10795750-DKP8P8EM-Download Komatsu Pc138us-8 Pc138uslc-8 Excavator Manual

SEN01968-02

HYDRAULIC EXCAVATOR

-8 PC138US PC138USLC -8 SERIAL NUMBERS

PC138US- 20001 PC138USLC- 20001

and up

SEN01977-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC138US-8 PC138USLC-8

Machine model

Serial number


20001 and up 20001 and up

00 Index and foreword

1

Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

PC138US, USLC-8

1

SEN01977-02


Composition of shop manual

1

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN01968-02

00 Index and foreword Index Foreword and general information

SEN01969-02 SEN01977-02 q SEN01978-01 q

01 Specification Specification and technical data

SEN01970-01 SEN01979-01

10 Structure, function and maintenance standard Engine and cooling system Power train Undercarriage and frame Hydraulic system, Part 1 Hydraulic system, Part 2 Hydraulic system, Part 3 Work equipment Cab and its attachments Electrical system

SEN01971-02 SEN02545-01 SEN02546-01 SEN02547-01 SEN02548-01 SEN02549-02 q SEN02550-01 SEN02551-00 SEN02552-01 SEN02553-01

20 Standard value table Standard service value table

SEN01972-01 SEN02457-01

30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3

SEN01973-01 SEN02458-01 SEN02459-00 SEN02460-01

40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 4 Troubleshooting of electrical system (E-mode)

SEN01974-01 SEN02461-01 SEN02462-00 SEN02463-01 SEN02464-01 SEN02465-01 SEN02466-00 SEN02467-00

2

PC138US, USLC-8


Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)

SEN01977-02

SEN02468-01 SEN02469-01

50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train Undercarriage and frame Hydraulic system Work equipment Body Cab and its attachments Electrical system

SEN01975-00 SEN02709-00 SEN02710-00 SEN02711-00 SEN02712-00 SEN02713-00 SEN02714-00 SEN02715-00 SEN02716-00

90 Diagrams and drawings Hydraulic circuit diagram Electrical diagrams and drawings

SEN01976-01 SEN01980-00 SEN01981-01

PC138US, USLC-8

3

SEN01977-02


Table of contents

1

00 Index and foreword Index SEN01977-02 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN01978-01 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard.......................................................................... 9 Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines.......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN01979-01 Specification dimension drawings ............................................................................................... 2 Working range diagram ............................................................................................................... 3 Specifications .............................................................................................................................. 4 List of weights.............................................................................................................................. 10 Table of fuel, coolant and lubricants ............................................................................................ 14 10 Structure, function and maintenance standard Engine and cooling system SEN02545-01 Engine mount .............................................................................................................................. 2 PTO ............................................................................................................................................. 3 Cooling system............................................................................................................................ 4 Power train SEN02546-01 Power train .................................................................................................................................. 2 Swing circle ................................................................................................................................. 3 Swing machinery ......................................................................................................................... 4 Undercarriage and frame SEN02547-01 Track frame ................................................................................................................................. 2 Idler cushion ................................................................................................................................ 4 Idler ............................................................................................................................................. 6 Track roller................................................................................................................................... 7 Carrier roller ................................................................................................................................ 8 Sprocket ...................................................................................................................................... 9 Track shoe................................................................................................................................... 10 Hydraulic system, Part 1 SEN02548-01 Hydraulic equipment layout drawing ........................................................................................... 2 Valve control................................................................................................................................ 4 Hydraulic tank and filter............................................................................................................... 6 Hydraulic pump ........................................................................................................................... 8 Hydraulic system, Part 2 SEN02549-02 Control valve ............................................................................................................................... 2 CLSS ........................................................................................................................................... 14 Functions and operation by valve................................................................................................ 18 Hydraulic system, Part 3 SEN02550-01 PPC valve.................................................................................................................................... 2

4

PC138US, USLC-8


SEN01977-02

Swing motor ................................................................................................................................ 19 Travel motor ................................................................................................................................ 27 Center swivel joint ....................................................................................................................... 36 Solenoid valve............................................................................................................................. 40 PPC accumulator ........................................................................................................................ 44 Holding valve............................................................................................................................... 46 Multi-control valve ....................................................................................................................... 51 Work equipment SEN02551-00 Work equipment .......................................................................................................................... 2 Dimensions of components ......................................................................................................... 4 Hydraulic cylinder........................................................................................................................ 8 Cab and its attachments SEN02552-01 Air conditioner ............................................................................................................................. 2 Electrical system SEN02553-01 Electronic control system ............................................................................................................ 2 Monitor system............................................................................................................................ 35 KOMTRAX system ...................................................................................................................... 49 Sensor......................................................................................................................................... 51 20 Standard value table Standard service value table SEN02457-01 Standard value table for engine related parts.............................................................................. 2 Standard value table for chassis related parts ............................................................................ 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN02458-01 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Testing engine speed .................................................................................................................. 6 Testing exhaust temperature....................................................................................................... 7 Checking exhaust gas color ........................................................................................................ 8 Adjusting valve clearance ........................................................................................................... 9 Testing compression pressure .................................................................................................... 11 Testing blow-by pressure ............................................................................................................ 13 Testing engine oil pressure ......................................................................................................... 14 Handling fuel system parts .......................................................................................................... 15 Releasing residual pressure from fuel system ............................................................................ 15 Testing fuel pressure ................................................................................................................... 16 Testing fuel return rate and fuel leakage ..................................................................................... 17 Bleeding air from fuel circuit........................................................................................................ 19 Checking fuel circuit for leakage ................................................................................................. 21 Testing and adjusting alternator belt tension............................................................................... 22 Testing swing circle bearing clearance........................................................................................ 23 Checking and adjusting air conditioner compressor belt tension ................................................ 24 Checking and adjusting track shoe tension................................................................................. 25 Testing and adjusting oil pressure in work equipment, swing, and travel circuits........................ 27 Testing control circuit basic pressure .......................................................................................... 30 Testing and adjusting oil pressure in pump PC control circuit..................................................... 31 Testing and adjusting oil pressure in pump LS control circuit ..................................................... 34 Testing solenoid valve output pressure ....................................................................................... 38 Testing PPC valve output pressure ............................................................................................. 39 Adjusting play of work equipment and swing PPC valves........................................................... 41 Checking parts which cause hydraulic drift of work equipment................................................... 42 Testing and adjusting travel deviation ......................................................................................... 44 Releasing residual pressure from hydraulic circuit...................................................................... 46 Testing oil leakage....................................................................................................................... 47 Bleeding air from each part ......................................................................................................... 50 PC138US, USLC-8

5

SEN01977-02


Checking cab tipping stopper ...................................................................................................... 52 Adjusting mirrors ......................................................................................................................... 52 Testing and adjusting, Part 2 SEN02459-00 Special functions of machine monitor.......................................................................................... 2 Testing and adjusting, Part 3 SEN02460-01 Handling voltage circuit of engine controller................................................................................ 2 Preparation work for troubleshooting of electrical system........................................................... 3 Procedure for testing diodes ....................................................................................................... 8 Pm Clinic service......................................................................................................................... 9 40 Troubleshooting Failure code table and fuse locations SEN02461-01 Failure code table........................................................................................................................ 2 Fuse locations ............................................................................................................................. 6 General information on troubleshooting SEN02462-00 Points to remember when troubleshooting.................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3 Checks before troubleshooting.................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Information in troubleshooting table ............................................................................................ 6 Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8 Wiring table for connector pin numbers....................................................................................... 11 T-adapter box and T-adapter table .............................................................................................. 44 Troubleshooting by failure code, Part 1 SEN02463-01 Failure code [989L00] Engine controller lock caution 1............................................................... 3 Failure code [989M00] Engine controller lock caution 2.............................................................. 3 Failure code [989N00] Engine controller lock caution 3 .............................................................. 4 Failure code [AB00KE] Charge voltage low ................................................................................ 6 Failure code [B@BAZG] Eng oil press. low................................................................................. 8 Failure code [B@BAZK] Eng oil level low ................................................................................... 8 Failure code [B@BCNS] Eng coolant overheat........................................................................... 9 Failure code [B@HANS] Hydr oil overheat ................................................................................. 9 Failure code [CA111] ECM critical internal failure ....................................................................... 10 Failure code [CA115] Eng. Ne and Bkup speed sensor error ..................................................... 13 Failure code [CA122] Charge air press sensor high error........................................................... 14 Failure code [CA123] Charge air press sensor low error ............................................................ 16 Failure code [CA131] Throttle sensor high error ......................................................................... 18 Failure code [CA132] Throttle sensor low error........................................................................... 20 Failure code [CA144] Coolant temp. sensor high error ............................................................... 21 Failure code [CA145] Coolant temp. sensor low error ................................................................ 22 Failure code [CA153] Charge air temp. sensor high error........................................................... 23 Failure code [CA154] Charge air temp. sensor low error ............................................................ 24 Failure code [CA187] Sensor sup. 2 volt. low error..................................................................... 24 Failure code [CA221] Ambient air press. sensor high error ........................................................ 26 Failure code [CA222] Ambient air press. sensor low error.......................................................... 28 Failure code [CA227] Sensor sup. 2 volt. high error ................................................................... 30 Failure code [CA234] Eng. overspeed ........................................................................................ 32 Failure code [CA238] Ne speed sensor sup. volt. error .............................................................. 34 Failure code [CA271] IMV/PCV1 short error ............................................................................... 36 Failure code [CA272] IMV/PCV1 open error ............................................................................... 37 Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 38 Failure code [CA324] Injector #3 (L/B #3) system open/short error ............................................ 40 Failure code [CA331] Injector #2 (L/B #2) system open/short error ............................................ 42 Failure code [CA332] Injector #4 (L/B #4) system open/short error ............................................ 44 Troubleshooting by failure code, Part 2 SEN02464-01 Failure code [CA351] Inj. drive circuit error ................................................................................. 3

6

PC138US, USLC-8


SEN01977-02

Failure code [CA352] Sensor sup. 1 volt. low error..................................................................... 6 Failure code [CA386] Sensor sup. 1 volt. high error ................................................................... 8 Failure code [CA435] Abnormality in engine oil pressure switch ................................................ 10 Failure code [CA441] Battery voltage low error .......................................................................... 11 Failure code [CA442] Battery voltage high error ......................................................................... 11 Failure code [CA449] Rail press. very high error ........................................................................ 12 Failure code [CA451] Rail press. sensor high error .................................................................... 14 Failure code [CA452] Rail press. sensor low error...................................................................... 16 Failure code [CA553] Rail press. high error ................................................................................ 16 Failure code [CA559] Rail press. low error ................................................................................. 17 Failure code [CA689] Eng. Ne speed sensor error ..................................................................... 20 Failure code [CA731] Eng. Bkup speed sensor phase error....................................................... 22 Failure code [CA757] All persistent data lost error...................................................................... 22 Failure code [CA778] Eng. Bkup speed sensor error.................................................................. 24 Failure code [CA1633] KOMNET datalink timeout error ............................................................. 26 Failure code [CA2185] Throttle sens. sup. volt. high error.......................................................... 28 Failure code [CA2186] Throttle sens. sup. volt. low error ........................................................... 30 Failure code [CA2249] Rail press. very low error........................................................................ 30 Failure code [CA2311] Abnormality in IMV solenoid ................................................................... 31 Failure code [D110KB] Battery relay drive short ......................................................................... 32 Failure code [D19JKZ] Personal code relay abnormality ............................................................ 34 Failure code [D862KA] GPS antenna discon .............................................................................. 36 Failure code [DA22KK] Pump solenoid power low error ............................................................. 38 Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................. 40 Failure code [DA26KP] 5V sensor 2 power abnormality ............................................................. 43 Troubleshooting by failure code, Part 3 SEN02465-01 Failure code [DA2RMC] CAN discon (Pump controller detected) ............................................... 4 Failure code [DAF8KB] Short circuit in camera power supply .................................................... 6 Failure code [DAFGMC] GPS module error ................................................................................ 8 Failure code [DAFRMC] CAN discon (Monitor detected) ............................................................ 10 Failure code [DGH2KB] Hydr oil sensor short............................................................................. 12 Failure code [DHPAMA] Pump press sensor abnormality........................................................... 14 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality ............................... 16 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality ............................ 18 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality............................... 20 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................. 22 Failure code [DHSKMA] Blade raise PPC press sensor abnormality ......................................... 24 Failure code [DHSLMA] Blade lower PPC press sensor abnormality ......................................... 26 Failure code [DHX1MA] Overload sensor abnormality (Analog) ................................................. 28 Failure code [DV20KB] Travel alarm S/C.................................................................................... 29 Failure code [DW43KA] Travel speed sol discon ........................................................................ 30 Failure code [DW43KB] Travel speed sol short .......................................................................... 31 Failure code [DW45KA] Swing brake sol discon......................................................................... 32 Failure code [DW45KB] Swing brake sol short ........................................................................... 34 Failure code [DW91KA] Travel junction sol discon ..................................................................... 36 Failure code [DW91KB] Travel junction sol short........................................................................ 37 Failure code [DWJ0KA] Merge-divider sol discon....................................................................... 38 Failure code [DWJ0KB] Merge-divider sol short ......................................................................... 39 Troubleshooting by failure code, Part 4 SEN02466-00 Failure code [DXA8KA] PC-EPC sol discon................................................................................ 2 Failure code [DXA8KB] PC-EPC sol short .................................................................................. 4 Failure code [DXE4KA] Service current EPC discon .................................................................. 6 Failure code [DXE4KB] Service current EPC short..................................................................... 7 Failure code [DY20KA] Wiper working abnormality .................................................................... 8 Failure code [DY20MA] Wiper parking abnormality .................................................................... 10 Failure code [DY2CKA] Washer drive discon.............................................................................. 12 Failure code [DY2CKB] Washer drive short ................................................................................ 14

PC138US, USLC-8

7

SEN01977-02


Failure code [DY2DKB] Wiper drive (for) short ........................................................................... 16 Failure code [DY2EKB] Wiper drive (rev) short........................................................................... 18 Troubleshooting of electrical system (E-mode) SEN02467-00 Before carrying out troubleshooting of electrical system............................................................. 3 Information in troubleshooting table ............................................................................................ 5 E-1 When starting switch turned ON, machine monitor displays nothing.................................... 6 E-2 When starting switch turned ON (before starting engine), basic check item lights up .......... 8 E-3 Engine does not start (Engine does not turn) ....................................................................... 9 E-4 Preheater does not operate .................................................................................................. 12 E-5 Automatic warm-up system does not operate (in cold season) ............................................ 14 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked.......... 16 E-7 Precaution lights up while engine is running......................................................................... 18 E-8 Emergency stop item lights up while engine is running ........................................................ 21 E-9 Engine coolant temperature gauge does not indicate normally............................................ 22 E-10 Hydraulic oil temperature gauge does not indicate normally .............................................. 23 E-11 Fuel level gauge does not indicate normally ....................................................................... 25 E-12 Contents of display by machine monitor are different from applicable machine................. 27 E-13 Machine monitor does not display some items................................................................... 27 E-14 Function switch does not work............................................................................................ 27 E-15 Auto-decelerator does not operate normally....................................................................... 28 E-16 Working mode does not change ......................................................................................... 29 E-17 Travel speed does not change............................................................................................ 30 E-18 Alarm buzzer cannot be stopped ........................................................................................ 31 E-19 Windshield wiper and window washer do not operate........................................................ 32 E-20 Swing holding brake does not operate normally................................................................. 36 E-21 Travel alarm does not sound or does not stop sounding .................................................... 38 E-22 Air conditioner does not operate normally (including air conditioner abnormality record) .. 39 E-23 While starting switch is in OFF position, service meter is not displayed............................. 51 E-24 Machine monitor cannot be set in service mode ................................................................ 51 E-25 Monitoring function does not display lever control signal normally..................................... 52 E-26 KOMTRAX system does not operate normally ................................................................... 68 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02468-01 Information contained in troubleshooting table............................................................................ 3 System chart for hydraulic and mechanical systems .................................................................. 4 H-1 Speed or power of all work equipment, swing, and travel are low........................................ 6 H-2 Engine speed sharply drops or engine stalls ........................................................................ 7 H-3 No work equipment, travel and swing move......................................................................... 8 H-4 Abnormal noise is heard from around hydraulic pump ......................................................... 8 H-5 Fine control mode does not function .................................................................................... 9 H-6 Speed or power of boom is low ............................................................................................ 10 H-7 Speed or power of arm is low ............................................................................................... 11 H-8 Speed or power of bucket is low........................................................................................... 12 H-9 Work equipment does not move in its single operation ........................................................ 13 H-10 Hydraulic drift of work equipment is large........................................................................... 14 H-11 Time lag of work equipment is large ................................................................................... 15 H-12 Work equipment loaded more is slower during compound operation................................. 15 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE ..................... 15 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel .. 16 H-15 Machine deviates during travel........................................................................................... 17 H-16 Travel speed is low ............................................................................................................. 18 H-17 Machine cannot be steered easily or steering power is low ............................................... 19 H-18 Travel speed does not change or it is kept low or high....................................................... 20 H-19 Track does not move (Only either side).............................................................................. 20 H-20 Machine does not swing ..................................................................................................... 21 H-21 Swing acceleration or swing speed is low .......................................................................... 22 H-22 Excessive overrun when stopping swing............................................................................ 23 H-23 When upper structure stops swinging, it makes large shock.............................................. 24

8

PC138US, USLC-8


SEN01977-02

H-24 When upper structure stops swinging, it makes large sound ............................................. 24 H-25 Hydraulic drift of swing is large........................................................................................... 25 H-26 Flow rate in attachment circuit cannot be adjusted ............................................................ 26 Troubleshooting of engine (S-mode) SEN02469-01 Method of using troubleshooting chart ........................................................................................ 4 S-1 Starting performance is poor ................................................................................................ 8 S-2 Engine does not start............................................................................................................ 9 S-3 Engine does not pick up smoothly........................................................................................ 12 S-4 Engine stops during operations ............................................................................................ 13 S-5 Engine does not rotate smoothly .......................................................................................... 14 S-6 Engine lacks output (or lacks power).................................................................................... 15 S-7 Exhaust smoke is black (incomplete combustion)................................................................ 16 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 17 S-9 Oil becomes contaminated quickly ....................................................................................... 18 S-10 Fuel consumption is excessive........................................................................................... 19 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20 S-12 Oil pressure drops .............................................................................................................. 21 S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 22 S-14 Coolant temperature becomes too high (overheating) ....................................................... 23 S-15 Abnormal noise is made ..................................................................................................... 24 S-16 Vibration is excessive ......................................................................................................... 25 50 Disassembly and assembly General information on disassembly and assembly SEN02709-00 How to read this manual ............................................................................................................. 2 List of adhesives ......................................................................................................................... 4 Special tool list ............................................................................................................................ 7 Sketche of special tool ................................................................................................................ 11 Engine and cooling system SEN02710-00 Removal and installation of fuel supply pump assembly............................................................. 2 Removal and installation of fuel injector assembly ..................................................................... 4 Removal and installation of front oil seal..................................................................................... 7 Removal and installation of rear oil seal ..................................................................................... 9 Removal and installation of cylinder head assembly .................................................................. 12 Removal and installation of radiator assembly............................................................................ 19 Removal and installation of aftercooler assembly ....................................................................... 21 Removal and installation of work equipment oil cooler assembly ............................................... 23 Removal and installation of engine and work equipment pump assembly.................................. 26 Removal and installation of fuel tank assembly .......................................................................... 31 Power train SEN02711-00 Removal and installation of travel motor and final drive assembly ............................................. 2 Removal and installation of swing motor and swing machinery assembly.................................. 4 Disassembly and assembly of swing machinery assembly......................................................... 6 Removal and installation of swing circle assembly ..................................................................... 12 Undercarriage and frame SEN02712-00 Disassembly and assembly of track roller................................................................................... 2 Disassembly and assembly of idler assembly............................................................................. 5 Disassembly and assembly of recoil spring ................................................................................ 8 Removal and installation of of track shoe assembly ................................................................... 11 Removal and installation of sprocket .......................................................................................... 13 Removal and installation of revolving frame assembly ............................................................... 14 Removal and installation of counterweight assembly (Machine without add-on weight)............. 16 Removal and installation of counterweight assembly (Machine with add-on weight).................. 18 Hydraulic system SEN02713-00 Removal and installation of center swivel joint assembly ........................................................... 2 Disassembly and assembly of center swivel joint assembly ....................................................... 4 PC138US, USLC-8

9

SEN01977-02


Removal and installation of hydraulic tank assembly .................................................................. 5 Removal and installation of hydraulic pump assembly................................................................ 8 Removal and installation of control valve assembly.................................................................... 12 Disassembly and assembly of control valve assembly ............................................................... 17 Disassembly and assembly of work equipment PPC valve assembly ........................................ 27 Disassembly and assembly of travel PPC valve assembly ......................................................... 30 Disassembly and assembly of hydraulic cylinder assembly........................................................ 32 Work equipment Body SEN02714-00 Removal and installation of work equipment assembly............................................................... 2 Cab and its attachments SEN02715-00 Removal and installation of operator cab assembly.................................................................... 2 Removal and installation of operator's cab glass (stuck glass) ................................................... 4 Removal and installation of front window assembly.................................................................... 13 Removal and installation of floor frame assembly....................................................................... 14 Electrical system SEN02716-00 Removal and installation of air compressor assembly ................................................................ 2 Removal and installation of air conditioner condenser................................................................ 3 Removal and installation of air compressor unit assembly ......................................................... 4 Removal and installation of machine monitor assembly ............................................................. 7 Removal and installation of pump controller assembly ............................................................... 8 Removal and installation of engine controller assembly ............................................................. 9 Removal and installation of KOMTRAX communications module............................................... 10 90 Diagrams and drawings Hydraulic circuit diagram SEN01980-00 Hydraulic circuit diagram ............................................................................................................. 3 Electrical diagrams and drawings SEN01981-01 Electrical circuit diagram ............................................................................................................. 3 Connectors table and arrangement drawing ............................................................................... 5

10

PC138US, USLC-8


PC138US, USLC-8

SEN01977-02

11

SEN01977-02


PC138US, USLC-8 Hydraulic excavator Form No. SEN01977-02

© 2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (02)

12

PC138US, USLC-8

SEN01978-01



Machine model

Serial number




1

Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36

PC138US, USLC-8

1

SEN01978-01

Safety notice


1

(Rev. 2007/03)

Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.

2

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

2.

Precautions against work which you are not used to or you are used to too much

Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

PC138US, USLC-8


3) 4)

3.

When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.

PC138US, USLC-8

SEN01978-01

8)

9) 10)

11)

12)

13) 14) 15)

16)

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 and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

3

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4.

4

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.


8)

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

PC138US, USLC-8


If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN01978-01

13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

q

5.

6.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.

PC138US, USLC-8

7.

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

5

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8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2)

Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.

a

Example of O-ring (Fitted to every joint of hoses and tubes)

a

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

6


PC138US, USLC-8


How to read the shop manual q q q

1.

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1

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

PC138US, USLC-8

7

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3.

4.


Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)

q

Revisions Revised brochures are shown in the shop manual composition table.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol

Item

k

Safety

a

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

4

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

3

Tightening torque

2

Coat

5

Oil, coolant

6

Drain

Remarks Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

5.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

8

PC138US, USLC-8


SEN01978-01

Explanation of terms for maintenance standard

1

The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1.

Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q

Example: Standard size 120

Tolerance –0.022 –0.126

a

The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)

q

Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

q

Example: Standard size 60

PC138US, USLC-8

Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

9

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2.

Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.


5.

q

3.

4.

Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

6.

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit must be replaced or repaired. q The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the “allowable value”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. q

10

PC138US, USLC-8


Handling of electric equipment and hydraulic component

SEN01978-01

1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.

Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

PC138US, USLC-8

11

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12

3)

Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

4)

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

5)

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.


PC138US, USLC-8


3.

SEN01978-01

Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q

When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

q

When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.

3]

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

PC138US, USLC-8

13

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2)

14


Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a 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 connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

PC138US, USLC-8


3)

Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks

PC138US, USLC-8

SEN01978-01

q

Disconnection

q

Connection (Example of incomplete setting of (a))

15

SEN01978-01

4)

16


Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

PC138US, USLC-8


4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

5.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

PC138US, USLC-8

SEN01978-01

17

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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1.

Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

2.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

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 entering. 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 leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

4.

Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

18

PC138US, USLC-8


5.

Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

6.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7.

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

PC138US, USLC-8

SEN01978-01

19

SEN01978-01


Handling of connectors newly used for engines a

1.

Mainly, following engines are object for following connectors. q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

2.

1

Pull lock type (PACKARD-2) 107 – 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

q

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

20

PC138US, USLC-8


3.

SEN01978-01

Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

q

114 engine

q

107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

3)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

a

2)

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

PC138US, USLC-8

21

SEN01978-01

q

4)

125 – 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)


4.

Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

q

1)

Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

2)

Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.

Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

22

PC138US, USLC-8


SEN01978-01

How to read electric wire code a

1

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile

Symbol AV

AVS

Heat-resistant low-voltAEX age wire for automobile

PC138US, USLC-8

Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

23

SEN01978-01

2.


Dimensions

(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

8

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

24

PC138US, USLC-8


3.

SEN01978-01

Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

PC138US, USLC-8

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

–

R B R D Y G L

–

–

WG

–

–

–

–

–

–

–

–

–

– –

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

YW GL

– –

Gr Br – –

25

SEN01978-01


Precautions when carrying out operation

1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q

a

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

26

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30

27

07049-02734

27

22.5

34

PC138US, USLC-8


2. q q q q q q q q q q q q q

a

a 3.

SEN01978-01

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. 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 idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 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. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

PC138US, USLC-8

27

SEN01978-01

4)

5)

28


Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.

PC138US, USLC-8


SEN01978-01

Method of disassembling and connecting push-pull type coupler k k

1

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

2.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

PC138US, USLC-8

29

SEN01978-01


Type 2 1.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

2.

Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

30

PC138US, USLC-8


SEN01978-01

Type 3 1.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

2.

Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

PC138US, USLC-8

31

SEN01978-01


Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a

The following table corresponds to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 153 – 190 15.5 – 19.5 235 – 285 23.5 – 29.5 320 – 400 33.0 – 41.0 455 – 565 46.5 – 58.0 610 – 765 62.5 – 78.0 785 – 980 80.0 – 100.0 1,150 – 1,440 118 – 147 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12

32

1

Width across flats mm 10 13 14 27

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

PC138US, USLC-8


2.

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Nominal No. 02 03,04 05,06 10,12 14

4.

SEN01978-01

Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

PC138US, USLC-8

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

33

SEN01978-01

5.


Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

02

19

03 04 05 06 (10) (12) (14)

6.

22 24 27 32 36 41 46 55

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

mm 6 8 10 12 14

– 14 – 18 22 24 30 33 36 42

Tightening torque Bolts and nuts Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14

34

Thread size (mm)

Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Thread size

7.

Taper seal

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

PC138US, USLC-8


8.

SEN01978-01

Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1

PC138US, USLC-8

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

35

SEN01978-01


Conversion table

1

Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.

Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters 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 it 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.

Millimeters to inches

(A)

36

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

PC138US, USLC-8


SEN01978-01

Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

13.473 16.115 18.756 21.398 24.040

PC138US, USLC-8

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

37

SEN01978-01


Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

38

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

PC138US, USLC-8


SEN01978-01

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

PC138US, USLC-8

39

SEN01978-01


Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

40

PC138US, USLC-8


PC138US, USLC-8

SEN01978-01

41

SEN01978-01



42

SEN01979-01



Machine model

Serial number



01 Specification Specification and technical data Specification dimension drawings ................................................................................................................... 2 Working range diagram................................................................................................................................... 3 Specifications .................................................................................................................................................. 4 List of weights ............................................................................................................................................... 10 Table of fuel, coolant and lubricants.............................................................................................................. 14

PC138US, USLC-8

1

SEN01979-01

01 Specification

Specification dimension drawings

Item

1

Unit

Standard specification Machine weight

Reinforced blade specification

13,400

14,500

14,050

15,150

m3

0.50

Engine type

—

Komatsu SAA4D95LE-5 Diesel engine

kW{HP}/rpm

68.4{91.7}/2,200 72.1{96.6}/2,200

A

B

PC138USLC-8

Bucket capacity Engine rated output • Net [ISO 9249/SAE J1349] • Gross [SAE J1955]

A'

kg

PC138US-8

Overall length

Standard specification

mm

7,260

7,390


mm

7,970

8,040

Overall height

mm

2,850

C Overall width

mm

2,490

2,590

D Shoe width

mm

500

600

E

Tail swing radius

mm

1,480

1,545

F

Crawler overall length

mm

3,610

3,870

G Distance between tambler center

mm

2,880

3,140

H Cab height

mm

2,815

Ground clearance

mm

395

Traveling speed (Low/High)

km/h

2.9/5.1

Continuous swing speed

rpm

11.0

a

There are net value and gross value for displaying engine rate output. Gross value is measurement of engine alone, and net value is measurement with close to on-board conditions.

2

PC138US, USLC-8

01 Specification

SEN01979-01

Working range diagram

Working range (mm)

1

PC138US-8

PC138USLC-8

A

Maximum digging reach

8,300

8,300

B

Maximum digging depth

5,480

5,480

C

Maximum digging height

9,340

9,340

D

Maximum vertical wall digging depth

4,900

4,900

E

Maximum dumping height

6,840

6,840

F

Minimum swing radius of work equipment

1,980

1,980

G

Maximum reach at ground level

8,180

8,180

H

Maximum raising distance of blade

470

470

I

Maximum lowering distance of blade

525

490

PC138US, USLC-8

3

SEN01979-01

01 Specification

Specifications

1 PC138US-8

Machine model


Serial No.

Working ranges

Performance

20001 and up

Bucket capacity

m3

0.50

0.50

Operating weight

kg

13,400

14,050

mm

5,480

5,480

Max. digging depth Max. vertical wall depth

mm

4,900

4,900

Max. digging reach

mm

8,300

8,300

Max. reach at ground level

mm

8,180

8,180

Max. digging height

mm

9,340

9,340

Max. dumping height

mm

6,840

6,840

Max. blade lifting amount

mm

—

470

Max. blade lowering amount

mm

—

525

kN{kg}

93.2{9,500}

93.2{9,500}

Maximum digging force (bucket) Swing speed

rpm

11.0

11.0

Swing max. slope angle

Degree

19.0

19.0

Travel speed (Low/High)

km/h

2.9/5.1

2.9/5.1

Gradeability

deg.

35

35

kPa{kg/cm }

42.2{0.43}

44.1{0.45}

Overall length (for transport)

mm

7,260

7,970

Overall width

mm

2,490

2,490

Overall height (for transport)

mm

2,850

2,850

Overall height (for work)

mm

2,830

2,830

Ground clearance of counterweight

mm

900

900

Min. ground clearance

mm

395

395

Tail swing radius

mm

1,480

1,480

Min. swing radius of work equipment

mm

1,980

1,980

Height of work equipment at min. swing radius

mm

6,770

6,770

Crawler overall width

mm

2,490

2,490

Crawler overall length

mm

3,610

3,610

Length of track on ground

mm

2,880

2,880

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

2,090

2,090

Blade width x height

mm

—

2,490 x 590

Ground pressure

Dimension


2

The values are based on the machine with the triple grouser shoe.

4

PC138US, USLC-8

01 Specification

SEN01979-01

1 PC138USLC-8 Standard specification


20001 and up 0.50

0.50

14,500

15,150

5,480

5,480

4,900

4,900

8,300

8,300

8,180

8,180

9,340

9,340

6,840

6,840

—

470

—

490

93.2{9,500}

93.2{9,500}

11.0

11.0

19.0

19.0

2.9/5.1

2.9/5.1

35

35

35.3{0.36}

37.3{0.38}

7,390

8,040

2,590

2,590

2,850

2,850

2,830

2,830

900

900

395

395

1,545

1,545

1,980

1,980

6,770

6,770

2,590

2,590

3,870

3,870

3,140

3,140

1,990

1,990

2,145

2,145

—

2,590 x 590

PC138US, USLC-8

5

SEN01979-01

01 Specification

PC138US-8

Machine model


SAA4D95LE-5

Type

4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and air cooled aftercooler

No. of cylinders-bore x stroke

mm

95 x 115

Piston displacement

l{cc}

3.260{3,260}

kW{HP}/rpm

68.4{91.7}/2,200 72.1{96.6}/2,200

Nm{kgm}/rpm

350{35.7}/1,500

High idling speed

rpm

2,300

Low idling speed

rpm

1,100

g/kWh {g/HPh}

224{167}

Rated horsepower • Net [ISO 9249/SAE J1349] • Gross [SAE J1995] Max. torque

Min. fuel consumption ratio Starting motor

24 V, 4.5 kW

Alternator

24 V, 35 A

Battery (*1)

12 V, 64 Ah x 2

Radiator core type

4-array aluminum mesh core Aluminum mesh core

Carrier roller

1 on each side

Track roller

7 on each side

Track shoe (iron shoe) (road liner) Hydraulic motor Control valve Hydraulic pump

Undercarriage

Aftercooler core type

Hydraulic system


20001 and up

Model

Performance

Engine

Serial No.

Assembly-type triple grouser shoe, 43 on each side Assembly-type road liner, 43 on each side

Type x no. Discharge Set pressure Type x no. Control method

Variable displacement piston type x 1 l/min

121+121 (at 2,200 rpm)

MPa{kg/cm2}

34.8{355} 6-spool type x 1 Hydraulic type

Travel motor

Variable displacement piston type (with brake valve and parking brake) x 2

Swing motor

Fixed displacement piston type (with safety valve and holding brake) x 1

Hydraulic tank

Box-shaped, open

Hydraulic oil filter

Tank return side

Hydraulic cooler

Air cooled (CF40)

*1. Battery capacity (Ah) is based on 5-hour rate. a There are net value and gross value for displaying engine rate horsepower. Gross value is measurement of engine alone, and net value is measurement with close to on-board conditions.

6

PC138US, USLC-8

01 Specification

SEN01979-01

PC138USLC-8 Standard specification


20001 and up SAA4D95LE-5 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and air cooled aftercooler 95 x 115 3.260{3,260} 68.4{91.7}/2,200 72.1{96.6}/2,200 350{35.7}/1,500 2,300 1,100 224{167} 24 V, 4.5 kW 24 V, 35 A 12 V, 64 Ah x 2 4-array aluminum mesh core Aluminum mesh core 2 on each side 8 on each side Assembly-type triple grouser shoe, 46 on each side Assembly-type road liner, 46 on each side Variable displacement piston type x 1 121+121 (at 2,200 rpm) 34.8{355} 6-spool type x 1 Hydraulic type Variable displacement piston type (with brake valve and parking brake) x 2 Fixed displacement piston type (with safety valve and holding brake) x 1 Box-shaped, open Tank return side Air cooled (CF40)

PC138US, USLC-8

7

SEN01979-01

01 Specification

PC138US-8

Machine model


Serial No.

20001 and up

Boom cylinder

Type mm

105

105

mm

70

70

Stroke

mm

1,055

1,055

Max. length between pins

mm

2,555

2,555

Min. length between pins

mm

Arm cylinder

1,500

1,500

Reciprocating piston type


Cylinder inner diameter

mm

110

110

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,798

2,798


mm

1,623

1,623




mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885


mm

2,263

2,263


mm

1,378

1,378

—


Type Blade cylinder


Piston rod diameter

Type Bucket cylinder

Work equipment cylinder

Hydraulic system



Type

8



mm

—

110

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

PC138US, USLC-8

01 Specification

SEN01979-01

PC138USLC-8 Standard specification


20001 and up Reciprocating piston type


105

105

70

70

1,055

1,055

2,555

2,555

1,500

1,500



110

110

75

75

1,175

1,175

2,798

2,798

1,623

1,623



95

95

65

65

885

885

2,263

2,263

1,378

1,378

—


—

110

—

75

—

181

—

870

—

689

PC138US, USLC-8

9

SEN01979-01

01 Specification

List of weights k

1

This weight table is prepared for your reference when handling or transporting the components. Unit: kg Machine model

PC138US-8 Standard specification

Serial No.

Blade specification

20001 and up

Engine assembly (excl. coolant and oil)

458

458

• Engine (excl. coolant and oil)

332

332

• Engine mount

18.1

18.1

• PTO

5.5

5.5

• Hydraulic pump

102

102

(6 x 2)

(6 x 2)

82.2

82.2

• • Filter (for KA specification) Cooling assembly (excl. coolant and oil) • Radiator (excl. coolant)

7.9

7.9

• Oil cooler (excl. oil)

10.2

10.2

• Aftercooler

8.1

8.1

• Fuel cooler (excl. fuel)

0.7

0.7

Revolving frame

1,400

1,400

Operator cab

375

375

Operator seat

38

38

Fuel cooler (excl. fuel)

90.6

90.6

Hydraulic tank (excl. hydraulic oil)

79.5

79.5

95

99

3,240

2,855

500

500

Control valve Counterweight Added counterweight Swing motor (incl. brake valve)

20

20

Swing circle

152.6

152.6

Swing machinery

71.6

71.6

Center swivel joint

28.6

43.6

Track frame assembly (excl. track shoe)

2,300

2,410

• Track frame

1,305

1,415

• Idler assembly

79 x 2

79 x 2

• Recoil spring assembly

69 x 2

69 x 2

• Carrier roller

16.5 x 2

16.5 x 2

• Track roller

22 x 14

22 x 14

• Travel motor (with final drive)

145 x 2

145 x 2

• Sprocket

33.1 x 2

33.1 x 2

• Triple grouser shoe (500 mm)

755 x 2

755 x 2


840 x 2

840 x 2


930 x 2

930 x 2


975 x 2

975 x 2

• Single grouser shoe (510 mm)

860 x 2

860 x 2

• City pad shoe (500 mm)

750 x 2

750 x 2

• City pad shoe (600 mm)

—

—

810 x 2

810 x 2

Track shoe assembly

• Road liner (500 mm)

10

PC138US, USLC-8

01 Specification

SEN01979-01

1 Unit: kg PC138USLC-8 Standard specification

Blade specification

20001 and up 458

458

332

332

18.1

18.1

5.5

5.5

102

102

(6 x 2)

(6 x 2)

82.2

82.2

7.9

7.9

10.2

10.2

8.1

8.1

0.7

0.7

1,400

1,400

375

375

39

39

90.6

90.6

79.5

79.5

95

99

3,240

2,855

500

500

20

20

152.6

152.6

71.6

71.6

28.6

43.6

2,540

2,680

1,460

1,600

79 x 2

79 x 2

71 x 2

71 x 2

16.5 x 4

16.5 x 4

22 x 16

22 x 16

145 x 2

145 x 2

33.1 x 2

33.1 x 2

805 x 2

805 x 2

895 x 2

895 x 2

995 x 2

995 x 2

—

—

—

—

800 x 2

800 x 2

895 x 2

895 x 2

870 x 2

870 x 2

PC138US, USLC-8

11

SEN01979-01

01 Specification

Unit: kg Machine model

PC138US-8 Standard specification

Serial No.

Blade specification

20001 and up

Boom assembly

820

820

Arm assembly

356

356

Bucket link assembly

85.6

85.6

• 955 mm width (incl. side cutter)

—

—

• 980 mm width (incl. side cutter)

399

399

• Reinforced blade (BOC type, incl. BOC)

—

688

• Blade (edge-welding type)

—

668

• Reinforced wide blade (BOC type, incl. BOC)

—

702

• Wide blade (edge-welding type)

—

682

101.3 x 2

101.3 x 2

Arm cylinder assembly

125.3

125.3

Bucket cylinder assembly

77.8

77.8

Blade cylinder assembly

—

59.5 x 2

Bucket assembly

Blade assembly

Boom cylinder assembly

a

BOC: Bolt-On Cutting edge

1

12

PC138US, USLC-8

01 Specification

SEN01979-01

Unit: kg PC138USLC-8 Standard specification

Blade specification

20001 and up 820

820

356

356

85.6

85.6

—

—

399

399

—

688

—

668

—

702

—

682

101.3 x 2

101.3 x 2

125.3

125.3

77.8

77.8

—

59.5 x 2

PC138US, USLC-8

13

SEN01979-01

01 Specification

Table of fuel, coolant and lubricants a

14

1

For details of the notes (Note. 1, Note. 2 …) in the table, see the Operation and Maintenance Manual.

PC138US, USLC-8

01 Specification

SEN01979-01

Unit: l Specified capacity

Refill capacity

Engine oil pan

Reservoir

11.5

11.0

Swing machinery case

2.5

2.5

Final drive case (each side)

2.1

2.1

PTO case

0.75

0.75

Hydraulic system

120

69

Fuel tank

195

—

Cooling system

12.4

—

PC138US, USLC-8

15

SEN01979-01

01 Specification



16

PC138US, USLC-8

SEN02545-01

HYDRAULIC EXCAVATOR PC138US-8 PC138USLC-8

Machine model

Serial number



10 Structure, function and maintenance standard

1

Engine and cooling system Engine mount.................................................................................................................................................. 2 PTO................................................................................................................................................................. 3 Cooling system ............................................................................................................................................... 4

PC138US, USLC-8

1

SEN02545-01

Engine mount

2


1

PC138US, USLC-8


PTO a

PTO: Abbreviation for Power Take Off

1. 2. 3. 4. 5. 6.

Flywheel Coupling Hydraulic pump shaft Drain plug Oil filler plug Oil level plug

PC138US, USLC-8

SEN02545-01

1

3

SEN02545-01

Cooling system

4


1

PC138US, USLC-8


1. 2. 3. 4. 5. 6. 7. 8. 9.

SEN02545-01

10. 11. 12. 13. 14. 15. 16. 17.

Radiator cap Shroud Reservoir tank Oil cooler inlet Oil cooler Aftercooler Radiator Fuel cooler Fuel cooler outlet

Fuel cooler inlet Radiator outlet hose Radiator inlet hose Aftercooler outlet hose Fan guard Oil cooler outlet Aftercooler inlet hose Drain plug

Specifications Radiator

Oil cooler

Aftercooler

Fuel cooler

4-array aluminum mesh core

CF40

Aluminum mesh core

Drawn cup

Fine pitch (mm)

3.5/2

3.0/2

4.0/2

4.0/2

Total heat dissipation surface (m²)

22.03

12.78

6.68

0.59

Pressure valve cracking pressure (kPa{kg/cm²})

49.0 ± 14.7 {0.5 ± 0.15}

—

—

—

Vacuum valve cracking pressure (kPa{kg/cm²})

-4.9 – 0 {-0.05 – 0}

—

—

—

Core type

PC138US, USLC-8

5

SEN02545-01




6

PC138US, USLC-8

SEN02546-01


Machine model

Serial number




1

Power train Power train...................................................................................................................................................... 2 Swing circle..................................................................................................................................................... 3 Swing machinery............................................................................................................................................. 4

PC138US, USLC-8

1

SEN02546-01


Power train

1. 2.

3. 4. 5. 6.

2

Idler Control valve 2a. Self pressure reducing valve 2b. Pump merge-divider valve 2c. Travel junction valve PPC lock solenoid valve 2nd travel speed select solenoid valve Swing holding brake solenoid valve Pump merge-divider solenoid valve

1

7. 8. 9. 10. 11. 12. 13. 14.

Travel junction solenoid valve Travel motor Hydraulic pump Engine Swing motor Center swivel joint Swing machinery Swing circle

PC138US, USLC-8


SEN02546-01

Swing circle

1

Unit: mm No. 1

2. 3. 4. 5. 6. 7.

Item Bearing clearance

Swing circle bearing lubrication Swing circle pinion lubrication Outer race Ball Seal Inner race (Number of teeth: 90)

Criteria

Remedy

Basic clearance

Clearance limit

0.5 – 1.6

2.6

a. b.

Inner race soft zone position Outer race soft zone position

Specifications Reduction ratio Grease Grease quantity (l)

PC138US, USLC-8

Replace

90/11=8.182 G2-LI 9.1

3

SEN02546-01


Swing machinery

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

4

Level gauge Oil feed pipe Oil filler cap Swing pinion (Number of teeth: 11) Swing machinery case No. 2 planetary carrier No. 2 sun gear (Number of teeth: 17) Ring gear (Number of teeth: 61) No. 1 planetary carrier No. 1 sun gear (Number of teeth: 14) Swing motor No. 1 planetary gear (Number of teeth: 24) No. 2 planetary gear (Number of teeth: 22) Drain plug

1

Specifications Reduction ratio

(14+61) / 14 × (17+61) / 17 = 24.58

Swing reduction ratio

24.58 × 8.182 = 201.11

Swing speed (rpm)

11.0

PC138US, USLC-8


SEN02546-01

Unit: mm No.

Item

1

Backlash between swing motor shaft and No. 1 sun gear

2

Criteria

Remedy

Standard clearance

Clearance limit

0.07 – 0.18

0.4

Backlash between No. 1 sun gear and No. 1 planetary gear

0.13 – 0.31

0.6

3

Backlash between No. 1 planetary gear and ring gear

0.15 – 0.34

0.7

4

Backlash between No. 1 planetary carrier and No. 2 sun gear

0.14 – 0.34

0.7

5

Backlash between No. 2 sun gear and No. 2 planetary gear

0.13 – 0.31

0.6

6

Backlash between No. 2 planetary gear and ring gear

0.15 – 0.34

0.7

7

Backlash between No. 2 planetary carrier and swing pinion

0.08 – 0.19

0.4

8

Back lash between swing pinion and swing circle

0.13 – 1.16

2.3

9

Outside diameter of oil seal contacting surface on swing pinion collar

Replace

Standard size

Tolerance

Repair limit

145

0 -0.100

144.8

Repair by hard chrome-plating or replace

1

PC138US, USLC-8

5

SEN02546-01




6

PC138US, USLC-8

SEN02547-01


Machine model

Serial number




1

Undercarriage and frame Track frame ..................................................................................................................................................... 2 Idler cushion.................................................................................................................................................... 4 Idler ................................................................................................................................................................. 6 Track roller ...................................................................................................................................................... 7 Carrier roller .................................................................................................................................................... 8 Sprocket .......................................................................................................................................................... 9 Track shoe .................................................................................................................................................... 10

PC138US, USLC-8

1

SEN02547-01


Track frame

1

PC138US-8

Unit: mm No.

1

2

3. 4. 5. 6.

2

Item

Length at idler guide

Width at idler guide

Idler Track frame Carrier roller Travel motor

Criteria

Remedy

Standard size

Repair limit

Track frame

84

89

Idler support

82

77

Rebuilding or replace

Track frame

185

193

Rebuilding

Idler support

183

175


7. 8. 9. 10.

Rebuilding

Sprocket Track roller Idler cushion Track shoe

PC138US, USLC-8


SEN02547-01

PC138USLC-8

Unit: mm No.

1

2

3. 4. 5. 6. 7. 8. 9. 10.

Item

Length at idler guide

Width at idler guide

Criteria

Remedy

Standard size

Repair limit

Track frame

84

89

Idler support

82

77


Track frame

185

193

Rebuilding

Idler support

183

175


Rebuilding

Idler Track frame Carrier roller Travel motor Sprocket Track roller Idler cushion Track shoe

PC138US, USLC-8

3

SEN02547-01


Idler cushion

1

PC138US-8

Unit: mm No.

Item

Criteria

Remedy

Standard size 1

2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

4

Recoil spring

Idler Support Rod Recoil spring Cylinder U-packing Pilot Nut Valve Grease fitting

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

501.4

390

84.3 kN {8,600 kg}

489

75.0 kN {7,650 kg}

Replace

Specifications Grease Grease quantity (cc)

G2-LI 118

PC138US, USLC-8


SEN02547-01

PC138USLC-8

Unit: mm No.

Item

Criteria

Remedy

Standard size 1

Recoil spring

Free length 513.3

2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Idler Support Rod Recoil spring Cylinder U-packing Pilot Nut Valve Grease fitting

PC138US, USLC-8

Repair limit

Installed length

Installed load

390

93.2 kN {9,500 kg}

Free length

Installed load

500

83.0 kN {8,460 kg}

Replace

Specifications Grease Grease quantity (cc)

G2-LI 135

5

SEN02547-01


Idler

1

Unit: mm No.

Item

Criteria Standard size

Repair limit

527

—

Outside diameter of tread

489

477

3

Tread depth

19

25

4

Width of projection

52

42

5

Overall width

115

107

6

Tread width

31.5

36.5

1

Outside diameter of projection

2

7

8

Clearance between idler shaft and bushing

Interference between bushing and idler

Standard size 54 Standard size 61

9 10

Side clearance of idler (each side) Tread thickness (at tread center)

— Oil capacity

6

Remedy

Tolerance


— Rebuilding or replace

Shaft

Hole

Standard clearance

Clearance limit

-0.250 -0.280

+0.074 0

0.250 – 0.354

1.5

Tolerance Shaft

Hole

Standard interference

+0.117 +0.087

+0.030 0

0.057 – 0.117

Standard clearance

InterferReplace ence limit —

Clearance limit

0.18 – 0.38

1.5

Basic dimension

Repair limit

15

9

90 cc (engine oil: SAE30CD)

Rebuilding or replace —

PC138US, USLC-8


SEN02547-01

Track roller

1

Unit: mm No.

Item


Remedy Repair limit

1

Outside diameter of projection

158

—

2


130

120

3

Flange width

26.5

—

4

Overall width

176

—

5

Tread width

35

—

6

7

Clearance between Shaft and bushing

Interference between roller and bushing


8 9

Side clearance of track roller (each side) Tread thickness (at tread center)

— Oil capacity

PC138US, USLC-8

Tolerance

Rebuilding or replace — Rebuilding or replace

Shaft

Hole

Standard clearance

Clearance limit

-0.220 -0.240

+0.190 +0.030

0.250 – 0.430

1.5

Tolerance Shaft

Hole

+0.190 +0.140

± 0.030

Standard clearance


InterferReplace ence limit

0.110 – 0.220

—

Clearance limit

0.41 – 0.90

1.5

Standard size

Repair limit

38

33

145 – 155 cc (engine oil: SAE30CD)


7

SEN02547-01


Carrier roller

1

Unit: mm No.

Item

1


2

Tread width

3

4

Clearance between shaft and bushing

Interference between collar and bushing

Criteria


5

Side clearance of carrier roller (each side)

6

Tread thickness (at 10 mm from roller outer edge)

— Oil capacity

8

Remedy

Standard size

Repair limit

116

106

123

—

Tolerance


Shaft

Hole

Standard clearance

Clearance limit

+0.055 +0.035

+0.261 +0.200

0.145 – 0.226

—

Tolerance Shaft

Hole


+0.061 +0.036

+0.025 0

0.011 – 0.061

Standard clearance

InterferReplace ence limit —

Clearance limit

0.363 – 0.537

1.5

Standard size

Repair limit

17.7

12.7

68 – 76 cc (engine oil: SAE30CD)


PC138US, USLC-8


SEN02547-01

Sprocket

1

Unit: mm No.

Item

1

Wear on tooth bottom diameter

2

Wear on tooth tip diameter

3

Criteria

Remedy

Standard size

Tolerance

Repair limit

542.8

+1.0 -2.0

530

607.5

—

595

Wear on tooth tip width

27

—

22

4

Wear on tooth bottom width

42

±1.5

39

5

Thickness at tooth bottom

109.4

+0.465 -1.160

103

PC138US, USLC-8


9

SEN02547-01


Track shoe

1

Triple grouser shoe, road liner, city pad shoe

*1. Triple grouser shoe, city pad shoe *2. Road liner a

10

P portion shows the link of bushing press fitting end.

PC138US, USLC-8


SEN02547-01

Unit: mm No.

Item

1

Link pitch

2

Bushing external diameter

3

Bushing thickness

4

Link height

5

Link thickness (bushing press fit part)

6 7


Repair limit

175.3

178.3

Standard size

Reverse

50.6

46.6

9

5

Standard size

Repair limit

90

85

23.9

18.9 102.4

Shoe bolt pitch Internal width

52.4

10 Link

Overall width

35

11

Tread width

12 Pin projection

30.1

Replace

3.75

14 Pin overall length

168

Bushing overall length (master bushing)

16 Spacer thickness 17 Press-fit force

Repair or replace

3

13 Regular bushing projection

19 (*)

Repair or replace

57

9

18

Reverse or replace

86.4

8

15

Remedy

86.7

Adjust or replace

— Bushing

58.8 – 176.5 kN {6 – 18 ton}

Regular pin

98.1 – 235.4 kN {10 – 24 ton}

Master pin

98.1 – 235.4 kN {10 – 24 ton}

—

*: In case of dry type track.

PC138US, USLC-8

11

SEN02547-01


Unit: mm No.

Item

Criteria Tightening torque (Nm {kgm})

20 Shoe bolt

• Triple grouser shoe a. Regu- • City pad shoe lar link • Single grouser shoe

Interference between bushing 21 and link

22

23

Interference between regular pin and link Clearance between regular pin and bushing

24 Interference between master (*) pin and link

25 Clearance between master pin (*) and bushing 26 Grouser height (road liner)

Retightening angle (degree)

196 ± 20 {20 ± 2}

90 ± 10 Retighten

176 ± 20 {18 ± 2}

• Road liner b. Master link

Remedy

Tightening torque (Nm {kgm})

Retightening angle (degree)

Torque lower limit (Nm {kgm})

—

—

— Standard size

60 ± 5

Tolerance


Shaft

Hole

50.2

+0.387 +0.347

+0.074 +0.074

0.273 – 0.387

32

+0.150 +0.050

-0.188 -0.250

0.238 – 0.400

Standard size 32 Standard size 32 Standard size 32 58

Tolerance Shaft

Hole

+0.150 +0.050

+0.830 +0.330

Tolerance Shaft

Hole

+0.060 +0.020

+0.188 -0.250

Standard clearance 0.180 – 0.780 Standard interference 0.208 – 0.310

Tolerance Shaft

Hole

-0.200 -0.300

+0.830 +0.330

Adjust or replace

Standard clearance 0.530 – 1.130 21

Replace

*: In case of dry type track.

12

PC138US, USLC-8


SEN02547-01

Triple grouser shoe

Unit: mm No.

Item

1

Grouser overall height

2

Shoe overall height

3

Plate thickness

4 5

Grouser bottom length

6 7

Criteria

Remedy

Standard size

Repair limit

20

10

29.5

19.5 9.5 20 20


14 Grouser tip length

8

PC138US, USLC-8

13 15

13

SEN02547-01


Single shoe

Unit: mm No.

Item


Repair limit

50

20.5

1

Grouser overall height

2

Shoe overall height

3

Plate thickness

12

4

Grouser bottom length

25

5

Grouser tip length

14

14

Remedy

62

32.5


PC138US, USLC-8


PC138US, USLC-8

SEN02547-01

15

SEN02547-01




16

PC138US, USLC-8

SEN02548-01


Machine model

Serial number




1

Hydraulic system, Part 1 Hydraulic equipment layout drawing ............................................................................................................... 2 Valve control ................................................................................................................................................... 4 Hydraulic tank and filter .................................................................................................................................. 6 Hydraulic pump ............................................................................................................................................... 8

PC138US, USLC-8

1

SEN02548-01

Hydraulic equipment layout drawing


1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Bucket cylinder Arm cylinder Control valve Solenoid valve Accumulator (for PPC circuit) Boom cylinder Hydraulic tank Swing motor Hydraulic pump R.H. travel motor Oil cooler L.H. travel motor L.H. work equipment PPC valve Blade PPC valve R.H. work equipment PPC valve Center swivel joint Travel PPC valve Attachment PPC valve (Machine ready for attachment) 19. Blade cylinder (blade specification)

2

PC138US, USLC-8


PC138US, USLC-8

SEN02548-01

3

SEN02548-01


Valve control

1. 2. 3. 4. 5. 6. 7. 8. 9.

4

Connecting valve Solenoid valve Accumulator (for PPC circuit) Control valve Blade PPC valve (blade specification) R.H. work equipment control lever (for boom and bucket control) Blade control lever (blade specification) L.H. work equipment control lever (for arm and swing control) L.H. work equipment PPC valve

1

10. 11. 12. 13. 14. 15.

Lock lever R.H. work equipment PPC valve Travel lever Travel pedal Travel PPC valve Attachment PPC valve (Machine ready for attachment) 16. Attachment control pedal (Machine ready for attachment) 17. Lock pin

PC138US, USLC-8


PC138US, USLC-8

SEN02548-01

5

SEN02548-01


Hydraulic tank and filter

1. 2. 3. 4. 5. 6. 7.

6

Hydraulic tank Suction strainer Filter element Bypass valve Drain plug Sight gauge Oil filler cap combined with breather

1

Specifications Hydraulic tank capacity (l)

99

Oil level in hydraulic tank (l)

69

Bypass valve set pressure (MPa{kg/cm²})

0.15 ± 0.03 {1.53 ± 0.3}

PC138US, USLC-8


SEN02548-01

Breather

1. 2. 3. 4. 5.

Filter element Bottom plate Gasket Seam valve Spring

Prevention of negative pressure in tank q The hydraulic tank is enclosed and pressurized. When the oil level in the hydraulic tank drops, negative pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) is opened to draw the atmosphere to the tank. (Intake valve set pressure: 0 – 0.49 kPa {0 – 0.005 kg/cm²}) Prevention of pressure rise in tank q When the hydraulic circuit is operating, the pressure in the hydraulic tank increases as the hydraulic cylinder operates and the oil level and temperature increase in the tank. If the pressure in the tank rises above the set value, bottom plate (2) is pushed up to release the pressure in the tank. (Exhaust valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm²})

PC138US, USLC-8

7

SEN02548-01

Hydraulic pump


1

Type: HPD56+56

8

PC138US, USLC-8


SEN02548-01

Outline q This pump consists of a variable-displacement swash plate type piston pump, PC valve, LS valve and EPC valve. Features of double pump system The common single pump system makes much loss in the pressure compensation valve. Accordingly, the machine travel speed is reduced much when the machine is steered. q The double pump system does not make much loss in the pressure compensation valve, since the right and left travel circuits are independent from each other. Accordingly, the machine travel speed is less reduced when the machine is steered. q The double pump has simpler structure than the tandem pump. q

BMP : Breather mounting port IM : PC mode selector current OCP : Oil level check port P1T : Travel deviation control orifice P2T : Travel deviation control orifice PA1 : Pump discharge port PA1C : Pump discharge pressure pickup port PA2 : Pump discharge port PA2C : Pump discharge pressure pickup port PB : Pump pressure input port PD1 : Case drain port PD2 : Drain plug PEN : Control pressure pickup port PEPB : EPC basic pressure pickup port PEPC: EPC basic pressure input port PLS : Load pressure input port PLSC : Load pressure pickup port PM : PC mode selector pressure pickup port PS : Pump suction port 1. 2. 3. 4. 5. 6. 7.

Main pump LS valve PC valve PC-EPC valve Shuttle valve No. 1 check valve No. 2 check valve

PC138US, USLC-8

9

SEN02548-01

1. 2. 3. 4. 5. 6.

10

Shaft Cradle Case Rocker cam Shoe Piston


7. 8. 9. 10. 11.

Cylinder block Valve plate End cap Servo piston PC valve

PC138US, USLC-8


Function q The pump converts the engine rotation and torque transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.

SEN02548-01

q

q

q

Structure Cylinder block (7) is supported to shaft (1) by spline (10). q Shaft (1) is supported by front and rear bearings (11). q Tip of piston (6) is shaped as a concave ball and shoe (5) is caulked to it to form one unit. q Piston (6) and shoe (5) constitute the spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement. q

PC138US, USLC-8

q q

Rocker cam (4) conducts high pressure oil to the cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside the respective cylinder chambers of cylinder block (7) is suctioned and discharged through valve plate (8).

11

SEN02548-01

Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the ax ial di rec tio n of cy li nder b loc k (7) changes. q (a) is named the swash plate angle.

q

q

q q

q

12


q

q

As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)

With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) suctions and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.

PC138US, USLC-8


SEN02548-01

Control of delivery q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b ec o me s l ar g er a nd pu m p d el i v e r y ( Q ) increases. q Servo piston (12) is used for changing swash plate angle (a). q Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. q This linear movement is transmitted to rocker cam (4) via slider (13). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. Main pump discharge pressure (check valve output pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).

PC138US, USLC-8

13

SEN02548-01


LS valve

PA PDP PLP PLS PP PPL

: Pump port : Drain port : LS control pressure output port : LS pressure input port : Pump port : Control pressure input port

1. 2. 3. 4. 5. 6.

Sleeve Piston Spool Spring Sheet Sleeve

7. Plug 8. Locknut

Function q The LS (load sensing) valve detects the load and controls the delivery. q This valve controls main pump delivery (Q) according to differential pressure ( PLS) [= (PP) — (PLS)], called the LS differential pressure (the difference between main pump pressure (PP) and control valve outlet port pressure (PLS)). q Main pump pressure (PP), pressure (PLS) (called the LS pressure) coming from the control valve output enters this valve.

14

PC138US, USLC-8


SEN02548-01

Operation

1. When the control valve is situated at neutral

q

q

q

q

q

The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the outlet port of the control valve brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery pressure (check valve output pressure) (PP) determine the position of spool (6). Before the engine is started, servo piston (12) is pushed to the left. (See the diagram on the right) If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool) Spool (6) is pushed to the left, and port (C) and port (D) will be connected.

PC138US, USLC-8

q q q

Pump pressure (PP) is conducted to the larger diameter end from the port (K). The same pump pressure (PP) is conducted to the smaller diameter end from the port (J). According to the difference in the areas on servo piston (12), the pressure moves in such that the swash plate angle may be minimized.

15

SEN02548-01


2. Action for the direction of maximizing the pump delivery

q

q

q

q

16

When the difference between the main pump pressure (PP) and LS pressure (PLS), in other words, LS differ ential press ure ( P LS) becomes smaller [for example, when the area of opening of the control valve becomes larger and pump pressure (PP) drops], spool (6) is pushed to the right by the combined force of LS pressure (PLS) and the force of spring (4). When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve. The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT). (The operation of the PC valve is explained later.) The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT), and pump pressure (PP) enters port (J) at the small diameter end, so servo piston (12) is pushed to the right side. Therefore, the swash plate is moved in the direction to make the delivery larger. PC138US, USLC-8


SEN02548-01

3. Action for the direction of minimizing the pump delivery

q

q

q

When LS differential pressure ( PLS) becomes larger [for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises] because of the leftward move (it reduces delivery) of servo piston (12), pump pressure (PP) pushes spool (6) to the left. When spool (6) moves, main pump pressure (PP) flows from port (C) to port (D) and from port (K), it enters the large diameter end of the piston. Main pump pressure (PP) also enters port (J) of the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end on servo piston (12), it is pushed to the left. As the result, the servo piston (12) moves into the direction of reducing the swash plate angle.

PC138US, USLC-8

17

SEN02548-01


4. When servo piston is balanced

q

q

q

q

18

Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) × (PP) = (A1) × (PEN), servo piston (12) will stop in that position. The swash plate of the pump will be held at the intermediate position. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] At this point, the relationship between the pressure receiving areas across servo piston (12) is (A0) : (A1) = 1 : 2, so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 2 : 1.

q

Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when (PP) — (PLS) = 2.2 MPa {22.5 kg/cm2} at the median of the specified value.

PC138US, USLC-8


SEN02548-01

PC valve

PA : Pump port PA2 : Pump pressure pilot port PDP : Drain port PM : Mode selector pressure pilot port PPL : PC control pressure output port PPL2: LC control pressure output port

Function q When the pump discharge pressure (PP1) (check valve output pressure) and (PP2) (shuttle valve output pressure) are high, the PC valve controls the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it may not exceed the engine hose power. q If the pump discharge pressure (PP1) increases due to increased load during operation, this valve decreases the pump delivery. q And if the pump delivery pressure goes low, it increases the pump delivery. q In this case, relation between the mean average discharge pressure of the pump [(PP1) + (PP2)]/2 and the pump delivery (Q) will becomes as shown in the diagram if the relation is represented as the parameter of the current value to be given to PC-EPC valve solenoid. q The controller continues counting the actual engine speed. q If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed. PC138US, USLC-8

1. 2. 3. 4. 5. 6. 7. 8.

Plug Servo piston assembly Pin Spool Retainer Sheet Cover Wiring

q

If the engine speed goes below the specified value because of increased load, the controller sends a command current to PC-EPC valve solenoid in order to reduce the slope angle in proportion to reduction in the engine speed.

19

SEN02548-01


Operation

1. When pump controller is normal 1)

When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low

Action of PC-EPC valve solenoid (1) q Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller. q This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston (2). q Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4) and (6) as well as the pump pressures (PP1) (check valve output pressure) and (PP2) (shuttle valve output pressure).

20

q

q

The pressure [port (C) pressure] output from PC valve is changed depending on the above position. The size of command current (X) is determined by the nature of the operation (lever operation), the selected working mode, and the set value and actual value of the engine speed.

PC138US, USLC-8


PC138US, USLC-8

SEN02548-01

21

SEN02548-01

Action of spring q Load of springs (4) and (6) on the PC valve is determined by the swash plate position. q As servo piston (9) moves to left, spring (6) is retracted. q If the servo piston moves further, it will be contacted again seat (5) and spring (6) will be fixed. q After that, spring (4) alone will operate. q The spring load is changed by servo piston (9) as it extends or compresses springs (4) and (6). q If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2).

22


q

q q

q

q

Spring load of springs (4) and (6) is also affected by the command current (X) to PCEPC valve solenoid. Port (C) of the PC valve is connected to port (E) of the LS valve. Check valve output pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and shuttle valve output pressure (PP2) enters port (A). When pump pressures (PP1) and (PP2) are small, spool (3) will be positioned in the right side. Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).

PC138US, USLC-8


q

q q

q

q

q

SEN02548-01

If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes drain pressure (PT), and servo piston (9) moves to the right side. The pump delivery will be set to the increasing trend. Accompanied with move of servo piston (9), springs (4) and (6) will be expanded and the spring force becomes weaker. As the spring force is weakened, spool (3) moves to the left, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are connected. As a result, the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the rightward move of servo piston (9) is stopped. Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the pressures (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve generates and the pushing force of springs (4) and (6) are balanced.

PC138US, USLC-8

23

SEN02548-01

2)

When load on actuator is large and pump discharge pressure is high

Outline q When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the left becomes larger and spool (3) will be moved to the position shown in above figure. q Part of the pressure to be conducted from port (C) to LS valve flows from port (A) to port (C) and (D) through LS valve. At the end this flow, level of this pressure becomes approximately half of the main pump pressure (PP).

24


Operation q When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of servo piston (9), stopping servo piston (9). q If main pump pressure (PP) increases further and spool (3) moves further to the left, main pump pressure (PP1) flows to port (C) and acts to make the pump delivery the minimum. q When servo piston (9) moves to the left, springs (4) and (6) are compressed and push back spool (3). q When spool (3) moves to the right, the opening of port (C) and port (D) becomes larger.

PC138US, USLC-8


q

q

q

q

q

q

SEN02548-01

As a result, the pressure on port (C) (= J) is decreased and the rightward move of servo piston (9) is stopped. The position in which servo piston (9) stops at this time is further to the left than the position when pump pressures (PP1) and (PP2) are low. The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their positions can be represented by the broken line in the figure because springs (4) and (6) form the double springs. The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q) becomes as shown below.

If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/ 2, and pump delivery (Q) is proportional to the force of the PC-EPC valve solenoid and moves in parallel. Namely, the force of PC-EPC valve solenoid (1) is added to the pushing force to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased.

PC138US, USLC-8

25

SEN02548-01


2. As the emergency pump drive switch is turned on due to failure on the pump controller 1)

When the main pump is under light load

q

If there is a failure in the pump controller, the emergency pump drive switch is turned on to hand the control to the resistor side. In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the resistor is set in between to control the current flowing to PC-EPC valve solenoid (1). The current becomes constant, so the force pushing piston (2) is also constant.

q

q

26

q

q

q

If the main pump pressures (PP1) and (PP2) are low, the combined force of the pump pressure and the PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the right. The port (C) is connected to the drain pressure of the port (D), and the large diameter end of the servo piston (9) also becomes the drain pressure (PT) through the LS valve. Since the pressure on the small diameter end of the piston is large, servo piston (9) moves in the direction to make the delivery larger.

PC138US, USLC-8


2)

When the main pump is under heavy load

q

If the emergency pump drive switch is turned on in the same way as in above, the command current (X) sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. If main pump pressures (PP1) and (PP2) increase, spool (3) moves further to the left than when the main pump load is light, and is balanced at the position in the figure above. In this case, the pressure from port (A) flows to port (C), so servo piston (9) moves to the left (smaller pump delivery) and stops at a position to the further to the left then when the load on the pump is light.

q q

q

PC138US, USLC-8

SEN02548-01

27

SEN02548-01

q

q

28


When the emergency pump drive switch is turned on, too, the pump pressure (PP) and pump delivery (Q) have a relationship as shown with the curve in the figure corresponding to the current sent to the PC-EPC valve solenoid through the resistor. The curve resulting when the emergency pump drive switch is ON is situated further to the left (B) than when the pump controller is normal (A).

PC138US, USLC-8


SEN02548-01

PC-EPC valve

C : To PC valve P : From self pressure reducing valve T : To tank 1. 2. 3. 4. 5. 6. 7.

Connector Coil Body Spring Spool Rod Plunger

PC138US, USLC-8

29

SEN02548-01

Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the PC valve.


Operation

1. When signal current is 0 (coil is deenergized) q

q q

q

30

When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. Spool (5) is pushed to the left by spring (4). Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the PC valve. The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).

PC138US, USLC-8


2. When signal current is very small (coil is energized) q

q q

q q q

q

When a very small signal current flows to coil (2), coil (2) is energized, and a propulsion force is generated on the right side of plunger (7). Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C). Pressure on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become larger than the propulsion force of plunger (7). Spool (5) is pushed to the left, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (5) moves up and down so that the propulsion force of plunger (7) may be balanced with pressure of port (C) + spring load of spring (4). The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the size of the signal current.

PC138US, USLC-8

SEN02548-01

3. When signal current is maximum (coil is energized) q q

q q

q

As the signal current flows to coil (2), coil (2) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (7) is also at its maximum. Spool (5) is pushed toward right side by rod (6). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and PC valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the tank.

31

SEN02548-01


Check valve

PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP1: Output pressure of check valve

1. 2.

Poppet valve Poppet valve

Function q A set of 2 check valves is used to select and output the higher discharge pressure of the 2 main pumps.

Operation

1. When (PA1) > (PA2) q

Discharge pressures (PA1) and (PA2) of the main pumps are applied to poppet valves (1) and (2). Since (PA1) > (PA2), however, poppet valve (2) is kept closed and (PA1) is output to (PP1).

2. When (PA1) < (PA2) q

32

Reversely to 1., poppet valve (1) is kept closed and (PA2) is output to (PP1).

PC138US, USLC-8


SEN02548-01

Shuttle valve

PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP2: Output pressure of shuttle valve 1. 2. 3.

Poppet valve Poppet valve Pin

Function q The shuttle valve selects and outputs the lower discharge pressure of the 2 main pumps.

PC138US, USLC-8

Operation q The discharge pressures (PA1) and (PA2) of the 2 main pumps are applied to poppet valves (1) and (2) respectively. q Since poppet valves (1) and (2) push each other through pin (3), either one of them receiving higher pressure is closed and the other one receiving lower pressure is opened. q Accordingly, lower discharge pressure of the 2 main pumps is output.

33

SEN02548-01




34

PC138US, USLC-8

SEN02549-02


Machine model

Serial number




1

Hydraulic system, Part 2 Control valve ................................................................................................................................................... 2 CLSS............................................................................................................................................................. 14 Functions and operation by valve ................................................................................................................. 18

PC138US, USLC-8

1

SEN02549-02


Control valve

1

Outline The control valves of the following types are set. q 6-spool valve (Without service valve) q 7-spool valve (6-spool valve + service valve) q 7-spool valve (Blade) q 8-spool valve (Blade + service valve) q 8-spool valve (6-spool valve + 2 service valves) q 9-spool valve (Blade + 2 service valves) The appearance and section of only the 8-spool valve (blade + service valve) are shown here. A1 : To swing motor A2 : To blade cylinder bottom A3 : To left travel motor A4 : To right travel motor A5 : To boom cylinder bottom A6 : To arm cylinder head A7 : To bucket cylinder head A8 : To attachment B1 : To swing motor B2 : To blade cylinder head B3 : To left travel motor B4 : To right travel motor B5 : To boom cylinder head B6 : To arm cylinder bottom B7 : To bucket cylinder bottom B8 : To attachment LS : To pump LS valve P1 : From main pump P2 : From main pump PP : To main pump PR : To solenoid valve, EPC valve PS : From solenoid valve of merge-divider valve TB : To tank TC : To oil cooler BP1: From boom raise PPC valve LS1: LS1 pressure pickup port LS2: LS2 pressure pickup port

LS3 : LS3 pressure pickup port PA1 : From swing left PPC valve PA2 : From blade lower PPC valve PA3 : From left travel forward PPC valve PA4 : From right travel forward PPC valve PA5 : From boom raise PPC valve PA6 : From arm dump PPC valve PA7 : From bucket dump PPC valve PA8 : From service PPC valve PB1 : From swing right PPC valve PB2 : From blade raise PPC valve PB3 : From left travel reverse PPC valve PB4 : From right travel reverse PPC valve PB5 : From boom lower PPC valve PB6 : From arm in PPC valve PB7 : From bucket curl PPC valve PB8 : From attachment PPC valve PMAX: Pressure sensor port PP1 : PP1 pressure pickup port PP2 : PP2 pressure pickup port PPI1 : Pump 1 pressure pickup port PPI2 : Pump 2 pressure pickup port PRI : PR pressure pickup port PST : From travel junction solenoid valve TS1 : To tank PS2 : To tank TSW : To swing motor

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15. 16.

2

Cover Service valve Bucket valve Arm valve Boom valve Right travel valve Left travel valve Blade valve

Swing valve Block Swing bleeding valve LS check valve Travel junction valve + LS check valve Arm regeneration valve Boom hydraulic drift prevention valve Merge-divider valve block

PC138US, USLC-8


PC138US, USLC-8

SEN02549-02

3

SEN02549-02

4


PC138US, USLC-8


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

SEN02549-02

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Suction safety valve (Service) Suction valve (Bucket) Suction valve (Arm) Suction valve (Boom) Lift check valve Suction valve (Right travel) Suction valve (Left travel) Suction valve (Blade) Suction safety valve (Blade) Suction valve (Left travel) Suction valve (Right travel) Main relief valve Suction valve (Boom) Suction valve (Arm)

Suction valve (Bucket) Suction safety valve (Service) Suction safety valve Spool (Service) Spool (Bucket) Spool (Arm) Spool (Boom) Spool (Right travel) Spool (Left travel) Spool (Blade) Spool (Swing) Unload valve Unload valve

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

Free length × Outside diameter

Installed length

Installed load

Free length

Installed load

46.8 × 7.5

40.6

5.49 N {0.56 kg}

—

4.41 N {0.45 kg}

29 Piston return spring

72.7 × 20.6

42.5

135 N {13.8 kg}

—

108 N {11.0 kg}

30 Suction valve spring

39.2 × 4.45

33.5

5.1 N {0.52 kg}

—

4.12 N {0.42 kg}

31 Spool return spring

41.8 × 19

38.5

141 N {14.4 kg}

—

113 N {11.5 kg}


41.44 × 19.3

38.5

137 N {13.96 kg}

—

110 N {11.2 kg}


27.14 × 25.8

25.5

55.9 N {5.7 kg}

—

44.7 N {4.56 kg}


32.4 × 11

31.4

60.2 N {6.137 kg}

—

48.2 N {4.91 kg}


76.78 × 20.9

70

423 N {43.1 kg}

—

338 N {34.5 kg}


45.7 × 28

43

221 N {22.55 kg}

—

177 N {18.04 kg}


42.4 × 28

39

222 N {22.6 kg}

—

178 N {18.1 kg}


45.6 × 28

43

230 N {23.5 kg}

—

184 N {18.8 kg}


45.81 × 28

43

203 N {20.7 kg}

—

163 N {16.6 kg}

28 Suction valve spring

PC138US, USLC-8

If damaged or deformed, replace spring

5

SEN02549-02

6


PC138US, USLC-8


1 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

LS selector valve Cooler bypass valve Pressure compensation valve R (Service) Pressure compensation valve R (Bucket) Pressure compensation valve R (Arm) Pressure compensation valve R (Boom) Pressure compensation valve R (Right travel) Pressure compensation valve R (Left travel) Pressure compensation valve R (Blade) Pressure compensation valve R (Swing) Pressure compensation valve F (Swing) Pressure compensation valve F (Blade) Pressure compensation valve F (Left travel) Pressure compensation valve F (Right travel) Merge-divider valve spool Pressure compensation valve F (Boom) Pressure compensation valve F (Arm) Pressure compensation valve F (Bucket) Pressure compensation valve F (Service)

F: R:

Flow control valve Pressure reducing valve

SEN02549-02

Unit: mm No.

Check item

Criteria

Remedy

Standard size 20 Check valve spring

21 Check valve spring

PC138US, USLC-8

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

41.5 x 8.5

31.5

5.88 N {0.6 kg}

—

4.71 N {0.48 kg}

20.3 x 13.7

16

2.94 N {0.3 kg}

—

2.35 N {0.24 kg}


7

SEN02549-02

8


PC138US, USLC-8


1.

SEN02549-02

LS selector valve

Swing valve 2. Pressure compensation valve F 3. Spool 4. Pressure compensation valve R 5. Swing bleed valve Blade valve 6. Suction safety valve 7. Suction valve 8. Spool 9. Pressure compensation valve R 10. Pressure compensation valve F L.H. travel valve 11. Pressure compensation valve F 12. Suction valve 13. Suction valve 14. Spool 15. Pressure compensation valve R 16. LS check valve F: R:

Flow control valve Pressure reducing valve Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Repair limit


Installed length

Installed load

Free length

Installed load

23.3 × 12.5

23

3.92 N {0.4 kg}

—

3.14 N {0.32 kg}


21.9 × 5

15.8

1.96 N {0.2 kg}

—

1.57 N {0.16 kg}

19 Retainer spring

9.1 × 4.2

7.4

0.98 N {0.1 kg}

—

0.78 N {0.08 kg}


PC138US, USLC-8


9

SEN02549-02

10


PC138US, USLC-8


SEN02549-02

R.H. Travel valve 1. Pressure compensation valve F 2. Suction valve 3. Suction valve 4. Spool 5. Pressure compensation valve R 6. Travel junction valve + LS check valve 7. 8. 9. 10. 11. 12.

Unload valve LS bypass valve Merge-divider valve spool Main relief valve Cooler bypass valve Lift check valve

Boom valve 13. Pressure compensation valve F 14. Suction valve 15. Hydraulic drift prevention valve 16. Suction valve 17. Spool 18. Pressure compensation valve R F: R:


No.

