SEBM018419

MACHINE MODEL SERIAL NUMBER

PC128US-2 5001 and up

PC138US-2 4501 and up
PC138USLC-2 1001 and up

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

• PC128US-2, PC138US-2, PC138USLC-2 mounts the S4D102E and SAA4D95LE engine.

For details of the engine, see the 102 Series and 95 Series Engine Shop Manual.

© 2004
All Rights Reserved
Printed in Japan 12-04(02) 00-1
(19)
 CONTENTS

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

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

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

30 DISASSEMBLY AND ASSEMBLY ..........................................................30-1

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

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

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01-4-2 (10) 01-14-10 (15) 10-27 (10) 10-53 10-94
01-4-3 (15) 01-15 (15) 10-27-1 (15) 10-54 10-95 (18)
01-4-4 (15) 01-16 (11) 10-27-2 (10) 10-55 10-96 (2)
01-4-5 (15) 10-27-3 (18) 10-56 10-97 (2)
01-4-6 (15) 10-1 (15) 10-28 10-57 10-98 (18)
01-4-7 (15) 10-2 10-29 10-58 10-99
01-4-8 (15) 10-3 (15) 10-30 10-59 10-100
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10-103 10-133 (15) 10-148 (15) 20-106 (17) 20-210 (1)
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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)
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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)
10-122-9 (13) 10-143-4 (15) q 20-8-10 (19) 20-126 (1) 20-230 (17)
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10-126 (10) 10-144-4 (15) 20-12 (10) 20-132 (1) 20-230-6 (17)
10-127 (15) 10-144-5 (15) 20-13 (1) 20-133 (14) 20-230-7 (17)
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10-130 (10) 10-146-1 (11) 20-18 (7) 20-138 (17) q 20-230-12 (19)
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20-251 (7) 20-402 (10) 20-563 (17) 20-722 (17) 20-905 (17)
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20-253 (7) 20-403-1 (10) 20-565 (17) 20-724 (17) 20-907 (17)
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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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20-967 (14) 30-43 (16) 30-95 (16) q 30-146 (19) 40-26-2 (15)
20-968 (14) 30-44 (16) 30-96 (16) q 30-147 (19) 40-26-3 (15)
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)
20-971 (14) 30-47 (16) 30-99 (16) 30-150 (16) 40-26-6 (15)
20-972 (14) 30-48 (16) 30-100 (16) q 30-151 (19) 40-26-7 (15)
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30-2 (16) 30-53 (16) 30-105 (16) 30-156 (16) 40-28
30-3 (16) 30-54 (16) 30-106 (16) 30-157 (16) 40-29 (10)
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)
30-7 (16) 30-58 (16) 30-110 (16) 40-3 (14) 40-33 (11)
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)
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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
q 30-21 (19) 30-72 (16) 30-124 (16) 40-12 (10) 40-43 (11)
30-22 (16) 30-73 (16) 30-125 (16) 40-13 (7) 40-44 (2)
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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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Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
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90-9-2 (15)
90-11 (10)
90-11-2 (15)
90-13 (10)
90-13-2 (15)
90-13-4 (10)
90-13-6 (15)
90-13-8 (10)
90-13-10 (15)
90-15 (10)
90-17 (10)
90-17-2 (10)
90-17-4 (10)
90-17-6 (11)
90-17-8 (11)
90-17-10 (15)
90-17-12 (15)
90-17-14 (15)
90-17-16 (15)
90-17-18 (15)
90-19 (10)
90-21 (10)
90-23 (10)
90-25 (10)
90-27 (15)
90-29 (15)
90-31 (15)
90-33 (15)
90-35 (15)

PC128US-2 00-2-5
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TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC138USLC-2

Cate- Standard value

gory Item Measurement conditions Unit Service limit value
for new machine

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.

• Engine at full throttle

• Hydraulic oil temperature: 45 – 55°C
Leakage from swing • Relieve swing circuit.
motor ¬/min Max. 3 Max. 6

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
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TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC138USLC-2

Cate- Standard value

gory Item Measurement conditions Unit Service limit value
for new machine

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.

• Engine at full throttle

• Hydraulic oil temperature: 45 – 55°C
Leakage from travel • Lock shoes and relieve travel circuit. ¬/min
motor Max. 1.1 Max. 1.65

Total work fl See Fig. G

equipment
(hydraulic drift • Place in above posture and measure Max. 500 Max. 700
extension or retraction of each cyl-
at tip of bucket inder and downward movement at
teeth) tip of bucket teeth.
• Horizontal, flat ground
Boom cylinder • Bucket: Rated load (450 kg)
• Levers at HOLD
(amount of • Engine stopped
Hydraulic drift of work equipment

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

Arm cylinder utes, and judge from results for 15

minutes.
(amount of
mm Max. 50 Max. 75
extension of
cylinder)

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

Applicable model PC138USLC-2

Cate- Standard value

gory Item Measurement conditions Unit Service limit value
for new machine

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.

• Engine at full throttle

• Hydraulic oil temperature: 45 – 55°C
Leakage from swing • Relieve swing circuit.
motor ¬/min Max. 3 Max. 6

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

Applicable model PC138USLC-2

Cate- Standard value

gory Item Measurement conditions Unit Service limit value
for new machine

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.

