–0.200 +0.630
30 0.430 – 0.930
–0.300 +0.230
Standard size Repair limit
26 Grouser
height Replace
a. Road liner 58 21
PC128US-2 40-15
(15)
MAINTENANCE STANDARD TRACK SHOE
PC138US-2
(1/2) Unit: mm
5 102.4
Replace
6 Shoe bolt pitch 86.4
7 57
Adjust or
14 Total bushing length 86.7 replace
(master bushing)
16 Spacer thickness —
Press fitting
18 force Regular pin 98.1 – 235.4 kN {10 – 24 ton} —
ª
19 Master pin 98.1 – 235.4 kN {10 – 24 ton}
40-15-1 PC128US-2
(15)
MAINTENANCE STANDARD TRACK SHOE
PC138US-2
(2/2) Unit: mm
Number of shoes 43 —
(on one side)
Tolerance Standard
Standard size interference
Interference between Shaft Hole
21
bushing and link
+0.387 +0.074
50.2 0.273 –0.387
+0.347 0
Tolerance Standard
Standard size clearance
Clearance between regular Shaft Hole
23 pin and bushing
+0.150 +0.830
32 0.180 – 0.780 Adjust or
+0.050 +0.330 replace
Tolerance Standard
Standard size interference
ª Interference between Shaft Hole
24 master pin and link
+0.060 –0.188
32 –0.250 0.208 – 0.310
+0.020
Tolerance Standard
Standard size clearance
ª Clearance between master Shaft Hole
25 pin and bushing
–0.200 +0.830
32 0.530 – 1.130
–0.300 +0.330
Standard size Repair limit
26 Grouser height Replace
— —
PC128US-2 40-15-2
(15)
MAINTENANCE STANDARD
PC138USLC-2
(1/2) Unit: mm
5 102.4
Replace
6 Shoe bolt pitch 86.4
7 57
Adjust or
14 Total bushing length 86.7 replace
(master bushing)
16 Spacer thickness —
Press fitting
18 force Regular pin 98.1 – 235.4 kN {10 – 24 ton} —
ª
19 Master pin 98.1 – 235.4 kN {10 – 24 ton}
40-15-3 PC128US-2
(15)
MAINTENANCE STANDARD TRACK SHOE
PC138USLC-2
(2/2) Unit: mm
Number of shoes 46 —
(on one side)
Tolerance Standard
Standard size interference
Interference between Shaft Hole
21
bushing and link
+0.387 +0.074
50.2 0.273 –0.387
+0.347 0
Tolerance Standard
Standard size clearance
Clearance between regular Shaft Hole
23 pin and bushing
+0.150 +0.830
32 0.180 – 0.780 Adjust or
+0.050 +0.330 replace
Tolerance Standard
Standard size interference
ª Interference between Shaft Hole
24 master pin and link
+0.060 –0.188
32 –0.250 0.208 – 0.310
+0.020
Tolerance Standard
Standard size clearance
ª Clearance between master Shaft Hole
25 pin and bushing
–0.200 +0.830
32 0.530 – 1.130
–0.300 +0.330
Standard size Repair limit
26 Grouser height Replace
— —
PC128US-2 40-15-4
(15)
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
40-16 PC128US-2
(15)
MAINTENANCE STANDARD HYDRAULIC PUMP
PC128US-2 40-17
(15)
MAINTENANCE STANDARD HYDRAULIC PUMP
40-17-1 PC128US-2
(15)
MAINTENANCE STANDARD HYDRAULIC PUMP
PC128US-2 40-17-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
7 SPOOL (6 SPOOL + SERVICE VALVE)
PC128US-2 Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 – 1500
(1/9)
40-18 PC128US-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