Check item

Criteria

Remedy

Standard size

Repair limit


Installed length

Installed load

Free length

Installed load

19.26 × 7.5

14

15.7 N {1.6 kg}

—

12.6 N {1.28 kg}


21.9 × 5

15.8

1.96 N {0.2 kg}

—

1.57 N {0.16 kg}

21 Valve return spring

58.9 × 13

53

83.4 N {8.5 kg}

—

66.7 N {6.8 kg}


49.8 × 18.8

33

98.1 N {10 kg}

—

78.5 N {8 kg}


16.4 × 8.9

11.5

13.7 N {1.4 kg}

—

11.0 N {1.12 kg}

24 Spool return valve spring

72.7 × 20.6

42.5

135 N {13.8 kg}

—

108 N {11 kg}


PC138US, USLC-8


11

SEN02549-02

12


PC138US, USLC-8


SEN02549-02

Arm valve 1. Pressure compensation valve F 2. Suction valve 3. Suction valve 4. Spool 5. Pressure compensation valve R 6. Regeneration valve Bucket valve 7. Pressure compensation valve F 8. Suction valve 9. Suction valve 10. Spool 11. Pressure compensation valve R Service valve 12. Pressure compensation valve F 13. Suction safety valve 14. Suction safety valve 15. Spool 16. Pressure compensation valve R 17. Suction safety valve 18. Pressure release plug F: R:


No.

Check item

Criteria

Remedy

Standard size 19 Valve spring

PC138US, USLC-8

Repair limit

Free length × Outside diameter

Installed length

Installed load

Free length

Installed load

41.5 × 8.5

31.5

5.88 N {0.6 kg}

—

4.71 N {0.48 kg}


13

SEN02549-02


CLSS

1

Outline of CLSS

1

Features CLSS stands for Closed center Load Sensing System, which has the following characteristics: q q q

q

14

Fine control not influenced by load Controllability enabling digging even with fine control Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations Energy saving using variable pump control

Configuration q CLSS is configured with variable capacity piston pumps, control valves, and respective actuators. q The hydraulic pump is configured with pump body, PC valve and LS valve.

PC138US, USLC-8


Basic principle

SEN02549-02

1

1. Pump swash plate angle control q

q

The pump swash plate angle (pump delivery) is controlled so that LS differential pressure ( P L S ) ( t h e d i ff e r e n c e b e t w e e n p u m p pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. [LS differential pressure ( PLS) = Pump discharge pressure (PP) — LS pressure (PLS)]

q

q

The pump swash plate angle shifts toward the maximum position if LS differential pressure ( PLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high). If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate angle shifts toward the minimum position.

LS differential pressure ( PLS) and pump swash plate angle

a

PC138US, USLC-8

For details of functions, see the "Hydraulic pump" paragraph.

15

SEN02549-02


2. Pressure compensation control

q

q

q

16

A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When actuators are operated together, the p r e s s u r e d i ff e r e n c e ( P ) b e t w e e n t h e upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve.

PC138US, USLC-8


PC138US, USLC-8

SEN02549-02

17

SEN02549-02


Functions and operation by valve

1

Hydraulic circuit diagram and the name of valves

1

18

PC138US, USLC-8


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

SEN02549-02

Swing valve Blade valve Left travel valve Right travel valve Boom valve Arm valve Bucket valve Service valve Swing spool Blade spool Left travel spool Right travel spool Boom spool Arm spool Bucket spool Service spool Pressure compensation valve Suction valve LS service valve Merge-divider valve Arm regeneration valve Self pressure reducing valve Travel junction valve Lift check valve Cooler bypass valve Boom hydraulic drift prevention valve Swing bleeding valve Suction safety valve Set pressure: 36.8 MPa {375 kg/cm²} Suction safety valve Set pressure: 24.5 MPa {250 kg/cm²} Suction safety valve Set pressure: 35.8 MPa {365 kg/cm²} Main relief valve Set pressure: 34.8 MPa {355 kg/cm²} Unload valve

PC138US, USLC-8

19

SEN02549-02


Unload valve 1. When control valve is at HOLD

Function q When the control valve is at HOLD, pump delivery (Q) discharged by the minimum swash plate angle is released to the tank circuit. At this time, pump discharge pressure (P1) and (P2) is set by spring (2) in the valve. [LS pressure (LS1) and (LS2) = 0 MPa {0 kg/cm²}] q Since the pump merge-divider valve is at the merge position, pump discharge pressures (P1) and (P2) are merged. LS pressures (LS1), (LS2), and (LS3) are also merged.

q

q

When the control valve is at HOLD, LS pressures (LS1) and (LS2) are not generated, so only pump discharge pressures (P1) and (P2) act, and (P1) and (P2) are set by only the load of spring (2). As pump discharge pressure (P1) and (P2) rises and reaches the load of spring (2), spool (1) is moved to the left. Pump discharge pressures (P1) and (P2) are connected to tank circuit (T) through the notch of spool (1).

Operation Pump discharge pressures (P1) and (P2) are applied to pump pressure receiving (SA) face of unload spool (1). q LS pressures (LS1) and (LS2) are applied to LS pressure receiving (SB) face. [(P1) = (P2), (LS1) = (LS2)] q

20

PC138US, USLC-8


SEN02549-02

2. When work equipment valve is operated

Function q When any work equipment valve is operated if the demand flow for the actuator becomes greater than the pump discharge from the minimum swash plate angle, the oil flow to tank circuit (T) is cut off, and all pump delivery (Q) flows to the actuator circuit. q Since the pump merge-divider valve is at the merge position, pump discharge pressures (P1) and (P2) are merged. LS pressures (LS1), (LS2), and (LS3) are also merged.

PC138US, USLC-8

Operation q When any work equipment valve is operated for a long stroke, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of unload spool (1) [(P1) = (P2), (LS1) = (LS2)]. q For this reason, the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). q As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump delivery (Q) flows to the actuator circuit.

21

SEN02549-02


3. During fine control of both travel valves

Function q When the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) reaches the load of spring (2), unload spool (1) opens, so excessive oil (maximum pump delivery - demand flow) flows into the tank circuit. q Since the pump merge-divider valve is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve.)

22

Operation q When fine control is carried out on both travel valves, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of spool (1) [(P1), (P2), (LS1), and (LS2) are separated]. q When the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) reaches the load of spring (2), spool (1) moves to the left, and pump discharge pressures (P1) and (P2) are connected to tank circuit (T) and the excessive oil (maximum pump delivery - demand flow) flows. q In other words, the excessive oil (maximum pump delivery - demand flow) above the strokes of both travel valves flows into tank circuit (T).

PC138US, USLC-8


SEN02549-02

4. When both travel valves are operated

Function q During operation of both travel valves, when the demand flow becomes maximum, the oil flow to tank circuit (T) is cut off, and all pump delivery (Q) flows to both travel circuits. q Since the pump merge-divider spool is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve .)

PC138US, USLC-8

Operation q When both travel valves are operated to the stroke ends, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of unload spool (1) [(P1), (P2), (LS1), and (LS2) are separated]. q The area of the openings of both travel valve spools is large, so LS pressures (LS1) and (LS2) are not so different from pump discharge pressures (P1) and (P2). q For this reason, the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). q As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump delivery (Q) flows to the actuator circuit.

23

SEN02549-02


5. When either travel valve is operated

Function q The demand flow decided by the valve stroke is sent to the travel circuit on the operated travel valve side and the all pump delivery is sent to the tank circuit on the non-operated travel valve side. q Since the pump merge-divider valve is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve.)

q

q

q

q

q

Operation When left travel valve is operated to stroke end and right one is at HOLD. q When the left travel valve is operated to the stroke end, LS pressure (LS1) is generated and acts on the face (SB) of unload spool (1).

24

The area of the openings of left travel valve spool is large, so LS pressures (LS1) is not so different from pump discharge pressures (P1). For this reason, the difference between pump discharge pressure (P1) and LS pressure (LS1) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). As a result, pump discharge pressures (P1) and tank circuit (T) are shut off, and all pump delivery (QP1) on the (P1) side flows to the left travel circuit. Since the right travel valve is at HOLD, LS pressure (LS2) is not generated, so only pump discharge pressure (P2) acts. When pump discharge pressure (P2) reaches the load of spring (2), spool (1) moves to the left, and all pump delivery (QP2) on the (P2) side flows into tank circuit (T).

PC138US, USLC-8


PC138US, USLC-8

SEN02549-02

25

SEN02549-02


Merge-divider valve 1. When oil is merged: (PS) = 0 kg/cm2

Function q Pump discharge pressures (P1) and (P2) are merged in pump merge-divider spool (3). (LS1), (LS2), and (LS3) are also merged. q At this time, (P1) = (P2) and (LS1) = (LS2) = (LS3) and the pump swash plate is controlled by the difference between (P) and (LS).

26

PC138US, USLC-8


SEN02549-02

2. When oil is divided: (PS) = 30 kg/cm2

Function q Pump discharge pressures (P1) and (P2) are divided in pump merge-divider spool (3). (LS1), (LS2), and (LS3) are also divided. q At this time, higher one of (P1) and (P2) is applied through pump merge-divider spool (3) to the output port of the LS pressure. q As a result, there is not difference between (P) and (LS) and the pump swash plate is set to the maximum position.

PC138US, USLC-8

27

SEN02549-02


Introduction of LS pressure 1. Work equipment valve

Function q The LS pressure is the actuator load pressure at the outlet port end of the control valve. q Actually, pump discharge pressure (PP) is reduced by reducing valve (3) of the pressure compensation valve to the same pressure as actuator circuit pressure (A) and sent to LS circuit (PLS). q In the travel valve, actuator circuit pressure (A) is directly introduced to LS circuit (PLS). Operation When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit (A). q At the same time, reducing valve (3) also moves to the right, so pump discharge pressure (PP) is reduced by the pressure loss at notch (c). It goes to LS circuit (PLS), and then goes to spring chamber (PLSS). q

28

q

q

q

When this happens, LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4) (See the section on the LS bypass valve). The areas at both ends of reducing valve (3) are the same [(SA) = (SLS)], and actuator circuit pressure (PA) acts on the (SA) end. The reduced pump discharge pressure (PP) acts on (SLS) at the other end. As a result, reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of spring chamber (PLSS) are the same. Pump discharge pressure (PP) reduced at notch (c) becomes actuator pressure (A) and is introduced into LS circuit (PLS).

PC138US, USLC-8


SEN02549-02

2. Travel valve

Operation q When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit (A). q Actuator circuit pressure (PA) (= A) is introduced through the check valve (5) into LS circuit (PLS). a

The travel circuit is different from the work equipment circuit: actuator circuit pressure (PA) is directly introduced into LS circuit (PLS).

PC138US, USLC-8

29

SEN02549-02


LS bypass valve 1. When work equipment valve is operated (including compound operation of work equipment + travel)

Function q The LS bypass valve releases the remaining pressure of LS pressure (PLS). q This lowers the rising speed of LS pressure (PLS). In addition, the discarded throttled flow causes a pressure loss in the throttled flow in the reducing valve, and that lowers the effective LS differential pressure to improve the stability.

30

Operation q Since pump merge-divider spool (1) is at the merge position, the hydraulic oil in LS circuits (PLS1), (PLS2), and (PLS3) flows from tip filter (a) of LS bypass valve (2) through orifice (b) to tank circuit (T).

PC138US, USLC-8


SEN02549-02

2. When either or both travel valves are operated (Including operation of only one travel valve)

Operation q Since pump merge-divider spool (1) is at the separate position, LS circuits (PLS1) and (PLS2) are separated. q The hydraulic oil (PLS1) flows from tip filter (a) of LS bypass valve (2) through orifice (b) to tank circuit (T).

PC138US, USLC-8

q

The hydraulic oil (PLS2) flows from tip filter (c) of LS bypass valve (3) through orifice (d) to tank circuit (T).

31

SEN02549-02


Pressure compensation valve

32

PC138US, USLC-8


SEN02549-02

Function q When the load pressure becomes lower than another actuator and the flow is going to increase during a compound operation, this valve compensates the load pressure. [At the time, the load pressure of another actuator under compound operation (the upper side) is higher than that of the actuator on this side (the lower side)]. Operation When the load pressure (Ab) of another actuator side (the upper side) rises during a compound operation, the flow in the actuator circuit (Aa) on this side (the lower side) is apt to increase. q In this case, the LS pressure (PLS) of another actuator is applied to the spring chamber (PLS1) and pushes the pressure reducing valve (1) and the flow control valve (2) to the left side. q The flow control valve (2) throttles the opening area between the pump circuit (PP) and the spool upstream (PPA) and causes a pressure loss between (PP) and (PPA). q 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 reducing valve (1) and (PLS) becomes the same as the pressure loss between (PP) before and after the flow control valve (2) and (PPA). q So, the pressure differences between the upstream pressures (PPA) and the downstream pressures (PA) of the both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch (a). q

PC138US, USLC-8

33

SEN02549-02


Area ratio of pressure compensation valve

Function q The pressure compensation valve slightly adjusts the ratio (S2) and (S1) of the area (S1) on the left side of the flow control valve (2) and the area (S2) on the right side of the pressure reducing valve (1) to suite the characteristics of each actuator and determines the compensation characteristics. S1 : Area of the flow control valve (2) – area of the piston (3) S2 : Area of the pressure reducing valve (1) – area of the piston (3)

34

Area ratio (S1) : (S2) and compensation characteristics q When the ratio is 1.00 : The expression [Pump (discharge) pressure (PP) – Spool notch upstream pressure (PPB)] C [LS circuit pressure (PLS) – Actuator circuit pressure (PA) (= A)] can be held, and the flow is distributed as per the spool opening area ratio. q When the ratio is more than 1.00: The expression (PP) – (PPB) > (PLS) – (PA) (= A) can be held, and the flow is distributed less than the spool opening area ratio. q When the ratio is less than 1.00: The expression (PP) – (PPB) < (PLS) – (PA) (= A) can be held, and the flow is distributed more than the spool opening area ratio.

PC138US, USLC-8


SEN02549-02

Boom regeneration circuit 1. At boom lower and own weight fall

Function q When the boom is lowered and falls due to its own weight because the bottom pressure (A) in the cylinder (1) is higher than the head pressure (B), this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed.

q

q

At the time, part of the return flow on the bottom side passes through the regeneration passage (a) of the boom spool (2), pushes the check valve (3) to open it and flows to the head side. This increases the boom lower speed.

Operation When the boom is lowered and falls due to its own weight, the bottom side pressure (A) in the boom cylinder (1) will rise above the head side pressure (B).

q

PC138US, USLC-8

35

SEN02549-02


2. At boom lower load process

Function q When the head pressure (B) of the cylinder (1) is higher than the bottom pressure (A) while the boom is lowered and the boom is in the load process, the check valve (3) will be closed, and the circuits on the head side and the bottom side will be interrupted.

q

At the time, the head side pressure (B) and the spring (4) close the check valve (3), and the circuits on the head side and the bottom side are interrupted.

Operation q When the boom is lowered and is in the load process, the head side pressure (B) of the boom cylinder (1) rises above the bottom side pressure (A).

36

PC138US, USLC-8


SEN02549-02

Arm regeneration circuit 1. At arm in and own weight fall

A : Head circuit B : Bottom circuit PP : Pump circuit

1. 2. 3.

Arm cylinder Arm spool Check valve

Function q When the arm falls due to its own weight because the head pressure (A) in the arm cylinder (1) is higher than the bottom pressure (B) during arm digging, this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed.

q

At the time, part of the return flow on the head side passes through the regeneration passage (a) of the arm spool (2), pushes the check valve (3) to open it and flows to the bottom side. This increases the arm digging speed.

q

Operation When the arm falls for digging due to its own weight, the head side pressure (A) in the arm cylinder (1) will rise above the bottom side pressure (B).

q

PC138US, USLC-8

37

SEN02549-02


2. At arm in process

A : Head circuit B : Bottom circuit PP : Pump circuit

1. 2. 3.

Arm cylinder Arm spool Check valve

Function q When the bottom pressure (B) of the cylinder (1) rises above the head pressure (A) and the arm enters the digging process, the check valve (3) will be closed and the circuits on the head side and the bottom side will be interrupted. Operation When the arm is in the digging process, the bottom side pressure (B) of the arm cylinder (1) will rise, close the check valve (3) and interrupt the circuits on the head side and the bottom side.

q

38

PC138US, USLC-8


SEN02549-02

Hydraulic drift prevention valve 1. When boom is raised

Function q While the boom lever is not operated, the hydraulic drift prevention valve prevents pressurized oil from leaking from the boom bottom through spool (1) to prevent the boom from drifting hydraulically.

PC138US, USLC-8

Operation q If the boom is raised out, the main pressure from the control valve pushes up poppet (5). As a result, the main pressure from the control valve flows through the valve into the boom cylinder bottom.

39

SEN02549-02


2. When boom and arm are set in neutral

Operation q If the control lever is returned to the neutral position while the boom is raised out, the holding pressure in the boom cylinder bottom and arm cylinder head is blocked by poppet (5) and the pressurized oil flowing in through orifice (a) is blocked by pilot spool (3). Accordingly, the boom is held.

40

PC138US, USLC-8


SEN02549-02

3. When boom is lowered

Operation q If the boom is lowered, pilot pressure (P1) from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber (b) in the poppet is drained. q The pressurized oil in port (Ab) is raised by the pressurized oil from the boom cylinder bottom, but the pressurized oil in chamber (b) is lowered by orifice (a). q If the pressure in chamber (b) is lowered below the pressure in port (Aa), poppet (5) opens and the pressurized oil from port (Ab) flows through port (Aa) into the control valve.

PC138US, USLC-8

41

SEN02549-02


Swing bleeding valve

Function q When the machine swings, the bleeding valve installed to the pressure reducing valve works so that the LS pressure rises gradually and the machine swings smoothly.

q

q

Accordingly, the intermediate pressure is set lower than pump discharge pressure (PP) and raised as bleeding spool (3) moves. As a result, LS pressure (PLS) rises gradually. When the lever is in neutral or operated fully, the bleed-off circuit is closed.

Operation (In fine control operation) q The pressure reducing valve moves to the right and notch (a) connects to the LS circuit. As a result, pump circuit (PP), bleed-off circuit, and LS circuit are connected through piston (2). q Bleeding spool (3) moves to the left in proportion as swing PPC pressure (PA) rises. In the fine control area, notch (b) chokes the bleedoff circuit and determines the intermediate pressure before the lowered pressure is applied to pump discharge pressure (PP) and LS pressure (PLS).

42

PC138US, USLC-8


SEN02549-02

LS select valve 1. During normal operation

Function q At the time of simultaneous operation of swing + boom RAISE, this valve prevents high swing LS pressure from entering the LS circuit (PLS) and also prevents the boom RAISE speed from reducing by securing the pump flow at the time of swing drive. Operation The pilot pressure is not generally applied to the pilot port (BP) except for boom RAISE operation. q In this state, the pump discharge pressure (PP) pushes the valve (1) to open it and is led to the pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure (PLS) suitable for the load pressure, and the pressure is led to the pump LS valve. q

PC138US, USLC-8

43

SEN02549-02


2. At simultaneous operation of swing + boom RAISE

Operation q At the simultaneous operation of swing + boom RAISE, the signal pressure of the PPC circuit is led to the pilot port (BP). q When this pilot pressure (BP) is applied to the piston (2) and reaches a pressure that is stronger than the spring (3), the piston (2) will be pushed to the left side, the valve (1) will close and the pump discharge pressure (PP) will not come to flow to the pressure reducing valve (4) of the swing valve. q Then, the swing pressure does not cause LS pressure (PLS), but the LS pressure (PLS) caused by the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. q The pilot pressure (BP) depends on the control lever stroke.

44

PC138US, USLC-8


SEN02549-02

Travel junction valve

Function q This valve connects both travel circuits to each other so that hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. q When the machine is steered, outside pilot pressure (PST) closes the travel junction valve to secure high steering performance.

PC138US, USLC-8

Operation When pilot pressure is turned ON q If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (2), travel junction spool (1) moves to the left stroke end and the junction circuit between port (PTL) (Left travel circuit) and (PTR) (Right travel circuit) is closed.

45

SEN02549-02


Self pressure reducing valve

Function q The self pressure reducing valve lowers the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valves, PPC valves, etc. Operation If the (PR) pressure rises higher than the set level, poppet (1) opens and the hydraulic oil flows from port (PR) through orifice (a) in spool (4) and opening of poppet (1) into seal drain port (TS). q Accordingly, differential pressure is generated over orifice (a) in spool (4) and spool (4) moves in the direction to close the opening between ports (P) and (PR). The (P) pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio at this time and supplied as the (PR) pressure. q

46

When abnormally high pressure is generated q If the (PR) pressure of the self pressure reducing valve is raised abnormally, ball (6) separates from the seat against the force of spring (5). As a result, the hydraulic oil flows from output port (PR) to (TS) and the (PR) pressure lowers. q Accordingly, the devices receiving the oil pressure (PPC valves, solenoid valves, etc.) are protected from abnormally high pressure.

PC138US, USLC-8


SEN02549-02

Lift check valve and cooler bypass valve

Lift check valve Function q The lift check valve generates back pressure in the drain circuit to prevent negative pressure on each actuator (motor, cylinder, etc.) Operation q Drain circuit pressure (PA) of the control valve acts on the left side of piston (2) to move the piston to the right. q The piston is so balanced that the back pressure will be as follows. q (PA) – (PB) = Force of spring (3) / Area of piston (2) at diameter (d1) [(PB) C 0 kg/cm²]

PC138US, USLC-8

Cooler bypass valve Function The cooler bypass valve protects oil cooler (4) from breakage when the return flow rate from the control valve increases and oil cooler inlet pressure (PB) increases. q The cooler bypass valve returns the return oil to the tank directly without passing it through oil cooler (4). q

Operation q Oil cooler inlet pressure (PB) acts on the underside of piston (1) to push up the piston. q Piston (1) is so balanced that oil cooler inlet pressure (PB) will be as follows. q (PB) – (PT) = Force of spring (5) / Area of piston (1) at diameter (d2) [(PT) C 0 kg/cm²]

47

SEN02549-02




48

PC138US, USLC-8

SEN02550-01


Machine model

Serial number




1

Hydraulic system, Part 3 PPC valve ....................................................................................................................................................... 2 Swing motor .................................................................................................................................................. 19 Travel motor .................................................................................................................................................. 27 Center swivel joint......................................................................................................................................... 36 Solenoid valve............................................................................................................................................... 40 PPC accumulator .......................................................................................................................................... 44 Holding valve ................................................................................................................................................ 46 Multi-control valve ......................................................................................................................................... 51

PC138US, USLC-8

1

SEN02550-01


PPC valve

1

Work equipment and swing PPC valve 1

P P1 P2 P3 P4 T

2

: From self pressure reducing valve : L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port : L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port : L.H. PPC valve: Swing LEFT port/R.H PPC valve: Bucket CURL port : L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port : To tank

PC138US, USLC-8


PC138US, USLC-8

SEN02550-01

3

SEN02550-01

1. 2. 3. 4. 5. 6. 7. 8. 9.


Spool Piston Disc Nut (for lever connection) Joint Plate Retainer Body Filter

Unit: mm No.

Check item


Centering spring 10 (for ports P3 and P4)

11

Centering spring (for ports P1 and P2)

12 Metering spring

4

Remedy Repair limit

Free length Installation Installation Installation Free length × Outside length load load diameter 42.48 × 15.5

34

17.7 N {1.8 kg}

—

14.1 N {1.44 kg}

44.45 × 15.5

34

29.4 N {3 kg}

—

23.5 N {2.40 kg}

26.9 × 8

24.9

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

If damaged or deformed, replace spring.

PC138US, USLC-8


Operation

SEN02550-01

q

1. When in neutral q

Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).

q q q

The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.

2. During fine control (Neutral o fine control) q

q

q

q

q

When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).

PC138US, USLC-8

5

SEN02550-01

3. During fine control (When control lever is returned) q

q

q

q

q

q

6

When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.


4. At full stroke q q

q

q

Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).

PC138US, USLC-8


SEN02550-01

Travel PPC valve

P P1 P2 P3 P4 T

: From self pressure reducing valve : L.H. reverse : L.H. forward : R.H. reverse : R.H. forward : To tank

PC138US, USLC-8

7

SEN02550-01

8


PC138US, USLC-8


1. 2. 3. 4. 5. 6.

SEN02550-01

Plate Body Piston Seal Valve Damper Unit: mm

No.

Check item


7

Centering spring

8

Metering spring

PC138US, USLC-8

Remedy Repair limit

Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 48.57 × 108 N 86.3 N replace spring. 32.5 — 15.5 {11 kg} {8.8 kg} 26.53 × 8.15

24.9

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

9

SEN02550-01

Operation


q

1. When in neutral q

Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).

q q q

The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.

2. During fine control (Neutral o fine control) q

q

q

q

q

10

When piston (4) is pushed by lever (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1).

PC138US, USLC-8


3. During fine control (When control lever is returned) q

q

q

q

q

q

When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.

PC138US, USLC-8

SEN02550-01

4. At full stroke q q

q

q

Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).

11

SEN02550-01

Blade PPC valve

a

12


1

For the details of operation, see the paragraph of "Work equipment and swing PPC valve".

PC138US, USLC-8


P P1 P2 T

: From self pressure reducing valve : To blade valve : To blade valve : To tank

1. 2. 3. 4. 5. 6. 7.

Spool Piston Lever Plate Retainer Body Filter

SEN02550-01

Unit: mm No.

Check item


8

Centering spring

9

Metering spring

PC138US, USLC-8

Remedy Repair limit

Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 42.36 × 147 N 118 N replace spring. 32.5 — 15.5 {15 kg} {12.0 kg} 22.73 × 8.1

22

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

13

SEN02550-01

Attachment PPC valve (with EPC valve)

a

14


1

For the details of operation, see the paragraph of "Work equipment and swing PPC valve".

PC138US, USLC-8


P P1 P2 T

: From self pressure reducing valve : To service valve : To service valve : To tank

1. 2. 3. 4. 5. 6. 7. 8.

Spool Piston Lever Plate Retainer Block Body EPC valve

SEN02550-01

Unit: mm No.

Check item


9

Centering spring

10 Metering spring

PC138US, USLC-8

Remedy Repair limit

Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 125 N 100 N replace spring. 33.9 × 15.3 28.4 — {12.7 kg} {10.2 kg} 22.7 × 8.10

22 .0

16.7 N {1.70 kg}

—

13.3 N {1.36 kg}

15

SEN02550-01


1. EPC valve

C: P: T:

To control valve From self pressure reducing valve To hydraulic tank

1. 2.

Body Plug

3. 4. 5. 6. 7.

Spool Push pin Coil Plunger Connector

Unit: mm No.

Check item


8

Return spring

Free length 9.0

16

Remedy Repair limit

If damaged or Installation Installation Installation Free length deformed, length load load replace EPC 3.1 N valve assembly. 8.4 — — {0.32 kg}

PC138US, USLC-8


Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the control valve.

SEN02550-01

Operation

1) When signal current is 0 (coil is de-energized) q

q q q

PC138US, USLC-8

When there is no signal current flowing from the controller to coil (14), coil (14) is de-energized. Spool (11) is pushed to the right by spring (12). Port (P) closes and the pressurized oil from the front pump does not flow to the control valve. The pressurized oil from the control valve is drained to the tank via port (C) and port (T).

17

SEN02550-01

2) When signal current is very small (coil is energized) q

q q

q

q

q

18

When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated on the left side of plunger (6). Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port (P) to port (C). Pressures on port (C) increases and the force to act on surface (a) of spool (2) and the spring load on spring (3) become larger than the propulsion force of plunger (6). Spool (2) is pushed to the right, port (P) is shut off from port (C) and ports (C) and (T) are connected. Spool (2) moves up and down so that the propulsion force of plunger (6) may be balanced with pressure of port (C) + spring load of spring (3). The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current.


3) When signal current is maximum (coil is energized) q q

q q

q

As the signal current flows to coil (5), coil (5) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. Spool (2) is pushed to the left by push pin (4). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and the control valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the hydraulic tank.

PC138US, USLC-8


SEN02550-01

Swing motor

1

Type: KMF45ABE-5

B: From swing holding brake solenoid valve MA: From control valve MB: From control valve S: From control valve T: To tank 1. 2.

Reverse prevention valve Safety valve

PC138US, USLC-8

Specifications Type Theoretical displacement Safety valve set pressure Rated speed Brake release pressure

: KMF45ABE-5 : 143.8 cm³/rev : 27.1 MPa {276 kg/cm²} : 2,111 rpm : 1.1 MPa {11 kg/cm²}

19

SEN02550-01

20


PC138US, USLC-8


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

SEN02550-01

Brake spring Drive shaft Spacer Case Disc Plate Brake ring Brake piston Housing Piston Cylinder block Valve plate Center shaft Center spring Check valve Shuttle valve Unit: mm

No.

Check item



18 Shuttle valve spring

PC138US, USLC-8

Remedy Repair limit

Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 6.96 N 5.59 N replace spring. 66.5 × 25.6 45.0 — {0.71 kg} {0.57 kg} 24.5 × 11.6

14.5

7.45 N {0.76 kg}

—

5.98 N {0.61 kg}

21

SEN02550-01


Swing holding brake 1.

When solenoid valve is de-energized

Operation q As the swing holding brake solenoid valve is de-energized, the pressurized oil from the self pressure reducing valve is shut off. q Port (B) is connected to tank circuit (T). q Brake piston (8) is pushed down by brake spring (1). q Disc (5) and plate (6) are pushed together, and the brake is applied.

22

2.

When solenoid valve is energized

Operation q As the swing holding brake solenoid valve is energized, the valve is switched. q The pressurized oil from the self pressure reducing valve is conducted brake chamber (a) via port (B). q After entering chamber (a), the pressurized oil compresses brake spring (1) and pushes brake piston (8) up. q Disc (5) is separated from plate (6), releasing the brake.

PC138US, USLC-8


SEN02550-01

Relief valve portion Outline q The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function q When the machine is in the swing holding mode, control valve (6) closes the motor outlet circuit, but the motor rotation is continued by inertial force. q The motor output, therefore, is abnormally increased, resulting in damaging the motor. q In order to prevent the motor damages, the relief valve relieves the abnormally high pressure to port (S) from the motor outlet side (high-pressure side) of the motor. Operation 1. When starting swing q When the swing control lever is operated to the right- swing, the pressurized oil from the pump is supplied to port (MA) via control valve (6). q The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. q The pressurized oil from the outlet port of the motor passes from port (MB) through the control valve (6) and returns to the tank.

PC138US, USLC-8

2. q

q

q q q

q q

q

When swing is stopped When the swing control lever is returned to neutral, the supply of pressurized oil from the pump to port (MA) is stopped. The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (6). Thus, pressure on port (MB) increases. Rotation resistance is generated on the motor and hence the brake starts working. Shuttle valve (4) is pressed as pressure on port (MB) goes above port (MA). The pressure on chamber (C) is increased to the se t pr es sur e of r el ief va lv e ( 1) an d becomes the same as that of port (MB). A high braking torque works on the motor, thereby stopping the motor. When relief valve (1) is being actuated, the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) via check valve (3). Above prevents cavitation on port (MA).

23

SEN02550-01


Reverse prevention valve

24

PC138US, USLC-8


MA: MB: T1: T2:

1. 2. 3. 4. 5. 6. 7.

SEN02550-01

From control valve From control valve To tank To tank

Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)

Explanatory drawing of effects

PC138US, USLC-8

25

SEN02550-01


Function q This valve reduces the swing back generation in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. q The valve contributes in preventing collapsing of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, enabling you to proceed to the next work quicker than ever).

2.

Operation

q

1. q q

q q

26

When port (MB) brake pressure is generated Pressure (MB) is conducted to chamber (d) via notch (g). The pressure compresses spring (6) by use of the difference in areas of circles (øD1 > øD2) of spool (5) and moves spool (5) to the left side. Port (MB) o chamber (e) will be interconnected. Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is kept in. Thus the braking force is ensured.

q

q q

q

When motor is stopped temporarily The motor rotation is reversed by the closing pressure generated at port (MB). (1st time: reverse rotation) Reversing pressure is generated on port (MA). Pressure (MA) is conducted to chamber (a). The pressure compresses spring (3) by use of the difference in areas of circles (øD3 > øD4) of spool (2) and moves spool (2) to the right side. Port (MA) o chamber (b) will be interconnected. Ports (b) and (f) will be interconnected through the drilled hole (h) on spool (5). This interconnection bypasses the reversing pressure on port (MA) to port (T), thereby preventing the reverse rotation of the 2nd time.

PC138US, USLC-8


Travel motor

A:

D: P:

From center swivel joint, port B2 (L.H. travel motor) From center swivel joint, port C2 (R.H. travel motor) From center swivel joint, port D2 (L.H. travel motor) From center swivel joint, port A2 (R.H. travel motor) To center swivel joint, port DR2 From center swivel joint, port E2

1. 2. 3.

Oil filler plug Oil level plug Drain plug

B:

PC138US, USLC-8

SEN02550-01

1

27

SEN02550-01

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

28

Plug Check valve Counterbalance valve Sleeve Relief valve End cover Brake piston Disc Plate Swash plate Pivot Bearing Hub Planetary pinion B Planetary pinion A


16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Cover Sun gear A Carrier A Sun gear B Carrier B Regulator piston Shaft Piston Floating seal Spindle Cylinder Timing plate Regulator valve Check valve Piston

PC138US, USLC-8


SEN02550-01

Specifications Type

GM21VA-A

Stroke volume (cm³/rev)

Hi

44.2

Lo

79.1

Rated speed (rpm)

Hi

2,609

Lo

1,486

Brake releasing pressure (MPa{kg/cm²})

0.76 {7.71}

Hi-Lo switching pressure (MPa{kg/cm²})

2.94 {30}

Reduction ratio

54.0

Outline

1.

Final drive Consists of 2-stage planetary gear mechanism. Reduces the hydraulic motor speed from high speed to low speed high torque.

2.

Hydraulic motor Swash plate type axial piston motor mechanism. Converts oil pressure from the hydraulic pump into rotary motion.

3.

4.

2nd travel speed selector mechanism Consists of the regulator valve and regulator piston. Changes the rotation speed in 2 stages by changing the stroke volume of the hydraulic motor.

5.

Parking brake Multiple disc type brake mechanism. Forms a unit with the hydraulic motor.

Brake valve Consists of various valves. Provides the following functions: stops the hydraulic motor smoothly, prevents runway of hydraulic motor, prevents generation of abnormally high pressure when the hydraulic motor is stopped suddenly.

PC138US, USLC-8

29

SEN02550-01


Operation Operation of motor At low speed (the motor swash plate angle is maximized.)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

2nd travel speed select solenoid valve Regulator valve Spring Check valve Regulator piston Swash plate Parking brake piston Hydraulic pump Travel control valve Pump merge-divider valve Self pressure reducing valve Brake valve

q

q q

q

q

30

Since 2nd travel speed select solenoid valve (1) is de-energized, the pressurized oil from self pressure reduction valve (11) is not fed to port (P). Regulator valve (2) is pushed down with spring (3) reaction force. The main pressurized oil, sent from the control valve through check valve (4), is controlled by regulator valve (2) and used to shuts off the circuit to regular piston (5). The pressurized oil in control chamber (C) is drained from port (D) through oil passage (e) of regulator valve (2). Swash plate (7) reaches its maximum tilt angle, and the machine travels at low speed with the maximum motor capacity.

PC138US, USLC-8


SEN02550-01

At high speed (the motor swash plate angle is minimized.)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

2nd travel speed select solenoid valve Regulator valve Spring Check valve Regulator piston Swash plate Parking brake piston Hydraulic pump Travel control valve Pump merge-divider valve Self pressure reducing valve Brake valve

PC138US, USLC-8

q

q q

q

When 2nd travel speed select solenoid valve (1) is energized, the pressurized oil from self pressure reduction valve (11) is fed to port (P). Regulator valve (2) is pushed up with the pressurized oil that is sent to port (P). The main pressurized oil from the control valve passes through check valve (4), and passes through oil passage (F) in regulator valve (2) to control chamber (C), and is used to push to regular piston (5) to the left. Swash plate (7) reaches its minimum tilt angle, and the machine travels at high speed with the minimum motor capacity.

31

SEN02550-01


Brake valve Operation when pressure oil is supplied

q

q

q

32

When the travel lever is operated, the pressurized oil from the control valve is fed to port (A) and check valve (1) is opened. The oil is further sent from port (C) to port (D) through the motor. At the same time, when the pressure of the hydraulic oil that entered in chamber (G) through orifice (f) exceeds spring (3) reaction force, counterbalance valve (2) moves to the right, opening ports (D) and (B), and the motor becomes ready to rotate. As ports (A) and (E) also open, parking brake piston (4) is pressed down by the hydraulic pressure. This releases the parking brake and the motor starts to rotate.

Operation when pressure is shut off

q

q

q

When the travel lever is returned to its neutral position, the hydraulic oil circuit from the control valve is closed. And counterbalance valve (2) starts to return to the left by spring (3) reaction force. The hydraulic oil in chamber (G) tends to flow to port (A) through orifice (f). However, the back pressure is generated by closing of orifice (f), controlling the return speed of counterbalance valve (2) to the right. The motor tends to rotate by inertia even when the hydraulic oil from the control valve is stopped.During this time, the oil return circuit is gradually closed by controlling the movement speed of counterbalance valve (2) and by using its cutout portion. By this, the motor is smoothly stopped.

PC138US, USLC-8


SEN02550-01

Brake operation at travelling downhill

q

q

q

q

q

If the machine is going to run away when traveling downhill, the motor idles and the hydraulic pressure at port (C) drops. The pressure of hydraulic oil that is sent to chamber (G) through orifice (f) also drops. When the hydraulic oil pressure in chamber (G) goes below spring (3) reaction force, counterbalance valve (2) starts to return to the left. The hydraulic oil in chamber (J) tends to flow to port (B) through orifice (h). However, the back pressure is generated by closing of orifice (h), controlling the return speed of counterbalance valve (2) to the right. When ports (D) and (B) are closed and when the hydraulic pressure at port (D) increases, a resistance is generated in motor rotation to protect the machine from running away. Counterbalance valve (2) is moved to the position where the hydraulic pressure at port (B) is well balanced with the pressure by the weight of machine itself and the pressure at port (A). The motor speed is controlled according to the pump delivery by controlling the opening of hydraulic oil output circuit.

PC138US, USLC-8

33

SEN02550-01


Relief valve When starting

q

q

q

q

q

34

The pressurized oil from the control valve is fed from port (A) to port (C). As port (C) is connected to the motor, the pressure drives the motor to rotate. When the hydraulic pressure at port (C) exceeds the specified value, relief valve (1a) is pushed up and the hydraulic oil is fed to port (D).However, relief valve (1b) is kept closed independent from the hydraulic pressure at port (C). The hydraulic oil is fed from port (C) to chamber (E) through the oil passages of relief valve (1a) and sleeve (2a). By this pressure, piston (3) is moved to the right. When piston (3) reaches its stroke end position, the hydraulic pressure from relief valve (1a) to chamber (E) increases. Therefore, ports (C) and (D) are closed by relief valve (1a). The hydraulic pressure at port (C) at the inlet side is controlled so that the motor is smoothly started to rotate.

When stopping

q

q

q

q

q

When the hydraulic oil from the control valve is stopped, ports (A) and (C) are closed. At the same time, ports (D) and (B) are closed, but the motor continues to rotate by the inertia. When the hydraulic pressure at port (D) exceeds the specified value, relief valve (1b) is pushed up and the hydraulic oil is fed to port (C).The hydraulic pressure applied to port (D) at the outlet side is fed to port (C) at the inlet side, and it is used to prevent the oil cavitation. The hydraulic oil from port (D) passes through the oil passages of relief valve (1b) and sleeve (2b), and sent to chamber (F). By this pressure, piston (3) is moved to the left. When piston (3) reaches its stroke end position, the hydraulic pressure from relief valve (1b) to chamber (F) increases. Therefore, ports (D) and (C) are closed by relief valve (1b). The hydraulic pressure at port (D) at the outlet side is controlled so that the motor is smoothly stopped.

PC138US, USLC-8


PC138US, USLC-8

SEN02550-01

35

SEN02550-01


Center swivel joint

1


A1: B1: C1: D1: E1: DR1: 1. 2. 3.

36

From control valve (R.H. travel FORWARD) From control valve (L.H. travel FORWARD) From control valve (R.H. travel REVERSE) From control valve (L.H. travel REVERSE) From 2nd travel speed select solenoid valve To hydraulic tank

Cover Body Slipper seal

A2: B2: C2: D2: E2: DR2: 4. 5.

To R.H. travel motor port B To L.H. travel motor port A To R.H. travel motor port A To L.H. travel motor port B To L.H. and R.H. travel motor port P From L.H. and R.H. travel motor port D

O-ring Shaft

PC138US, USLC-8


SEN02550-01

Unit: mm No. 1

Item Clearance between rotor and shaft

PC138US, USLC-8

Criteria

Remedy

Standard size

Standard clearance

Clearance limit

80

0.056 – 0.105

0.111

Replace

37

SEN02550-01


Blade specification (if equipped)

A1: B1: C1: D1: E1: F1: G1: DR1: 1. 2. 3.

38

From control valve (R.H. travel REVERSE) From control valve (L.H. travel FORWARD) From control valve (R.H. travel FORWARD) From control valve (L.H. travel REVERSE) From 2nd travel speed select solenoid valve From control valve (blade LOWER) From control valve (blade RAISE) To hydraulic tank

Cover Body Slipper seal

A2: B2: C2: D2: E2: F2: G2: DR2: 4. 5.

To R.H. travel motor port A To L.H. travel motor port A To R.H. travel motor port B To L.H. travel motor port B To L.H. and R.H. travel motor port P To L.H. and R.H. blade cylinder bottom To L.H. and R.H. blade cylinder head From L.H. and R.H. travel motor port D

Dust seal Shaft

PC138US, USLC-8


SEN02550-01

Unit: mm No. 1

Item clearance between rotor and shaft

PC138US, USLC-8

Criteria

Remedy

Standard size

Standard clearance

Clearance limit

80

0.056 – 0.105

0.111

Replace

39

SEN02550-01

Solenoid valve

40


1

PC138US, USLC-8


P1 A1 A2 A3 A4 A5 T ACC 1. 2. 3. 4. 5.

: From self pressure reducing valve : To PPC valve : To center swivel joint, port E1 : To swing motor, port B : To control valve, port PS : To control valve, port PST : To hydraulic tank : To accumulator (for PPC circuit)

SEN02550-01

Operation Check valve

PPC lock solenoid valve 2nd travel speed select solenoid valve Swing holding brake solenoid valve Pump merge-divider solenoid valve Travel junction solenoid valve

Solenoid valve 6. Coil (ON/OFF type) 7. Push pin 8. Valve spool 9. Sleeve 10. Block 11. Plug

q

q

Check valve 12. Plunger 13. Plug

PC138US, USLC-8

Installed between port (P) and PPC solenoid valve. When the engine is stopped, plunger (1) is pushed back to the left with spring (2) reaction force, and ports (ACC) and (P) are closed to maintain the pressure in the accumulator. When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P), and ports (P) and (ACC) are interconnected.

41

SEN02550-01


Solenoid valve When solenoid valve is “de-energized“ (circuit is closed)

q q q

42

Coil (1) is de-energized when no signal current is supplied to coil (1). Spool (2) is pushed back to the left with spring (3) reaction force. As ports (P) and (A) are closed, the pilot pressure is not fed to the actuator through port (A). At the same time, port (T) is opened, allowing the oil from the actuator to drain to the hydraulic tank.

When solenoid valve is “energized“ (circuit is connected)

q q q

Coil (1) is energized when signal current is supplied to coil (1). Spool (2) is pushed to the right with push pin (4). As ports (P) and (A) are opened, the pilot pressure is fed to the actuator through port (A). At the same time, port (T) is closed, shutting off the oil from the actuator to the hydraulic tank.

PC138US, USLC-8


PC138US, USLC-8

SEN02550-01

43

SEN02550-01


PPC accumulator

1

For PPC circuit 1. 2. 3. 4. 5. 6.

Gas plug Shell Poppet Holder Bladder Oil port

Outline q Mounted on the solenoid valve. If the engine is stopped with the work equipment is kept at an elevated position, the pilot pressure is supplied to the control valve by the pressure of the compressed nitrogen gas in the accumulator. Therefore, the spool can be operated to lower the work equipment by its own weight. Specifications Gas to be used: Nitrogen gas Gas capacity: 300 cc Sealed gas pressure: 1.18 MPa {12 kg/cm²} (at 80°C) Maximum operating pressure: 6.86 MPa {70 kg/cm²}

44

PC138US, USLC-8


For breaker (Machine ready for attachment) For low pressure

1. 2. 3. 4. 5. 6. 7.

Cap Core Guard rubber Ring Lid Bladder Shell

SEN02550-01

For high pressure

1. 2. 3. 4. 5. 6.

Cap Core Locknut Gas port Bladder Shell

Outline q Connected to the attachment piping. When the breaker operates, the oil pulsation is absorbed by the pressure of compressed nitrogen gas of the accumulator, to protect the hydraulic system devices and piping.

Outline q Connected to the attachment piping. When the breaker operates, the oil pulsation is absorbed by the pressure of compressed nitrogen gas of the accumulator, to protect the hydraulic system devices and piping.

Specifications Gas to be used: Nitrogen gas Gas capacity: 480 cc Sealed gas pressure: 0.1 MPa {1 kg/cm²} (at 80°C) Maximum operating pressure: 0.69 MPa {7 kg/cm²}

Specifications Gas to be used: Nitrogen gas Gas capacity: 500 cc Sealed gas pressure: 5.88 MPa {60 kg/cm²} (at 80°C) Maximum operating pressure: 20.6 MPa {210 kg/cm²}

PC138US, USLC-8

45

SEN02550-01

Holding valve


1

(For boom and arm)

46

PC138US, USLC-8


SEN02550-01

CY : To work equipment cylinder PCY: For pressure pickup port and equalizer circuit PI : From PPC valve T : To tank V : From control valve 1. 2. 3.

Pilot spool Safety valve Check valve Unit: mm

No.

Check item


4

Check valve spring

Remedy Repair limit

Free length Installation Installation Installation × Outside Free length length load load diameter 20.8 × 12.2

13.5

12.7 N {1.3 kg}

—

10.2 N {1.04 kg}

5

Spool return spring

41.1 × 9.6

35.0

58.8 N {6.0 kg}

—

47.1 N {4.8 kg}

6

Spool return spring

41.9 × 25.8

41.0

78.5 N {8.0 kg}

—

62.8 N {6.4 kg}

PC138US, USLC-8

If damaged or deformed, replace spring.

47

SEN02550-01


Function q Prevents the pressurized oil from reversing from the work equipment cylinder in order to prevents sudden drift of the work equipment at breaking of the piping between the control valve and the work equipment cylinder. Operation 1. When the work equipment lever is in neutral When the piping is free of breakage Check valve (5) is closed under the holding pressure of the cylinder led from port (CY) to chamber (b). q At the neutral, pilot pressure led to port (PI) from the PPC valve is 0 MPa {0 kg/cm²}. q Spool (1) is pressed to the left by the force of springs (2) and (3). q Chambers (a) and (b) are shut off. q No pressurized oil flows between the control valve and the work equipment cylinder. q Accordingly, the work equipment is held in position. q If the work equipment cylinder has abnomally high pressure, safety valve (4) is actuated by the holding pressure of the work equipment cylinder. q Chambers (b) of L.H. and R.H. holding valve for the boom are interconnected by port (PCY). q Chambers (b) will have the same pressure if the L.H. and R.H. holding valves have a difference in leakage. q

48

If the piping is bursted q If piping (A) is broken between the control valve and the work equipment cylinder, chambers (a) and (b) are shut off in the same way as the piping is free from damages. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment.

PC138US, USLC-8


2.

SEN02550-01

When pressurized oil flows from the main valve to the cylinder

When the piping is free of breakage q Pressurized oil led to chamber (a) from the control valve becomes higher than the combined force of pressure from work equipment cylinder circuit chamber (b) and spring (6). q Check valve (5) opens and chambers (a) and (b) are interconnected. q Pressurized oil flows from the control valve to the work equipment cylinder. If the piping is bursted If piping (A) between the control valve and the work equipment cylinder is broken, pressurized oil in chamber (a) flows outside from the damaged portion. q Pressure force in chamber (a) drops. q Pressure force in chamber (a) drops lower than the combined pressure force of chamber (b) and spring (6). q Check valve (5) closes and chambers (a) and (b) are cut off. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment. q

PC138US, USLC-8

49

SEN02550-01

3.

When returning pressurized oil to the main valve from the work equipment cylinder

When the piping is free of burst q Holding pressure of the work equipment cylinder is led to chamber (b) and check valve (5) closes. q Pilot pressure from the PPC valve is led to port (PI) and reaches [Pilot Pressure > Force of Spring (3)] (area of d). q Spool (1) moves to the right to the standby position.(1st stage stroke) q At this point, chambers (a) and (b) are not interconnected. q Pilot pressure further rises, and reaches [Pilot pressure > Force of spring (2)] (area of d). q Spool (1) moves further to the right, and chambers (a) and (b) are interconnected. (2nd stage stroke) q Pressurized oil returns to the control valve from the work equipment cylinder.

50


If the piping is bursted q If piping (A) bursts between the control valve and the work equipment cylinder. q Pressurized oil in chamber (a) flows out to the bursted portion but resupplied from chamber (b). q Since pressurized oil flows via opening (c) of spool (1), a sudden drop of the cylinder is prevented.

PC138US, USLC-8


SEN02550-01

Multi-control valve

1

(if equipped)

(1) JIS pattern

(2) Backhoe pattern

Control pattern switching diagram (Port names correspond to the marks on the above figures.)

PC138US, USLC-8

51

SEN02550-01




52

PC138US, USLC-8

SEN02551-00


Machine model

Serial number




1

Work equipment Work equipment .............................................................................................................................................. 2 Dimensions of components............................................................................................................................. 4 Hydraulic cylinder............................................................................................................................................ 8

PC138US, USLC-8

1

SEN02551-00


Work equipment

1

Unit: mm No.

1

2

Item Clearance between mounting pin and bushing of boom and revolving frame


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

70

-0.030 -0.100

+0.143 +0.063

0.093 – 0.245

0.8

2

Clearance between mounting pin and bushing of boom and arm

70

-0.030 -0.100

+0.145 +0.065

0.095 – 0.245

0.8

3

Clearance between mounting pin and bushing of arm and bucket

60

-0.030 -0.080

+0.129 +0.074

0.104 – 0.209

0.8

4

Clearance between mounting pin and bushing of arm and link

60

-0.030 -0.080

+0.133 +0.075

0.105 – 0.213

0.8

5

Clearance between mounting pin and bushing of link and link

65

-0.030 -0.080

+0.132 +0.075

0.105 – 0.212

0.8

6

Clearance between mounting pin and bushing of link and bucket

60

-0.030 -0.080

+0.130 +0.078

0.108 – 0.210

0.8

7

Clearance between mounting pin and bushing of blade and track frame

70

-0.030 -0.100

+0.190 +0.090

0.120 – 0.290

1.5

Replace pin and bushing

PC138US, USLC-8


PC138US, USLC-8

SEN02551-00

3

SEN02551-00

Dimensions of components


1

Arm

4

PC138US, USLC-8


SEN02551-00

Unit: mm PC138US-8, PC138USLC-8 No.

Measurement point

1

2

—

Standard size 70

Tolerance Shaft

Hole

-0.030 -0.100

+0.100 0

81.5

+1.0 0

Cylinder head side

80

±1.2

Boom side

226

+0.5 0

Arm side

226

-0.2 -0.7

Arm side

3

70

-0.030 -0.100

+0.100 0

4

—

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

—

1,241.3

—

15

—

60

16

+0.200 0

Link side

259

0 -1.0

Bucket side

261

±1.0

17

—

60

-0.030 -0.080

+0.200 0

Arm side

226

0 -0.5

Bucket side

274

+2.0 0

Min.

1,378

—

Max.

2,263

—

18

19

-0.030 -0.080

PC138US, USLC-8

5

SEN02551-00


Bucket

6

PC138US, USLC-8


SEN02551-00

Unit: mm No.

PC138US-8, PC138USLC-8 Measurement point

Standard size

Tolerance

1

—

371.3

±0.5

2

—

51.6

±0.5

3

—

97.9°

—

4

—

374.9

—

5

—

1,226.6

—

6

—

190.2

—

7

—

5°

—

8

—

0°

—

9

—

60

+0.2 0

10

—

64

—

11

—

80

+0.25 0

12

—

261

±1.0

13

—

50

—

14

—

85

—

15

—

380

+1.0 0

16

—

18

—

17

—

110

—

18

—

130

—

19

—

132

—

20

—

108

—

21

—

274

+2.0 0

22

—

51

—

23

—

34

—

24

—

100.5

—

25

—

115.3

—

26

—

74

—

27

—

65

—

PC138US, USLC-8

7

SEN02551-00

Hydraulic cylinder


1

Boom cylinder

Arm cylinder

Bucket cylinder

8

PC138US, USLC-8


SEN02551-00

Blade cylinder

Unit: mm No.

1

2

3

Item

Clearance between piston rod and bushing

Clearance between piston rod support shaft and bushing

Clearance between cylinder bottom support shaft and bushing

PC138US, USLC-8

Criteria Cylinder name

Standard size

Boom

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

70

-0.030 -0.076

+0.259 +0.063

0.093 – 0.335

0.435

Arm

75

-0.030 -0.076

+0.279 +0.065

0.095 – 0.355

0.455

Bucket

65

-0.030 -0.076

+0.250 +0.055

0.085 – 0.326

0.426

Blade

75

-0.030 -0.076

+0.279 +0.065

0.095 – 0.355

0.455

Boom

70

-0.030 -0.100

+0.190 +0.090

0.120 – 0.290

1.0

Arm

70

-0.030 -0.100

+0.190 +0.090

0.120 – 0.290

1.0

Bucket

65

-0.030 -0.080

+0.170 +0.070

0.100 – 0.250

1.0

Blade

70

-0.030 -0.100

+0.190 +0.090

0.120 – 0.290

1.0

Boom

70

-0.030 -0.100

+0.190 +0.090

0.120 – 0.290

1.0

Arm

70

-0.030 -0.100

+0.190 +0.090

0.120 – 0.290

1.0

Bucket

65

-0.030 -0.080

+0.170 +0.070

0.100 – 0.250

1.0

Blade

70

-0.030 -0.100

+0.190 +0.090

0.120 – 0.290

1.0

Replace bushing

9

SEN02551-00




10

PC138US, USLC-8

SEN02552-01


Machine model

Serial number




1

Cab and its attachments Air conditioner ................................................................................................................................................. 2

PC138US, USLC-8

1

SEN02552-01

Air conditioner


1

Air conditioner piping diagram

2

PC138US, USLC-8


A: B: C: D: E: F:

Front warm/cool air outlet Rear warm/cool air outlet Foot warm/cool air outlet Defroster warm/cool air outlet Internal air flow outlet External air flow outlet

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Sunlight sensor Machine monitor Refrigerant piping Compressor Condenser (with built-in receiver) Air conditioner controller Sight glass External air filter Air conditioner unit Internal air filter Dual pressure switch Hot water take-out piping Ambient temperature sensor Hot water return piping

SEN02552-01

Dual pressure switch q If abnormally low or high pressure was generated in the refrigerant circulation circuit, this switch releases the magnet clutch of the compressor to protect a series of cooler-related equipment. High-pressure OFF: 3.14 ± 0.20 MPa {32 ± 2 kg/cm²} Low-pressure OFF: 0.20 ± 0.02 MPa {2 ± 0.2 kg/cm²}

Specifications Refrigerant to be used

R134a

Refrigerant capacity (g)

800

PC138US, USLC-8

3

SEN02552-01


1. 2. 3.

Engine Compressor Condenser 3a. Receiver 4. Sight glass 5. Air conditioner unit 6. Dual pressure switch Table of tightening torque for refrigerant piping adapter Unit: Nm{kgm} No.

4

Item

Criteria

7

Compressor refrigerant piping lock bolt

7.85 – 11.8 {0.8 – 1.2} (Screw size: M6 × 1.0)

8

Condenser refrigerant piping lock bolt

3.92 – 6.86 {0.4 – 0.7} (Screw size: M6 × 1.0)

9

Air conditioner unit refrigerant piping connector lock bolt

7.85 – 11.8 {0.8 – 1.2} (Screw size: M6 × 1.0)

Remedy

Retighten

PC138US, USLC-8


PC138US, USLC-8

SEN02552-01

5

SEN02552-01


Air conditioner unit

6

PC138US, USLC-8


A: B: C: D:

From condenser To compressor Hot water inlet Hot water outlet

1. 2. 3. 4. 5. 6. 7. 8. 9.

Evaporator Heater core Expansion valve Blower motor Air mix damper actuator Air mix damper Mode selector damper actuator Mode selector damper Internal/external air changeover damper actuator Internal/external air changeover damper Power transistor Evaporator temperature sensor Internal air temperature sensor Internal air filter

10. 11. 12. 13. 14.

PC138US, USLC-8

SEN02552-01

Outline q The horizontal air conditioner unit on which evaporator (1) and heater core (2) is arranged in parallel. Blower motor (4) is driven to to generate cool and hot air. q Selecting the temperature on the machine monitor controls air mix damper (6) to adjust the spurting out temperature. Cooler The cooler circulates refrigerant through evaporator (1) to cause heat exchange (dehumidification and cooling). q Air taken in by blower motor (4) is cooled with evaporator (1) and then blown out from the duct and grill. q

Heater q The heater circulates engine coolant in heater core (2) to cause heat exchange (heating). q Air taken in by blower motor (4) is heated with heater core (2) and then blown out through the duct and grill.

7

SEN02552-01

Functions of major components Evaporator q Evaporator fin is cooled by the low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air from the blower motor is cooled and dehumidified when passing through the fin. Heater core Fin of the heater core is heated by the hot water (coolant) being sent from the engine. Air from the blower motor is heated as it passes through the fin.

q

Expansion valve q This valve converts high-pressure, high-temperature liquid refrigerant from the condenser to low-pressure, low-temperature misty refrigerant through the throttling function. It controls flow rate of refrigerant by changing level of throttling depending on the thermal load in the operator's cab. Blower motor It suctions air by rotating the fin installed on the blower motor. And it is also used for sending air to the evaporator and heater core.

q

Air mix damper actuator q It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the air mix damper through the link mechanism. q The motor rotating direction is determined as the air conditioner controller reads the position of the potentiometer being built in the actuator. This reading is done as the target temperature is set on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned “OFF“.


Internal/external air changeover damper actuator q It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the internal/external air flow selector damper through the link mechanism. q The motor rotating direction is determined by selecting internal/external air flow on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned “OFF“. Evaporator temperature sensor In order to prevent freezing of the evaporator, it senses the evaporator temperature and sends necessary signals to the air conditioner controller.The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.

q

Internal air temperature sensor q It senses the internal air temperature and sends necessary signals to the air conditioner controller.The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.

Mode selector damper actuator It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the mode selector damper through the link mechanism. q The motor rotating direction is determined as the air conditioner controller reads the position of the potentiometer being built in the actuator. This reading is done as the mode is selected on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned “OFF“. q

8

PC138US, USLC-8


SEN02552-01

Air conditioner controller

Input and output signals AMP040-36P Pin No. 1 2 3

Signal name NC Air mix dumper actuator potentiometer signal Actuator potentiometer power supply

4

Dual pressure switch

5 6 7 8

NC Back-up power supply Blower feedback signal Power transistor control signal Mode selector actuator potentiometer signal NC Internal air temperature sensor Evaporator temperature sensor External air temperature sensor NC Sunlight sensor GND

9 10 11 12 13 14 15 16

PC138US, USLC-8

Input and output signals

Pin No.

—

17

CAN_H

Input

18

CAN_L

Output

19

Input

20

— Input Input Output

Signal name

Input and output signals Input/ output Input/ output

21 22 23 24

Internal/external air changeover dumper actuator (A) Internal/external air changeover dumper actuator (B) Air mix dumper actuator (A) Air mix dumper actuator (B) Mode selector actuator (A) Mode selector actuator (B)

Output Output Output Output

Input

25

Relay power supply

Output

— Input Input Input — Input Output

26 27 28 29 30 31 32 33 34 35 36

NC GND (sensor) NC NC Test terminal RAM monitor (for switching display) RAM monitor I/F RAM monitor output NC Compressor clutch relay Blower main relay

Output Output

— Input — — — — — — — Input Input

9

SEN02552-01


Compressor

A: B:

From air conditioner unit To condenser

Function q Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator to high-pressure, high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature. q Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure. Specifications Number of cylinders - bore x stroke (mm) Piston capacity (cc/rev)

129.2

Allowable maximum speed (rpm)

6,000

Refrigerant oil to be used Refrigerant oil capacity (cc)

10

10-32 x 20.8

Denso: ND-OIL 8 180

PC138US, USLC-8


SEN02552-01

Condenser

A: B:

From compressor To air conditioner unit

Specifications Fine pitch (mm)

4.0

1. 2.

Core Receiver

Total heat dissipation surface (m²)

3.58

Function q It cools and liquefies the high-pressure and high-temperature misty refrigerant from the compressor. q The receiver holds high-pressure, high-temperature liquid refrigerant.It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent. a

Max. pressure used (MPa{kg/cm²}) Weight of desiccating agent (g)

3.53 {36} 290

If the fin crushes or is clogged with dusts, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.

PC138US, USLC-8

11

SEN02552-01

Sensor


External air temperature sensor

Sunlight sensor

Outline q The sunlight sensor is installed on top of the machine monitor of the air duct. q It senses intensity of the sun light and sends signals to the air conditioner controller. The signal sent to the air conditioner controller is used to control the blower motor and compressor. Output characteristics

12

Outline q The external air temperature sensor is installed in the battery room at the rear left of the machine. q It senses the external air temperature and sends signals to the air conditioner controller. The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.

PC138US, USLC-8


PC138US, USLC-8

SEN02552-01

13

SEN02552-01




14

PC138US, USLC-8

SEN02553-01


Machine model

Serial number




1

Electrical system Electronic control system ................................................................................................................................ 2 Monitor system.............................................................................................................................................. 35 KOMTRAX system........................................................................................................................................ 49 Sensor........................................................................................................................................................... 51

PC138US, USLC-8

1

SEN02553-01

Electronic control system


1

Machine control system diagram

2

PC138US, USLC-8


SEN02553-01

1

PC138US, USLC-8

3

SEN02553-01


Engine control function

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

4

Battery Battery relay Fusible link Fuse box Starting switch Engine controller Lock lever PPC lock switch Starting motor cut-out relay (for PPC lock) Starting motor cut-out relay (for personal code) Fuel control dial Safety relay Starting motor Fuel supply pump Sensors Engine controller power cut-off relay A Engine controller power cut-off relay B Machine monitor KOMTRAX terminal

Function 1.

The neutral safety circuit is employed to secure safety when the engine is started. q The engine does not start until the lock lever is set in the “LOCK“ position.

2.

The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX terminal receives an engine cut command issued through external operation.

PC138US, USLC-8


SEN02553-01

Starting engine q When starting switch (5) is turned “ON“, engine controller (6) sends command current to fuel supply pump (14). For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an electrical failure occurs. q When starting switch (5) is turned to “START“ with lock lever (7) set in the “LOCK“ position, a starting current is supplied to starting motor (13) causing the engine to start. However, as the neutral safety mechanism is provided, the engine will not start if lock lever (7) is set in the “FREE“ position at this time; starting motor cut-out relay (9) cuts off the starting current to starting motor (13). q Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the signal to machine monitor (18). Machine monitor (18) causes starting motor cut-out relay (10) to cut off the starting current to starting motor (13), therefore the engine does not start. Engine speed control Upon receipt of a fuel control dial (11) control signal, engine controller (6) sends a command current to fuel supply pump (14) to adjust the fuel injection amount to control the engine speed.

q

Stopping engine q When starting switch (5) is turned “OFF“, the current from the ACC terminal of starting switch (5) to engine controller (6) is cut off, and consequently the command current to fuel supply pump (14) is cut off. Fuel supply pump (14) stops fuel feed, causing the engine speed to go down and the engine stops.

PC138US, USLC-8

5

SEN02553-01


Pump and engine mutual control function

1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Fuel supply pump 12. Sensors 13. Pump oil pressure sensor 14. Oil pressure sensor 15. Oil pressure switch 16. Hydraulic pump 16a. Servo 16b. LS valve 16c. PC valve 17. Control valve 17a. Pump merge-divider valve 17b. Self pressure reducing valve 18. PC-EPC valve

6

Input and output signals a. Constant power supply b. CAN signal c. PC-EPC valve drive signal d. Solenoid valve GND e. Oil pressure sensor signal f. Oil pressure switch signal g. Throttle signal h. Fuel supply pump control signal i. Sensor signals

PC138US, USLC-8


SEN02553-01

Function q A function that selects working mode with the working mode selector switch in the machine monitor. 5 modes (P, E, L, ATT, B) are available, allowing the operator to select appropriate engine torque (T) and pump absorption torque depending on the work. In the default setting of the service mode, only 3 modes (P, E, L) are available in which “Without“ is selected for the attachment. q According to the pump absorption torque set at each mode, based on the engine governor set speed with the fuel control dial and the actual engine speed, the controller controls so that the pump absorbs all torques at each engine output point. q When the engine speed is lowered, the controller prevents the engine from stopping by throttling the pump absorption torque.

PC138US, USLC-8

7

SEN02553-01


Control method in each mode P mode, E mode, and ATT mode q Matching point: Working mode

P, ATT

Travel Working (At arm digging)

64.4 kW/2,050 rpm {86.4 HP/2,050 rpm}

Working (Except arm digging)

66.3 kW/2,050 rpm {88.9 HP/2,050 rpm}

E q

q

8

Matching point 68.4 kW/2,200 rpm {91.7 HP/2,200 rpm}

60.0 kW/1,980 rpm {80.5 HP/1,980 rpm}

In P, E, or ATT mode, engine speed is always controlled so that it is kept around the matching point specified for each mode. When a load to the pump increases and the pressure rises, the engine speed (N) lowers. At the time, the controller reduces the pump delivery (Q) to increase the engine speed to the matching point. If the pressure drops, the controller increases the pump delivery to increase the engine speed to the matching point.

PC138US, USLC-8


SEN02553-01

Modes B and L

q

q q

q

Working mode

Partial output

B

75%

L

70%

Matching point: Working mode

Matching point

B

50.9 kW/1,870 rpm {68.2 HP/1,870 rpm}

L

47.8 kW/1,640 rpm {64.1 HP/1,640 rpm}

In B or L mode, engine output is controlled to a constant level. The controller controls the pump absorption torque to decrease the engine speed while keeping the engine torque at a constant level along the equal engine horsepower curve. The controller controls pump delivery (Q) so that the engine torque can be kept at a constant level along the equal engine horsepower curve.

PC138US, USLC-8

9

SEN02553-01

Control function during travel q Traveling the machine in P or ATT mode increases engine speed (N). q Traveling the machine in E, L or B mode does not change engine speed (N) or pump absorption torque.

10


Control function with emergency pump drive switch “ON“ q If the controller gets out of order and no work is possible because the hydraulic pump does not work properly, operating emergency pump drive switch (1) temporarily enables to maintain functions of the machine with absorption torques quite similar to those in the Mode E. In this case, a constant current flows from the battery to the PC-EPC valve, and the valve detects the oil pressure only. a. Emergency b: Normal a Emergency pump drive switch (1) is of the alternative type. If the machine is operated after the switch is set to “Emergency (a)“ even though the machine is normal, the user code “E02“ will be shown on the display.

PC138US, USLC-8


PC138US, USLC-8

SEN02553-01

11

SEN02553-01


Auto-decelerator function

1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Fuel supply pump 6. Sensors 7. Oil pressure sensor 8. Oil pressure switch 9. Hydraulic pump 10. Control valve 10a. Pump merge-divider valve 10b. Self pressure reducing valve 11. PPC lock solenoid valve

12

Input and output signals a. CAN signal b. Oil pressure sensor signal c. Oil pressure switch signal d. Throttle signal e. Fuel supply pump control signal f. Sensor signals

PC138US, USLC-8


SEN02553-01

Function q When all the control levers are set to NEUTRAL for waiting for a dump track or work, the engine speed is automatically reduced to a control speed, and fuel consumption and noise are lowered. q When any control lever is operated, the engine speed returns immediately to the speed that is set with the fuel control dial. Operation When control levers are set in neutral q If all the control levers are set to NEUTRAL for 4 seconds or more with the engine speed exceeding approx. 1,400 rpm, the engine speed lowers down to the control speed (approx. 1,400 rpm) and is held until the control lever is operated again. When any control lever is operated With the engine speed at the control speed (approx. 1,400 rpm), when any control lever is operated, the engine speed increases immediately to the speed that is set with the fuel control dial.

q

A : All work equipment control levers in “NATURAL“ B : All work equipment control levers “OPERATED“ C: Fuel control dial set speed D: Engine control speed (approx. 1,400 rpm) E : 4 sec. F : Max. 2 sec. G: Max. 0.2 sec.

PC138US, USLC-8

13

SEN02553-01


Engine automatic warm-up function

1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Fuel supply pump 12. Sensors 13. Hydraulic oil temperature sensor 14. Hydraulic pump 14a. Servo 14b. LS valve 14c. PC valve 15. Control valve 15a. Pump merge-divider valve 15b. Self pressure reducing valve 16. PC-EPC valve

14

Input and output signals a. CAN signal b. PC-EPC valve drive signal c. Solenoid valve GND d. Hydraulic oil temperature signal e. Throttle signal f . Fuel supply pump control signal g. Sensor signals

PC138US, USLC-8


SEN02553-01

Function q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after start-up of the engine. Operational conditions (all required)

Operation o

Coolant temperature: Max. 30°C Fuel control dial: Max. 70% of full rotation

Engine speed: 1,300 rpm

O Release conditions (either one required) Automatic Manual

Release

Coolant temperature: Min. 30°C Duration of automatic warming-up: Min. 10 minutes

o

Engine speed: Any

Fuel control dial: Held at Min. 70% of full rotation for Min. 3 seconds

Overheat prevention function a

See “Engine automatic warm-up function“ for system circuit diagram.

q

Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil temperature becomes too high. Operational conditions

Working mode: P, ATT Coolant temperature: Min. 95°C Hydraulic oil temperature: Min. 95°C Traveling status check: OFF

Operational conditions Working mode: P, ATT Coolant temperature: Min. 98°C Hydraulic oil temperature: Min. 98°C Traveling status check: ON

Operational conditions Working mode: P, ATT Coolant temperature: Min. 100°C Hydraulic oil temperature: Min. 100°C Traveling status check: Any

Operational conditions Working mode: P, ATT, E, B Coolant temperature: Min. 102°C Hydraulic oil temperature: Min. 102°C Traveling status check: Any

Operational conditions

Operation and actions taken Engine speed: Remains same

o • Sends torque control signal to lower the pump absorption torque and reduce the engine load.

Operation and actions taken

Release conditions Coolant temperature: Max. 95°C

o Hydraulic oil temperature: Max. 95°C

• The original conditions are restored if above requirements are met (automatic restoration).


o • Engine speed: Remains same • Travel speed: Down

Operation and actions taken Engine speed: Remains same

o • Sends torque control signal to lower the pump absorption torque and reduce the engine load.


o Hydraulic oil temperature: Max. 98°C


Release conditions Coolant temperature: Max. 100°C o Hydraulic oil temperature: Max. 100°C


Release conditions

Engine speed: Remains same

Coolant temperature: Max. 102°C Alarm monitor: ON o o Hydraulic oil temperature: Max. 102°C • The original conditions are restored if • Sends torque control signal to above requirements are met (autolower the pump absorption torque matic restoration). and reduce the engine load.



Working mode: Any Coolant temperature: Min. 105°C Hydraulic oil temperature: Min. 105°C Traveling status check: Any

o Engine speed: Low idle Alarm monitor: ON Alarm monitor: Sounds

Hydraulic oil temperature: Max. 105°C o Fuel control dial: Returns to low idle (MIN) position. • The original conditions are restored if above requirements are met (man-

ual restoration).

PC138US, USLC-8

15

SEN02553-01


Turbocharger protection function a

See “Engine automatic warm-up function“ for system circuit diagram.

q

When the engine is started at low temperatures and the engine speed is increased sharply, the turbocharger may be seized. Controlling the engine speed prevents this problem. Duration of engine speed control depends on the coolant temperature.

q

Operational conditions Engine oil pressure: Max. 50 kPa {0.51 kg/cm2}

A: B: C: D: E: F:

Operating o

Turbocharger protection (See the following figure)

Start engine Duration of turbocharger protection (approx. 0 – 20 sec) Modulating time (approx. 1.5 sec) 500 rpm 1,100 rpm 2,300 rpm (*1)

*1. Working mode: Mode P Fuel control dial: Full rotation (MAX) position Travel lever operated

16

PC138US, USLC-8


SEN02553-01

Swing control function

1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Swing holding brake release switch 6. Swing lock switch 7. Pump controller 8. Machine monitor 9. Oil pressure switch 10. Hydraulic pump 11. Control valve 11a. Pump merge-divider valve 11b. Self pressure reducing valve 12. Swing motor 13. Swing holding brake solenoid valve

PC138US, USLC-8

Input and output signals a. Swing holding brake release signal b. Swing holding brake solenoid valve drive signal c. CAN signal d. Solenoid valve GND e. Oil pressure switch signal

17

SEN02553-01

Function Swing lock and swing holding brake functions q Turning swing lock switch (1) to “ON“ locks the swing lock (manual lock) at any position. q Interlocked with the swing operation, the swing holding brake (auto lock) prevents hydraulic drift from occurring after the swing stops. q Interlocked with the arm retract operation, the swing holding brake is released to reduce the load on the swing equipment during excavation work.


Swing lock switch

OFF

ON

Swing lock monitor

OFF

ON

Function

Swing holding brake

Swing lock

• When the L.H. work • The swing holding brake works to equipment control lock the swing. lever is set to NEUTRAL, the swing • Even if the L.H. holding brake works work equipment in 5 sec. control lever is operated for • When the L.H. work swing, the swing equipment control Operation holding brake lever is operated for cannot be swing or the arm released, and no lever is operated for swing is possible. retract, the swing holding brake is released allowing free swing operation.

A: B: C: D:

18

L.H. work equipment control lever “SWING“ (Swing holding brake “RELEASE“) L.H. work equipment control lever “NEUTRAL“ Swing holding brake “OPERATED“ 5 sec

PC138US, USLC-8


SEN02553-01

Swing holding brake release function q If the controller gets out of order and no swing is possible because the swing holding brake does not work properly, operating swing holding brake release switch (2) releases the swing holding brake and allows swing operation. a: Release (Emergency) b: Normal Swing holding brake release switch

Release (when the controller is out of order)

Normal (when the controller is in order)

Swing lock switch

ON

OFF

ON

OFF

Swing brake

Swing lock works.

Swing holding brake is released. (*1)

Swing lock works.

Swing holding brake works.

*1: Hydraulic brake by the safety valve. a

a

a

Even if the swing holding brake release switch is set to “RELEASE“, the swing holding brake is not be released while the swing lock switch is set to “ON“. When the swing holding brake is released, only the hydraulic brake with the safety valve is effective for swing. So, note that, when the swing stops on a slope, a hydraulic drift may occur. Swing holding brake release switch (2) is of the alternator type. When the switch is turned to “RELEASE (a)“ position, the swing lock monitor in the machine monitor will blink.

PC138US, USLC-8

19

SEN02553-01


Travel control function

1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Fuel supply pump 6. Sensors 7. Pump oil pressure sensor 8. Oil pressure sensor 9. Travel alarm buzzer 10. Hydraulic pump 11. Control valve 11a. Pump merge-divider valve 11b. Self pressure reducing valve 11c. Travel junction valve 11d. Pump merge-divider valve 12. Travel motor 13. 2nd travel speed select solenoid valve 14. Travel junction solenoid valve 15. Pump merge-divider solenoid valve

20

Input and output signals a. Oil pressure sensor signal b. CAN signal c. Pump merge-divider solenoid valve drive signal d. Travel junction solenoid valve drive signal e. 2nd travel speed select solenoid valve drive signal f . Oil pressure sensor signal g. Travel alarm buzzer operation signal h. Throttle signal i . Fuel supply pump control signal j . Sensor signals

PC138US, USLC-8


SEN02553-01

Function Travel speed select function 1.

Travel speed “Manual“ change Turning the travel speed selector switch “Hi“ and “Lo“ changes the motor capacity and allows the machine to select travel speed.

q

Lo (low speed)

Hi (high speed)

Motor capacity (cc/rev.)

79.1

44.2

Travel speed (km/h)

2.9

5.1

Max.

Min.

Travel speed selector switch

Travel motor swash plate angle

2.

Travel speed “Automatic“ change 1) Automatic selection corresponding to engine speed q When the engine speed is lowered to below 1,500 rpm with the fuel control dial, the travel speed changes to “Lo“ automatically. 2)

Automatic selection corresponding to pump discharge pressure q If the travel pressure increases on an uphill with the travel speed selector switch in “Hi“, and the travel hydraulic pressure exceeding 32.4 MPa {330 kg/cm²} continues for 0.02 seconds or more, the travel motor capacity is switched to low speed (corresponds to “Lo“) automatically (the travel speed switch position is remain “Hi“). q If the travel pressure decreases on a flat or downhill with low speed (caused by the automatic gear shifting due to high pressure), and the travel hydraulic pressure below 17.7 MPa {180 kg/cm²} continues for 0.1 seconds or more, the travel motor capacity is switched back to the set speed of “Hi“ automatically.

PC138US, USLC-8

A: B: C: D:

17.7 MPa {180 kg/cm²} 32.4 MPa {330 kg/cm²} Min. 0.1 sec. Min. 0.02 sec.

Pump control function during travel a See “Pump and engine mutual control function“ for details. Travel junction function When the travel lever is operated, detects the pilot pressure and judges whether it is for straight-travel or for steering. q For straight-travel, a signal is sent to the travel junction solenoid valve, controlling the pump flow between the right and left to be equal, to prevent travel deviation and improve straight line stability. q When steering, the signal to the travel junction solenoid valve is cut-off, separating the pump flow between the right and left, to improve steering stability. q

21

SEN02553-01


Pump merge-divider function q When the travel lever is operated, detects the pilot pressure and judges if it is for straight-travel. q For straight-travel, a signal is sent to the pump merge-divider solenoid valve, dividing the pump delivery, to improve travel performance. Pattern

1

Criterion of travel operation

Criterion of work equipment and blade operation

Stop or travel at very low speed (All of following conditions are satisfied) • P1 = Min. 1.6 {16} • P2 = Min. 1.6 {16} • P3 = Min. 1.6 {16} • P4 = Min. 1.6 {16}

3

Travel at normal speed (One of following conditions is satisfied) • P1 = Min. 1.8 {18} • P2 = Min. 1.8 {18} • P3 = Min. 1.8 {18} • P4 = Min. 1.8 {18}

Mergedivider valve

Merge

(All of following conditions are satisfied) • Work equipment is not operated (Work equipment PPC pressure switch is Straight travel operation "OFF"). (All of following conditions • Blade is not operated (P5 = Max. 0.3 are satisfied) • P1 – P2 absolute value = {3}). Max. 0.3 {3} (One of following conditions is satisfied) • P3 – P4 absolute value = • Work equipment is operated (Work Max. 0.3 {3} equipment PPC pressure switch is "ON"). • Blade is operated (P5 = Min. 0.5 {5}).