• Engine at full throttle

• Hydraulic oil temperature: 45 – 55°C
Leakage from travel • Lock shoes and relieve travel circuit. ¬/min
motor Max. 1.1 Max. 1.65

Total work fl See Fig. G

equipment
(hydraulic drift • Place in above posture and measure Max. 500 Max. 700
extension or retraction of each cyl-
at tip of bucket inder and downward movement at
teeth) tip of bucket teeth.
• Horizontal, flat ground
Boom cylinder • Bucket: Rated load (450 kg)
• Levers at HOLD
(amount of • Engine stopped
Hydraulic drift of work equipment

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

Arm cylinder utes, and judge from results for 15

minutes.
(amount of
mm Max. 50 Max. 75
extension of
cylinder)

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

Tools for testing, adjusting and troubleshooting ................................................................................. 20-102

Measuring engine speed ........................................................................................................................ 20-103
Measuring exhaust color ........................................................................................................................ 20-105
Adjusting valve clearance ....................................................................................................................... 20-106
Measuring blow-by pressure ................................................................................................................. 20-108
Measuring engine oil pressure ........................................................................................................... 20-108-1
Testing and adjusting fuel injection timing ........................................................................................ 20-108-2
Testing and adjusting belt tension for air conditioner compressor ................................................. 20-108-7
Testing and adjusting fan belt tension ............................................................................................... 20-108-8
Adjusting engine speed sensor ........................................................................................................... 20-108-9
Adjusting fuel control cable ................................................................................................................... 20-109
Adjusting engine stop solenoid linkage ................................................................................................ 20-110
Testing clearance of swing circle bearing ............................................................................................. 20-111
Checking wear of sprocket ..................................................................................................................... 20-112
Testing and adjusting track shoe tension .............................................................................................. 20-113
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ......................... 20-114
Testing and adjusting output pressure of PC valve (servo piston input pressure) ............................ 20-117
Testing and adjusting LS valve output pressure
(servo piston input pressure)and LS differential pressure .................................................................. 20-119
Testing and adjusting control circuit oil pressure ................................................................................ 20-122
Measuring solenoid valve output pressure .......................................................................................... 20-123
Measuring PPC valve output pressure .................................................................................................. 20-124
Adjusting PPC valve ................................................................................................................................ 20-125
Testing and adjusting travel deviation .................................................................................................. 20-126
Checking location of cause of hydraulic drift of work equipment ...................................................... 20-127
Measuring oil leakage in swing motor .................................................................................................. 20-128
Measuring oil leakage in travel motor ................................................................................................... 20-128
Bleeding air .............................................................................................................................................. 20-129
Releasing remaining pressure in hydraulic circuit ............................................................................... 20-131
Releasing remaining pressure in hydraulic tank .................................................................................. 20-131
Procedure for checking diode ................................................................................................................ 20-132
Pm clinic inspection table ....................................................................................................................... 20-133

PC128US-2 20-101
(17)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Check or measurement item Symbol Part No. Part Name Remarks

1 799-205-1100 Tachometer kit Digital display :

Engine speed A 2 795-790-2500 Take-off drive 6.0 – 99,999.9rpm

3 6090-02-9190 Gear box

Coolant and oil temperatures
B 799-101-1502 Digital temperature gauge - 99.9 – +1,299 ºC
Pressure gauge
1 799-101-5002 Hydraulic tester : 2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester

• 799-101-5160 Nipple PT1/8

2 799-101-5220 Nipple 10 x 1.25

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}

5 799-401-2701 Differential pressure gauge

Adjusting fuel injection timing D 795-799-1131 Gear

1 799-201-1504 Blow-by checker

Blow-by pressure E
2 795-790-1950 Tool
Valve clearance Commercially
F available Feeler gauge

1 790-201-9001 Handy Smoke Checker

Exhaust color G Bosch index: 0 – 9
Commercially
2 available Smoke meter

1 79A-264-0021 0 – 294N{0 – 30kg}

Operating effort H Push-pull scale
2 79A-264-0091 0 – 490N{0 – 50kg}

Stroke, hydraulic drift I Commercially Scale

available
Work equipment speed J Commercially Stop watch
available
Measuring voltage and resis- K Commercially
tance values available
Tester

1 790-601-8000 T-adapter kit

2 799-601-7370 For 6-pin relay

3 799-601-7050 SW-6P

Troubleshooting of wiring 4 799-601-7080 M-1P

L Adapter
harnesses and sensors SW-12P
5 799-601-7310

6 799-601-7320 SW-16P

7 799-601-7340 M-16P

8 799-601-7540 070-18P

Measuring wear of sprocket M 796-127-1140 Wear gauge

20-102 PC128US-2
(19)
TESTING AND ADJUSTING MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

PC128US-2 Serial No.: 5001 – 7730
fl Measure the engine speed under the following
conditions.
• Coolant temperature: Within operating range
• Hydraulic oil temperature : 45 – 55 ºC

1. Remove air conditioner compressor top cover.

2. Remove air conditioner compressor belt.

3. Remove cover (1) at timing gear case end.

4. Install tool A2 to speed pick-up port.

5. Connect bracket of tool A1, probe and tachom-

eter to tool A2.

6. Start the engine, and measure the engine speed

when it is set to the conditions for measuring.
1) Measuring at low idling and high idling :
Measure the engine speed with the fuel con-
trol lever set to low idling and high idling.
2) Measuring speed at pump relief :
Run the engine at full throttle and measure
the engine speed when the main pump is re-
lieved.
3) Measuring speed at near rated speed :
Run the engine at full throttle, operate the arm
lever, and measure the engine speed when
the arm is relieved.

PC128US-2 Serial No.: 7731 and up

PC138USLC-2 Serial No.: 1001 and up
Measurement of engine speed
ª The measuring method is identical with the
method described above.
ª The engine speed can be displayed in monitoring
mode "1010".

PC128US-2 20-103
(19)
TESTING AND ADJUSTING MEASURING ENGINE SPEED

PC138US-2 Serial No.: 4501 and up

PC138USLC-2 Serial No.: 1501 and up
fl Measure the engine speed under the follow-
ing condition.
• Coolant temperature: Within operating
range
• Hydraulic oil temperature: 45 – 55 ºC

1. Remove the cover for setting the injection tim-

ing of the injection pump from the timing gear
case and install tool A3.