PC128US-2 40-18-1
(15)
MAINTENANCE STANDARD CONTROL VALVE
(2/9)
Unit: mm
1.20 N 0.98 N
3 Piston spring 20.0 × 7.0 14.0 {0.12 kg} — {0.10 kg}
PC128US-2 40-19
(15)
MAINTENANCE STANDARD CONTROL VALVE
‘2
B-B 9JYOOO59
Unit: mm
(4/9)
Unit: mm
74.5 N 59.8 N
5 Relief valve spring 17.1 × 9.0 15.5 {7.60 kg} — {6.10 kg}
PC128US-2 40-21
(15)
MAINTENANCE STANDARD CONTROL VALVE
(5/9)
Unit: mm
40-22 PC128US-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
(6/9)
Unit: mm
PC128US-2 40-23
(15)
MAINTENANCE STANDARD CONTROL VALVE
(7/9)
Unit: mm
40-24 PC128US-2
MAINTENANCE STANDARD CONTROL VALVE
(8/9)
Unit: mm
5.88 N 4.71 N
3 Check valve spring 41.5 × 8.50 31.5 {0.60 kg} — {0.48 kg}
PC128US-2 40-25
(15)
MAINTENANCE STANDARD CONTROL VALVE
(9/9)
40-26 PC128US-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
40-26-2 PC128US-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
(1/8)
Unit: mm
2N 1.6 N
3 Piston spring 10.5 × 7.0 6.8 {0.21 kg} — {0.17 kg}
PC128US-2 40-26-3
(15)
MAINTENANCE STANDARD CONTROL VALVE
(2/8)
Unit: mm
222±13.7N 178 N
3 Spool return spring 42.4 × 28.0 39.0 {22.6±1.40kg} — {18.1 kg}
40-26-4 PC128US-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
(3/8)
Unit: mm
PC128US-2 40-26-5
(15)
MAINTENANCE STANDARD CONTROL VALVE
(4/8)
Unit: mm
40-26-6 PC128US-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
(5/8)
Unit: mm
PC128US-2 40-26-7
(15)
MAINTENANCE STANDARD CONTROL VALVE
(6/8)
Unit: mm
40-26-8 PC128US-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
(7/8)
Unit: mm
5.88 N 4.71 N
3 Check valve spring 41.5 × 8.50 31.5 {0.60 kg} — {0.48 kg}
PC128US-2 40-26-9
(15)
MAINTENANCE STANDARD CONTROL VALVE
(8/8)
40-26-10 PC128US-2
(15)
MAINTENANCE STANDARD SUCTION SAFETY VALVE
Unit: mm
PC128US-2 40-27
(15)
MAINTENANCE STANDARD SELF PRESSURE REDUCTION VALVE
Unit: mm
61.7 N 58.8 N
4 Spring (safety valve) 16.1 × 7.80 13.4 {6.30 kg} — {6.0 kg}
40-28 PC128US-2
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
GM18VL-J : PC128US-2 STD (Serial No. 5001 and up)
GM20VL-J : PC128US-2 OPT (Traction up) (Serial No. 5001 – 6072)
GM20VL-P : PC128US-2 OPT (Traction up) (Serial No. 6073 and up)
PC138USLC-2 STD (Serial No. 1001 – 1500)
GM20VL2-P : PC138US-2 STD (Serial No. 4501 and up)
PC138USLC-2 STD (Serial No. 1501 and up)
PC128US-2 40-29
(15)
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF40ABE-3
Unit: mm
40-30 PC128US-2
2
MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECTOR, SWING AND PARK BRAKE, AND 2-
STAGE RELIEF SOLENOID VALVE
21.6*2.2Nm
(2.2*0.22kPml
B-B
Unit: mm
40-32 PC128US-2
A
MAINTENANCE STANDARD CENTER SWIVEL JOINT
Unit: mm
PC128US-2 40-33
A
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
FOR SWING, WORK EQUIPMENT
17.0 N 13.3 N
3 Metering spring 26.53 × 8.15 24.9 {1.70 kg} — {1.36 kg}
40-34 PC128US-2
(15)