2

(*1) 4

Criterion of steering operation

Steering operation (One of following conditions is satisfied) • P1 – P2 = Min. 0.5 {5} • P3 – P4 = Min. 0.5 {5}

5

Divide

Merge

(All of following conditions are satisfied) • Work equipment is not operated (Work equipment PPC pressure switch is "OFF"). • Blade is not operated deeply (P5 = Max. 2.0 {20}). • Pivot turn is not made. Example) Right forward pivot turn (P1 = Max. 2.0 {20} or P2, P4 = Min. 0.5 {5})

Divide

(One of following conditions is satisfied) • Work equipment is operated (Work equipment PPC pressure switch is "ON"). • Blade is operated deeply (P5 = Max. 2.2 {22}) • Pivot turn is made. Example) Right forward pivot turn (P1 = Max. 2.2 {22} and P2, P4 = Max. 0.3 {3})

Merge

*1. If the work equipment etc. is operated in pattern 4, the pump merge-divider valve is set to the merge mode of pattern 5. Even if the work equipment operation is stopped after the pump merge-divider valve is set in pattern 5, the pump merge-divider valve is not returned to pattern 4. P1: Left forward PPC pressure (MPa {kg/cm2}) P2: Right forward PPC pressure (MPa {kg/cm2}) P3: P1: Left reverse PPC pressure (MPa {kg/cm2}) P4: Right reverse PPC pressure (MPa {kg/cm2}) P5: Blade PPC pressure (MPa {kg/cm2})

22

PC138US, USLC-8


SEN02553-01

PPC lock function

1. 2. 3. 4. 5. 6. 7. 8. 9.

Battery Battery relay Fusible link Fuse box Starting switch Lock lever PPC lock switch Hydraulic pump Control valve 9a. Pump merge-divider valve 9b. Self pressure reducing valve 10. PPC lock solenoid valve

PC138US, USLC-8

Function Interlocked with the lock lever, the PPC lock switch is turned “OFF“ when operating the lock lever to “LOCK“ position. q When the PPC lock switch is turned “OFF“, the current to the PPC lock solenoid valve is cutoff, causing neither the work equipment nor machine moves even if levers or pedal is operated. q

23

SEN02553-01


Oil flow adjuster function for attachment (Machine ready for attachment)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Pump controller Engine controller Machine monitor Fuel control dial Fuel supply pump Sensors Emergency pump drive switch Oil pressure switch Hydraulic pump 9a. Servo 9b. LS valve 9c. PC valve 10. Control valve 10a. Pump merge-divider valve 10b. Self pressure reducing valve 11. PPC lock solenoid valve 12. Oil flow adjuster EPC valve for attachment 13. PC-EPC valve 14. Attachment circuit selector valve 15. Attachment

24

Input and output signals a. Oil flow adjuster EPC valve drive signal for attachment b. Oil pressure switch signal c. CAN signal d. PC-EPC valve drive signal e. Solenoid valve GND f . Throttle signal g. Fuel supply pump control signal h. Sensor signals Function Setting of the working mode and oil flow rate on the machine monitor controls the oil flow to the attachment when the attachment control pedal is depressed all the way.

q

PC138US, USLC-8


PC138US, USLC-8

SEN02553-01

25

SEN02553-01


System components Engine controller

Input and output signals q The following is the list of the symbols used for signal classification in the input/output signal chart. A: Power supply B: Input C: Ground/shield/return D: Output E: Communication DTP-4P [CN-CE03] Pin No. 1 2 3 4

26

Signal name GND NC Constant power supply (24 V) NC

Signal classification C — A —

PC138US, USLC-8


SEN02553-01

DRC-60P(1) [CN-CE01] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Signal name NC NC NC NC NC NC NC NC NC Fuel supply pump regulator (+) Boost temperature sensor NC NC Fuel supply pump regulator (–) NC NC NC NC Boost pressure sensor Ambient pressure sensor NC NC NC NC NC Crankshaft speed sensor (5 V) NC NC Common rail pressure sensor NC

Signal classification — — — — — — — — — B B — — C — — — — B B — — — — — A — — B —

Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Signal name NC Engine oil pressure switch NC NC NC Sensor power supply (5 V) Camshaft speed sensor NC NC NC NC Crankshaft speed sensor NC Crankshaft speed sensor GND Injector #2 (+) NC Coolant temperature sensor GND Sensor GND Coolant temperature sensor NC Injector #4 (–) NC Injector #1 (–) NC Injector #3 (+) Injector #4 (+) Injector #1 (+) Injector #2 (–) Injector #3 (–) NC

Signal classification — B — — — A B — — — — B — C D — C C D — C — C — D D D C C —

DRC-60P(2) [CN-CE02] Pin No.

Signal name

Signal classification E

Pin No.

1

CAN(+)

2

NC

—

32

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC CAN (–) NC NC NC NC NC Fuel control dial (5 V) Fuel control dial (–) NC NC

— — — — — — — — — — — — — — — — — — E — — — — — A C — —

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

PC138US, USLC-8

31

Signal name NC Engine controller power cut-off relay GND NC NC Fuel control dial (+) NC NC NC NC NC NC NC NC NC Starting switch ACC signal NC NC NC NC NC NC NC NC NC Engine controller power cut-off relay NC NC NC NC NC

Signal classification — C — — B — — — — — — — — — B — — — — — — — — — D — — — — —

27

SEN02553-01


Pump controller

28

PC138US, USLC-8


SEN02553-01

Input and output signals AMP-81P [CN-C01] Pin No.

Signal name

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Constant power supply (24 V) GND Window washer Constant power supply (24 V) GND NC NC Potentiometer power supply (5 V) Potentiometer power supply (5 V) NC Arm angle sensor NC L.H. travel REVERSE oil pressure sensor Boom LOWER oil pressure switch Arm OUT pressure switch Swing oil pressure switch Arm IN pressure switch GND (analog signal) Swing lock switch NC Model select 2 NC NC Starting switch ACC signal NC NC NC NC Hydraulic oil temperature sensor NC Boom cylinder bottom oil pressure sensor Blade RAISE oil pressure sensor NC Bucket DUMP oil pressure switch NC R.H. travel REVERSE oil pressure sensor GND (digital signal) Swing holding brake cancel switch Model select 5 Model select 1

Input/output signal Input Input Output Input Input — — Output Output — Input — Input Input Input Input Input Input Input — Input — — Input — — — — Input — Input Input — Input — Input Input Input Input Input

Pin No. 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

Input/output signal NC — NC — Starting switch ACC signal Input GND (pulse signal) Input CAN_H Input/output GND (analog signal) Input GND (analog signal) Input NC — Pump oil pressure sensor Input NC — Blade LOWER oil pressure sensor Input Attachment oil pressure switch Input Boom RAISE oil pressure switch Input NC — R.H. travel FORWARD oil pressure sensor Input Wiper motor reverse (W) Input Cab front window open limit switch Input Model select 4 Input NC — Starting switch C signal Input NC — External start signal Input NC — CAN_L Input/output NC — NC — Boom angle sensor Input NC — L.H. travel FORWARD oil pressure sensor Input GND (analog signal) Input NC — NC — Bucket CURL oil pressure switch Input NC — Wiper motor stop (P) Input Blade specification signal Input Model select 3 Input Overload alarm enable signal Input Starting switch ACC signal Input NC — GND (digital signal) Input Signal name

AMP-40P [CN-C02] Pin No. 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101

Input/output signal NC — NC — NC — NC — NC — 2nd travel speed select solenoid Output NC — NC — NC — NC — NC — Arm crane relay drive signal Output Bucket DUMP operation lock solenoid Output NC — PC-EPC Output Oil flow adjuster EPC for attachment Output NC — NC — NC — Swing holding brake solenoid Output Signal name

PC138US, USLC-8

Pin No. 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121

Signal name NC NC NC NC NC Travel and swing alarm buzzer Battery relay drive NC Travel junction solenoid NC Pump merge-divider solenoid NC Wiper motor (–) GND (solenoid) Solenoid power supply GND (solenoid) Solenoid power supply Wiper motor (+) GND (solenoid) Solenoid power supply

Input/output signal — — — — — Output Output — Output — Output — Output Input Input Input Input Output Input Input

29

SEN02553-01


Fuel control dial

1. 2. 3. 4. 5. 6.

Knob Dial Spring Ball Potentiometer Connector

Function q Installed in the right console box. Potentiometer (5) is installed inside knob (1). Turning knob (1) causes potentiometer (5) shaft to rotate. q This rotation changes the resistance of the variable resistor within potentiometer (5), and a throttle signal is sent to the controller. q The hatched areas in the graph are error detection areas. If the throttle voltage is within the area, the engine drops down to low idle.

30

PC138US, USLC-8


SEN02553-01

Resistor

1. 2.

Resistance Connector

Specifications For PC-EPC valve: 30 z Function q Sends an electric current to each EPC valve that is appropriate for each condition, when the emergency pump drive switch is turned to “ON“. a No electric current flows in the normal condition.

PC138US, USLC-8

31

SEN02553-01


Engine oil pressure switch

1. 2. 3.

Connector Sensor O-ring

Specifications Contact type: Normal close Function q Installed in the cylinder block. Detects engine oil pressure, and turns the switch “ON“ when the pressure goes below the specified value.

32

PC138US, USLC-8


SEN02553-01

PPC oil pressure switch

1. 2. 3.

Plug Switch Connector

Specifications Contact type: Normal open Operating pressure to make contact point ON: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2} Operating pressure to break contact point OFF: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2} Function q Installed (8 places) in the connecting valve. Detects the PPC oil pressure when each actuator is operated, and turns the switch “ON“ when the pressure exceeds the specified value.

PC138US, USLC-8

33

SEN02553-01

34


PC138US, USLC-8


SEN02553-01

Monitor system

1. 2. 3. 4. 5. 6. 7. 8.

Machine monitor Battery Pump controller Engine controller Air conditioner controller KOMTRAX terminal Sensors, switches Wiper motor, window washer motor

Input and output signals a. Power supply b. CAN signal c. Sensor and switch signals d. Drive signal

PC138US, USLC-8

1

Outline The monitor system keeps the operator informed of all machine functions, by monitoring the machine conditions using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor. The information displayed on the machine monitor falls into the following types: 1. Alarm when an error occurs 2. Machine status display (coolant temperature, hydraulic oil temperature and fuel level) q The switches on the machine monitor controls the machine. q

35

SEN02553-01


Machine monitor

Outline q The machine monitor provides monitor display function, mode selection function and switch function of the electrical equipment etc. Also it provides an alarm buzzer. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The machine monitor consists of display and switches: the display is of LCD type, and the switches are of flat sheet switch. q If an error occurs in the machine monitor itself, controller or wiring circuit between monitor and controller, the monitor does not display properly.

36

Precautions on the machine monitor display q The LCD panel may have black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, it does not indicate a failure or a defect. q When the engine is started, the battery voltage may drop suddenly depending on ambient temperatures and battery conditions. In this case, the machine monitor may go off for a moment. However, this phenomenon is not a failure. q After the machine monitor is used continuously, blue points (points which do not go off) may be seen on the black background. This phenomenon does not indicate a failure or a defect. Blue points can never be a problem as the screen has usually blue or white background. (White in the LCD is made up of red, green and blue.)

PC138US, USLC-8


SEN02553-01

Input and output signals 070-18P(1) [CN-CM01] Pin No. 1 2 3 4 5 6 7 8 9

Signal name Constant power supply (24 V) Constant power supply (24 V) GND (constant power supply) GND (constant power supply) Wake-up Starting motor cut-out relay (for personal code) GND (machine signal) Hydraulic oil temperature Fuel level

Input/output signal Input Input — — Input/output

Pin No.

Signal name

10 11 12 13 14

Engine coolant temperature Battery level GND (machine analog signal) Lamp switch Starting switch ACC signal

Output

15

Starting switch C signal

— Input Input

16 17 18

Preheat USB power supply (5 V) GND (USB power supply)

Input/output signal Input Input — Input Input Input Input Output —

070-12P(1) [CN-CM02] Pin No. 1 2 3 4 5 6

Signal name Engine oil pressure sensor Engine oil level sensor Radiator coolant level sensor Air cleaner clogging sensor Swing lock switch Spare

Input/output signal Input Input Input Input Input Input

Pin No. 7 8 9 10 11 12

Signal name GND (machine signal) CAN terminal signal CAN_H CAN_L USB data (–) USB data (+)

Input/output signal — — Input/output Input/output Input/output Input/output

070-18P(2) [CN-CM03] Pin No. 1 2 3 4 5 6 7 8 9

Signal name For communication terminal, RS232C CD For communication terminal, RS232C RXD For communication terminal, RS232C SG GND (communication terminal control signal) Communication terminal selection signal For communication terminal, RS232C RTS For communication terminal, RS232C TXD For communication terminal, RS232C DTR For communication terminal, RS232C DSR

Input/output signal

Pin No.

Input

10

Input

11

—

12

—

13

Input

14

Output

15

Output

16

Output

17

Input

18

Input/output signal

Pin No.

—

7

Reserved

—

Output

8

Reserved

—

—

9

Reserved

—

Output

10

Reserved

—

Input

11

Reserved

—

—

12

Peripheral equipment power supply (12 V)

Signal name For communication terminal, RS232C CTS For communication terminal, RS232C RI GND (communication terminal power supply) Communication terminal status signal CH1 Communication terminal power supply control signal Communication terminal control signal CH1 Communication terminal control signal CH2 Communication terminal status signal CH2 Communication terminal power supply (12 V)

Input/output signal Input Input — Input Output Output Output Input Output

070-12P(2) [CN-CM04] Pin No. 1 2 3 4 5 6

Signal name GND (peripheral equipment power supply) Peripheral equipment control signal GND (for peripheral equipment, RS232C) For peripheral equipment, RS232C TXD For peripheral equipment, RS232C RXD Reserved

Signal name

Input/output signal

Output

B60-8P [CN-CM05] Pin No. 1 2 3 4

Signal name Camera power supply (8 V) Camera NTSC signal 1 Camera NTSC signal 2 Camera NTSC signal 3

PC138US, USLC-8

Input/output signal Output Input Input Input

Pin No. 5 6 7 8

Signal name GND (Camera power supply) GND (Camera signal 1) GND (Camera signal 2) GND (Camera signal 3)

Input/output signal — — — —

37

SEN02553-01


Display

A: B:

C:

38

Normal operation screen All indicators light-up screen q When monitor items (14) to (16) are faulty after starting the engine, monitor items are displayed on the screen in chronological order from the upper left. q If the hydraulic oil temperature goes High or Low while the hydraulic oil temperature gauge is displayed at the center of the screen, the screen displays only hydraulic oil temperature monitor (2b). Screen with maintenance interval reminder

PC138US, USLC-8


No. Classification

1a

Gauge

1b

Caution

2a

Gauge

2b

Caution

3a

Gauge

3b

Caution

4

Display item

(*1) Coolant temperature

(*1) Hydraulic oil temperature

(*1) Fuel level

ECO gauge

Service meter

SEN02553-01

Description Display Tempera- Background location ture (°C) color W1 105 Red W2 102 Red W3 100 Blue W4 85 Blue W5 60 Blue W6 30 White See the column “Gauge“. Display Tempera- Background location ture (°C) color H1 105 Red H2 102 Red H3 100 Blue H4 85 Blue H5 40 Blue H6 20 White See the column “Gauge“. Display Background Quantity (l) location color F1 139 Blue F2 116 Blue F3 96 Blue F4 66 Blue F5 52 Blue F6 33 Red See the column “Gauge“. Segment Load level Light to Green 1–8 medium Orange 9,10 Heavy

6

Message

7

Air conditioner

8

Wiper

9

Pilot

Swing lock

• Indicates corresponding temperature range. • Alarm buzzer sounds when the temperature exceeds 105°C. • If the monitor background appears white, warm-up the engine.

• Indicates corresponding temperature range. • Alarm buzzer sounds when the temperature exceeds 105°C. • If the monitor background appears white, warm-up the hydraulic components.

• Indicates corresponding fuel level.

• Indicates average load per minute on a scale of 1 to 10. (Indicates when “Default (ECO display setting)“ of the service mode is “ON“.) • Indicates accumulated engine operating hours (the alternator is generating). (F4 switch changes for clock display.)

00000 h – 99999 h

5 Clock

Remarks

• 12-hour display (AM/PM) • Displays time. (F4 switch changes for service meter.) • 24-hour display Background Status (If KOMTRAX is equipped.) color • Displays message status. Green There is unread message. (OFF when no message is available.) Blue There is unsent message. Light ON: ON Light OFF: OFF INT: Intermittent ON: Continuous Light OFF: Stop Swing lock Swing holding brake switch release switch OFF OFF ON OFF OFF ON ON ON

• Indicates air conditioner and air blower operating status. • Indicates front glass wiper operating status. Monitor display OFF ON Blink Blink

• Indicates swing lock operating status.

*1: If the gauge signal is not available due to disconnection of CAN communication line, the gauge pointer goes off. PC138US, USLC-8

39

SEN02553-01

No. Classification

10

11


Display item

Preheat

Pilot

Description Remarks Elapsed time after turning Monitor disthe starting switch to play “HEAT (preheat)“. • Indicates preheat operating status. 0 – 30 sec. ON 30 – 40 sec. Blink 40 sec. or more OFF

Auto-decelera- Light ON: ON tor Light OFF: OFF

• Indicates auto-decelerator operating status.

P: Heavy-duty operation E: Low-fuel consumption operation Working mode L: Fine operation B: Breaker operation ATT: Compound attachment operation Lo: Low speed Travel speed Hi: High speed

12

13

• Displays working mode.

• Displays travel speed setting.

14

(*2) Engine oil level

Light ON: Abnormal range (below the specified value) Light OFF: Normal range

• When an error is detected with the engine running, the monitor lights up on the screen and the alarm buzzer sounds at the same time.

15

(*2) Engine oil pressure

Light ON: Abnormal range (below the specified value) Light OFF: Normal range

• When an error is detected with the engine stopped, the monitor lights up on the screen.

16

(*2) Battery level

Light ON: Defective battery charge (Charge voltage < Battery voltage) Light OFF: Normal range

• When an error is detected with the engine running, the monitor lights up on the screen.

Caution

Background color 17

Maintenance interval

Yellow

Red

Status

• The display changes depending on the time to/after the maintenance. There is a maintenance item which is 30 hours or • After the starting switch is turned “ON“, less left before next mainthe monitor turns ON if the monitor tenance. light-up conditions are met, and then There is a maintenance turns OFF in 30 seconds. overdue item.

*2: Included in the star-up check. After the staring switch is turned “ON“, the monitor turns ON for 2 seconds, and changes to a normal operation screen if no error is found.

40

PC138US, USLC-8


PC138US, USLC-8

SEN02553-01

41

SEN02553-01


Switches

No.

Name

Function

Auto-decelerator switch [Numeric keypad: 1]

Turns the auto-decelerator function ON/ OFF. Light ON: ON Light OFF: OFF

2

(*1) Working mode selector switch [Numeric keypad: 2]

Displays the working mode selector screen.

3

Travel speed selector switch [Numeric keypad: 3]

Changes the travel speed. Lo light ON: Low speed Hi light ON: High speed

4

Stops the alarm buzzer. Buzzer cancel switch (Some alarm buzzer does not stop even if [Numeric keypad: 4] the switch is pressed.)

5

Wiper switch [Numeric keypad: 5]

1

6

Window washer switch [Numeric keypad: 6]

Operates the front glass wiper. INT: Intermittent ON: Continuous Light OFF: Stop

Sprays washer fluid onto the front glass.

Operation • When the working mode is in “L“, the autodecelerator does not work. OFF io ON P: Heavy-duty operation E: Low-fuel consumption operation L: Fine operation B: Breaker operation ATT: Compound attachment operation Lo (low speed) io Hi (high speed) • Stops the alarm buzzer. • The alarm buzzer resumes when another error is detected. o INT o ON o OFF o I (Intermittent) (Continuous) (Stop) O i i i ON: Washer fluid is sprayed and wiper works continuously. [When wiper is not working] OFF: Wiper works twice and stops after the switch is released. [When wiper is working intermittently] OFF: Wiper works twice continuously and returns to intermittent operation after the switch is released.

*1: When the working mode is changed, the auto-decelerator function turns “ON“.

42

PC138US, USLC-8


No.

Name

7

Fan switch (Up) [Numeric keypad: 7]

7a

Fan switch (Down)

8

Temperature control switch (Up) [Numeric keypad: 8]

8a

Temperature control switch (Down) [Numeric keypad: 0]

Function Controls the fan speed of the air conditioner in 6 levels. (Low, Medium 1, Medium 2, Medium 3, Medium 4, High)

Controls the temperature inside the cab. (18.0°C – 32.0°C: Aailable at every 0.5°C)

9

(*2) Auto switch [Numeric keypad: 9]

Auto-runs the air conditioner and air blower. AUTO light ON: Auto run

10

(*3) Air conditioner switch

Turns the air conditioner ON/OFF. A/C ON lights-up: Manual operation Light OFF: Stop

11

FRESH/RECIRC selector switch

Changes the FRESH/RECIRC.

SEN02553-01

Operation • The air flow increases immediately after the air conditioner adjustment screen appears. • The air flow decreases immediately after the air conditioner adjustment screen appears. • The temperature control increases immediately after the air conditioner adjustment screen appears. • The temperature control decreases immediately after the air conditioner adjustment screen appears. • Automatically controls the fan speed, air outlet port, internal/external air flow according to the temperature setting, immediately after the air conditioner adjustment screen appears. • Switches to the air conditioner adjustment screen, and pressing it again switches ON/ OFF. OFF io ON • Switches to the air conditioner adjustment screen, and pressing it again switches internal/external air flow. RECIRC io FRESH

12

13

Vent selector switch

OFF switch

14a Guidance icon 14b Function switch

Selects the air vent mode from 6 modes. 1. Front 2. Front and rear 3. Front and rear-foot 4. Foot 5. Foot and defroster 6. Defroster Turns the fan and air conditioner OFF. Light OFF: OFF

• Switches to the air conditioner adjustment screen, and pressing it again switches air outlet mode. • Mode 1, 5 and 6 are not available with auto mode. o 1 o 2 o 3 o 4 o 5o 6 o I O i i i i i i i • Turns the fan and air conditioner OFF.

a See “Guidance icon and function switch.“

*2: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at “High“. Even if the set temperature is reached, the fan speed remains the same. *3: When the fan is set at Stop, the air conditioner does not start even if the switch is pressed.

PC138US, USLC-8

43

SEN02553-01


Guidance icon and function switch q Functions available with the function switch depend on the guidance icon displayed above the switch. q No function is available if no guidance icon appears above the function switch. q The following is the list of guidance icons and the functions displayed above the function switches.

Function switch

Guidance icon

Item

1

Clear

Clears selected/displayed item.

2

Move selection

Moves selection down one page. (To the top page from the bottom page.)

3

Set

Sets function.

4

Start

Starts function. (Used for starting measurement of spilt fuel consumption.)

5

Stop

Stops function. (Used for stopping measurement of spilt fuel consumption.)

1

Default

Sets selected item back to default. (Used for screen adjustment.)

2

Move selection

Moves selection up one page. (To the bottom page from the top page.)

3

Clear

Clears selected/displayed item.

1

Camera image

Switches to camera image.

2

Move selection

Moves selection down one item. (To the top item from the bottom item.) Releases holding of the monitor.

3

Move selection

Moves selection to the left. (To the rightmost item from the leftmost item.)

1

Switching clock/service meter

Switches clock/service meter display.

2

Move selection

Moves selection up one item. (To the bottom item from the top item.) Holds the monitor.

3

Move selection

Moves selection to the right. (To the leftmost item from the rightmost item.)

F1

F2

F3

F4

44

Function

PC138US, USLC-8


Function switch

Guidance icon

F5 F6

PC138US, USLC-8

Item

SEN02553-01

Function

1

Selecting maintenance screen

Selects maintenance screen.

2

Return

Returns to the previous screen or condition.

1

Selecting user mode screen

Selects user mode screen.

2

Fix

Fixes selected/displayed item.

45

SEN02553-01


Operator mode function q

q

The functions in this mode are displayed in normal operation. Display and setting of these functions are available from the operator's switch operations. Display and setting of some functions require special operation of the switch. Items available in the operator mode are as follows:

Category (*1)

A

B

C

D

Item Display of KOMATSU logo Display of inputting password Display of start-up check Display of warning after start-up check Display of overdue maintenance Display of check of working mode and travel speed Display of normal operation screen Display of end screen Selection of auto-decelerator Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Operation to display clock/service meter Check of maintenance information Setting and display of user mode • Breaker/attachment setting • Display of message (including KOMTRAX messages for user) • Screen adjustment • Clock adjustment • Language setting • Economy mode adjustment Display of energy-saving guidance Display of caution monitor Display of user code and failure code Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing attachment/maintenance password

Display order (*2) W X Y Z 1 1 1 1 2 — — — 3 2 2 2 — — 3 — — — — 3 4 3 4 4 5 4 5 5

*1: The items available in the operator mode fall into the following categories. A: Display from the time starting switch is turned “ON“ until the ordinary screen appears. Display after the starting switch is turned “OFF“. B: Display when the switch of machine monitor is operated. C: Display when a certain condition is satisfied D: Display when special switch operation is necessary. *2: For the category A, the order in which items are displayed varies depending on the setting and conditions of the machine as follows: W: When the engine start lock is set on X: When the engine start lock is set off Y: When an error is detected during start-up check. Z: When a maintenance overdue is detected. a a

46

For how to operate the operator mode functions, see the Operation and Maintenance Manual or “Special functions of machine monitor“ in Testing and adjusting. For how to set the engine start lock on/off, see “Password setting/cancel manual“.

PC138US, USLC-8


Oil flow setting for breaker

q q

SEN02553-01

Oil flow setting for attachment

Oil flow for the breaker can be changed in the “Breaker/attachment setting“ of the user mode. Oil flow level can be set as follows:

q

Oil flow for the compound attachment can be changed in the “Breaker/attachment setting“ of the user mode. Oil flow level can be set as follows:

Oil flow level

Quantity (l/min)

1

60

Oil flow level

Quantity (l/min)

2

70

1

30

3

80

2

85

4

90

3

105

5

100

4

130

6

110

5

155

7

120

6

175

8

130

7

200

8

225

9

140

10

150

11

160

12

170

13

180

14

190

15

200

Remarks

q

Default

Default

Language setting

q

q

PC138US, USLC-8

Remarks

The language used in the machine monitor can be changed in the “Language setting“ of the user mode. The available languages are as follows: English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian and Thai

47

SEN02553-01


Service mode function q

q

The functions in this mode are not accessible from the normal operation screen. Display and setting of these functions are available by the serviceman's special operations of the switch. This mode is used for special setting, testing, adjusting or troubleshooting. Items available in the service mode are as follows:

Monitoring Mechanical systems Abnormality record

Electrical systems Air conditioner system

Maintenance record Change of maintenance mode Setting of telephone No. Working mode with key ON Selection of units of measure Default

With/Without attachment Setting of attachment/maintenance password Setting of camera Setting of ECO display

Adjustment

Pump absorption torque

Cylinder cut-out operation No injection cranking Display of fuel consumption Setting condition of KOMTRAX terminal Display of KOMTRAX setting

Condition of positioning and communication Modem IP address (Model TH201) Modem S/N (Model TH300)

Display of KOMTRAX message

a

48

For how to operate the service mode functions, see “Special functions of machine monitor“ in Testing and adjusting.

PC138US, USLC-8


KOMTRAX system

q

q

q

a

SEN02553-01

1

The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, machine monitor and GPS antenna. This system sends various information of the machine via wireless communication. It allows operators of the KOMTRAX to obtain the machine information from the office and to provide various services with the customers. The information available from the KOMTRAX system are as follows: 1. Operation map 2. Service meter 3. Machine location 4. Error record To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.

PC138US, USLC-8

49

SEN02553-01


KOMTRAX terminal TH300

q

1. 2. 3.

The KOMTRAX system uses satellite communication technology. Communication antenna connection Machine harness connection (AMP-14P) Machine harness connection (AMP-10P)

Outline q The KOMTRAX terminal sends various machine information based on the network signals and input signals obtained through the machine monitor, as well as GPS position data, via wireless communication. The KOMTRAX terminal can sends information via communication antenna. q Conditions of the KOMTRAX terminal can be checked with the “Display of KOMTRAX setting“ in the service mode of the machine monitor. q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.

Input and output signals AMP-14P [CN-CK01] Pin No.

Input/output signal

Signal name

A1

Power supply (5 V)

A2

NC

Input —

A3

NC

—

A4

Selection of power supply voltage

A5

NC

—

A6

NC

—

A7

GND

Input

A8

GND

Input

Output

A9

NC

—

A10

NC

—

A11

NC

—

A12

NC

—

A13

NC

—

A14

NC

—

AMP-10P [CN-CK02] Pin No.

50

Signal name

Input/output signal

B1

RS232C DCD

Output

B2

RS232C RXD

Output

B3

RS232C TXD

Input

B4

RS232C DTR

Input

B5

RS232C SGND

Input

B6

RS232C DSR

B7

NC

—

B8

NC

—

B9

NC

—

B10

NC

—

Output

PC138US, USLC-8


Sensor

SEN02553-01

1

Atmospheric pressure sensor

1. 2.

Connector Pressure inlet port

Function q Installed in the bracket on the side face of the cylinder block. Detects the ambient pressure and outputs variable voltage. Boost pressure, temperature sensor

1. 2. 3.


Function Installed in the intake manifold. Detects the boost pressure and boost temperature, and outputs signal as a variable voltage for pressure, and a resistance change for temperature.

q

PC138US, USLC-8

51

SEN02553-01


Coolant temperature sensor

1. 2. 3.


Function q Installed in the water pump. Detects the temperature change and outputs signal as a resistance change. Crankshaft speed sensor Camshaft speed sensor

1. 2. 3.


Function The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is installed in the gear of the camshaft. Each of the sensors outputs a pulse voltage according to the gear rotation.

q

52

PC138US, USLC-8


SEN02553-01

Common rail pressure sensor

1. 2. 3.

Common rail Sensor Connector

Function q Installed in the common rail. Detects the fuel pressure and outputs variable voltage. Engine oil level sensor

1. 2.

Connector Bracket

3. 4.

Float Switch

Function The engine oil level sensor is installed to the side of the oil pan. If the oil level lowers below the specified level, the float lowers and the switch is turned “OFF“.

q

PC138US, USLC-8

53

SEN02553-01


Fuel level sensor

1. 2. 3. 4.

Connector Float Arm Body

5. 6. 7.

Spring Contact Spacer

Function q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the fuel level. The float moves the variable resistor through the arm. The resistance changes according to the operating angle and signal voltage is generated from the source voltage according to the change of the resistance.

54

PC138US, USLC-8


SEN02553-01

Hydraulic oil temperature sensor

1. 2. 3.

Connector Plug Thermistor

Function q Installed in the suction pipe of the hydraulic pump. Detects the temperature change and outputs signal as a resistance change of the thermistor. Pump oil pressure sensor

1. 2. 3.

O-ring Sensor Connector

Output characteristics

Function The pump oil pressure sensor is installed in the control valve. Detects the pump discharge pressure and outputs variable voltage.

q

PC138US, USLC-8

55

SEN02553-01


PPC oil pressure sensor (For travel and blade operation)

1. 2. 3.

O-ring Sensor Connector

Output characteristics

Function q The PPC oil pressure sensor is installed in the control valve connecting part of the pilot circuit for travel and blade operation. Detects the pilot pressure and outputs variable voltage.

56

PC138US, USLC-8


PC138US, USLC-8

SEN02553-01

57

SEN02553-01




58

PC138US, USLC-8

SEN02457-01



Machine model

Serial number



20 Standard value table

1

Standard service value table Standard value table for engine related parts ................................................................................................. 2 Standard value table for chassis related parts ................................................................................................ 3

PC138US, USLC-8

1

SEN02457-01


Standard value table for engine related parts

Category

Item

Engine speed

Exhaust gas color

Engine

Valve clearance

Applicable model

PC138US-8

Engine

SAA4D95LE-5 Unit

Standard value for new machine

Service limit value

High idle

rpm

2,300 ± 60

—

Low idle

rpm

1,100 ± 50

—

Rated speed

rpm

2,200

—

At sudden acceleration

%

Max. 30

30

At high idle

%

Max. 10

20

Intake valve

mm

0.35

—

Exhaust valve

mm

0.50

—

Test conditions

• Coolant temperature: operating range

• Coolant temperature: operating range

• Normal temperature

Compression pressure

• Oil temperature: 40 – 60°C • Engine speed: 320 – 360 rpm • SAE0W30E0S

MPa {kg/cm2}

Min. 2.9 {Min. 30}

2.0 {20}

Blow-by pressure

• Coolant temperature: operating kPa range {mmH2O} • Arm IN relief

Max. 0.59 {Max. 60}

0.98 {100}

0.34 – 0.59 {3.5 – 6.0}

0.25 {2.5}

0.29 – 0.49 {3.0 – 5.0}

0.2 {2.1}

Min. 0.18 {Min. 1.8}

0.15 {1.5}

Min. 0.15 {Min. 1.5}

0.13 {1.3}

Oil pressure (Hydraulic oil temperature: Min. 80°C)

• At sudden acceleration

SAE30 Oil SAE10W Oil SAE30 Oil

MPa {kg/cm2}

• Low idle SAE10W Oil

2

1

Oil temperature

• Whole speed range (inside oil pan)

°C

80 – 115

120

Fan belt tension

• Between fan pulley and alternator pulley • Deflection when pressed with finger force of approx. 60 N {6.1 kg}

mm

6 – 10

—

Air conditioner compressor belt tension

• Between fan pulley and compressor pulley • Deflection when pressed with finger force of approx. 60 N {6.1 kg}

mm

12 – 15

12 – 15

PC138US, USLC-8


SEN02457-01

Standard value table for chassis related parts

1

Applicable model

Engine speed

Category

Item

At 1-pump relief

Boom control lever

Travel of control levers

Arm control lever Bucket control lever Swing control lever

Unit


Service limit value

• Hydraulic oil temperature: 45 – 55°C • Engine oil pressure: Within operating range • Engine water temperature: Within operating range

rpm

2,050 ± 100

—

No RAISE, LOWER

100 ± 11

100 ± 21

N o IN, OUT

85 ± 11

85 ± 21

No CURL, DUMP

100 ± 11

100 ± 21

No LEFT, RIGHT

85 ± 11

85 ± 21

53 ± 6

Min. 47 Max. 59

• Center of lever knob • Tip of pedal • Read max. value to end of travel • Engine stopped

mm

No RAISE, LOWER

Travel control lever

N o FORWARD, REVERSE (LEFT, RIGHT)

115 ± 12

Min. 103 Max. 127

Work equipment, swing

3–5

5–8

Travel

10 ± 3

10 ± 5

16.7 ± 3.3 {1.7 ± 0.3}

Max. 25.5 {Max. 2.6}

16.7 ± 3.3 {1.7 ± 0.3}

Max. 25.5 {Max. 2.6}

13.7 ± 2.7 {1.4 ± 0.3}

Max. 22.6 {Max. 2.3}

13.7 ± 2.7 {1.4 ± 0.3}

Max. 22.6 {Max. 2.3}

Blade control lever

25.5 ± 6.9 {2.6 ± 0.7}

Max. 32.4 {Max. 3.3}

Travel control lever

24.5 ± 5.9 {2.5 ± 0.6}

Max. 39.2 {Max. 4.0}

Travel pedal

74.5 ± 18.6 {7.6 ± 1.9}

Max. 107.6 {Max. 11}

4.9 – 6.9 {50 – 70}

4.9 – 6.9 {50 – 70}

34.8 ± 1.0 {355 ± 10}

34.8 –1.0 {355 +20 –10 }

34.8 ± 1.0 {355 ± 10}

34.8 –1.0 {355 +20 –10 }

34.8 ± 1.0 {355 ± 10}

34.8 –1.0 {355 +20 –10 }

Boom control lever Operating effort of control lever

Test conditions

Blade control lever

Play of control lever

Hydraulic pressure

PC138US-8

Arm control lever Bucket control lever Swing control lever

Unload pressure

Boom relief Arm relief Bucket relief

PC138US, USLC-8

• Engine at high idle • Oil temperature: 45 – 55°C • Fit push-pull scale to center of control lever knob to test • Fit push-pull scale to tip of control pedal to test • Test max. value to end of travel N {kg}

• Hydraulic oil temperature: 45 – 55°C • Engine at high idle MPa • Working mode: P mode {kg/cm2} • Hydraulic pump output pressure with all control levers in NEUTRAL position • Hydraulic oil temperature: MPa 45 – 55°C {kg/cm2} • Engine at high idle • Pump discharge pressure Target • Relieve only circuit to be tested value (Range)

+2.0

+2.0

+2.0

3

SEN02457-01


Applicable model Category

Item Swing relief

Hydraulic pressure

Unit

• Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Pump discharge pressure • Relieve only circuit to be tested


Service limit value

27.1 ± 1.0 {276 ± 10}

27.1 –2.5 {276 +15 –25 }

+2.0

+1.5

+2.0

34.8 –1.0 {355 +20 –10 }

Blade LOWER

34.8 ± 1.5 {355 ± 15}

34.8 ± 2.5 {355 ± 25}

Travel relief

34.8 ± 1.0 {355 ± 10}

34.8 ± 2.0 {355 ± 20}

3.2 ± 0.2 {33 ± 2}

3.2 ± 0.5 {33 ± 5}

3.4 ± 1.0 {35 ± 10}

3.4 ± 1.0 {35 ± 10}

16.0 ± 1.5 {163 ± 15}

16.0 ± 2.5 {163 ± 25}

2.75 ± 0.98 {28 ± 10}

— {—}

2.2 ± 0.1 {22.5 ± 1}

— {—}

Max. 60 (Max. 580)

Max. 70 (Max. 676)

2.8 ± 0.3 {3.4 ± 0.3}

Max. 3.5 (Max. 4.0)

4.0 ± 0.4 {4.9 ± 0.5}

Max. 6.2 (Max. 6.4)

27.3 ± 2

27.3 ± 4

Control circuit source pressure Servo piston input pressure

LS differential pressure

Swing

Test conditions

34.8 +0 {355 +20 +0 }

Blade RAISE

MPa 2 • Hydraulic oil Control levers at {kg/cm } temperature: HOLD Target 45 – 55°C At pump relief value • Engine at (normal actuation) (Range) high idle • Hydraulic oil temperature: 45 – 55°C • Engine at high idle a LS differential pressure = pump outlet port pressure – LS pressure

All levers at HOLD

Travel rotating under no load Travel lever at half-way position

Overrun when stopping swing

• For testing posture, see Swing 1 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Stop after swinging one turn and test distance that swing circle moves • Figure in ( ) shows movement at outside of swing circle

Time taken to start swing

• For testing posture, see Swing 1 • Engine at high idle 90° • Hydraulic oil temperature: 45 – 55°C • Time taken to swing 90° and 180° from starting position 180° • Figure in ( ) shows time when bucket is at rated load

sec.

• For testing posture, see Swing 1 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Swing one turn, and test time taken to swing next 5 turns

sec.

Time taken to swing

4

PC138US-8

Deg. (mm)

PC138US, USLC-8


SEN02457-01

Applicable model Test conditions

Unit


Service limit value

Hydraulic drift of swing

• For testing posture, see Swing 2 • Engine stopped • Hydraulic oil temperature: 45 – 55°C • Bucket at rated load (450 kg) • Set machine on 15° slope, and set upper structure at an uphill angle of 45°. • Make match marks on swing circle outer race and track frame. • Test distance that match marks move apart after 15 minutes.

Deg. (mm)

0 (0)

0 (0)

Leakage from travel motor

• Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Relieve swing circuit.

l/min

Max. 3

Max. 6

Max. 39.5

49

Travel speed (without load)

• For testing posture, see Travel 1 Lo • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Raise track on one side at a time, rotate one turn, then Hi test time taken for next 5 turns with no load.

Max. 22.3

27

Max. 24.8

Max. 30

Max. 14.1

Max. 17

Item

Swing

Category

PC138US-8

Travel

Travel speed (actual run)

• For testing posture, see Travel 2 Lo • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Run up for at least 10 m, and test time taken to travel Hi next 20 m on flat ground.

sec.

sec.

Travel deviation

• For testing posture, see Travel 2 and 3 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Run up for at least 10 m, and test deviation when traveling next 20 m on flat ground. a Use a hard horizontal surface.

mm

Max. 200

220

Hydraulic drift of travel

• For testing posture, see Travel 4 • Engine stopped • Hydraulic oil temperature: 45 – 55°C • Stop machine on 12° slope with sprocket facing straight up the slope. • Test the distance the machine moves in 5 minutes.

mm

0

0

PC138US, USLC-8

5

SEN02457-01


Service limit value

• Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Lock shoes and relieve travel circuit.

l/min

Max. 1.1

Max. 1.7

Max. 310

Max. 460

Max. 15

Max. 23

Max. 50

Max. 75

Max. 40

Max. 60

Max. 31

Max. 47

RAISE

3.8 ± 0.3 (Until touching cushion)

Max. 4.4 (Until touching cushion)

LOWER

3.1 ± 0.3

Max. 4.2

IN





2.9 ± 0.3

Max. 3.7

2.3 ± 0.2

Max. 2.9

1.2 ± 0.3

Max. 2.5

1.3 ± 0.3

Max. 2.5

Total work • For testing posture, see Work equipment equipment 1 (hydraulic drift at • Place in above posture and test tip of bucket extension or retraction of each teeth) cylinder and downward movement at tip of bucket teeth. Boom cylinder (amount of • Horizontal, flat ground retraction of • Bucket: Rated load (450 kg) cylinder) • Levers at HOLD • Engine stopped Arm cylinder • Hydraulic oil temperature: (amount of extension of 45 – 55°C cylinder) • Start testing immediately after setting. Bucket cylinder • Test hydraulic drift every 5 (amount of minutes, and judge from results retraction of cylinder) for 15 minutes.

Arm Cylinder fully retracted I O Fully extended Bucket Cylinder fully retracted I O Fully extended

• For testing posture, see Work equipment 2 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C

• For testing posture, see Work equipment 3 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • For testing posture, see Work equipment 4 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C

Blade • For testing posture, see Blade in contact Work equipment 5 with ground • Engine at high idle I • Hydraulic oil temperature: O 45 – 55°C Blade fully raised

6

mm

• Engine stopped • Hydraulic oil temperature: Blade (hydraulic 45 – 55°C drift at tip of • Set blade at maximum lifting blade) height and test downward movement at edge of blade for 15 minutes. Boom Bucket teeth in contact with ground I O Cylinder fully extended

Work equipment speed


LOWER RAISE

Work equipment

Unit

OUT


Test conditions

CURL

Item

Hydraulic drift of work equipment

Travel

Category

PC138US-8

DUMP

Applicable model

sec.

PC138US, USLC-8


SEN02457-01

Applicable model


Service limit value

Boom

• For testing posture, see Work equipment 6 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Fully retract arm and bucket cylinders, then lower boom from maximum height and test time taken from point where bucket contacts ground to point where chassis rises from ground.

Max. 3

Max. 3

Arm

• For testing posture, see Work equipment 7 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Set top surface of boom horizontal, retract bucket cylinder fully, then extend arm cylinder and test time taken for arm to start moving again after stopping at bottom.

Max. 2

Max. 2

Bucket

• For testing posture, see Work equipment 8 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Set top surface of boom horizontal, retract arm cylinder fully, then extend bucket cylinder and test time taken for bucket to start moving again after stopping at bottom.

Max. 2

Max. 2

Blade

• For testing posture, see Work equipment 9 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Lower blade from maximum height and test time taken from point where blade contacts ground to point where chassis rises from ground.

Max. 2

Max. 2

Each cylinder

• Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Circuit to be tested is relieved.

Max. 3.5

Max. 15

Max. 10

Max. 50

Time lag

Item

Internal leakage level

Work equipment

Category

PC138US-8

Center swivel joint

PC138US, USLC-8

Test conditions

Unit

sec.

cc/min

7

SEN02457-01


Pump performance curve

q q

a

TVC current: 0.4 A Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm) Check point

Test pump discharge pressure (MPa {kg/cm2})

Discharge pressure of other pump (MPa {kg/cm2})

Average pressure (MPa {kg/cm2})

Standard value for discharge amount Q (l/min)

Judgement standard lower limit Q (l/min)

As desired

P1

P2

P1 + P2 2

See graph

See graph

a

As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when testing. The error is large near the point where the graph curves, so avoid testing at this point. When testing 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 test, and use them as a base for calculating the pump discharge amount at the specified speed. Pump delivery Q in the graph is the delivery from 1 side of the pump.

8

PC138US, USLC-8

a


Posture of machine for testing performance and test procedure Swing 1: Swing brake angle, time taken to start swing, time taken to swing

SEN02457-01

Travel 2: Travel speed (actual run), travel deviation

Travel 3: Travel deviation Swing 2: Hydraulic drift of swing

Travel 4: Hydraulic drift of travel Travel 1: Travel speed (without load)

PC138US, USLC-8

9

SEN02457-01

Work equipment 1: Hydraulic drift of work equipment


Work equipment 4: Bucket speed

Work equipment 5: Blade speed Work equipment 2: Boom speed

Work equipment 6: Boom time lag Work equipment 3: Arm speed

10

PC138US, USLC-8


SEN02457-01

Work equipment 7: Arm time lag

Work equipment 8: Bucket time lag

Work equipment 9: Blade time lag

PC138US, USLC-8

11

SEN02457-01




12

PC138US, USLC-8

SEN02458-01



Machine model

Serial number



30 Testing and adjusting

1

Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting............................................................................................. 3 Testing engine speed ...................................................................................................................................... 6 Testing exhaust temperature........................................................................................................................... 7 Checking exhaust gas color............................................................................................................................ 8 Adjusting valve clearance ............................................................................................................................... 9 Testing compression pressure .......................................................................................................................11 Testing blow-by pressure .............................................................................................................................. 13 Testing engine oil pressure ........................................................................................................................... 14 Handling fuel system parts............................................................................................................................ 15 Releasing residual pressure from fuel system .............................................................................................. 15 Testing fuel pressure..................................................................................................................................... 16 Testing fuel return rate and fuel leakage....................................................................................................... 17 Bleeding air from fuel circuit.......................................................................................................................... 19 Checking fuel circuit for leakage ................................................................................................................... 21 Testing and adjusting alternator belt tension................................................................................................. 22 Testing swing circle bearing clearance ......................................................................................................... 23

PC138US, USLC-8

1

SEN02458-01


Checking and adjusting air conditioner compressor belt tension .................................................................. 24 Checking and adjusting track shoe tension................................................................................................... 25 Testing and adjusting oil pressure in work equipment, swing, and travel circuits ......................................... 27 Testing control circuit basic pressure ............................................................................................................ 30 Testing and adjusting oil pressure in pump PC control circuit....................................................................... 31 Testing and adjusting oil pressure in pump LS control circuit ....................................................................... 34 Testing solenoid valve output pressure ......................................................................................................... 38 Testing PPC valve output pressure ............................................................................................................... 39 Adjusting play of work equipment and swing PPC valves............................................................................. 41 Checking parts which cause hydraulic drift of work equipment..................................................................... 42 Testing and adjusting travel deviation ........................................................................................................... 44 Releasing residual pressure from hydraulic circuit........................................................................................ 46 Testing oil leakage......................................................................................................................................... 47 Bleeding air from each part ........................................................................................................................... 50 Checking cab tipping stopper........................................................................................................................ 52 Adjusting mirrors ........................................................................................................................................... 52

2

PC138US, USLC-8


SEN02458-01

Testing/Adjusting item

Symbol

Exhaust temperatures

R

Part No.

Part name

799-101-1502 Digital thermometer 1 799-201-9001 Handy smoke checker

Checking exhaust gas color

A

Adjusting valve clearance

B

1

Q'ty

Tools for testing, adjusting, and troubleshooting Remarks

1 -99.9 – 1,299°C 1 Bosch index: 0 – 9

2

Commercially Smoke meter available

1

1

795-799-1131 Gear

1

2

Commercially Thickness gauge available

1

Intake: 0.35 mm Exhaust: 0.57 mm

1 795-502-1590 Compression gauge Testing compression presC 795-471-1420 Adapter sure 2 6261-11-3880 Gasket

1 0 – 6.9 MPa {0 – 70 kg/cm2}

Testing blow-by pressure

1 0 – 5 kPa {0 – 500 mmH2O}

Testing engine oil pressure

D 1 799-201-1504 Blow-by checker

1 1

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

799-261-1204 Digital hydraulic tester

1

Pressure gauge:58.8 MPa {600 kg/cm2}

1



1



1


795-471-1450 Adapter

1 Size: 8 x 1.25 mm

07005-00812 Washer

1

1 E

2 799-401-2320 Gauge

1 Testing fuel pressure

F 2

3 799-401-2320 Gauge

Testing fuel return rate and leakage

G

Testing swing circle bearing clearance

Testing and adjusting oil pressure in work equipment, swing, and travel circuits

1


1 6151-51-8490 Spacer

1 ø14

2 6164-81-5750 Joint

1 ø14

3

07042-20108 Plug

1

4

Commercially Hose available

1 Internal dimensions: Approx. 6 mm

5

Commercially Hose available

1 Internal dimensions: Approx. 12 mm

6

Commercially Measuring cylinder available

1

7

Commercially Stopwatch available

1

Commercially Dial gauge available

1


1



1

Pressure gauge: 58.8 MPa {600 kg/cm2}

799-101-5220 Nipple

2 Size: 10 x 1.25 mm

07002-11023 O-ring

2

H

1 J 2

PC138US, USLC-8

For 95E-5 engine

3


Testing basic pressure of control circuit


Symbol

Q'ty

SEN02458-01

Remarks


1



1


Part No.

Part name

1 K 2

799-101-5220 Nipple

2 Size: 10 x 1.25 mm

07002-11023 O-ring

2


1


1


1 Testing and adjusting oil pressure in pump PC con- L 790-261-1204 Digital hydraulic tester trol circuit 2

799-101-5220 Nipple

2 Size: 10 x 1.25 mm

07002-11023 O-ring

2


1



1


1 Testing and adjusting oil pressure in pump LS con- M trol circuit

2 799-401-2701 3

1 Testing solenoid valve outN put pressure

Differential pressure gauge

799-101-5220 Nipple

2 Size: 10 x 1.25 mm

07002-11023 O-ring

2


1



1


2 799-401-3100 Adapter

Testing PPC valve output pressure

Troubleshooting for engine controller/sensors/ actuators

4

1 Size: 02


1



1


1

P

2 799-401-3100 Adapter Testing oil leakage

1 49 MPa {500 kg/cm2}

Q

S

1 Size: 02

Commercially Measuring cylinder available

1

799-601-4100 or T-adapter assembly 799-601-4200

1

799-601-4130 • T-adapter

1 CAM

799-601-4160 • T-adapter

1 Ne sensor

799-601-4220 • T-adapter

1 Engine controller

799-601-4240 • Socket

1 For ambient pressure sensor

799-601-4190 • Socket

1 Common rall pressure sensor

799-601-4340 • Socket

1 Injector

795-799-5530 • Socket

1 Engine water temprature sensor

799-601-4380 Socket

1 Boost pressure sensor

799-601-4390 Socket

1 Engine controller

PC138US, USLC-8


Troubleshooting for chassis sensors/wiring harnesses

Testing coolant temperature and oil temperature Testing operating effort and depressing force

SEN02458-01

Symbol

T

—

Part No.

Part name

Q'ty


799-601-4100 or 799-601-4200 or T-adapter assembly 799-601-9000 or 799-601-9200

1

799-601-9020 • Adapter for DT

1 For DT2P


1

For DT3P (Does not include 799-6014100 and 799-601-4200)


1



1


799-601-9220 • Adapter for HD30

1

For HD30P (Does not include 799601-4100 and 799-601-4200)

799-601-7000 or 799-601-7100 or T-adapter kit 799-601-7400 or 799-601-8000

1

799-601-7050 • Adapter for SWP

1

799-601-7090 • Adapter for M

1 For M2P

799-601-7110 • Adapter for M

1 For M3P

799-101-1502 Digital thermometer

1 -99.9 – 1,299°C

79A-264-0021 Push-pull scale

1

79A-264-0091 Push-pull scale

1 1

Testing stroke and hydraulic drift

—

Commercially Ruler available

Testing work equipment speed

—

Commercially Stopwatch available

1

Testing voltage and resistance

—

Commercially Circuit tester available

1

a

Remarks

For SW6P (Does not include 799601-8000)

For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Troubleshooting (General information on troubleshooting), List of T-boxes and T-adapters".

PC138US, USLC-8

5

SEN02458-01

Testing engine speed a a


1

Testing pump relief speed 1) Start the engine and operate the arm cylinder to the IN stroke end. 2) Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P). 3) Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and test the engine speed.

5.

Testing auto-deceleration speed 1) Start the engine, set the fuel control dial in the high idle position (MAX), and turn the auto-decelerator ON. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed when the auto-decelerator operates. a The engine speed lowers to a certain level about 5 seconds after all the levers and pedals are set in neutral. This level is the auto-deceleration speed.

Test the engine speed with the monitoring function of the machine monitor. Test the engine speed under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range

1.

Preparation work Operate the machine monitor so that the engine speed can be monitored. a For the operating method of the machine monitor, see Special functions of machine monitor. a Monitoring code: 01002 Engine speed

2.

Testing low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed.

3.

Testing high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the working mode in the power mode (P) and turn the auto-decelerator OFF. 3) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed.

6

4.

PC138US, USLC-8


SEN02458-01

Testing exhaust temperature a

1

Run the engine and test the exhaust temperature over the speed range.

5.

After finishing test, remove the testing instrument and return the removed parts.

Testing tools for exhaust temperature

Symbol

Part No.

R

799-101-1502

k

Part name Digital thermometer

Install or remove the testing instrument after the exhaust manifold temperature has lowered.

1.

Remove the engine compartment side cover and exhaust manifold cover.

2.

Remove exhaust temperature pickup plug (1) from the side of the center of the exhaust manifold.

3.

4.

Install sensor [1] of digital thermometer R and connect it to thermometer [2].

PC138US, USLC-8

7

SEN02458-01


Checking exhaust gas color a

Checking tools for exhaust gas color

Symbol A k k

a

a

1.

1

Part No.

Part name

1

799-210-9001

Handy smoke checker

2

Commercially available

Smoke meter

Stop the machine on a level ground and lower the work equipment to the ground. Be careful not to touch any hot part when removing or installing the checking tools. Check the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range If an air source and an electric power source are not available in the field, use handy smoke checker A1. When recording official data, use smoke meter A2. Testing with handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Start the engine and accelerate it suddenly or run it at high idle and operate the handle of smoke checker A1 so that the filter paper will absorb the exhaust gas. a Absorbing time: 1.4 ± 0.2 sec

2)

3)

4)

5)

6) 4) 5) 2.

8

Remove the filter paper and compare it with the attached scale. After finishing checking, remove the testing tools and return the removed parts.

Checking with smoke meter A2 1) Insert probe [1] of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip.

7)

8)

Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter A2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. Connect the power cable to an AC receptacle. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of smoke meter A2.

Start the engine and accelerate it suddenly or run it at high idle and depress the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing checking, remove the checking tools and return the removed parts.

PC138US, USLC-8


SEN02458-01

Adjusting valve clearance a

k

a

3.

Remove plate (5) on the starting motor and insert gear B1.

4.

Remove compression top dead center TDC check plug (6) from the flywheel housing. Rotate the crankshaft forward with gear B1 and set it so that you can see the white mark of the flywheel.

Adjusting tools for valve clearance

Symbol B

1

Part No.

Part name

1

795-799-1131

Gear

2


Thickness gauge

Stop the machine on a level ground and lower the work equipment to the ground. Adjust the valve clearance under the following condition. q Engine coolant temperature: Normal temperature

1.

Open the engine hood and remove air intake hose (1), air conditioner compressor hose clamp (2) and heater hose clamp (3).

2.

Remove cylinder head cover (4). a

PC138US, USLC-8

When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn.

9

SEN02458-01

5.

Adjust the valve clearances marked with q in the valve arrangement drawing according to the following procedure.

1) 2)

3)

6.

10


7.

After finishing adjustment, remove the adjusting tools and return the removed parts. k Take care not to forget remove gear B1. 3 Cylinder head cover mounting nut: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}

While fixing adjustment screw (1), loosen locknut (2). Insert thickness gauge B2 in the clearance between rocker arm (3) and valve stem (4) and adjust the valve clearance with adjustment screw (1). a With the thickness gauge inserted, turn the adjustment screw to a degree that you can move the thickness gauge lightly. While fixing adjustment screw (1), tighten locknut (2). 3 Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm} a After tightening the locknut, check the valve clearance again.

Rotate the crankshaft forward 1 turn according to step 4 to set the No. 4 cylinder to the compression top dead center and adjust the valve c l ea r a nc e s m a r k ed wi th Q i n t he va l v e arrangement drawing similarly to those marked with q.

PC138US, USLC-8


SEN02458-01

Testing compression pressure a

Testing tools for compression pressure

Symbol 1 C k

a

1.

1

2

Part No.

Part name

795-502-1590

Compression gauge

795-471-1420

Adapter

6261-11-3880

Gasket

When testing the compression pressure, take care not to burn you rself on t he exhaust manifold or muffler or get caught in a rotating part. Test the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60°C) Remove the injector of the cylinder to be tested according to the following procedure. a Test of the No. 1 cylinder is explained below as an example. 1) Remove wiring harness connector (2) from injector (1). 2) Move fuel scatter prevention cover (3) from the joint. 3) Remove clamp (4) and high-pressure pipe (5). 4) Pull spill hose connector (6) out of injector (1).

5)

2.

Install adapter C2 to the injector mounting part with holder (7) and connect compression gauge C1. a Fit the gasket to the adapter end without fail. 3

a

Holder mounting bolt: 27 – 30 Nm {2.8 – 3.1 kgm} Tighten the mounting bolt after the fulcrum of the holder is seated perfectly.

Remove holder (7) and injector (1). a If the injector is stuck and is not removed easily, pass a wire under the fuel inlet and pull it up to remove the injector. a Do not apply an external force to the terminal at the injector top.

PC138US, USLC-8

11

SEN02458-01

3.

Disconnect CE03 connector (5) of the engine controller. k If the connector is not disconnected, the engine may starts during test and that is dangerous. Accordingly, be sure to disconnect the connector. k Since the CE03 connector is the power supply circuit of the engine controller, cover the connector on the machine side with a vinyl sheet etc. to prevent leak and ground fault.

4.

Rotate the engine with the starting motor and test the compression pressure. a Test the compression pressure when the gauge pointer is stabilized.

5.

After finishing test, remove the testing instruments and return the removed parts. a Install the injector and spill hose connector according to the following procedure. 1) Fit O-ring (8) and gasket (9) to injector (1). a Do not fit O-ring (8) to groove (a).

12


PC138US, USLC-8


SEN02458-01

Testing blow-by pressure a

Testing tools for blow-by pressure

Symbol D k

a

1

1

Part No. 799-201-1504

Part name Blow-by checker

Stop the machine on a level ground and lower the work equipment to the ground. Test the blow-by pressure under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range

1.

Remove the undercover of the hydraulic pump.

2.

Install tool and adapter [1] of blow-by checker D1 to breather hose (1) and connect gauge [2].

3.

Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON. a If the swing lock switch is turned ON, the main relief valve is set for high-pressure relief.

4.

While running the engine at high idle, relieve the arm circuit and test the blow-by pressure. a Read the gauge when the pointer is stabilized.

PC138US, USLC-8

5.

After finishing test, remove the testing tools and return the removed parts.

13

SEN02458-01


Testing engine oil pressure a

Testing tools for engine oil pressure

Symbol E

1 2

k

a

1

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Gauge

Stop the machine on a level ground and lower the work equipment to the ground. Test the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range

1.

Remove the engine compartment side cover and oil pressure pickup plug (1) from the engine block.

2.

Install nipple [1] of hydraulic tester E1 and connect hydraulic tester E2.

3.

Start the engine and turn the auto-decelerator OFF.

4.

Run the engine and test the engine oil pressure at high idle and low idle.

14

5.

After finishing test, remove the testing tools and return the removed parts. 3 Oil pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm}

PC138US, USLC-8


Handling fuel system parts a

a

SEN02458-01

1

Precautions for checking and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When checking and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.

PC138US, USLC-8

Releasing residual pressure from fuel system 1 a

a

a

k

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel main filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is checked and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before checking the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

15

SEN02458-01


Testing fuel pressure a

Testing tools for fuel pressure

Symbol 1 F

2 3

k

a

k

1.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


795-471-1450

Adapter (8 x 1.25 mm)

07005-00812

O-ring

799-401-2320

Gauge

Stop the machine on a level ground and lower the work equipment to the ground. Test only the fuel pressure in the low-pressure circuit from the priming pump through the fuel main filter to the supply pump and the return circuit from the supply pump/common rail/ injector to fuel tank. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be tested. Testing pressure in fuel low-pressure circuit 1) Open the engine hood and remove fuel pressure pickup plug (1) from the fuel main filter.

2)

16

1

3)

Run the engine at high idle and test the pressure in the fuel low-pressure circuit. a If the pressure in the fuel low-pressure circuit is in the following range, it is normal. Engine speed At high idle

4)

Fuel pressure -49 – 0 kPa {-0.5 – 0 kg/cm2}

After finishing test, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

Install adapter F2 and nipple [1] of hydraulic tester F1 and connect them to oil pressure gauge [2] a Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.

PC138US, USLC-8


SEN02458-01 a

Testing fuel return rate and fuel leakage 1 a

Testing tools for fuel return rate and fuel leakage

Symbol

G

Lay test hose G4 so that it will not slacken and put its end in the oil pan.

Part No.

Part name

1

6151-51-8490

Spacer

2

6164-81-5750

Joint

3

07042-20108

Plug

4


Hose

5


Hose

6


Measuring cylinder

7


Stopwatch

6)

a

Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.

1.

Preparation work 1) Remove tube (3) and spill hose (4) between common rail (1) and return block (2).

Remove spill hose connector joint (5) and install plug G3.

a

2)

3)

4) 5)

The above is the preparation work for test of the leakage from the pressure limiter and return rate from the injector.

Insert spacer G1 on return block (2) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the spacer. Insert joint G2 on common rail (1) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose G4 to the end of joint G2. Connect test hose G5 to connector (6) side of spill hose (4). a Bind the connecting part of the test hose with a wire etc. to prevent it from coming off.

PC138US, USLC-8

17

SEN02458-01

2.


Testing leakage from pressure limiter 1) Lay test hose G4 so that it will not slacken and put its end in the oil pan. 2) Start the engine and keep its speed at 1,600 rpm with no load. 3) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder G6. a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following standard range, it is normal.

4)

Engine speed (rpm)

Leakage (cc/min)

1,600

Max. 20

3.

Testing return rate from injector a While testing the return rate from the injector, keep the test hose on the pressure limiter side connected and keep its end in the oil pan. 1) Run the engine at the rated output. 2) After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder G6. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump pressure is low, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following standard range, it is normal. Limit of return rate (spill) (cc/min)

1,600

190

1,700

200

1,800

210

1,900

220

2,000

230

After finishing test, stop the engine.

3) 4.

18

Rated output speed (rpm)

After finishing test, stop the engine.

After finishing test, remove the testing tools and return the removed parts. 3 Joint bolt: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}

PC138US, USLC-8


Bleeding air from fuel circuit a k

SEN02458-01

1

If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. Stop the machine on a level ground and lower the work equipment to the ground.

1.

Fill the fuel tank with fuel. a Add fuel until the float of the sight gauge reaches the maximum position.

2.

Open the side cover of the pump room.

3.

Loosen knob (1) of the feed pump and pull it out, and then operate it forward and backward. a Move the knob until it becomes heavy. a The plug at the top of the fuel main filter does not need to be removed.

4.

After bleeding air, push in and tighten knob (1).

PC138US, USLC-8

19

SEN02458-01


a

Air bleeding route of fuel circuit Fuel tank o Pre-filter o Main filter o Feed pump o Metering unit o Fuel tank

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Fuel tank Priming pump Pre-filter with water separator Main filter Feed pump IMV (Inlet Metering Valve) Overflow valve Rail Injector Safety valve High pressure pump

20

PC138US, USLC-8


Checking fuel circuit for leakage 1 k

k

a

Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After checking the fuel system or removing its parts, check it for fuel leakage according to the following procedure. Stop the machine on a level ground and lower the work equipment to the ground. Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage.

1.

Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.

3.

Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.

4.

Run the engine at low idle.

5.

Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.

6.

Run the engine at high idle.

7.

Check the fuel piping and devices for fuel leakage. a Check around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.

8.

Run the engine at high idle and load it. a Relieve the arm circuit at the IN stroke end.

PC138US, USLC-8

SEN02458-01

9.

Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2. a If no fuel leakage is detected, check is completed.

21

SEN02458-01

Testing and adjusting alternator belt tension 1 Testing 1. Remove the engine compartment side cover and air intake pipe (1).

Press the intermediate point of the belt between the alternator pulley and fan pulley with a finger and test deflection (a) of the belt. a Pressing force: Approx. 60 Nm {Approx. 6.1 kg} a Deflection (a): 6 – 10 mm

22


Adjusting a If the deflection is out of the standard range, adjust the belt tension according to the following procedure. 1.

Loosen alternator fixing bolts (1) and (2). a Loosen fixing bolt (2) from the rear side of the engine.

2.

Adjust the tension of alternator belt (4) by turning adjustment bolt (3). a Do not loosen double nut (5) at the adjustment bolt end. (If you have loosened it, apply LOCTITE (LT-2) to it when tightening.) Reference: If adjustment bolt (3) is tightened (turned to the right), the alternator belt (4) is loosened. If the former is turned to the left, the latter is tightened.

3.

After adjusting the belt tension, tighten alternator fixing bolts (1) and (2).

4.

Check again that the tension of alternator belt (4) is in the standard range.

PC138US, USLC-8


SEN02458-01

Testing swing circle bearing clearance a

Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats. a At this time the front of the upper structure rises and the rear lowers.

5.

Under this condition, read dial gauge H. a The value indicated by dial gauge H is the clearance of the bearing. a For the standard value, see Structure, function and maintenance standard, "Swing circle".

6.

Return the machine to the condition of step 2 and check that dial gauge H indicates 0. a If the dial gauge does not indicate 0, repeat steps 2 through 5.

1

Testing tools for swing circle bearing clearance

Symbol

Part No.

H


a k k

1.

4.

Part name Dial gauge

When testing the swing circle bearing clearance installed to the machine, perform the following procedure. Stop the machine on a level ground and lower the work equipment to the ground. Do not put your hands or feet under the undercarriage during test. Fix dial gauge H to the track frame and apply the probe to the lower end of the outer race.

2.

Set the work equipment to the maximum reach position and set the bucket tip to the height of the under side of the revolving frame. a At this time the front of the upper structure lowers and the rear rises.

3.

Set dial gauge H to the 0 point.

PC138US, USLC-8

23

SEN02458-01

Checking and adjusting air conditioner compressor belt tension k


1

Stop the machine on a level ground and lower the work equipment to the ground.

Checking 1. Open the engine hood, press the intermediate point of the belt between the fan pulley and compressor pulley with a finger, and test deflection (a) of the belt. q Belt pressing force: 60 N {6.1 kg}

24

Adjusting a If the belt deflection is abnormal, adjust it according to the following procedure. 1.

Loosen bolts (1) and (2) and locknut (6).

2.

Move compressor (3) and bracket (4) as a set with adjustment bolt (5) to adjust the belt tension.

3.

After positioning compressor (3), tighten bolts (1) and (2) and locknut (6). a Check each pulley for breakage, wear of the V-groove, and contact of the V-belt and V-groove. a If the V-belt is so lengthened that the adjustment allowance is eliminated or it has a cut or a crack, replace it. a If the belt is replaced, adjust their tension again after operating the machine for 1 hour. a After tightening the bolts, check the belt tension again according the above procedure.

4.

After finishing test, return the removed parts.

PC138US, USLC-8


Checking and adjusting track shoe tension

SEN02458-01

1

Checking 1. Run the engine at low idle and drive the machine forward by the length of track on ground, and then stop slowly. 2.

Place square bar [3] longer than the distance between idler (1) and carrier roller (2) on the track shoe. a As the steel bar, use an angle steel, etc. which will be deflected less.

3.

Test maximum clearance (a) between steel bar [3] and track shoe. q Standard maximum clearance (a): 10 – 30 mm

Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1.

Increasing tension 1) Add grease through grease fitting (2) with a grease gun. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track shoe tension again according to the above procedure.

a

PC138US, USLC-8

You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. If the tension is still low, the pins and bushings are worn much. In this case, reverse or replace the pins and bushings.

25

SEN02458-01

2.

26


Decreasing tension 1) Loosen valve (1) to discharge grease, and then tighten it. k Do not loosen the valve more than 1 turn. If it is loosened more, it may jump out because of the highpressure grease in it. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track shoe tension again according to the above procedure.

PC138US, USLC-8


SEN02458-01

Testing and adjusting oil pressure in work equipment, swing, and travel circuits 1 a

Testing and adjusting tools for oil pressure in work equipment, swing, and travel circuits

Symbol 1 J 2 k

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-101-5220

Nipple (10 × 1.25 mm)

07002-11023

O-ring

Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit".

2)

Install nipples J2 and connect oil pressure gauges [1] of hydraulic tester J1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.

Testing a The oil pressure in the work equipment, swing, and travel circuits (pump discharge pressure) can be checked with monitoring function of the machine monitor, too (For details, see "Special functions of machine monitor"). q Monitoring code: 01100 pump pressure a Test the oil pressure in the work equipment, swing, and travel circuits under the following condition. q Hydraulic oil temperature: Within operating range 1.

Preparation work 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure port (1) check plug q (2): Pump discharge pressure port (2) check plug

PC138US, USLC-8

2.

Testing unload pressure 1) Start the engine, set the working mode in the power mode (P), and turn the autodecelerator OFF. 2) Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure. a The pressure tested when the unload valve is unloaded is indicated.

27

SEN02458-01

3.

Testing work equipment relief pressure 1) Start the engine and move the cylinder to be tested to the stroke end. 2) Set the working mode in the power mode (P). 3) Run the engine at high idle, operate the right and left work equipment control levers to relieve the cylinder, and test the oil pressure. a The pressure tested when the main relief valve is relieved is indicated (If t he boo m is l owe r ed si ng ly, t he safety-suction valve of the control valve for lowering the boom is relieved).

4.

Testing swing relief pressure 1) Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON. 2) Run the engine at high idle, operate the left work equipment control lever to relieve the swing motor, and test the oil pressure. a The pressure tested when the swing motor relief valve is relieved is indicated. a The swing relief pressure is lower than the main relief pressure.

5.

Testing travel relief pressure 1) Run the engine and lock the travel mechanism. k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely.

28


2) 3)

6.

Set the working mode in the power mode (P). Run the engine at high idle, operate the travel lever and pedal to relieve the travel motor, and test the oil pressure. k Before operating the travel lever and pedal, check the position and locking direction of the locked sprocket again. a The pressure tested when the main relief valve of the control valve is relieved is indicated. The travel circuit is always relieved at high pressure.

Work after finishing test After finishing test, remove the testing tools and return the removed parts. 3 Oil pressure pickup plug: 20 – 27 Nm {2.0 – 2.8 kgm}

PC138US, USLC-8


Adjusting a The unload valve and safety-suction valve for lowering the boom cannot be adjusted. 1.

SEN02458-01

2.

Adjusting swing relief pressure a If the swing relief pressure is abnormal, adjust safety valve (6) of the swing motor according to the following procedure.

Adjusting work equipment and travel relief pressure a If the relief pressure of the work equipment circuit and travel circuit is abnormal, adjust main relief valves (3) according to the following procedure. q (3): Main relief valve a When adjusting the main relief valves, remove the side cover of the control valve.

1) 2)

1) 2) 3)

4)

Remove the control valve left side cover. While fixing holder (4), loosen locknut (5). Turn holder (4) to adjust the set pressure. a If the holder is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} While fixing holder (4), tighten locknut (5). 3 Locknut: 49 – 58.8 Nm {5 – 6 kgm}

3)

4)

5)

While fixing adjustment screw (7), loosen locknut (8). Turn adjustment screw (7) to adjust the pressure. a If the adjustment screw is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of adjustment screw: Approx. 6.7 MPa {Approx. 68.4 kg/cm2} While fixing adjustment screw (7), tighten locknut (8). 3 Locknut: 78 – 103 Nm {8 – 10.5 kgm}

After finishing adjustment, check again that the oil pressure is normal according to the above described test procedure.

After finishing adjustment, check again that the oil pressure is normal according to the above described test procedure.

PC138US, USLC-8

29

SEN02458-01


Testing control circuit basic pressure a

1 K 2

a

1.

2.

30

Start the engine, set the working mode in the power mode (P), and turn the auto-decelerator OFF.

4.

Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure.

5.


a

The control circuit basic pressure may be tested with oil pressure pickup plug (2) on the hydraulic pump side.

a

Do not adjust the relief valve for control circuit basic pressure.

1

Testing tools for control circuit basic pressure

Symbol

k

3.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-101-5220

Nipple (10 × 1.25 mm)

07002-11023

O-ring

Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Test the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range Remove the control valve cover and oil pressure pickup plug (1).

Install nipple K2 and connect oil pressure gauge [1] of hydraulic tester K1. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.

PC138US, USLC-8


SEN02458-01

Testing and adjusting oil pressure in pump PC control circuit 1 a

Testing and adjusting tools for oil pressure in pump PC control circuit

Symbol 1 L 2 k

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-101-5220

Nipple (10 × 1.25 mm)

07002-11023

O-ring


2)

Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1.

Testing a Before testing the oil pressure in the PC control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure of the control circuit are normal. a Test the oil pressure in the pump PC control circuit under the following condition. q Hydraulic oil temperature: Within operating range 1.

a

Testing PC valve output pressure (servo piston inlet pressure) a Test the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): PC valve output pressure pickup plug

a

3) 4)

PC138US, USLC-8

Install nipple L2 to the inspection part of plug (2) and connect it to oil pressure gauge [1] by hose [2] of hydraulic tester L1. Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.

Start the engine and move the arm cylinder to the IN stroke end. Set the working mode in the power mode (P).

31

SEN02458-01

5)


Run the engine at high idle, operate the left work equipment control lever to relieve the arm circuit at the IN stroke end, and test the oil pressure.

2)

Install nipples L2 and connect them to oil pressure gauges [1]. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.

a

3)

Start the engine and set the working mode in the power mode (P). Run the engine at high idle and low idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed.

Testing condition and method of judgment: If the pressures are in the following ratio, the PC valve is normal. Tested oil pressure

Pump discharge pressure PC valve output pressure

Operation of lever

4)

Ratio of oil pressures 1

Arm IN relief

Approx. 0.6 (Approx. 3/5)

a

6) 2.

If the PC valve or the servo piston is abnormal, the PC valve output pressure (servo piston inlet pressure) is "the same as the pump discharge pressure" or "almost 0". After finishing test, remove the testing tools and return the removed parts.

Testing PC-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup plugs (3). (3): PC-EPC valve output pressure pickup plug

a

Testing condition and method of judgment: If the output pressures are in the following ratio, the PC-EPC valve is normal.

Engine Low idle High idle

5)

32

Operation of lever All control levers and pedals in neutral

Output pressure Approx. 2.9 MPa {Approx. 30 kg/cm2} Approx. 3.4 MPa {Approx. 35 kg/cm2}


PC138US, USLC-8


Adjusting Adjusting pump PC valve a If the following phenomenon occurs and PC valve (4) seems to be defective, adjust PC valve (4) according to the following procedure. q As the working load increases, the engine speed lowers remarkably. q The engine speed is normal but the work equipment speed is low. a The width across flats of the PC valve locknut is 13 mm and that of the adjustment screw (inside width) is 4 mm. Do not turn any other locknuts or adjustment screws since they affects the hydraulic pump performance.

1.

Loosen locknut (5). a Before loosening the locknut, make counter mark at the adjustment screw end so that you can see the position of the locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse).

2.

Turn adjustment screw (6) clockwise or counterclockwise to adjust. a Turn the adjustment screw q Clockwise when the work equipment s pee d i s low ( to i nc re ase pu mp absorption torque) and q Counterclockwise when the engine speed lowers (to decrease pump absorption torque).

3.

Tighten locknut (5). 3 Locknut: 27 – 34 Nm {2.8 – 3.5 kgm}

PC138US, USLC-8

SEN02458-01

4.

After finishing adjustment, check again that the PC valve output pressure (servo piston inlet pressure) is normal according to the above described test procedure.

33

SEN02458-01


Testing and adjusting oil pressure in pump LS control circuit 1 a

Testing and adjusting tools for oil pressure in pump LS control circuit

Symbol 1 M

2 3

k

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-401-2701

Differential pressure gauge

799-101-5220

Nipple (10 × 1.25 mm)

07002-11023

O-ring


2)

Install nipple M3 and connect it to oil pressure gauge [1] of hydraulic tester M1.

Testing a Before testing the oil pressure in the LS control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure of the control circuit are normal. a Test the oil pressure in the pump LS control circuit under the following condition. q Hydraulic oil temperature: Within operating range 1.

a

Testing LS valve output pressure (servo piston inlet pressure) a Test the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): LS valve output pressure pickup plug

a

3)

34

Install nipple M3 to the inspection part of plug (2) and connect it to oil pressure gauge [1] by hose [2] of hydraulic tester M1. Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.

Start the engine and push up the track shoe on the side to be tested with the work equipment and prepare for running the track shoe idle. k Since the raised track shoe will be run idle during test, secure a sufficient working area.

PC138US, USLC-8


4) 5)

SEN02458-01

Set the working mode in the power mode (P) and set the travel speed in the High position. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed. Then, operate the travel lever to run the track shoe idle and test the oil pressure. k While checking the safety around the machine extremely, run the track shoe pushed up idle. a Do not operate the travel lever to the stroke end (but stop it halfway).

a

Testing condition and method of judgment: If the pressures are in the following ratio, the LS valve is normal. Operation of lever and ratio of oil pressures Tested oil pressure

Pump discharge pressure LS valve output pressure

6) 2.

All control Travel lever levers and moved halfpedals in neu- way (Track tral shoe run idle) 1 Almost same

Approx. 0.6 (Approx. 3/5)

2)

Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): LS pressure pickup plug

3)

Install nipples M3 and connect it to differential pressure gauge M2 or the oil pressure gauge [1] of hydraulic tester M1. a When using differential pressure gauge M2: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12V power source, connect it to a battery. a When using oil pressure gauge (in M1): Use the oil pressure gauge of 58.8 MPa {600 kg/cm2} having the unit of 0.98 MPa {10 kg/cm2}. Since the differential pressure is about 3.9 MPa {40 kg/cm 2 } at maximum, test it by installing the same gauge to the pickup plugs alternately. q The figure shows the pump discharge pressure side.