2. Connect bracket [1], probe [2] and tachometer

to tool A3.

3. Start the engine and measure the following re-

volving speeds.
1) Measure the low idling speed and high
idling speed.
2) Set the fuel control lever to the low idling
and high idling positions and measure the
revolving speeds at the respective posi-
tions.
3) Revolving speed when pump is relieved
Relieve the pump and run engine at full
throttle and measure its revolving speed.

20-104 PC128US-2
(19)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Num- AMP040 Type Connector

ber of T-adapter Part
Pins Male (Female housing) Female (Male housing)
Number

BWP04752
BWP04751
8 799-601-7180

Housing part number: 79A-222-3430

— (Quantity: 5 pieces)

BWP04753 BWP047544
12 799-601-7190

Housing part number: 79A-222-3440

— (Quantity: 5 pieces)

BWP04755 BWP04756
16 799-601-7210

Housing part number: 79A-222-3450

— (Quantity: 5 pieces)

BWP04757 BWP04758
20 799-601-7220

— Housing part number: 79A-222-3460

(Quantity: 5 pieces)
a Terminal part number: 79A-222-3470 (for all numbers of pins).

PC128US-2 20-227
(17)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Num- AMP070 Type Connector

ber of T-adapter Part
Pins Male (Female housing) Female (Male housing)
Number

10 799-601-7510

— Part number: 7821-92-7330

BWP04761 BWP04762
12 799-601-7520

— Part number: 7891-92-7340

BWP04763 BWP04764
14 799-601-7530

— Part number: 7891-92-7350

BWP04765 BWP04766
18 799-601-7540

— Part number: 7891-92-7360

BWP04767 BWP04768
20 799-601-7550

— Part number: 7891-92-7370

20-228 PC128US-2
(19)
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

Part number: 08192-02200 Part number: 08192-02100

DTHD Series connector

Number
of Pins T-adapter Part
Body (plug) Body (receptacle) Number

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)]

DRC26 Series connector

No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.

24 799-601-9360

— Part No.: 7821-93-3110

40
799-601-9350
(A)

— Part No.: 7821-93-3120

40
799-601-9350
(B)

— Part No.: 7821-93-3130

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.

799-601-2600 For measuring box Econo-21P Q Q Q Q Q Q

799-601-3100 For measuring box MS-37P Q
799-601-3200 For measuring box MS-37P Q
799-601-3300 For measuring box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3370 Plate For MS box
799-601-3380 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 CASE Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 CASE Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q

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

799-601-9420 For boost pres- 3P Q

sure, fuel
799-601-9430 PVC socket 2P Q
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P Q
for HST controller
AMP 1-963215-1
799-601-9720 AMP 1-963217-1 16P Q
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P Q
for HST controller

PC128US-2 20-230-13
(19)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

8. Boom Angle Potentiometer Correction Mode

(Only at Arm Crane)
This mode is used to adjust the boom angle po-
tentiometer.

1) Boom Angle Potentiometer Correction Mode

display method
(1) Use the following procedure to switch to
the boom angle potentiometer correction
mode.
i) Continue pressing “Buzzer cancel
switch (8)” + “Auto decelerator switch
(7)” for 2.5 seconds or more.
ii) Press “Buzzer cancel switch (8)” +
“Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4))” and set them so
that “06” can be displayed on the sec-
ond or third digit from the left of ser- (1) Digital meter display portion
vice meter display portion (2). (2) Service meter display portion
iii) Press “Setting switch (5)”. (3) Working mode selector (UP) switch
fl Check that “1 SET” is displayed (4) Working mode selector (DOWN) switch
on service meter display portion (5) Setting switch
(1) (the central three segments of (6) Travel speed switch
digital display portion (1) flash). (7) Auto decelerator switch
(8) Buzzer cancel switch
(2) Use the following procedure to adjust the
boom angle potentiometer correction
mode.
i) After switching to the mode of item
i), start the engine and operate
“Boom” to the RAISE side stroke end.
fl “ --” (correctable range) or “---”
(uncorrectable range)” flashes on
the digital display portion.
fl For the correctable range, because
incorrect mounting of the boom
angle potentiometer is assumed,
check it.
ii) Press setting switch (5) for three sec-
onds or more.
fl The same item as item i) flashes
on digital meter display portion
(1).

PC128US-2 20-245
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

iii) When normal adjustment can be

made (when the boom angle belongs
to a theoretical value, “ ” is dis-
played on digital meter display por-
tion (2) for five seconds and process-
ing returns to item i) (boom angle po-
tentiometer correction mode).
fl When correction was disabled,
“---” flashes (buzzer sounds five
times) on digital portion (2) and
processing returns to item i).
fl If correction is impossible, be-
cause incorrect mounting of the
boom angle potentiometer is as-
sumed, check it.

20-246 PC128US-2
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TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

9. Display and Setting of “OIL MAINTENANCE FUNCTION”

In an oil maintenance function setting machine, the LED of “Oil maintenance lamp (9)” of the moni-
tor portion and an elapsed time is displayed on the service meter display portion (2) from 10 hours
before of the oil replacement setting time to the time when it is reset. (The elapsed time is displayed
for 20 seconds after the starting switch is turned ON and returns to the display of the service time
later.)
fl Digital meter display portion (1) is not displayed (does not come ON).
The oil maintenance function can perform the setting, change, or release of the display.