MAINTENANCE STANDARD PPC VALVE
17.0 N 13.3 N
3 Metering spring 26.53 × 8.15 24.9 {1.70 kg} — {1.36 kg}
PC128US-2 40-34-1
(15)
MAINTENANCE STANDARD PPC VALVE
FOR TRAVEL
PC128US-2 Serial No.: 5001 – 6300
Unit: mm
PC128US-2 40-35
(15)
MAINTENANCE STANDARD PPC VALVE
Unit: mm
40-35-1 PC128US-2
(15)
MAINTENANCE STANDARD PPC VALVE
40-36 PC128US-2
(15)
MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION VALVE
Unit: mm
69.6 N 55.9 N
3 Spool return spring 30.9 × 20.6 29.0 {7.1 kg} — {5.7 kg}
PC128US-2 40-37
C
MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION VALVE
Unit: mm
69.6 N 55.9 N
3 Spool return spring 30.9 × 20.6 29.0 {7.1 kg} — {5.7 kg}
40-37-1 PC128US-2
(15)
MAINTENANCE STANDARD ARM HYDRAULIC DRIFT PREVENTION VALVE
Unit: mm
69.6 N 55.7 N
3 Spool return spring 30.9 × 20.6 29 {7.1 kg} — {5.7 kg}
PC128US-2 40-37-2
(15)
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
2 4 1 5 3
9JA01392
ARM CYLINDER
9JA01393
BUCKET CYLINDER
9JA01394
BLADE CYLINDER
9JAOl395
40-38 PC128US-2
0
MAINTENANCE STANDARD HYDRAULIC CYLINDER
PC128US-2 40-39
(15)
MAINTENANCE STANDARD HYDRAULIC CYLINDER
40-40 PC128US-2
(15)
MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
9JAOI396
9JA01397
Unit: mm
PC128US-2 40-43
A
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
A-A B-B
c-c
9JA01398
40-44 PC128US-2
0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit: mm
PC138US-2
PC138USLC-2
No.
Tolerance
Measuring position Standard size
Shaft Hole
1 — ø 70 – 0.030 +0.100
– 0.100 0
4 — ø 70 – 0.030 +0.100
– 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 — 487 ± 0.2
12 — 415 ± 0.5
13 — 374.9 —
14 — 1,246.2 —
15 — ø 60 – 0.030 +0.200
– 0.080 0
17 — ø 60 – 0.030 +0.200
– 0.080 0
Min. 1,378 —
19
Max. 2,263 —
40-45-1 PC128US-2
(15)
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit: mm
PC138US-2
PC138USLC-2
No.
Tolerance
Measuring position Standard size
Shaft Hole
1 — ø 70 – 0.030 +0.100
– 0.100 0
4 — ø 70 – 0.030 +0.100
– 0.100 0
5 — 284.3 ± 2.0
6 — 230.3 ± 1.0
7 — 635.8 ± 1.0
8 — 2,991.1 —
9 — 2,098.9 ± 1.5
10 — 289.8 ± 0.5
11 — 487 ± 0.2
12 — 415 ± 0.5
13 — 374.9 —
14 — 1,246.2 —
15 — ø 60 – 0.030 +0.200
– 0.080 0
17 — ø 60 – 0.030 +0.200
– 0.080 0
Min. 1,378 —
19
Max. 2,263 —
40-45-5 PC128US-2
(15)
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit: mm
PC138US-2
PC138USLC-2
No.
Tolerance
Measuring position Standard size
Shaft Hole
1 — ø 70 – 0.030 +0.100
– 0.100 0
4 — ø 70 – 0.030 +0.100
– 0.100 0
5 — 280.5 ± 2.0
6 — 213.0 ± 1.0
7 — 640.7 ± 1.0
8 — 2,088.5 —
9 — 2,101.7 ± 1.5
10 — 290.0 ± 0.5
11 — 487 ± 0.2
12 — 415 ± 0.5
13 — 374.9 —
14 — 1,246.2 —
15 — ø 60 – 0.030 +0.200
– 0.080 0
17 — ø 60 – 0.030 +0.200
– 0.080 0
Min. 1,378 —
19
Max. 2,263 —
40-45-9 PC128US-2
(15)
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit:mm
PC128US-2
No.