Testing LS differential pressure a Test the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the difference between them. 1) Remove connector V5 (Port A4) of the solenoid valve. Purpose: Remove the connector to set the merge-divider valve in the constant merge state and stabilize the LS differential pressure.

PC138US, USLC-8

35

SEN02458-01

q

30 Testing and adjusting a

The figure shows the LS pressure side.

7)

4)

5) 6)

36

Run the engine, push up the track shoe on the side to be tested with the work equipment, and prepare for running track shoe idle. q When testing P1 circuit: Right track shoe q When testing P2 circuit: Left track shoe k Since the raised track shoe will be run idle during test, secure a sufficient working area. Set the working mode in the power mode (P) and set the travel speed in the High position. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed. Then, operate the travel lever to run the track shoe idle and test the oil pressure. k While checking the safety around the machine extremely, run the track shoe pushed up idle. a Do not operate the travel lever to the stroke end (but stop it halfway).

Testing condition and method of judgment: If the pressures are in the following ratio, the LS valve is normal. Operation of levers

LS differential pressure

All control levers and pedals in neutral

2.8 ± 1.0 MPa {28 ± 10 kg/cm2}

Travel lever moved halfway (No-load travel operation of one side)

2.2 ± 0.1 MPa {22.5 ± 1 kg/cm2}

After finishing test, remove the testing tools and return the removed parts. Insert the removed connector V5 of the solenoid valve in its original position.

PC138US, USLC-8


SEN02458-01

Adjusting Adjusting LS valve a If the LS differential pressure is abnormal, adjust the LS valve according to the following procedure. q (3): Pump LS valve

1.

While fixing adjustment screw (4), loosen locknut (5).

2.

Turn adjustment screw (4) to adjust the differential pressure. a If the adjustment screw is q Turned to the right, the differential pressure is increased. q Turned to the left, the differential pressure is decreased. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. 1.1 MPa {Approx. 10.8 kg/cm2}

3.

While fixing adjustment screw (4), tighten locknut (5). 3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}

4.

After finishing adjustment, check again that the LS differential pressure is normal according to the above described test procedure.

PC138US, USLC-8

37

SEN02458-01


Testing solenoid valve output pressure a

1

N

2 k

a a

1.

Part No. 799-101-5002

Install adapter N2 and connect the disconnected hose again.

3.

Install nipple [1] of hydraulic tester N1 and connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. a The figure shows the testing tools connected to outlet hose (1) of the PPC lock solenoid valve.

4.

Start the engine.

5.

Run the engine at high idle, operate the control levers and switches to turn the solenoid valve ON or OFF, and test the oil pressure. a For the conditions for turning the solenoid valve ON and OFF, see the operation table of each solenoid valve. a The operating condition of the solenoid valve can be checked with the monitoring function of the machine monitor (For details, see "Special functions of machine monitor"). q Monitoring code: 02300 Solenoid 1 a If the output pressure is as follows, the solenoid valve is normal.

1

Testing tools for solenoid valve output pressure

Symbol

2.

Part name Hydraulic tester

790-261-1204


799-401-3100

Adapter (Size: 02)

Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Before testing the solenoid valve output pressure, check that the basic pressure of the control circuit is normal. Test the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range Remove the control valve left side cover and disconnect outlet hoses (1) – (5) of the solenoid valve to be checked.

No.

Solenoid valve to be tested

1

PPC lock solenoid valve

2

Travel speed shifting solenoid valve

3

Swing holding brake solenoid valve

4

Merge-divider valve

5

Travel junction solenoid valve

a

When testing with hose (1), remove the undercover (rear side) of the operator's cab.

6.

38

Solenoid valve

Output pressure

OFF (Demagnetization)

0 MPa {0 kg/cm2}

ON (Excitation)

2.9 MPa {30 kg/cm2}


PC138US, USLC-8


Testing PPC valve output pressure

SEN02458-01 a

1

Testing tools for PPC valve output pressure

Symbol

Connecting points of PPC piping P

1 2

k

a a a

a

The above figure shows the connecting points of the PPC piping on the control valve of 1 attachment installation specification. The colors in ( ) are the colors of the bands installed for distinction of the pipes. The figure at right shows the check points of the steering signal voltage of the travel PPC valve. When testing the steering signal voltage, remove the undercover of the operator's cab (front side).

PC138US, USLC-8

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204


799-401-3100

Adapter (Size: 02)

Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Before testing the PPC valve output pressure, check that the basic pressure of the control circuit is normal. Test the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range

1.

Disconnect the hose of the PPC circuit to be tested. a For the hose to be disconnected, see "Connecting points of PPC piping".

2.

Install adapter P2 and connect the disconnected hose again.

3.

Install nipple [1] of hydraulic tester P1 and connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. a The figure shows the testing tools connected to the hose of the bucket dump PPC circuit.

39

SEN02458-01


4.

Start the engine and set the working mode in the power mode (P).

5.

Run the engine at high idle and test the oil pressure with the control lever in neutral and moved to the stroke end.

a

6.

40

If the output pressure is as follows, the PPC valve is normal. Operation of lever

Output pressure

Neutral

0 MPa {0 kg/cm2}

Stroke end

Almost same as control circuit basic pressure (See standard values table)


PC138US, USLC-8


SEN02458-01

Adjusting play of work equipment and swing PPC valves 1 a

If the right and left work equipment levers have large play, adjust them according to the following procedure.

1.

Remove the work equipment and swing PPC valve assembly.

2.

Remove bellows (1).

3.

Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4).

4.

Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 93.1 – 112.7 Nm {9.5 – 11.5 kgm}

5.

Install bellows (1).

6.

Install the work equipment and swing PPC valve assembly.

PC138US, USLC-8

41

SEN02458-01

Checking parts which cause hydraulic drift of work equipment1 a

If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylind e r pa c k i n g s i d e o r c o n t r o l v a l v e s i d e according to the following procedure.

1.

Checking boom cylinder and bucket cylinder 1) Set the machine in the position for testing hydraulic drift and stop the engine. a Fill the bucket with a rated load or with dirt and sand.


2.

Checking arm cylinder 1) Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine.

2)

2)

42

When checking the boom cylinder, set the boom control lever in the RAISE position. When checking the bucket cylinder, set the bucket control lever in the CURL position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator.

Operate the arm control lever in the IN position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator. [Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2) As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then the lowering speed is lowered. 3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.

PC138US, USLC-8


3.

SEN02458-01

Checking PPC valve While the pressure in the accumulator is high, set the lock lever in the LOCK/FREE position and test the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator. a If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).

PC138US, USLC-8

43

SEN02458-01

Testing and adjusting travel deviation


1

Inspection 1. Run the engine and heighten the hydraulic oil temperature to the operating range and set the machine in the travel posture. a To set the machine in the travel posture, extract the bucket cylinder and arm cylinder fully and set the boom angle to 45°. 2.

Set the working mode to P and travel speed to Lo.

3.

Run up for 10 m with the engine speed at high idle and continue travel under the same condition for 20 m and measure the deviation (a). a Install an oil pressure gauge and check that the P1 and P2 discharge pressures of the hydraulic pump are even.

44

PC138US, USLC-8


Adjustment a If the machine deviates, it can be corrected by partially draining the oil discharged more from the pump through the travel deviation adjusting plug. (If the travel deviation is corrected by this method, however, the pump discharge is reduced. As a result, the travel speed, work equipment speed in compound operation, and relief pressure may lower.) a If the machine deviates in the same direction regardless of the travel direction, correct it according to the following procedure. (If the deviating direction of the machine depends on the travel direction, the cause of deviation may not be in the hydraulic pump. In this case, carry out troubleshooting.) a Only when the travel deviation is 200 mm or less, it can be corrected by the following method. k If the adjusting plug is loosened more than the adjustment limit, high-pressure oil will spout out. Take care extremely. k Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the residual pressure from the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 1.

Check the deviating direction and the locations of travel deviation adjusting plugs (1) and (2). q (1): Right deviation adjusting plug (P1 pump) q (2): Left deviation adjusting plug (P2 pump) a Loosen only the plug on either side for adjustment. Do not loosen the plugs on both sides.

PC138US, USLC-8

SEN02458-01

2.

Fixing plug (3) with a hexagonal wrench (Width across flats: 4 mm), loosen locknut (4). a If the locknut is sealed with a vinyl tape, remove that tape. a Before loosening the locknut, make match marks on it and pump case. q Loosening angle of locknut: Approx. 90 – 180°

3.

Loosen plug (3) to adjust the travel deviation. q Quantity of adjustment of deviation per turn of plug: 150 mm (Reference) a The plug is fully tightened when shipped. Adjust the deviation by the loosening angle of the plug from the fully tightened position. a If the plug is turned together with the locknut, tighten it fully again, then start adjustment. a The plug can be loosened by 2 turns (720°) from the fully tightened position.

4.

Fixing plug (3) with a hexagonal wrench, tighten locknut (4). 3 Locknut: 2.9 – 4.9 Nm {0.3 – 0.5 kgm} a After tightening the locknut, seal its hole with a vinyl tape.

5.

After finishing adjustment, check travel deviation again according to the procedure for inspection described above.

45

SEN02458-01


Releasing residual pressure from hydraulic circuit 1 1.

2.

46

Releasing residual pressure from hydraulic tank k Since the hydraulic tank is enclosed and pressurized, release the residual pressure from it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable position and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank.

4)

Repeat steps 2) and 3) above 2 – 3 times, and the residual pressure in the piping is released completely.

3.

Releasing residual pressure from swing motor circuit The residual pressure in the swing motor circuit can be released by performing the operation for "Releasing residual pressure from hydraulic cylinder circuit" (Operate the lever in the swing direction only, however).

4.

Releasing residual pressure from travel motor circuit Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by performing "Releasing residual pressure from hydraulic tank".

Releasing residual pressure from hydraulic cylinder circuit k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the residual pressure from the piping according to the following procedure. 1) Lower the work equipment and release the residual pressure from the hydraulic tank. For details, see "Releasing residual pressure from hydraulic tank". a Keep the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch ON and set the lock lever in the FREE position, and then operate the right and left work equipment control levers forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up, however, after the control valve is operated 2 – 3 times. 3) Run the engine at low idle for 5 seconds to heighten the pressure in the accumulator. a The engine does not start until the lock lever is set in the LOCK position once.

PC138US, USLC-8


SEN02458-01

Testing oil leakage a

1

Testing tools for oil leakage

Symbol

Part No.

Q


Part name Measuring cylinder

a

Test the oil leakage under the following condition. q Hydraulic oil temperature: Within operating range

1.

Testing oil leakage from boom cylinder 1) Move the boom cylinder to the RAISE stroke end and stop the engine. k Release the residual pressure from the piping on the boom cylinder head side. For details, see "Releasing residual pressure from hydraulic circuit" (Operate the lever in the boom RAISE direction only, however). 2) Disconnect hose (1) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-00640 (Flange #06)

2.

Testing oil leakage from arm cylinder 1) Move the arm cylinder to the IN stroke end and stop the engine. k Release the residual pressure from the piping on the arm cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the arm IN direction only, however). 2) Disconnect hose (2) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70522 (Plug #05)

3)

4) 5)

3) 4) 5)

Run the engine at high idle and relieve the arm circuit by moving the arm IN. k Take care not to "move the arm OUT". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.

Run the engine at high idle and relieve the boom circuit by raising the boom. k Take care not to "lower the boom". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.

PC138US, USLC-8

47

SEN02458-01

3.

Testing oil leakage from bucket cylinder 1) Move the bucket cylinder to the CURL stroke end and stop the engine. k Release the residual pressure from the piping on the bucket cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the bucket CURL direction only, however). 2) Disconnect hose (3) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70422 (Plug #04)


4.

Testing oil leakage from swing motor 1) Disconnect 2 drain hoses (4) and block the hose side with plugs. a Use the following parts to block the hose side. 07376-70315 (Plug #03)

2) 3)

4) 3) 4) 5)

48

Turn the swing lock switch ON. Run the engine at high idle and relieve the swing circuit by swinging. a Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. a After testing 1 time, swing 180°, and then test again. After finishing test, return the removed parts.

Run the engine at high idle and relieve the bucket circuit by curling the bucket. k Take care not to "dump the bucket". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.

PC138US, USLC-8


5.

Testing oil leakage from travel motor 1) Remove the travel motor cover. 2) Run the engine, lock the travel mechanism, and stop the engine. k Put pin [1] between the sprocket and track frame to lock the travel mechanism securely.

3)

Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Use the following part to block the hose side. 07376-70422 (Plug #04)

4)

Run the engine at high idle, relieve the travel circuit, and test the oil leakage. k Before operating the travel lever, check the position and locking direction of the locked sprocket again. k Wrong operation of the lever can cause an accident. Accordingly, make signs and checks securely. a Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. a Test several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time.

PC138US, USLC-8

SEN02458-01

5)

After finishing test, return the removed parts.

49

SEN02458-01


Bleeding air from each part Air bleeding item

1 Air bleeding procedure 1

2

3

Bleeding air from hydraulic pump

Starting engine

q

q

4

5

6

Bleeding air Bleeding air Bleeding air from swing from travel from cylinder motor motor

Checking oil level and starting operation

q

q (See note)

q (See note)

q

q

o

o

o

q

q

q

o

o

q

• Replacing and repairing control valve • Removing control valve piping

q

q

o

o

q

• Replacing and repairing cylinder • Removing cylinder piping

q

q

o

o

q

• Replacing and repairing swing motor • Removing swing motor piping

q

o

q

o

q

• Replacing and repairing travel motor • Removing travel motor piping

q

o

o

q

q

• Replacing and repairing swivel joint • Removing swivel joint piping

q

o

o

o

q

Contents of work • Replacing hydraulic oil • Cleaning strainer • Replacing return filter element • Replacing and repairing hydraulic pump • Removing suction piping

q

Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1.

50

Bleeding air from hydraulic pump 1) Loosen air bleeder (1) and check that oil oozes out through the air bleeder. 2) After the oil oozes out, tighten air bleeder (1). 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} a Do not use an impact wrench to tighten the air bleeder.

2.

Starting engine When running the engine after performing step 1, keep its speed at low idle for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).

3.

Bleeding air from cylinder a If a cylinder is replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idle for about 5 minutes. 2) While running the engine at low idle, raise and lower the boom 4 – 5 times. a Stop the piston rod about 100 mm b efo re e ac h s tr ok e en d. Do no t relieve the oil.

PC138US, USLC-8


3) 4)

5) 4.

While running the engine at high idle, perform step 2). While running the engine at low idle, move the piston rod to the stroke end and relieve the oil. Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4).

SEN02458-01

6.

Checking oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.

Bleeding air from swing motor 1) Turn the swing lock switch "ON" and run the engine at low idle for 5 minutes. a Bleed air from the swing motor by applying the S-port pressure. 2) Remove the swing motor top cover, disconnect hose (1) from the swing motor, and block the hose with a plug. a Use the following plug to block the hose. 07379-70628 (Plug #06) 2)

3)

4) 5.

Check the oil level by sight gauge (3) on the rear side of the hydraulic tank. a If the oil level is below line L, it is insufficient. Add oil. a The oil level changes according to the oil temperature. Add oil when the oil level is out of the following standard ranges. q When oil temperature is 10 – 30°C: Between line H and line L q When oil temperature is 50 – 80°C: Near line H

Run the engine at low idle and check that oil flows out of elbow (2). a If no oil flows out of the elbow, perform step 1) again. Connect hose (1) under its normal condition.

Bleeding air from travel motor 1) Remove the travel motor cover and disconnect motor drain hose (2). 2) Run the engine at low idle and check that oil flows out of nipple (3).

PC138US, USLC-8

51

SEN02458-01

Checking cab tipping stopper


1

Adjusting mirrors

1

Adjusting mirrors (a1) and (b1) Loosen bolts (1) and (2) of the mirrors and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator's seat. a Adjust the mirrors so that the operator can see persons (or things 1 m high and about 30 cm in diameter) at the right and left rear of the machine.

a

Check the cab tipping stopper according to the following procedure.

1.

Remove the side lower cover of the operator's cab. a Perform this step only when the additional undercover is installed.

2.

Check the tightening torque of the mounting bolt (2) of the lock plate (1). 3 Bolt (2): 98 – 123 Nm {10 – 12.5 kgm}

[Reference] q The tightening torque of mounting bolt (4) of cab tipping stopper (3) is different from that of a common bolt 30 mm in diameter. Take care. 3 Bolt (4): 245 – 309 Nm {25 – 31.5 kgm}

52

Adjusting mirrors (c1) and (d1) Adjust the mirrors so that the operator can see the ground at 1 m around the machine from the operator's seat. a If the mirror is hard to move for adjustment, loosen bolts (3) and (4).

PC138US, USLC-8


PC138US, USLC-8

SEN02458-01

53

SEN02458-01




54

PC138US, USLC-8

SEN02459-00



Machine model

Serial number




1

Testing and adjusting, Part 2 Special functions of machine monitor ............................................................................................................. 2

PC138US, USLC-8

1

SEN02459-00

Special functions of machine monitor


1

Air conditioner specification

2

PC138US, USLC-8


SEN02459-00

Upper section of machine monitor (Display section) (a): Multi-display a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Auto-decelerator switch [2]: Numeral 2 input switch/Working mode selector switch [3]: Numeral 3 input switch/Travel speed shifting switch [4]: Numeral 4 input switch/Alarm buzzer cancel switch [5]: Numeral 5 input switch/Wiper switch [6]: Numeral 6 input switch/Windshield washer switch [7]: Numeral 7 input switch/Air conditioner or heater switch [8]: Numeral 8 input switch/Air conditioner or heater switch [9]: Numeral 9 input switch/Air conditioner or heater switch [0]: Numeral 0 input switch/Air conditioner or heater switch Switch having no numerals: Air conditioner or heater switch a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multidisplay.

PC138US, USLC-8

3

SEN02459-00


t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.

t Operator mode (Outline)

Page

Page

Service mode

6p

19p

6p

Monitoring

20p

A Display of inputting password

7p

25p

A Display of check before starting

7p

A Display of warning after check before starting

7p

Mechanical Systems Abnormality Electrical Systems Record Air-conditioning System

32p

A Display of ending of maintenance interval

7p

Maintenance Record

33p

A Display of check of working mode and travel speed

8p

Maintenance Mode Change

34p

A Display of ordinary screen

8p

Phone Number Entry

36p

A Display of end screen

8p

Key-on Mode

37p

B Selection of auto-deceleration

8p

Unit

38p

B Selection of working mode

9p

With/Without Attachment

39p

Attachment/Maintenance Password

40p

Camera

41p

ECO Display

42p

Pump Absorption Torque

43p

Attachment Flow Adjustment

44p

O (Special operation)

A Display of KOMATSU logo

Default

26p

B Selection of travel speed

10p

B Operation to stop alarm buzzer

10p

B Operation of windshield wiper

10p

B Operation of window washer

10p

B Operation of air conditioner/heater

11p

B Operation to display camera mode

11p

Cylinder Cut-Out

45p

B Operation to display clock and service meter

12p

No Injection

46p

B Check of maintenance information

12p

Fuel Consumption

48p

B

Setting and display of user mode (Including KOMTRAX messages for user)

13p

C Display of energy-saving guidance

14p

C Display of caution monitor

14p

C Display of user code and failure code

14p

O (Special operation) D

Function of checking display of LCD (Liquid Crystal Display)

D Function of checking service meter D

4

Function of changing attachment/maintenance password

Adjustment

Terminal Status

49p

KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300) MODEM IP Address (TH200/201) Display of KOMTRAX message

50p 51p 52p 53p

16p 16p 17p

PC138US, USLC-8


SEN02459-00

Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch

PC138US, USLC-8

5

SEN02459-00 t a

a


Operator mode (Outline) Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see the Structure, function and maintenance standard, or Operation and Maintenance Manual. The following are the displays or functions of the operator mode explained in this section (including some items which need special operations).

a

Display pattern A B C D E Display of KOMATSU logo

1 1 1 1 1

Display of inputting password

2 — — — —

Display of check before starting

3 2 3 2 2

Display of warning after check before starting

— — — 3 —

Display of ending of maintenance interval

— — — — 3

Display of check of working mode and travel speed

4 3 4 4 4

Display of ordinary screen

5 4 5 5 5

Display pattern of operator mode The contents of display from the time when starting switch is turned ON to time when screen changes to ordinary screen depends on the setting and condition of the machine. A : When engine start lock is set effective B : When engine start lock is set ineffective C : When working mode at start is set to breaker mode (B) D : When there is abnormal item in checkbefore-starting items E : When there is maintenance item which is not maintained after specified interval

Display of KOMATSU logo When the s tarting switch is turned ON, the KOMATSU logo is displayed for 2 seconds. a After the KOMATSU logo is displayed for 2 seconds, the screen changes to "Display of inputting password", or "Display of check before starting".

Display of end screen Selection of auto-deceleration Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user)

a

Display of energy-saving guidance Display of caution monitor Display of user code and failure code O (Special operation)

a

The following screen may be displayed instead of the above Display of inputting password screen. If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.

Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing attachment/maintenance password

6

PC138US, USLC-8


Display of inputting password After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective. a If the password is input normally, the screen changes to "Display of check before starting". a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.

Display of check before starting When the screen changes to the check-beforestarting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of ending of maintenance interval". a If no abnormality is detected by the check before starting, the screen changes to "Display of check of working mode and travel speed". a The monitors (3 pieces) displayed on the screen are the items under the check before starting.

PC138US, USLC-8

SEN02459-00

Display of warning after check before starting If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the engine oil level monitor (a) is warning of low of engine oil level.

Display of ending of maintenance interval When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode. a After display of this screen is finished, the screen changes to "Display of check of working mode and travel speed".

7

SEN02459-00

Display of check of working mode and travel speed If the check before starting is finished normally, the screen to check the working mode and travel speed is displayed for 2 seconds. a After display of check of the working mode and travel speed is finished, the screen changes to "Display of ordinary screen".

Display of ordinary screen If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a ECO gauge (b) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).

8


Display of end screen When the starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.

Selection of auto-deceleration While the ordinary screen is displayed, if the autodeceleration switch is pressed, large auto-deceleration monitor (a) is displayed for 2 seconds and the setting of the auto-deceleration is changed. a Each time the auto-deceleration switch is pressed, the auto-deceleration is turned ON and OFF alternately. a If the auto-deceleration is turned ON, large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously. a If the auto-deceleration is turned OFF, autodeceleration monitor (b) goes off.

PC138US, USLC-8


Selection of working mode Select a working mode according to the following procedure. 1. While the ordinary screen is displayed, press the working mode selector switch, and the working mode selection screen is displayed. a The following figure is the working mode selection screen displayed when "With attachment" is set (If "With attachment" is not set in the service mode, the attachment mode [ATT] is not displayed).

2.

Operate the function switches or working mode selector switch to select and confirm the working mode which you will use. Function switches q [F3]: Move to lower working mode q [F4]: Move to upper working mode q [F5]: Cancel selection and return to ordinary screen q [F6]: Confirm selection and return to ordinary screen Working mode selector switch q Press: Move to lower working mode q Hold down:Confirm selection and return to ordinary screen a If you do not touch any of the function switches and working mode selector switch for 5 seconds, the selection is confirmed and the screen changes to the ordinary screen.

PC138US, USLC-8

SEN02459-00

3.

When the ordinary screen is displayed again, large working mode monitor (a) is displayed for 2 seconds, and then the setting of the working mode is changed. a When large monitor (a) is displayed, the display of working mode monitor (b) is changed, too.

q If breaker mode [B] is selected, both of the control of the hydraulic pump and the setting of the hydraulic circuit are changed. q If an attachment other than the breaker is used, the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged.

9

SEN02459-00

Selection of travel speed While the ordinary screen is displayed, if the travel speed shifting switch is pressed, large travel speed monitor (a) is displayed for 2 seconds and the setting of the travel speed is changed. a Each time the travel speed shifting switch is pressed, the travel speed is changed to Lo, Hi, and Lo again in order. a When large monitor (a) is displayed, the display of travel speed monitor (b) is changed, too.

Operation to stop alarm buzzer While the alarm buzzer is sounding, if the alarm buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the alarm buzzer cancel switch is pressed, the screen does not change.

10


Operation of windshield wiper While the ordinary screen is displayed, if the wiper switch is pressed, large wiper monitor (a) is displayed for 2 seconds and the windshield wiper starts or stops. a Each time the wiper switch is pressed, the windshield wiper setting is changed to INT, ON, OFF, and INT again in order. a When large monitor (a) is displayed, the display of wiper monitor (b) is changed or turned OFF, too. a If the windshield wiper is turned OFF, large monitor (a) is not displayed.

Operation of window washer While the ordinary screen is displayed, if the window washer switch is pressed, the washing liquid is splashed only while the switch is held down. a Even if the window washer switch is pressed, the screen does not change.

PC138US, USLC-8


Operation of air conditioner/heater While the ordinary screen is displayed, press the air conditioner switch and the air conditioner adjustment screen is displayed. a While the air conditioner adjustment screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the ordinary screen. a Air conditioner specification

SEN02459-00

Operation to display camera mode When a camera is installed, if [F3] is pressed, the multi-display changes to the camera image (Set the connection of the camera in the service mode).

a

a

PC138US, USLC-8

If a caution is generated in the camera mode, the caution monitor is displayed at the left upper of the screen (The low hydraulic oil temperature caution is not displayed there, however). When an error that there is a user code occurs in the camera mode, if you do not touch any control lever for 10 seconds, the screen changes to the ordinary screen and displays the error information.

11

SEN02459-00

Operation to display clock and service meter While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function.


Check of maintenance information While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.

a

12

To reset the time left after finishing maintenance, more operations are necessary.

PC138US, USLC-8


Setting and display of user mode (Including KOMTRAX messages for user) While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.

a

SEN02459-00

[KOMTRAX message] q There are 2 types of KOMTRAX message; 1 is for the user and the other is for the service. q For user: A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is displayed on the ordinary screen. To see the contents of the message, operate "User Message" in the above user menu. q For service: A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed on the ordinary screen. To see the contents of the message, operate "KOMTRAX message" display in the service menu.

There are following items in the user menu. Breaker/Attachment Settings User Message Screen Adjustment Clock Adjustment Language Economy Mode Adjustment

a

The breaker/attachment setting menu is displayed only when "With attachment" is set in the service mode.

PC138US, USLC-8

13

SEN02459-00

Display of energy-saving guidance When the machine is set in a certain operating condition, the energy-saving guidance screen is displayed automatically to urge the operator to the energy-saving operation. a The energy-saving guidance is displayed when the following condition is satisfied while the display setting is set effective in the service mode. a Condition for display: Engine is running + All levers have been in neutral for 5 minutes + Caution (Note) or user code is not generated (Note) Note: Excluding hydraulic oil low temperature caution a If any lever or pedal is operated, or [F5] is pressed, the screen returns to the ordinary screen.

Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor flashes at the left upper of the screen when the caution is generated.

14


Display of user code and failure code If an abnormality which displays a user code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a): User code (3 digits) (b): Failure code (5 or 6 digits) (c): Telephone mark (d): Telephone No. a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the abnormality record in the service mode, check the details in the service mode.

a

When the caution monitor is also displayed, the telephone mark is not displayed.

PC138US, USLC-8


SEN02459-00

Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual)

User code

Failure mode

Action

Pump control system error

When emergency pump drive switch is at the up (emergency) position, normal operations become possible, but have inspection carried out immediately.

E03

Swing brake system error

Move the swing brake cancel switch up to release the brake. When applying the swing brake, operate the swing lock switch manually. Depending on the cause of the problem, it may not be possible to release it. In any case, have inspection carried out immediately.

E10

Engine controller power source error Engine controller drive system circuit error Have inspection carried out immediately. (engine stopped)

E11

Engine controller system error Output reduced to protect engine

Operate machine to a safe posture and have inspection carried out immediately.

E14

Abnormality in throttle system


E15

Engine sensor (coolant temperature, fuel pressure, oil pressure) system error

Operations are possible, but have inspection carried out immediately.

E20

Abnormality in travel system

Operations are possible, but have inspection carried out immediately.

E0E

Network error


E02

PC138US, USLC-8

15

SEN02459-00

Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.

16


Function of checking service meter To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.

PC138US, USLC-8


Function of changing attachment/maintenance password When changing the attachment/maintenance password used for the attachment setting function and maintenance setting function, follow these procedures. 1. While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [5] o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.

2.

After the Attachment/Maintenance PASSWORD screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.

PC138US, USLC-8

SEN02459-00

3.

After the New password input screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. a Set a new password of 4 – 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral

4.

After the New password input screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.

17

SEN02459-00

5.

18


If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully.

PC138US, USLC-8


SEN02459-00

t Service mode To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode.

a

1.

Mechanical Systems 02 Abnormality Electrical Systems Record Air-conditioning System

Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a This operation of the switches is accepted only while the ordinary screen is displayed.

The items which can be selected in the service menu are as follows (including some items which need special operations).

01 Monitoring

03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Unit With/Without Attachment 06 Default

Attachment/Maintenance Password Camera ECO Display

07 Adjustment

Pump Absorption Torque Attachment Flow Adjustment

08 Cylinder Cut-Out 09 No Injection 10 Fuel Consumption Terminal Status

2.

Selection of service menu When the Service menu screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].

PC138US, USLC-8

11 KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300) MODEM IP Address (TH200/201)

19

SEN02459-00


Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1.

Selecting menu Select "Monitoring" on the service menu screen.

3.

2.

20

Selecting monitoring items After the "Monitoring selection menu screen" is displayed, select items to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Reset input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.

Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.

PC138US, USLC-8


4.

Executing monitoring After the "Executing monitoring screen" is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be set to SI unit, metric unit, or inch unit with the Initialization function in the service mode.

5.

Holding monitoring information The monitoring information can be held and reset with the function switches. q [F3]: Reset holding q [F4]: Hold information (displayed data) q [F5]: Return to monitoring selection menu screen

PC138US, USLC-8

SEN02459-00

6.

Changing machine setting mode To change the setting of the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished.

21

SEN02459-00


Monitoring items table Unit (Initial setting: ISO) Code No.

Monitoring item (Display on screen)

ISO

meter

inch

rpm rpm psi psi psi psi psi psi psi °F °F mA mA V V V psi psi °F

Component in charge PUMP ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP ENG PUMP PUMP PUMP PUMP ENG MON ENG ENG ENG

psi

ENG

00200 00201 01002 01601 01100 07102 07103 07104 07105 07106 07107 04107 04401 01300 01700 03200 03203 04300 36400 37400 18500

Controller model select Machine ID Engine speed 2nd eng. speed command Pump pressure Travel FW L PPC pressure Travel FW R PPC pressure Travel BW L PPC pressure Travel BW R PPC pressure Blade raise PPC pressure Blade lower PPC pressure Coolant temperature Hyd oil temperature PC-EPC sol current Attachment sol current Battery voltage Battery power supply Battery charge vol. Rail pressure Ambient pressure Charge temperature

r/min r/min MPa MPa MPa MPa MPa MPa MPa °C °C mA mA V V V MPa kPa °C

— — rpm rpm kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 °C °C mA mA V V V kg/cm2 kg/cm2 °C

36500

Charge pressure-abs

kPa

kg/cm2

36700 18700 03000 04200 04105 04402 37401 18501 36501 36401 17500 31701 31706 18600 36200 36300 37300 01602 13113 15900

Engine torque ratio Engine output torque Fuel dial pos sens volt Fuel level sensor volt Coolant temp sens volt Hyd temp sens volt Ambient press sens volt Charge temp sens volt Charge press sens volt Rail pressure sens volt Engine power mode Throttle position Final throttle position Inject fueling command Rail press command Injection timing command Fuel rate 2nd eng. speed command Main pump absorb torque Boom bottom pressure Swing Boom lower Pressure switch 1 Boom raise Arm curl Arm dump

% Nm V V V V V V V V

01900

22

% % kgm lbft V V V V V V V V V V V V V V V V — % % % % % % mg/st mg/st mg/st MPa kg/cm2 psi CA CA CA l/h l/h gal/h % % % Nm kgm lbft MPa kg/cm2 psi ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF

Remarks

All items (including the ambient pressure) are indicated by absolute values.

ENG ENG ENG MON ENG PUMP ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP

PC138US, USLC-8


SEN02459-00

Unit (Initial setting: ISO) Code No.

01901

02300

02200 02201 02202 02204 03701 04500

04501 04502

04503

04504

04505

04506 20216 20217 18900 20400 20227 20402

Monitoring item (Display on screen) Bucket curl Pressure switch 2 Bucket dump Attachment Travel junction Swing brake Solenoid valve 1 Merge-divide Travel speed Swing release sw Switch input 1 Swing brake sw Blade spec Switch input 2 Overload alarm Switch input 3 Key switch Window limit sw. Switch input 5 P limit sw. W limit sw. Controller output 2 Travel alarm Key switch Start Monitor input 1 Preheat Light Eng. oil level Monitor input 2 Battery charge Monitor input 3 Swing brake sw. F1 F2 F3 Monitor function switches F4 F5 F6 SW1 SW2 Monitor 1st & 2nd SW3 row switches SW4 SW5 SW6 SW7 SW8 Monitor 3rd & 4th SW9 row switches SW10 SW11 SW12 SW13 Monitor 5th row SW14 switches SW15 ECM build version ECM calibration data ver ECM internal temp ECM serial No Monitor ass'y P/N Monitor serial No

PC138US, USLC-8

ISO

°C

meter ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF — — °C — — —

inch

°F

Component in charge PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON ENG ENG ENG ENG MON MON

Remarks

23

SEN02459-00


Unit (Initial setting: ISO) Code No. 20228 20229 20403 20230

a a

a

24

Monitoring item (Display on screen) Monitor prog. P/N Pump con ass'y P/N Pump con serial No Pump con. prog P/N

ISO

meter — — — —

inch

Component in charge MON PUMP PUMP PUMP

Remarks

Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen. Unit The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in Initialization of the service menu). "CA" in the display unit is an abbreviation for crankshaft angle. "mg/st" in the display unit is an abbreviation for milligram/stroke. Component in charge MON: The machine monitor is in charge of detection of monitoring information. ENG: The engine controller is in charge of detection of monitoring information. PUMP: The pump controller is in charge of detection of monitoring information.

PC138US, USLC-8


Abnormality Record (Mechanical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning system or heater system. To check the mechanical system abnormality record, perform the following procedures. 1.

Selecting menu Select "Abnormality Record" on the "Service Menu" screen.

2.

Selecting sub menu After the "Abnormality Record" screen is displayed, select "Mechanical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heaterless specification.

PC138US, USLC-8

SEN02459-00

3.

Information displayed on "abnormality record" screen On the "Mechanical Systems" screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to abnormality record screen a If no abnormality record is recorded, "No abnormality record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table in "Abnormality Record (Electrical Systems)".

25

SEN02459-00

4.


Resetting abnormality record The contents of the mechanical system abnormality record cannot be reset.

Abnormality Record (Electrical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning system. To check the electrical system abnormality record, perform the following procedures. 1.

Selecting menu Select "Abnormality Record" on the "Service Menu" Screen.

2.

Selecting sub menu After the "Abnormality Record" screen is displayed, select "Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heaterless specification.

26

3.

Information displayed on "abnormality record" screen On the "Electrical Systems" screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "abnormality record" screen a If no abnormality record is recorded, "No abnormality record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table.

PC138US, USLC-8


4.

Resetting abnormality record 1) While the "Electrical Systems" screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3]

2)

Check that the screen is set in the reset mode, and then reset the items one by one or together with the function switches. a If the screen is set in the reset mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Reset all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to abnormality record screen q [F6]: Reset selected item a To reset items one by one: Select the item to be reset with [F3] or [F4] and press [F6]. a To reset all items together: Press [F2], and all the items are reset, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the resetting operation is accepted but the information is not reset.

PC138US, USLC-8

SEN02459-00

3)

After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to "Electrical systems" screen (Reset mode) q [F6]: Execute reset a The following figure shows the screen displayed when the items are reset one by one (which is a little different from the screen displayed when all the items are reset together).

4)

If the screen to notify completion of reset is displayed and then the "Electrical Systems" (reset mode) screen is displayed, the reset of the abnormality record is completed. a After a while, the screen returns to the "Electrical Systems" screen.

27

SEN02459-00


Failure codes table User code

Failure code

Trouble (Displayed on screen)

Alarm buzzer

Component Category of in charge record

989L00

Engine controller lock caution 1

MON

989M00


MON

989N00


MON

AB00KE

Charge voltage low

MON

B@BAZG

Eng oil press. low

B@BAZK

Eng oil level low

B@BCNS

Eng coolant overheat

e

ENG

B@HANS

Hydr oil overheat

e

PUMP

e

ENG MON

E10

CA111

ECM critical internal failure

q

ENG

E10

CA115

Eng. Ne and Bkup speed sensor error

q

ENG

E11

CA122

Charge air press sensor high error

q

ENG

E11

CA123

Charge air press sensor low error

q

ENG

E14

CA131

Throttle sensor high error

q

ENG

E14

CA132

Throttle sensor low error

q

ENG

E15

CA144

Coolant temp. sensor high error

q

ENG

E15

CA145

Coolant temp. sensor low error

q

ENG

E15

CA153

Charge air temp. sensor high error

q

ENG

E15

CA154

Charge air temp. sensor low error

q

ENG

E15

CA187

Sensor sup. 2 volt. low error

q

ENG

E11

CA221

Ambient air press. sensor high error

q

ENG

E11

CA222

Ambient air press. sensor low error

q

ENG

E15

CA227

Sensor sup. 2 volt. high error

q

ENG

CA234

Eng. overspeed

E15

CA238

Ne speed sensor sup. volt. error

q

ENG

E10

CA271

IMV/PCV1 short error

q

ENG

E10

CA272

IMV/PCV1 open error

q

ENG

E11

CA322

Injector #1 (L #1) system open/short error

q

ENG

E11

CA324


q

ENG

E11

CA331


q

ENG

E11

CA332


q

ENG

28

ENG

Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system

PC138US, USLC-8


SEN02459-00

User code

Failure code

E10

CA351

Inj. drive circuit error

q

E15

CA352


q

E15

CA386


q

E15

CA435

Abnormality in engine oil pressure switch

q

E10

CA441

Battery voltage low error

q

E10

CA442

Battery voltage high error

q

E11

CA449

Rail press. very high error

q

E11

CA451

Rail press. sensor high error

q

E11

CA452

Rail press. sensor low error

q

E15

CA553

Rail press. high error

q

E15

CA559

Rail press. low error

q

E15

CA689

Eng. Ne speed sensor error

q

E15

CA731

Eng. Bkup speed sensor phase error

q

E10

CA757

All persistent data lost error

q

E15

CA778

Eng. Bkup speed sensor error

q

E0E

CA1633

KOMNET datalink timeout error

q

E14

CA2185

Throttle sens. sup. volt. high error

q

E14

CA2186

Throttle sens. sup. volt. low error

q

E11

CA2249

Rail press. very low error

q

E11

CA2311

Abnormality in IMV solenoid

q

D110KB

Battery relay drive short

D19JKZ

Personal code relay abnormality

D862KA

GPS antenna discon

DA22KK

Pump solenoid power low error

DA25KP

5V sensor 1 power abnormality

DA26KP


DA2RMC

CAN discon (Pump con detected)

DAF8KB

Short circuit in camera power supply

DAFGMC

GPS module error

DAFRMC

CAN discon (Monitor detected)

E01

E0E

E0E

E0E

PC138US, USLC-8


Alarm buzzer

q

q

q

q

Component Category of in charge record Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical PUMP system Electrical KOM system Electrical KOM system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical MON system Electrical KOM system Electrical MON system

29

SEN02459-00

User code

Failure code



Alarm buzzer

DGH2KB

Hydr oil sensor short

DHPAMA

Pump press sensor abnormality

E20

DHSFMA

Travel left forward PPC press sensor abnormality

q

E20

DHSGMA

Travel right forward PPC press sensor abnormality

q

E20

DHSHMA

Travel left reverse PPC press sensor abnormality

q

E20

DHSJMA

Travel right reverse PPC press sensor abnormality

q

DHSKMA

Blade raise PPC press sensor abnormality

DHSLMA

Blade lower PPC press sensor abnormality

DHX1MA

Overload sensor abnormality (Analog)

DV20KB

Travel alarm S/C

DW43KA

Travel speed sol discon

DW43KB

Travel speed sol short

E03

DW45KA

Swing brake sol discon

q

E03

DW45KB

Swing brake sol short

q

DW91KA

Travel junction sol discon

DW91KB

Travel junction sol short

DWJ0KA

Merge-divider sol discon

DWJ0KB

Merge-divider sol short

E02

DXA8KA

PC-EPC sol discon

q

E02

DXA8KB

PC-EPC sol short

q

DXE4KA

Service current EPC discon

DXE4KB

Service current EPC short

DY20KA

Wiper working abnormality

DY20MA

Wiper parking abnormality

DY2CKA

Washer drive discon

DY2CKB

Washer drive short

DY2DKB

Wiper drive (for) short

DY2EKB

Wiper drive (rev) short

30

Component Category of in charge record Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system

PC138US, USLC-8

30 Testing and adjusting a a

a

a

a

SEN02459-00

Entry order of items in table The items are entered in the order of their failure codes (incremental order). User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the abnormality. Alarm buzzer q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). e: Since the caution monitor is also turned ON, its function sounds the buzzer. Component in charge MON: The machine monitor is in charge of detection of abnormality. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. ENG: The engine controller is in charge of detection of abnormality. PUMP: The pump controller is in charge of detection of abnormality. Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record.

PC138US, USLC-8

31

SEN02459-00

Abnormality Record (Air-conditioning System) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning abnormalities. To check the air-conditioning abnormality record or heater abnormality record, perform the following procedures. 1.

Selecting menu Select "Abnormality Record" on the "Service Menu" screen.

2.

Selecting sub menu After the "Abnormality Record" screen is displayed, select "Air-conditioning System" or "Heater System" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].

32


3.

Information displayed on "abnormality record" screen On the "Air-conditioning System" screen, the following information is displayed. (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) q [F2]: Reset abnormality record q [F5]: Return to abnormality record screen If [E] is displayed on the left of a condition, the abnormality is still occurring or resetting of it has not been confirmed. If CAN disconnection is displayed in Communication condition, communication cannot be carried out normally. Accordingly, the conditions of other items are turned OFF.

4.

Resetting abnormality record While the "abnormality record" screen is displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.

PC138US, USLC-8


SEN02459-00 a

Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section. 1.

01 Engine oil change 02 Engine oil filter change 03 Fuel main filter change 41 Fuel pre-filter change 04 Hydraulic oil filter change 05 Hydraulic tank breather change 06 Corrosion resistor change 07 Damper case service 08 Final drive case oil change 09 Machinery case oil change 10 Hydraulic oil change

Selecting menu Select "Maintenance Record" on the "Service Menu" screen.

3.

2.

The following items can be selected in the maintenance record.

Items displayed on maintenance record screen The following items are displayed. (a) : Maintenance items (b) : Number of times of replacement up to now (c) : Service meter reading (SMR) at previous replacement

Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.

PC138US, USLC-8

33

SEN02459-00


Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set replacement interval (by items) q Initialize all set replacement intervals 1.

00 Maintenance mode on/off 01 Engine oil change int. 02 Engine oil filter change int. 03 Fuel main filter change int. 41 Fuel pre filter change int. 04 Hyd oil filter change int. 05 Hyd tank breather change int. 06 Corrosion resistor change int. 07 Damper case service int. 08 Final drive case oil change int. 09 Machinery case change int. 10 Hydraulic oil change int. 99 Initialize all items

Selecting menu Select of "Maintenance Mode Change" on the "Service Menu" screen.

3.

2.

34

Selecting sub menu After the "Maintenance Mode Change" screen is displayed, select an item to change the setting with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].

The following items can be selected on the Change of maintenance mode screen.

Contents of setting of Maintenance mode on/ off After selecting "Maintenance Mode On/Off", if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode change screen q [F6]: Confirm selection and return to Maintenance mode change screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.

PC138US, USLC-8


4.

Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches. q Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). q Set value: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 50 hours). q ON: Maintenance function of this item is set effective in operator mode. q OFF: Maintenance function of this item is set ineffective in operator mode. q [F3]: Select Reduce set value (Upper) or OFF (Lower). q [F4]: Select Increase set value (Upper) or ON (Lower). q [F5]: Cancel setting before confirmation and return to Maintenance mode change screen. q [F6]: Confirm setting of upper or lower line. a After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode change screen with [F5], the setting is effective. a If the set value of an item set to "ON" is changed after 1 or more operating hours since the start of setting, the change is recognized as a resetting operation.

PC138US, USLC-8

SEN02459-00

5.

Function of initializing all items After selecting "All Default Value", if the screen is displayed, set with the function switches. q If this operation is executed, the set values of all the maintenance items are initialized. q [F5]: Return to Maintenance mode change screen q [F6]: Execute initialization a A while after [F6] is pressed, the initialization completion screen is displayed. Then, if the "Maintenance Mode Change" screen is displayed, initialization is completed.

35

SEN02459-00

Phone Number Entry The telephone No. displayed when the user code/ failure code is displayed in the operator mode can be input and changed according to the following procedure. If a telephone No. is not input with this function, no telephone No. is displayed in the operator mode. 1.

Selecting menu Select "Phone Number Entry" on the "Service Menu" screen.

2.

Registering and changing telephone No. After the "Phone Number Entry" screen is displayed, register or change the telephone No. q [F2]: Reset all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Reset input digit/Return to service menu q [F6]: Confirm input

a a

36


If [F6] is pressed without inputting a digit, there is not information of telephone No. Accordingly, no telephone No. is displayed in the operator mode.

Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (orange background) and overwrite it with the correct digit.

PC138US, USLC-8


SEN02459-00

Default (Key-on Mode) Check or change various settings related to the machine monitor and machine by "Default". The function of working mode with key ON is used to set the working mode displayed on the machine monitor when the starting switch is turned ON.

q

1.

q

Selecting menu Select "Default" on the "Service Menu" screen.

q q q

a a a

a

2.

Selecting sub menu After the "Default" screen is displayed, select "Key-on Mode" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set with the function switches. q Power Mode: [P] is displayed when key is ON q Economy Mode: [E] is displayed when key is ON q Lifting Mode: [L] is displayed when key is ON q Breaker Mode: [B] is displayed when key is ON q Attachment Mode: [ATT] is displayed when key is ON

PC138US, USLC-8

Mode at Previous Key-off: Final mode in previous operation is displayed when key is ON [F3]: Move to lower item [F4]: Move to upper item [F5]: Cancel selection and return to "Default" screen [F6]: Confirm selection and return to "Default" screen When the machine is delivered, Mode at previous key-OFF is set. If "With attachment" is not set, the attachment mode cannot be selected. While Attachment mode [ATT] is selected, if "Without attachment" is set, Power mode [P] is displayed when the key is turned ON. If the engine is stopped while breaker mode [B] is selected in the operator mode, Breaker mode [B] is always displayed, regardless of the above setting.

37

SEN02459-00

Default (Unit) Check or change various settings related to the machine monitor and machine by "Default". The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1.


2.

Selecting sub menu After the "Default" screen is displayed, select "Unit" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Selecting unit After the "Unit" screen is displayed, select the unit to be set with the function switches. q [F3]: Move to lower unit q [F4]: Move to upper unit q [F5]: Cancel selection and return to "Default" screen q [F6]: Confirm selection and return to "Default" screen

38


When the machine is delivered, the SI unit system is set.

PC138US, USLC-8


Default (With/Without Attachment) Check or change various settings related to the machine monitor and machine by "Default". The "With/Without attachment" function is used to set an installed or a remove attachment. 1.


2.

Selecting sub menu After the "Default" screen is displayed, select "With/Without Attachment" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

3.

Selecting With/Without After the "With/Without Attachment" screen is displayed, select the setting with the function switches. q Without Attachment: When attachment is not installed q With Attachment: When attachment is installed q [F3] : Move to lower item q [F4] : Move to upper item q [F5] : Cancel selection and return to Default screen q [F6] : Confirm selection and return to Default screen

PC138US, USLC-8

SEN02459-00 a

When an attachment is installed, if this setting is not carried out normally, the attachment cannot be set in the operator mode. As a result, the attachment may not work normally or the hydraulic components may have trouble.

39

SEN02459-00

Default (Attachment/Maintenance Password) Check or change various settings related to the machine monitor and machine by "Default". The function of setting attachment/maintenance password is used to set the display of the password screen when the functions related to the attachment and maintenance are used in the operator mode. 1.


2.

Selecting sub menu After the "Default" screen is displayed, select "Attachment/Maintenance Password" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

40


3.

Selecting Disable/Enable After the Attachment/Maintenance Password screen is displayed, select the setting with the function switches. q Disable : Password screen is not displayed q Enable : Password screen is displayed q [F3] : Move to lower item q [F4] : Move to upper item q [F5] : Cancel selection and return to "Default" screen q [F6] : Confirm selection and return to "Default" screen

4.

Displaying attachment/maintenance password screen When the following operation is performed, the password screen is displayed in the operator mode. q Maintenance mode: The Maintenance table screen is changed to the Maintenance interval reset screen. q User mode: On the User menu screen, the Breaker/Attachment setting menu is selected and the screen is changed to the Attachment setting menu screen.

5.

Changing attachment/maintenance password The password can be changed by operating the switches specially in the operator mode. a See Attachment/Maintenance password changing function in the operator mode. a Default password: [000000] a If the password setting is changed from Enable to Disable, the password is reset to the default. When Enable is set again, be sure to set a new password. a The attachment/maintenance password is different from the engine start lock password.

PC138US, USLC-8


Default (Camera) Check or change various settings related to the machine monitor and machine by "Default". The camera setting function is used to set installation and removal of a camera. 1.


2.

Selecting sub menu After the "Default" screen is displayed, select "Ca mer a" with the fu ncti on s witc hes or numeral input switches. a Select this item similarly to an item on the "Service Menu" Screen.

PC138US, USLC-8

SEN02459-00

3.

Selecting camera setting After the "Camera" setting screen is displayed, select the setting with the function switches. q OFF: Camera is not used q Original Image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse Image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to "Default" screen q [F6]: Confirm selection in each line a After "Camera" screen is displayed, camera 1 can be always set. a After confirming the setting of each line with [F6], return to the "Default" screen with [F5], and the setting is effective. a If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a When a camera is installed, check that the displayed image is not inverted horizontally.

41

SEN02459-00

Default (ECO Display) Check or change various settings related to the machine monitor and machine by "Default". The ECO display setting function is used to set the display of the ECO gauge and energy saving guidance. 1.

2.

3.

42


If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen. Even if the energy saving guidance is turned ON, however, it is not displayed if the condition for display is not satisfied on the ordinary screen.

a

Display of ECO gauge (a)

a

Display of energy saving guidance


Selecting sub menu After the "Default" screen is displayed, select "ECO Display" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

Selecting display setting After the "ECO Display" screen is displayed, select the setting with the function switches. q ON : Display ECO q OFF: Do not display ECO q [F3] : Move to left item q [F4] : Move to right item q [F5] : Cancel setting before confirmation and return to "Default" screen q [F6] : Confirm selection in each line a After confirming the setting of the upper and lower lines with [F6], return to the "Default" screen with [F5], and the setting is effective.

PC138US, USLC-8


Adjustment (Pump Absorption Torque) The operator can adjust various items related to the machine with the machine monitor. The pump absorption torque function is used to finely adjust the absorption torque on the hydraulic pump. 1.

Selecting menu Select "Adjustment" on the "Service Menu" screen.

2.

Selecting sub menu After the "Adjustment" screen is displayed, select "Pump Absorption Torque" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

SEN02459-00

3.

Selecting absorption torque After the "Pump Absorption Torque" screen is displayed, select a set value on the right side with the function switches. q Set value: For actual torque adjustment value, see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.

a

Relationship between set value torque adjustment value Code

022

PC138US, USLC-8

Set value 000 001 002 003 004 005 006 007 008

and

Torque adjustment value +39.2 Nm {+4 kgm} +29.4 Nm {+3 kgm} +19.6 Nm {+2 kgm} +9.8 Nm {+1 kgm} 0 Nm {0 kgm} –9.8 Nm {–1 kgm} –19.6 Nm {–2 kgm} –29.4 Nm {–3 kgm} –39.2 Nm {–4 kgm}

43

SEN02459-00

Adjustment (Attachment Flow Adjustment) The operator can adjust various items related to the machine with the machine monitor. The function of "Attachment Flow Adjustment" is used to finely adjust the oil flow to the attachment in compound operation. 1. Selecting menu Select "Adjustment" on the "Service Menu" screen.

2.

Selecting sub menu After the "Adjustment" screen is displayed, select "Attachment Flow Adjustment" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.


3.

Selecting distribution of oil flow After the screen of "Attachment Flow Adjustment" is displayed, select a set value on the right side with the function switches. q Set value: For actual distribution of flow, see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.

a

Relationship between set value and distribution of flow to attachment Code

037

44

Set value 000 001 002 003

Distribution of flow to attachment 50 % 70 % 100 % 40 %

PC138US, USLC-8


SEN02459-00

Cylinder Cut-Out The operator can perform "Cylinder Cut-Out" operation with the machine monitor. "Cylinder Cut-Out" operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1.

2.

Selecting menu Select "Cylinder Cut-Out" on the "Service Menu" screen.

Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be Cut-Out with the function switches. q [F1]: Move selection mark (R) to left q [F2]: Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to service menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is Cut-Out. a If the machine monitor Cut-Out a cylinder but the engine controller cannot Cut-Out that cylinder, the background (a) of the cylinder No. becomes yellow. a One or more cylinders can be Cut-Out. a In the cylinder Cut-Out operation, the auto-deceleration function can be selected. If the auto-deceleration is turned ON, auto-deceleration monitor (b) is displayed.

PC138US, USLC-8

3.

Resetting Cut-Out cylinder When changing a cylinder to be Cut-Out or when Cylinder Cut-Out operation is finished, select a Cut-Out cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset. a If the machine monitor resets a Cut-Out cylinder but the engine controller cannot reset that Cut-Out cylinder, the background (a) of the cylinder No. becomes red. a The Cut-Out operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the cylinder cut-out operation is finished.

4.

Function of holding displayed information If [F4] is pressed during the cylinder Cut-Out operation, the displayed information is newly held (c) (The real-time information is kept displayed on the left side). While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the reduced cylinder mode operation.

45

SEN02459-00

[Reference] q If a normally operating cylinder is Cut-Out, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.

46


No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the no-injection cranking while the engine is stopped. 1.

Selecting menu Select "No Injection" on the "Service Menu" screen.

2.

Displaying check screen If the "No injection" screen is displayed, the machine monitor asks the operator if no injection cranking should be performed. Answer with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform a While the screen is changing to the following screen, the screen of "Communication between controllers is being checked" is displayed.

PC138US, USLC-8


3.

Starting no injection cranking If no injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of "Setting is being prepared" is displayed. a Limit the cranking time to 20 seconds to protect the starting motor.

4.

Finishing no injection cranking After completing the no injection cranking operation, press [F6], and finish of no injection cranking is displayed and the screen returns to the "Service Menu" screen automatically.

PC138US, USLC-8

SEN02459-00

5.

Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running, the message that the engine is running is displayed and the no injection cranking is not set effective. a This function can be selected even while the engine is running. If the no injection cranking is performed, however, the message of "Engine is running" is displayed on the screen.

47

SEN02459-00

Fuel Consumption This function calculates the hourly fuel consumption from the actual fuel consumption in a testing period and indicates it. 1. Selecting menu Select "Fuel Consumption" on the "Service Menu" screen.

2.

Starting test After the screen of "Fuel Consumption" is displayed, start test with the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to Service menu screen a When the screen of Fuel consumption is displayed, if a data is indicated, it is the data of the previous test. This data is not an obstacle to new test and can be reset by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and test starts.

a

48


3.

Display and function during test Clock mark (a) flashes during test. a While the fuel consumption is being tested, the operator can work with the operator mode and other functions. Test is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is tested only while the engine is running).

4.

Finishing test Press [F1], and test is finished and the data are displayed on the finishing date and time side.

5.

Displaying fuel consumption If the test is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.

The display unit of the fuel changes according to the unit set with the default (unit setting) function. SI and meter: l/h inch: gal/h

PC138US, USLC-8


KOMTRAX Settings (Terminal Status) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX setting. Setting condition of terminal is used to check the setting condition of the KOMTRAX terminal. 1.

Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.

2.

Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Terminal Status" with the function switches or numeral input switches. a Select this item similarly to an item on the Service menu screen. a The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is displayed.

PC138US, USLC-8

SEN02459-00

3.

Contents of display of terminal status On the "Terminal Status" screen, the following items are displayed. q Terminal type: Model name of KOMTRAX communication MODEM q KOMTRAX communication: Executing condition of station opening inspection q GMT time: Greenwich Meant Time q [F5]: Return to KOMTRAX settings screen

49

SEN02459-00

KOMTRAX Settings (GPS & Communication Status) The setting condition and operating condition of KOMTRAX can be checked with "KOMTRAX Settings". GPS & communication status is used to check the condition of positioning and communication of the KOMTRAX terminal. 1.


2.

Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select GPS & communication status with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen. a The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is displayed.

50


3.

Contents of display of GPS & communication status On the screen of "GPS & Communication Status", the following items are displayed. q Positioning: Positioning condition of GPS q Communication: Communication environment of communication MODEM and connecting condi tion of c ommunication MODEM q Number of message not yet sent: Number of mails which are saved in machine monitor and not transmitted yet q [F5]: Return to KOMTRAX settings screen

PC138US, USLC-8


KOMTRAX Setting (MODEM S/N: TH300) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX setting. MODEM S/N is used to check the serial No. of the KOMTRAX communication MODEM. 1.


2.

Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

PC138US, USLC-8

SEN02459-00

3.

Contents of display of Modem S/N The serial No. of TH300 Modem is displayed. q [F5]: Return to KOMTRAX settings screen

51

SEN02459-00

KOMTRAX Settings (IP Address: TH200/201) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX settings. IP address is used to check the IP address of the KOMTRAX communication MODEM. 1.

Selecting menu Select "KOMTRAX Settings" on the service menu screen.

2.

Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "IP Address" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.

52


3.

Contents of display of IP address The telephone No. and IP address (2 systems) of TH200 MODEM are displayed. q [F5]: Return to KOMTRAX setting screen a The IP address is a No. specific to each MODEM which is required when communication is made between the MODEM and the server.

PC138US, USLC-8


Display of KOMTRAX message Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this function. If there is setting in a message, a return mail can be sent by using numeral input switches. 1.

Operation to display menu Select "Service message" on the service menu screen.

2.

Display of message (Read-only) If there is a message, its contents are displayed. If there is not a message, "No message" is displayed. q [F5]: Return to service menu screen a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.

PC138US, USLC-8

SEN02459-00

3.

Display of message (with return mail function) If a box to enter a value with the numeral keys is displayed under the message, enter a proper number with the numeral input switches and function switches and confirm it, and the information is returned to the KOMTRAX base station. q [F5]: Return to service menu screen q [F6]: Confirm and return input value a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.

53

SEN02459-00




54

PC138US, USLC-8

SEN02460-01



Machine model

Serial number




1

Testing and adjusting, Part 3 Handling voltage circuit of engine controller ................................................................................................... 2 Preparation work for troubleshooting of electrical system .............................................................................. 3 Procedure for testing diodes ........................................................................................................................... 8 Pm Clinic service ............................................................................................................................................ 9

PC138US, USLC-8

1

SEN02460-01


Handling voltage circuit of engine controller 1 1.

Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF.

2.

If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.

2

PC138US, USLC-8


Preparation work for troubleshooting of electrical system a

a

1.

SEN02460-01

3)

1

When carrying out troubleshooting of an electric circuit related to the machine monitor, e n g i n e c o n t r o l l e r, p u m p c o n t r o l l e r, o r KOMTRAX communication MODEM, expose the related connectors according to the following procedure. Disconnect and connect the connectors having special locking mechanisms according to the procedure shown below. Machine monitor 1) Remove 2 mounting bolts and cover (1). a One of the mounting bolts is installed in the cover on the right of the daylight sensor. a While removing the mounting bolts, disconnect connector P31 of the daylight sensor. a The following figure shows the model of the arm crane specification equipped with a level. If the machine which you are working on has the arm crane specification, remove level (2).

2)

2.

Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM03 of machine monitor (4). a Connectors CM02 and CM03 are of the same type. When returning them, check the mark plates of the mounting brackets and take care not to make a wrong connection.

Engine controller 1) Open the engine hood. a The engine controller is mounted on the engine (on the counterweight side). 2) Insert or connect troubleshooting T-adapters in or to connectors CE01, CE02, and CE03 of engine controller (5). a Connectors CE01 and CE02 are fixed with screws. When disconnecting them, loosen the screws. a When returning connectors CE01 and CE02, tighten the screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

Remove 1 mounting bolt and duct (3).

PC138US, USLC-8

3

SEN02460-01

3.

Pump controller 1) Slide the operator's seat and seat stand to the forward end.


2)

Connect the troubleshooting adapters to connectors C01 and C02 of pump controller (12). a Install the adapters to only the wiring harness side.

a

4

The pump controller connector has a special locking mechanism. Disconnect it according to procedures (a) – ( c ) s ho wn be lo w a nd c on ne ct i t according to procedures (d) – (f). Disconnection: (a) Unlock – (b) Slide lever – (c) Disconnect connector. Connection: (d) Position connector – (e) Slide lever – (f) Lock.

PC138US, USLC-8


4.

SEN02460-01

KOMTRAX communication module 1) Slide the operator's seat and seat stand to the forward end.

2)

5.

Engine Ne speed sensor (Crank sensor) Engine Bkup speed sensor (Cam sensor) Engine oil pressure switch (Oil pressure switch) a Disconnection and connection of connectors The connectors of the engine Ne speed s ens or, eng ine Bku p sp eed s ens or, engine oil pressure switch have a special locking mechanism. Disconnect them according to steps (a) – (c) and connect them according to steps (d) – (f) as shown below. Disconnection: (a) Slide lever – (b) Unlock – (c) Disconnect connector. Connection: (d) Connect connector – (e) Lock – (f) Slide lever.

a

PC138US, USLC-8

Connect troubleshooting T-adapters to connectors CK01 and CK02 of KOMTRAX communication module (13). a Cable (14) is for the communication antenna.

Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. See "Tools for testing, adjusting, and troubleshooting".

5

SEN02460-01

6.

Boost pressure and temperature sensor (Boost press & IMT) a Disconnection and connection of connector The connector of the boost pressure and temperature sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.


7.

Supply pump IMV solenoid (Fuel regulator) a Disconnection and connection of connector The connector of the supply pump IMV solenoid has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.

a a

6

Removal and installation of sensor A torque wrench is necessary for removal and installation of the boost pressure and temperature sensor. See "Tools for testing, adjusting, and troubleshooting".

Precautions for disconnecting connector The direction of the lock of the connector varies with the tightened position of the sensor and the lock may be in a direction in which it is difficult to reset (on the underside or engine side). In this case, pinch the lock in direction (a) with bent-nose nippers [1] (commercially available), and the lock is reset. Since the lock clicks when it is reset, disconnect the connector after a click is heard.

PC138US, USLC-8


8.

Precautions for connecting connector Take care not to connect the connector reversely. Engage lock (e) on the wiring harness side with triangular notch (f) on the sensor side (Do not engage lock (e) with square guide (g) on the opposite side of triangular notch (f)).

Common rail pressure sensor (Fuel rail press) a Disconnection and connection of connector The connector of the common rail pressure sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.

PC138US, USLC-8

SEN02460-01

9.

Engine coolant temperature sensor (Coolant temp) a Disconnection and connection of connector The connector of the engine coolant temperature sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.

a

Removal and installation of sensor A deep socket is necessary for removal and installation of the engine coolant temperature sensor. See "Tools for testing, adjusting, and troubleshooting".

7

SEN02460-01

Procedure for testing diodes a a


1

Test the assembled-type diode (8-pin) and the single diode (2-pin) according to the following procedure. The conductive directions of the assembledtype diode are as follows.

2.

a

The conductive direction of the single diode is indicated on the surface of the diode.

1.

When using digital circuit tester 1) Set the tester in the diode range and check the indicated value. a When an ordinary circuit tester is used, the voltage of the internal battery is indicated. 2) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode (N) side and check the indicated value. 3) Judge the condition of the diode by the indicated value. q The indicated value does not change: The diode does not have conductivity (Defective). q The indicated value changes: The diode has conductivity (Normal). Note: In the case of a silicon diode, a value in the range from 460 to 600 is indicated.

8

When using analog circuit tester 1) Set the tester in the resistance range. 2) Apply the leads of the tester as explained below and check the movement of the pointer. i) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode (N) side. ii) Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (–) lead to the anode (P) side. 3) Judge the condition of the diode by the movement of the pointer. q The pointer does not move in i) but moves in ii): The diode is normal (The moving range (resistance) depends on the type and selected range of the tester, however). q The pointer moves in both i) and ii): The diode is defective (Internal short circuit). q The pointer moves in neither of i) and ii): The diode is defective (Internal disconnection).

PC138US, USLC-8


SEN02460-01

Pm Clinic service

1

Model name

Serial No.

Service meter

T PC138US-8

h

User's name

Date of execution /

Inspector

/

Specifications Main components Boom Arm Bucket

T Standard T ( T Standard T ( T Standard T (

Attachments ) ) )

Shoe width

T Breaker T( T(

) )

T 500 mm T 600 mm T 700 mm

T(

)

Check of oil/coolant level T Radiator coolant T Engine oil T Hydraulic oil

When necessary T Damper case oil T Final drive case oil

T Machinery case oil T(

Ambient temperature

)

Altitude

°C

m Operator's opinion

Result of visual inspection

Mechanical equipment system fault history

Electrical equipment system fault history

989EKX

times/1st time

h/last

h

times/1st time

h/last

h

AB00KE

times/1st time

h/last

h

times/1st time

h/last

h

B@BAZG

times/1st time

h/last

h

times/1st time

h/last

h

B@BAZK

times/1st time

h/last

h

times/1st time

h/last

h

B@BCNS

times/1st time

h/last

h

times/1st time

h/last

h

B@HANS

times/1st time

h/last

h

times/1st time

h/last

h

CA234

times/1st time

h/last

h

times/1st time

h/last

h

Max. range of engine coolant temperature gauge

PC138US, USLC-8

Max. range of hydraulic oil temperature gauge

9

SEN02460-01


Check sheet (PC138US-8) Model

Serial No.

Service meter

User's name

Date of execution /

1

Engine speed

2

Engine oil pressure

3

Engine speed

Operation of work equipment

MAX

All levers in neutral P

OFF

Unit


rpm

2,090 – 2,210 2,090 – 2,210

MPa 0.34 – 0.59 {kg/cm2} {3.47 – 6.02} rpm

MIN

All levers in neutral

Min. 0.10 {Min. 1.0}

0.07 {0.7}

2

Arm IN

3

Arm OUT

4

Bucket CURL

5

Swing (5 turns)

6

Travel (5 idle turns)

Fuel control dial

Working mode

Unit


Service limit value

sec

3.5 – 4.1

Max. 4.4

sec

2.9 – 3.5

Max. 4.0

sec

2.4 – 3.0

Max. 3.7

Boom top horizontal Arm cylinder retracted fully

sec

2.6 – 3.2

Max. 3.7

Work equipment extended fully Swing right and left

sec

25.3 – 29.3

23.3 – 31.3

LO STD

sec

Max. 39.5

Max. 49

HI STD

sec

Max. 22.3

Max. 27

Unit


Service limit value

mm/ 15 min

Max. 310

Max. 460

Checking posture, etc. Work equipment extended fully Boom top horizontal

MAX

P

One side of track pushed up and turned forward and backward

10

Measured value

Hydraulic drift of work equipment Checking condition

1

Measured value

Bad

Check item

Boom RAISE

No.

1,050 – 1,150 1,050 – 1,150

Work equipment speed

1

3.

Measured value

0.25 {2.5}

MPa {kg/cm2}

Checking condition No.

Service limit value

Bad

2.

Engine oil pressure

Work- Autoing decelmode eration

Good

4

Fuel control dial

Bad

Check item

Good

Engine Checking condition

No.

/

Good

1.

Inspector

Check item

Fuel control dial

Working mode

Hydraulic drift of Engine stopped bucket tip

Checking posture, etc. Boom top horizontal Arm cylinder retracted fully Bucket loaded

PC138US, USLC-8


[3]

[4]

[5]

No.

Checked part

1

Self pressure reducing valve

2

Main relief valve

3

Unload valve

4

5

6

Fuel control dial

Working mode

600K

600K

600K

600K

60K


Pump main 1

Pump main 2

Pump LS 1

Pump LS 2

Control

All lever in neutral

—

—

—

—

—

—

Arm out relief All levers in neutral Right track driven idle Lever moved halfway

LS valve

Swing motor safety valve

B

C1

C1

D1

Left track driven idle Lever moved halfway MAX

Main relief valve Travel motor Safety valve Travel junction valve

E

Swing lock Left swing relief

E

E

Right travel lock Right forward relief

F

Right travel lock Right reverse relief

F

Left travel lock Left forward relief

—

Left travel lock Left reverse relief

—

— D2

— —

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

F F

Service limit value

3.0 – 3.4 {31 – 35}

2.7 – 3.7 {28 – 35}

33.8 – 35.8 {345 – 365}

33.8 – 36.8 {345 – 375}

1.8 – 3.8 {18 – 38}

1.8 – 3.8 {18 – 38}

B (Work equipment relief pressure) MPa {kg/cm2}

D (LS differential pressure)

— —

D2

—

A


A (Control circuit basic pressure) C (Unload pressure)

C2

D1

— E

Unit

C2

—

Swing lock Right swing relief

P

Checked oil pressure Standard value

B

Bad

[2]

Good

[1]

Checking condition

Bad

Hydraulic circuit

Good

4.

SEN02460-01

2.1 – 2.3 {21.5 – 23.5}

2.1 – 2.3 {21.5 – 23.5}

E (Swing relief pressure)

28.2 – 30.2 {288 – 308}

26.7 – 30.7 {273 – 313}

F (Travel relief pressure)

33.8 – 35.8 {345 – 365}

32.8 – 36.8 {335 – 375}

* Gauge changing work: Change hoses of gauges [3] and [4]. Checking condition No.

Standard value

7

Check item

Servo piston

Fuel control dial

Working mode


MAX

P

Arm out relief

Checked oil pressure

Unit

H (Servo control pressure)

—

PC138US, USLC-8

[1]

[2]

[3a]

[4a]

[5]

600K

600K

600K

600K

60K

F pump main

R pump main

F pump servo

R pump servo

Control

H1

H1

H2

H2


—

Service limit value

H1 : H2 = 1 : 0.6 (Oil pressure ratio)

11

SEN02460-01


[2]

[3b]

[4b]

[5a]

No.

Check item

Fuel control dial

600K

600K

60K

60K

60K

F pump main

R pump main

F pump (F)

R pump (R)

LS-EPC

—

—

J1

J1

—

—

J2

J2

—

—

J3

J3

L

—

—

J4

J4

B

—

—

J5

J5

Working mode


MIN P

8

PC-EPC valve

E

All levers in neutral

MAX

Standard value

Checked oil pressure J2 (PC-EPC valve output pressure 2) J3 (PC-EPC valve output pressure 3) J4 (PC-EPC valve output pressure 4) J5 (PC-EPC valve output pressure 5)

12

Unit

J1 (PC-EPC valve output pressure 1)


Bad

[1]

Checking condition

Good

* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].

— — — — —

Service limit value

Approx. 1.7 {Approx. 18} MPa {kg/cm2}

Approx. 0.3 {Approx. 3} Approx. 0.5 {Approx. 5} Approx. 0.4 {Approx. 5} Approx. 0.4 {Approx. 5}

PC138US, USLC-8


PC138US, USLC-8

SEN02460-01

13

SEN02460-01




14

PC138US, USLC-8

SEN02461-01



Machine model

Serial number



40 Troubleshooting

1

Failure code table and fuse locations Failure code table ........................................................................................................................................... 2 Fuse locations................................................................................................................................................. 6

PC138US, USLC-8

1

SEN02461-01

40 Troubleshooting

Failure code table User code

Failure code

1


Alarm buzzer

989L00


MON

989M00


MON

989N00


MON

AB00KE

Charge voltage low

MON

B@BAZG Eng oil press. low

e

B@BAZK Eng oil level low

2

Component Category of Reference in charge record documents No.

ENG MON

B@BCNS Eng coolant overheat

e

ENG

B@HANS Hydr oil overheat

e

PUMP

E10

CA111

ECM critical internal failure

q

ENG

E10

CA115

Eng. Ne and Bkup speed sensor error

q

ENG

E11

CA122

Charge air press sensor high error

q

ENG

E11

CA123

Charge air press sensor low error

q

ENG

E14

CA131

Throttle sensor high error

q

ENG

E14

CA132

Throttle sensor low error

q

ENG

E15

CA144

Coolant temp. sensor high error

q

ENG

E15

CA145

Coolant temp. sensor low error

q

ENG

E15

CA153

Charge air temp. sensor high error

q

ENG

E15

CA154

Charge air temp. sensor low error

q

ENG

E15

CA187


q

ENG

E11

CA221

Ambient air press. sensor high error

q

ENG

E11

CA222

Ambient air press. sensor low error

q

ENG

E15

CA227


q

ENG

CA234

Eng. overspeed

E15

CA238

Ne speed sensor sup. volt. error

q

ENG

E10

CA271

IMV/PCV1 short error

q

ENG

E10

CA272

IMV/PCV1 open error

q

ENG

E11

CA322


q

ENG

E11

CA324


q

ENG

ENG

Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical Troubleshooting system by failure code, Part 1 Electrical SEN02463-00 system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system

PC138US, USLC-8

40 Troubleshooting

SEN02461-01

User code

Failure code


Alarm buzzer

E11

CA331


q

E11

CA332


q

E10

CA351

Inj. drive circuit error

q

E15

CA352


q

E15

CA386


q

E15

CA435

Abnormality in engine oil pressure switch

q

E10

CA441

Battery voltage low error

q

E10

CA442

Battery voltage high error

q

E11

CA449

Rail press. very high error

q

E11

CA451

Rail press. sensor high error

q

E11

CA452

Rail press. sensor low error

q

E15

CA553

Rail press. high error

q

E15

CA559

Rail press. low error

q

E15

CA689

Eng. Ne speed sensor error

q

E15

CA731

Eng. Bkup speed sensor phase error

q

E10

CA757

All persistent data lost error

q

E15

CA778

Eng. Bkup speed sensor error

q

E0E

CA1633

KOMNET datalink timeout error

q

E14

CA2185

Throttle sens. sup. volt. high error

q

E14

CA2186

Throttle sens. sup. volt. low error

q

E11

CA2249

Rail press. very low error

q

E11

CA2311

Abnormality in IMV solenoid

q

D110KB

Battery relay drive short

D19JKZ

Personal code relay abnormality

D862KA

GPS antenna discon

DA22KK

Pump solenoid power low error

DA25KP


DA26KP


DA2RMC

CAN discon (Pump controller detected)

DAF8KB

Short circuit in camera power supply

E01

E0E

E0E

PC138US, USLC-8

q

q

q

Component Category of in charge record Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical PUMP system Electrical KOM system Electrical KOM system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical MON system

Reference documents No. Troubleshooting by failure code, Part 1 SEN02463-00

Troubleshooting by failure code, Part 2 SEN02464-00


3

SEN02461-01

User code

E0E

Failure code


DAFGMC

GPS module error

DAFRMC

CAN discon (Monitor detected)

DGH2KB

Hydr oil sensor short

DHPAMA

Pump press sensor abnormality

E20

DHSFMA

E20

DHSGMA

E20

DHSHMA

E20

DHSJMA DHSKMA DHSLMA

4

40 Troubleshooting

Travel left forward PPC press sensor abnormality Travel right forward PPC press sensor abnormality Travel left reverse PPC press sensor abnormality Travel right reverse PPC press sensor abnormality Blade raise PPC press sensor abnormality Blade lower PPC press sensor abnormality

Alarm buzzer

q

q q q q

DHX1MA

Overload sensor abnormality (Analog)

DV20KB

Travel alarm S/C

DW43KA

Travel speed sol discon

DW43KB

Travel speed sol short

E03

DW45KA

Swing brake sol discon

q

E03

DW45KB

Swing brake sol short

q

DW91KA

Travel junction sol discon

DW91KB

Travel junction sol short

DWJ0KA

Merge-divider sol discon

DWJ0KB

Merge-divider sol short

E02

DXA8KA

PC-EPC sol discon

q

E02

DXA8KB

PC-EPC sol short

q

DXE4KA

Service current EPC discon

DXE4KB

Service current EPC short

DY20KA

Wiper working abnormality

DY20MA

Wiper parking abnormality

DY2CKA

Washer drive discon

DY2CKB

Washer drive short

DY2DKB

Wiper drive (for) short

DY2EKB

Wiper drive (rev) short

Component Category of in charge record Electrical KOM system Electrical MON system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system

Reference documents No.



PC138US, USLC-8

40 Troubleshooting a a

a

a

a

SEN02461-01

Entry order of items in table The items are entered in the order of their failure codes (incremental order). User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the abnormality. Alarm buzzer q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). e : Since the caution monitor is also turned ON, its function sounds the buzzer. Component in charge MON: The machine monitor is in charge of detection of abnormality. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. ENG: The engine controller is in charge of detection of abnormality. PUMP: The pump controller is in charge of detection of abnormality. Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record.

PC138US, USLC-8

5

SEN02461-01

40 Troubleshooting

Fuse locations

1

Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally. Type of power supply

Switch power supply

Switch power supply

Switch power supply

Constant power supply

Switch power supply

6

Fusible link

F02 (45A)

F02 (45A)

F02 (45A)

F03 (45A)

Starting switch ACC

Fuse No.

Fuse capacity

1

10A

Emergency operating circuit

2

30A

Solenoid valve

3

15A

Cigarette lighter

4

10A

Windshield washer

Destination of power

5

10A

Horn

6

5A

Working lamp relay, horn relay

7

10A

Rotary lamp (If equipped)

8

20A

Working lamp

9

10A

Radio, speaker

10

5A

Air conditioner

11

20A


12

10A

Optional power supply (1)

13

10A

Optional power supply (2), power supply of 12 volt

14

10A

Spare

15

5A

Air conditioner

16

10A

Radio backup, room lamp

17

20A

Machine monitor, pump controller, starting switch

18

30A

Engine controller

19

5A

Engine controller

20

5A

PPC oil pressure lock solenoid

PC138US, USLC-8

40 Troubleshooting

SEN02461-01

Locations of fusible links

Location of fuse box and fuse Nos.

PC138US, USLC-8

7

SEN02461-01

40 Troubleshooting



8

PC138US, USLC-8

SEN02462-00



Machine model

Serial number



40 Troubleshooting

1

General information on troubleshooting Points to remember when troubleshooting ..................................................................................................... 2 Sequence of events in troubleshooting........................................................................................................... 3 Checks before troubleshooting ....................................................................................................................... 4 Classification and procedures for troubleshooting .......................................................................................... 5 Information in troubleshooting table................................................................................................................ 6 Phenomena looking like troubles and troubleshooting Nos. ........................................................................... 8 Wiring table for connector pin numbers .........................................................................................................11 T-adapter box and T-adapter table................................................................................................................ 44

PC138US, USLC-8

1

SEN02462-00

40 Troubleshooting

Points to remember when troubleshooting k k k k k k

1

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. 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 questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

2.