1) Display of oil maintenance function

(1) The oil maintenance display mode is au-
tomatically displayed when the setting
time exceeds “minus 10 hours” as de-
scribed above.
(2) To terminate the oil maintenance function
(within 20 seconds after the starting
switch is turned ON), pressing setting
switch (5) short returns to the normal dis-
play mode.

Example) When the oil replacement interval

setting of 250 hours and the
elapsed time of 245 hours after oil
is replaced are displayed:

PC128US-2 20-246-1
(19)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

2) Setting of interval time and resetting of

elapsed time
(1) Interval time setting
i) Continue pressing “Buzzer cancel
switch (8)” + “Auto-decelerator switch
(7)” for 2.5 seconds or more.
ii) Press “Buzzer cancel switch (8)” +
“Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4))” and set them so
that “04” can be displayed on the sec-
ond or third digit from the left of ser-
vice meter display portion (2).
iii) Press “Setting switch (5)” (every time (1) Digital meter display portion
it is pressed, it is switched) to select (2) Service meter display portion
an interval time.Example) When the (3) Working mode selector (UP) switch
interval time of 250h is selected (not (4) Setting switch
displayed on digital meter display (5) Travel speed switch
portion (1)) (6) Auto-decelerator switch
fl Display of an interval time (se-
quentially displayed repetitively)
0 : Default mode (Oil maintenance
function is not set)
125h : Sets an interval time every 125
hours.
250h : Sets an interval time every 250
hours.
500h : Sets an interval time every 500
hours.
d : Sets the demonstration mode.
(For details, refer to item iv.)
fl Select an interval time according
to the “INSTRUCTION MANUAL”.
iv) When “Buzzer cancel switch (8)” +
“Auto decelerator switch (7)” con-
tinue being pressed for 2.5 seconds
or more, the setting of an interval time
is terminated.

20-246-2 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

(2) Confirmation of elapsed time

fl If an elapsed time does not reach ten
hours before of a replacement inter-
val, nothing is displayed.
(If the elapsed time must be watched
in this state, turn ON the starting
switch continuing pressing “Setting
switch (5)” and continue pressing set-
ting switch (5).
(3) Elapsed time resetting after oil replace-
ment
While an elapsed time and a telephone
number are displayed on the monitor
panel (within 20 seconds), if setting switch
(5) starts being pressed and is held for
about three seconds as is, the elapsed
time is reset and the elapsed time of 0h is
displayed for one second.
(4) Demonstration mode
If the demonstration mode is used, the
demonstration of the oil maintenance
function can be performed at delivery.
fl The elapsed time is fixed to 240 hours and
the same function as the oil maintenance
function is performed.
fl After the demonstration is set, if the start-
ing switch is set to OFF → ON again, the
demonstration starts.
However, if the starting switch OFF ←→
ON is performed four times or more, the
demonstration mode is reset (demonstra-
tion display is performed up to the third
time) and is automatically switched to the
default mode.
(If demonstration must be continued, the
demonstration mode need be set again.)

PC128US-2 20-246-3
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

10. Setting model and attachment

Set the specification of machine model and attachment.
(PC128US with standard arm does not need this setting)

No. Operation Display

1 1) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds. Display section displays "10" and service
meter section displays "19SET".
2) Set the code in the service meter section to "19".
(If 19SET has been set, current set value is
(8) + (3): Next code
displayed in display section.)
(8) + (4): Previous code
3) Press switch (5). Display

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

3 1) To finish selection of model and attachment

Perform the operation in 1-(1), and the monitor panel displays
normally.
<Caution>
After setting 18SET and 19SET, be sure to turn the starting
switch OFF once.
This setting becomes effective only after the starting switch
is turned OFF once.

B: The buzzer cancel switch is in-

stalled on the right console.

20-246-4 PC128US-2
(19)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

11. Service adjustment

This service adjustment is set for adjustment of dispersion of components and parts and for replay to
requests of each user. Perform this adjustment for the following phenomena and users' requests.
fl Basically, the following items do not need to be adjusted, since they are adjusted when delivered.
fl This service adjustment is not effective when a component or a part is broken.
1) Service adjustment items table
The phenomena of the machine which need service adjustment, procedure for changing the set
values, and precautions are listed.
fl Usually, each adjustment value is set to the initial value.
Service adjust- Adjustment Phenomenon of machine/ Procedure for changing Precautions
ment item code/set value Users' request set value
Adjustment of 204 Engine speed lowers Change set value to Adjust to degree that work
PC-EPC valve largely during work. decrease pump absorp- equipment cycle time is not
current tion torque. lengthened.
Work equipment speed Change set value to Adjust to degree that engine
is low. increase pump absorp- speed is not lowered largely.
tion torque.
Travel/Swing 210 Set for each user who Set to 211. Alarm sounds when machine
alarm output wants to sound alarm travels or swings.
(If travel alarm is during swinging.
installed)
Adjustment of 264 Engine speed lowers Change set value to Adjust to degree that work
LS-EPC valve largely during work. decrease pump absorp- equipment cycle time is not
current tion torque. lengthened.
fl Perform this when adjust-
ment with PC-EPC valve
current is insufficient.
fl Even if LS-EPC valve
current is not increased
even if adjusted toward
positive (+) side.
Type of fuel * 310 • Change fuel. 310: Diesel fuel
• When kerosene is
used, engine speed 311: Kerosene
lower largely.
Adjustment of 324 Low idling speed is Set to (–) side. * Since the low idling speed
low idling speed remarkably high. is set by the governor
* stopper, it does not change
Low idling speed is Set to (+) side. under normal condition.
remarkably low.
Adjustment of 334 Arm crane idling speed Set to (–) side.
arm crane mode is remarkably high.
speed * Arm crane idling speed
is remarkably low. Set to (+) side.