Measuring position Standard size Tolerance
I I
- 371.3 zk0.5
2 - 51.6 i 0.5
3 - 97.9' -
4 - 374.9 -
~. -
I I I
- 1,I 59.6 -
6 - 190.5 -
I
7 - 5' -
I
- 0' -
- +0.2
9 0 60 0
- 0 64 I -
- +0.25
11 0 80
0
12 - 261 t 1.0
I
73 I-- - 50 -
14 - 85 -
- +l.O
15 380
I I I 0
16 - 018 -
17 - 0110 -
- 0130
19 - 0132 -
- 0108
I
21 - 274 -
22 - 51 -
I
23 - 34 -
106.7 -
25 - 124.3 -
26 - 74 -
27 - 65 -
PC128US-2 40-47
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit: mm
PC138US-2
No. PC138USLC-2
Measuring position Standard size Tolerance
1 — 371.3 ± 0.5
2 — 51.6 ± 0.5
3 — 97.9˚ —
4 — 374.9 —
5 — 1,231.6 —
6 — 190.2 —
7 — 5˚ —
8 — 0˚ —
9 — ø 60 +0.2
0
10 — ø 64 —
11 — ø 80 +0.25
0
12 — 261 ± 1.0
13 — 50 —
14 — 85 —
15 — 380 +1.0
0
16 — ø 18 —
17 — ø 110 —
18 — ø 130 —
19 — ø 132 —
20 — ø 108 —
21 — 274 —
22 — 51 —
23 — 34 —
24 — 104.2 —
25 — 119.6 —
26 — 74 —
27 — 65 —
40-47-1 PC128US-2
(15)
90 OTHERS
Hydraulic circuit diagram (Attachment)
(Breaker : 1 service valve : 50% amount) ..................................................... 90- 3
Hydraulic circuit diagram (Attachment)
(Crasher : 1 service valve : 100% amount) ................................................... 90- 5
Hydraulic circuit diagram (Attachment)
(Crasher : 2 service valve : 100% amount) .................................................. 90-5-2
Electric circuit diagram (Air conditioner)
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 7
Electric circuit diagram (Air conditioner)
PC128US-2 (Serial No.: 7731 and up)
PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-7-2
Hydraulic circuit diagram
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 9
Hydraulic circuit diagram
PC128US-2 (Serial No.: 7731 and up)
PC138US-2 (Serial No.: 4501 and up)
PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-9-2
Hydraulic circuit diagram
(With 1 actuator attachment)
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 11
Hydraulic circuit diagram
PC128US-2 (Serial No.: 7731 and up)
PC138US-2 (Serial No.: 4501 and up)
PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-11-2
Hydraulic circuit diagram
(With blade + 1 actuator attachment)
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 13
Hydraulic circuit diagram
(With blade + 1 actuator attachment)
PC128US-2 (Serial No.: 7731 and up)
PC138US-2 (Serial No.: 4501 and up)
PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-13-2
Hydraulic circuit diagram (For KUK spec.)
PC128US-2 (Serial No.: 5001 – 7730) ..................................................... 90-13-4
Hydraulic circuit diagram (For KUK spec.)
PC128US-2 (Serial No.: 7731 and up)
PC138US-2 (Serial No.: 4501 and up) .................................................... 90-13-6
Hydraulic circuit diagram
(With 2 actuator attachment) (For KUK spec.)
PC128US-2 (Serial No.: 5001 – 7730) ..................................................... 90-13-8
Hydraulic circuit diagram
(With 2 actuator attachment) (For KUK spec.)