3.

2

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

4)

Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4.

Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.

5.

Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting table or troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information.

6.

Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.To prevent this, always investigate why the problem occurred. Then, remove the root cause.

Check before troubleshooting 1) Is there any sign of irregularities of the machine? 2) Make checks before starting day's work. 3) Make checks of other items.

PC138US, USLC-8

40 Troubleshooting

SEN02462-00

Sequence of events in troubleshooting

1

PC138US, USLC-8

3

SEN02462-00

40 Troubleshooting

Checks before troubleshooting Item

Lubricating oil/Coolant

Hydraulic/ Mechanical equipment

4

Remedy

—

Add fuel

2. Check of fuel for foreign matter

—

Clean and drain

3. Check of fuel filter

—

Replace

4. Check of hydraulic oil level

—

Add fuel

5. Check of hydraulic oil strainer

—

Clean and drain

6. Check of swing machinery oil level

—

Add fuel

7. Check of level and type of engine oil (in oil pan)

—

Add fuel

8. Check of coolant level

—

Add coolant

9. Check of dust indicator for clogging

—

Clean or replace

—

Replace

1. Check of battery terminals and wiring for looseness and corrosion

—

Retighten or replace

2. Check of alternator terminals and wiring for looseness and corrosion

—


3. Check of starting motor terminals and wiring for looseness and corrosion

—


1. Check for abnormal noise and smell

—

Repair

2. Check for oil leakage

—

Repair

3. Bleeding air

—

Bleed air

20 – 30 V

Replace

2. Check of electrolyte level

—

Add or replace

3. Check of wires for discoloration, burn, and removal of cover

—

Replace

4. Check for released wire clamp and drooping wire

—

Repair

5. Check of wires for wetness (Check connectors and terminals for wetness, in particular)

—

Disconnect the connectors and dry

6. Check of fuse for disconnection and corrosion

—

Replace

7. Check of alternator voltage (while engine speed is at middle or higher)

After operating for several minutes: 27.5 – 29.5 V

Replace

8. Check of battery relay for operating sound (when starting switch is turned ON or OFF)

—

Replace

1. Check of battery voltage (with engine stopped)

Electric, electrical equipment

Criterion

1. Check of level and type of fuel

10. Check of hydraulic oil filter

Electrical equipment

1

PC138US, USLC-8

40 Troubleshooting

SEN02462-00

Classification and procedures for troubleshooting

1

Classification for troubleshooting Mode Display of code

Contents Troubleshooting by failure code

E-mode

Troubleshooting of electrical system

H-mode

Troubleshooting of hydraulic and mechanical system

S-mode

Troubleshooting of engine

Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1.

Procedure for troubleshooting to be taken when user code and failure code are displayed on machine monitor: If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for the corresponding "Display of code" according to the displayed failure code.

2.

When electrical system error code or mechanical system error code is recorded in abnormality record: If a user code and a failure code are not displayed on the machine monitor, check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according to the recorded code. a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is still detected. a An error code of the mechanical system cannot be deleted. a If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the abnormality record function, carry out the corresponding troubleshooting in E-mode.

3.

When user code and failure code is not displayed and no failure code is recorded in abnormality record: If a user code and failure code are not displayed on the machine monitor and no failure code is recorded in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode".

PC138US, USLC-8

5

SEN02462-00

40 Troubleshooting

Information in troubleshooting table a

1

The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. User code

Failure code

Display on Display on machine machine monimonitor tor Contents of trouble

Trouble

Trouble name displayed in abnormality record machine monitor

Contents of trouble detected by machine monitor or controller

Action of Action taken by machine monitor or controller to protect system or devices when engine conmachine monitroller detects trouble tor or controller Problem that appears on machine

Problem that appears on machine as result of action taken by machine monitor or controller (shown above)

Related information

Information related to detected trouble or troubleshooting

Cause

1

2

Possible causes and standard value in normal state

6

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment • Disconnection Connector is connected imperfectly or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.

Possible causes of trouble 3 (Given numbers are reference numbers, which do not (1) Method of indicating connector No. and handling of Tindicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of “male” and “female”, disconnect connector and insert T-adapters in both male 4 side and female side. • If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 5 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.

PC138US, USLC-8

40 Troubleshooting

SEN02462-00

Related circuit diagram

This drawing is a part of the electric circuit diagram related to troubleshooting. q q

q

PC138US, USLC-8

Connector No.: Indicates (Model – Number of pins) and (Color). “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. Arrow ( ): Roughly shows the location on the machine.

7

SEN02462-00

40 Troubleshooting

Phenomena looking like troubles and troubleshooting Nos.

1

Troubleshooting No.

Phenomena looking like troubles

Display of code

E-mode

H-mode

S-mode

Phenomena related to user code/failure code User code and failure code are displayed on ordinary screen of machine monitor According to disWhen abnormality record is checked, failure code is displayed in 2 played mechanical system abnormality record code When abnormality record is checked, failure code is displayed in 3 electrical system abnormality record 1

4

When abnormality record is checked, failure code is displayed in air conditioner or heater abnormality record

E-22

Phenomena related to engine 5 Starting performance is poor

S-1

6 Engine does not start (Engine does not turn)

E-3

S-2

7 Engine does not pick up smoothly

S-3

8 Engine stops during operations

S-4

9 Engine does not rotate smoothly

S-5

10 Engine lacks output (or lacks power)

S-6

11 Exhaust smoke is black (incomplete combustion)

S-7

12 Oil consumption is excessive (or exhaust smoke is blue)

S-8

13 Oil becomes contaminated quickly

S-9

14 Fuel consumption is excessive

S-10

15 Oil is in coolant (or coolant spurts back or coolant level goes down)

S-11

16 Oil pressure drops

S-12

17 Oil level rises (Entry of coolant or fuel)

S-13

18 Coolant temperature becomes too high (overheating)

S-14

19 Abnormal noise is made

S-15

20 Vibration is excessive

S-16

21 Preheater does not operate

E-4

22 Automatic warm-up system does not operate (in cold season)

E-5

23 Auto-decelerator does not operate normally

E-15

Phenomena related to work equipment/swing/travel 24

All work equipment, swing, and travel mechanism do not move or cannot be locked

E-6

25 Speed or power of all work equipment, swing, and travel are low

H-1

26 Engine speed sharply drops or engine stalls 27 Working mode does not change

H-3

H-2

S-6

E-16

28 Abnormal noise is heard from around hydraulic pump

H-4

29 Fine control mode does not function

H-5

Phenomena related to work equipment 30 Speed or power of boom is low

H-6

31 Speed or power of arm is low

H-7

32 Speed or power of bucket is low

H-8

33 Work equipment does not move in its single operation

H-9

8

PC138US, USLC-8

40 Troubleshooting

SEN02462-00

Troubleshooting No.


Display of code

E-mode

H-mode

34 Hydraulic drift of work equipment is large

H-10

35 Time lag of work equipment is large

H-11

36

Flow rate in attachment circuit cannot be adjusted (when attachment is installed)

S-mode

H-26

Phenomena related to compound operation 37 Work equipment loaded more is slower during compound operation

H-12

38

Boom RAISE speed is low in compound operation of swing + boom RAISE

H-13

39

Travel speed lowers largely during compound operation of work equipment/swing + travel

H-14

Phenomena related to travel 40 Machine deviates during travel

H-15

41 Travel speed is low

H-16

42 Machine cannot be steered easily or steering power is low

H-17

43 Travel speed does not change or it is kept low or high

E-17

44 Track does not move (Only either side)

H-18 H-19

45 Travel alarm does not sound or does not stop sounding

E-21

Phenomena related to swing 46 Machine does not swing

H-20

47 Swing acceleration or swing speed is low

H-21

48 Excessive overrun when stopping swing

H-22

49 When upper structure stops swinging, it makes large shock

H-23

50 When upper structure stops swinging, it makes large sound

H-24

51

Swing holding brake does not operate normally Hydraulic drift of swing is large

E-20

H-25

Phenomena related to machine monitor 52 When starting switch turned ON, machine monitor displays nothing 53

When starting switch turned ON (before starting engine), basic check item lights up

E-1 E-2

54 Precaution lights up while engine is running

E-7

55 Emergency stop item lights up while engine is running

E-8

56 Engine coolant temperature gauge does not indicate normally

E-9

57 Hydraulic oil temperature gauge does not indicate normally

E-10

58 Fuel level gauge does not indicate normally

E-11

59

Contents of display by machine monitor are different from applicable machine

E-12

60 Machine monitor does not display some items

E-13

61 Function switch does not work

E-14

62 Alarm buzzer cannot be stopped

E-18

63 Windshield wiper and window washer do not operate

E-19

Air conditioner does not operate normally (including air conditioner abnormality record)

E-22

65 While starting switch is in OFF position, service meter is not displayed

E-23

66 Machine monitor cannot be set in service mode

E-24

67 Monitoring function does not display lever control signal normally

E-25

64

PC138US, USLC-8

9

SEN02462-00

40 Troubleshooting

Troubleshooting No.


Display of code

E-mode

H-mode

S-mode

Other phenomena 68 KOMTRAX system does not operate normally

10

E-26

PC138US, USLC-8

40 Troubleshooting

SEN02462-00

Wiring table for connector pin numbers

(Rev. 2006.11)

a

The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.

PC138US, USLC-8

11

SEN02462-00

12

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

13

SEN02462-00

14

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

15

SEN02462-00

16

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

17

SEN02462-00

18

40 Troubleshooting

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40 Troubleshooting

PC138US, USLC-8

SEN02462-00

19

SEN02462-00

20

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

21

SEN02462-00

22

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

23

SEN02462-00

24

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

25

SEN02462-00

26

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

27

SEN02462-00

28

40 Troubleshooting

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40 Troubleshooting

PC138US, USLC-8

SEN02462-00

29

SEN02462-00

30

40 Troubleshooting

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40 Troubleshooting

PC138US, USLC-8

SEN02462-00

31

SEN02462-00

32

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

33

SEN02462-00

34

40 Troubleshooting

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40 Troubleshooting

PC138US, USLC-8

SEN02462-00

35

SEN02462-00

36

40 Troubleshooting

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40 Troubleshooting

PC138US, USLC-8

SEN02462-00

37

SEN02462-00

38

40 Troubleshooting

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40 Troubleshooting

PC138US, USLC-8

SEN02462-00

39

SEN02462-00

40

40 Troubleshooting

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40 Troubleshooting

PC138US, USLC-8

SEN02462-00

41

SEN02462-00

42

40 Troubleshooting

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02462-00

43

SEN02462-00

40 Troubleshooting

T-adapter box and T-adapter table a

(Rev. 2006.11) 1

799-601-2600 T-box (for ECONO)

21

799-601-3100 T-box (for MS)

37

799-601-3200 T-box (for MS)

37

q

q

q q

Out of kit

799-601-4200

799-601-4100

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.

q

q

799-601-3380 • Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)

24

MS-24P

q

799-601-3420 Adapter for BENDIX (MS)

24

MS-24P

q


17

MS-17P

q


17

MS-17P

q


5

MS-5P

q


10

MS-10P

q


5

MS-5S

q


17

MS-17P

q


19

MS-19P

q


14

MS-14P

q

799-601-2710 Adapter for MIC

5

MIC-5P

q q


13

MIC-13P

q q


17

MIC-17P

q q q

q q

q


21

MIC-21P

q q q

q q

q


9

MIC-9P

q q q

q

799-601-2750 Adapter for ECONO

2

ECONO2P

q q


3

ECONO3P

q q


4

ECONO4P

q q


8

ECONO8P

q q


12 ECONO12P q q

q

799-601-3470 Case

799-601-2810 Adapter for DLI

8

DLI-8P

q q


12

DLI-12P

q q


16

DLI-16P

q q

799-601-2840 Extension cable (ECONO type)

12 ECONO12P q q

q q

q

q

799-601-2850 Case 799-601-4210 Adapter for DRC

50

799-601-7010 Adapter for X (T-adapter)

1

799-601-7020 Adapter for X

2


3


q

DRC50 q

q

X2P

q q q

q

X3P

q q q

q

4

X4P

q q q

q

799-601-7050 Adapter for SWP

6

SW6P

q q q


8

SW8P

q q q


12

SW12P


14

SW14P


16

SW16P

799-601-7080 Adapter for M (T-adapter)

1

q q

q

q

q

q

799-601-7090 Adapter for M

2

M2P

q q q

q


3

M3P

q q q

q

44

PC138US, USLC-8

40 Troubleshooting

SEN02462-00

q q q

q q

Out of kit

S8P

799-601-4200

8

799-601-4100

799-601-7140 Adapter for S

799-601-9300

q

799-601-9200

q q q

M8P

799-601-9100

M6P

8

799-601-9000

6


799-601-8000


799-601-7500

q

799-601-7400

q q q

799-601-7100

M4P

799-601-7000

4

799-601-2800


Part name

799-601-2700


Part No.

799-601-2500

Number of pins

T-adapter kit

q

799-601-7150 Adapter for S (White)

10

S10P

q q q

799-601-7160 Adapter for S (Blue)

12

S12P

q q q

799-601-7170 Adapter for S (Blue)

16

S16P

q q q


16

S16PW


12

S12PW

799-601-7180 Adapter for AMP040

8

A8P


12

A12P

q

q


16

A16P

q q q

q


20

A20P

q q q

q

799-601-7230 Short connector for X

2

q q q

q

q q q

q

q q

799-601-7240 Case

q

799-601-7270 Case 799-601-7510 Adapter for 070

10

07-10

q

799-601-7520 Adapter for 070

12

07-12

q

799-601-7530 Adapter for 070

14

07-14

q

799-601-7540 Adapter for 070

18

07-18

q

799-601-7550 Adapter for 070

20

07-20

q

799-601-7360 Adapter for relay

5

REL-5P

q

799-601-7370 Adapter for relay

6

REL-6P

q

799-601-7380 Adapter for JFC

2

799-601-9010 Adapter for DTM

2

DTM2

q

q

799-601-9020 Adapter for DT

2

DT2

q

q


3

DT3

q

q


4

DT4

q

q


6

DT6

q

q

799-601-9060 Adapter for DT (Gray)

8

DT8GR

q

q

799-601-9070 Adapter for DT (Black)

8

DT8B

q

q

799-601-9080 Adapter for DT (Green)

8

DT8G

q

q

q

799-601-9090 Adapter for DT (Brown)

8

DT8BR

q

q

799-601-9110 Adapter for DT (Gray)

12

DT12GR

q

q

799-601-9120 Adapter for DT (Black)

12

DT12B

q

q

799-601-9130 Adapter for DT (Green)

12

DT12G

q

q


12

DT12BR

q

q

799-601-9210 Adapter for HD30-18

8

D18-8

q q

799-601-9220 Adapter for HD30-18

14

D18-14

q q

799-601-9230 Adapter for HD30-18

20

D18-20

q q

799-601-9240 Adapter for HD30-18

21

D18-21

q q

799-601-9250 Adapter for HD30-24

9

D24-9

q q

799-601-9260 Adapter for HD30-24

16

D24-16

q q

799-601-9270 Adapter for HD30-24

21

D24-21

q q

799-601-9280 Adapter for HD30-24

23

D24-23

q q

799-601-9290 Adapter for HD30-24

31

D24-31

q q

799-601-9310 Plate for HD30 (24-pin)

PC138US, USLC-8

q q

q q q q

q

45

799-601-9320 T-box (for DT/HD)

q q

12

Out of kit

799-601-4200

799-601-4100

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800


799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

40 Troubleshooting

Number of pins

SEN02462-00

q

q

799-601-9330 Case

q

799-601-9340 Case 799-601-9350 Adapter for DRC

40

DRC-40

q q

799-601-9360 Adapter for DRC

24

DRC-24

799-601-9410* Socket for engine (CRI-T2)

2

G

Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL

3

A3

q q

2

P

q q

799-601-9440* Socket for engine (CRI-T2)

3

1,2,3

q

795-799-5520* Socket for engine (HPI-T2)

2

S

q

Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor

2

C

q q

2

A

q q

799-601-9430*

795-799-5540*

Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV

Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM

q

795-799-5460 Cable for engine (HPI-T2)

3

q


3

q


3

q

799-601-4110 Adapter for engine (140-T3) PIM

4

ITT3N

799-601-4130 Adapter for engine (CRI-T3) NE, CAM

3

FCIN

q q

3

FCIG

q q

3

FCIB

q q

2

4160

q q

3

4180

q q

799-601-4140

Adapter for engine (CRI-T3) Atomosphere pressure

799-601-4150 Adapter for engine (CRI-T3) POIL 799-601-4160

Adapter for engine (CRI-T3) Oil pressure switch

799-601-4180 Adapter for engine (CRI-T3) PEVA

q

799-601-4190*

Socket for engine (CRI-T3) Commonrail pressure

3

1,2,3L

q q

799-601-4230*

Socket for engine (CRI-T3) Air intake pressure/temperature

4

1,2,3,4C

q q

799-601-4240* Socket for engine (CRI-T3) PAMB

3

1,2,3A

q q

799-601-4250* Socket for engine (CRI-T3) PIM

3

1,2,3B

q q

799-601-4330* Socket for engine (CRI-T3) G

3

1,2,3,G

q q

Socket for engine (CRI-T3) 799-601-4340* Pump actuator

2

2,PA

q q

4

1,2,3,4T

799-601-4380*

Socket for engine (CRI-T3)(95) Air intake pressure/temperature

q q q

799-601-4260 Adapter for controller (ENG)

4

DTP4


50

DRC50

q

DRC60

q


60

799-601-4390* Socket for controller (95 ENG)

60

q

799-601-4280 Box for controller (PUMP)

121

q

799-601-9720 Adapter for controller (HST)

16

HST16A

q


16

HST16B

q


26

HST26A

q

“*” Shows not T-adapter but socket.

46

PC138US, USLC-8

SEN02462-00

40 Troubleshooting



48

PC138US, USLC-8

SEN02463-01



Machine model

Serial number



40 Troubleshooting

1

Troubleshooting by failure code, Part 1 Failure code [989L00] Engine controller lock caution 1 .................................................................................. 3 Failure code [989M00] Engine controller lock caution 2 ................................................................................. 3 Failure code [989N00] Engine controller lock caution 3.................................................................................. 4 Failure code [AB00KE] Charge voltage low.................................................................................................... 6 Failure code [B@BAZG] Eng oil press. low .................................................................................................... 8 Failure code [B@BAZK] Eng oil level low ....................................................................................................... 8 Failure code [B@BCNS] Eng coolant overheat .............................................................................................. 9 Failure code [B@HANS] Hydr oil overheat ..................................................................................................... 9 Failure code [CA111] ECM critical internal failure ......................................................................................... 10 Failure code [CA115] Eng. Ne and Bkup speed sensor error ....................................................................... 13 Failure code [CA122] Charge air press sensor high error ............................................................................ 14 Failure code [CA123] Charge air press sensor low error.............................................................................. 16 Failure code [CA131] Throttle sensor high error........................................................................................... 18 Failure code [CA132] Throttle sensor low error ............................................................................................ 20 Failure code [CA144] Coolant temp. sensor high error................................................................................. 21 Failure code [CA145] Coolant temp. sensor low error .................................................................................. 22

PC138US, USLC-8

1

SEN02463-01

40 Troubleshooting

Failure code [CA153] Charge air temp. sensor high error ............................................................................ 23 Failure code [CA154] Charge air temp. sensor low error.............................................................................. 24 Failure code [CA187] Sensor sup. 2 volt. low error....................................................................................... 24 Failure code [CA221] Ambient air press. sensor high error .......................................................................... 26 Failure code [CA222] Ambient air press. sensor low error............................................................................ 28 Failure code [CA227] Sensor sup. 2 volt. high error ..................................................................................... 30 Failure code [CA234] Eng. overspeed .......................................................................................................... 32 Failure code [CA238] Ne speed sensor sup. volt. error ................................................................................ 34 Failure code [CA271] IMV/PCV1 short error ................................................................................................. 36 Failure code [CA272] IMV/PCV1 open error ................................................................................................. 37 Failure code [CA322] Injector #1 (L #1) system open/short error ................................................................. 38 Failure code [CA324] Injector #3 (L #3) system open/short error ................................................................. 40 Failure code [CA331] Injector #2 (L #2) system open/short error ................................................................. 42 Failure code [CA332] Injector #4 (L #4) system open/short error ................................................................. 44

2

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Failure code [989L00] Engine controller lock caution 1 User code

Failure code

—

989L00

Contents of trouble

Trouble

1

Engine controller lock caution 1 (Machine monitor system)

• Engine controller lock is detected (Factor 1).

Action of • None in particular. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine Related information


• Engine cannot be started. • If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. • Method of reproducing failure code: Turn starting switch ON. Cause 1

Standard value in normal state/Remarks on troubleshooting

Replacement of machine monitor

This trouble may be caused by replacement of machine monitor.

Failure code [989M00] Engine controller lock caution 2 User code

Failure code

—

989M00

Contents of trouble

Trouble

1



Action of • None in particular. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine Related information

• Engine cannot be started. • If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. • Method of reproducing failure code: Turn starting switch ON. Cause


1

Replacement of machine monitor

2 Defective machine monitor

PC138US, USLC-8

Standard value in normal state/Remarks on troubleshooting This trouble may be caused by replacement of machine monitor. If this failure code is displayed while machine monitor is not replaced, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

3

SEN02463-01

40 Troubleshooting

Failure code [989N00] Engine controller lock caution 3 User code

Failure code

—

989N00

Contents of trouble

Trouble

1



Action of • Tries automatic resetting. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine Related information Possible causes and standard value in normal state

4

• Method of reproducing failure code: Failure code is not reproduced since system is reset automatically. Cause


1 Defective engine controller

If this failure code is displayed repeatedly, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02463-01

5

SEN02463-01

40 Troubleshooting

Failure code [AB00KE] Charge voltage low User code

Failure code

—

AB00KE

Contents of trouble

Trouble

1

Charge voltage low (Machine monitor system)

• While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).

Action of • Displays charge level monitor on machine monitor. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information

• If machine is operated as it is, battery may not be charged. • Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage) • Method of reproducing failure code: Start engine. Cause


1

2

6

Defective charge of alternator (when system is normal)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. E12 (male)

Engine speed

Voltage

Between (1) – chassis ground

Min. medium speed

27.5 – 29.5 V

If cause 1 is not detected, charge level monitor system may be Defective charge level monidefective. Carry out troubleshooting for "E-7 Caution item flashes tor while engine is running" in E-mode.

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Circuit diagram related

PC138US, USLC-8

7

SEN02463-01

40 Troubleshooting

Failure code [B@BAZG] Eng oil press. low User code

Failure code

— Contents of trouble Action of controller Problem that appears on machine Related information


B@BAZG

Trouble

1

Engine oil pressure low (Engine controller system)

• While engine was running, signal circuit of engine oil pressure switch detected low engine oil pressure (sensor contact opened). • Displays engine oil pressure monitor on machine monitor. • If cause of failure disappears, system resets itself. • If machine is operated as it is, engine may be damaged. • Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor. • Method of reproducing failure code: Start engine. Cause


Lowering of engine oil pres1 sure (when system is normal)

Engine oil pressure may be low. Check it and remove cause if it is low.

2

Defective engine oil pressure If cause 1 is not detected, engine oil pressure switch system may switch system be defective. Carry out troubleshooting for failure code [CA435].

Failure code [B@BAZK] Eng oil level low User code

Failure code

—

B@BAZK

Contents of trouble

Trouble

1

Engine oil level low (Machine monitor system)

• When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch detected low engine oil level (sensor contact opened).

Action of • Displays engine oil level monitor on machine monitor. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information

• If machine is operated as it is, engine may be damaged. • Engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2) • Method of reproducing failure code: Turn starting switch ON. Cause


8

1

Lowering of engine oil level (when system is normal)

Defective engine oil level 2 monitor system

Standard value in normal state/Remarks on troubleshooting Engine oil level may be low. Check it and add new oil if it is low. If cause 1 is not detected, engine oil level monitor system may be defective. Carry out troubleshooting for "E-2 Basic check item lights up when starting switch is turned ON (but engine is not started)" in E-mode.

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Failure code [B@BCNS] Eng coolant overheat User code

Failure code

— Contents of trouble Action of controller Problem that appears on machine Related information

B@BCNS

Trouble

Engine coolant overheat (Engine controller system)

• While engine was running, signal circuit of engine coolant temperature sensor detected overheating of engine coolant (above about 102°C). • Displays engine coolant temperature monitor with red on machine monitor. • If cause of failure disappears, system resets itself. • If machine is operated as it is, engine may be seized. • Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor. • Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature) • Method of reproducing failure code: Start engine. Cause



Overheating of engine Engine coolant may be overheating. Check it and remove cause if 1 coolant (when system is norit is overheating. mal) 2

Defective engine coolant temperature sensor system

If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].

Failure code [B@HANS] Hydr oil overheat User code

Failure code

—

B@HANS

Contents of trouble Action of controller Problem that appears on machine Related information


1

Trouble

1

Hydraulic oil overheat (Pump controller system)

• While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of hydraulic oil (above about 102°C). • Displays hydraulic oil temperature monitor with red on machine monitor. • If cause of failure disappears, system resets itself. • If machine is operated as it is, engine may be seized. • Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine monitor. • Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature) • Method of reproducing failure code: Start engine. Cause


Overheating of hydraulic oil 1 (when system is normal)

Hydraulic oil may be overheating. Check it and remove cause if it is overheating.

Defective hydraulic oil temperature gauge system

If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for "E-10 Hydraulic oil temperature gauge does not work normally" in E-mode.

2

PC138US, USLC-8

9

SEN02463-01

40 Troubleshooting

Failure code [CA111] ECM critical internal failure User code

Failure code

E10

CA111

Contents of trouble Action of controller Problem that appears on machine

Trouble

1

ECM critical internal failure (Engine controller system)

• Abnormality occurred in controller. • None in particular. • Engine runs normally but it may stop during operation or may not be able to start.

Related information Cause 1 Defective fuse

Defective power supply cut2 out relay

Standard value in normal state/Remarks on troubleshooting Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) – (32)

Resistance

185 – 265 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

10

Wiring harness between CE02 (female) (55) – R23 (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between CE03 (female) (1) – T12

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between R23 (female) (3) – battery (+)

Resistance

Max. 1 z


Resistance

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between CE02 (female) (55) – R23 (1) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Wiring harness between R23 (female) (3) – battery (+) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Ground fault in wiring harWiring harness between CE02 (female) (32) 4 ness (Short circuit with GND – R24 (2) and chassis ground circuit) Wiring harness between CE03 (female) (3) – R23 (5) and chassis ground


PC138US, USLC-8

a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. CE03

Voltage

Between (3) – (1)

20 – 30 V

11

SEN02463-01

40 Troubleshooting


12

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Failure code [CA115] Eng. Ne and Bkup speed sensor error User code

Failure code

E10

CA115


Trouble

1

Eng. Ne and Bkup speed sensor error (Engine controller system)

• Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously. • None in particular. • Engine cannot be started (if engine has been stopped). • Engine stops (if engine has been running).

Related information Causes



1

Defective Ne speed sensor system

Carry out troubleshooting for failure code [CA689].

2

Defective Bkup speed sensor system

Carry out troubleshooting for failure code [CA778].

3

Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, internal of flywheel, etc.)

4

Defective mount of Bkup speed sensor

5

Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defecconnection) tive connection (wrong connection).


PC138US, USLC-8

Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal of supply pump, etc.)

If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

13

SEN02463-01

40 Troubleshooting

Failure code [CA122] Charge air press sensor high error User code

Failure code

E11

CA122


Trouble

1

Charge air press sensor high error (Engine controller system)

• High voltage was detected in charge pressure sensor circuit. • Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation. • Acceleration performance of engine drops. • Signal voltage of charge pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage). • Method of reproducing failure code: Turn starting switch ON. Causes


Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble1 ply system shooting for it first. Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective charge pressure 2 sensor (Internal trouble)


PTIM Between (2) – (4)

Voltage Power supply

4.75 – 5.25 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Wiring harness between CE01 (female) (19) – PTIM (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)

14

Wiring harness between CE01 (female) (19) – PTIM (female) (1) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Causes



Short circuit in wiring harness 5 (With another wiring harness)


Wiring harness between CE01 (female) (19) – PTIM (female) (1) and wiring harness between CE01 (female) (36) – PTIM (female) (2)

Resistance

Min. 1 Mz

Wiring harness between CE01 (female) (19) – PTIM (female) (1) and wiring harness between CE01 (female) (48) – PTIM (female) (4)

Resistance

Min. 1 Mz

Chassis ground between CE01 (female) (36) – PTIM (female) (2) and chassis ground between CE01 (female) (48) – PTIM (female) (4)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. CE01 Between (36) – (48)

Voltage Power supply

4.75 – 5.25 V


PC138US, USLC-8

15

SEN02463-01

40 Troubleshooting

Failure code [CA123] Charge air press sensor low error User code

Failure code

E11

CA123



16

Trouble

1

Charge air press sensor low error (Engine controller system)

• Low voltage was detected in charge pressure sensor circuit. • Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation. • Acceleration performance of engine drops. • Signal voltage of charge pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage). • Method of reproducing failure code: Turn starting switch ON. Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA122].

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02463-01

17

SEN02463-01

40 Troubleshooting

Failure code [CA131] Throttle sensor high error User code

Failure code

E14

CA131


Trouble

1

Throttle sensor high error (Engine controller system)

• High voltage was detected in fuel control dial circuit. • Sets throttle angle with signal other than fuel control dial signal and continues operation (depending on each model) • Engine speed cannot be controlled with fuel control dial. • Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) • Method of reproducing failure code: Turn starting switch ON. Causes


Defective sensor power sup- If failure code [CA2185] or [CA2186] is indicated, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2

Defective fuel control dial (Internal trouble)

P20 (male)

Resistance

Between (1) – (3)

4.0 – 6.0 kz

Between (2) – (1)

0.25 – 5.0 kz

Between (2) – (3)

0.25 – 5.0 kz




Wiring harness between CE02 (female) (27) – P20 (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Wiring harness between CE02 (female) (27) – P20 (female) (1) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

18

CE02

Voltage

Between (27) – (28)

Power supply

4.75 – 5.25 V

Between (35) – (28)

Signal

0.5 – 4.5 V

PC138US, USLC-8

40 Troubleshooting

SEN02463-01


PC138US, USLC-8

19

SEN02463-01

40 Troubleshooting

Failure code [CA132] Throttle sensor low error User code

Failure code

E14

CA132



20

Trouble

1

Throttle sensor low error (Engine controller system)

• Low voltage was detected in fuel control dial circuit. • Sets throttle angle with signal other than fuel control dial signal and continues operation (depending on each model) • Engine speed cannot be controlled with fuel control dial. • Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) • Method of reproducing failure code: Turn starting switch ON. Cause


PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Failure code [CA144] Coolant temp. sensor high error User code

Failure code

E15

CA144

Contents of trouble Action of controller

Trouble

1

Coolant temp. sensor high error (Engine controller system)

• High voltage was detected in coolant temperature sensor circuit. • Fixes coolant temperature (90°C) and continues operation.

Problem that appears on machine Related information

• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Engine coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause

1

Defective coolant temperature sensor (Internal trouble)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male)

Coolant temperature

Resistance

Between (1) – (2)

10 – 100°C

0.6 – 20 kz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (47) 2 or defective contact in con- – TWTR (female) (1) nector) Wiring harness between CE01 (female) (49) – TWTR (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (49) Resiscircuit) Min. 1 Mz – TWTR (female) (2) and chassis ground tance


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CE01 (female)

Coolant temperature

Resistance

Between (47) – (49)

10 – 100°C

0.6 – 20 kz


PC138US, USLC-8

21

SEN02463-01

40 Troubleshooting

Failure code [CA145] Coolant temp. sensor low error User code

Failure code

E15

CA145


Trouble

1

Coolant temp. sensor low error (Engine controller system)

• Low voltage was detected in coolant temperature sensor circuit. • Fixes coolant temperature (90°C) and continues operation.



22

• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Engine coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA144].

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Failure code [CA153] Charge air temp. sensor high error User code

Failure code

E15

CA153


Trouble

1

Charge air temp. sensor high error (Engine controller system)

• High voltage was detected in charge temperature sensor circuit. • Fixes charge temperature (intake air temperature) (70°C) and continues operation.


• Signal voltage of charge temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause


1


Defective charge temperature sensor (Internal trouble)

PTIM (male)

Intake air temperature

Resistance

Between (3) – (4)

10 – 100°C

0.5 – 20 kz


All range

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring ing without turning starting switch ON. harness Wiring harness between CE01 (female) (11) Resis2 (Disconnection in wiring or Max. 1 z – PTIM (female) (3) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z – PTIM (female) (4) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (11) Resiscircuit) Min. 1 Mz – PTIM (female) (3) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

CE01 (female)

Intake air temperature

Resistance

Between (11) – (48)

10 – 100°C

0.5 – 20 kz


PC138US, USLC-8

23

SEN02463-01

40 Troubleshooting

Failure code [CA154] Charge air temp. sensor low error User code

Failure code

E15

CA154


Trouble

1

Charge air temp. sensor low error (Engine controller system)

• Low voltage was detected in charge temperature sensor circuit. • Fixes charge temperature (intake air temperature) (70°C) and continues operation.



• Signal voltage of charge temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA153].

Failure code [CA187] Sensor sup. 2 volt. low error User code

Failure code

E15

CA187

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

24

Trouble

1

Sensor sup. 2 volt. low error (Engine controller system)

• Low voltage was detected in sensor power supply 2 (5 V) circuit. • Operates Bkup speed sensor with signals of Ne speed sensor. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. • Output drops. • Method of reproducing failure code: Turn starting switch ON.

Causes


PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02463-01

25

SEN02463-01

40 Troubleshooting

Failure code [CA221] Ambient air press. sensor high error User code

Failure code

E11

CA221


Trouble

1

Ambient air press. sensor high error (Engine controller system)

• High voltage was detected in ambient pressure sensor circuit. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Output drops. • Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Causes


Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective atmospheric pres2 sure sensor (Internal trouble)

PAMB

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.3 – 4.7 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Wiring harness between CE01 (female) (36) – PAMB (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


26

Wiring harness between CE01 (female) (36) – PAMB (female) (1) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Causes




Wiring harness between CE01 (female) (36) – PAMB (female) (1) and wiring harness between CE01 (female) (20) – PAMB (female) (2)

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller

CE01

Voltage

Between (36) – (48)

4.75 – 5.25 V

Between (20) – (48)

0.3 – 4.7 V


PC138US, USLC-8

27

SEN02463-01

40 Troubleshooting

Failure code [CA222] Ambient air press. sensor low error User code

Failure code

E11

CA222



28

Trouble

1

Ambient air press. sensor low error (Engine controller system)

• Low voltage was detected in ambient pressure sensor circuit. • Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Output drops. • Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Causes


PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02463-01

29

SEN02463-01

40 Troubleshooting

Failure code [CA227] Sensor sup. 2 volt. high error User code

Failure code

E15

CA227


Trouble

1

Sensor sup. 2 volt. high error (Engine controller system)

• High voltage was detected in sensor power supply 2 (5 V) circuit. • Operates Bkup speed sensor with signals of Ne speed sensor. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. • Output drops. • Method of reproducing failure code: Turn starting switch ON.

Causes 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

2


Defective sensor (Internal trouble)

Bkup speed sensor

CAM connector

Atmospheric pressure sensor

PAMB connector

Charge pressure sensor

PTIM connector

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between CE01 (female) (36) Resis3 (Disconnection in wiring or Max. 1 z – each sensor (female) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z – each sensor (female) tance Ground fault in wiring harness 4 (Short circuit with GND circuit)


6

30

Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.

Defective engine controller

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) – each sensor (female) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CE01 (female) (48) – each sensor (female) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) – each sensor (female) and Wiring harness between CE01 (female) (48) – each sensor (female)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE01

Voltage

Between (36) – (48)

4.75 – 5.25V

PC138US, USLC-8

40 Troubleshooting

SEN02463-01


PC138US, USLC-8

31

SEN02463-01

40 Troubleshooting

Failure code [CA234] Eng. overspeed User code

Failure code

—

CA234


Trouble

32

Eng. overspeed (Engine controller system)

• Engine speed is above operating range. • Limits fuel injection rate until engine speed lowers to operating range. • Engine speed fluctuates. • Engine speed can be checked with monitoring function. (Code: 01002 Engine speed) • Method of reproducing failure code: Run engine at high idle. Cause


1


1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Improper way of use

Way of use may be improper. Teach proper way of use to operator.


If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02463-01

33

SEN02463-01

40 Troubleshooting

Failure code [CA238] Ne speed sensor sup. volt. error User code

Failure code

E15

CA238


Trouble

1

Ne speed sensor sup. volt. error (Engine controller system)

• Abnormality occurred in Ne speed sensor power supply (5 V) circuit. • Controls Ne speed sensor with signals of Bkup speed sensor. • Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal). • Method of reproducing failure code: Turn starting switch ON.

Cause


1

Defective Ne speed sensor (Internal trouble)


Ne speed sensor

NE connector



Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (26) 2 or defective contact in con- – NE (female) (1) nector) Wiring harness between CE01 (female) (44) – NE (female) (2)

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between CE01 (female) (26) 3 ness (Short circuit with GND – NE (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (44) – NE (female) (2) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)


34

Resistance

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (26) – NE (female) (1) and between CE01 (female) (44) – NE (female) (2)

Resistance

Min. 1 Mz


Voltage

Between (26) – (44)

4.75 – 5.25 V

PC138US, USLC-8

40 Troubleshooting

SEN02463-01


PC138US, USLC-8

35

SEN02463-01

40 Troubleshooting

Failure code [CA271] IMV/PCV1 short error User code

Failure code

E10

CA271


Trouble

1

IMV/PCV1 short error (Engine controller system)

• There is short circuit in IMV circuit of supply pump. • None in particular.


• Method of reproducing failure code: Turn starting switch ON.

Causes


1


Defective supply pump IMV (Internal trouble)

Ground fault in wiring harness 2 (Short circuit with GND circuit)

PREG (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z

Between (1), (2) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (10) – PREG (female) (2)

Resistance

Min. 1 Mz

Wiring harness between CE01 (female) (14) – PREG (female) (1)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3

Hot short (Short circuit with Wiring harness between CE01 (female) (10) 24V circuit) in wiring harness – PREG (female) (2) and chassis ground

Voltage

Max. 1V

Wiring harness between CE01 (female) (14) – PREG (female) (1) and chassis ground

Voltage

Max. 1V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

CE01 (female)

Resistance

Between (10) – (14)

2.3 – 5.3 z


Min. 1 Mz


36

PC138US, USLC-8

40 Troubleshooting

SEN02463-01

Failure code [CA272] IMV/PCV1 open error User code

Failure code

E10

CA272


Trouble

1

IMV/PCV1 open error (Engine controller system)

• There is disconnection in IMV circuit of supply pump. • None in particular.



Causes


1


Defective supply pump IMV (Internal disconnection)

PREG (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness ResisWiring harness between CE01 (female) (10) 2 (Disconnection in wiring or Max. 1 z – PREG (female) (2) tance defective contact in connecWiring harness between CE01 (female) (14) Resistor) Max. 1 z – PREG (female) (1) tance Ground fault in wiring harness 3 (Short circuit with GND circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (10) – PREG (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CE01 (female) (14) – PREG (female) (1) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

CE01 (female)

Resistance

Between (10) – (14)

2.3 – 5.3 z

Between (10) (14) – chassis ground

Min. 1 Mz


PC138US, USLC-8

37

SEN02463-01

40 Troubleshooting

Failure code [CA322] Injector #1 (L #1) system open/short error User code

Failure code

E11

CA322


Trouble

1

Injector #1 (L #1) system open/short error (Engine controller system)

• There is disconnection or short circuit in injector #1 circuit. • None in particular. • Output drops. • Rotation is unstable. • Method of reproducing failure code: Start engine.

Causes


1


Defective injector #1 (Internal trouble)

CN1 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness ResisWiring harness between CE01 (female) (57) 2 (Disconnection in wiring or Max. 1 z – CN1 (female) (1) tance defective contact in connecWiring harness between CE01 (female) (53) Resistor) Max. 1 z – CN1 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit)

4

Defective injector or wiring harness of another cylinder

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (57) – CN1 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CE01 (female) (53) – CN1 (female) (2) and chassis ground

Resistance

Min. 1 Mz

If another failure code for injector abnormality is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


38

CE01 (female)

Resistance

Between (57) – (53)

0.4 – 1.1 z


Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02463-01


PC138US, USLC-8

39

SEN02463-01

40 Troubleshooting


Failure code

E11

CA324


Trouble

1



Cause


1


CN3 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (55) 2 or defective contact in con- – CN3 (female) (1) nector) Wiring harness between CE01 (female) (59) – CN3 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between CE01 (female) (55) 3 ness (Short circuit with GND – CN3 (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (59) – CN3 (female) (2) and chassis ground 4


Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



40

CE01 (female)

Resistance

Between (55) – (59)

0.4 – 1.1 z


Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02463-01


PC138US, USLC-8

41

SEN02463-01

40 Troubleshooting


Failure code

E11

CA331


Trouble

1



Cause


1


CN2 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



42

CE01 (female)

Resistance

Between (45) – (58)

0.4 – 1.1 z


Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02463-01


PC138US, USLC-8

43

SEN02463-01

40 Troubleshooting


Failure code

E11

CA332


Trouble

1



Cause


1


CN4 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z




Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



44

CE01 (female)

Resistance

Between (56) – (51)

0.4 – 1.1 z


Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02463-01


PC138US, USLC-8

45

SEN02463-01

40 Troubleshooting



46

PC138US, USLC-8

SEN02464-01



Machine model

Serial number



40 Troubleshooting

1

Troubleshooting by failure code, Part 2 Failure code [CA351] Inj. drive circuit error..................................................................................................... 3 Failure code [CA352] Sensor sup. 1 volt. low error ........................................................................................ 6 Failure code [CA386] Sensor sup. 1 volt. high error ....................................................................................... 8 Failure code [CA435] Abnormality in engine oil pressure switch .................................................................. 10 Failure code [CA441] Battery voltage low error .............................................................................................11 Failure code [CA442] Battery voltage high error ............................................................................................11 Failure code [CA449] Rail press. very high error .......................................................................................... 12 Failure code [CA451] Rail press. sensor high error ...................................................................................... 14 Failure code [CA452] Rail press. sensor low error ....................................................................................... 16 Failure code [CA553] Rail press. high error.................................................................................................. 16 Failure code [CA559] Rail press. low error ................................................................................................... 17 Failure code [CA689] Eng. Ne speed sensor error ....................................................................................... 20 Failure code [CA731] Eng. Bkup speed sensor phase error......................................................................... 22 Failure code [CA757] All persistent data lost error ....................................................................................... 22 Failure code [CA778] Eng. Bkup speed sensor error ................................................................................... 24 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 26

PC138US, USLC-8

1

SEN02464-01

40 Troubleshooting

Failure code [CA2185] Throttle sens. sup. volt. high error............................................................................ 28 Failure code [CA2186] Throttle sens. sup. volt. low error ............................................................................. 30 Failure code [CA2249] Rail press. very low error.......................................................................................... 30 Failure code [CA2311] Abnormality in IMV solenoid ..................................................................................... 31 Failure code [D110KB] Battery relay drive short ........................................................................................... 32 Failure code [D19JKZ] Personal code relay abnormality .............................................................................. 34 Failure code [D862KA] GPS antenna discon ................................................................................................ 36 Failure code [DA22KK] Pump solenoid power low error ............................................................................... 38 Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................................... 40 Failure code [DA26KP] 5V sensor 2 power abnormality ............................................................................... 43

2

PC138US, USLC-8

40 Troubleshooting

SEN02464-01

Failure code [CA351] Inj. drive circuit error User code

Failure code

E10

CA351


Trouble

1

Inj. drive circuit error (Engine controller system)

• Abnormality occurred in injector drive circuit. • Limits output and continues operation (Limits common rail pressure). • Output drops. • Method of reproducing failure code: Start engine.

Cause



If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.

2 Defective fuse

Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)

3

Defective power supply cutout relay

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) – (32)

Resistance

185 – 265 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)

PC138US, USLC-8


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between CE03 (female) (1) – T12

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

3

SEN02464-01

40 Troubleshooting

Cause



Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Ground fault in wiring harWiring harness between CE02 (female) (32) 5 ness (Short circuit with GND – R24 (2) and chassis ground circuit) Wiring harness between CE03 (female) (3) – R23 (5) and chassis ground


4


a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. CE03

Voltage

Between (3) – (1)

20 – 30 V

PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

5

SEN02464-01

40 Troubleshooting

Failure code [CA352] Sensor sup. 1 volt. low error User code

Failure code

E15

CA352


6

Trouble

1

Sensor sup. 1 volt. low error (Engine controller system)

• Low voltage was detected in sensor power supply 1 (5 V) circuit. • Limits output of common rail pressure sensor and continues operation (Limits common rail pressure). • Output drops. • Method of reproducing failure code: Turn starting switch ON.

Causes


PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02464-01

7

SEN02464-01

40 Troubleshooting

Failure code [CA386] Sensor sup. 1 volt. high error User code

Failure code

E15

CA386


Trouble

1

Sensor sup. 1 volt. high error (Engine controller system)

• High voltage was detected in sensor power supply 1 (5 V) circuit. • Limits output of common rail pressure sensor and continues operation (Limits common rail pressure). • Output drops. • Method of reproducing failure code: Turn starting switch ON.

Causes 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective sensor (Internal 2 trouble)


Common rail pressure sensor

PFUEL connector

a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between CE01 (female) (36) Resis3 (Disconnection in wiring or Max. 1 z – PFUEL (female) (1) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z – PFUEL (female) (3) tance Ground fault in wiring harness 4 (Short circuit with GND circuit)


6

8


Defective engine controller

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CE01 (female) (48) – PFUEL (female) (3) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and wiring harness between CE01 (female) (48) – PFUEL (female) (3)

Resistance

Min. 1 Mz


Voltage

Between (36) – (48)

4.75 – 5.25V

PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

9

SEN02464-01

40 Troubleshooting

Failure code [CA435] Abnormality in engine oil pressure switch User code

Failure code

E15

CA435


Trouble

Abnormality in engine oil pressure switch (Engine controller system)

• Abnormality occurred in engine oil pressure switch signal circuit. • None in particular. • Engine oil pressure switch-based engine protection function does not function. • Engine oil pressure monitor does not display normally. • Method of reproducing failure code: Turn starting switch or start engine. Causes

1


1

Defective engine oil pressure switch

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. POIL (Male)

Resistance


Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshootness ing without turning starting switch ON. 2 (Disconnection in wiring or Resisdefective contact in connec- Wiring harness between CE01 (female) (32) Max. 1 z – POIL (female) (1) tance tor) a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Short circuit in wiring harness Wiring harness among all pins between (With another wiring harness) CE01 (female) (32) – CE01 (female) (With all connectors of wiring harness disconnected)


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CE01 (Female)

Resistance


Max. 1 z


10

PC138US, USLC-8

40 Troubleshooting

SEN02464-01

Failure code [CA441] Battery voltage low error User code

Failure code

E10

CA441


Trouble

1

Battery voltage low error (Engine controller system)

• Low voltage was detected in controller power supply voltage circuit. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start. • Method of reproducing failure code: Turn starting switch ON.


Cause


Failure code [CA442] Battery voltage high error User code

Failure code

E10

CA442


Trouble

1

Battery voltage high error (Engine controller system)

• High voltage was detected in controller power supply voltage circuit. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start. • Method of reproducing failure code: Turn starting switch ON.


PC138US, USLC-8

Cause


11

SEN02464-01

40 Troubleshooting

Failure code [CA449] Rail press. very high error User code

Failure code

E11

CA449



12

Trouble

1

Rail press. very high error (Engine controller system)

• Common rail pressure sensor circuit detected abnormally high pressure (level 2). • Limits output and continues operation (Limits common rail pressure). • Output drops. • Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. Causes


PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02464-01

13

SEN02464-01

40 Troubleshooting

Failure code [CA451] Rail press. sensor high error User code

Failure code

E11

CA451


Trouble

1

Rail press. sensor high error (Engine controller system)

• High voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Output drops. • Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Causes 1


Defective sensor power sup- If failure code [CA352] or [CA386] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.

Defective common rail pres2 sure sensor (Internal trouble)

PFUEL

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.25 – 4.6 V

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Wiring harness between CE01 (female) (36) – PFUEL (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


14


Resistance

Min.1 Mz


Resistance

Min.1 Mz


Resistance

Min.1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02464-01

Causes




Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and wiring harness between CE01 (female) (29) – PFUEL (female) (2)

Resistance

Min.1 Mz


Resistance

Min.1 Mz


Resistance

Min.1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller

CE01

Voltage

Between (36) – (48)

4.75 – 5.25 V

Between (29) – (48)

0.25 – 4.6 V


PC138US, USLC-8

15

SEN02464-01

40 Troubleshooting

Failure code [CA452] Rail press. sensor low error User code

Failure code

E11

CA452


Trouble

1

Rail press. sensor low error (Engine controller system)

• Low voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Output drops. • Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON.


Cause


Failure code [CA553] Rail press. high error User code

Failure code

E15

CA553


Trouble

16

Rail press. high error (Engine controller system)

• Common rail pressure sensor circuit detected abnormally high pressure (level 1). • None in particular. • Output drops. • Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. Causes


1



If another failure code is indicated, carry out troubleshooting for it.

2 Use of improper fuel

Check fuel used directly (for high viscosity).

3

Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out common rail pressure sensor troubleshooting for failure code [CA451].

Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve

Check overflow valve directly for broken spring, worn seat, and stuck ball.

6 Clogging of overflow piping

Check overflow piping directly for clogging.

7 Defective pressure limiter

Check pressure limiter directly for mechanical defect.

PC138US, USLC-8

40 Troubleshooting

SEN02464-01

Failure code [CA559] Rail press. low error User code

Failure code

E15

CA559


Trouble

Rail press. low error (Engine controller system)

• Supply pump does not feed fuel (level 1). • Limits common rail pressure. • Output drops. • Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. Causes 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it.

2 Use of improper fuel

Check fuel used directly (for high viscosity).

3 Clogging of fuel filter

a If a fuel filter is clogged, replace it.

4


1

Defective low-pressure circuit device

a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel pressure". Pressure in fuel low-pressure circuit (At high idle or rated load)

-49 – 0 kPa {-0.5 – 0 kg/cm2}

5

Defective electrical system of Supply pump IMV may have electric trouble. Carry out troublesupply pump IMV shooting for following failure codes [CA271], [CA272].

6

Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor ness for damage.

7 Defective pressure limiter

a For testing of leakage from pressure limiter, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector". Leakage from pressure limiter *:

Max. 20 cc/min (*)

A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)".

a For testing of return rate (spill) from injector, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector".

8 Defective injector

9 Defective supply pump

Speed at rated operation

Return (Spill) limit from injector

1,600 rpm

190 cc/min

1,700 rpm

200 cc/min

1,800 rpm

210 cc/min

1,900 rpm

220 cc/min

2,000 rpm

230 cc/min

If causes 1 – 8 are not detected, supply pump may be defective.

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed“. Note 1: Check the low-pressure circuit parts for the following items. 1) Fuel level 2) Clogging of fuel tank breather 3) Sticking and wear of feed pump and clogging of filter 4) Leakage through and clogging of low-pressure fuel piping 5) Clogging of fuel filter PC138US, USLC-8

17

SEN02464-01

40 Troubleshooting

Check sheet for no-pressure feed Model Machine serial No.

Work No. #

Date of check

Engine Engine serial No.

/

#

h

Worker's name

A. Visual check

Good NG

1

Fuel leakage to outside

2

Clogging of fuel tank breather

B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3

/

Service meter

Check of failure code

/

/

/

Good NG

/

Check of monitoring information Code

*1

4

Unit

Standard value (Reference value)

Low idle

rpm

1,100 ± 50

High idle

rpm

2,300 ± 60

Equivalent to rating

rpm

2,200

Displayed item

Engine speed

Checking condition

Measured value

Good NG

Low idle

%

0

High idle

%

100 —

—

—

*2

Throttle opening degree

*3

Fuel injection command


mm3

*4

Common rail pressure command


MPa

*5

Common rail fuel pressure


MPa

*6

Fuel injection timing command

Low idle

CA

—

—

—

High idle

CA

—

—

—


CA

—

—

—

*7

Boost pressure


kPa

—

—

—

*8

Engine coolant temperature

Low idle

°C

—

—

—

*9

Fuel temperature

Low idle

°C

—

—

—

Unit


Check of reduced cylinder mode operation (Engine speed) Function

5 *10

Reduced cylinder

Measured value

Low idle

rpm

—

—

—

No. 2 cylinder

Low idle

rpm

—

—

—

No. 3 cylinder

Low idle

rpm

—

—

—

No. 4 cylinder

Low idle

rpm

—

—

—

Unit


MPa {kg/cm2}

-49 – 0 kPa {-0.5 – 0 kg/cm2}

Checking condition

Fuel low-pressure circuit pressure High idle or rated load

Measured value

D. Check of strainers and filters 7

9

18

Good NG

Good NG

Visual check of fuel filter

E.Check of leakage and return rate 8

Good NG

No. 1 cylinder

C. Check of fuel circuit pressure 6

Checking condition

Leakage through pressure limiter

Return rate from injector

Checking condition

Unit



cc/min

Max. 20 (*)

Equivalent to rating 1,600 rpm

cc/min

190


cc/min

200


cc/min

210


cc/min

220


cc/min

230

Measured value

Good NG

Speed: Return rate:

PC138US, USLC-8

40 Troubleshooting

SEN02464-01

*1 – *10: See Testing and adjusting, "Special functions of machine monitor", Monitoring items table. *: A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)". Rating or equivalent: Relieve the circuit under the following condition. 1) Engine: Full throttle 2) Mode: P 3) Boom: Raise

PC138US, USLC-8

19

SEN02464-01

40 Troubleshooting

Failure code [CA689] Eng. Ne speed sensor error User code

Failure code

E15

CA689


Trouble

1

Eng. Ne speed sensor error (Engine controller system)

• Abnormality occurred in engine Ne speed sensor circuit. • Operates with signals of Bkup speed sensor. • Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal). • Method of reproducing failure code: Start engine.

Causes 1


Defective sensor power sup- If failure code [CA238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between CE01 (female) (26) – NE (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state

Wiring harness between CE01 (female) (26) – NE (female) (1) and chassis ground

Resistance

Min.1 Mz


Resistance

Min.1 Mz


Resistance

Min.1 Mz



Wiring harness between CE01 (female) (26) – NE (female) (1) and wiring harness between CE01 (female) (44) – NE (female) (2)

Resistance

Min.1 Mz


Resistance

Min.1 Mz


Resistance

Min.1 Mz

Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (crankshaft pulley) part directly for defect. 6

20

Defective engine Ne speed sensor

If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting


SEN02464-01

Causes





PC138US, USLC-8

21

SEN02464-01

40 Troubleshooting

Failure code [CA731] Eng. Bkup speed sensor phase error User code

Failure code

E15

CA731



Trouble

1

Eng. Bkup speed sensor phase error (Engine controller system)

• Engine Bkup speed sensor circuit detected abnormality in phase. • Controls with signals of engine Ne speed sensor. • Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal). • Method of reproducing failure code: Start engine.

Cause


1

Defective engine Ne speed sensor system

Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA698].

2

Defective engine Bkup speed sensor system

Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].

Failure code [CA757] All persistent data lost error User code

Failure code

E10

CA757


22

Trouble

1

All persistent data lost error (Engine controller system)

• All data in engine controller are lost. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start. • Method of reproducing failure code: Turn starting switch ON.

Cause


PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02464-01

23

SEN02464-01

40 Troubleshooting

Failure code [CA778] Eng. Bkup speed sensor error User code

Failure code

E15

CA778


Trouble

1

Eng. Bkup speed sensor error (Engine controller system)

• Abnormality occurred in engine Bkup speed sensor circuit. • Operates with signals of Ne speed sensor. • Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal). • Method of reproducing failure code: Start engine.

Causes 1


Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between CE01 (female) (36) – CAM (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state

Wiring harness between CE01 (female) (36) – CAM (female) (1) and chassis ground

Resistance

Min.1 Mz


Resistance

Min.1 Mz


Resistance

Min.1 Mz



Wiring harness between CE01 (female) (36) – CAM (female) (1) and between CE01 (female) (48) – CAM (female) (2)

Resistance

Min.1 Mz


Resistance

Min.1 Mz


Resistance

Min.1 Mz

Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly part for defect. Defective engine Bkup speed sensor

If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)



6

24

PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

25

SEN02464-01

40 Troubleshooting

Failure code [CA1633] KOMNET datalink timeout error User code E0E Contents of trouble Action of controller Problem that appears on machine Related information

Failure code CA1633

Trouble

1

KOMNET datalink timeout error (Engine controller system)

• Engine controller detected communication error in KOMNET communication circuit between pump controller and machine monitor. • Continues operation in default mode. • If cause of failure disappears, system resets itself. • Information may not transmitted normally by KOMNET communication and machine may not operate normally. (Trouble phenomenon depends on failed section.) • Method of reproducing failure code: Turn starting switch ON.

Cause


Disconnection in wiring harness (Disconnection in wiring 1 or defective contact in connector)

Wiring harness between CM02 (female) (8), (9) – C01 (female) (45), – CE02 (female) (1), – K02 (female) (A)

Resistance

Max. 1 z

Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B)

Resistance

Max. 1 z



Wiring harness between CM02 (female) (8), Ground fault in wiring har(9) – C01 (female) (45), – CE02 (female) 2 ness (Short circuit with GND (1), – K02 (female) (A), – N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) – C01 (female) (45), – CE02 (female) 3 24V circuit) in wiring harness (1), – K02 (female) (A), – N08 (male) (3) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10) Defective CAN terminal 4 resistance (Internal short circuit or disconnection)

5 Defective pump controller

26

Resistance

Voltage

Max. 5.5 V

Voltage

Max. 5.5 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. K02 (male)

Resistance

Between (A) – (B)

120 ± 12 z


PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

27

SEN02464-01

40 Troubleshooting

Failure code [CA2185] Throttle sens. sup. volt. high error User code

Failure code

E14

CA2185


Trouble

1

Throttle Sens. sup. volt. high error (Engine controller system)

• High voltage was detected in throttle sensor power supply (5 V) circuit. • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model). • Engine speed cannot be controlled with fuel control dial. • Method of reproducing failure code: Turn starting switch ON.

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

1


Defective fuel control dial (Internal trouble)


Fuel control dial

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE02 (female) (27) Resis2 Max. 1 z or defective contact in con- – P20 (female) (1) tance nector) Wiring harness between CE02 (female) (28) ResisMax. 1 z – P20 (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring harWiring harness between CE02 (female) (27) 3 ness (Short circuit with GND – P20 (female) (1) and chassis ground circuit) Wiring harness between CE02 (female) (28) – P20 (female) (3) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)


28

P20 connector

Resistance

Min.1 Mz

Resistance

Min.1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (27) – P20 (female) (1) and between CE02 (female) (28) – P20 (female) (3)

Resistance

Min.1 Mz


Voltage

Between (27) – (28)

4.75 – 5.25 V

PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

29

SEN02464-01

40 Troubleshooting

Failure code [CA2186] Throttle sens. sup. volt. low error User code

Failure code

E14

CA2186


Trouble

1

Throttle sens. sup. volt. low error (Engine controller system)

• Low voltage was detected in throttle sensor power supply (5 V) circuit. • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model). • Engine speed cannot be controlled with fuel control dial. • Method of reproducing failure code: Turn starting switch ON.

Cause


Failure code [CA2249] Rail press. very low error User code

Failure code

E11

CA2249



30

Trouble

1

Rail press. very low error (Engine controller system)

• Supply pump does not feed fuel (level 2). • Limits common rail pressure. • Output drops. • Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. Cause


PC138US, USLC-8

40 Troubleshooting

SEN02464-01

Failure code [CA2311] Abnormality in IMV solenoid User code

Failure code

E11

CA2311


Trouble

1

Abnormality in IMV solenoid (Engine controller system)

• Resistance in supply pump actuator is abnormally high or low. • None in particular. • Engine output drops. • Method of reproducing failure code: Start engine. Causes 1

Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2

Defective supply pump actuator

PREG (Male)

Resistance

Between (1) – (2)

Max. 1 z


Min. 1 Mz



Disconnection in wiring harness Wiring harness between CE01 (female) (10) 3 (Disconnection in wiring or – PREG (female) (2) defective contact in connecWiring harness between CE01 (female) (14) tor) – PREG (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between CE01 (female) (14) ResisMin.1 Mz – PREG (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller

CE01 (Female)

Resistance

Between (14) – (10)

Max. 1 z


Min. 1 Mz


PC138US, USLC-8

31

SEN02464-01

40 Troubleshooting

Failure code [D110KB] Battery relay drive short User code

Failure code

—

D110KB


Trouble

1

Battery relay drive short (Pump controller system)

• Abnormal current flowed at output to battery relay drive circuit. • Turns output to battery relay drive circuit OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Engine does not stop.

Related information Cause


1


Defective battery relay (Internal defect)

Ground fault in wiring harness 2 (Short circuit with GND circuit)

Battery relay

Resistance

Between BR (terminal BR) – RE (terminal E)

There is continuity

Between BR (terminal BR) – chassis ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (108) – D02 – J06 – BR (terminal BR) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective pump controller

32

C02 (female)

Turn starting switch OFF.

Voltage


ON o OFF

20 – 30 V (4 – 7 sec.)

PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

33

SEN02464-01

40 Troubleshooting

Failure code [D19JKZ] Personal code relay abnormality User code

Failure code

E01

D19JKZ


Trouble

1

Personal code relay abnormality (KOMTRAX system in machine monitor)

• Disconnection or short circuit was detected in personal code relay circuit. • • • •

None in particular (when disconnection is detected). Turns output to personal code relay OFF (when short circuit is detected). If cause of failure disappears, system resets itself (when disconnection is detected). Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF (when disconnection is detected).


• This failure code is displayed only when engine lock function is effective. • Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble cannot be reproduced on machine (Short circuit). Cause 1 Defective fuse No. 20

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (Troubleshooting for relay unit) R07 (male)

Resistance

Defective personal code Between (1) – (2) (300 – 600 z) 2 relay (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON or short circuit) and carry out troubleshooting. (Troubleshooting by replacement)


Replace personal code relay (R07) with another relay and perform reproducing operation. If "E" of failure code goes off at this time, replaced relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (20) – R07 Resis3 Max. 1 z or defective contact in con- (female) (1) tance nector) Wiring harness between R07 (female) (2) – ResisMax. 1 z CM01 (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring harWiring harness between F01 (20) – R07 4 ness (Short circuit with GND (female) (1) circuit) Wiring harness between R07 (female) (2) – CM01 (female) (6) 5

34

Defective machine monitor (KOMTRAX section)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

If causes 1 – 4 are not detected, machine monitor (KOMTRAX) may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

35

SEN02464-01

40 Troubleshooting

Failure code [D862KA] GPS antenna discon User code

Failure code

—

D862KA


Trouble

1

GPS antenna disconnection (KOMTRAX system in machine monitor)

• Disconnection was detected in GPS antenna circuit. • None in particular. • If cause of failure disappears, system resets itself. • GPS cannot measure position. • Method of reproducing failure code: Turn starting switch ON.

Cause 1

Defective GPS antenna or antenna cable

Standard value in normal state/Remarks on troubleshooting Possible causes are defective GPS antenna, disconnection or short circuit in antenna cable, and defective connection of antenna cable connector (GPS).

Configuration drawing

36

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02464-01

37

SEN02464-01

40 Troubleshooting

Failure code [DA22KK] Pump solenoid power low error User code

Failure code

E0E

DA22KK


Trouble

1

Lowering of solenoid power supply voltage (Pump controller system)

• Solenoid power supply voltage of controller is below 20 V. • While this failure code is displayed, detection of failure codes (disconnection/short circuit) of all the solenoid systems is stopped. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Since no solenoid valve is driven normally, machine does not operate normally. • Method of reproducing failure code: Turn starting switch ON.

Cause 1 Defective fuse F01

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See Cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Wiring harness between C02 (female) (116), (118), (121) – F01-2

Resistance

Max. 1 z

Wiring harness between F01-1A – F02 (male) (2)

Resistance

Max. 1 z

Wiring harness between F02 (male) (1) – RM

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (116), Ground fault in wiring har(118), (121) – F01-2 3 ness (Short circuit with GND Wiring harness between F01-1A – F02 circuit) (male) (2), – circuit branch end Wiring harness between F02 (male) (1) – RM

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective pump controller

38

C01 (female), C02 (female)

Voltage

Between C02 (116), (118), (121) – C01 (2), (5)

20 – 30 V

PC138US, USLC-8

40 Troubleshooting

SEN02464-01


PC138US, USLC-8

39

SEN02464-01

40 Troubleshooting

Failure code [DA25KP] 5V sensor 1 power abnormality User code

Failure code

—

DA25KP

Contents of trouble

Trouble

1

5V sensor power supply output 1 abnormality (Pump controller system)

• Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.

Action of controller

• Turns output of 5V sensor power supply output 1 OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that appears on machine

• Automatic gear shifting function does not work (pump pressure sensor system). • Auto-decelerator keeps working and is not reset or fine control performance of work equipment is lowered (PPC pressure sensor system).

Related information


Cause

Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective pressure sensor 1 (Internal short circuit)


40

Disconnect sensors at right in order and carry out operation to reproduce trouble. If "E" of failure code goes off when a sensor is disconnected, that sensor is defective.

Bucket DUMP PPC pressure switch

P01

Boom RAISE PPC pressure switch

P03

Bucket CURL PPC pressure switch

P04

Arm IN PPC pressure switch

P05

Swing RIGHT PPC pressure switch

P07

Swing LEFT PPC pressure switch

P08

Pump pressure sensor

P25

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C01 (female) (34) – P01 (female) (2), P01 (female) (1) – J03 – ground (T08) [Bucket DUMP PPC pressure switch system]

Resistance

Min. 1 Mz

Wiring harness between C01 (female) (53) – P03 (female) (2), P03 (female) (1) – J03 – ground (T08) [Boom RAISE PPC pressure switch system]

Resistance

Min. 1 Mz

Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C01 (female) (73) – P04 (female) (2), P04 (female) (1) – J03 – circuit) ground (T08) [Bucket CURL PPC pressure switch system]

Resistance

Min. 1 Mz

Wiring harness between C01 (female) (17) – P05 (female) (2), P05 (female) (1) – J03 – ground (T08) [Arm IN PPC pressure switch system]

Resistance

Min. 1 Mz

Wiring harness between C01 (female) (16) – P07 (female) (2), P07 (female) (1) – J03 – ground (T08) [Swing RIGHT PPC pressure switch system]

Resistance

Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02464-01

Cause


Wiring harness between C01 (female) (16) – P08 (female) (2), P08 (female) (1) – J03 – ground (T08) Ground fault in wiring har2 ness (Short circuit with GND [Swing LEFT PPC pressure switch system] circuit) Wiring harness between C01 (female) (9) – J07 – P25 (female) (3) [Pump pressure sensor system]

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between C01 (female) (34) – P01 (female) (2), P01 (female) (1) – J03 – ground (T08) [Bucket CURL PPC pressure sensor system]

Voltage

Max. 1 V

Wiring harness between C01 (female) (53) – P03 (female) (2), P03 (female) (1) – J03 – ground (T08) [Swing LEFT PPC pressure sensor system]

Voltage

Max. 1 V

Wiring harness between C01 (female) (73) – P04 (female) (2), P04 (female) (1) – J03 – ground (T08) [Arm IN PPC pressure sensor system]

Voltage

Max. 1 V

Hot short (Short circuit with Wiring harness between C01 (female) (17) 24V circuit) in wiring harness – P05 (female) (2), P05 (female) (1) – J03 – ground (T08) [Bucket DUMP PPC pressure sensor system]

Voltage

Max. 1 V

Wiring harness between C01 (female) (16) – P07 (female) (2), P07 (female) (1) – J03 – ground (T08) [Boom RAISE PPC pressure sensor system]

Voltage

Max. 1 V

Wiring harness between C01 (female) (16) – P08 (female) (2), P08 (female) (1) – J03 – ground (T08) [Swing RIGHT PPC pressure sensor system]

Voltage

Max. 1 V

Wiring harness between C01 (female) (9) – J07 – P25 (female) (3) [Pump pressure sensor system]

Voltage

Max. 1 V

Possible causes and standard value in normal state 3


PC138US, USLC-8

If causes 1 – 3 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

41

SEN02464-01

40 Troubleshooting


42

PC138US, USLC-8

40 Troubleshooting

SEN02464-01

Failure code [DA26KP] 5V sensor 2 power abnormality User code

Failure code

—

DA26KP


Trouble

1

5V sensor power supply output 2 abnormality (Pump controller system)

• Voltage of 5V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V. • Turns output of 5V sensor power supply output 2 OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.



Cause



a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 1 ness (Short circuit with GND Wiring harness between C01 (female) (8) – Resiscircuit) Min. 1 Mz A08 (female) (3) (6) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between C01 (female) (8) – Voltage Max. 1 V A08 (female) (3) (6) 3 Defective pump controller



PC138US, USLC-8

43

SEN02464-01

40 Troubleshooting



44

PC138US, USLC-8

SEN02465-01



Machine model

Serial number



40 Troubleshooting

1

Troubleshooting by failure code, Part 3 Failure code [DA2RMC] CAN discon (Pump controller detected)................................................................... 4 Failure code [DAF8KB] Short circuit in camera power supply ........................................................................ 6 Failure code [DAFGMC] GPS module error.................................................................................................... 8 Failure code [DAFRMC] CAN discon (Monitor detected).............................................................................. 10 Failure code [DGH2KB] Hydr oil sensor short .............................................................................................. 12 Failure code [DHPAMA] Pump press sensor abnormality............................................................................. 14 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality ................................................. 16 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality .............................................. 18 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality ................................................ 20 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................................... 22 Failure code [DHSKMA] Blade raise PPC press sensor abnormality ........................................................... 24 Failure code [DHSLMA] Blade lower PPC press sensor abnormality........................................................... 26 Failure code [DHX1MA] Overload sensor abnormality (Analog)................................................................... 28 Failure code [DV20KB] Travel alarm S/C...................................................................................................... 29 Failure code [DW43KA] Travel speed sol discon.......................................................................................... 30 Failure code [DW43KB] Travel speed sol short ............................................................................................ 31

PC138US, USLC-8

1

SEN02465-01

40 Troubleshooting

Failure code [DW45KA] Swing brake sol discon........................................................................................... 32 Failure code [DW45KB] Swing brake sol short ............................................................................................. 34 Failure code [DW91KA] Travel junction sol discon ....................................................................................... 36 Failure code [DW91KB] Travel junction sol short.......................................................................................... 37 Failure code [DWJ0KA] Merge-divider sol discon......................................................................................... 38 Failure code [DWJ0KB] Merge-divider sol short ........................................................................................... 39

2

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02465-01

3

SEN02465-01

40 Troubleshooting

Failure code [DA2RMC] CAN discon (Pump controller detected) User code E0E Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DA2RMC

Trouble

1

CAN disconnection (Pump controller detected) (Pump controller system)

• Pump controller detected communication error in CAN communication circuit between machine monitor and engine controller. • Continues operation with information of CAN communication just before detection of error. • If cause of failure disappears, system resets itself. • Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble phenomenon depends on failed section.) • Method of reproducing failure code: Turn starting switch ON.

Cause




Resistance

Max. 1 z


Resistance

Max. 1 z




Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) – C01 (female) (45), – CE02 (female) 3 24V circuit) in wiring harness (1), – K02 (female) (A), – N08 (male) (3) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10) Defective CAN terminal 4 resistance (Internal short circuit or disconnection) 5 Defective pump controller

4

Resistance

Voltage

Max. 5.5 V

Voltage

Max. 5.5 V


Resistance

Between (A) – (B)

120 ± 12 z


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

5

SEN02465-01

40 Troubleshooting

Failure code [DAF8KB] Short circuit in camera power supply User code

Failure code

— Contents of trouble

DAF8KB

Trouble

1

Short circuit in camera power supply (Machine monitor system)

• Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above 10 V.

Action of • Turns output power supply voltage (Rating: 8 V) to camera OFF. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information

• Camera image is not displayed on monitor screen. • Method of reproducing failure code: Turn starting switch ON.

Cause Defective camera (Internal 1 short circuit)


Standard value in normal state/Remarks on troubleshooting a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Disconnect camera and perform failure reproduction operation. If failure code disappears at this time, camera is defective.

a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Ground fault in wiring har(Disconnect camera and check that it is not defective in 2 ness (Contact with GND ciradvance.) cuit) Between CM05 (female) (1) – CAMERA Voltage Min. 6 V (female) (F) wiring harness and ground

3

Hot short (Contact with 24V circuit) in wiring harness

a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Disconnect camera and check that it is not defective in advance.) Between CM05 (female) (1) – CAMERA (female) (F) wiring harness and ground


6

Voltage

Max. 10 V

If causes 1 – 3 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

7

SEN02465-01

40 Troubleshooting

Failure code [DAFGMC] GPS module error User code — Contents of trouble

Failure code DAFGMC

Trouble

1

GPS module operation error (KOMTRAX system in machine monitor)

• Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication MODEM in 50 seconds after KOMTRAX is started.

Action of • None in particular. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine Related information Possible causes and standard value in normal state

8

• Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting switch is turned ON). Cause



GPS module of machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02465-01

9

SEN02465-01

40 Troubleshooting

Failure code [DAFRMC] CAN discon (Monitor detected) User code E0E Contents of trouble

Failure code DAFRMC

Trouble

1

CAN disconnection (Monitor detected) (Machine monitor system)

• Machine monitor detected communication error in CAN communication circuit between pump controller and engine controller.

Action of • If cause of failure disappears, system resets itself. machine monitor Problem that appears on machine Related information

• Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble phenomenon depends on failed section.) • Method of reproducing failure code: Turn starting switch ON.

Cause




Resistance

Max. 1 z


Resistance

Max. 1 z




Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) – C01 (female) (45), – CE02 (female) 3 24V circuit) in wiring harness (1), – K02 (female) (A), – N08 (male) (3) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10) Defective CAN terminal 4 resistance (Internal short circuit or disconnection)


10

Resistance

Voltage

Max. 5.5 V

Voltage

Max. 5.5 V


Resistance

Between (A) – (B)

120 ± 12 z


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

11

SEN02465-01

40 Troubleshooting

Failure code [DGH2KB] Hydr oil sensor short User code

Failure code

—

DGH2KB


Trouble

Hydraulic oil temperature sensor short (Pump controller system)

• Ground fault was detected in hydraulic oil temperature sensor circuit. • Controls pump in normal mode (as when hydraulic oil temperature is 20°C to below 95°C). (Overheat prevention function does not work.) • While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from top of white range (bottom of green range). • Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function. (Code: 04402 Hydraulic oil temperature sensor voltage) • Method of reproducing failure code: Start engine. Cause Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P22 (male)

Resistance

Between (1) – (2)

3.5 – 90 kz


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND ResisWiring harness between C01 (female) (29) circuit) Min. 1 Mz – P22 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller

C01 (female)

Resistance

Between (29) – (46)

3.5 – 90 kz


Min. 1 Mz


12

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02465-01

13

SEN02465-01

40 Troubleshooting

Failure code [DHPAMA] Pump press sensor abnormality User code

Failure code

—

DHPAMA


Trouble

1

Pump pressure sensor abnormality (Pump controller system)

• Signal voltage of pump pressure sensor circuit is below 0.3 V or above 4.4 V. • Fixes pump pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself. • Automatic gear shifting function does not work. • Straight travel performance or steering performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Pump pressure can be checked with monitoring function. (Code: 01100 Pump pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause


Defective 5V sensor power 1 supply 1 system

a If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case.

Defective pump pressure 2 sensor (Internal defect)

P25

Voltage

Between (3) – (1)

Power supply

4.5 – 5.5 V

Between (2) – (1)

Signal

0.3 – 4.5 V

If voltage is abnormal, check failure code. (If "E" of failure code goes off at this time, pump pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state


Wiring harness between C01 (female) (18) – P25 (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between C01 (female) (9) – J07 – P25 (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (49) Resiscircuit) Min. 1 Mz – P25 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (49) Voltage Max. 1 V – P25 (female) (2) 6 Defective pump controller

14


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

15

SEN02465-01

40 Troubleshooting

Failure code [DHSFMA] Travel left forward PPC press sensor abnormality User code

Failure code

E20

DHSFMA


Trouble

1

Travel left forward PPC pressure sensor abnormality (Pump controller system)

• Signal voltage of travel left forward PPC pressure sensor circuit is below 0.3 V or above 4.5 V. • Fixes travel left forward PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself. • Automatic decelerator cannot be reset. • Travel left forward performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel left forward PPC pressure can be checked with monitoring function. (Code: 07102 Travel left forward PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1

Defective 5V sensor power supply 1 system

Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P10

Defective travel left forward 2 PPC pressure sensor (Internal defect)


Voltage

Between (3) – (1)

Power supply

4.5 – 5.5 V

Between (2) – (1)

Signal

0.3 – 4.5 V

If voltage is abnormal, replace travel left forward PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel left forward PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


16


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

17

SEN02465-01

40 Troubleshooting

Failure code [DHSGMA] Travel right forward PPC press sensor abnormality User code

Failure code

E20

DHSGMA


Trouble

1

Travel right forward PPC pressure sensor abnormality (Pump controller system)

• Signal voltage of travel right forward PPC pressure sensor circuit is below 0.3 V or above 4.5 V. • Fixes travel right forward PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself. • Automatic decelerator cannot be reset. • Travel right forward performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel right forward PPC pressure can be checked with monitoring function. (Code: 07103 Travel right forward PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1



Defective travel right forward 2 PPC pressure sensor (Internal defect)


Voltage

Between (3) – (1)

Power supply

4.5 – 5.5 V

Between (2) – (1)

Signal

0.3 – 4.5 V

If voltage is abnormal, replace travel right forward PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel right forward PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


18


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

19

SEN02465-01

40 Troubleshooting

Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality User code

Failure code

E20

DHSHMA


Trouble

1

Travel left reverse PPC pressure sensor abnormality (Pump controller system)

• Signal voltage of travel left reverse PPC pressure sensor circuit is below 0.3 V or above 4.5 V. • Fixes travel left reverse PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself. • Automatic decelerator cannot be reset. • Travel left reverse performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel left reverse PPC pressure can be checked with monitoring function. (Code: 07104 Travel left reverse PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1



Defective travel left reverse 2 PPC pressure sensor (Internal defect)


Voltage

Between (3) – (1)

Power supply

4.5 – 5.5 V

Between (2) – (1)

Signal

0.3 – 4.5 V

If voltage is abnormal, replace travel left reverse PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel left reverse PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


20


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

21

SEN02465-01

40 Troubleshooting

Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality User code

Failure code

E20

DHSJMA


Trouble

1

Travel right reverse PPC pressure sensor abnormality (Pump controller system)

• Signal voltage of travel right reverse PPC pressure sensor circuit is below 0.3 V or above 4.5 V. • Fixes travel right reverse PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself. • Automatic decelerator cannot be reset. • Travel right reverse performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel right reverse PPC pressure can be checked with monitoring function. (Code: 07105 Travel right reverse PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1



Defective travel right reverse 2 PPC pressure sensor (Internal defect)


Voltage

Between (3) – (1)

Power supply

4.5 – 5.5 V

Between (2) – (1)

Signal

0.3 – 4.5 V

If voltage is abnormal, replace travel right reverse PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel right reverse PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


22


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

23

SEN02465-01

40 Troubleshooting

Failure code [DHSKMA] Blade raise PPC press sensor abnormality User code

Failure code

—

DHSKMA


Trouble

1

Blade raise PPC pressure sensor abnormality (Pump controller system)

• Signal voltage of blade raise PPC pressure sensor circuit is below 0.3 V or above 4.5 V. • Fixes blade raise PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself. • Automatic decelerator cannot be reset. • Blade raise performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Blade raise PPC pressure can be checked with monitoring function. (Code: 07106 Blade raise PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1



Defective blade raise PPC 2 pressure sensor (Internal defect)


Voltage

Between (3) – (1)

Power supply

4.5 – 5.5 V

Between (2) – (1)

Signal

0.3 – 4.5 V

If voltage is abnormal, replace blade raise PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, blade raise PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (32) Resiscircuit) Min. 1 Mz – P28 (female) (2) tance

5

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (32) – P28 (female) (2)


24

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage

Max. 1 V


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

25

SEN02465-01

40 Troubleshooting

Failure code [DHSLMA] Blade lower PPC press sensor abnormality User code

Failure code

—

DHSLMA


Trouble

1

Blade lower PPC pressure sensor abnormality (Pump controller system)

• Signal voltage of blade lower PPC pressure sensor circuit is below 0.3 V or above 4.5 V. • Fixes blade lower PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself. • Automatic decelerator cannot be reset. • Blade lower performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Blade lower PPC pressure can be checked with monitoring function. (Code: 07107 Blade lower PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1



Defective blade lower PPC 2 pressure sensor (Internal defect)


Voltage

Between (3) – (1)

Power supply

4.5 – 5.5 V

Between (2) – (1)

Signal

0.3 – 4.5 V

If voltage is abnormal, replace blade lower PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, blade lower PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (51) Resiscircuit) Min. 1 Mz – P11 (female) (2) tance

5

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (51) – P11 (female) (2)


26

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage

Max. 1 V


PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

27

SEN02465-01

40 Troubleshooting

Failure code [DHX1MA] Overload sensor abnormality (Analog) User code

Failure code

—

DHX1MA


Trouble

1

Overload sensor (Analog) (Pump controller system)

• Monitor which is not set to be displayed (Overload alarm monitor) is displayed. • None in particular. • If cause of failure disappears, system resets itself.