Adjustment of E- 344 E-idling speed is Set to (–) side.

mode speed * remarkably high.
E-idling speed is Set to (+) side.
remarkably low.
Adjustment of B- 354 B-idling speed is Set to (–) side. * If the B-mode speed is
mode speed * remarkably high. heightened, it is set near
the high idling speed and
B-idling speed is Set to (+) side. the auto-decelerator may
remarkably low.
not operate normally.
White smoke 810 Set for each user who Change set value so fl Since air heater consumes
prevention logic cares white smoke that air heater will much current, battery can
(Air heater relay when engine is started operate automatically be dead. Teach user to so
output) at low temperature. after engine is started. operate machine that
battery will be charged
sufficiently.
Initialization of
set values 400 If 401 is selected, all service adjustment items are set to initial values.
(Only contents of
service adjustment)
* The engine speed adjustment is an auxiliary adjustment method.
(1) Check the installation condition of the governor cable.
(2) Check the condition of the governor cable motor.
PC128US-2 20-246-5
(19)
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 Disconnection of rotor from
T • 790-101-2630 • Leg 2
swivel joint shaft
• 790-101-2570 • Washer 4

• 790-101-2560 • Nut 2

• 791-112-2650 • Adapter 2

790-502-1003 Repair stand t 1

1 Disassembly, assembly of
cylinder
790-101-1102 Pump t 1

790-102-4300 Wrench ass’y t 1

Removal, installation of
2
piston
790-201-4310 Pin t 1

790-201-1702 Push tool KIT t 1

• 790-201-1791 • Push tool 1 Press fit of bucket cylinder

roll bushings
• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

790-201-1702 Push tool KIT t 1

• 790-201-1811 • Push tool 1

3 Press fit of boom cylinder roll
bushings
• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

790-201-1702 Push tool KIT t 1

• 790-201-1821 • Push tool 1

Press fit of arm and blade
Disassembly, assembly of cylinder roll bushings
hydraulic cylinder U • 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

790-201-1500 Push tool KIT q 1

• 790-201-1610 • Push tool 1 Press fit of bucket cylinder

dust seal
• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

790-201-1500 Push tool KIT q 1

• 790-201-1620 • Push tool 1

Application of boom cylinder
4
dust seal
• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

790-201-1500 Push tool KIT q 1

• 790-201-1630 • Push tool 1

Application of arm and blade
cylinder dust seal
• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

5 790-720-1000 Expander t 1 Extension of piston ring

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

796-720-1650 Ring t 1 Removal,

Bucket installation
cylinder of piston
07281-01029 Clamp t 1 (PC128UU-2) ring
Disassembly, assembly of
U 6
hydraulic cylinder Bucket cylinder Removal,
796-720-1660 Ring t 1 (PC138US-2) installation
(PC138USLC-2) of piston
07281-01159 Clamp t 1 Arm, boom, blade
ring
cylinder
792-785-1100 Remover t 1

• 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

1 793-498-1210 Lifter (Suction cup) t 2

Operator’s cab glass Removal and installation opera-
(stuck glass) tiors cab glass (stuck glass)
2 20Y-54-13180 Adapter t 2

799-703-1200 Service tool KIT t 1

Floor frame assembly
airconditioner compressor X 799-703-1100 Vacuum pump(100V) t 1 For Japan
assembly Charging of
airconditioner condenser 3 799-703-1110 Vacuum pump(220V) t 1 For overseas air-condi-
assembly tioning gas
airconditioner unit 790-703-1120 Vacuum pump(240V) t 1 For overseas
assembly
799-703-1401 Gas leak detector t 1

30-8 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP

ENGINE AND MAIN PUMP

ASSEMBLY
PC128US-2 Serial No. : 8101 and up
PC138US-2 Serial No. : 3201 – 4500

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.

1. Remove the counterweight (See REMOVAL OF

COUNTERWEIGHT).

2. Drain hydraulic oil and coolant.

6 Hydraulic oil: 69 l
(Oil level in hydraulic tank)
6 Coolant: 17.2 l

3. Collect air conditioner gas from air conditioner

circuit.

4. Remove battery (1).

5. Disconnect air hose (2), aftercooler inlet hose

(3), and radiator inlet hose (4). [*1]

6. Disconnect aftercooler outlet hose (5) and radia-

tor outlet hose (6). [*2]

7. Disconnect reservoir tank hose (7) and remove

reservoir tank (8).

8. Disconnect wiring connector (9) (M28) and win-

dow washer hose (10) and remove washer tank
(11).

9. Remove bracket (12) from the main pump.

10. Disconnect wiring connectors (13) (C13) and

(14) (C14).

11. Disconnect suction tube (15)

PC128US-2 30-21
(19)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP

12. Disconnect LS pressure input hose (16).

13. Disconnect main pump output hose (17).

14. Disconnect main pump pressure input hose (18).

15. Disconnect case drain hose (19).

16. Remove engine oil filter (20) from the hydraulic

tank and move it toward the main pump.

17. Disconnect engine wiring connectors (21) (E15),

(22) (E20), (23) (E16), and (24) (E07) and
remove clamp (25).

18. Remove stays (26), (27), and (28).

19. Remove heat insulation cover (29).

20. Remove muffler drain tube (30).

21. Remove muffler (31).

a Loosen the turbocharger clamp.

22. Disconnect heater hose (32).

23. Disconnect 2 air conditioner hoses (33).

a Take measures to prevent dirt, water, etc.
from entering the piping.

30-22 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC OIL COOLER

RADIATOR, HYDRAULIC OIL

COOLER
PC128US-2 Serial No. : 5001 – 8100
PC138US-2 Serial No. : 1001 – 3200
PC138USLC-2 Serial No. : 1001 – 1500

REMOVAL
kGradually loosen the hydraulic oil tank cap to
bleed the internal air after completely grounding
the work equipment and stopping the engine.