PC128US-2 (Serial No.: 7731 and up)
PC138US-2 (Serial No.: 4501 and up) .................................................. 90-13-10
Electric circuit diagram (1/2)
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-15
Electric circuit diagram (2/2)
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-17
PC128US-2 90-1
(15)
Electric circuit diagram (1/2)
PC128US-2 (Serial No.: 6301 – 7730) ..................................................... 90-17-2
Electric circuit diagram (2/2)
PC128US-2 (Serial No.: 6301 – 7730) ..................................................... 90-17-4
Electric circuit diagram (1/2)
PC128US-2 (Serial No.: 7731 – 7874) ..................................................... 90-17-6
Electric circuit diagram (2/2)
PC128US-2 (Serial No.: 7731 – 7874) ..................................................... 90-17-8
Electric circuit diagram (1/2)
PC128US-2 (Serial No.: 7875 and up)
PC138USLC-2 (Serial No.: 1001 – 1500) ................................................... 90-17-10
Electric circuit diagram (2/2)
PC128US-2 (Serial No.: 7875 and up)
PC138USLC-2 (Serial No.: 1001 – 1500) ................................................... 90-17-12
Electric circuit diagram (1/3)
PC138US-2 (Serial No.: 4501 and up)
PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-14
Electric circuit diagram (2/3)
PC138US-2 (Serial No.: 4501 and up)
PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-16
Electric circuit diagram (3/3)
PC138US-2 (Serial No.: 4501 and up)
PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-18
Electric circuit diagram (For KUK spec.) (1/2)
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-19
Electric circuit diagram (For KUK spec.) (2/2)
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-21
Electric circuit diagram (For KUK spec.) (1/2)
PC128US-2 (Serial No.: 6301 – 7730) ........................................................ 90-23
Electric circuit diagram (For KUK spec.) (2/2)
PC128US-2 (Serial No.: 6301 – 7730) ........................................................ 90-25
Electric circuit diagram (For KUK spec.) (1/2)
PC128US-2 (Serial No.: 7731 and up) ....................................................... 90-27
Electric circuit diagram (For KUK spec.) (2/2)
PC128US-2 (Serial No.: 7731 and up) ....................................................... 90-29
Electric circuit diagram (For KUK spec.) (1/3)
PC138US-2 (Serial No.: 4501 and up) ....................................................... 90-31
Electric circuit diagram (For KUK spec.) (2/3)
PC138US-2 (Serial No.: 4501 and up) ....................................................... 90-33
Electric circuit diagram (For KUK spec.) (3/3)
PC138US-2 (Serial No.: 4501 and up) ....................................................... 90-35
90-2 PC128US-2
(15)
OTHERS HYDRAULIC CIRCUIT DIAGRAM
SERVICE I
(PPC valve)
Selector valve ~2
__-__--__
Ii
IPl P2 I
L-_-__*--__-_qL____-_XL__f\ -c---i
I A7 87 I I
!__ _! Bl -f2 --Al 71
SERVICE I - -
I
Control valve
SERVICE I
(PPC valve)
Lock Din
(Large amount)
--i
I
I A7
-
Ii I-
!--C
SERVICE 1
Crusher
ilOO% amount1
To oil cooler
SXPO7809
PC128US-2 90-5-2
A
HYDRAULIC CIRCUIT DIAGRAM
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Serial No.: 1501 and up
PC128US-2 90-9-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACTUATOR ATTACHMENT)
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Serial No.: 1501 and up
PC128US-2 90-11-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT)
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Serial No.: 1501 and up
PC128US-2 90-13-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.)
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up
PC128US-2 90-13-6
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.)
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up
PC128US-2 90-13-10
(15)
9JB00694
ELECTRIC CIRCUIT DIAGRAM (1/2)
PC128US-2 Serial No.: 7731 – 7874
PC128US-2 90-17-6
A
ELECTRIC CIRCUIT DIAGRAM (2/2) 9JB00695
PC128US-2 Serial No.: 7731 – 7874
PC128US-2 90-17-8
A
ELECTRIC CIRCUIT DIAGRAM (1/2)
PC128US-2 Serial No.: 7875 and up
PC138USLC-2 Serial No.: 1001 – 1500
PC128US-2 90-17-10
(15)
ELECTRIC CIRCUIT DIAGRAM (2/2)
PC128US-2 Serial No.: 7875 and up
PC138USLC-2 Serial No.: 1001 – 1500
PC128US-2 90-17-12
(15)
ELECTRIC CIRCUIT DIAGRAM (1/3)
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2 90-17-14
(15)
ELECTRIC CIRCUIT DIAGRAM (2/3)
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2 90-17-16
(15)
ELECTRIC CIRCUIT DIAGRAM (3/3)
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2 90-17-18
(15)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2)
PC128US-2 Serial No.: 7731 and up
PC128US-2 90-27
(15)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2)
PC128US-2 Serial No.: 7731 and up
PC128US-2 90-29
(15)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/3)
PC138US-2 Serial No.: 4501 and up
PC128US-2 90-31
(15)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/3)
PC138US-2 Serial No.: 4501 and up
PC128US-2 90-33
(15)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (3/3)
PC138US-2 Serial No.: 4501 and up
PC128US-2 90-35
(15)