Problem that appears on machine Related information Possible causes and standard value in normal state

28

Method of reproducing failure code: Turn starting switch ON.

Cause 1 Defective pump controller

Standard value in normal state/Remarks on troubleshooting Pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting

SEN02465-01

Failure code [DV20KB] Travel alarm S/C User code

Failure code

—

DV20KB


Trouble

1

Travel alarm S/C (Pump controller system)

• Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit. • Power to the travel alarm circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF. • The travel alarm does not sound. • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function. (Code: 03701 Controller output 2) Cause

Standard value in normal state/Remarks on troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.

Travel alarm defective 1 (Internal defect)


M14 (female) Between (1) and (2)

Travel lever

Voltage

Neutral

Max. 1 V

Operated

20 – 30 V

If the above voltage is normal but the travel alarm does not operate, the travel alarm is defective. a Turn the engine starting switch OFF for the preparations, and Grounding fault of wiring harhold it in the OFF position during the troubleshooting. ness 2 (Contact with grounding cir- Between wiring harness between C02 ResisMin. 1 Mz (female) (107) and M14 (female) (1) and cuit) tance grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 3 Pump controller defective

C02

Travel lever

Voltage


Neutral

Max. 1 V

Operated

20 – 30 V


PC138US, USLC-8

29

SEN02465-01

40 Troubleshooting

Failure code [DW43KA] Travel speed sol discon User code

Failure code

—

DW43KA


Trouble

1

Travel speed solenoid system disconnection (Pump controller system)

• When output to travel speed shifting solenoid was turned ON, disconnection was detected in circuit. • None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself.


• Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle).

Related information

• Operating condition of travel speed shifting solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. Cause Defective travel speed shift1 ing solenoid (Internal disconnection)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V02 (male)

Resistance

Between (1) – (2)

20 – 60 z


Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (87) 2 or defective contact in con- – V02 (female) (2) nector) Wiring harness between C02 (female) (115), (117), (120) – V02 (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller

C01 (female)

Resistance

Between (87) – (115), (117), (120)

20 – 60 z


30

PC138US, USLC-8

40 Troubleshooting

SEN02465-01

Failure code [DW43KB] Travel speed sol short User code

Failure code

—

DW43KB

Trouble

1

Travel speed solenoid system short (Pump controller system)

Contents of trouble

• When output to travel speed shifting solenoid was turned ON, short circuit was detected in circuit.


• Turns output to travel speed shifting solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.


• Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle).

Related information

• Operating condition of travel speed shifting solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. Cause Defective travel speed shift1 ing solenoid (Internal disconnection)



Resistance

Between (1) – (2)

20 – 60 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND ResisWiring harness between C02 (female) (87) circuit) Min. 1 Mz – V02 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller

C02 (female)

Resistance

Between (87) – (115), (117), (120)

20 – 60 z


Min. 1 Mz


PC138US, USLC-8

31

SEN02465-01

40 Troubleshooting

Failure code [DW45KA] Swing brake sol discon User code

Failure code

E03 Contents of trouble Action of controller Problem that appears on machine

Related information

DW45KA

Trouble

1

Swing holding brake solenoid system disconnection (Pump controller system)

• When output to swing holding brake solenoid was turned OFF, disconnection was detected in circuit. • None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself. • Machine cannot swing (Swing holding brake is not reset). • If solenoid and wiring harness are normal, operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work, however, when machine stops). • Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. • Operating condition of swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Turn starting switch ON. Cause Defective swing holding 1 brake solenoid (Internal disconnection)

Defective assembled-type 2 diode D01 (Internal disconnection)


Resistance

Between (1) – (2)

20 – 60 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D01 (male)

Digital circuit tester

Continuity

Between (7) – (3)

Diode mode

There is continuity

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Defective swing lock switch (Internal disconnection)

S04 (male) Between (3) – (4)


Swing lock switch

Resistance

OFF

Max. 1 z

ON

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (101) – D01 (female) (7)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between D01 (female) (3) – 4 or defective contact in con- J04 – S04 (female) (3) nector) Wiring harness between S04 (female) (4) – V03 (female) (2)

Wiring harness between C02 (female) (115), (117), (120) – V03 (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z


C02 (female) Between (101) – (115), (117), (120)

32

Disconnect D01 and connect pins (3) and (7) on female side directly.

Resistance 20 – 60 z

PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

33

SEN02465-01

40 Troubleshooting

Failure code [DW45KB] Swing brake sol short User code

Failure code

E03

DW45KB

Trouble

1

Swing holding brake solenoid system short (Pump controller system)

Contents of trouble

• When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit.


• Turns output to swing holding brake solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.


Related information

• Machine cannot swing (Swing holding brake is not reset). • If solenoid and wiring harness are normal, operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work, however, when machine stops). • Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. • Operating condition of swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Swing with left work equipment control lever. Cause Defective swing holding 1 brake solenoid (Internal short circuit or ground fault)



Resistance

Between (1) – (2)

20 – 60 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. ness (Disconnection in wiring 2 Wiring harness between C02 (female) (101) or defective contact in conResisMin. 1 Mz – D01 – J04 – S04 – V03 (female) (2), – S25 nector) tance (female) (14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C02 (female) 3 Defective pump controller

Between (101) – (115), (117), (120) Between (101) – chassis ground

34

Disconnect D01 and connect pins (3) and (7) on female side directly.

Resistance 20 – 60 z Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02465-01


PC138US, USLC-8

35

SEN02465-01

40 Troubleshooting

Failure code [DW91KA] Travel junction sol discon User code

Failure code

—

DW91KA


Trouble

Travel junction solenoid system disconnection (Pump controller system)

• When output to travel junction solenoid was turned ON, disconnection was detected in circuit. • None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself. • Machine is not steered easily during travel. • Operating condition of travel junction solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. Cause Defective travel junction 1 solenoid (Internal disconnection)


1


Resistance

Between (1) – (2)

20 – 60 z



Resistance

Max. 1 z

Resistance

Max. 1 z


C02 (female)

Resistance

Between (110) – (115), (117), (120)

20 – 60 z


36

PC138US, USLC-8

40 Troubleshooting

SEN02465-01

Failure code [DW91KB] Travel junction sol short User code

Failure code

—

DW91KB


Trouble

Travel junction solenoid system short (Pump controller system)

• When output to travel junction solenoid was turned ON, short circuit was detected in circuit. • Turns output to travel junction solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Machine is not steered easily during travel. • Operating condition of travel junction solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. Cause Defective travel junction 1 solenoid (Internal short circuit or ground fault)


1


Resistance

Between (1) – (2)

20 – 60 z


Min. 1 Mz


C02 (female)

Resistance

Between (110) – (115), (117), (120)

20 – 60 z


Min. 1 Mz


PC138US, USLC-8

37

SEN02465-01

40 Troubleshooting

Failure code [DWJ0KA] Merge-divider sol discon User code

Failure code

—

DWJ0KA


Trouble

Merge-divider solenoid disconnection (Pump controller system)

• When merge-divider EPC solenoid was driven, disconnection was detected in circuit. • None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself. • Single operation speed of work equipment and swing is high in lifting mode (L). • Method of reproducing failure code: Turn starting switch ON.

Cause Defective merge-divider EPC 1 solenoid (Internal disconnection)


1


Resistance

Between (1) – (2)

7 – 14 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (112) Resis2 Max. 1 z or defective contact in con- – V05 (female) (2) tance nector) Wiring harness between C02 (female) (115), ResisMax. 1 z (117), (120) – V05 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller

C02 (female)

Resistance

Between (112) – (115), (117), (120)

7 – 14 z


38

PC138US, USLC-8

40 Troubleshooting

SEN02465-01

Failure code [DWJ0KB] Merge-divider sol short User code

Failure code

—

DWJ0KB


Trouble

Merge-divider solenoid short (Pump controller system)

• When merge-divider EPC solenoid was driven, short circuit was detected in circuit. • Turns output to merge-divider EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Single operation speed of work equipment and swing is high in lifting mode (L). • Method of reproducing failure code: Turn starting switch ON.

Cause Defective merge-divider EPC 1 solenoid (Internal short circuit or ground fault) Possible causes and standard value in normal state

1


Resistance

Between (1) – (2)

7 – 14 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C02 (female) (112) Resiscircuit) Min. 1 Mz – V05 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller

C02 (female)

Resistance

Between (112) – (115), (117), (120)

7 – 14 z


Min. 1 Mz


PC138US, USLC-8

39

SEN02465-01

40 Troubleshooting



40

PC138US, USLC-8

SEN02466-00



Machine model

Serial number



40 Troubleshooting

1

Troubleshooting by failure code, Part 4 Failure code [DXA8KA] PC-EPC sol discon ................................................................................................... 2 Failure code [DXA8KB] PC-EPC sol short...................................................................................................... 4 Failure code [DXE4KA] Service current EPC discon ...................................................................................... 6 Failure code [DXE4KB] Service current EPC short ........................................................................................ 7 Failure code [DY20KA] Wiper working abnormality ........................................................................................ 8 Failure code [DY20MA] Wiper parking abnormality ...................................................................................... 10 Failure code [DY2CKA] Washer drive discon ............................................................................................... 12 Failure code [DY2CKB] Washer drive short.................................................................................................. 14 Failure code [DY2DKB] Wiper drive (for) short ............................................................................................. 16 Failure code [DY2EKB] Wiper drive (rev) short ............................................................................................ 18

PC138US, USLC-8

1

SEN02466-00

40 Troubleshooting

Failure code [DXA8KA] PC-EPC sol discon User code

Failure code

E02

DXA8KA


Trouble

1

PC-EPC solenoid system disconnection (Pump controller system)

• When PC-EPC solenoid was driven, disconnection was detected in circuit. • None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.


• If pump load increases, engine speed lowers largely and engine may stall.

Related information

• Drive current of PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. Cause

1

Defective PC-EPC solenoid (Internal disconnection)


Resistance

Between (1) – (2)

7 – 14 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump 2 drive switch (Internal disconnection)

S25 (male) Between (3) – (2) Between (6) – (5)


Emergency pump drive switch

Resistance

Normal

Max. 1 z

Emergency

Min. 1 Mz

Normal

Max. 1 z

Emergency

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (96) – S25 (female) (3)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between S25 (female) (2) – 3 or defective contact in con- V11 (female) (1) nector) Wiring harness between C02 (female) (115), (117), (120) – S25 (female) (6) Wiring harness between S25 (female) (5) – V11 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z


2

C02 (female)

Resistance

Between (96) – (115), (117), (120)

7 – 14 z

PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

3

SEN02466-00

40 Troubleshooting

Failure code [DXA8KB] PC-EPC sol short User code

Failure code

E02

DXA8KB


Trouble

1

PC-EPC solenoid system short (Pump controller system)

• When PC-EPC solenoid was driven, short circuit was detected in circuit. • Turns output to PC-EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.


• If pump load increases, engine speed lowers largely and engine may stall.

Related information

• Drive current of PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. Cause Defective PC-EPC solenoid 1 (Internal short circuit or ground fault)


Resistance

Between (1) – (2)

7 – 14 z


Min. 1 Mz



Defective emergency pump 2 drive switch (Internal short circuit or ground fault)

S25 (male)


Between (2), (3) – (4) Between (2), (3) – chassis ground

Resistance Min. 1 Mz

Normal

Min. 1 Mz


Ground fault in wiring harWiring harness between C02 (female) (96) 3 ness (Contact with GND cir– S25 (female) (3) cuit) Wiring harness between S25 (female) (5) – V11 (female) (2)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


4

C02 (female)

Resistance

Between (96) – (115), (117), (120)

7 – 14 z


Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

5

SEN02466-00

40 Troubleshooting

Failure code [DXE4KA] Service current EPC discon User code

Failure code

—

DXE4KA


Trouble

1

Service current EPC solenoid disconnection (Pump controller system)

• When service EPC solenoid was driven, disconnection was detected in circuit. • None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself. • Attachment does not operate. • Drive current of service EPC solenoid can be checked with monitoring function. (Code: 01700 Service solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective service EPC sole1 noid (Internal disconnection) V30 (male) Resistance Between (1) – (2) Possible causes and standard value in normal state

7 – 14 z



Resistance

Max. 1 z

Resistance

Max. 1 z


C02 (female)

Resistance

Between (97) – (115), (117), (120)

7 – 14 z


6

PC138US, USLC-8

40 Troubleshooting

SEN02466-00

Failure code [DXE4KB] Service current EPC short User code

Failure code

—

DXE4KB


Trouble

Service current EPC solenoid short (Pump controller system)

• When service EPC solenoid was driven, short circuit was detected in circuit. • Turns output to service EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Attachment does not operate. • Drive current of service EPC solenoid can be checked with monitoring function. (Code: 01700 Service EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause Defective service EPC sole1 noid (Internal short circuit or ground fault)


1


Resistance

Between (1) – (2)

7 – 14 z


Min. 1 Mz


C02 (female)

Resistance

Between (97) – (115), (117), (120)

7 – 14 z


Min. 1 Mz


PC138US, USLC-8

7

SEN02466-00

40 Troubleshooting

Failure code [DY20KA] Wiper working abnormality User code

Failure code

—

DY20KA


Trouble

1

Wiper working abnormality (Pump controller system)

• When windshield wiper works, W signal of working ends is not input. • Turns working output to wiper motor OFF. • If cause of failure disappears, system resets itself. • Wiper motor does not work. • Condition of W contact signal of wiper working area can be checked with monitoring function. (Code: 02204 Switch input 5) • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON. Cause


Defective wiper motor (Inter1 nal disconnection)

M05 (female)

Wiper blade

Resistance

Operating range top

Max. 1 z

Between (6) – (5)

Other than operating range top

Min. 1 Mz

Between (1) – (3)

All range

Max. 20 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state

Wiring harness between C01 (female) (56) – M05 (male) (6)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between M05 (female) (5) – 2 or defective contact in con- J01 – chassis ground (T09) nector) Wiring harness between C02 (female) (114) – M05 (male) (1) Wiring harness between C02 (female) (119) – M05 (male) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C01 (female) 3 Defective pump controller

8

Wiper blade

Resistance

Operating range top

Max. 1 z

Between (56) – chasOther than operating sis ground range top

Min. 1 Mz

Between (114) – (119)

Max. 20 z

All range

PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

9

SEN02466-00

40 Troubleshooting

Failure code [DY20MA] Wiper parking abnormality User code

Failure code

—

DY20MA


Trouble

1

Wiper parking abnormality (Pump controller system)

• When windshield wiper parks, P signal of storage area is not input. • Turns parking output to wiper motor OFF. • If cause of failure disappears, system resets itself. • Wiper motor does not park. • Condition of P contact signal of wiper parking area can be checked with monitoring function. (Code: 02204 Switch input 5) • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF. Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female)

Defective wiper motor (Inter1 nal disconnection)


Between (4) – (5) Between (1) – (3)

Wiper blade

Resistance

Storage area

Max. 1 z

Working area

Min. 1 Mz

All range

Max. 20 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C01 (female) (75) – M05 (male) (4)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between M05 (female) (5) – 2 or defective contact in con- J01 – chassis ground (T09) nector) Wiring harness between C02 (female) (114) – M05 (male) (1) Wiring harness between C02 (female) (119) – M05 (male) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z


10

C01 (female)

Wiper blade

Resistance


Storage area

Max. 1 z

Working area

Min. 1 Mz

Between (114) – (119)

All range

Max. 20 z

PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

11

SEN02466-00

40 Troubleshooting

Failure code [DY2CKA] Washer drive discon User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DY2CKA

Trouble

1

Window washer drive system disconnection (Pump controller system)

• When output to window washer drive system was turned OFF (when ground circuit was connected), disconnection was detected in circuit. • None in particular (Since no current flows, washer motor does not operate). • If cause of failure disappears, system resets itself. • Window washer does not operate. • Method of reproducing failure code: Turn starting switch ON.

Cause 1 Defective fuse No. 4

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective washer motor 2 (Internal short circuit or ground fault)

Defective assembled-type 3 diode D02 (Internal short circuit) Possible causes and standard value in normal state

M06 (male)

Resistance

Between (1) – (2)

5 – 20 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D02 (female)

Continuity (Resistance)

Between (3) – (7)

No continuity (Min. 1 Mz)


Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (4) – J05 – 4 or defective contact in con- M06 (female) (1) nector) Wiring harness between C01 (female) (3) – J01 – M06 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between F01 (4) – J05 – 5 ness (Short circuit with GND M06 (female) (1), – D02 (female) (3) circuit) Wiring harness between C01 (female) (3) – J01 – M06 (female) (2), – D02 (female) (7)


12

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C01 (female)

Voltage


20 – 30 V

PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

13

SEN02466-00

40 Troubleshooting

Failure code [DY2CKB] Washer drive short User code — Contents of trouble Action of controller Problem that appears on machine Related information

Failure code DY2CKB

Trouble

• Turns output to washer motor OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. • Window washer does not operate. • Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.

Defective washer motor 1 (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M06 (male)

Resistance

Between (1) – (2)

5 – 20 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between C01 (female) (3) – Voltage Max. 1 V J01 – M6 (female) (2), – D02 (female) (7) 3 Defective pump controller

14

Window washer drive system short (Pump controller system)

• When output to window washer drive system was turned ON (ground circuit was disconnected), short circuit was detected in circuit.

Cause


1

If causes 1 and 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

15

SEN02466-00

40 Troubleshooting

Failure code [DY2DKB] Wiper drive (for) short User code

Failure code

—

DY2DKB

Trouble

1

Wiper motor drive forward system short (Pump controller system)

Contents of trouble

• When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.


• Turns output to wiper motor drive forward side OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.


• Windshield wiper does not operate. • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.

Cause


Defective wiper motor (Inter1 nal short circuit or ground fault)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female)

Resistance

Between (3) – (1)

There is continuity


Min. 1 Mz


Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (119) circuit) – M05 (male) (3) 3 Defective pump controller

16


Resistance

Min. 1 Mz


PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

17

SEN02466-00

40 Troubleshooting

Failure code [DY2EKB] Wiper drive (rev) short User code

Failure code

—

DY2EKB

Trouble

1

Wiper motor drive reverse system short (Pump controller system)

Contents of trouble

• When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.


• Turns output to wiper motor drive reverse side OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.


• Windshield wiper does not operate. • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.

Cause


Defective wiper motor (Inter1 nal short circuit or ground fault)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female)

Continuity/Resistance

Between (1) – (3)

There is continuity


Min. 1 Mz


Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (114) circuit) – M05 (male) (1) 3 Defective pump controller

18


Resistance

Min. 1 Mz


PC138US, USLC-8

40 Troubleshooting

SEN02466-00


PC138US, USLC-8

19

SEN02466-00

40 Troubleshooting



20

PC138US, USLC-8

SEN02467-00



Machine model

Serial number



40 Troubleshooting

1

Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting of electrical system ................................................................................ 3 Information in troubleshooting table................................................................................................................ 5 E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 6 E-2 When starting switch turned ON (before starting engine), basic check item lights up.............................. 8 E-3 Engine does not start (Engine does not turn) ........................................................................................... 9 E-4 Preheater does not operate.................................................................................................................... 12 E-5 Automatic warm-up system does not operate (in cold season).............................................................. 14 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ........................... 16 E-7 Precaution lights up while engine is running .......................................................................................... 18 E-8 Emergency stop item lights up while engine is running.......................................................................... 21 E-9 Engine coolant temperature gauge does not indicate normally ............................................................. 22 E-10 Hydraulic oil temperature gauge does not indicate normally................................................................ 23 E-11 Fuel level gauge does not indicate normally ........................................................................................ 25 E-12 Contents of display by machine monitor are different from applicable machine .................................. 27

PC138US, USLC-8

1

SEN02467-00

40 Troubleshooting

E-13 Machine monitor does not display some items..................................................................................... 27 E-14 Function switch does not work ............................................................................................................. 27 E-15 Auto-decelerator does not operate normally ........................................................................................ 28 E-16 Working mode does not change ........................................................................................................... 29 E-17 Travel speed does not change ............................................................................................................. 30 E-18 Alarm buzzer cannot be stopped.......................................................................................................... 31 E-19 Windshield wiper and window washer do not operate.......................................................................... 32 E-20 Swing holding brake does not operate normally................................................................................... 36 E-21 Travel alarm does not sound or does not stop sounding...................................................................... 38 E-22 Air conditioner does not operate normally (including air conditioner abnormality record) .................... 39 E-23 While starting switch is in OFF position, service meter is not displayed .............................................. 51 E-24 Machine monitor cannot be set in service mode .................................................................................. 51 E-25 Monitoring function does not display lever control signal normally....................................................... 52 E-26 KOMTRAX system does not operate normally..................................................................................... 68

2

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

Before carrying out troubleshooting of electrical system

1

Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally. Type of power supply

Switch power supply

Switch power supply

Switch power supply

Constant power supply

Switch power supply

PC138US, USLC-8

Fusible link

F02 (45A)

F02 (45A)

F02 (45A)

F03 (45A)

Starting switch ACC

Fuse No.

Fuse capacity

1

10A

Emergency operating circuit

2

30A

Solenoid valve

3

15A

Cigarette lighter

4

10A

Windshield washer

Destination of power

5

10A

Horn

6

5A

Working lamp relay, horn relay

7

10A

Rotary lamp (If equipped)

8

20A

Working lamp

9

10A

Radio, speaker

10

5A

Air conditioner

11

20A


12

10A

Optional power supply (1)

13

10A

Optional power supply (2), power supply of 12 volt

14

10A

Spare

15

5A

Air conditioner

16

10A

Radio backup, room lamp

17

20A

Machine monitor, pump controller, starting switch

18

30A

Engine controller

19

5A

Engine controller

20

5A

PPC oil pressure lock solenoid

3

SEN02467-00

40 Troubleshooting

Locations of fusible links

Location of fuse box and fuse Nos.

4

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

Information in troubleshooting table a

1

The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information

Trouble which occurred in the machine Information related to detected trouble or troubleshooting Cause

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment

1


• Disconnection Connector is connected imperfectly or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 2 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally. Possible causes of trouble (Given numbers are reference numbers, which do 1) Method of indicating connector No. and handling of Tnot indicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of “male” and “female”, 3 disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 4 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.

Related circuit diagram This drawing is a part of the circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow ( ): Roughly shows the location on the machine.

PC138US, USLC-8

5

SEN02467-00

40 Troubleshooting

E-1 When starting switch turned ON, machine monitor displays nothing 1 Trouble Related information

• When starting switch turned ON, machine monitor displays nothing. • When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password (if set), screen to check breaker mode (if set), screen of check before starting, screen to check working mode and travel speed, and ordinary screen in order. • When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. Cause


1 Low charge level of battery

Battery voltage (2 pieces)

Electrolyte specific gravity (1 piece)

Min. 24 V

Min. 1.26

2

Defective fusible link F03 or fuse No. 17

If fusible link or fuse is broken, circuit probably has ground fault. (See Cause 5.)

3

Wrong connection of connec- Machine monitor connector may be connected wrongly. Check it tor directly. (Check mounting bracket plate with connector.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection in wiring 4 or defective contact in connector) Possible causes and standard value in normal state

Wiring harness between battery (–) – chassis ground

Resistance

Max. 1 z

Wiring harness between battery (+) – RB – F03 (male) (1)

Resistance

Max. 1 z

Wiring harness between F03 (male) (2) – F01-15D

Resistance

Max. 1 z

Wiring harness between F01-17 – J07 – CM01 (female) (1), (2)

Resistance

Max. 1 z

Wiring harness between CM01 (female) (3), (4) – chassis ground (T09)

Resistance

Max. 1 z

Wiring harness between F01-17 – H15 (female) (1)

Resistance

Max. 1 z

Wiring harness between H15 (female) (5) – J05 – CM01 (female) (14)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (+) – RB – F03 (male) (1)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between F01-17 – H15 (female) (1)

Resistance

Min. 1 Mz

Wiring harness between H15 (female) (5) – J05 – CM01 (female) (14)

Resistance

Min. 1 Mz

Wiring harness between F03 (male) (2) – Ground fault in wiring harF01-15D 5 ness (Short circuit with GND Wiring harness between F01-17 – J07 – circuit) CM01 (female) (1), (2)

a Prepare with starting switch OFF, then hold starting switch OFF and ON and carry out troubleshooting in each case. 6 Defective machine monitor

6

CM01

Starting switch

Voltage

Between (1), (2) – (3), (4)

OFF

20 – 30 V

Between (14) – (3), (4)

ON

20 – 30 V

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

7

SEN02467-00

40 Troubleshooting

E-2 When starting switch turned ON (before starting engine), basic check item lights up Trouble Related information

• Engine oil level monitor lights up red. • Condition of engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2) Cause 1

Lowering of engine oil level (When system is normal)

Defective engine oil level 2 switch (Internal disconnection) Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting Engine oil level may be low. Check it and add oil if necessary. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P44 (male)

Engine oil level

Resistance


Between H – L

Max. 1 z

Below L

Min. 1 Mz

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 3 or defective contact in con- Wiring harness between CM02 (female) (2) ResisMax. 1 z nector) – P44 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective machine monitor

CM02

Engine oil level

Voltage


Between H – L

Max. 1 V

Below L

20 – 30 V


8

PC138US, USLC-8

40 Troubleshooting

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E-3 Engine does not start (Engine does not turn) Trouble Related information

1

• Engine does not start (Engine does not turn). • Engine starting circuit has following 2 start lock mechanisms. 1) Start lock with password of machine monitor 2) Start lock with lock lever Cause


1 Low charge level of battery

2 Defective fuse No. 20

3

Defective starting switch (Internal disconnection)

Battery voltage (2 pieces)

Electrolyte specific gravity (1 piece)

Min. 24 V

Min. 1.26

If fuse is broken, circuit probably has ground fault. (See cause 10.) a Prepare with starting switch OFF, then keep starting switch OFF and turn it to START and carry out troubleshooting in each case. H15 (male)

Starting switch

Resistance

OFF

Min. 1 Mz

START

Max. 1 z

Between (1) – (4)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4

Defective lock lever switch (Internal disconnection)

S14 (female)

Lock lever

Resistance

Free

Min. 1 Mz

Lock

Max. 1 z

Between (1) – (3)


Defective starting motor cutout relay R06 or R07 (Inter5 nal disconnection or short circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R06 (male), R07 (male)

Resistance

Between (1) – (2)

300 – 600 z

Between (3) – (4)

Max. 1 z

Between (3) – (5)

Min. 1 Mz

a Prepare with starting switch OFF (with only terminal C disconnected), then turn starting switch to START and carry out troubleshooting. Safety relay terminal

6

Defective starting motor safety relay (Internal defect)

Voltage

Between B – E

Power supply

20 – 30 V

Between R (R17-2) – E

Generation input

Max. 1 V

Between S (R17-1) – E

Starting input

20 – 30 V

Between C (R18) – E

Starting output

20 – 30 V

If power supply, generation input, and starting input are normal but starting output is not normal, starting motor safety relay is defective. a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Starting motor terminals 7

Defective starting motor (Internal defect)

Voltage

Between B – chassis ground

Power supply

20 – 30 V

Between C (E10) – chassis ground

Starting input

20 – 30 V

If power supply and starting input are normal but starting motor does not turn, starting motor is defective.

PC138US, USLC-8

9

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40 Troubleshooting

Cause

8

Defective alternator (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Alternator Between L (AR-1) – chassis ground

Generation output

Voltage Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between H15 (male) (4) – R06 (female) (5)

Resistance

Max. 1 z

Wiring harness between R06 (female) (3) – R07 (female) (4)

Resistance

Max. 1 z


Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between starting motor safety relay C – starting motor C (E10)

Resistance

Max. 1 z

Wiring harness between F01-20 – S14 (male) (1)

Resistance

Max. 1 z

Wiring harness between S14 (male) (3) – R06 (female) (1)

Resistance

Max. 1 z

Wiring harness between R06 (female) (2) – J02 – chassis ground (T08)

Resistance

Max. 1 z

Wiring harness between starting motor Disconnection in wiring har- safety relay B – heater relay – battery relay ness (Disconnection in wiring B 9 or defective contact in conWiring harness between starting motor nector) safety relay E – chassis ground


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between H15 (male) (4) – R06 (female) (5), – circuit branch end

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Wiring harness between R07 (female) (3) – R17 (female) (1) Ground fault in wiring har10 ness (Short circuit with GND Wiring harness between starting motor circuit) safety relay B – heater relay – battery relay B

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between starting motor safety relay C – starting motor C (E10)

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Wiring harness between S14 (male) (3) – R06 (female) (1)

Resistance

Min. 1 Mz

11

10

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between R17 (female) (2) – Voltage Max. 1 V alternator L (AR-1), – circuit branch end

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40 Troubleshooting

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PC138US, USLC-8

11

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E-4 Preheater does not operate Trouble

Related information

1

(1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash. • Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds after to notify completion of preheating (It stops flashing about 10 seconds after). • If engine coolant temperature is below 20°C, automatic warm-up system operates and preheating monitor lights up for up to 30 seconds. • Condition of starting switch (preheating) signal can be checked with the monitoring function. (Code: 04500 Monitor input 1) Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case.

1

Defective starting switch (Internal disconnection)

H15 (female) Between (1) – (3)


Starting switch OFF


HEAT Max. 1 z Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) ResisMax. 1 z nector) (16) – J04 – H15 (female) (3) tance a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. 3 Defective machine monitor

CM01 Between (16) – chassis ground

Starting switch OFF

Voltage Max. 1 V

HEAT

20 – 30 V

Trouble

(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm.

Related information

• Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-1 Engine does not start (Engine does not turn)). Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF (with wiring harness connected), then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. Continuity/ResisHeater relay Starting switch tance Defective heater relay (Inter1 nal disconnection) Between R15 – OFF There is continuity chassis ground


2

Defective intake air heater (Internal disconnection)

Between power supply terminal – HEAT Max. 1 z R16 a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting in each case. E01 Starting switch Voltage Between terminal – chassis ground

HEAT

20 – 30 V

If voltage is normal but heater mounting part does not become warm, intake air heater is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisDisconnection in wiring har- Wiring harness between H15 (female) (3) – Max. 1 z tance ness (Disconnection in wiring J04 – heater relay R15 3 or defective contact in con- Wiring harness between battery relay RM – ResisMax. 1 z nector) heater relay contact terminal (F04) tance Wiring harness between heater relay R16 – intake air heater E01

12

Resistance

Max. 1 z

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40 Troubleshooting

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PC138US, USLC-8

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E-5 Automatic warm-up system does not operate (in cold season) Trouble

Related information

1

• Automatic warm-up system does not operate (in cold season). • When engine coolant temperature is below 30°C automatic warm-up system raises engine speed to 1,300 rpm. • If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after engine is started, automatic warm-up system is turned OFF. (Automatic warm-up system stops automatically after operating for 10 minutes.) • If engine coolant temperature is below 10°C turbocharger protection function operates to keep the engine speed at low idle. Cause

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting. Monitoring code


Defective engine coolant 1 temperature signal system

04107 Engine coolant temperature

Engine coolant temperature

Coolant temperature level

105°C

6 (a: Red)

102°C

5 (a: Red)

100°C

4 (a: Blue)

85°C

3 (a: Blue)

60°C

2 (a: Blue)

30°C

1 (a: White)

If level of coolant temperature gauge is different from actual coolant temperature, carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally. 2 Defective engine controller

If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Engine coolant temperature gauge and engine coolant temperature monitor

14

PC138US, USLC-8

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40 Troubleshooting

E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 1 Trouble

(1) All work equipment, swing, and travel mechanism do not move.

Related information Cause 1 Defective fuse No. 20

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2

Defective lock lever switch (Internal disconnection)

S14 (female) Between (1) – (2)

Defective PPC lock solenoid 3 (Internal disconnection or short circuit)


Defective assembled-type 4 diode D01 (Internal short circuit)

Lock lever

Resistance

Lock

Min. 1 Mz

Free

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V01 (male)

Resistance

Between (1) – (2)

20 – 60 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D01 (male)

Resistance (Continuity)

Between (4) – (8)

Min. 1 Mz (No continuity)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 5 or defective contact in connector)


Resistance

Max. 1 z

Wiring harness between S14 (male) (2) – V01 (female) (2)

Resistance

Max. 1 z

Wiring harness between V01 (female) (1) – chassis ground (T08)

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between F01-20 – S14 6 ness (Short circuit with GND (male) (1), – circuit branch end circuit) Wiring harness between S14 (male) (2) – V01 (female) (2), – D01 (female) (4)

16

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

PC138US, USLC-8

40 Troubleshooting

Trouble

SEN02467-00

(2) All work equipment, swing, and travel mechanism cannot be locked.




1

Defective lock lever switch (Internal short circuit)

S14 (female) Between (1) – (2)

2

Lock lever

Resistance

Lock

Min. 1 Mz

Free

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between S14 (male) (2) – V01 (female) (2), – D01 (female) (4)

Voltage

Max. 1 V


PC138US, USLC-8

17

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40 Troubleshooting

E-7 Precaution lights up while engine is running Trouble Related information

(1) Charge level monitor lights up red. • Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage) Cause Defective generation by 1 alternator (when system is normal)


1

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. AR (male)

Engine speed

Voltage

Between (L) – chassis ground

Middle or higher

27.5 – 29.5 V

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) ResisMax. 1 z nector) (11) – J06 – AR (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CM01 (female) circuit) (11) – J06 – AR (female) (1), – circuit branch end

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective machine monitor

18

CM02

Engine

Voltage


Running

Min. 7.8 V

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

19

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Trouble Related information

40 Troubleshooting

(2) Fuel level monitor lights up red. • Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage) Cause



1

Low fuel level (when system Fuel level may be low (below about 41 l). Check it and add fuel if is normal) necessary.

2

Defective fuel level gauge system

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature)

Insufficient warm-up of 1 machine (when system is normal) 2


Defective engine coolant temperature gauge system

If monitor lights up white, engine coolant temperature may be low (below about 30°C). Warm up engine. • Lighting up white: Engine coolant temperature is low. • Lighting up blue: Engine coolant temperature is proper. If cause 1 is not detected, engine coolant temperature gauge system may be defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally.

• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature)

Insufficient warm-up of 1 machine (when system is normal) 2

20


(4) Hydraulic oil temperature monitor lights up white.

Cause Possible causes and standard value in normal state

If cause 1 is not detected, fuel level gauge system may be defective. Carry out troubleshooting for E-11 Fuel level gauge does not indicate normally.

(3) Engine coolant temperature monitor lights up white.

Cause Possible causes and standard value in normal state



Standard value in normal state/Remarks on troubleshooting If monitor lights up white, hydraulic oil temperature may be low (below about 20°C). Warm up engine. • Lighting up white: Hydraulic oil temperature is low. • Lighting up blue: Hydraulic oil temperature is proper. If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally.

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

E-8 Emergency stop item lights up while engine is running Trouble Related information

(1) Engine coolant temperature monitor lights up red. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause


Related information

Carry out troubleshooting for S-14 Coolant temperature becomes too high (overheating). Defective engine coolant temperature gauge system



If cause 1 is not detected, engine coolant temperature gauge system may be defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally.

(2) Hydraulic oil temperature monitor lights up red. • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause



If monitor lights up red, engine coolant temperature may be high (above about 102°C). Cool down engine coolant (Run engine at low idle). Overheating of engine cool- • Lighting up red: Engine coolant temperature is high 1 (overheating). ant (when system is normal) • Lighting up blue: Engine coolant temperature is proper.

2

Trouble

1


1

Overheating of hydraulic oil (when system is normal)

If monitor lights up red, hydraulic oil temperature may be high (above about 102°C). Cool down hydraulic oil (Run engine at low idle). • Lighting up red: Hydraulic oil temperature is high (overheating). • Lighting up blue: Hydraulic oil temperature is proper.

2


If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally.

(3) Engine oil pressure monitor lights up red. • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine monitor through communication system. Cause


Lowering of engine oil pres1 sure (when system is normal)

Engine oil pressure may be low. If it is low, carry out troubleshooting for S-12 Oil pressure lowers.

2

PC138US, USLC-8

Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may switch system be defective. Carry out troubleshooting for failure code [CA435].

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40 Troubleshooting

E-9 Engine coolant temperature gauge does not indicate normally

1

Trouble

(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C). (2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).

Related information

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause



Defective engine coolant temperature sensor system

If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].


If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

1

Trouble

(3) Display of coolant temperature gauge is different from actual engine coolant temperature. (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.

Related information

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.


Engine coolant temperature 1 Defective machine monitor

Coolant temperature Color of monitor light level (a)

105°C

6

102°C

5

100°C

4

85°C

3

60°C

2

30°C

1

Red

Blue White

Engine coolant temperature gauge and engine coolant temperature monitor

22

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

E-10 Hydraulic oil temperature gauge does not indicate normally Trouble

Related information

1

(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C). (2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H). • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit)


Resistance

Between (1) – (2)

3.5 – 90 kz


Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (29) 2 or defective contact in con- – P22 (female) (2) nector) Wiring harness between C01 (female) (46) – P22 (female) (1) Possible causes and standard value in normal state

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (29) Resiscircuit) Min. 1 Mz – P22 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (29) Voltage Max. 1 V – P22 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective pump controller


C01 (female)

Resistance

Between (29) – (46)

3.5 – 90 kz


Min. 1 Mz



PC138US, USLC-8

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Trouble

(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor.

Related information

• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause



Hydraulic oil temperature 1 Defective machine monitor

Hydraulic oil temper- Color of monitor light ature level (a)

105°C

6

102°C

5

100°C

4

85°C

3

40°C

2

20°C

1

Red

Blue White

Hydraulic oil temperature gauge and hydraulic oil temperature monitor

24

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

E-11 Fuel level gauge does not indicate normally Trouble Related information

(1) While fuel is added, fuel level gauge does not rise from red range (E). (2) While fuel level is low, fuel level gauge does not lower from green range top (F) • Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor voltage) Cause Defective fuel level sensor 1 (Internal disconnection or short circuit)


1


Fuel level

Resistance


FULL

7 – 11 z

EMPTY

85 – 95 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) (9) ResisMax. 1 z nector) – P21 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CM01 (female) (9) Resiscircuit) Min. 1 Mz – P21 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between CM01 (female) (9) Voltage Max. 1 V – P21 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective machine monitor

CM01 (female)

Fuel level

Resistance


FULL

7 – 11 z

EMPTY

85 – 95 z


PC138US, USLC-8

25

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40 Troubleshooting

(3) Display of fuel level gauge is different from actual fuel level. (4) Display of fuel level gauge is different from display of fuel level monitor. • Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor voltage) Cause



Quantity of fuel 1 Defective machine monitor

Reading of fuel level Color of monitor light gauge (a)

139 l

6

116 l

5

96 l

4

66 l

3

52 l

2

33 l

1

Blue

Red

Fuel level gauge and fuel level monitor

26

PC138US, USLC-8

40 Troubleshooting

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E-12 Contents of display by machine monitor are different from applicable machine Trouble

1

Contents of display by machine monitor are different from applicable machine.

Related information Cause Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting (with monitoring function).

1 Defective model code signal

Monitoring code 00200 Controller model code


Normal display Blade spec

PC128/138US-a

Not blade spec

PC128/138US-a BL


E-13 Machine monitor does not display some items Trouble Related information

• Machine monitor does not display some items. • The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. Cause


Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting.

Defective machine monitor 1 (LCD panel)

2

Defective machine monitor (body)

When following switches are operated, if all LCD panel is lighted up (all surface becomes white), LCD panel is normal. • Operation of switches: [4] + [F2] (Press simultaneously) If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

E-14 Function switch does not work Trouble Related information Possible causes and standard value in normal state

1

1

• Function switch does not work. • Condition of signal of function switch can be checked with monitoring function. (Code: 04503 Monitor function switch) Cause



Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

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E-15 Auto-decelerator does not operate normally Trouble Related information Possible causes and standard value in normal state


1

(1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off. • Condition of signal of auto-decelerator switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor

Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

(2) Auto-decelerator is not operated or reset with lever. • Set speed of auto-decelerator is 1,400 rpm. If fuel control dial is not set above this speed, autodecelerator is not operated or reset. Cause

Standard value in normal state/Remarks on troubleshooting a Start engine and carry out troubleshooting (with monitoring function). Monitoring code

Item

Normal display

Swing Travel 01900 Pressure switch 1 1 Possible causes and standard value in normal state

Defective PPC pressure signal

Boom lower Boom raise Arm curl

When lever is operated: ON When lever is in neutral: OFF

Arm dump Bucket curl 01901 Pressure switch 2

Bucket dump Service

When lever is operated: ON When lever is in neutral: OFF

If display of monitoring is abnormal, carry out troubleshooting for E-26 Monitoring function does not display lever control signal normally.

28




If cause 1 is not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

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40 Troubleshooting

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E-16 Working mode does not change Trouble Related information Possible causes and standard value in normal state

Trouble

1

(1) When working mode switch is operated, working mode selection screen is not displayed. • Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor


(2) When working mode is changed, setting of engine and hydraulic pump is not changed.

Related information Possible causes and standard value in normal state

Cause





Pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

PC138US, USLC-8

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E-17 Travel speed does not change Trouble Related information Possible causes and standard value in normal state


(1) When travel speed switch is operated, travel speed monitor does not change. • Condition of signal of travel speed switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor


(2) When travel speed is shifted, actual travel speed does not change. • If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo. Cause


1


a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between C02 (female) (87) Voltage Max. 1 V – V02 (female) (2) 2 Defective machine monitor



If cause 1 is not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


30

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

E-18 Alarm buzzer cannot be stopped Trouble Related information Possible causes and standard value in normal state

1

• Alarm buzzer cannot be stopped. • Condition of signal of alarm buzzer cancel switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor

PC138US, USLC-8


31

SEN02467-00

40 Troubleshooting

E-19 Windshield wiper and window washer do not operate Trouble

(1) When wiper switch is operated, wiper monitor does not light up or go off.

Related information

• Condition of wiper switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)



Cause 1 Defective machine monitor

1


(2) When wiper switch is operated, wiper does not operate. • Condition of window rear limit switch signal can be checked with monitoring function. (Code: 02204 Switch input 5) Cause


1

Defective window rear limit switch (Internal short circuit)

W03 (male)

Between (1) – (2)

Front window

Resistance

When installed to front

Min. 1 Mz

When retracted to rear

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective wiper motor (Inter2 nal disconnection) M05 (female) Continuity Between (1) – (3)

There is continuity



Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (119) 3 or defective contact in con- – M05 (male) (3) nector) Wiring harness between C02 (female) (114) – M05 (male) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Resiscircuit) C01 (female) (57) – W03 (female) (1) Min. 1 Mz tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective pump controller (Rear limit switch system) 5

Defective pump controller (Wiper motor system)

32

C01 (female) Between (57) – chassis ground

Front window

Resistance

When installed to front

Min. 1 Mz

When retracted to rear

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C02 (female)

Continuity

Between (119) – (114)

There is continuity

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

33

SEN02467-00

Trouble Related information Possible causes and standard value in normal state

34

40 Troubleshooting

(3) When window washer switch is operated, window washer does not operate. • Condition of window washer switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor


PC138US, USLC-8

SEN02467-00

40 Troubleshooting

E-20 Swing holding brake does not operate normally Trouble Related information

(1) When swing lock switch is operated, swing lock monitor does not light up or go off. • Condition of swing lock switch signal can be checked with monitoring function. (Machine monitor system code: 04502 Monitor input 3) (Pump controller system code: 02200 Switch input 1) Cause Defective swing lock switch 1 (Internal disconnection or short circuit)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (male) Between (5) – (6)

Swing lock switch OFF


ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (5) Resis2 Max. 1 z or defective contact in con- – J01 – S04 (female) (5) tance nector) Wiring harness between S04 (female) (6) – ResisMax. 1 z J02 – chassis ground (T08) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CM02 (female) (5) Resiscircuit) – J01 – S04 (female) (5), – C01 (female) Min. 1 Mz tance (19)


a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CM02 Swing lock switch Voltage Between (5) – chassis ground

Trouble

1

OFF ON

20 – 30 V Max. 1 V

(2) When swing lock switch is turned ON, swing lock does not operate. (Hydraulic drift of swing occurs on slope.)


1

Defective swing lock switch (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (male) Between (3) – (4)


Defective swing holding 2 brake release switch (Internal short circuit)

Swing lock switch OFF


ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Swing holding brake S25 (male) Resistance release switch Between (13) – (14)

Lock Release

Min. 1 Mz Max. 1 z


36

Hot short (Short circuit with Wiring harness between D01 (female) (3) – 24V circuit) in wiring harness J04 – S04 (female) (3), – S25 (female) (14)

Voltage

Max. 1 V

Wiring harness between S04 (female) (4) – V03 (female) (2), – D03 (female) (3)

Voltage

Max. 1 V

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

37

SEN02467-00

40 Troubleshooting

E-21 Travel alarm does not sound or does not stop sounding Trouble

1

• Alarm does not sound during travel. • Alarm does not stop sounding while machine is stopped.




a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (107) Resis1 Max. 1 z or defective contact in con- – M14 (female) (1) tance nector) Wiring harness between C02 (female) (115) ResisMax. 1 z (117) (120) – M14 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C02 (female) (107) Resiscircuit) Min. 1 Mz – M14 (female) (1) tance Defective travel alarm (Inter3 If causes 1, 2 are not detected, travel alarm is defective. nal defect)


38

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

E-22 Air conditioner does not operate normally (including air conditioner abnormality record) Trouble Related information Possible causes and standard value in normal state

Trouble

1

(1) When air conditioner switch is operated, air conditioner control screen is not displayed. • Condition of air conditioner switch signal can be checked with monitoring function. (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch) Cause 1 Defective machine monitor


(2) When air conditioner switch is operated, air conditioner does not operate at all.



1 Defective fuse No. 15

If fuse is broken, circuit probably has ground fault. (See cause 4.)

2 Defective fuse in unit

If fuse in unit is broken, circuit in unit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01-15 – fuse in 3 or defective contact in con- unit – ACW (wiring side) (6) nector) Wiring harness between ACW (wiring side) (16) – chassis ground (T14) Possible causes and standard value in normal state

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har4 ness (Short circuit with GND Wiring harness between F01-15 – fuse in Resiscircuit) Min. 1 Mz unit – ACW (wiring side) (6), – circuit branch tance end a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5

Defective air conditioner controller

ACW (wiring side)

Voltage

Between (6) – (16)

20 – 30 V

If above voltage is normal, air conditioner controller may be defective. 6 Defective machine monitor

PC138US, USLC-8


39

SEN02467-00

Trouble

40 Troubleshooting

(3) Air does not come out (Air flow is insufficient).


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side). R20 (male)

1

2

Resistance

Between (1) – (3) 140 – 340 z Defective blower relay (Intera Prepare with starting switch OFF, then turn starting switch ON nal disconnection) and carry out troubleshooting (contact side).

Defective power transistor (Internal defect)

R20

Air conditioner switch

Voltage


Air blow position

20 – 30 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch Operate between Low and Medium and High.

If air flow changes according to operation of fan switch, power transistor is normal.

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state

3

Defective blower motor (Internal defect)

MB (wiring side)


Voltage

Between (1) – (2)

Air blow position

20 – 30 V

If above voltage is normal and blower motor does not revolve, blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-10 – fuse in unit – R20 (female) (1)

Resistance

Max. 1 z

Wiring harness between R20 (female) (3) – ACW (wiring side) (36)

Resistance

Max. 1 z

Wiring harness between F01-11 – R20 (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between PTR (wiring side) (1) – chassis ground (T14)

Resistance

Max. 1 z

Wiring harness between PTR (wiring side) (2) – ACW (wiring side) (8)

Resistance

Max. 1 z

Wiring harness between PTR (wiring side) (4) – ACW (wiring side) (7)

Resistance

Max. 1 z

Disconnection in wiring harness (Disconnection in wiring Wiring harness between R20 (female) (2) – 4 or defective contact in con- MB (wiring side) (1) nector) Wiring harness between MB (wiring side) (2) – PTR (wiring side) (3)

40

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between R20 (female) (3) – ACW (wiring side) (36)


Ground fault in wiring harWiring harness between R20 (female) (2) – 5 ness (Short circuit with GND MB (wiring side) (1) circuit) Wiring harness between MB (wiring side) (2) – PTR (wiring side) (3) Wiring harness between PTR (wiring side) (2) – ACW (wiring side) (8)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

6

If causes 1 – 5 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)

7

If causes 1 – 5 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume of Shop Manual, Air tem conditioner, Troubleshooting.

PC138US, USLC-8

41

SEN02467-00

Trouble

40 Troubleshooting

(4) Air is not cooled (Cooling performance is insufficient).


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side).

1

Defective compressor relay (Internal disconnection)

2 Defective internal air sensor

R21 (male)

Resistance

Between (1) – (3)

140 – 340 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (contact side). R21


Voltage


Cooling position

20 – 30 V

Internal air sensor may be defective. Carry out troubleshooting for Abnormality in internal air sensor.

3

Defective high and low pres- High and low pressure switches may be defective. Carry out trousure switches bleshooting for “Abnormality in refrigerant”.

4

Defective compressor clutch Compressor clutch may be defective. Check it directly. (Internal defect)

5

Defective compressor (InterCompressor may be defective. Check it directly. nal defect)


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-10 – fuse in unit – R21 (female) (1)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between R21 (female) (3) – 6 or defective contact in con- ACW (wiring side) (35) nector) Wiring harness between F01-11 – R21 (female) (4) Wiring harness between R21 (female) (2) – AC02 (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harWiring harness between R21 (female) (3) – 7 ness (Short circuit with GND ACW (wiring side) (35) circuit) Wiring harness between R21 (female) (2) – AC02 (female) (1)

42

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

8


9

If causes 1 – 7 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume of Shop Manual, Air tem conditioner, Troubleshooting.

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

Trouble

(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communication condition “Abnormal”

Related information

• While abnormality in communication is being detected, “CAN disconnection” is displayed. • If abnormality in communication has been detected and reset, “Abnormality” is displayed. • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, condition of other items is not displayed. • Method of reproducing abnormality record: Turn starting switch ON. Cause


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between N10 (female) (1) – Resis1 Max. 1 z or defective contact in con- CM02 (female) (8), (9) tance nector) Wiring harness between N10 (female) (2) – ResisMax. 1 z CM02 (female) (10) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between N10 (male) (1) – CM02 (female) (8), (9), – C01 (female) (45), Ground fault in wiring har– CE02 (female) (1), – K02 (female) (A), – 2 ness (Short circuit with GND N08 (male) (3) circuit) Wiring harness between N10 (female) (2) – CM02 (female) (10), – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


3

Hot short (Short circuit with 24V circuit) in wiring harness

Defective CAN terminal 4 resistance (Internal short circuit or disconnection)

N10 (male) (1) – CM02 (female) (8), (9), – C01 (female) (45), – CE02 (female) (1), – K02 (female) (A), – N08 (male) (3)

Voltage

Max. 5.5 V

Wiring harness between N10 (female) (2) – CM02 (female) (10), – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)

Voltage

Max. 5.5 V


Resistance

Between (A) – (B)

47 – 67 z

If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be 5 troller carried out.) 6 Defective machine monitor

PC138US, USLC-8


43

SEN02467-00




40 Troubleshooting

(6) Air conditioner abnormality record: Setting condition “Abnormality” • If setting of air conditioner controller model is different from setting of machine monitor model, “Abnormality” is displayed. • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON. Cause 1


Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in troller system, troubleshooting cannot be carried out.)



(7) Air conditioner abnormality record: Internal air sensor “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective internal air sensor 1 (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (device side)

Resistance

Between (1) – (2)

300 z – 430 kz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side) 2 or defective contact in con- (11) – THI (wiring side) (2) nector) Wiring harness between ACW (wiring side) (27) – THI (wiring side) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND ResisWiring harness between ACW (wiring side) circuit) Min. 1 Mz tance (11) – THI (wiring side) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between ACW (wiring side) Voltage Max. 1 V (11) – THI (wiring side) (2) 5

44


PC138US, USLC-8

40 Troubleshooting

Trouble Related information Possible causes and standard value in normal state


SEN02467-00

(8) Air conditioner abnormality record: External air sensor “Unused” • External air sensor is not used in air conditioner system of this machine. • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Cause 1 Normal display

Standard value in normal state/Remarks on troubleshooting Since external air sensor is not used in air conditioner system of this machine, above display is normal.

(9) Air conditioner abnormality record: Air flow sensor “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective air flow sensor 1 (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THF (device side)

Resistance

Between (1) – (2)

100 z – 115 kz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side) 2 or defective contact in con- (12) – THF (wiring side) (2) nector) Wiring harness between ACW (wiring side) (27) – THF (wiring side) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND ResisWiring harness between ACW (wiring side) circuit) Min. 1 Mz tance (12) – THF (wiring side) (2)

4

5

PC138US, USLC-8


Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ACW (wiring side) (12) – THF (wiring side) (2)

Voltage

Max. 1 V


45

SEN02467-00


40 Troubleshooting

(10) Air conditioner abnormality record: Daylight sensor “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1

Defective daylight sensor (Internal defect)

Standard value in normal state/Remarks on troubleshooting Daylight sensor may be defective.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side) Max. 1 z 2 tance or defective contact in con- (36) – P31 (female) (1) nector) ResisWiring harness between ACW (wiring side) Max. 1 z (15) – P31 (female) (2) tance Possible causes and standard value in normal state


Ground fault in wiring harWiring harness between ACW (wiring side) 3 ness (Short circuit with GND (3) – P31 (female) (1), – circuit branch end circuit) Wiring harness between ACW (wiring side) (15) – P31 (female) (2)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


5

46

Hot short (Short circuit with Wiring harness between ACW (wiring side) 24V circuit) in wiring harness (3) – P31 (female) (1), – circuit branch end

Voltage

Max. 1 V

Wiring harness between ACW (wiring side) (15) – P31 (female) (2)

Voltage

Max. 1 V


PC138US, USLC-8

40 Troubleshooting


SEN02467-00

(11) Air conditioner abnormality record: Air outlet damper “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1

Defective air outlet servomotor (Internal defect)

Standard value in normal state/Remarks on troubleshooting Air outlet servomotor may be defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between MV1 (wiring side) (1) – ACW (wiring side) (27)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV1 (wiring side) (1) – ACW (wiring side) (27), – circuit branch end Possible causes and standard value in normal state

Wiring harness between MV1 (wiring side) Ground fault in wiring har(5) – ACW (wiring side) (9), – circuit branch 3 ness (Short circuit with GND end circuit) Wiring harness between MV1 (wiring side) (6) – ACW (wiring side) (23), – circuit branch end Wiring harness between MV1 (wiring side) (7) – ACW (wiring side) (24), – circuit branch end

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between MV1 (wiring side) (1) – ACW (wiring side) (27), – circuit branch end

Voltage

Max. 1 V

Wiring harness between MV1 (wiring side) Hot short (Short circuit with (5) – ACW (wiring side) (9), – circuit branch 4 24V circuit) in wiring harness end

Voltage

Max. 1 V

Wiring harness between MV1 (wiring side) (6) – ACW (wiring side) (23), – circuit branch end

Voltage

Max. 1 V

Wiring harness between MV1 (wiring side) (7) – ACW (wiring side) (24), – circuit branch end

Voltage

Max. 1 V

5

PC138US, USLC-8


47

SEN02467-00


40 Troubleshooting

(12) Air conditioner abnormality record: A/M damper “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1


Defective air mix servomotor Air mix servomotor may be defective. (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between MAM (wiring side) (1) – ACW (wiring side) (27)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MAM (wiring side) (3) – ACW (wiring side) (3), – circuit branch end Possible causes and standard value in normal state

Wiring harness between MAM (wiring side) Ground fault in wiring har(5) – ACW (wiring side) (2), – circuit branch 3 ness (Short circuit with GND end circuit) Wiring harness between MAM (wiring side) (6) – ACW (wiring side) (21), – circuit branch end Wiring harness between MAM (wiring side) (7) – ACW (wiring side) (22), – circuit branch end

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between MAM (wiring side) (3) – ACW (wiring side) (3), – circuit branch end

Voltage

Max. 1 V

Wiring harness between MAM (wiring side) Hot short (Short circuit with (5) – ACW (wiring side) (2), – circuit branch 4 24V circuit) in wiring harness end

Voltage

Max. 1 V

Wiring harness between MAM (wiring side) (6) – ACW (wiring side) (21), – circuit branch end

Voltage

Max. 1 V

Wiring harness between MAM (wiring side) (7) – ACW (wiring side) (22), – circuit branch end

Voltage

Max. 1 V

5

48


PC138US, USLC-8

40 Troubleshooting


SEN02467-00

(13) Air conditioner abnormality record: Refrigerant “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1


Insufficient refrigerant (gas) (when system is normal)

Defective high and low pres2 sure switches (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting Refrigerant (gas) may be insufficient. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P17 (male)

Resistance

Between (1) – (2)

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side) Max. 1 z 3 tance or defective contact in con- (4) – P17 (female) (1) nector) Wiring harness between P17 (female) (2) – ResisMax. 1 z chassis ground (T08) tance 4

PC138US, USLC-8


49

SEN02467-00

40 Troubleshooting


50

PC138US, USLC-8

40 Troubleshooting

SEN02467-00

E-23 While starting switch is in OFF position, service meter is not displayed Trouble Related information

• When starting switch is turned OFF, service meter is not displayed. • While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] + [1] (Press simultaneously) Cause


1


When starting switch is turned ON, if machine monitor displays Defective backup power sup- nothing, backup power supply system may be defective. In this 1 ply system case, carry out troubleshooting for “E-1 When starting switch turned ON, machine monitor displays nothing”. 2 Defective machine monitor


E-24 Machine monitor cannot be set in service mode Trouble Related information Possible causes and standard value in normal state

1

• Machine monitor cannot be set in service mode. • If following switches are operated, machine monitor is set in service mode. Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order) Cause 1 Defective machine monitor

PC138US, USLC-8


51

SEN02467-00

40 Troubleshooting

E-25 Monitoring function does not display lever control signal normally 1 Trouble Related information

(1) Boom raise operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.

Defective boom raise PPC 1 pressure switch (Internal disconnection or short circuit)

P03 (male) Between (1) – (2)

Right work equipment control lever

Resistance

Neutral

Min. 1 Mz

Boom raise

Max. 1 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (53) 2 or defective contact in con- – P03 (female) (2) nector) Wiring harness between P03 (female) (1) – chassis ground (T08)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (53) Resiscircuit) Min. 1 Mz – P03 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (53) Voltage Max. 1 V – P03 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller


52


Resistance

Neutral

Min. 1 Mz

Boom raise

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

53

SEN02467-00


40 Troubleshooting

(2) Arm curl operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause


Defective arm curl PPC pres1 sure switch (Internal disconnection or short circuit)


Left work equipment control lever

Resistance

Neutral

Min. 1 Mz

Arm curl

Max. 1 z




Resistance

Max. 1 z

Resistance

Max. 1 z



54


Resistance

Neutral

Min. 1 Mz

Arm curl

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

55

SEN02467-00


40 Troubleshooting

(3) Bucket curl operation is not displayed normally by monitoring function. • Monitoring code: 01901 Pressure switch 2 Cause


Defective bucket curl PPC 1 pressure switch (Internal disconnection or short circuit)



Resistance

Neutral

Min. 1 Mz

Bucket curl

Max. 1 z




Resistance

Max. 1 z

Resistance

Max. 1 z



56


Resistance

Neutral

Min. 1 Mz

Bucket curl

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

57

SEN02467-00


40 Troubleshooting

(4) Bucket dump operation is not displayed normally by monitoring function. • Monitoring code: 01901 Pressure switch 2 Cause


Defective bucket dump PPC 1 pressure switch (Internal disconnection or short circuit)



Resistance

Neutral

Min. 1 Mz

Bucket dump

Max. 1 z




Resistance

Max. 1 z

Resistance

Max. 1 z



58


Resistance

Neutral

Min. 1 Mz

Bucket dump

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

59

SEN02467-00


40 Troubleshooting

(5) Boom lower operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause


Defective boom lower PPC 1 pressure switch (Internal disconnection or short circuit)



Resistance

Neutral

Min. 1 Mz

Boom lower

Max. 1 z




Resistance

Max. 1 z

Resistance

Max. 1 z



60


Resistance

Neutral

Min. 1 Mz

Boom lower

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

61

SEN02467-00


40 Troubleshooting

(6) Arm dump operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause


Defective arm dump PPC 1 pressure switch (Internal disconnection or short circuit)



Resistance

Neutral

Min. 1 Mz

Arm dump

Max. 1 z




Resistance

Max. 1 z

Resistance

Max. 1 z



62


Resistance

Neutral

Min. 1 Mz

Arm dump

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

63

SEN02467-00


40 Troubleshooting

(7) Swing operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause


Defective swing PPC pres1 sure switch (Internal disconnection or short circuit)

P07 (male) P08 (male)


Resistance

Neutral

Min. 1 Mz

Between (1) – (2)

Swing left Swing right

Max. 1 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (16) 2 or defective contact in con- – P07 (female) (2) or P08 (female) (2) nector) Wiring harness between P07 (female) (1) or P08 (female) (2) – chassis ground (T08)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (16) Resiscircuit) Min. 1 Mz – P07 (female) (2) or P08 (female) (2) tance

4


Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (16) – P07 (female) (2) or P08 (female) (2)

Voltage

Max. 1 V

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller


64


Resistance

Neutral

Min. 1 Mz

Swing left Swing right

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

65

SEN02467-00


40 Troubleshooting

(8) Service operation is not displayed normally by monitoring function. • Monitoring code: 01901 Pressure switch 2 Cause Defective service front PPC 1 pressure switch (Internal disconnection or short circuit)

Defective service rear PPC 2 pressure switch (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. P14 (male) Between (1) – (2)

Service pedal

Resistance

Neutral

Min. 1 Mz

Forward

Max. 1 z

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. P15 (male) Between (1) – (2)

Service pedal

Resistance

Neutral

Min. 1 Mz

Reverse

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state


Wiring harness between C01 (female) (52) – P14 (female) (1), – P15 (female) (1)

Resistance

Max. 1 z

Wiring harness between P14 (female) (2) – chassis ground (T08)

Resistance

Max. 1 z

Wiring harness between P15 (female) (2) – chassis ground (T08)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (52) Resiscircuit) Min. 1 Mz – P14 (female) (1), – P15 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (52) Voltage Max. 1 V – P14 (female) (1), – P15 (female) (1) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 6 Defective pump controller

66

C01 (female)

Service pedal

Resistance


Neutral

Min. 1 Mz

Forward or reverse

Max. 1 z

PC138US, USLC-8

40 Troubleshooting

SEN02467-00


PC138US, USLC-8

67

SEN02467-00

40 Troubleshooting

E-26 KOMTRAX system does not operate normally Trouble Related information

1

• KOMTRAX system does not operate normally. • If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry out following troubleshooting. • Even if KOMTRAX system has trouble, it does not particularly appear on machine. • Carry out all troubleshooting on service menu screen of machine monitor. Cause

1 Defective communication 1

Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and check “Setting condition or terminal” screen. Check item

Normal display

Communication start check

Completion

a Turn starting switch ON and check “Condition of positioning and communication” screen. Check item 2 Defective GPS Possible causes and standard value in normal state

Normal display N ###,##,## (Latitude)

Positioning

E ###,##,## (Longitude) In positioning

If latitude and longitude are not displayed in 5 minutes on open ground, notify KOMTRAX service hot line. a Turn starting switch ON and check “Condition of positioning and communication” screen. 3

Defective communication environment

Check item

Normal display

Communication

Zone level 1 – Zone level 3

If zone level 1 – 3 is not displayed within communication zone of ORBCOMM, notify KOMTRAX service hot line.

4 Defective communication 2

a

68

a Turn starting switch ON and check “Condition of positioning and communication” screen. Check item

Normal display

Number of items not transmitted

0 – 9 (Normally 0)

Select “Terminal Status” from “12 Display of KOMTRAX setting” in the service menu of the machine monitor.

a

Select “GPS & Communication Status” from “12 Display of KOMTRAX setting” in the service menu of the machine monitor.

PC138US, USLC-8

SEN02467-00

40 Troubleshooting



70

PC138US, USLC-8

SEN02468-01



Machine model

Serial number



40 Troubleshooting

1

Troubleshooting of hydraulic and mechanical system (H-mode) Information contained in troubleshooting table ............................................................................................... 3 System chart for hydraulic and mechanical systems ...................................................................................... 4 H-1 Speed or power of all work equipment, swing, and travel are low ........................................................... 6 H-2 Engine speed sharply drops or engine stalls............................................................................................ 7 H-3 No work equipment, travel and swing move ............................................................................................ 8 H-4 Abnormal noise is heard from around hydraulic pump............................................................................. 8 H-5 Fine control mode does not function ........................................................................................................ 9 H-6 Speed or power of boom is low .............................................................................................................. 10 H-7 Speed or power of arm is low..................................................................................................................11 H-8 Speed or power of bucket is low ............................................................................................................ 12 H-9 Work equipment does not move in its single operation.......................................................................... 13 H-10 Hydraulic drift of work equipment is large ............................................................................................ 14 H-11 Time lag of work equipment is large..................................................................................................... 15 H-12 Work equipment loaded more is slower during compound operation .................................................. 15

PC138US, USLC-8

1

SEN02468-01

40 Troubleshooting

H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE....................................... 15 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel ............... 16 H-15 Machine deviates during travel............................................................................................................. 17 H-16 Travel speed is low............................................................................................................................... 18 H-17 Machine cannot be steered easily or steering power is low ................................................................. 19 H-18 Travel speed does not change or it is kept low or high ........................................................................ 20 H-19 Track does not move (Only either side)................................................................................................ 20 H-20 Machine does not swing....................................................................................................................... 21 H-21 Swing acceleration or swing speed is low ............................................................................................ 22 H-22 Excessive overrun when stopping swing.............................................................................................. 23 H-23 When upper structure stops swinging, it makes large shock ............................................................... 24 H-24 When upper structure stops swinging, it makes large sound ............................................................... 24 H-25 Hydraulic drift of swing is large............................................................................................................. 25 H-26 Flow rate in attachment circuit cannot be adjusted .............................................................................. 26

2

PC138US, USLC-8

40 Troubleshooting

SEN02468-01

Information contained in troubleshooting table a

1

Troubleshooting table collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Trouble Related information

Phenomena occurring on machine Information on occurred failures and troubleshooting

Cause


1

2 Possible causes and standard value in normal state

Cause for presumed failure (The attached No. for 3 filing and reference purpose only. It does not stand for any priority) 4

• The standard values in normalcy by which to judge "good" or "no good" about presumed causes. • References for making judgement of "good" or "no good"

5

PC138US, USLC-8

3

SEN02468-01

System chart for hydraulic and mechanical systems

4

40 Troubleshooting

1

PC138US, USLC-8

40 Troubleshooting a

SEN02468-01

This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.

PC138US, USLC-8

5

SEN02468-01

40 Troubleshooting

H-1 Speed or power of all work equipment, swing, and travel are low Trouble Related information

1

• Speed or power of all work equipment, swing, and travel are low. • Conduct the troubleshooting in working mode P. Cause

Standard value in normal state/Remarks on troubleshooting a

1 Malfunction of unload valve

a

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers

Unload pressure

All levers in NEUTRAL

2.8 ± 1.0 MPa {28 ± 10 kg/cm2}

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control lever

2

Defective adjustment or operation of main relief valve

Main relief pressure +2.0 –1.0 MPa +20 2 –10 kg/cm }

34.8

Arm relieved in IN direction

{355

If the oil pressure cannot be set normally by adjustment, the main relief valve may be malfunction or may have an internal defect. Check the main relief valve directly. a 3

Malfunction of self-pressure reducing valve

a



Control circuit basic pressure


3.2 ± 0.5 MPa {33 ± 5 kg/cm2}

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Measured oil pressure

4

Defective adjustment or operation of PC valve


Measurement conditions Swing lock: ON Arm: Relieved in IN direction

Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure cannot be set normally by adjustment, the PC valve may be malfunction or may have an internal defect. Check the PC valve directly. Measured oil pressure Defective adjustment or 5 operation of LS valve


Oil pressure ratio All levers in NEUTRAL Almost same pressure

Bucket curled (Lever at stroke end) 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure cannot be set normally by adjustment, the LS valve may be malfunction or may have an internal defect. Check the LS valve directly.

6

6 Malfunction of servo piston

The servo piston may have malfunction. Check it directly.

7 Piston pump defective

If there is none of the causes listed above, the piston pump may have problems of lowering of performance, malfunction, internal defect, etc.

PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-2 Engine speed sharply drops or engine stalls Trouble

• Engine speed sharply drops or the engine stalls.

Related information

• Conduct the troubleshooting in working mode P. Cause

1


Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control lever

1

Defective adjustment or operation of main relief valve

Main relief pressure +2.0 –1.0 MPa +20 2 –10 kg/cm }

34.8

Arm relieved in IN direction

{355

If the oil pressure cannot be set normally by adjustment, the main relief valve may be malfunction or may have an internal defect. Check the main relief valve directly. a

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Measured oil pressure


2

Defective adjustment or operation of PC valve


Measurement conditions Swing lock: ON Arm: Relieved in IN direction

Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure cannot be set normally by adjustment, the PC valve may be malfunction or may have an internal defect. Check the PC valve directly. Measured oil pressure Defective adjustment or 3 operation of LS valve


Oil pressure ratio All levers in NEUTRAL Almost same pressure

Bucket curled (Lever at stroke end) 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure cannot be set normally by adjustment, the LS valve may be malfunction or may have an internal defect. Check the LS valve directly. 4

Orifice or filter in servo equipment clogged

5 Malfunction of servo piston

PC138US, USLC-8

The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself. The servo piston may have malfunction. Check it directly.

7

SEN02468-01

40 Troubleshooting

H-3 No work equipment, travel and swing move Trouble Related information

• No work equipment, travel and swing move. • Set the working mode at P mode for the troubleshooting. Cause


1


1

Malfunction of PPC lock solenoid valve

a 2

Malfunction of self reducing pressure valve

Stop engine for preparations. Start troubleshooting at engine high idle. Work equipment lock lever

Solenoid output pressure

Locked

0 MPa {0 kg/cm2}

Released

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Stop engine for preparations. Start troubleshooting at engine high idle. Control lever

Control circuit source pressure

All control levers in NEUTRAL position

3.2 ± 0.5 MPa {33 ± 5 kg/cm2}


The piston pump is suspected of malfunction or an internal failure. Diagnose it in the following manner. • Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal condition.

4 Damper defective

It is presumed that the pump shaft does not rotate due to some internal failure of the dumper. Check the damper itself.

H-4 Abnormal noise is heard from around hydraulic pump Trouble Related information

• An abnormal noise is heard from around the hydraulic pump. — Cause 1 Hydraulic oil level lowered 2 Quality of hydraulic oil bad


Standard value in normal state/Remarks on troubleshooting Make a visual check. Air may have get mixed with the oil. Make a visual check.

3

Hydraulic tank cap breather clogged

It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside the tank. Make a visual check.

4

Hydraulic tank strainer clogged

It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction circuit. Make a visual check.


8

1

The piston pump is suspected of an internal failure. Check the pump itself.

PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-5 Fine control mode does not function Trouble Related information

1

• Fine control mode does not function. • Set the working mode at P mode for the troubleshooting. Cause


1 Orifice in LS circuit clogged

The orifice in the LS circuit is presumed to be clogged. Check the orifice itself. a

Stop engine for preparations. Start troubleshooting at engine high idle. Oil pressure ratio


Oil pressure to be measured 2

Defective adjustment or malfunction of LS valve

Pump delivery pressure LS valve output pressure

All control levers in NEUTRAL Nearly equal oil pressure

At bucket CURL (Control lever full stroke) 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment, malfunction of the LS valve or its internal failure is suspected. In that case, check the valve itself. 3 Malfunction of servo piston

PC138US, USLC-8

Malfunction of the servo piston is suspected. Check the piston itself.

9

SEN02468-01

40 Troubleshooting

H-6 Speed or power of boom is low Trouble Related information

• Speed or power of boom is low. • Conduct the troubleshooting in working mode P. Cause


1

Malfunction of right PPC valve (boom circuit)

2

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.


PPC valve output pressure

NEUTRAL

0 MPa {0 kg/cm2}

Boom RAISE position Boom LOWER position

Above 2.7 MPa {Above 28 kg/cm2}

a


1

Malfunction of pump mergedivider solenoid valve




0 MPa {0 kg/cm2}

Position for travel only (On either or both sides)

2.84 – 3.43 MPa {29 – 35 kg/cm2}

3

Malfunction of pump merge- The pump merge-divider valve of the control valve may have a divider valve malfunction. Check it directly.

4

Malfunction of boom control valve (spool)

The spool of the boom control valve may have a malfunction. Check it directly (Including stroke limiting mechanism on RAISE side).

Malfunction of boom control 5 valve (pressure compensation valve)

The pressure compensation valve of the boom control valve may have a malfunction. Check it directly.

Malfunction of boom control valve (lock valve)

The lock valve of the boom control valve may have a malfunction. Check it directly.

6

Malfunction or defective The safety-suction valve of the boom control valve (on the head 7 sealing of boom control valve side) may have a malfunction or its sealing may be defective. (safety-suction valve) Check it directly. Malfunction or defective The suction valve of the boom control valve (on the bottom side) 8 sealing of boom control valve may have a malfunction or its sealing may be defective. Check it (suction valve) directly. Malfunction or defective The centralized safety-suction valve of the control valve may have 9 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 10 Boom cylinder defective

10

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Boom cylinder

Leakage from cylinder

Relieved in RAISE direction

15 cc/min

PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-7 Speed or power of arm is low Trouble Related information

• Speed or power of arm is low. • Conduct the troubleshooting in working mode P. Cause


1

Malfunction of left PPC valve (arm circuit)

a 2


1


Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever


NEUTRAL

0 MPa {0 kg/cm2}

Arm IN position Arm OUT position





0 MPa {0 kg/cm2}


2.84 – 3.43 MPa {29 – 35 kg/cm2}

3


4

Malfunction of arm control valve (spool)

The spool of the arm control valve may have a malfunction. Check it directly (Including stroke limiting mechanisms on IN side and OUT side).

Malfunction of arm control 5 valve (pressure compensation valve)

The pressure compensation valve of the arm control valve may have a malfunction. Check it directly.

Malfunction or defective 6 sealing of arm control valve (safety-suction valves)

The safety-suction valves of the arm control valve (on the bottom side and head side) may have a malfunction or their sealing may be defective. Check them directly.

Malfunction or defective The centralized safety-suction valve of the control valve may have 7 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 8 Arm cylinder defective

PC138US, USLC-8

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Arm cylinder


Relieved in IN direction

15 cc/min

11

SEN02468-01

40 Troubleshooting

H-8 Speed or power of bucket is low Trouble Related information

• Speed or power of bucket is low. • Conduct the troubleshooting in working mode P. Cause


1

Malfunction of right PPC valve (bucket circuit)

2




NEUTRAL

0 MPa {0 kg/cm2}

Bucket CURL position Bucket DUMP position


a


1





0 MPa {0 kg/cm2}


2.84 – 3.43 MPa {29 – 35 kg/cm2}

3


4

Malfunction of bucket control The spool of the bucket control valve may have a malfunction. valve (spool) Check it directly.

Malfunction of bucket control The pressure compensation valve of the bucket control valve may 5 valve (pressure compensahave a malfunction. Check it directly. tion valve) Malfunction or defective The safety-suction valves of the bucket control valve (on the bot6 sealing of bucket control tom side and head side) may have a malfunction or their sealing valve (safety-suction valves) may be defective. Check them directly. Malfunction or defective The centralized safety-suction valve of the control valve may have 7 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 8 Bucket cylinder defective

12

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Bucket cylinder


Relieved in CURL direction

15 cc/min

PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-9 Work equipment does not move in its single operation

Trouble

Related information

(1) The boom does not move when operated independently. • Work equipment does not move in its sin- (2) The arm does not move when operated indepengle operation dently. (3) The bucket does not move when operated independently. • Set the working mode at P mode for the troubleshooting. Cause



1

1 Malfunction of PPC valve

2

PC138US, USLC-8

Malfunction of work equipment control valve (spool)

Stop engine for preparations. Start troubleshooting at engine high idle.