1. Remove the counterweight assembly by refer-

ring to "REMOVAL OF COUNTERWEIGHT
ASSEMBLY".
2. Drain hydraulic oil and coolant.
6 Hydraulic oil : 69 l
6 Cooling : 18.2 l
3. Collect air conditioner gas from air conditioner
circuit.
4. Remove stay (1).
5. Remove stay (2).
a Disconnect the accelerator cable clamped to
stay (2).
6. Remove bracket (3) together with the washer
tank.
a Disconnect the washer motor connector
(M28) from the hose.
7. Remove two batteries (4).
8. Remove battery relay (5).
9. Remove silencer (6) and tube (7) to remove air
cleaner assembly (8).
10. Remove bracket (9).
11. Disconnect airconditioner capacitor pipings (10)
and (11). [*1]
a Make sure to double-engage the wrench
before disconnection.
12. Remove the mounting bolt to remove air condi-
tioner capacitor assembly (12).
13. Remove clamp (13) to remove bracket (14).
14. Disconnect oil cooler outlet hose (15) and inlet
hose (16).
15. Disconnect radiator outlet hose (17) and inlet
hose (18) as well as reserve tank hose (19).

PC128US-2 30-31
(19)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC OIL COOLER

16. Temporarily lift radiator, hydraulic oil cooler

assembly (20) to remove the four mounting bolts
on the bottom.
a Carefully lift and remove the assembly after
slightly lifting it and pulling it to the opposite
side from the engine to make sure that it
does not come in contact with the fan.
4 Radiator/hydraulic oil cooler assembly :
55 kg

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.

• Using tool X3, charge air conditioner gas

(R134a) to air conditioner circuit.

• Refilling with coolant

Add coolant through the coolant filler to the spec-
ified level. Run the engine to circulate the water
through the system. Then check the coolant
level again.

5 Hydraulic oil: 69 l

• Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

5 Coolant: 18.2 l

30-32 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW

FRONT WINDOW ASSEMBLY

k Lower the work equipment to the ground and
stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor’s cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.

REMOVAL
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides). [*1]

2. Remove left lower block (1) and right lower block

(2). [*2]

3. Reset the lock at the rear of the cab.

4. Lower front window assembly (3) carefully a lit-

tle. Put out rollers (4) and (5) under the right and
left sides of the front window through the portion
from which the right and left lower blocks were
removed in step 2 (the bottom of the rails).

5. Twist front window assembly (3) to the right and

left to remove right and left upper rollers (6) and
(7) from the rails, and then remove front window
assembly (3).
a For (6) and (7), see the figure above.

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

k Disconnect the cable from the negative (-) ter-

of the hydraulic tank.

minal of the battery.

1. Remove operator’s cab.

(See REMOVAL OF OPERATOR’S CAB)

2. Remove left side cover (1).

3. Disconnect wiring connectors (2) (CN1), (3)

(CN2), (4) (CN4), and (5) (CN3).

4. Disconnect ground cable (6).

5. Remove handrail (7).

6. Remove covers (8) and (9).

7. Disconnect PPC hoses (10) (Bucket dump, arm

out, boom raise, bucket tilt from above).

8. Disconnect PPC hoses (11) (Arm tilt, boom

lower, right swing, and left swing from above).
a If the color tapes are broken and cannot be
judged correctly, put tags, etc. for correct
judgment.

9. Disconnect PPC hoses (12) and (13) for travel

(Right).

10. Disconnect PPC hoses (14) and (15) for travel

(Left).

30-136 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

11. Disconnect PPC main pressure hose (16) (A1).

12. Disconnect PPC drain hose (17).

a Drain hydraulic oil
6 Hydraulic oil : 90 l

13. Lift off floor frame assembly (18).

a Take care not to damage the PPC hoses.
4 Floor frame assembly : 65 kg

INSTALLATION
• Carry out installation in the reverse order to
removal.

• Refilling with oil

Add oil through the oil filler to the specified level.
Run the engine, then check the oil level again.
5 Hydraulic oil : 90 l

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

a Swing the upper structure to the left by 135

degrees. (For step 7)

REMOVAL
k Remove the negative (-) terminal from the bat-
tery before setting to work.

1. Drain coolant
6 Coolant: 17.2 l

2. Collect air conditioner gas (R134a) from air con-

ditioner circuit.

3. Remove the operator cab assembly by referring

to the "OPERATOR’S CAB ASSEMBLY
[REMOVAL]" section.

4. Remove the side cover (1).

5. Disconnect connectors (1)A01, (2)A03, (3)A04,

(4)A07, (5)A02, (6)A05, (7)A08 , (8)A010 ,and
earth wire(9) and remove tool tray (10).

6. Remove heater hose (11).

7. Remove undercover and disconnect PPC hoses

(12) (P port) and (13) (T port), and four travel
PPC valve hoses (14).
a Four travelling PPC valve hoses may be
removed on the control valve side.

30-138 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

8. Remove upper cover (15) which covers the con-

trol valves.

9. Separate eight work equipment and swing PPC

valve hoses (16).
a The PPC hoses are identified by the follow-
ing markings in the order from the top:
• For bucket CURL: Red
• For boom LOWER: Black
• For left swing: White
• For arm IN: Green
• For bucket DUMP: Red
• For boom RAISE: Yellow
• For right swing: Brown
• For arm OUT: Orange

10. Remove the clamp (17) at the right front of the

revolving frame.