Work equipment control lever


NEUTRAL

0 MPa {0 kg/cm2}

Operation


The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.

13

SEN02468-01

40 Troubleshooting

H-10 Hydraulic drift of work equipment is large Trouble Related information

• Hydraulic drift of work equipment is large.



1 Boom cylinder defective

Defective sealing of centralized safety-suction valve

Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.


(2) Hydraulic drift of arm is large.

• Conduct the troubleshooting in working mode P. Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Arm cylinder


Relieved in IN direction

15 cc/min

Defective sealing of arm con- Sealing of the spool of the arm control valve may be defective. 2 trol valve (spool) Check it directly. 3

Defective sealing of arm con- Sealing of the suction valve of the arm control valve (on the bottom trol valve (suction valve) side) may be defective. Check it directly.

4




(3) Hydraulic drift of bucket is large.

• Conduct the troubleshooting in working mode P. Standard value in normal state/Remarks on troubleshooting a 1 Bucket cylinder defective

14

15 cc/min

3

Cause



Sealing of the lock valve of the boom control valve may be defective. Check it directly.

1 Arm cylinder defective

Related information

Boom cylinder Relieved in RAISE direction

Defective sealing of boom control valve (lock valve)

a

Trouble


2

Cause


(1) Hydraulic drift of boom is large.



1

Defective sealing of bucket 2 control valve (spool)

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Bucket cylinder


Relieved in CURL direction

15 cc/min

Sealing of the spool of the bucket control valve may be defective. Check it directly.

3

Defective sealing of bucket control valve (suction valve)

Sealing of the suction valve of the bucket control valve (on the bottom side) may be defective. Check it directly.

4



PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-11 Time lag of work equipment is large Trouble Related information

• Time lag of work equipment is large. • Conduct the troubleshooting in working mode P. Cause


1

Malfunction of control valve 1 (regeneration valve) [Boom and arm] 2

Malfunction of control valve (suction valve)

Standard value in normal state/Remarks on troubleshooting The regeneration valve of the control valve may have a malfunction. Check it directly. The suction valve of the control valve (on the head side) may have a malfunction. Check it directly.

H-12 Work equipment loaded more is slower during compound operation Trouble Related information

1

• Work equipment loaded more is slower during compound operation. — Cause

Standard value in normal state/Remarks on troubleshooting The pressure compensation valve of the work equipment loaded less may have a malfunction. Check it directly.


Malfunction of pressure com1 pensation valve of work equipment loaded less

Compound operation

More loaded side

Less loaded side

Boom RAISE + Arm IN

Boom

Arm

Boom RAISE + Arm OUT

Arm

Boom

Boom RAISE + Bucket CURL

Boom

Bucket

Arm IN + Bucket CURL

Arm

Bucket

Boom LOWER + Arm OUT

Arm

Boom

H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE Trouble Related information Possible causes and standard value in normal state

1

• Boom RAISE speed is low in compound operation of swing + boom RAISE. • If the speed of single operation of the boom RAISE speed is slow, conduct troubleshooting for H-7 first. Cause 1

PC138US, USLC-8

Malfunction or defective sealing of LS selector valve

Standard value in normal state/Remarks on troubleshooting The LS selector valve of the control valve may have a malfunction or its sealing may be defective. Check it directly.

15

SEN02468-01

40 Troubleshooting

H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel 1 Trouble Related information

• Travel speed lowers largely during compound operation of work equipment/swing + travel. • Conduct the troubleshooting in working mode P. Cause


1


16

2





0 MPa {0 kg/cm2}


2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly.

Malfunction of work equipThe pressure compensation valve of the work equipment control 3 ment control valve (pressure valve may have a malfunction. Check it directly. compensation valve) Malfunction of swing control 4 valve (pressure compensation valve)

The pressure compensation valve of the swing control valve may have a malfunction. Check it directly.

Malfunction of travel control 5 valve (pressure compensation valve)

The pressure compensation valve of the travel control valve may have a malfunction. Check it directly.

PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-15 Machine deviates during travel Trouble Related information

• Machine deviates during travel. • Conduct the troubleshooting in working mode P. Cause


1


a

2

Malfunction of travel PPC valve

a 3

Malfunction of pump mergedivider valve

a Possible causes and standard value in normal state

1

4

Malfunction of travel junction solenoid valve

a 5 Malfunction of unload valve




3.2 ± 0.5 MPa {33 ± 5 kg/cm2}

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever


Forward or reverse position


Difference in above output between both sides

Below 0.4 MPa {Below 4 kg/cm2}


Solenoid valve output pressure


0 MPa {0 kg/cm2}


2.84 – 3.43 MPa {29 – 35 kg/cm2}




0 MPa {0 kg/cm2}

Position for travel only on either side

2.84 – 3.43 MPa {29 – 35 kg/cm2}


Unload pressure


2.8 ± 1.0 MPa {28 ± 10 kg/cm2}

6


7

Malfunction of travel junction The travel junction valve may have a malfunction. Check it directly. valve

8

Malfunction of travel control lever (spool)

The spool of the travel control lever may have a malfunction. Check it directly. a

9 Travel motor defective



Travel circuit relieved

1.65 l/min

10 Final drive defective

The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

Defective adjustment of 11 travel deviation adjustment plug

Adjust travel deviation adjustment plug. For details, see Testing and adjusting, "Testing and adjusting travel deviation".

PC138US, USLC-8

17

SEN02468-01

40 Troubleshooting

H-16 Travel speed is low Trouble Related information

1

• Travel speed is low. • Conduct the troubleshooting in working mode P. Cause


1


a

2


a 3 Possible causes and standard value in normal state


a 4 Malfunction of unload valve

Control levers



3.2 ± 0.5 MPa {33 ± 5 kg/cm2}



Forward or reverse position


Difference in above output between both sides

Below 0.4 MPa {Below 4 kg/cm2}




0 MPa {0 kg/cm2}


2.84 – 3.43 MPa {29 – 35 kg/cm2}


Unload pressure


2.8 ± 1.0 MPa {28 ± 10 kg/cm2}

5


6


The spool of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control 7 lever (pressure compensation valve)

The pressure compensation valve of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control lever (suction valve)

The suction valve of the travel control lever may have a malfunction. Check it directly.

8

a 9 Travel motor defective


18





1.65 l/min


PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-17 Machine cannot be steered easily or steering power is low Trouble Related information

• Machine cannot be steered easily or steering power is low. • Conduct the troubleshooting in working mode P. Cause


1


a 2


a 3 Possible causes and standard value in normal state

1

Malfunction of travel junction solenoid valve



In NEUTRAL on both sides

0 MPa {0 kg/cm2}

Operated on either side





0 MPa {0 kg/cm2}


2.84 – 3.43 MPa {29 – 35 kg/cm2}




0 MPa {0 kg/cm2}

Position for travel only on either side

2.84 – 3.43 MPa {29 – 35 kg/cm2}

4

Malfunction of hydraulic pump (check valve)

The check valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly.

5

Malfunction of hydraulic pump (shuttle valve)

The shuttle valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly.

6


7

Malfunction of travel junction The travel junction valve may have a malfunction. Check it directly. valve

8


The spool of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control 9 lever (pressure compensation valve)

The pressure compensation valve of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control lever (suction valve)

The suction valve of the travel control lever may have a malfunction. Check it directly.

10

Malfunction of travel motor 11 (safety and check valve)

PC138US, USLC-8

The safety and check valve of the travel motor may have a malfunction. Check it directly. (It may be checked by exchanging the front and rear motors or the right and left motors and checking change of the phenomenon.)

19

SEN02468-01

40 Troubleshooting

H-18 Travel speed does not change or it is kept low or high Trouble Related information

• Travel speed does not change or it is kept low or high. • Conduct the troubleshooting in working mode P. Cause



1

1

2

Malfunction of travel speed selector solenoid valve

Malfunction of travel motor (speed-changer unit)

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel speed

Travel lever


Lo

In NEUTRAL

0 MPa {0 kg/cm2}

Hi

Operated

2.84 – 3.43 MPa {29 – 35 kg/cm2}

The speed-changer unit of the travel motor may have a malfunction. Check it directly.

H-19 Track does not move (Only either side) Trouble Related information

• Track does not move (only either side). • Conduct the troubleshooting in working mode P. Cause 1



Defective seat of travel con- The suction valve seat of the travel control lever may be defective. trol valve (suction valve) Check it directly.

Defective seat of travel conThe safety and check valve seat of the travel control lever may be 2 trol valve (safety and check defective. Check it directly. valve) 3

Malfunction of travel motor (counterbalance valve)

The counterbalance valve of the travel motor may have a malfunction. Check it directly. a

4 Travel motor defective


20

1




1.65 l/min


PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-20 Machine does not swing Trouble Related information

1

• Machine does not swing.

(1) Machine does not swing in either direction.



1


2

Malfunction of swing holding brake solenoid valve

Malfunction of swing motor (holding brake)



In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

2.84 – 3.43 MPa {29 – 35 kg/cm2}

The holding brake of the swing motor may have a malfunction. Check it directly. a

3 Swing motor defective

4 Swing machinery defective



Leakage from swing motor

Swing circuit relieved

Below 6 l/min

The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

• Machine does not swing.

(2) Machine does not swing in only one direction.



1



2

Malfunction of swing PPC valve

Malfunction of swing control valve (spool)



In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing


The spool of the swing control valve may have a malfunction. Check it directly. a

Defective adjustment or mal3 function of swing motor (safety valve)



Swing lock switch ON

4

PC138US, USLC-8

Defective sealing of swing motor (suction valve)

Left work equipment Swing relief pressure control lever (Pump pressure) Swing circuits relieved (separately on both sides)

29.2 ± 1.5 MPa {298 ± 15 kg/cm2}

Sealing of the suction valve of the swing motor may be defective. Check it directly.

21

SEN02468-01

40 Troubleshooting

H-21 Swing acceleration or swing speed is low Trouble Related information

• Swing acceleration or swing speed is low.

Cause

2

Malfunction of swing motor (holding brake)

Related information

Standard value in normal state/Remarks on troubleshooting The pressure compensation valve of the swing control valve may have a malfunction. Check it directly. The holding brake of the swing motor may have a malfunction. Check it directly. a



Trouble




Below 6 l/min


• Swing acceleration or swing speed is low.

(2) Swing acceleration or swing speed is low in only one direction.



1


(1) Swing acceleration or swing speed is low in both directions.

• Conduct the troubleshooting in working mode P.

Malfunction of swing control 1 valve (pressure compensation valve) Possible causes and standard value in normal state

2





In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing






22

1


29.2 ± 1.5 MPa {298 ± 15 kg/cm2}

4



5

Malfunction of swing motor (reverse prevention valve)

Sealing of the reverse prevention valve of the swing motor may be defective. Check it directly.

PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-22 Excessive overrun when stopping swing Trouble Related information

• Excessive overrun when stopping swing.







Below 6 l/min

• Excessive overrun when stopping swing.

(2) Overrun of upper structure is large in only one direction.



1


(1) Overrun of upper structure is large in both directions.



1




In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing


2

The swing PPC slow return valves may be clogged. Check them Clogging of swing PPC slow directly. (They may be checked by exchanging with each other return valves and checking change of the phenomenon.)

3







29.2 ± 1.5 MPa {298 ± 15 kg/cm2}

5



6

Malfunction of swing motor (reverse prevention valve)

Sealing of the reverse prevention valve of the swing motor may be defective. Check it directly.

PC138US, USLC-8

23

SEN02468-01

40 Troubleshooting

H-23 When upper structure stops swinging, it makes large shock Trouble Related information

• When upper structure stops swinging, it makes large shock. • Conduct the troubleshooting in working mode P. Cause



1




In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing


2

Malfunction of swing PPC slow return valves

The swing PPC slow return valves may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

3

Malfunction of swing motor (safety valve)

The safety valve of the swing motor may have malfunction. Check it directly.

H-24 When upper structure stops swinging, it makes large sound Trouble Related information


24

1

1

• When upper structure stops swinging, it makes large sound. • Conduct the troubleshooting in working mode P. Cause


1

Malfunction of back pressure check valve

The back pressure check valve may have a malfunction. Check it directly.

2

Malfunction of swing motor (safety valve)

The swing motor (safety valves) may have a malfunction. Check the valves directly.

3

Malfunction of swing motor (suction valves)

The swing motor (suction valves) may have a malfunction. Check the valves directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)



PC138US, USLC-8

40 Troubleshooting

SEN02468-01

H-25 Hydraulic drift of swing is large Trouble Related information

• Hydraulic drift of swing is large.

(1) When swing holding brake is operated

• If the swing lock switch is turned ON or the swing holding brake release switch is in the normal position, the swing holding brake operates and the disc brake holds the upper structure. • Conduct the troubleshooting in working mode P. Cause



1

1

Malfunction of swing holding brake solenoid valve




In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunction or internal defect The holding brake of the swing motor may have a malfunction or 2 of swing motor (holding an internal defect. Check it directly. brake)


• Hydraulic drift of swing is large.

• If the swing holding brake release is in the emergency position, the swing holding brake is released and the upper structure is held with only hydraulic pressure. • Conduct the troubleshooting in working mode P. Cause


(2) When swing holding brake is released


1

Defective sealing of swing control valve (spool)

Sealing of the spool of the swing control valve may have a malfunction. Check it directly.

2

Defective sealing of swing motor (safety valve)

The safety valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

3


The suction valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

Malfunction or defective 4 sealing of swing motor (reverse prevention valve)

PC138US, USLC-8

The reverse prevention valve of the swing motor may have a malfunction or its sealing may be defective. Check it directly.

25

SEN02468-01

40 Troubleshooting

H-26 Flow rate in attachment circuit cannot be adjusted

1

When attachment is installed Trouble Related information

• Flow rate in attachment circuit cannot be adjusted. • If an attachment is installed, the flow rate in the service circuit changes according to the selected working mode. • How to adjust the flow rate in modes B and ATT is different from that in mode B. For details, see Operation manual. Cause Malfunction of attachment 1 flow rate adjustment EPC valve


26

Standard value in normal state/Remarks on troubleshooting The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly. a

Malfunction of service PPC 2 valve

Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Wiring harness connector

Disconnect connector V30 of attachment flow rate adjustment EPC valve.

Service pedal


In NEUTRAL

0 MPa {0 kg/cm2}

Operated


PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02468-01

27

SEN02468-01

40 Troubleshooting



28

PC138US, USLC-8

SEN02469-01



Machine model

Serial number



40 Troubleshooting

1

Troubleshooting of engine (S-mode) Method of using troubleshooting chart............................................................................................................ 4 S-1 Starting performance is poor .................................................................................................................... 8 S-2 Engine does not start ............................................................................................................................... 9 S-3 Engine does not pick up smoothly.......................................................................................................... 12 S-4 Engine stops during operations .............................................................................................................. 13 S-5 Engine does not rotate smoothly ............................................................................................................ 14 S-6 Engine lacks output (or lacks power) ..................................................................................................... 15 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17 S-9 Oil becomes contaminated quickly ......................................................................................................... 18 S-10 Fuel consumption is excessive............................................................................................................. 19 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20 S-12 Oil pressure drops ................................................................................................................................ 21 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 23

PC138US, USLC-8

1

SEN02469-01

40 Troubleshooting

S-15 Abnormal noise is made ....................................................................................................................... 24 S-16 Vibration is excessive ........................................................................................................................... 25

2

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02469-01

3

SEN02469-01

Method of using troubleshooting chart

40 Troubleshooting

1

The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. Questions Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. Check items Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the right. Causes Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. Troubleshooting Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applying troubleshooting tools or direct inspection.

Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w. E : Causes to be referred to for questions and check items Q : Causes related to questions and check items w : Causes highly probable among ones marked with Q a When narrowing the "causes", apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)

4

PC138US, USLC-8

40 Troubleshooting

PC138US, USLC-8

SEN02469-01

5

SEN02469-01

40 Troubleshooting

Exhaust gas is black Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].

6

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in the [Causes] section. The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is explained according to Step 1 – Step 3 shown below.

PC138US, USLC-8

7

SEN02469-01

40 Troubleshooting

S-1 Starting performance is poor

1

General causes why starting performance is poor q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.

Defective or deteriorated battery

Defective alternator (generator section)

Defective alternator (regulator section)

Defective intake air heater system

Defective injector

Stuck, seized supply pump plunger

Clogged fuel filter

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder

Defective contact of valve and valve seat

Clogged air cleaner element

Causes

Confirm recent repair history Degree of use of machine Operated for long period

E

E

Q w w

Q

E w

Engine starts easily when warm

w

Q Q Q

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual

w

w Q Q w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally

w w w

During operation, charge level monitor indicates abnormal charge w

Dust indicator is red

w

Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping

w

Q

When priming pump is operated, it makes no reaction or it is heavy

w Q w

Starting motor cranks engine slowly

Check items

While engine is cranked with starting motor,

If air bleeding plug of fuel filter is removed, fuel does not flow out

w w

If spill hose from injector is disconnected, little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q Q

Engine does not pick up smoothly and combustion is irregular

w Q w Q

There is hunting from engine (rotation is irregular) w

Blow-by gas is excessive q

Inspect air cleaner directly

q q

When compression pressure is measured, it is found to be low

q

Troubleshooting

When air is bled from fuel system, air comes out

q

Inspect fuel filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code

q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q

When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with engine at low idle?

q

Yes

q

No

q

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Clean

Replace

Clean

Remedy

Replace

When specific gravity of electrolyte and voltage of battery are measured, they are low

Replace

Questions

Starting performance

Became worse gradually

*1: Displayed failure codes [CA559] and [CA2249]

8

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-2 Engine does not start

1

a) Engine does not turn General causes why engine does not turn q Seized parts inside engine o See “S-4 Engine stops during operations” q Defective electrical system

Degree of use of machine

Operated for long period

Condition of horn when starting switch is turned ON

Horn does not sound

Q

When starting switch is turned to START, starting pinion does not move out

Q

Defective steering circuit wiring

Defective starting motor (motor section)

Defective safety relay

Defective starting switch

w

w

w

Speed of rotation is low w

Makes grating noise

w w

Soon disengages again Q

Makes rattling noise and does not turn

Q Q

q

When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 – 30 V) between battery relay terminal B and terminal E

q

When terminal B and terminal C of starting switch are connected, engine starts

q

When terminal B and terminal C at safety relay outlet are connected, engine starts

q

Replace

Replace

Remedy

Replace

q

Replace

When terminal at safety switch and terminal B at starting motor are connected, engine starts Replace

q

Replace

Even if terminal B and terminal C at safety relay outlet are connected, engine does not start

Carry out troubleshooting on E-mode

q

Inspect flywheel ring gear directly

PC138US, USLC-8

Q

w Q

Turn starting switch OFF, connect cord, and carry out troubleshooting at ON

w

w

When starting switch is turned ON, there is no operating sound from battery relay

When starting switch is turned to START, starting pinion moves out, but

Q

w

Horn volume is low

Battery terminal is loose

Check items

Defective battery relay

E E

Battery electrolyte is low

Troubleshooting

Defective connection of battery terminal

Defective or deteriorated battery

Confirm recent repair history

Correct

Questions

Broken flywheel ring gear

Causes

—

9

SEN02469-01

40 Troubleshooting

b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)

Defective fuel injector

Defective common rail pressure limiter

Defective operation of overflow valve (Does not close)

Defective supply pump MPROP


Broken supply pump shaft

Seized, abnormally worn feed pump

Clogged fuel filter



Insufficient fuel in tank

Use of improper fuel

Causes

Confirm recent repair history E E


w Q w w

Exhaust smoke suddenly stopped coming out (when starting again) Fuel other than specified one is used

w

Non-specified fuel is being used

w

Replacement of filters has not been carried out according to Operation and Maintenance Manual

Q

Q E

E E

w

Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained w

When fuel filter is removed, there is not fuel in it Check items

E

w

When fuel tank is inspected, it is found to be empty

w

Fuel is leaking from fuel piping

w


w Q

If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills

Q

Q

w Q

Q

w w w

Q

q


q

Inspect fuel filter directly Troubleshooting

w

E

q

Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code

q q

Carry out troubleshooting according to “Abnormality in supply pump IMV (*2)” indicated by code

q q

Inspect overflow valve directly

q

Engine can be started in reduced cylinder mode Replace

Replace

Replace

Replace

Replace

Replace

Correct

Clean

Add

Replace

Remedy

Replace

q

Fuel flows out when pressure limiter return piping is disconnected

Replace

Questions


*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA271] and [CA272]

10

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor, wiring harness

Defective, deteriorated battery

Clogged injector, defective spray


Clogging of fuel filter

Leaking or clogged fuel system, entry of air


Use of improper fuel


Worn dynamic valve system (Valve, rocker lever, etc.)


Causes

Confirm recent repair history E


E

w

Suddenly failed to start

E w

Q

Q Q


w

w w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally

w w


Q

Air breather hole of fuel tank cap is clogged

w

Rust and water are found when fuel tank is drained w

When fuel filter is removed, there is not fuel in it Fuel is leaking from fuel piping

w


w Q w

Starting motor cranks engine slowly w

Check items

When engine is cranked, abnormal sound is generated around cylinder head If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills

Q

w


w

q


q

Inspect dynamic valve system directly

q

When compression pressure is measured, it is found to be low Troubleshooting

w

q


q


q q

Engine can be started in reduced cylinder mode

q

When specific gravity of electrolyte and voltage of battery are measured, they are low

q

Coolant temperature gauge does not indicate normally

q

Replace

Replace

Replace

Replace

Replace

Correct

Clean

Replace

Replace

Clean

Remedy

Replace

When starting switch is turned to HEAT, intake air heater mount does not become warm

Replace

Questions


*1: Displayed failure codes [CA559] and [CA2249] PC138US, USLC-8

11

SEN02469-01

40 Troubleshooting

S-3 Engine does not pick up smoothly

1

General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

Clogged injector, defective spray






Seized turbocharger, interference of turbocharger

Improper valve clearance



Causes



E w

Engine pick-up suddenly became worse

E Q Q

Q w w w


w

w w

Oil must be added more frequently w


w


w

Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

w


w Q

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

Q w w

Blue under light load w Q

Black

w w

When engine is cranked, interference sound is generated around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied

Q

w

There is hunting from engine (rotation is irregular)

Q

Q

Q

w

Blow-by gas is excessive q


q

When compression pressure is measured, it is found to be low Troubleshooting

w

w

When engine is cranked, abnormal sound is generated around cylinder head

q q

Inspect valve clearance directly

q

When turbocharger is rotated by hand, it is found to be heavy

q


q


q q

Clean

Replace

Correct

Clean

Replace

Replace

Adjust

Clean

Remedy

Correct


Replace

Questions



12

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-4 Engine stops during operations General causes why engine stops during operations q Internal parts of engine seized q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine

1

Defective starting switch wiring

Defective hydraulic pump

Defective engine controller power supply wiring

Broken auxiliary equipment (pump, compressor, etc.)


w

Broken supply pump shaft

Q w Q w

Broken, seized feed pump

Clogging feed pump gauze filter


Leaking, clogged fuel piping



Broken, seized gear train

Broken, seized crankshaft bearing

Broken, seized piston, connecting rod

Broken dynamic valve system (valve, rocker arm, etc.)

Causes



Condition when engine stopped

w w w w w Q

Engine overheated and stopped

Q

Engine stopped slowly

w

Q Q

There was hunting and engine stopped

w Q

Q Q Q


Q Q Q


w w

Fuel level monitor indicates low level

w

When fuel tank is inspected, it is found to be empty

w w


w w

Rust and water are found when fuel tank is drained Metal particles are found when oil pan is drained

w w

Does not turn at all

w w

When engine is cranked by hand

Q Q Q

w


Check items

Q Q

Q Q

w

Turns in opposite direction

w

Moves by amount of gear backlash

w w

Supply pump shaft does not turn

w

Engine turns, but stops when load is applied to machine q


q

Inspect piston, connecting rod directly

q

Inspect crankshaft bearing directly

q

Troubleshooting

Inspect gear train directly

q

Inspect fuel filter directly

q

Inspect feed pump gauge filter directly

q

Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code

q q

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed

q

q

Check controller power supply wiring

q

Correct

—

Replace

Replace

Replace

Replace

Clean

Replace

Correct

Clean

Add

Replace

Replace

Replace

Remedy

Replace

Check starting switch wiring

Correct

Questions

Abnormal noise was heard and engine stopped suddenly

Carry out troubleshooting on applicable machine



PC138US, USLC-8

13

SEN02469-01

40 Troubleshooting

S-5 Engine does not rotate smoothly

1

General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)

Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Clogged injector, defective spray (dirt in injector)





Causes



Q Q

Occurs at a certain speed range

Q Q Q Q Q

Occurs at low idle Q

Occurs even when speed is raised

Q Q

w

Occurs on slopes

w

Replacement of filters has not been carried out according to Operation and Maintenance Manual w

When fuel tank is inspected, it is found to be empty Check items


w


w Q

Troubleshooting

w



q

Q

Rust and water are found when fuel tank is drained

q


q


q

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” indicated by code

q

Replace

Replace

Replace

Add

Remedy

Clean

Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” indicated by code

Replace

Hunting

Replace

Questions


*1: Displayed failure code [CA689] *2: Displayed failure code [CA778]

14

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-6 Engine lacks output (or lacks power) General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1

Clogged fuel spill piping

Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor (air leakage)

Defective drive of injector (signal, solenoid)

Clogged injector, defective spray (dirt in injector)



Leaking, clogged fuel piping






Air leakage from air intake piping and aftercooler


Causes


E

E

Q

Q

Q

Q w

Suddenly Q

Gradually

Q


w Q

Q

w w


w


w

Fuel is leaking from fuel piping w

Output becomes insufficient after short stop of operation

w

Black

w w

Blue under light load

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items

Q Q

w

Oil must be added more frequently

w w w

When engine is cranked, interference sound is generated around turbocharger

w


Q

High idle speed is too high Q

High idle speed under no load is normal, but speed suddenly drops when load is applied w w

Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular)

w

Blow-by gas is excessive

w Q Q

Q Q

w

Q Q Q

Q Q

w

q


q

Inspect air intake piping directly

q q q

When boost pressure is measured, it is found to be low

q


q q

Inspect valve clearance directly Troubleshooting

Q Q

Q Q Q


Color of exhaust gas is

Q

q

Inspect fuel piping

q


q

Inspect spill port check valve directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code

q


q q q

Inspect charge pressure sensor mount directly Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” indicated by code

Correct

Replace

Replace

Replace

Replace

Correct

Clean

Replace

Adjust

Correct

Correct

Replace

Clean

Remedy

q

Replace

Power was lost

E


Replace

Questions



PC138US, USLC-8

15

SEN02469-01

40 Troubleshooting

S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black q Insufficient intake of air q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1 Defective coolant temperature sensor, wiring harness

Improper fuel injection pressure

Improper injection timing

Abnormally worn injector

Clogged, seized injector



Crushed, clogged muffler

Leakage of air between turbocharger and cylinder head





Causes



Questions

Color of exhaust gas is

E

E

w

Suddenly became black

w

w

Gradually became black

Q

Q w


Q Q

Non-specified fuel is being used w

Oil must be added more frequently Power was lost

E Q Q Q

w

Suddenly Q

Gradually

Q Q

Q

Q Q Q

w


w

Muffler is crushed w

Air leaks between turbocharger and cylinder head, clamp is loosened

Q Q Q

Engine is operated in low-temperature mode at normal temperature

Check items


Q w w


w


Q

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal

Q

w

Engine does not pick up smoothly and combustion is irregular

Q

Q Q Q

Q Q w w


w

If spill hose from injector is disconnected, abnormally much fuel spills q


q

When turbocharger is rotated by hand, it is fount to be heavy

q

Troubleshooting


q q


q

When muffler is removed, exhaust sound improves Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code

q

q q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated by code

q

Replace

Replace

Replace

Replace

Replace

Correct

Replace

Adjust

Correct

Clean

Replace

Remedy

Replace

q q

Confirm with monitoring function

Replace



16

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of pats in lubrication system

1 Oil leakage from oil pan, cylinder head, etc.

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn, damaged rear oil seal


Broken piston ring

Clogged breather, breather hose

Turbocharger Worn seal at blower end

Worn seal at turbine end

Worn, damaged valve (stem, guide, seal)

Dust sucked in from intake system

Causes

E E E


E w

Oil consumption suddenly increased

Q

Oil must be added more frequently

w

Oil becomes contaminated quickly

Q Q w

Q w w w w w

Outside of engine is dirty with oil w

There are loose piping clamps in intake system

w

Inside of turbocharger intake outlet pipe is dirty with oil Q w

w

There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w w

Exhaust smoke is blue under light load

w w w

None q

When intake manifold is removed, dust is found inside

q

When intake manifold is removed, inside is found to be dirty abnormally Troubleshooting

Q

q q

Excessive play of turbocharger shaft

q

Check breather and breather hose directly

q q


q

Inspect rear oil seal directly

q q

Pressure-tightness test of oil cooler shows there is leakage

q q q q

PC138US, USLC-8

Replace

Replace

Replace

Replace

Replace

Clean

Replace

Replace

Correct

Remedy

Replace

There is external leakage of oil from engine

Correct

Amount of blow-by gas

Q

Excessive

Correct

Check items

Inside of turbocharger exhaust outlet pipe is dirty with oil

Correct


Correct

Questions


17

SEN02469-01

40 Troubleshooting

S-9 Oil becomes contaminated quickly

1


Q

Exhaust smoke is bad

Q

w

Oil must be added more frequently Metal particles are found when oil filter is drained

Q Q

Inside of exhaust pipe is dirty with oil

w

w w

Color of exhaust gas is Amount of blow-by gas

w


w

Black Q Q w

Excessive

Q w

None q

Excessive play of turbocharger shaft

q q


q

Check breather and breather hose directly

q

Inspect oil cooler directly

q

Inspect oil filter directly

q

Spring of oil filter safety valve is hitched or broken

q

Replace

Replace

Replace

Clean

Replace

Replace

Remedy

Replace

Inspect turbocharger lubrication drain tube directly

18

Clogged turbocharger lubrication drain tube

Defective oil filter safety valve

E E E



See S-7

Check items

Clogged oil filter


Engine oil temperature rises quickly

Troubleshooting

Clogged oil cooler

Clogged breather, breather hose


Worn valve, valve guide

Defective seal at turbocharger turbine end

Causes

Clean

Questions

General causes why oil becomes contaminated quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load

—

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-10 Fuel consumption is excessive

1

General causes why fuel consumption is excessive q Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel

Defective coolant temperature sensor, wiring harness

Improper injection timing

Defective operation of injector

Defective spray by injector

Defective common rail pressure

Defective supply pump plunger

Defective feed pump oil seal

Fuel leakage from fuel filter, piping, etc.

Fuel leakage inside head cover

Causes

E E


Condition of fuel consumption

E Q

More than for other machines of same model Q

Gradually increased Q Q

Suddenly increased

w

There is external leakage of fuel from engine

w

Combustion is irregular w

w


w Q

Low idle speed is high

Q

Torque converter stall speed or pump relief speed is high Color of exhaust gas is

Q Q

Black

Q Q

Q

White

q

Remove head cover and inspect directly

q

Inspect feed pump oil seal directly

q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code

q


q

If spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated by code

q

Replace

Replace

Replace

Correct

Correct

Remedy

q

Replace

q


Replace

Check items

Engine oil level rises and oil smells of diesel fuel

Troubleshooting

Q Q Q Q

Replace


Replace

Questions



PC138US, USLC-8

19

40 Troubleshooting

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) General causes why oil is in coolant q Internal leakage in lubrication system q Internal leakage in cooling system

1

Holes caused by pitting

Cracks inside cylinder block

Broken cylinder head, head gasket

Causes

Broken oil cooler core, O-ring

SEN02469-01

Oil level

E E

Operated for long period Q

Suddenly rose

Q Q Q

Gradually rose

Q Q

Hard water is being used as coolant

Q Q w

There are excessive air bubbles in radiator, coolant spurts back

w

Pressure-tightness test of cylinder head shows there is leakage

q q q

Inspect cylinder block, liner directly

q

Remedy

20

Replace

Pressure-tightness test of oil cooler shows there is leakage Replace

Troubleshooting

Check items

Oil level has risen and oil is milky

Replace


Replace

Questions


PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-12 Oil pressure drops

1

General causes why oil pressure drops q Leakage, clogging, wear or lubrication system q Defective oil pressure control q Improper selection of fuel (improper viscosity) q Deterioration of oil due to overheating

Defective oil level sensor, wiring harness

Leaking, crushed, clogged hydraulic piping

Clogged oil filter

Defective regulator valve

Defective oil pump

Clogged, broken pipe in oil pan

Clogged strainer in oil pan

Coolant, fuel in oil

Lack of oil in oil pan

Worn journal of bearing

Causes


E


E

Q w

Oil pressure monitor indicates low oil pressure Q

Non-specified oil is being used

Q


Oil pressure monitor (if installed)

w w

Indicates pressure drop at low idle Indicates pressure drop at low, high idle

Q

Indicates pressure drop on slopes

w

w w w Q w

Oil level monitor indicates oil level drop

w

Oil level in oil pan is low

w

Q w w

External hydraulic piping is leaking, crushed w

Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained

w

Metal particles are found when oil filter is drained

w

Metal particles are found in oil filter

q

Q

Inspect oil pan strainer, pipe directly

See S-13

Check items

Sometimes indicates pressure drop

Troubleshooting

E

Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged Inspect oil filter directly

q q q q q q

PC138US, USLC-8

Correct

Replace

Replace

Replace

Clean

—

Clean

Add

Remedy

Replace

If oil level sensor is replaced, oil level monitor indicates normally

Replace

Questions


21

SEN02469-01

40 Troubleshooting

S-13 Oil level rises (Entry of coolant or fuel)

1

General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”


Check items

E E

E

w

Fuel must be added more frequently

w

Coolant must be added more frequently

Q

There is oil in coolant

Q Q Q Q

Q w

w

Oil is milky

Q

When engine is started, drops of water come from muffler

Q

w Q

When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w or coolant spurts back

Q Q

Exhaust smoke is white

w

Oil level in damper chamber is low

w

Oil level in hydraulic tank is low q


q

Remove injector and inspect O-ring.

q q

Inspect cylinder block, liner directly

q

Inspect rear oil seal directly

q

Pressure-tightness test of oil cooler shows there is leakage

q

Remove and inspect supply pump directly

q

Replace

Replace

Replace

Replace

Replace

Replace

Remedy

Replace

Inspect seal of auxiliary equipment directly

22

Defective seal of auxiliary equipment (pump, compressor)

Defects in supply pump

Broken oil cooler core, O-ring

Worn, damaged rear oil seal


Cracks inside cylinder block

E


Oil smells of diesel fuel

Troubleshooting

Broken injector, O-ring


Replace

Questions


Causes

PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation, damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system

1

Rise in hydraulic oil temperature

Defective coolant temperature gauge

Slipping fan belt, worn fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged, crushed radiator fins

Defective operation of thermostat

Broken water pump

Lack of coolant

Clogged, broken oil cooler



Causes

Questions

Confirm recent repair history Degree of use of machine Condition overheating Coolant temperature gauge

E E


E E Q w

Sudden overheated

Q Q w w

Always tends to overheat Q

Rises quickly

Q

w w

Does not go down from red range w

Radiator coolant level monitor indicates drop of coolant level w Q

Engine oil level has risen, oil is milky

w

Fan belt tension is low w

When fan pulley is turned, it has play w

Milky oil is floating on coolant w

Check items

There are excessive air bubbles in radiator, coolant spurts back When light bulb is held behind radiator core, no light passes through

w

Radiator shroud, inside of underguard side are clogged with dirt or mud

w

w

w

Coolant is leaking because of cracks in hose or loose clamps

w

Coolant flows out from radiator overflow hose

w

Fan belt whines under sudden acceleration Hydraulic oil temperature enters red range faster than engine coolant temperature

w

q


q

Inspect oil cooler directly

q

Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is carried out, it does not open at cracking temperature

q q

Temperature difference between upper and lower tanks of radiator is slight

q

Inspect radiator core directly

q

When operation of radiator cap is carried out, its cracking pressure is low

q

Inspect fan belt, pulley directly

q

PC138US, USLC-8

Correct

Replace

Correct

Correct

Replace

Replace

Add

Replace

Replace

Remedy

Replace

When coolant temperature is measured, it is found to be normal

Replace

Troubleshooting

Carry out troubleshooting on H-mode

q

Inspect cylinder liner directly

—

23

SEN02469-01

40 Troubleshooting

S-15 Abnormal noise is made

1

General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 3 seconds. This does not indicate abnormality, however.

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Dirt caught in injector

Clogged, seized injector

Deformed cooling fan, loose fan belt, interference of fan belt

Removed, seized bushing

Improper gear train backlash

Excessive wear of piston ring, cylinder


Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger

Leakage of air between turbocharger and cylinder head

Causes

Degree of use of machine Condition of abnormal noise

E


Q

Gradually occurred

Q Q

Non-specified fuel is being used Oil must be added more frequently

w


w

w

w

Air leaks between turbocharger and cylinder head

w


w


w w

When engine is cranked, beat noise is generated around muffler Check items

Q

Q Q

Suddenly occurred

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

w Q w

Blue under light load Q w

Black

Q w

Engine does not pick up smoothly and combustion is irregular Q

Abnormal noise is loud when engine is accelerated

Q Q

q

When turbocharger is rotated by hand, it is found to be heavy

q


q

When muffler is removed, abnormal noise disappears Troubleshooting

Q w


q


q


q q


q

Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q q

Abnormal noise is heard only when engine is started

q

24

Replace

Replace

Correct

Replace

Replace

Replace

Adjust

Replace

Replace

Replace

Remedy

Replace


Replace

Questions


PC138US, USLC-8

40 Troubleshooting

SEN02469-01

S-16 Vibration is excessive

1

General causes why vibration is excessive q Defective parts (abnormal wear, breakage) q Misalignment between engine and chassis q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for “S-15 Abnormal noise is made”, too.

Broken output shaft, parts in damper

Loose engine mounting bolts, broken cushions

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Worn camshaft bushing

Improper gear train backlash

Worn main bearing, connecting rod bearing

Stuck dynamic valve system (valve, rocker lever)

Causes

E

E

E

Q

Q

Q

Non-specified oil is being used

Q

Q


w

w

Metal particles are found when oil pan is drained

w

w

Oil pressure is low at low idle

Q

Q

Degree of use of machine Condition of vibration

Operated for long period Q

Suddenly increased Gradually increased

Q

Q Q

Vibration occurs at mid-range speed Q

Vibration follows engine speed Exhaust smoke is black

w


q

Q Q Q

q

Inspect main bearing and connecting rod bearing directly

q


q

Inspect camshaft bushing directly

q


q

Inspect engine mounting bolts and cushions directly

q

PC138US, USLC-8

Replace

Replace

Replace

Replace

Replace

Remedy

Replace

Inspect output shaft or inside of damper directly

Replace

Troubleshooting

Check items

Questions


25

SEN02469-01

40 Troubleshooting



26

PC138US, USLC-8

SEN02709-00


Machine model

Serial number



50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 List of adhesives ............................................................................................................................................. 4 Special tool list ................................................................................................................................................ 7 Sketche of special tool ...................................................................................................................................11

PC138US, USLC-8

1

SEN02709-00

50 Disassembly and assembly

How to read this manual

1

1. Removal and installation of assemblies Special tools q Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts ).

* *** ****

a

2

General tools that are necessary for removal or installation are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described.

Removal The "Removal" section contains procedures and precautions for implementing the work, know how and the amount of oil or coolant to be drained. q Various symbols used in the "Removal" section are explained and listed below. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. [*1] : This mark shows that there are instructions or precautions for installing parts. 6 : This mark shows the amount of oil or coolant to be drained. 4 : Weight of part or component q

Installation q Except where otherwise instructed, installation of parts is done in the reverse order of removal. q Instructions and precautions for installing parts are shown with [*1] mark in the "Removal" section, identifying which step the instructions are intended for. q Marks shown in the "Installation" section stand for the following. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5

: Quantity of oil or coolant to be added

Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.

PC138US, USLC-8


SEN02709-00

2. Disassembly and assembly of assemblies Special tools q Special tools which are deemed necessary for disassembly and assembly of parts are described as A1,•••X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They respectively have a new part number. R : Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts ).

* *** ****

a

Disassembly In "Disassembly" section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant drained are described. q The meanings of the symbols used in "Disassembly" section are as follows. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. 6: Quantity of oil or coolant drained q

Assembly q In "Assembly" section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q The meanings of the symbols used in "Assembly" section are as follows. k : Precautions related to safety in execution of work a: This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5

: Quantity of oil or coolant to be added

Sketches of special tools Various special tools are illustrated for the convenience of local manufacture.

q

General tools that are necessary for disassembly and assembly are described as [1], [2]•••etc. and their part names, part numbers and quantities are not described.

PC138US, USLC-8

3

SEN02709-00


List of adhesives a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list.

Adhesive

Category

Komatsu code

Part No.

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.

LT-2

09940-00030

50 g

LT-3

790-129-9060 Adhesive: (Set of 1 kg adhesive and Hardener: hardener) 500 g

LT-4

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

ThreeBond 790-129-9140 1735

Aron-alpha 790-129-9130 201

Gasket sealant

4

• Used to stick and seal metal, glass, and plastics.

Polyethylene • Used to seal plugs. container Tube

• Heat-resistant seal used to repair engines.

50 g

2g

• Quick-setting adhesive. Polyethylene • Quick-setting type. container (max. strength is obtained after 30 minutes) • Used mainly to stick rubbers, plastics, and metals. Polyethylene • Features: Resistance to heat and chemicals. container • Used for fitted portions used at high temperatures.

79A-129-9110

50 cc

LG-1

790-129-9010

200 g

790-129-9080

Can

• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods.

Loctite 648-50

LG-5

Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.

1 kg

Tube

• Used to stick or seal gaskets and packings of power train case, etc.

• Used to seal various threaded portions, pipe joints, Polyethylene and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-6

790-129-9020

200 g

Tube

• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.

LG-7

790-129-9070

1 kg

Tube

• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

ThreeBond 790-129-9090 1211

100 g

Tube

• Gasket sealant used to repair engine.

ThreeBond 419-15-18131 1207B

100 g

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.

PC138US, USLC-8


Komatsu code

Part No.

Q'ty

Container


LM-G

09940-00051

60 g

Can

• To be sed as lubricant (anti squeaking) for sliding part.

Tube

• To be used for press fit, shrink fit and preventing scratching or seizure of thread. • To be used as lubricant for linkage and bearing etc..

LM-P

G2-LI G0-LI(*) * For cold region

Grease

G2-CA

200 g

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG0-400LI-A (*) SYG0-16CNLI (*)

Various kinds

Various kinds • Versatile type

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Various kinds

Various kinds

• To be used for the place where the bearing designed for normal temperature and low load condition is used and contacts water and steam.

400 g x 10 Bellows type 400 g x 20 16 kg Can

• Used for parts under heavy load. Caution: • Do not use this grease for ball bearings such as swing circle bearing. • Apply this grease to work equipment pins only when installing but do not use it after then.

Grease with molybdenum disulphide LM-G(G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper white grease G2-T G0-T(*) *: For cold region

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

400 g 16 kg

Bellows type Can

• Higher anti seizure and heat resistance than grease with molybdenum disulphide • Body dirt is not distinctive due to white color.

Biological grease G2-B G2-BT(*) *: For heat resistance and heavy load

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

400 g 16 kg

Bellows type Can

• To be shortly dissolved by a bacteria in nature so that the influence to microorganism and animals and plants is suppressed to the minimum.

20 ml

Glass container

• To be used as primer for cab side. (Term of validity: 4 months after manufacturing)

20 ml

Glass container

• To be used as primer for glass side. (Term of validity: 4 months after manufacturing)

20 ml

Glass container

Sunstar primer for painting plane 580 super Sunstar primer for glass 580 super Primer

09940-00040

Sunstar primer for painting plane 435-95 Sunstar primer for glass 435-41 Sunstar primer for sash GP-402

PC138US, USLC-8

417-926-3910

22M-54-27230

22M-54-27240

22M-54-27250

150 ml

Steel can

20 ml

Glass container

For adhesion of cab glass

Lubricant with molybdenum disulfide

Category

SEN02709-00

• To be used as primer for painting plane of cab side. (Term of validity: 4 months after manufacturing) • To be used as primer for black ceramic coated plane of glass side and polycarbonate hard coat plane. (Term of validity: 4 months after manufacturing) • To be used as primer for sash (Alumite surface treatment) (Term of validity: 4 months after manufacturing)

5

SEN02709-00

6

Komatsu code

Part No.

Q'ty

Container


Sunstar penguin seal 580 super "S" or "W"

417-926-3910

320 ml


• "S" and "W" are used as glass adhesive compound in high temperature (April October) and in low temperature (October -April ) respectively. (Term of validity: 4 months after manufacturing)

Sika Ltd, Japan Sika Flex 256HV

20Y-54-39850

310 ml


• To be used as glass adhesive compound. (Term of validity: 6 months after manufacturing)

Sunstar pengiun super 560

22M-54-27210

320 ml

ECOCART (special container)

Sunstar pengiun seal No. 2505

417-926-3920

320 ml


Sekisui silicone sealant

20Y-54-55130

333 ml


GE Toshiba Silicones Tosseal 381

22M-54-27220

333 ml

Cartridge

For adhesion of cab glass

Coaking compound

Adhesive compound

Category


• To be used as glass adhesive compound. (Term of validity: 6 months after manufacturing) • To be used as seal for joints of glass. (Term of validity: 4 months after manufacturing) • To be used for seal of front window. (Term of validity: 6 months after manufacturing) • To be used as seal for joints of glass. semi-transparent white seal (Term of validity: 12 months after manufacturing)

PC138US, USLC-8


Special tool list

SEN02709-00

1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity : t . . . . . . Cannot be substituted, must always be installed (used) : q . . . . . . Extremely useful if available or, can be substituted with commercially available

part. a New/Remodel: N. . . . . . Tools with new part numbers, newly developed for this model.

Engine front oil seal

Engine rear oil seal

Sketch

• Plate

1

790-101-5221

• Grip

1

01010-51225

• Bolt

1

795-931-1100

Seal puller assembly q

1

790-101-5401

Push tool (Kit)

t

1

790-101-5431

• Plate

1

790-101-5421

• Grip

1

01010-51240

• Bolt

1

796-460-1210

Oil stopper

q

1

795-799-1131

Adapter

q

1

Stop oil supply from hydraulic tank

790-201-2750

Spacer

t

1

Removal split collar

790-101-5201

Push puller (Kit)

q

1

790-101-2510

• Block

1

790-101-2550

• Leg

1

790-101-2560

• Nut

2

790-101-2570

• Plate

4

790-101-3101

Bearing puller

q

1

790-101-4200

Puller (294 kN {30 ton})

q

1

790-101-1102

Hydraulic oil pump

q

1

790-101-5401

Push tool (Kit) (C)

q

1

Instllation Bearing outer race

790-101-5461

• Plate

1

For main bearing

790-101-5441

• Plate

1

For sub bearing

790-101-5421

• Grip

1

01010-51240

• Bolt

1

4

790-201-2850

Spacer

t

1

5

790-201-2750

Spacer

t

1

796T-426-1140 Push tool

t

1

790-201-2680

q

1

3

D

2

F

3

6

PC138US, USLC-8

1

790-101-5271

1

Swing machinery

t

Nature of work, remarks

Push tool (Kit)

A 2

Hydraulic oil tank

Part Name

790-101-5201 1

Engine rear oil seal

Part No.

New/remodel

Symbol

Q’ty

Component

Necessity

: R. . . . . . Tools with upgraded part numbers, remodeled from items already available for other models. : Blank . . Tools already available for other models, can be used without any modification a Tools marked with Q in the Sketch column are tools introduced in the sketches of the special (See Sketches of special tools).

Plate

Instllation front oil seal

Removal rear oil seal

Instllation rear oil seal

Removal bearing

Instllation Bearing inner race Q

Instllation oil seal

7

1

2

Disassembly, assembly L of idler recoil spring

3

1 Disassembly, assembly M of track roller 2

Expansion, installation of track shoe

Disassembly of center swivel joint

8

R

T

Part Name

t

1

Sketch

Part No.

New/remodel

Symbol

Q’ty

Component


Necessity

SEN02709-00


791-675-1510

Installer

791-600-2001 or 791-685-8006

Compressor (A)

791-635-3160

Extension

t

1

790-201-2770

• Spacer

t

1

790-101-1600

Cylinder (686 kN {70 ton})

t

1

790-101-1102

Pump

t

1

790-201-1500

Push tool (Kit)

q

1

790-201-1590

• Plate (Periphery ø74)

1

790-201-1610

• Plate (Periphery ø79)

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-434-1650

Installer

t

1

Application of floating seal ø88

791-601-1000

Oil pump

q

1

Sealing of oil and checking of air leak

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

791-620-3530

Push

t

1

791-620-3260

Push

t

1

791-620-3270

Guide

t

1

Compressor (B)

t

Application of floating seal

1 1

01011-62260

Bolt

t

2

01643-62260

Washer

t

2

01011-61455

Bolt

t

3

01643-31445

Washer

t

3

790-105-1100


t

1

790-101-1102

Pump

t

1

790-101-2501

Push puller

q

1

790-101-2510

• Block

1

790-101-2520

• Screw

1

790-101-2540

• Washer

1

791-112-1180

• Nut

1

790-101-2630

• Leg

2

790-101-2570

• Washer

4

790-101-2560

• Nut

2

791-112-2650

• Adapter

2

Compression of spring

Press fit of piston dust seal

Q Removal, pressfit of master pin

Disconnection of rotor from shaft

PC138US, USLC-8

1 2

3

Disassembly, assembly U of hydraulic cylinder

4

790-101-1102

Pump

t

1

790-102-4300

Wrench assembly

t

1

790-201-4310

Pin

t

1

790-201-1702

Push tool (Kit)

t

1

790-201-1791

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1702

Push tool (Kit)

790-201-1811

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1702

Push tool (Kit)

790-201-1821

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool (Kit)

790-201-1610

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool (Kit)

790-201-1620

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool (Kit)

790-201-1630

• Push tool

1

790-101-5021

• Grip

1

t

t

q

q

q

Sketch

1

Disassembly, assembly of cylinder Removal, installation of piston

Press fit of bucket cylinder roll bushings

1 Press fit of boom cylinder roll bushings

1 Press fit of arm and blade cylinder roll bushings

1 Press fit of bucket cylinder dust seal

1 Application of boom cylinder dust seal

1 Application of arm and blade cylinder dust seal

• Bolt Expander

t

1

Extension of piston ring

796-720-1660

Ring

t

1

07281-01159

Clamp

t

1

Bucket cylin- Removal, der installation of Arm, boom, piston ring blade cylinder

792-785-1100

Remover

t

1

796-270-1110

• Adapter

1

790-101-4000

• Puller (490 kN {50 ton})

1

790-101-1102

• Pump

1

1

793-498-1210

Lifter (Suction cup)

t

2

2

20Y-54-13180

Adapter

t

2

Removal, installation, of work equipment and V 1 boom

PC138US, USLC-8

t


01010-50816

6

X

Repair stand

Part Name

790-720-1000

5

Operator’s cab glass (stuck glass)

790-502-1003

Part No.

New/remodel

Symbol

Q’ty

Component

SEN02709-00

Necessity


1

Removal of boom foot pin

Removal and installation operatiors cab glass (stuck glass)

9

Floor frame assembly airconditioner compressor assembly airconditioner condenser assembly airconditioner unit assembly

10

X 3

Service tool (Kit)

t

1

799-703-1100

Vacuum pump (100V)

t

1

799-703-1111

Vacuum pump (220V)

t

1

790-703-1121

Vacuum pump (240V)

t

1

799-703-1401

Gas leak detector

t

1

Part Name

Sketch

799-703-1200

Part No.

New/remodel

Symbol

Q’ty

Component


Necessity

SEN02709-00


Charging of air-conditioning gas

PC138US, USLC-8


Sketche of special tool

SEN02709-00

1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. F6 Push tool

a

Unless otherwise specified, there shall be on burrs or flushes at the corner.

R Adapter

PC138US, USLC-8

11

SEN02709-00




12

PC138US, USLC-8

SEN02710-00


Machine model

Serial number



50 Disassembly and assembly Engine and cooling system Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of fuel injector assembly ......................................................................................... 4 Removal and installation of front oil seal ........................................................................................................ 7 Removal and installation of rear oil seal ......................................................................................................... 9 Removal and installation of cylinder head assembly .................................................................................... 12 Removal and installation of radiator assembly ............................................................................................. 19 Removal and installation of aftercooler assembly......................................................................................... 21 Removal and installation of work equipment oil cooler assembly ................................................................. 23 Removal and installation of engine and work equipment pump assembly ................................................... 26 Removal and installation of fuel tank assembly ............................................................................................ 31

PC138US, USLC-8

1

SEN02710-00


Removal and installation of fuel supply pump assembly 1

6) 7)

Removal k

8)

Disconnect the negative (–) terminal of the battery beforehand.

1.

Remove the counterweight, referring to "Removal and installation of counterweight."

2.

Disconnecting engine controller and frame assembly 1) Remove engine controller mounting bolts (1) from the upper frame (2). 2) Remove 4 lower frame mounting bolts (3). 3) Disconnect the engine controller frame assembly (4).

4.

3.

2

Loosen sleeve nuts (12) and (13) and remove high pressure pipe (14). [*2] Remove the pin and disconnect spill hose (15). Remove joint bolts (16), (17) and (18) and remove fuel tubes (19) and (20). [*3]

Removal of supply pump and pump holder assembly 1) Remove 4 mounting bolts (21) from the gear case. 2) Loosen mounting bolts (22) completely from the pump holder side. [*4] a At this stage, mounting bolts (22) cannot be removed between the supply pump and the pump holder. 3) Remove supply pump and pump holder assembly (23).

Disconnecting wiring and piping 1) Disconnect pump regulator sensor connector PREG (5). 2) Disconnect wiring clamps (6), (7) and (8). 3) Disconnect clamp (10) from fuel hoses (9). 4) Disconnect fuel hose (9) from the fuel filter. 5) Remove two boots (11) from the injector and supply pump. [*1]

PC138US, USLC-8


5.

Removal of supply pump assembly 1) Loosen nut (24) and pull out supply pump gear (25) using gear puller [1]. [*5]

SEN02710-00

Installation q

Carry out the installation in the reverse order of removal.

[*1] a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. [*2]

k k

2)

Remove 3 nuts (26) and remove supply pump (27) from pump holder (28).

k

a

q

q

Never bens a high-pressure pipe for the convenience sake. The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Be sure to install the boot to the sleeve nut after installing the high-pressure pipe. Before installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2 mm inside the tip). No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).

3 3

Sleeve nut (12) on the common rail side: 25.5 – 29.4 Nm {2.6 – 3.0 kgm} Sleeve nut (13) on the supply pump side: 18 – 23 Nm {1.9 – 2.3 kgm}

[*3]

3 3

Joint bolts (16) and (17): 24.5 – 34.3 Nm {2.5 – 3.51 kgm} Joint bolt (18): 19.6 – 17.7 Nm {2.0 – 1.8 kgm}

[*4] a For mounting bolt (22), install M6 bolt with LT2A. [*5]

3

PC138US, USLC-8

Pump gear mount nut: 65 – 75 Nm {6.6 – 7.6 kgm}

3

SEN02710-00

Removal and installation of fuel injector assembly 1 Removal k


1.

Open engine hood (1).

2.

Disconnection of air conditioner compressor hose clamp and aftercooler hose a When removing injector assemblies No. 3 and No. 4, completing the following procedures in advance makes the work for Procedure 3 and onward easier. 1) Disconnect air conditioner compressor hose clamps (2) and (3) and keep the hose out of the way. 2) Disconnect aftercooler hose (4) on the side of the air intake connector and keep it out of the way.

4


3.

Removal of the high-pressure pipe a The following indicates the removal of injector assembly of cylinder No. 1 for example. 1) Remove clamp (5) from the high-pressure pipe. 2) Remove boot (6) from the injector and common rail sides. [*1]

3)

4) 5)

Remove injector wiring connector (7). Connector No. Cylinder No. 1: CN1 Cylinder No. 2: CN2 Cylinder No. 3: CN3 Cylinder No. 4: CN4 Remove pin (8) and disconnect spill hose (9). Loosen sleeve nut (10) both on the injector side and common rail side and remove high-pressure pipe (11). [*2]

PC138US, USLC-8


4.

Removal of injector assembly 1) Remove holder mounting bolt (12) and remove holder (13). [*3] 2) Remove injector assembly (14). [*4]

SEN02710-00

Installation q


[*1] a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. [*2]

k k

k

a

q

q

Never bend a high-pressure pipe for the convenience sake. The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Be sure to install the boot to the sleeve nut after installing the high-pressure hose. Before Installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2mm inside the tip). No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).

3

Sleeve nut (11): 25.5 – 29.4 Nm {2.6 – 3.0 kgm}

[*3]

3

PC138US, USLC-8

Holder mounting bolt (13): 27 – 30 Nm {2.8 – 3.1 kgm}

5

SEN02710-00


[*4] q

6

When reusing injector, always replace Oring (15) and gasket (16) with new ones.

PC138US, USLC-8


SEN02710-00

Removal and installation of front oil seal 1

A 1

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

3.

Loosen fan belt adjust bolt (3) and remove fan belt (4). [*1]

4.

Remove engine speed sensor connector (5).

5.

Remove speed sensor mounting bolt (6) and remove speed sensor (7). [*2]

6.

Remove crankshaft pulley mounting bolt (8) and remove crankshaft pulley (9). [*3]

7.

Remove front oil seal (10).

t 1

790-101-5201

Push tool (kit)

790-101-5271

• Plate

1

790-101-5221

• Grip

1

01010-51225

• Bolt

1

Removal 1.

Remove the engine assembly, referring to "Removal and installation of engine assembly."

2.

Remove fan mounting bolt (1) and remove fan (2).

PC138US, USLC-8

7

SEN02710-00


Installation 1.

Use tool A1 (outside diameter of 80 mm) to press front oil seal (10) in gear case (11). 1) Check the crankshaft end corner and the oil seal lip sliding surface for flaws, burrs, scars, or rust, before installing the oil seal. 2) Fill about 2 cc of grease to between the oil seal lips. 2 Front oil seal: grease (G2-LI)

2.

Install the crankshaft pulley. a Align key (a) of crankshaft (12) with key groove (b) of crankshaft pulley (9) and install the pulley.

3.

For the rest of the installation work, carry out the installation in the reverse order of removal.

[*1] Confirm the direction of the fan. [*2]

2

Speed sensor mounting bolt (6): 7.0 – 11 Nm {0.7 – 1.1 kgm}

[*3]

2

8

Crankshaft pulley mounting bolt (8): 343 – 402 Nm {35 – 41 kgm}

PC138US, USLC-8


SEN02710-00

Removal and installation of rear oil seal 1

2) 3)

Temporarily lift flywheel (3). Remove 7 flywheel mounting bolts (4) except one. [*2]

4)

Loosen flywheel mounting bolt (4). k Leave 3 threads or 4 engaged to prevent the flywheel from suddenly shooting out in the following procedure. Pull out the flywheel by prying with a bar, etc. Checking that flywheel (3) is manually removable, remove the flywheel mounting bolt (4). Lift flywheel (3) and remove it. 4 Flywheel: 25 kg

2 A 3

Part name

795-931-1100

Seal puller assemq 1 bly

790-101-5401

• Push tool (kit)

790-101-5431

• Plate

1

790-101-5421

• Grip

1

01010-51240

• Bolt

1

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

t 1

Removal k


1.

Remove the work equipment pump assembly, referring to "Removal and Installation of Work Equipment Pump Assembly."

2.

Removal of the flywheel 1) Remove coupling mounting bolt (1) and remove coupling (2). [*1]

PC138US, USLC-8

5) 6) 7)

9

SEN02710-00

3.

Removal of the rear oil seal 1) Screw the tip of tool A4 into the metal ring of seal (5) and pull it out with the impact of a slide hammer [1]. a For the ease of pulling out the seal, slightly hammer it in to unfasten it from the housing before pulling it out. a Do not use a drill as chips may enter the engine.

(Photo shows work on a single unit of engine, but the procedures are the same.)


Installation 1.

Rear oil seal mounting procedure Use tool A3 (outside diameter of 120 mm) to install rear oil seal to flywheel housing. a Fill about 3 cc of grease to between the rear oil seal lips. 2 Front oil seal: grease (G2 – LI)

2.

For the following installation work, carry out the installation in the reverse order of removal.

[*1]

3

Coupling mounting bolt: 98 – 122.6 Nm (10 – 12.5 Kgm)

[*2] q

Tighten the flywheel mounting bolts according to the following procedure: 1) Apply engine oil EO#30 to the bolt threads. 2 Mounting bolt threads: Engine oil (EO30) 2) Tighten the bolts in the order of 1 to 6 as shown in the diagram (CPP14824). 3) Tighten the bolts each in two actions by applying torque as specified in the order of item 2) above. 3 Mounting bolt: Unit: Nm{kgm}

procedure 1st time

target 88.2 {9.0}

range 58.7 – 117.7 {6.0 – 12.0}

2nd time 191.3 {19.5} 186.4 – 196.2 {19.0 – 20.0}

10

PC138US, USLC-8


SEN02710-00

[*3] q

Measuring radial runout of flywheel 1) Install dial gauge [2] to the flywheel housing. 2) Set the probe of the dial gauge at right angles to the spigot joint (a) or the outer periphery of the flywheel. 3) Rotate the crank shaft one full turn and measure the difference of the maximum values of runout of the needle. a Check that the position of needle remains in its original position after the flywheel is rotated one full turn. Radial runout: Max. 0.15 mm

q

Measuring face runout of flywheel 1) As with the measurement of radial runout, set the probe of the dial gauge at right angles to end face (b) close to the outer periphery of the flywheel. a For measurement, move the crank shaft forward or backward to prevent error caused by an end play. 2) Rotate the crank shaft one full turn and measure the difference of the maximum values of runout of the needle. Face runout: Max. 0.25 mm

PC138US, USLC-8

11

SEN02710-00

Removal and installation of cylinder head assembly


4.

Disconnect aftercooler hose (11) from the air intake connector (12) side.

5.

Remove 4 mounting bolts (13) and remove the air conditioner compressor mounting bracket.

6.

Remove bolts (14) and (15) and remove fuel filter (18). [*1] a Bolt (14) tightens the clamp of wiring to the air conditioner compressor together. a Bolt (15) tightens bracket (19) together.

7.

Remove bolts (16) to (18) and remove bracket (19). [*2] a Bolt (18) tightens the clamp of wiring to the injector together.

1

Removal k


1.

Remove the counterweight assembly, referring to "Removal of counterweight assembly."

2.

Removal of engine controller frame assembly 1) Remove engine controller mounting bolts (1) from the upper frame (2). 2) Remove 4 lower frame mounting bolts (3). 3) Disconnect engine controller frame assembly (4).

3.

12

Removal of air conditioner compressor 1) Disconnect wiring connector AC02 (5). 2) Disconnect air conditioner hose clamps (6) at two locations. a Do not disconnect the air conditioner hoses. 3) Remove air conditioner compressor drive belt protective cover (7). 4) Loosen air conditioner compressor mounting bolts (8) and remove drive belt (9). 5) Remove air conditioner compressor mounting bolts (8) and remove air conditioner compressor (10). (Keep the compressor out of the way.)

PC138US, USLC-8


8.

9.

Disconnection of wiring 1) Disconnect heater wiring E01 (20). 2) Disconnect injector wiring CN1 to CN4 (21). 3) Disconnect boost pressure sensor connector PTIM (22).

Removal of air intake connector and electrical intake air heater assembly 1) Remove 4 bolts (23) to (26) and remove air intake connector (27). [*3] a Because oil level gauge pipe bracket (28) is tightened together with bolt (24), tie the disconnected oil level gauge pipe with a string to keep it out of the way. a Bolt (25) tightens grounding (29) together. 2) Remove electrical intake air heater assembly (30). [*4]

SEN02710-00

6)

Remove 8 air intake manifold mounting bolts (37) and remove air intake manifold (38). [*7]

11. Removal of injector assembly 1) Remove 4 injector mounting bolts (39) and remove 4 holders (40). [*8] 2) Remove injector assembly (41). [*9]

12. Removal of muffler 1) Remove upper covers (42) and (43).

10. Removal of high-pressure pipe and air intake manifold 1) Remove coolant temperature sensor wiring clamp (31). 2) Remove spill hose mounting pin (32) and disconnect spill hose (33). 3) Remove high-pressure pipe clamps (34) at 2 locations. 4) Remove 8 boots (35) both from the cylinder head side and common rail side. [*5] 5) Loosen the sleeve nuts and remove 4 high-pressure pipes (36). [*6] PC138US, USLC-8

13

SEN02710-00

2)

Remove 2 clamp mounting bolts (44) and remove clamp (45). [*10]

3) 4)

Remove divider board (46). Remove rubber covers (47) and (48).

5)

Remove muffler drain tube (49). a Remove the lower clamp in advance. Remove 4 bracket mounting bolts (50). Lift muffler bracket assembly (51) and remove it. 4 Muffler bracket assembly: 22 kg

6) 7)

14


13. Removal of turbocharger and exhaust manifold assembly 1) Remove cover (52).

2) 3)

Disconnect blowby tube (53). Remove 3 mounting nuts (54) and remove cylinder head cover (55). [*11]

PC138US, USLC-8


4) 5)

6)

7) 8)

Remove mounting bolts (56) and disconnect turbocharger lubricant inlet port tube (57). [*12] Remove 2 mounting bolts (58) and disconnect turbocharger lubricant return tube (59). Remove 3 mounting bolts (60) and disconnect connector (61) between the turbocharger and aftercooler hose from the turbocharger. Remove 8 exhaust manifold mounting bolts (62). [*13] Lift turbocharger and exhaust manifold assembly (63) and remove them. 4 Turbocharger and exhaust manifold assembly: 15 kg

SEN02710-00

14. Removal of water pump 1) Disconnect coolant temperature sensor connector TWTR (64). 2) Disconnect radiator upper hose (65), heater hoses (66) and (67) and radiator lower hose (68). 3) Remove fan belt (69). 4) Remove 6 fan pulley mounting bolts (70). 5) Remove fan pulley assembly (71).

6) 7)

PC138US, USLC-8

Remove 3 water pump mounting bolts (72). [*14] Remove water pump (73).

15

SEN02710-00

15. Removal of rocker arm assembly 1) Loosing lock nut (74) and fully loosen adjustment screw (75). [*15] a Loosen the air intake and exhaust adjustment screws on all cylinders. 2) Remove 8 mounting bolts (76) and remove rocker arm assembly (77). [*16]


Installation q


[*1] [*2] a When installing fuel filter mounting bolts (14), tighten wiring clamp (81) for the air conditioner compressor together. a When installing bracket mounting bolts (18), tighten wiring clamp (21) for the injector together.

16. Removal of cylinder head assembly 1) Pull out 8 push rods (78). 2) Remove 17 cylinder head mounting bolts (79). [*17] [*3] [*4] When installing air intake connector (27) and electrical intake air heater (30), pay attention to the following matters: a When installing the air intake connector and electrical intake air heater, replace the gasket with new one. a When installing air intake connector mounting bolts (24), tighten it together with oil level gauge pipe bracket (28). a When installing air intake connector mounting bolts (25), tighten it together with oil level gauge pipe bracket (29). a If grounding (29) is removed from electrical intake air heater (30) by removing grounding mounting bolt (81), install the grounding mounting bolt (82) with the following torque: 3 Grounding mounting bolt (82): 4.9 – 5.9 Nm {0.5 – 0.6 kgm}

q

3)

16

Lift cylinder head assembly (80) and remove it. 4 Cylinder head assembly: 30 kg

PC138US, USLC-8


[*5] [*6] q Precautions when installing high-pressure piping k Never bend a high-pressure pipe for the convenience sake. k The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. k Be sure to install the boot to the sleeve nut after installing the high-pressure hose. a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. a Before Installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. q No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2mm inside the tip). q No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).

3 3

Sleeve nut on the supply pump side: 18 – 23 Nm {1.9 – 2.3 kgm} Sleeve nut on the common rail side: 25.5 – 29.4 Nm { 2.6 – 3.0 kgm}

SEN02710-00

[*7] a Apply gasket sealant to the air intake manifold before installation. Apply gasket sealant for about 1 mm of wire diameter. 2 Mounting face: Gasket sealant (LG – 7) [*8] [*9] q Injector mounting procedure: 1) Install seal (82) to injector (41). 2) Install copper gasket (84) to injector (41). 3) Insert injector (41) to the cylinder head. 4) Install holder (40) to injector (41). 5) Tighten holder (40) with mounting bolt (39). a Before tightening the bolt, check that holder (40) is securely installed to groove(a)of injector (41). 3 Holder mounting bolt: 27 – 30 Nm {2.8 – 3.1 kgm}

[*10] q Install the clamp mounting bolts between the turbocharger and muffler according to the following procedure: 3 Clamp mounting bolt: 1st time: 39.2 – 49 Nm {4 – 5 kgm} 2nd time: 68.6 - 122.5 Nm {7 – 12.5 kgm} [*11]

3

Cylinder head cover mounting nut: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}

[*12]

3

Lubricant inlet port tube mounting bolt: 34.3 – 53.9 Nm {3.5 – 5.5 kgm}

[*13] q Exhaust manifold mounting procedure: 1) Attach the guide bolt to the cylinder head and set the gasket. a Install the manifold with the gasket face stamped 6205 on the side of the manifold.

PC138US, USLC-8

17

SEN02710-00

2)


Install the exhaust manifold and tighten the mounting bolt. 3 Exhaust manifold mounting bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*14] a One (1) of the water pump mounting bolts is tightened together with the alternator mounting bracket. [*15] [*16] a Before installing rocker arm assembly (77), loosen lock nut (74) and fully loosen adjustment screw (75). a When installing rocker arm assembly (77), tighten the mounting bolts alternately by checking that the adjustment screw ball fits to the push rod socket. 3 Rocker arm mounting bolt (76): 19.6– 29.4 Nm {2.0– 3.0 kgm} q For adjustment of the valve clearance, refer to "Adjusting valve clearance" in Testing and adjusting.

(In the diagram, (F) indicates the front of engine, (R) the rear and (b) a plastic region turning angle tightening bolt.)

(In the diagram, (p1) indicates a cylinder head marking and (p2) the bolt head.)

[*17] Tightening procedure for the cylinder head mounting bolt Apply molybdenum disulphide lubricant (LM-P) to the threads of cylinder head mounting bolt, and tighten the bolts in the order shown in the diagram. 3 Cylinder head mounting bolt: 1st time: 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm} 2nd time: 107.8 ± 4.9 Nm {11.0 ± 0.5 kgm} 3rd time: Mark the bolt head and cylinder head, and turn the cylinder head by 90° (+30/0°) to tighten. a After tightening, stamp a punch mark (n), indicating the number of tightening, on the bolt head. a If a bolt has 5 punch marks, do not reuse. Replace it with a new one.

q

18

PC138US, USLC-8


Removal and installation of radiator assembly

SEN02710-00

6.

Open covers (9) and (10).

7.

Disconnect radiator overflow hose (11).

8.

Disconnect radiator upper hose (12). [*3]

9.

Remove 2 plate mounting bolts (13) and remove plate (14).

1

Removal k

k

1.

Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative (–) terminal of the battery beforehand. Remove lower cover (1).

10. Remove 2 radiator mounting bolts (15).

2.

Open the coolant drain valve (2) to drain. [*1] 6 Coolant: 12.4 l

3.

Remove 2 plate (3) mounting bolts (4) and remove the cover.

4.

Disconnect radiator lower hose (5). [*2]

11. Lift radiator assembly (16) and remove it.[*4] 4 Radiator assembly: 10 kg

5.

Remove 4 cover mounting bolts (6) and remove covers (7) and (8).

PC138US, USLC-8

19

SEN02710-00


Installation Carry out the installation in the reverse order of removal.

q

[*1]

5

Coolant: 12.4 l

[*2] [*3] 3 Radiator hose clamp bolt: (Both upper and lower hoses) 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*4] a When installing the radiator assembly, align the convex portion (a) on the bottom of the radiator assembly with the concave portion (b) on the machine.

20

PC138US, USLC-8


Removal and installation of aftercooler assembly

SEN02710-00

1.

Loosen 2 clamps (6) and disconnect the air aftercooler upper hose (7).

5.

Remove 2 mounting bolts (8) and remove plate (9).

6.

Remove 2 air aftercooler mounting bolts (10).

7.

Pull out air aftercooler (11). [*1] a Take care not to damage sponge around the aftercooler.

1

Removal k

4.

Disconnect the negative (–) terminal of the battery beforehand. Remove lower cover (1).

2.

Remove 2 mounting bolts (2) and disconnect the air aftercooler lower hose (3).

3.

Remove 2 mounting bolts (4) and remove plate (5).

PC138US, USLC-8

21

SEN02710-00


Installation q


[*1] a Take care not to damage sponge on the sides when installing the aftercooler. a When installing the radiator assembly, align the convex portion (a) on the bottom of the air aftercooler with the concave portion (b) on the machine.

22

PC138US, USLC-8


SEN02710-00 a

Removal and installation of work equipment oil cooler assembly 1

When using tool D to stop oil, remove the hydraulic oil tank strainer in advance.

D

Part name

796-460-1210

Oil stopper

q 1

795-799-1131

Adapter

q 1

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Removal k

k k

Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative (–) terminal of the battery beforehand. Loosen the hydraulic oil tank cap gradually to release the pressure in the tank.

a

Fasten tags to respective piping for identification to prevent any mistakes when re-installing.

1.

Remove the radiator assembly referring to "Removal and Installation of Radiator Assembly."

2.

Remove the air aftercooler assembly referring to "Removal and Installation of Air Aftercooler Assembly."

3.

Loosen hydraulic oil drain plug (1) to drain the work equipment oil. [*1] 6 Hydraulic tank: 69 l (Specified capacity: 120 l)

PC138US, USLC-8

4.

Remove lower cover (2).

5.

Remove 2 oil cooler lower mounting bolts (3) and disconnect lower hose (4).

23

SEN02710-00

6.

Remove air cleaner (5).

7.

Remove connector (6).

8.

Remove air cleaner hose clamp (7).

9.

Remove 2 hose mounting bolts (8) and disconnect oil cooler upper hose (9).


11. Pull out oil cooler assembly (11). [*2]

10. Remove 2 oil cooler mounting bolts (10).

24

PC138US, USLC-8


SEN02710-00


q

[*1]

3

5

Hydraulic oil drain plug (13): 58.8 – 78.4 Nm {6 – 8 kgm} Target: 68.6 Nm {7 kgm} Hydraulic tank: 69 l (Specified capacity: 120 l)

PC138US, USLC-8

25

SEN02710-00


Removal and installation of engine and work equipment pump assembly 1

3.

Open fuel drain valve (3) to drain fuel.

4.

Loosen hydraulic oil drain plug (4) to drain the work equipment oil. [*2] 6 Hydraulic tank: 69 l (Quantity of oil in hydraulic tank )

D

Part name

796-460-1210

Oil stopper

q 1

795-799-1131

Adapter

q 1

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Removal k

k k

1.

Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative (–) terminal of the battery beforehand. Loosen the hydraulic oil tank cap gradually to release the pressure in the tank. Remove lower cover (1).

a

2.

26


Drain coolant from the coolant drain port (2). [*1] 6 Coolant: 12.4 l

PC138US, USLC-8


5.

Remove covers (5), (6) and (7).

6.

Open covers (8) and (9).

7.

Remove the counterweight, referring to "Removal and Installation of Counterweight."

8.

Removal of frame cover assembly 1) Temporarily lift the frame cover assembly. 2) Remove lock pin (10). 3) Disconnect air conditioner hose mounting clamp (12).

SEN02710-00

9.

4) 5)

6) 7)

Disconnect wiring (13) to (16) from the frame. Disconnect wiring (17) to the engine controller. (Disconnect connector CE02 from engine controller (p).) a Keep wiring (17) out of the way. Disconnect resistor connector K02 (18). Remove bracket mounting bolt (19) and disconnect the wiring mounting bracket.

PC138US, USLC-8

8)

Remove frame mounting bolts (20), (21) and (22).

9)

Lift frame cover assembly (23) and remove it.

Removal of the engine upper hoses 1) Remove air conditioner hose mounting clamp (24). 2) Remove wiring clamp (25). 3) Remove air hose (26) between the turbocharger and air cleaner. [*3] 4) Remove after cooler hose (27). [*4] 5) Disconnect radiator hose (28). [*5]

10. Removal of air conditioner compressor 1) Disconnect wiring connector AC02 (29). 2) Remove drive belt protective cover (30). 3) Loosen drive belt adjusting and mounting bolts (31), and remove the drive belt (32).

27

SEN02710-00

4)

Remove adjustment and mounting bolts (31) and remove air conditioner compressor (33). a Do not disconnect the air conditioner hoses.


6) 7) 8) 9)

11. Disconnecting hoses and wiring from the L.H. side of the engine 1) Remove heater hose clamp (34) and disconnect heater hose (35). 2) Remove radiator lower hose clamp (35) and disconnect radiator lower hose (37). [*6]

3) 4) 5)

28

Disconnect electrical intake air heater connector E01 (38). Disconnect clamps (40) at 2 locations on wiring (39) and disconnect wiring (39) from the engine. Disconnect fuel hose (41) from the fuel tank.

Disconnect starting motor wiring terminals (42) and (42a). [*7] Remove wiring bracket mounting bolt (43) and disconnect bracket (44). Disconnect wiring (45) from the engine block and keep it out of the way. Disconnect grounding wire (46).

12. Disconnecting hoses and wiring from the R.H. side of the engine 1) Disconnect alternator wiring (47). 2) Remove 3 bolts (48) and remove hose mounting connector (49) between the after cooler and turbocharger.

3)

Disconnect engine oil temperature sensor wiring connector (50).

PC138US, USLC-8


13. Remove 4 bracket mounting bolts (51) and disconnect engine oil filter and bracket assembly (52). a Tie the assembly with a string to keep it out of the way.

SEN02710-00

3)

Disconnect 6 hoses (56) to (61).

4)

Remove 4 bolts (62) and disconnect suction tube (63).

14. Disconnecting work equipment pump wiring and hoses 1) Remove rubber cover (53).

15. Remove 4 engine mounting bolts (64). [*8]

2)

Disconnect oil temperature sensor wiring connector P22 (53) and EPC solenoid wiring connector A11 (54).

PC138US, USLC-8

29

SEN02710-00

16. Lift engine and work equipment pump assembly (65) and remove it. 4 Engine and work equipment pump assembly: 470 kg



q

[*1]

5

Coolant: 12.4 l

[*2]

3

5

Hydraulic oil drain plug (13): 58.8 – 78.4 Nm {6 – 8 kgm} Target: 68.6 Nm {7 kgm} Hydraulic tank: 69 l (Specified capacity: 120 l)

[*3]

3

Hose clamps between the turbocharger and air cleaner: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*4]

3

Aftercooler hose clamp: 10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}

[*5][*6] 3 Radiator hose clamp bolt: (Both upper and lower hoses) 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*7]

3 3 3

Starting motor wiring terminal (42): 17.7 – 24.5 Nm {1.8 – 2.5 kgm} Starting motor wiring terminal (42a): 2.6 – 4.6 Nm {0.27 – 0.47 kgm} Connector mounting bolt: 10 ± 2 Nm {1.02 ± 0.2 kgm}

[*8]

3

30

Engine mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

PC138US, USLC-8


SEN02710-00

Removal and installation of fuel tank assembly 1

7.