11. Remove the cover from under the seat and dis-
connect air conditioner tubes (18) and (19) from
the air conditioner unit. [*1]

12. Lift and remove floor frame assembly (20).

4 Floor frame assembly: 270 kg

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}

Filling air conditioning gas

• Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.
Hydraulic oil
• Start the engine, fill the pipings with hydraulic oil,
and refill to the specified level.
Coolant supply
• Feed coolant from the filling port to the specified
level. Recheck the level after starting the engine
and circulating coolant.

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

a Swing the upper structure to the left by 135

degrees. (For step 9)

REMOVAL
k Remove the negative (-) terminal from the bat-
tery before setting to work.

1. Drain coolant
6 Coolant: 13.2 l

2. Collect air conditioner gas (134a) from air condi-

tioner circuit.

3. Remove the operator cab assembly by referring

to the "OPERATOR’S CAB ASSEMBLY
[REMOVAL]" section.

4. Remove the side cover (1) and front cover (2).

5. Disconnect connectors (3)A01, (4)A02, (5)A03

and remove from a clip.

6. Disconnect hone connector (6) M18 and earth

wire (7)

7. Remove tool tray.

30-140 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

8. Disconnect 2 heater hoses (11), upper and lower

ones, from under the rear part of the seat.

9. Remove undercover and disconnect PPC hoses

(12) (P port: Blue and White) and (13)(T port:
Red and Green), and four travel PPC valve
hoses (14).
(From the top: Yellow and Black, Yellow and
Green, Yellow and Orange, Yellow and Brown)
a Four travelling PPC valve hoses may be
removed on the control valve side.

10. Remove upper cover (15) which covers the con-

trol valves.

11. Separate eight work equipment and swing PPC

valve hoses (16).
a The PPC hoses are identified by the follow-
ing markings in the order from the top:
• For bucket CURL: Red
• For boom LOWER: Black
• For left swing: White
• For arm IN: Green
• For bucket DUMP: Red
• For boom RAISE: Yellow
• For right swing: Brown
• For arm OUT: Orange

12. Remove the clamp (17) at the right front of the

revolving 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]

14. Lift and remove floor frame assembly (20).

4 Floor frame assembly: 270 kg

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}

Filling air conditioning gas

• Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.
Hydraulic oil
• Start the engine, fill the pipings with hydraulic oil,
and refill to the specified level.
Coolant supply
• Feed coolant from the filling port to the specified
level. Recheck the level after starting the engine
and circulating coolant.

30-142 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER COMPRESSOR

AIRCONDITIONER
COMPRESSOR
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599

REMOVAL
k Completely ground the work equipment.

k Disconnect the negative (-) terminal of the bat-

tery.

1. Collect air conditioner gas (R134a) from air con-

ditioner circuit.

2. Open cover (1).

3. Remove cover (2).

4. Disconnect hoses (3) and (4).

a Plug the hoses and compressor to prevent
dust, water, etc. from entering them.

5. Disconnect wiring connector (5) (M34).

6. Loosen belt tension adjustment bolt (6) and

mounting bolt (7) to remove drive belt (8).

7. Remove bolts (6) and (7) to remove air condi-

tioner compressor assembly (9).

INSTALLATION
• Installation is performed in the opposite way to
removal.

• Filling air-conditioning gas

Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.

PC128US-2 30-143
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER COMPRESSOR

AIRCONDITIONER
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.

k Remove the negative (-) terminal from the bat-

tery.

1. Collect air conditioner gas (R134a) from air con-

ditioner circuit.

2. Open the cover (1).

3. Remove bolt (2) and Loosen bolt (4) and remove

cover (3).

4. Separate hoses (5) and (7) by loosening bolt (6).

a Put blind caps to prevent the entry of dirt or
water into hoses and compressor.

5. Disconnect wire and connector (8)(M34).

6. Loosen mounting bolt (9), lock nut (11), and bolt

(12) to remove air compressor belt . a PC128US-2 Serial No. 9501 and up
PC138US-2 Serial No. 4501 and up
7. Remove the bolts (4) and (9) and reomve the air PC138USLC-2 Serial No. 1501 and up
compressor assembly (13).

INSTALLATION
• Carry out installation in reverse oder to reomval.

• Filling new chlorofluorocarbon

Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.

30-144 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER CONDENSER

AIRCONDITIONER
CONDENSER
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599

REMOVAL
k Completely ground the work equipment.

k Disconnect the negative (-) terminal of the bat-

tery.

1. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

2. Collect air conditioner gas (R134a) from air con-

ditioner circuit.

3. Remove covers (1) and (2).

4. Remove air cleaner assembly (3).

5. Disconnect battery relay (4) from bracket.

a Shift the disconnected battery relay forward.

6. Disconnect hose (5) connected to air conditioner

compressor and hose (6) connected to receiver
tank.
a When disconnecting these hoses, be sure to
use two spanners.

7. Remove mounting bolts to remove air conditioner

compressor (7).
a Since the fins are soft, take care when
removing the air conditioner compressor.

INSTALLATION
• Installation is performed in the opposite way to
removal.

• Filling air-conditioning gas

Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.

PC128US-2 30-145
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER CONDENSER

AIRCONDITIONER
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.

k Remove the negative (-) terminal from the bat-

tery.

1. Collect air conditioner gas (R134a) from air con-

ditioner circuit.

2. Loosen bolts (1) and remove cover (2).

3. Remove air cleaner cover (3) and remove the

element.

4. Loosen bolts (4) and remove the wire harness

clamp.

5. Loosen bolt (5) and remove the battery relay

assembly.
(The wire related to the battery relay must not be
removed.)

6. Loosen bolt (6) and remove the battery relay

mounting plate.

7. Remove battery cover fixing screws (7).

8. Remove hose mounting bolts (8) and (9) and dis-

connect the hose.
a Put blind caps to prevent the entry of dirt or
water into hoses and compressor.

9. Remove bolts (10) and remove condenser [11].

INSTALLATION
• Carry out installation in reverse oder to remaval.

• Filling air-conditioning gas

Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.

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AIRCONDITIONER UNIT
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599

REMOVAL
k Completely ground the work equipment.

k Disconnect the negative (-) terminal of the bat-

tery.

1. Collect air conditioner gas (R134a) from air con-

ditioner circuit.

2. Remove floor mat (1).

3. Remove covers (2) and (3).

4. Remove louver (4) and the four screws to

remove switch panel (5).

5. Remove screw (6) to slide duct (7) forward.

6. Disconnect airconditioner switch connectors (8)

and (9) to remove duct (7).
7. Remove grommet (10).
8. Remove the mounting bolt to disconnect duct
(11) from the airconditioner unit.
9. Disconnect airconditioner unit connector (12)
(M26).
a It is located on the bottom of the centralized
harness.
10. Disconnect heater hoses (13) and (14) at the
rear of the airconditioner unit.
a Since coolant flows out, bend and disconnect
the hose and apply the blind plug to it.

11. Disconnect airconditioner hoses (15) and (16).

a Make sure to double-engage the wrench
before disconnection.

12. Disconnect two relay connectors (17).

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13. Remove the mounting bolt to remove aircondi-

tioner unit assembly (18).
a Make sure that duct (11) is completely dis-
connected and remove it by sliding it for-
ward.

IINSTALLATION
• Installation is performed in the opposite way to
removal.

• Filling air-conditioning gas

Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.

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AIRCONDITIONER UNIT
PC128US-2 Serial No. : 7301 and up
PC138US-2 Serial No. : 2601 – 4500
PC138USLC-2 Serial No. : 1001 – 1500

REMOVAL
k Remove the negative (-) terminal from the bat-
tery before setting to work.

1. Drain coolant.
6 Coolant: 17.2 l

2. Collect air conditioner gas from air conditioner

circuit.

3. Remove covers (1), (2), (3), (4) from the monitor

panel.
a Be sure to remove in the order of (1), (2), (3),
(4). Otherwise, the covers may not be
removed.
a When removing the cover (2), disconnect the
cigarette lighter connector (CN-M19).

4. Remove cover in front of the operator seat and

remove ducts (6), (7), (8).

5. Remove covers (9), (10), (11), (12) at the rear of

the operator cab.

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6. Remove the cover (13) and separate the con-

nector (14)(CN-M87). (At the rear right in the
operator cab)

7. Remove ducts (15), (16), (17).

8. Disconnect connectors (CN-M26)(18), (CN-

M85)(19), and (CN-M84)(20) (at the rear of the
operator seat).

9. Disconnect the CR700 controller connector (CN-

021 – 023)(at three positions) and remove the
CR700 controller (21).

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10. Remove the heater hose (11).

11. Remove five seat stand mounting bolts and lift

the seat stand by screwing bolts [1] (M12, L =
100mm) into seat stand lifting nuts (left: 2, right:
1).

12. Disconnect two air conditioning hoses, remove

six air conditioning unit mounting bolts and
remove air conditioning unit assembly (25) by
pulling it out from the downside of the operator
seat.

IINSTALLATION
• Carry out installation in reverse oder to removal.

a When installing the hoses of the air conditioning

circuit, care should be taken to prevent the entry
of dirt, dust, water, etc. into hose.
a Check that the pipe couplers of the air condition-
ing hoses have O-rings in them before installa-
tion.
a Check the O-rings for flaw, deterioration, etc.

a Filling air-conditioning gas

Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.

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AIRCONDITIONER UNIT
ASSEMBLY
PC138US-2 Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up

REMOVAL
k Disconnect negative (-) terminal of the battery.

1. Collect air conditioner gas from air conditioner

circuit.

2. Drain engine coolant.

6 Drain 13.2 l of the cooling water.

3. Remove floor mat.

4. Remove cover (1).

5. Loosen right console (2) and move it inward.

6. Remove cover (3).

a There is the cigarette lighter, M40.

7. Remove covers (4) and (5).

8. Lower duct joint A, remove connector M88 (6),

and then remove duct (7).

9. Remove duct (8).

10. Disconnect 2 air conditioner tubes (9). [*1]

11. Remove covers (10), (11), (12), and (13).

12. Remove ducts (14) and (15).

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13. Remove duct (16).

14. Disconnect connector (17).

15. Remove the 2 mounting bolts and duct (18).

16. Remove cover (19).

17. Disconnect clip (20).

18. Disconnect connectors M26 (21), M85 (22), and

M84 (23) and remove them from the connector
clips.

19. Disconnect 2 heater hoses (24), upper one and

lower one.
a Do not wet controller B.

20. Remove five seat stand mounting bolts and lift

the seat stand by screwing bolts [1] (M12, L =
100mm) into seat stand lifting nuts (left: 2, right:
1).

21. Remove six air conditioning unit mounting bolts

and remove air conditioning unit assembly (25)
by pulling it out from the downside of the opera-
tor seat.

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IINSTALLATION
• Carry out installation in reverse order to removal.

a When installing the hoses of the air conditioning

circuit, care should be taken to prevent the entry
of dirt, dust, water, etc. into hose.
a Check that the pipe couplers of the air condition-
ing hoses have O-rings in them before installa-
tion.
a Check the O-rings for flaw, deterioration, etc.

[*1]
3 Air conditioner tube nut:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

• Filling air-conditioning gas

Using tool X3, charge air conditioner gas
(R134a) to air conditioner circuit.

• 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

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