Removal of exterior parts 1) Remove hand rail (7). 2) Remove covers (8) to (11).

8.

Removal of fuel tank mounting bracket and mounting bolts 1) Remove fuel tank rear mounting brackets (12).

Removal k

k

1.

Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative (–) terminal of the battery beforehand. Open the inspection cover on the rear R.H. side, and open fuel drain valve (1) to drain fuel. Fuel (When fuel tank is full): 195 l

2.

Disconnect fuel level sensor connector P21 (2).

3.

Disconnect fuel level sensor wiring (3).

4.

Disconnect hose (4) from the radiator.

5.

Disconnect water assembly (5).

6.

Disconnect reservoir tank (6).

separator

and

bracket

2) 3)

PC138US, USLC-8

Remove wiring and hose mounting brackets (13). Remove fuel tank front mounting brackets (14).

31

SEN02710-00

4) 5)

Disconnect hoses (15) and (16). Remove 4 fuel tank front mounting bolts (17).


Installation q


[*1]

2 3

9.

32

Fuel tank mounting bolt: liquid adhesive (LT–2) Fuel tank mounting bolt: 235 – 285 Nm {23.5 – 29.5 kgm}

Lift fuel tank assembly (18) and remove it. [*1] 4 Fuel tank assembly: 95 kg

PC138US, USLC-8


PC138US, USLC-8

SEN02710-00

33

SEN02710-00




34

PC138US, USLC-8

SEN02711-00


Machine model

Serial number



50 Disassembly and assembly Power train Removal and installation of travel motor and final drive assembly ................................................................. 2 Removal and installation of swing motor and swing machinery assembly ..................................................... 4 Disassembly and assembly of swing machinery assembly ............................................................................ 6 Removal and installation of swing circle assembly ....................................................................................... 12

PC138US, USLC-8

1

SEN02711-00


Removal and installation of travel motor and final drive assembly 1 Removal 1.

k

Remove track shoe assembly. For details, see "Removal of track shoe assembly". Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

2.

Swing work equipment 90°, then push up chasis with work equipment and set block [1] between track frame and track shoe.

3.

Lift off sprocket (1). [*1] 3 Sprocket : 40 kg

4.

Remove travel motor cover.

5.

Disconnect 4 travel motor hoses (2).

6.

Lift off travel motor and final drive assembly. [*2] a Be extremely careful not to damage the nipple tool surface of the hose mount. 4 Travel motor and final drive assembly: 150 kg

2

PC138US, USLC-8


SEN02711-00

Installation q

Carry out installation in the reverse order to removal.

[*1]

2 3

Thread of travel motor mounting bolt : Thread tightener (LT-2) 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".

q

Refilling with oil (hydraulic tank) a 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.

PC138US, USLC-8

3

SEN02711-00

Removal and installation of swing motor and swing machinery assembly 1


4.

Remove mounting bolt (9).

5.

Remove swing motor and swing machinery assembly (10) from the machine using forcing screw [1].

6.

Lift and remove swing motor and swing machinery assembly (10). a Lift the assembly carefully to prevent interference with the surrounding hoses. 4 Swing motor and swing machinery assembly: 95 kg

Removal k

k

k

a

Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative (–) terminal of the battery beforehand. Fasten tags to respective piping for identification to prevent any mistakes when reinstalling.

1.

Disconnect oil level pipe clamp (1).

2.

Remove covers (2) and (3).

3.

Disconnect hoses (4) to (8).

4

PC138US, USLC-8


SEN02711-00

Installation q


q

Refilling oil (Hydraulic tank) a Fill oil up to the specified level, start the engine to circulate oil in the pipe and check the oil level again.

q

Bleeding air a Bleed air from the piping, referring to "Bleeding air from each part" in Testing and adjusting.

[*1]

3

Wing machinery mounting bolt: 277 ± 31.9 Nm {28.25 ± 3.25 kgm}

PC138US, USLC-8

5

SEN02711-00


Disassembly and assembly of swing machinery assembly

1

790-201-2750

Spacer

t 1

790-101-5201

Push puller (Kit)

q 1

790-101-2510

• Block

1

790-101-2550

• Leg

1

790-101-2560

• Nut

2

790-101-2570

• Plate

4

790-101-3101

Bearing puller

790-101-4200

Puller q 1 (294 kN {30 ton})

790-101-1102

Hydraulic oil pump

790-101-5401

Push tool (Kit) (C) q 1

790-101-5461

• Plate

1

790-101-5441

• Plate

1

790-101-5421

• Grip

1

01010-51240

• Bolt

1

4

790-201-2850

Spacer

t 1

5

790-201-2750

Spacer

t 1

1

2

F

3

6

4) 5)

Disconnect swing motor assembly (4) using forcing screw [1]. Lift and remove swing motor assembly (4).

q 1

q 1

796T-426-1140 Push tool

t 1

790-201-2680

q 1

Plate

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

3. Q

Carrier No. 1 and Sun gear No. 2 assembly 1) Remove sun gear No. 1 (5). 2) Remove carrier No. 1 and sun gear No. 2 assembly (6).

Disassembly 1.

Oil drain Remove the drain plug and drain oil from the swing machinery. 6 Swing machinery case: 2.5 l

2.

Swing motor assembly 1) Remove oil level pipe (1). 2) Remove hose (2). 3) Remove 15 swing motor mounting bolts (3).

6

PC138US, USLC-8


3)

SEN02711-00

3)

ub-disassembly of carrier No. 1 and sun gear No. 2 assembly 1] Remove snap ring (7) and remove thrust washer (8), gear (9), bearing (10) and thrust washer (11).

2]

3]

Drive pin (12) in and punch out shaft (13). a Remove the shaft, then remove pin (12). Remove snap ring (14) and remove sun gear No. 2 (15) from carrier (16).

4.

Ring gear Remove ring gear (17).

5.

Carrier No. 2 assembly 1) Remove spacer (18). 2) Remove carrier No. 2 assembly (19).

PC138US, USLC-8

6.

Sub-disassembly of carrier No. 2 assembly. 1] Press pin (20) in and punch out shaft (21) from carrier (22). a Remove the shaft, then remove pin (20). 2] Remove thrust washer (23), gear (24), bearing (25) and thrust washer (26).

Retainer and collar 1) Remove retainer (27). 2) Set the shaft and case assembly to the press, and push 2-piece collar (28) using a push tool to press bearing (29). 3) Remove 2-piece collar (28).

7

SEN02711-00

7.

Shaft assembly 1) Set the shaft and case assembly (30) to block [2], and remove shaft assembly (31) with the press using push tool [3]. 2) Remove bearing (29).

3)

8.

8


2)

Use puller [4] to remove bearing outer races (37) and (38) from case (36).

Use tool F2 to remove bearing (32) and collar (33) from shaft (34).

Oil seal and bearing outer race 1) Remove oil seal (35) from case (36).

PC138US, USLC-8


SEN02711-00

Assembly 1.

Bearing outer race Use push tool F3 to press outer races (37) and (38) to case (36).

2.

Shaft assembly 1) Install O-ring to inside collar (33) and install to shaft (34). 2) Use push tool F4 to press bearing (32) with the press.

3) 4)

Set case (39) to shaft assembly (31). Use push tool F5 to press bearing (29) with the press to the position where the 2piece collar can be entered. a Press-fit force: 11,760 N {1,200kg} a Press the bearing gradually by rotating the case.

PC138US, USLC-8

5) 6)

Install 2-piece collar (28). Screw in bolt (12 mm, P=1.75) to the case. Using push-pull scale [5] to measure the tangential force in the direction of rotation. a Tangential force: Max. 176.4 N {18kg} a Tangential force refers to a maximum value at the start of rotation.

3.

Oil seal Using tool F6 to press oil seal (35). a Replace the oil seal with a new one. 2 Circumference of oil seal: LG-6 a Be careful not to allow LG-6 to attach to the lip and shaft. 2 Oil seal lip portion: Grease (G2-LI)

4.

Retainer Install retainer (27).

9

SEN02711-00

5.

Carrier No. 2 assembly 1) Sub-disassembly of carrier No. 2 assembly 1] Assemble bearing (25) to gear (24). 2] Install thrust washer (23) and (26) and set gear assembly to carrier (22).

3]

4]

2) 3)

10


6.

Ring gear Install O-ring (40) to the shaft and case assembly, and install ring gear (17).

7.

Carrier No. 1 and sun gear No. 2 assembly 1) Sub-disassembly of carrier No. 1 and sun gear No. 2 assembly 1] Install carrier No. 1 (16) to sun gear No. 2 (15) and Install snap ring (14). 2] Align the shaft to the carrier pin hole position, and install shaft (21) by lightly hammering with a plastic hammer, etc. 3] Insert pin (12). a Insert the pin, then caulk the pin of the carrier. a Check that difference (a) between the shaft and carrier is 0.2 mm or less.

Align the shaft to the carrier pin hole position, and install shaft (21) by lightly hammering with a plastic hammer, etc. a Install the shaft by turning the planetary gear. Be careful not to damage the thrust washer. Insert pin (20). a Insert the pin, then caulk the pin of the carrier.

Install carrier No. 2 assembly (19) to the shaft and case assembly. Install spacer (18).

PC138US, USLC-8


4]

2) 3)

Install thrust washer (11), bearing (10), gear (9) and thrust washer (8), and install snap ring (7). a Use new snap ring. a ?hen installing the snap ring, do not allow the mating space to expand wider than 11 mm to prevent the snap ring from deforming. a After installation, check that the snap ring is firmly in place.

Install carrier No. 1 and sun gear No.2 assembly (6) to the shaft case assembly. Install sun gear No. 1 (5).

PC138US, USLC-8

SEN02711-00

8.

Swing motor assembly 1) Install swing motor assembly (4). 2) Install 15 swing motor mounting bolts (3). 3 Swing motor mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm} 3) Install hose (2). 4) Install oil level pipe (1).

9.

Refilling with oil Tighten the drain plug, and refill engine oil E030 from the oil filler port. 5

Swing machinery case: 2.5 l

11

SEN02711-00

Removal and installation of swing circle assembly


Installation

1

q

Removal k

1.

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. Remove the revolving frame assembly by referring to "Removal of revolving frame assembly".

2.

Temporarily lift swing circle assembly (1) to remove the 38 mounting bolts. [*1]

3.

Remove swing circle assembly (1). [*2] 4 Swing circle assembly : 155 kg

12

Installation is performed in the opposite way to removal.

[*1]

2 3

Swing circle mounting bolt: Liquefied adhesive (LT-2) 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 grease (G2-LI)

PC138US, USLC-8


PC138US, USLC-8

SEN02711-00

13

SEN02711-00




14

PC138US, USLC-8

SEN02712-00


Machine model

Serial number



50 Disassembly and assembly Undercarriage and frame Disassembly and assembly of track roller....................................................................................................... 2 Disassembly and assembly of idler assembly ................................................................................................ 5 Disassembly and assembly of recoil spring .................................................................................................... 8 Removal and installation of of track shoe assembly ......................................................................................11 Removal and installation of sprocket ............................................................................................................ 13 Removal and installation of revolving frame assembly ................................................................................. 14 Removal and installation of counterweight assembly (Machine without add-on weight) .............................. 16 Removal and installation of counterweight assembly (Machine with add-on weight) ................................... 18

PC138US, USLC-8

1

SEN02712-00


Disassembly and assembly of track roller

3.

Pull out roller (4) from shaft (5). a It is filled with 75 – 85 cc of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.

4.

Remove floating seal (6) (on opposite side) from roller (4) and shaft (5).

5.

Remove collar (8) from shaft (5).

6.

Remove bushings (9) and (10) from roller (4).

1

M

Part name

1

790-434-1650

Installer

t 1

2

791-601-1000

Oil pump

q 1

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Disassembly 1.

Remove pin (1), then remove collar (2).

8

5 6 10 4

9 3 1 2 11 CLP00790

2.

2

Remove floating seal (3) from collar (2) and roller (4).

PC138US, USLC-8


Assembly 1.

Using push tool [1], press fit bushings (9) and (10) to roller (4).

2.

Assemble collar (8) to shaft (5).

3.

Using tool M1, install floating seal (6) to shaft (5). a When assembling the floating seal, clean the contact surface of O-ring (6c) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal.

SEN02712-00

6.

Turn over roller (4) and shaft (5) assembly.

7.

Using tool M1, install floating seal (3) to collar (2). a For details of the precautions when installing floating seals (3a) and (3c), see the precautions marked a for Step 3.

8.

Assemble collar (2) to shaft (5), and install pin (1).

2

4.

5.

Using tool M1, install floating seals (6) and (3) to roller (4). a For details of the precautions when installing floating seals (6b) and (6d), and (3b) and (3d), see the precautions marked a for Step 3.

5

CLP00867

Assemble shaft (5) to roller (4). 9.

PC138US, USLC-8

1

Using tool M2, apply standard pressure to roller oil filler port and check air leakage. a Standard pressure: 0.1 MPa {1 kg/cm²} a Method of checking: The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.

3

SEN02712-00


10. Using tool M2, fill track roller assembly with oil, then tighten plug (11). 5

4

Track roller oil: 75 – 85 cc (EO30-CD)

PC138US, USLC-8


SEN02712-00

Disassembly and assembly of idler assembly

1

L 1

791-675-1510

Part name

Installer

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

t 1

Disassembly 1.

Remove dowel pin (1), then remove support (2).

5.

Remove dowel pin (8), then remove support (7) from shaft (5).

2.

Remove floating seal (3) from support (2) and idler (4).

6.

Remove bushings (9) and (10) from idler (4).

3.

Pull out idler (4) from shaft (5) and support assembly (7). a It is filled with approx. 90 cc of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.

4.

Remove floating seal (6) (on opposite side) from idler (4) and shaft (5) and support assembly (7).

PC138US, USLC-8

5

SEN02712-00

Assembly 1.

Press fit bushings (9) and (10) to idler (4).

2.

Fit O-ring and install support (7) to shaft (5) with dowel pin (8).

3.


4.

Assemble shaft (5) and support assembly (7) to idler (4).

5.

Add oil between shaft (5) and idler (4). Oil: 90 – 105 cc (EO30)

Using tool L1, install floating seal (6) to idler (4) and shaft (5) and support assembly (7). a Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. a Remove all grease and oil from the contact surface of the O-ring and the floating seal.

6.

6

5

Using tool L1, install floating seal (3) to idler (4) and support (2). a Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. a Remove all grease and oil from the contact surface of the O-ring and the floating seal.

PC138US, USLC-8


7.

SEN02712-00

Install O-ring, then install support (2) with dowel pin (1).

PC138US, USLC-8

7

SEN02712-00


Disassembly and assembly of recoil spring

1

L 2

Part name

791-600-2001 or 791-685-8006

Compressor (A)

1

791-635-3160

Extension

t 1

790-201-2770

• Spacer

t 1

790-101-1600


t 1

790-101-1102

Pump

t 1

t Compressor (B)

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

1

Disassembly

1.

Remove lock plate (1), then remove seat (2) and valve (3). a Do not remove grease fitting (17) from the valve (3).

2.

Remove yoke piston assembly (5) from recoil spring assembly (4).

3.

Disassembly of recoil spring assembly (4) 1) Set recoil spring assembly (4) to tool L2. k The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. a Installed load of spring: 84,300 N {8,600 kg}

8

PC138US, USLC-8


2)

3) 4) 4.

SEN02712-00

Apply hydraulic pressure slowly to compress spring, then remove nut (6). a Compress the spring to a point where the nut becomes loose. a Release the hydraulic pressure slowly to remove the spring tension. Remove pilot (8), and spring (7). Remove snap ring (10), dust seal (11) and bush (12) from cylinder (9).

Disassembly of yoke piston (5) assembly 1) Remove snap ring (14), then remove Upacking (15). 2) Remove wear ring (16) from yoke piston (13).

PC138US, USLC-8

9

SEN02712-00


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).

2.

Assembly of recoil spring assembly 1) Using tool [1], press fit bush (12) to cylinder (9). 2) Using tool (L3), press fit dust seal (11) to cylinder (9).

5)

3) 4)

10

Assemble cylinder (9) and pilot (8) to spring (7), and set to tool L2. Apply hydraulic pressure slowly to compress spring, and tighten nut (6) so that installed length of spring is dimension (a). a Installed length (a) of spring: 390 mm

Remove recoil spring assembly (4) from tool L2.

3.

Assemble yoke piston assembly (5) to recoil spring assembly (4). 2 Yoke piston sliding portion wear ring : Grease (G2-LI)

4.

Fit valve (3) and seat (2), and secure with lock plate (1). a Install the valve so that the direction of the fitting (17) is to the outside.

5.

Fill inside of cylinder with a approximately 120 cc of grease. 2 Inside cylinder: Grease (G2-LI)

PC138US, USLC-8


SEN02712-00

Removal and installation of of track shoe assembly

R

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

791-620-3530

Push

t 1

791-620-3260

Push

t 1

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


t 1

790-101-1102

Pump

t 1

New/Remodel

Q'ty

Part name

Necessity

Part No.

Move machine forward so that position of master pin is at front of idler, and set block [1] in position.

3.

Using tool R, pull out master pin. [*2]

4.

Remove tool R, pull out temporary pin, and remove dust seal, then drive machine in reverse to lay out track (2). [*3]

1

Special tools Symbol

2.

Removal 1.

Lower work equipment to ground, then loosen lubricator (1), and relieve track tension. [*1] k The 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.

PC138US, USLC-8

11

SEN02712-00


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). a

12

If the rubber of the road liner (rubber pad type) becomes worn or broken and the head of the mounting bolt becomes damaged, replace the shoe with a new part immediately. If the head of the mounting bolt becomes fla ttened, it will be impossible to remove it.

PC138US, USLC-8


Removal and installation of sprocket

SEN02712-00

Installation

1

Removal 1.

Expand the track shoe assembly. For details, see Expansion of track shoe assembly.

2.

Swing the work equipment by 90° and push up the machine with it, and then set blocks [1] between the track frame and track shoe.

3.

Remove the 15 mounting bolts and lift off sprocket (1). [*1] 4 Sprocket: 35 kg

PC138US, USLC-8

q


[*1]

2 3

Threads of sprocket mounting bolt: Adhesive (LT-2) Sprocket mounting bolt: 323.6 – 362.8 Nm {33 – 37 kgm}

13

SEN02712-00

Removal and installation of revolving frame assembly


1.

Disconnect drain hose (8) and hoses (9) and (10) between control valve and left travel motor from center swivel joint.

8.

Disconnect hoses (11) and (12) between control valve and right travel motor.

9.

Disconnect hoses (13) between solenoid valve (Boost) and both travel motors.

1

Removal k

7.

Disconnect the negative (–) terminal of the battery. Remove the work equipment assembly by referring to "Removal of work equipment assembly".

2.

Disconnect boom cylinder hoses (1) (right) and (2) (left). a Be sure to apply the blind plug to the disconnected hose.

3.


4.

Temporarily lift the boom cylinder to remove pins (5) on the bottom. a Check the number and position of the shims mounted. [*1]

10. Disconnect plate (14) from revolving frame.

11. Remove mounting bolts (15), leaving one each at front and rear. [*2]

5.

Lift boom cylinder assembly (6) to remove it. 4 Boom cylinder assembly: 120 kg

6.

Remove operator cab assembly (7) by referring to "Removal of operator cab assembly".

14

PC138US, USLC-8


12. Lift revolving frame assembly (16) to loosen remaining bolts (15). a Carefully remove the remaining bolts by balancing them using the crane. a Carefully lift and remove them to prevent them from coming in contact with the center swivel joint or other parts. 4 Revolving frame assembly: 6,100 kg

SEN02712-00

Installation q


[*1]

2 2

k

a

Surface inside bushing during pin assembly: Hyper white grease (G2-T) Greasing after pin assembly: Hyper white grease (G2-T)

Never put your finger in the pin hole when adjusting the position. Adjust the clearance between the mount on the boom cylinder bottom and the frame using the shims so that it becomes 1mm or less.

[*2]

2 2 3

PC138US, USLC-8

Swing circle contacting face: Liquefied gasket (LG-1) Revolving frame mounting bolt screw: Liquefied adhesive (LT-2) Revolving frame mounting bolt: 277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}

q

Supplying oil (hydraulic oil tank) Supply oil from the oil filler port to the specified level, start the engine to circulate oil in the piping and recheck the oil level.

q

Bleeding air Bleed the air. For details , see Testing and adjusting, "Bleeding air from each part".

15

SEN02712-00

Removal and installation of counterweight assembly (Machine without add-on weight) 1


5.

Demporarily lift the counterweight, and remove 3 mounting bolts (9). [*1]

6.

Lift and remove counterweight assembly (10). a Shift the counterweight horizontally to backward before lifting so that it will not interfere with the machine main body. 4 Counterweight assembly : 3,300 kg (standard specification) : 2,900 kg (Blade specification)

Removal k

k

Stop the machine on a level ground, stop the engine, and lower the work equipment to the ground. Disconnect the cable from the negative (-) terminal of the battery.

1.

Remove monitor camera wiring protection cover (1).

2.

Remove engine upper covers (2) to (5).

3.

Disconnect monitor camera wiring (7).

4.

Disconnect flywheel case lubrication hose (8).

16

PC138US, USLC-8


SEN02712-00

Installation q


[*1]

2 3

Counterweight mounting bolt: Adhesive (LT-2) Counterweight mounting bolt: 3,430 – 4,212 Nm {350 – 430 kgm} Target: 3,626 Nm {370 kgm}

PC138US, USLC-8

17

SEN02712-00

Removal and installation of counterweight assembly (Machine with add-on weight)


6.

Sling the counterweight and remove 3 mounting bolts (5). [*2]

7.

Lift off counterweight assembly (6). a First, move the counterweight assembly horizontally toward the rear so that it will not interfere with the machine body, and then lift it up. 4 Counterweight assembly : 3,300 kg (Standard specification) : 2,900 kg (Blade specification)

1

Removal k

k

Stop the machine on a level ground, stop the engine, and lower the work equipment to the ground. Disconnect the cable from the negative (-) terminal of the battery.

1.

Perform steps 1 – 4 of "Removal and installation of counterweight assembly (Machine without add-on weight)

2.

Remove the 2 monitor camera mounting bolts to remove the monitor camerai1j.

3.

Remove mounting bolt (2) on the top of the add-on weight.

4.

Sling add-on weight (3) and remove 2 mounting bolts (4) from its side.

5.

Lift off add-on weight (3). [*1] 4 Add-on weight: 510 kg

18

PC138US, USLC-8


SEN02712-00

Installation q


[*1] Installation procedure for add-on weight 1) Put faces (X) and (Y) to the insert boss of the counterweight. 2) Install top bolt (2) and tighten it lightly. 2 Add-on weight mounting bolt: Adhesive (LT-2) 3) Adjust clearance (a) to 10 ± 3 and install side bolts (4). 2 Add-on weight mounting bolt: Adhesive (LT-2) 3 Add-on weight mounting bolt: 1,860 – 3,040 Nm {190 – 310 kgm} 4)

Tighten the top bolt. 3 Add-on weight mounting bolt: 1,860 – 3,040 Nm {190 – 310 kgm}

[*2]

2 3

Counterweight mounting bolt: Adhesive (LT-2) Counterweight mounting bolt: 3,430 – 4,212 Nm {350 – 430 kgm} Target: 3,626 Nm {370 kgm}

PC138US, USLC-8

19

SEN02712-00




20

PC138US, USLC-8

SEN02713-00


Machine model

Serial number



50 Disassembly and assembly Hydraulic system Removal and installation of center swivel joint assembly ............................................................................... 2 Disassembly and assembly of center swivel joint assembly........................................................................... 4 Removal and installation of hydraulic tank assembly...................................................................................... 5 Removal and installation of hydraulic pump assembly ................................................................................... 8 Removal and installation of control valve assembly ..................................................................................... 12 Disassembly and assembly of control valve assembly ................................................................................. 17 Disassembly and assembly of work equipment PPC valve assembly .......................................................... 27 Disassembly and assembly of travel PPC valve assembly........................................................................... 30 Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 32

PC138US, USLC-8

1

SEN02713-00


Removal and installation of center swivel joint assembly 1 Removal k

k

Gradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine. Disconnect the negative (–) terminal of the battery.

1.

Remove cover (1), (2) at rear of boom.

2.

Remove filter and bracket assembly (3). (for attachment specification)

3.

Disconnect hoses (4) – (9) between travel motor and swivel joint.

4.

Remove elbow (10).

5.

Disconnect drain hose (11).

6.

Disconnect hoses (12) – (15) between control valve and swivel joint.

7.

Disconnect hose (16) from solenoid valve.

8.

Remove plate (17).

2

9.

Disconnect hoses (for changing the speed) (18) and (19) between both travel motors and swivel joint.

10. Remove mounting bolts and lift off center swivel joint assembly (20). [*1] a Sling the joint assembly temporarily, then remove the bolts. 4 Center swivel joint assembly : 30 kg (Standard specification) : 45 kg (Blade specification)

PC138US, USLC-8


SEN02713-00

Installation q


[*1]

2 3

q

Mounting bolt screw: Liquefied adhesive (LT-2) 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".

PC138US, USLC-8

3

SEN02713-00


Disassembly and assembly of center swivel joint assembly

1

T

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

q 1

790-101-2501

Push puller

790-101-2510

• Block

1

790-101-2520

• Screw

1

790-101-2540

• Washer

1

Assembly 1.

Fit slipper seals (7) and O-rings (6) to swivel rotor.

2.

Set swivel shaft (5) to block, then fit it by using push tool and hitting swivel rotor (4) lightly with plastic hammer. 2 Contact surfaces of rotor and shaft : Grease (G2-LI) a When installing the rotor, take care not to damage the slipper seals and O-rings.

791-112-1180

• Nut

1

790-101-2630

• Leg

2

790-101-2570

• Washer

4

790-101-2560

• Nut

2

791-112-2650

• Adapter

2

Disassembly 1.

Remove cover (1).

2.

Remove snap ring (2).

3.

Install ring (3) and secure with snap ring (2).

3.

Using tool T, pull out swivel rotor (4) and ring (3) from swivel shaft (5).

4.

4.

Remove O-rings (6) and slipper seals (7) from swivel shaft (5).

Fit O-ring and install cover (1). 3 Swivel joint mounting bolt : 31.3 ± 2.9 Nm {3.2 ± 0.3 kgm}

4

PC138US, USLC-8


SEN02713-00

Removal and installation of hydraulic tank assembly

a


2.

Removal of exterior parts 1) Removal handrail(2) 2) Removal cover(3) – (6).

3.

Tank rear wiring, hose and clamps 1) Disconnect drain hose (7). 2) Disconnect hydraulic pump suction hose (8).

1

D

796-460-1210

Oil Stopper

q 1

795-799-1131

Adapter

q 1

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Removal k

k

k

1.

Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative (–) terminal of the battery beforehand. Loosen hydraulic drain plug(1) and drain the hydraulic oil. [*1] 6 Hydraulic oil tank: 69 l (Capacity: 120 l)

PC138US, USLC-8

5

SEN02713-00

3) 4) 5)

Remove engine oil filter bracket (9). a Move the filter assembly close to the engine. Disconnect hose (10) from radiator. Disconnect fuel level sensor wire (11).


7.

Removal of hydraulic oil tank mounting bracket and mounting bolts. 1) Remove fuel tank rear mounting brackets (23).

2) 4.

Disconnect 8 return hoses (12) to (19) in front of the tank. a Record the installed position of respective hoses.

5.

Disconnect swing machinery oil level pipe clamp (20).

6.

Disconnect 2 drain hoses (21) and clamps (22).

6

3)

4)

Remove wiring and hose mounting brackets (24). Remove fuel tank front mounting brackets (25).

Remove 4 hydraulic oil front mounting bolts (26). [*2]

PC138US, USLC-8


8.

Lift and remove hydraulic oil tank assembly (27). 4 Hydraulic oil tank assembly: 95 kg

SEN02713-00


q

[*1]

3 5

Drain plug (1): 58.8 – 78.4 Nm {6 – 8kgm} Target: 68.6 Nm {7 kgm} Hydraulic oil tank: 69 l (Capacity: 120 l)

[*2]

2 3

PC138US, USLC-8

Thread of hydraulic oil tank mounting bolt: Adhesive (LT-2) Hydraulic oil tank mounting bolt (27): 245 – 309 Nm {25 – 31.5 kgm}

7

SEN02713-00


Removal and installation of hydraulic pump assembly

a


2.


3.

Remove radiator sub tank (4).

4.

Disconnect water assembly (6).

5.

Remove engine oil filter bracket (5). a Move the filter assembly close to the engine.

1

D

796-460-1210

Oil Stopper

q 1

795-799-1131

Adapter

q 1

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Removal k

k

k

1.

8

Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative (-) terminal of the battery beforehand. Loosen hydraulic drain plug(1) and drain the hydraulic oil. [*1] 6 Hydraulic oil tank: 69 l (Capacity: 120 l)

separator

and

bracket

PC138US, USLC-8


6.

Disconnect damper case oil filler hose(7).

7.

Removal of muffler assembly 1) Remove divider boards (8) and rubber covers (9) and (10).

SEN02713-00

4)

9. 2) 3) 4)

8.

Remove muffler drain tube (11). Remove 4 muffler mounting bolts (12). Lift and remove muffler assembly (13).

Disconnect 6 hoses(17) to (22). a Record the installed position of respective hoses.

Disconnection hydraulic pump 1) Temporarily lift the pump (23) and remove mounting bolts (24). a Temporarily lift the pump by the engine side using chain block [1] and by the near side using wire rope [2]. 2) Lift and disconnect hydraulic pump (23) from engine. 4 Hydraulic pump assembly: 110 kg

Disconnecting wiring and hoses 1) Disconnect EPC solenoid wiring connector V11(14) and hydraulic oil temperature sensor wiring connector P22 (15). 2) Removes suction tube (16) from hydraulic pump.

PC138US, USLC-8

9

SEN02713-00

10. Removal procedures of work equipment pump Remove work equipment pump by pulling it toward the front according to the following procedures. 1) Shift the pump closer to the front end until wire rope [2] almost makes contact with the counterweight.


4)

Install wire rope [2] to the work equipment pump from outside the counterweight. a Apply rubber plates or cloth [3] to the counterweight to prevent it from being damaged by wire rope.

5)

Lower chain block [1] and hold the work equipment pump in level state. Shift the pump closer to the front end until chain block [1] almost makes contact with the counterweight.

6) 2) 3)

Pull chain block [1] up and loosen wire rope [2]. Disconnect wire rope [2] from the work equipment pump.

7)

10

Lower the chain block [1] and loosen chain block [1].

PC138US, USLC-8


8)

Disconnect chain block from the work equipment pump, shift the work equipment pump (23) forward to the front and remove it.

PC138US, USLC-8

SEN02713-00

Installation q


11

SEN02713-00


Removal and installation of control valve assembly

a

When using tool D to stop oil, remove the hydraulic tank strainer in advance.

2.

Removal of exterior parts 1) Removal handrail(2) 2) Removal cover (3) and (6).

3.

Removal of solenoid valve frame 1) Disconnect hoses (5) to (12). (Index No. , Color band , Hose Name) (5); (Red-Green) PPC basic pressure (6); (Red) Travel HI/LO (7); (Red-Red) Swing paring brake (8); (–) Merge-divider valve selection signal (9); (–) Travel junction valve (10); (–) P1Pilot pressure (11); (–) Travel junction valve (12); (–) Pilot pressure #3

1

D

796-460-1210

Oil Stopper

q 1

795-799-1131

Adapter

q 1

Sketch

Part name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Removal k

k

k

a a

1.

12

Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative (–) terminal of the battery beforehand. The following procedure explain about "Attachment and multi-pattern specifications." Fasten tags to respective connecters and piping for identification to prevent any mistakes when re-installing. Loosen hydraulic drain plug(1) and drain the hydraulic. [*1] 6 Hydraulic oil tank: 69 l (Capacity: 120 l)

PC138US, USLC-8


2)

Disconnect connectors (13) to (23). (13): V10 (Bucket dump solenoid) (14): M14 (ravel alarm buzzer)

4.

Removal of pressure switch connector 1) Disconnect wiring connectors (26) to (32). (26): P01 (Bucket dump switch) (27): P02 (Arm dump switch) (28): P03 (Boom raise switch) (29): P04 (Bucket digging switch) (30): P05 (Boom digging switch) (31): P06 (Boom lower switch) (32): P07 (Right swing switch) 2) Remove pressure switch mounting bracket (33).

5.

Disconnection of multi-valve assembly wiring and hose (for machines installed with the assembly) 1) Disconnect connectors (34) and (35). (34): (P08) Left swing switch (35): (P67) Right swing switch a Connector P67 is connected to connector P07. a For a machine without the multi-valve assembly, connector P08 is positioned under P07 of the pressure switch connector mounting bracket.

(15): (16): (17): (18): (19):

3) 4)

V1 (PPC Basic pressure) V2 (Travel HI/LO) V3 (Swing paring brake) V4 (Travel junction valve) V5 (Merge-divider valve selection signal) (20): P25 (Pump pressure sensor) (21): P26 (Travel right rear pressure sensor) (22): P27 (Travel left rear pressure sensor) (23): P29 (Dummy) Disconnect clamp (24) from solenoid valve frame. Remove solenoid valve frame assembly (25).

SEN02713-00

PC138US, USLC-8

13

SEN02713-00

2)

6.

14

Disconnect hoses (36) to (39). (Index No. , Color band , Hose Name) (36); (Orange) Arm dump (37); (White) Swing left (38); (Red) Bucket dump (39); (Red-Yellow) Boom raise

Disconnection of control valve connectors and hoses (Connectors) 1) Disconnect connectors (40) to (42) from right side of control valve. (40): P64 (Bucket digging switch) (41): P65 (Arm digging switch) (42): P66 (Boom lower switch)

2)


Disconnect connectors (43) to (47) from left side (operator cab side) of control valve. (43): P61 (Bucket dump switch) (44): P62 (Arm dump switch) (45): P63 (Boom raise switch) (46): P09 (Right travel forward switch) (47): P10 (Left travel forward switch)

(Hoses) 3) Disconnect 15 hoses (48) to (62) right and front side of control valve. (48); (–) (49); (Blue) (50); (Blue) (51); (Green) (52); (Green) (53); (Black) (54); (Black) (55); (–) (56); (Yellow) (57); (Yellow) (58); (Brown) (59); (–) (60); (–) (61); (Black) (62); (Black)

PC138US, USLC-8


SEN02713-00

(78); (79); (80); (81); (82); (83);

4)

5)

Disconnect 5 hoses (63) to (67) left side (operator cab side) of control valve. (63); (–) (64); (Red- Red) (65); (Red) (66); (Black- Yellow) (67); (Brown- Yellow)

Disconnect all of hoses (68) to (83) back side(engine side) of control valve. (68); (White) (69); (Brown) (70); (Red) (71); (Blue) (72); (Orange) (73); (Green) (74); (–) (75); (Black) (76); (–) (77); (–)

PC138US, USLC-8

(Yellow- Black) (Yellow- Green) (Yellow- Brown) (Yellow- Orange) (White) (Brown)

7.

Disconnect attachment select valve connecting hose (84).

8.

Remove 3 multi-valve mounting bolts (85) and remove multi-valve assembly (86).

15

SEN02713-00

9.

Remove bracket mounting bolt (87) and r emov e multi - val ve as sem bly m ounti ng bracket (88).


Installation q


10. Loosen 4 control valve mounting bolt(89) and lift and remove control valve assembly (90). 4 Control valve assembly: 95 kg

16

PC138US, USLC-8


Disassembly and assembly of control valve assembly

SEN02713-00

1

Assembly

PC138US, USLC-8

17

SEN02713-00


The appearance and section of only the 8-spool valve (blade + service valve) are shown here. A1 : To swing motor A2 : To blade cylinder bottom A3 : To left travel motor A4 : To right travel motor A5 : To boom cylinder bottom A6 : To arm cylinder head A7 : To bucket cylinder head A8 : To attachment B1 : To swing motor B2 : To blade cylinder head B3 : To left travel motor B4 : To right travel motor B5 : To boom cylinder head B6 : To arm cylinder bottom B7 : To bucket cylinder bottom B8 : To attachment LS : To pump LS valve P1 : From main pump P2 : From main pump PP : To main pump PR : To solenoid valve, PPC valve and EPC valve PS : From solenoid valve of merge-divider valve TB : To tank TC : To oil cooler BP1: From boom raise PPC valve LS1: LS1 pressure pickup port LS2: LS2 pressure pickup port

LS3 : LS3 pressure pickup port PA : From swing left PPC valve PA2 : From blade lower PPC valve PA3 : From left travel forward PPC valve PA4 : From right travel forward PPC valve PA5 : From boom raise PPC valve PA6 : From arm dump PPC valve PA7 : From bucket dump 1 PPC valve PA8 : From service PPC valve PB1 : From swing right PPC valve PB2 : From blade raise PPC valve PB3 : From left travel reverse PPC valve PB4 : From right travel reverse PPC valve PB5 : From boom lower PPC valve PB6 : From arm in PPC valve PB7 : From bucket curl PPC valve PB8 : From service PPC valve PMAX: Pressure sensor port PP1 : PP1 pressure pickup port PP2 : PP2 pressure pickup port PPI1 : Pump 1 pressure pickup port PPI2 : Pump 2 pressure pickup port PRI : PR pressure pickup port PST : From travel junction solenoid valve TS1 : To tank PS2 : To tank TSW : To swing motor TSW : To swing motor

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18.

18

Cover Service valve Bucket valve Arm valve Boom valve Right travel valve Left travel valve Blade valve Swing valve

Block Swing bleed valve LS check valve Travel junction valve + LS check valve Arm regeneration valve Boom hydraulic drift prevention valve Merge-divider valve block Nut Bolt

PC138US, USLC-8

50 Disassembly and assembly a

In this section, only the precautions for assembling the control valve assembly are described.

q

Before assembling the parts, apply engine oil to their sliding surfaces. 2 Mating face: Liquid sealant (Sealend 242 or equivalent)

a

The tightening torque of the parts and the precautions are shown below (in random order).

q

Install cover (1): Tighten the 4 nuts (17) in the diagonal order ([1] – [4]) according to the following procedure. 1st time: 3 58.8 – 68.6 Nm {6 – 7 kgm} 2nd time: 3 78.5 – 88.3 Nm {8 – 9 kgm} 3rd time: 3 98.1 – 113 Nm {10 – 11.5 kgm} The height of the stud top above the nut top: 0.5 – 3 mm

a

q

Assembling block (10): Tighten the 4 bolts (18) in the diagonal order ([1] – [4]) according to the following procedure. 1st time: 3 19.6 – 29.4 Nm {2 – 3 kgm} 2nd time: 3 39.2 – 49.0 Nm {4 – 5 kgm} 3rd time: 3 58.8 – 73.5 Nm {6 – 7.5 kgm}

a

Degrease and dry up the threads of the plugs and female screws in advance. Do not apply pressure for 2 hours after tightening them.

PC138US, USLC-8

SEN02713-00

19

SEN02713-00

20


PC138US, USLC-8


PC138US, USLC-8

SEN02713-00

21

SEN02713-00

22


PC138US, USLC-8


PC138US, USLC-8

SEN02713-00

23

SEN02713-00

24


PC138US, USLC-8


AA1. AA2. AA3. AA4. AA5. AA6. AA7. AA8. AA9. AA10. AA11. AA12. AA13. AA14.

Safety-suction valve (Service) Suction valve (Bucket) Suction valve (Arm) Suction valve (Boom) Lift check valve Suction valve (Right travel) Suction valve (Left travel) Suction valve (Blade) Safety-suction valve (Blade) Suction valve (Left travel) Suction valve (Right travel) Main relief valve Suction valve (Boom) Suction valve (Arm)

SEN02713-00

AA15. AA16. AA17. BB18. BB19. BB20. BB21. BB22. BB23. BB24. BB25. BB26. BB27.

Suction valve (Bucket) Safety-suction valve (Service) Safety-suction valve Spool (Service) Spool (Bucket) Spool (Arm) Spool (Boom) Spool (Right travel) Spool (Left travel) Spool (Blade) Spool (Swing) Unload valve Unload valve

LS selector valve Cooler bypass valve Pressure compensation valve R (Service) Pressure compensation valve R (Bucket) Pressure compensation valve R (Arm) Pressure compensation valve R (Boom) Pressure compensation valve R (Right travel) DD8. Pressure compensation valve R (Left travel) DD9. Pressure compensation valve R (Blade) DD10. Pressure compensation valve R (Swing)

DD11. Pressure compensation valve F (Swing) DD12. Pressure compensation valve F (Blade) DD13. Pressure compensation valve F (Left travel) DD14. Pressure compensation valve F (Right travel) DD15. Merge-divider valve spool DD16. Pressure compensation valve F (Boom) DD17. Pressure compensation valve F (Arm) DD18. Pressure compensation valve F (Bucket) DD19. Pressure compensation valve F (Service)

FF1. FF2. FF3. FF4. FF5. FF6. FF7. FF8. FF9. FF10.

FF11. FF12. FF13. FF14. FF15. FF16.

CC1 CC2. DD3. DD4. DD5. DD6. DD7.

LS selector valve Pressure compensation valve F (Swing) Spool (Swing) Pressure compensation valve R (Swing) LS bleed valve Safety-suction valve (Blade) Suction valve (Blade) Spool (Blade) Pressure compensation valve R (Blade) Pressure compensation valve F (Blade)

PC138US, USLC-8

F: R:

Pressure compensation valve R (Left travel) Suction valve (Left travel) Suction valve (Left travel) Spool (Left travel) Pressure compensation valve F (Left travel) LS check valve


25

SEN02713-00

JJ1. JJ2. JJ3. JJ4. JJ5. JJ6. JJ7. JJ8.

Pressure compensation valve F (Right travel) Suction valve (Right travel) Suction valve (Right travel) Spool (Right travel) Pressure compensation valve R (Right travel) Travel junction valve + LS check valve Unload valve LS bypass valve

NN1. Pressure compensation valve F (Arm) NN2. Suction valve (Arm) NN3. Suction valve (Arm) NN4. Spool (Arm) NN5. Pressure compensation valve R (Arm) NN6. Hydraulic drift prevention valve (Arm) NN7. Pressure compensation valve F (Bucket) NN8. Suction valve (Bucket) NN9. Suction valve (Bucket) NN10. Spool (Bucket) NN11. Pressure compensation valve R (Bucket)

26


JJ9. JJ10. JJ11. JJ12. JJ13. JJ14. JJ15. JJ16. JJ17. JJ18.

Merge-divider valve spool Main relief valve Cooler bypass valve Lift check valve Pressure compensation valve F (Boom) Suction valve (Boom) Hydraulic drift prevention valve (Boom) Suction valve (Boom) Spool (Boom) Pressure compensation valve R (Boom)

NN12. Pressure compensation valve F (Service) NN13. Safety-suction valve NN14. Safety-suction valve NN15. Spool (Service) NN16. Pressure compensation valve (Service) NN17. Safety-suction valve NN18. Pressure release plug F: R:


PC138US, USLC-8


Disassembly and assembly of work equipment PPC valve assembly (For boom, bucket, arm, swing control)

SEN02713-00

1

Disassembly 1.

Remove nut (13), then remove disc (12), nut (11) and boot (15).

2.

Remove bolts, then remove plate (5). a Do not remove joint (10) unless it is to be replaced.

3.

Remove seal (16) and collar (17).

4.

Pull out piston (8), and remove retainer (18), springs (7), (6) and (5), and shim (4). a Spring (6), (5) and spring (7), (5) consists of each one of two types of springs with different installed loads in four places, so check the mounting position (oil pressure port) and mark with tags to prevent mistakes when installing.

5.

Pull out valve (19) from body (1). a Do not remove plugs (2), (3).

PC138US, USLC-8

27

SEN02713-00


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.

1.

When installing plug (2) to body (1), take care that its tip will not enter the hole of the body 20 mm in diameter. 3 Plug (2): 4 – 9 Nm {0.4 – 0.9 kgm}

2.

The head of plug (3) must not be projected from the body surface. 3 Plug (3): 6 – 11 Nm {0.6 – 1.1 kgm}

3.

When installing piston (8), apply grease (G2LI) to its outside and the inside of the body hole.

4.

Install spring (5) with its small diameter side on the shim (4) side. q Diameter of spring (Inside diameter) Small diameter side: ø4.9, Large diameter side: ø5.4

5.

When installing springs (6) and (7), note that they are different and they must be installed to different hydraulic ports. q Installed height: 34 mm (Common to both springs) q Installed load: Spring (6) (P1, P2): 29 N {3 kg} Spring (7) (P3, P4): 17.7 N {1.8 kg} 3 Bolt (9): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

28

PC138US, USLC-8


6.

When installing joint (10) to body (1), apply LOCTITE as shown below. 1) When installing the joint, apply 1 drop (approx. 0.02 g) of LOCTITE (No. 262) each to 2 places of the female screw (A) of the body. Before installing the joint, thoroughly degrease and dry its male screw and the female screw of the body with DRYSOL. 2) Drop LOCTITE to the following positions. 2 Female screw (A) of body: LOCTITE No. 262 3 Joint (10): 39 – 49 Nm {4 – 5 kgm}

7.

Install nut (11). 2 Apply 1 drop (about 0.02 g) of LOCTITE No. 641 to each of the points shown below.

8.

Apply grease (G2-LI) to the rocking part of joint (10) and the contact surfaces of disc (12) and piston (8). 2 Quantity of grease (G2-LI) 1) Rocking part of joint: 2 – 4 cc/periphery 2) Contact surfaces of disc and piston: 0.3 – 0.8 cc/place

PC138US, USLC-8

SEN02713-00

9.

Installation of disc (12) 1) Install disc (12) so that each bolt (9) will be the center of each side of disc (12) and they will not interfere with each other during compound operation. (Error: ± 3 °) 2) When installing disc (12), adjust it so that the play of the lever end will be 0.5 – 3 mm (at 200 mm from the center of rotation of the lever). 3) Fixing disc (12) with [1], tighten nut (13). a At this time, give play to body (1) or plate (14) and lock with [2]. 3 Nut (13): 93.1 – 112.7 Nm {9.5 – 11.5 kgm}

29

SEN02713-00

Disassembly and assembly of travel PPC valve assembly


1

Disassembly 1.

Remove screw (13) to remove lever (9).

2.

Remove pin (5) from plate (8), and remove the plate (8) from the lever (9).

3.

Remove mounting bolt (15) to remove case shaft assembly (17).

4.

Remove shaft (6) from the case.

5.

Remove lever (7), bushing (4) and pin (5) from the case.

6.

Remove mounting bolt (16) to remove plate (18) together with damper assembly (19). a Check the thickness and the mounting position of washer (10).

7.

Remove mounting bolt (12) to remove damper assembly (19) from plate (18).

8.

Remove seal (20) and collar (21).

9.

Remove piston (1) to remove retainer (22), springs (23) and (2) and shim (3). a Store shim (3) after checking the thickness and the number of shims at each mounting position.

10. Remove valve (24) from body (25). a Do not remove plug (11).

30

PC138US, USLC-8


SEN02713-00

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.

1.

When installing piston (1), apply grease (G2LI) to its outside and the inside of the body hole.

2.

Install spring (2) with its small diameter side on the shim (3) side. q Diameter of spring (Inside diameter) Small diameter side: 4.9, Large diameter side: 5.55

3.

Use the insertion jig to insert bushing (4). (Do not drive in the bushing with impact loads of a hammer, etc.)

4.

Use the insertion jig to insert pin (5). (Do not drive in the pin with impact loads of a hammer, etc.)

5.

Apply grease (G2-LI) to the rocking part of shaft (6) and the contact surfaces of lever (7) and piston (1) and the contact surfaces of plate (8) and pin of lever (9). 2 Quantity of grease (G2-LI) Rocking part of shaft: 4 – 8 cc/periphery Contact surfaces of lever and piston: 0.3 – 0.8 cc/place Contact surfaces of plate and pin: 0.3 – 0.8 cc/place

6.

Install plate (8) with the cut part on the outside of the PPC assembly.

7.

Install washer (10) 1.6 mm thick first. If the difference between both sides at the stroke end of the lever exceeds 0.7°, change the washer thickness to reduce the difference to below 0.7°. (If the washer thickness is reduced by 0.3 mm, the stroke end angle is increased by 0.39°.) q Thickness of washer t: 1.0, 1.3, 1.6

8.

Tighten each part to the following torque. Plug (11): 6 – 11 Nm {0.6 – 1.1 kgm} q Bolt (12): 3.9 – 4.9 Nm {0.4 – 0.5 kgm} (Apply LOCTITE #262.) q Screw (13): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} q Plug (14): 4 – 9 Nm {0.4 – 0.9 kgm} q Bolt (15): 25 – 30 Nm {2.5 – 3.2 kgm} q Bolt (16): 27 – 34 Nm {2.8 – 3.5 kgm} q

PC138US, USLC-8

31

SEN02713-00


Disassembly and assembly of hydraulic cylinder assembly

1

a

This section explains how to disassemble and assemble the boom, arm, bucket and blade cylinders. For how to disassemble and assemble the offset cylinder, refer to "Disassembly and assembly of offset cylinder assembly".

Sketch

Disassembly

1.

Piston rod assembly 1) Remove the piping from the cylinder assembly. 2) Remove the mounting bolt to disconnect head assembly (1). 3) Remove piston rode assembly (2). a Place an oil pan or the like under the cylinder to receive oil. 4) Disassemble the piston rod assembly with the following procedure. 1] Set piston rod assembly (2) on tool U1.

1 2

3

U

4

5 6

32

Part name

790-502-1003

Repair stand

t 1

790-101-1102

Pump

t 1

790-102-4300

Wrench assembly t 1

790-201-4310

Pin

t 1

790-201-1702

Push tool (Kit)

t 1

790-201-1791

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1702

Push tool (Kit)

790-201-1811

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1702

Push tool (Kit)

790-201-1821

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool (Kit)

790-201-1610

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool (Kit)

790-201-1620

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1500

Push tool (Kit)

790-201-1630

• Push tool

1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-720-1000

Expander

t 1

796-720-1660

Ring

t 1

07281-01159

Clamp

t 1

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

t 1

t 1

q 1

q 1

q 1

PC138US, USLC-8


2]

SEN02713-00

Remove piston assembly lock screw (3). Screw size M12 x 1.75 pitch: Boom, arm and blade M10 x 1.5 pitch: Bucket

a

If screw (3) is caulked too tightly to be removed, force the screw in once and then tap it to remove it.

3]

Use tool U2 to remove piston assembly (4). q If tool (U2) is not used, use the four drill holes (diameter = 10) to loosen the piston assembly. Remove plunger (5). q Arm cylinder and boom cylinder. Remove collar (6). q Arm cylinder and boom cylinder.

2.

4] 5]

PC138US, USLC-8

6]

Remove the head assembly (7).

7]

Remove cap (8) to remove eleven balls (9) and cushion plunger (10). q For the arm cylinder only. a Since cap (8) is made of nylon, tighten a screw into it and pull it out with pliers.

Sub-disassembly of piston assembly 1) Remove ring (11). 2) Remove wear ring (12). 3) Remove piston ring (13). 4) Remove the O-ring and backup ring (14).

33

SEN02713-00

3.

Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).


Assembly a a

1.

34

Be careful not to damage the packing, the dust seal, the O-ring or the like Do not forcibly insert the backup ring but make it warm with hot water (50 to 60°C) before insertion. Sub-assembly of cylinder head assembly 1) Press fit bushing (20) using tool (U3). 2) Engage buffer ring (19). 3) Engage rod packing (18). 4) Mount dust seal (17) using tool (U4) and fix it with snap ring (16). 5) Mount the backup ring and O-ring (15).

PC138US, USLC-8


2.

Sub-assembly of piston assembly 1) Expand piston ring (13) using tool (U5). a Set the piston ring on tool (U5) and expand it by rotating the handle eight to ten times. 2) Reduce piston ring (13) using tool (U6).

3) 4) 5)

3.

Mount the backup ring and O-ring (14). Engage wear ring (12). Engage ring (11). a Be careful not to expand the ring abutment joint too much. 2 Ring groove: Grease (G2-LI)

Piston rod assembly 1) Set piston rod assembly (2) on tool (U1).

PC138US, USLC-8

SEN02713-00

2) 3) 4)

5)

6)

Assemble head assembly (7). Fit O-ring and backup ring to collar (6), and assemble. q Arm cylinder and boom cylinder. Assemble plunger (5). q Arm cylinder and boom cylinder. a Check that there is a small amount of play at the tip of the plunger.

Set cushion plunger (10) on the piston rod and engage 11 balls (9) and fix them using cap (8). q For the arm cylinder only. Assemble piston assembly (4) in the following procedure. q When the rod and piston assembly (2) are reused a Completely wash them and clear them of cut powder or dust. 1] Screw piston assembly (4) and tighten it using tool U2 until the screw hole position completely fits. a Eliminate screw burrs using a file or the like. 2] Tighten screw (3). 2 Screw (3): LOCTITE No. 262 3 Screw (3) : Boom, arm and blade : 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} Bucket: 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}

35

SEN02713-00


2]

3]

q

Caulk the screw at two points through punching.

Cylinder

Tap drill diameter

Boom, arm and blade

10.3

27

12 x 1.75

20

Bucket

8.5

27

10 x 1.5

20

3] 4]

When new rod or/and piston assembly (2) is/are used a For the bottom cushion-equipped rod, mark the cap hole (8) on the rod end surface. q For the arm cylinder only. 5]

1]

Tap drill depth Tap used

Tap depth

Clear it of cut powder and dust and completely wash it after processing. Tighten screw (3). 2 Screw thread: LOCTITE No. 262 3 Screw (3) : Boom, arm and blade : 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} Bucket: 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm} Caulk the screw at four points through punching.

Screw piston assembly (4) until it comes in contact with rod (2) end surface (a). 3 Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm} a q

36

Drill a hole for mounting screw (3). a Engage the drill with the screw Vshaped grooves of piston (4) and rod (2) for horizontal processing. a Process the bottom cushionequipped cylinder (arm cylinder) on other part than the cap hole (8).

After tightening the piston, make sure that there is some play with plunger. For the boom and arm cylinders only.

PC138US, USLC-8


7)

Engage piston rod assembly (2) 2 Seal: Grease (G2-LI) a Set the ring abutment joint horizontally and align the axes of the piston rod assembly and the cylinder tube to insert them. a After insertion, make sure that the ring is not damaged or dropped and completely push the piston rod.

8)

Mount head assembly (1) and tighten it with the mounting bolt. 3 Mounting bolt :

9)

Cylinder

Tightening torque

Bucket

172 ± 25 Nm {17.5 ± 2.5 kgm}

Arm

270 ± 39 Nm {27.5 ± 4.0 kgm}

Boom

172 ± 25 Nm {17.5 ± 2.5 kgm}

Blade

270 ± 39 Nm {27.5 ± 4.0 kgm}

SEN02713-00

Mount the piping.

PC138US, USLC-8

37

SEN02713-00




38

PC138US, USLC-8

SEN02714-00



Machine model

Serial number



50 Disassembly and assembly1 Work equipment Body Removal and installation of work equipment assembly .................................................................................. 2

PC138US, USLC-8

1

SEN02714-00


Disconnect working lamp wiring connector (6) and clamp (7).

Special tools

4.

Remove guard (8).

5.

Disconnect hoses (9) (Arm cylinder bottom), (10) (Bucket cylinder bottom), (11) (Arm cylinder head), and (12) (Bucket cylinder head). a Since the engine will be started, be sure to plug the disconnected hoses.

6.

Disconnect grease tube (13).

7.

Remove lock bolt (14). [*1]

8.

Remove plate and push out pin (15) to the opposite side until it is removed from cylinder head. [*2] a Check the number and location of the shims.

9.

Lower boom cylinder (16) onto block [1]. a Connect the cable of the negative (–) terminal of the battery and start the engine and retract the boom cylinder. a Disconnect the cable from the negative (–) terminal of the battery again.

Symbol

V 1

Part No.

Part name

New/Remodel

3.

Necessity Q'ty

Removal and installation of work equipment assembly 1

t 1

792-785-1100

Remover

796-270-1110

• Adapter

1

790-101-4000

• Puller (490 kN {50 ton})

1

790-101-1102

• Pump

1

Removal k

k

Fully extend the work equipment and set a block at the arm end and lower the bucket tip to the ground. Disconnect the cable from the negative (–) terminal of the battery.

1.

Remove handrail (1), then remove covers (2) and (3).

2.

Remove undercovers (4) and (5) from boom mounting section.

10. Remove plug (17) from boom foot pin (19). 11. Remove mounting bolts to remove lock plate (18).

2

PC138US, USLC-8


12. Set tool V to boom foot pin (19).

SEN02714-00

Installation q


[*1] a When tightening the locknut, tighten so that the clearance (a) between the plate and nut is 0.5 – 1.5 mm.

13. Sling work equipment assembly(20) slightly,then remove pin(19) by using tool V. [*3] a Lift off work equipment assembly from revolving frame by using crane. 4 Work equipment assembly: 1,860 kg [*2]

2

Inside surface of bushing when assembling pin: Molybdenum disulphide lubricant (LM-P) 2 Grease after assembling pin : Grease (LM-G) k When 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

PC138US, USLC-8

3

SEN02714-00


[*3]

2

Inside surface of bushing when assembling pin : Molybdenum disulphide lubricant (LM-P) 2 Grease after assembling pin : Grease (LM-G) k When 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

q

Bleeding air Bleed the air. For details, see Testing and adjusting, "Bleeding air from hydraulic cylinder".

q

Refilling with oil (hydraulic tank) Run the engine to circulate the oil through the system. Then add oil to the specified level.

4

PC138US, USLC-8


PC138US, USLC-8

SEN02714-00

5

SEN02714-00




6

PC138US, USLC-8

SEN02715-00



Machine model

Serial number



50 Disassembly and assembly1 Cab and its attachments Removal and installation of operator cab assembly ....................................................................................... 2 Removal and installation of operator's cab glass (stuck glass)....................................................................... 4 Removal and installation of front window assembly ..................................................................................... 13 Removal and installation of floor frame assembly ........................................................................................ 14

PC138US, USLC-8

1

SEN02715-00

Removal and installation of operator cab assembly


7.

Remove cover (11).

8.

Remove cover (12) and duct (13).

9.

Disconnect cover (14).

1

Removal k

k

Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative (–) terminal of the batterybeforehand.

1.

Remove floor mat (1).

2.

Remove machine monitor (2), referring to "Removal and installation of machine monitor assembly."

3.

Remove covers (3) to (6). a When removing cover (5), simultaneously remove cigar lighter wiring connector that attached to the back of the cover.

4.

Remove ducts (7) and (8).

5.

Loosen R.H. console (9) and shift toward the inside.

10. Remove cover (15).

11. Disconnect KOMTRAX antenna cable (16). 12. Disconnect wiring connectors (17) to (21).

6.

2

Disconnect window washer hose (10).

PC138US, USLC-8


13. Removal of operator cab mounting bolts and nuts. 1) Remove 6 mounting bolts (22b) (marked with *) and 4 nuts (22n) (marked with #) from inside the operator cab. a Nuts (22n) tightens floor frame together.

SEN02715-00

14. Lift and remove operator cab assembly (27). a Before removing the operator cap assembly, make sure that all wiring and piping are disconnected. 4 Operator cab assembly: 380 kg

Installation 2)

Remove L.H. side cover (23).

3)

Remove lock plate mounting bolt (24) and remove plate (25). Remove cab tip-over stopper mounting bolt (26).

4)

PC138US, USLC-8

q


3

SEN02715-00


Removal and installation of operator's cab glass (stuck glass)

*

4

Amoung the panes of window glass on the 4 sides of the operator’s cab, 5 panes (1) – (5) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (5), remove front window assembly (6). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator’s cab.) For the procedure for replacing the front window assembly, see "Removal and installation of front window assembly".

1

( 1 ): Right side window glass ( 2 ): Left side rear window glass ( 3 ): Door upper window glass ( 4 ): Door lower window glass ( 5 ): Front window glass ( 6 ): Front window assembly (Front window glass + Front frame) ( 7 ): Both-sided adhesive tape (16): Center trim seal

PC138US, USLC-8


SEN02715-00 a

X

Part name

1

793-498-1210

Lifter (Suction cup) t 2

2

20Y-54-13180

Adapter

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

t 2

a

If the window glass is broken finaly, it may be removed with knife [4] and a screwdriver. Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4].

(The figure shows the operator’s cab of a wheel loader.)

Removal a

Remove the window glass to be replaced accoring to the following procedure.

1.

Using seal cutter [1], cut the adhesive between broken window glass (7) and operator’s cab (metal sheet) (8).

2.

a

Remove the window glass.

If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.

(The figure shows the operator’s cab of a wheel loader.)

PC138US, USLC-8

5

SEN02715-00


Installation 1.

Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator’s cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfac e s. (If th e pai nt ed s urf ac es are scratched, adhesion will be lowered.) (The figure shows the operator’s cab of a wheel loader.) 3.

2.

6

Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all back part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry.

Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Disc ar d t h e p r i m e r 2 4 ho u r s a ft e r i t i s packed.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a dry before stirring it. (If the primer is unpacked just after taken out of the refrigertor, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.

PC138US, USLC-8


3)

SEN02715-00 a

Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator’s cab (8) which will be coated with the adhesive. 2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPER or equivalant a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)

a q

Parts to be coated with primer: Apply the primer all over dimension (a). Dimension to apply primer (a): 25 mm

PC138US, USLC-8

a a

4)

As for right side window glass (1), apply the primer to only the periphery of the glass to stick the both-sided adhesive tapes and the areas out of it to apply the adhesive. q Part (b) After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. Never apply wring primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

Evenly apply glass primer to the sticking surfaces of window glass (9). 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER or equivalant a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)

7

SEN02715-00 a

a

a a

Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (7) and operator’s cab (8). Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. After applying the primer, leave it for at least 5 minutues (within 8 hours) to dry. Never apply wring the primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

50 Disassembly and assembly a

1)

a q

4.

8

Stick both-sided adhesive tape (7) along the inside edge of the glass sticking section. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before stiking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.

2)

When sticking both-sided adhesive tape (7) around a frame, do not lap its finishing end over the starting end but make clearance e of about 5 mm between them. Stick both-sided adhesive tape (7) for right side window glass (1) as shown in the figure.

Stick both-sided adhesive tape (7a) additionally for right side window glass (1). Positions to stick additional both-sided adhesive tape for right side window glass. (f) : 140 mm (g): 500 mm

Stick both-sided adhesive tape (7) for left side rear window glass (2) as shown in the figure.

PC138US, USLC-8


3)

Stick both-sided adhesive tape (7) for door upper window glass (3) and lower window glass (4) as shown in the figure. (The figure shows the door upper window glass.)

(The figure shows the door lower window glass.)

4)

SEN02715-00

Stick both-sided adhesive tape (7) for front window glass (5) as shown i the figure. a Both-sided adhesive tape: 1,004 mm × 2 pieces

PC138US, USLC-8

q

5.

Details of the sticking positions are as follows. (h): Stick to inside end of right and left front frames (17). (j) : Retract by "3.0 mm" from the end of front frame (17).

Possition the new window glass. 1) Check the clearance between the window glass and the operator’s cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operator’s cab (8) and draw positioning line (n). a Stick tapes [6] to the right, left, and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. 3) Cut the tape between window glass (9) and operator’s cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator ’s cab before installing the window glass.

9

SEN02715-00 a

6.

10

When positioning front window glass (5), set its horizontal and vertical positions as shown below. Part (m) (Right side): Project by "3.8 mm" from the frame end. Part (o) (Upper side): Retract by "3.0 mm" from the frame end.

Apply adhesive. a Use either of the 2 types of the adhesive. 2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S" 2 Adhesive (Winter): 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.


1)

Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.

2)

Cut the tip of the adhesive nozzle (14) so that dimension (q) and r will be as follows. q Dimension (q): 10 mm q Dimension (r) : 15 mm

3)

Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.

PC138US, USLC-8


4) 5)

Remove the release tape of the bothsided adhesive tape on the glass side. Apply adhesive (15) to the outside of bothsided adhesive tape (7) of the operator’s cab.

a

a a

a

Apply adhesive (15) to dimensions s and t of both-sided adhesive tape (7) of operator’s cab (8). q Dimension (s): 10 mm q Dimension (t) : 15 mm Apply adhesive (15) higher than bothsided adhesive tape (7). Apply the adhesive evenly.

SEN02715-00

7.

Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. a Sine the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly. a You can perform this work efficiently by pulling window glass (9) from inside of the operator’s cab with suction cup X1. (The figure shows the operator's cab of PC200-7.)

As for the right side window glass, apply the adhesive to the outside of the both-sided adhesive tape on the periphery of the glass.

PC138US, USLC-8

11

SEN02715-00


a

(The figure shows the operator's cab of PC2007.)

After installing front window glass (5), install the center trim seal to its bottom. Then, apply caulking material all a r ou nd t he g la s s to fi ll par t ( U) between the glass and center trim seal. a When caulking, neatly arrange the form of the adhesive at the right and left ends with a rubber spatula. 2 Adhesive: Sikaflex 256HV manufactured by Sika Japan

2)

Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape of fit them completely. (The figure shows the operator's cab of PC2007.)

9.

8.

12

Fix the window glass. 1) After installing right window glass (1) to the operator’s cab, insert stopper rubbers X2 to 2 places (v) at the bottom of the glass to fix the glass. (The figure shows the operator's cab of PC2007.)

After installing the window glass, remove the primer and adhesive from the operator’s cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact to it.

10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene form blocks, and rubber bands installed for 10 hours (at temperature of 20°C and humidity of 60%). 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually.

PC138US, USLC-8


SEN02715-00

Removal and installation of front window assembly 1 k

a

Lower the work equipment to the ground and stop the engine. To replace the front window glass, the front window assembly must be removed from the operator’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 little. 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.

PC138US, USLC-8

Installation q


13

SEN02715-00


Removal and installation of floor frame assembly 1

1.

Remove lower cover (1).

2.

Open the coolant drain valve (2) and drain coolant. 6 Coolant: 12.4 l

3.

Removal of exterior parts 1) Remove handrail (2). 2) Remove covers (3) and (4).

X 3

Part name

799-703-1200

Service tool (Kit)

t 1

799-703-1100

Vacuum pump (100V)

t 1

799-703-1111

Vacuum pump (220V)

t 1

799-703-1121

Vacuum pump (240V)

t 1

799-703-1401

Gas leak detector

t 1

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Removal k

k

k

a

14

Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in Testing and adjusting. Disconnect the negative (–) terminal of the battery beforehand. Fasten tags to respective connecters and piping for identification to prevent any mistakes when re-installing.

PC138US, USLC-8


3)

4.

Remove covers (111), (112) and (113).

Disconnecting wiring and hoses around the solenoid valve 1) Disconnect bucket damp solenoid wiring connector V10 (5) and travel alarm M14 (6).

PC138US, USLC-8

SEN02715-00

2)

3)

4)

Disconnect wiring connectors (8) to (16) around the solenoid valves connected to wring (7). (8) : V01 (PPC basic pressure) (9) : V02 (Travel HI/LO) (10): V03 (Swing paring brake) (11) : V04 (Travel junction valve) (12): V05 (Merge-divider valve selection signal) (13): P25 (Pump pressure sensor) (14): P26 (Travel right rear pressure sensor) (15): P27 (Travel left rear pressure sensor) (16): P29 (Dummy) Remove wiring mounting clamp and disconnect wiring (7) from solenoid valve mounting frame assembly (17). Disconnect PPC basic pressure hose (18) (color band: Red-Green).

15

SEN02715-00

5.

Disconnecting pressure switch and pressure sensor connector wiring 1) Disconnect wiring connectors (20) to (29) connected to wiring (19). (20): P01 (Bucket dump switch) (21): P02 (Arm dump switch) (22): P03 (Boom raise switch) (23): P04 (Bucket digging switch) (24): P05 (Boom digging switch) (25): P06 (Boom lower switch) (26): P07 (Right swing switch) (27): P08 (Left swing switch) (Multi-valve-installed machine) (28): P67 (Right swing switch) (Multi-valve-installed machine) a Connector P67 is connected to connector P07. a For a machine without the multivalve, connector P08 is positioned under P07 of the pressure switch connector mounting bracket. (29): P12 (Pressure sensor) 2)

Remove wiring mounting clamps and disconnect wiring (19) from the pressure switch connector mounting bracket (30).


6.

Disconnection of control valve assembly wiring and hoses (R.H. side of control valve-inspection cover side-) 1) Disconnect hose (31) to the attachment. (Machine with the attachment) (Band color: Blue-Blue) 2) Disconnect wiring connectors (32) to (34). (32): P64 (Bucket digging switch) (33): P65 (Arm digging switch) (34): P66 (Boom lower switch)

3)

4)

16

Disconnect wiring connectors (35) and (36). (35): P26 (Right travel reverse) (36): P27 (Left travel reverse) Disconnect hoses (37) and (38). (37): (Yellow-Green) (Right travel reverse) (38): (Yellow-Orange) (Left travel reverse)

PC138US, USLC-8


(Operator cab side) 5) Disconnect wiring connectors (39) to (41). (39): P61 (Bucket dump switch) (40): P62 (Arm dump switch) (41): P63 (Boom raise switch) 6) Disconnect hose (42) to the attachment. (Machine with the attachment) (Color band: Red-Red)

7)

8)

Disconnect travel switch connectors (38) and (39). (43): (Black-Yellow) (44): (Brown-Yellow) Disconnect travel motor hoses (40) and (41). (Color band) (45): (Black-Yellow) (46): (Brown-Yellow)

PC138US, USLC-8

SEN02715-00

7.

Disconnect 8 hoses (47) to (54) from the operation pattern select valve assembly. (Machine with the select valve) (From the upper side of operator cab) (47): Brown (Swing right) (48): Green (Arm digging) (49): White (Swing left) (50): Orange (Arm dump) (From the upper side of the hydraulic tank) (51): Yellow (Boom raise) (52): Black (Boom lower) (53): Red (Bucket dump) (54): Blue (Bucket digging) a For a machine without the operation pattern select valve, disconnect 8 hoses installed in the following order from the top to the solenoid valve installation frame as s hown i n Procedure 4- 4 (Photo No. CPP15287). Red (Bucket dump) Orange (Arm dump) Yellow (Boom raise) Blue (Bucket digging) Green (Arm digging) Black (Boom lower) White (Swing left) Brown (Swing right)

17

SEN02715-00

8.

Disconnect PPC drain hose (55).


12. Disconnect buzzer wiring connector (60). 13. Disconnect buzzer wiring clamp (61) and disconnect the buzzer wiring.

9.

Disconnect wiring A13 (56) and A08 (57). a

How to remove clamp (61) Hold a flat-head screwdriver [1] to section (a) and push it downward. Simultaneously br ing whole clamp (61) upwar d and unhook it from plate (b).

10. Disconnect boom bottom pressure sensor connector P46 (58). 11. Disconnect wiring clamp (59) and disconnect the wiring.

18

PC138US, USLC-8


SEN02715-00

14. Remove operator cab assembly, referring to "Removal of operator cab assembly." 15. Disconnecting floor lower wiring and clamps 1) Disconnect wiring and hose clamps (62) to (73).

2) 3) 4)

5)

PC138US, USLC-8

Disconnect air conditioner Hi-Lo pressure switch wiring connector (74). Disconnect air conditioner hoses (75) and (76). Disconnect heater hoses (77) and (78).

Pull out wiring lock pad (79) and draw out wiring (80).

19

SEN02715-00

6)

Disconnect grounding wire (81).


Installation q

16. Lift and remove floor frame assembly (82). a Before lifting the floor frame assembly, check that every wiring connector and clamp is disconnected. a Pull out the control valve wiring while lifting floor frame assembly (82) little by little. a When pulling out the wiring on the control valve side, it may catch obstacles on the way to resist smooth removal. Do not pull by force. Manage to evade obstacles patiently. 4 Floor frame assembly: Approx. 210 kg

20


[*1] a Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. a Make sure that O-ring is installed to the pipe joint section of the air conditioner hoses before installing a Check the O-ring for scratches or degradation. a When installing O-ring, apply the compressor oil (Denso: ND-OIL8 or ZEXEL: ZXL100PG (PAG46 or equivalent)). 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm} q

Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a). a Filling capacity: 800 (+50/0) g

PC138US, USLC-8


PC138US, USLC-8

SEN02715-00

21

SEN02715-00




22

PC138US, USLC-8

SEN02716-00



Machine model

Serial number



50 Disassembly and assembly1 Electrical system Removal and installation of air compressor assembly .................................................................................... 2 Removal and installation of air conditioner condenser ................................................................................... 3 Removal and installation of air compressor unit assembly ............................................................................. 4 Removal and installation of machine monitor assembly ................................................................................. 7 Removal and installation of pump controller assembly ................................................................................... 8 Removal and installation of engine controller assembly ................................................................................. 9 Removal and installation of KOMTRAX communications module ................................................................ 10

PC138US, USLC-8

1

SEN02716-00


Removal and installation of air compressor assembly

Installation

1

Special tools

X 3


Part name

799-703-1200

Service tool (Kit)

t 1

799-703-1100

Vacuum pump (100V)

t 1

799-703-1111

Vacuum pump (220V)

t 1

799-703-1121

Vacuum pump (240V)

t 1

799-703-1401

Gas leak detector

t 1

New/Remodel

Part No.

Q'ty

[*1] Necessity

Symbol

q

q

a a

q

Precautions when installing piping Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. When jointing the air conditioner piping, apply compressor oil (Denso ND-01L8 equivalent) to the threaded portions. 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm} Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a).

[*2]

Removal k

k k

Stop the machine on a level place and lower the work equipment to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative (–) terminal of the battery beforehand. Bleed the air conditioner gas using the special tool.

1.

Disconnect wiring connector AC02 (1).

2.

Disconnect air conditioner pipes (2) and (3). [*1]

3.

Loosen drive belt tension adjust bolt (4).

4.

Remove drive belt protective cover (6).

5.

Remove drive belt protective cover (6).

6.

Remove drive belt (7).

7.

Remove mounting bolts (8) and remove air compressor assembly (9). [*2]

2

3

Air compressor mounting bolt: 24.5 – 29 Nm {2.5 – 3.0 kgm}

PC138US, USLC-8


SEN02716-00

Removal and installation of air conditioner condenser

X 3

799-703-1200

Service tool (Kit)

t 1

799-703-1100

Vacuum pump (100V)

t 1

799-703-1111

Vacuum pump (220V)

t 1

799-703-1121

Vacuum pump (240V)

t 1

799-703-1401

Gas leak detector

t 1

5.

Remove 4 bolts and remove condenser (4).

New/Remodel

Q'ty

Part name

Necessity

Part No.

Disconnect 2 hoses (3). a Put blind caps to prevent the entry of dirt or water into hoses and compressor.

1


4.

Removal k k

Lower the work equipment to the ground completely. Remove the negative (–) terminal from the battery.

1.

Collect air conditioner gas (R134a) from air conditioner circuit.

2.

Remove air cleaner cover (1) and remove the element.

3.

Loosen bolts and remove the wire harness clamp (2).

Installation

PC138US, USLC-8

q

Carry out installation in reverse oder to remaval.

q

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

3

SEN02716-00


Removal and installation of air compressor unit assembly

X 3

799-703-1200

Service tool (Kit)

t 1

799-703-1100

Vacuum pump (100V)

t 1

799-703-1111

Vacuum pump (220V)

t 1

799-703-1121

Vacuum pump (240V)

t 1

799-703-1401

Gas leak detector

t 1

New/Remodel

Q'ty

Part name

Necessity

Part No.

Removal k

k k

1.

4

Disconnect wiring connector (2) of the air conditioner high and low pressure switch.

3.

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

4.

Disconnect heater hoses (5) and (6).

5.

Remove floor mat (7).

6.

Remove machine monitor (8), referring to "Removal and installation of machine monitor assembly."

7.

Remove covers (9) to (12). a When removing cover (11), simultaneously remove cigar lighter wiring connector that attached to the back of the cover.

8.

Remove ducts (13) and (14).

1


2.

Park the machine on a level place and lower the work equipment to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative (–) terminal of the battery beforehand. Bleed the air conditioner gas using the special tool. Remove side cover (1).

PC138US, USLC-8


9.

Remove cover (15).


SEN02716-00


15. Remove 3 cover mounting bolts (24) on the left and right.

11. Remove duct (17). 12. Remove covers (18) and (19).

16. Lift cover (25) using 3 forcing bolts [1].

13. Disconnect connectors (20), (21) and (22) and disconnect the wiring clamps.

PC138US, USLC-8

17. Remove 3 air conditioner unit mounting bolts (26) in front and rear, and remove air conditioner unit (27).

5

SEN02716-00


Installation q


[*1] q

a

q

6

Precautions when installing piping Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a). a Filling capacity: 800 (+50/-0) g

PC138US, USLC-8


Removal and installation of machine monitor assembly

SEN02716-00

1

3.

Disconnect connector (3) to (5).

4.

Remove 3 mounting bolts (6) and remove machine monitor assembly (7).

Removal k

1.

Disconnect the negative (–) terminal of the battery beforehand. Remove the 2 mounting bolts and cover (1). a One of the mounting bolts is installed inside the cap on the right of the daylight sensor. a While removing cover (1), simultaneously disconnect wiring connector P31 of the daylight sensor. a A level gauge is installed to the top of the monitor panel on the machine of arm crane specifications. Remove the level gauge.

Installation q

2.


Remove duct (2).

PC138US, USLC-8

7

SEN02716-00

Removal and installation of pump controller assembly 1 Removal k


1.

Remove cover (1).

2.

Remove cover (2).

3.

Remove duct (3).

4.

Remove cover (4).


5.

Disconnect wiring (5) and (6). a Pull each connector lever (a) and (b) inward.

6.

Remove 4 mounting bolts (7) and 2 mounting bolts (8), and remove pump controller assembly (9).

Installation q

8


PC138US, USLC-8


Removal and installation of engine controller assembly

SEN02716-00

Installation

1

Removal k


1.

Open the engine hood.

2.

DReferring to "Removal and installation of air compressor assembly," disconnect air conditioner compressor (1). a Do not disconnect the air conditioner hoses from the air conditioner compressor.

3.

Remove wiring connectors CE01 (2), CE02 (3) and CE03 (4). [*1]

4.

Remove mounting bolts (5) and remove engine controller (6).

PC138US, USLC-8

q


[*1]

3

Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

9

SEN02716-00

Removal and installation of KOMTRAX communications module


1

5.

Disconnect wiring connector CK02 (5), CK01 (6) and antenna (7).

6.

Remove 4 mounting bolts (8) and remove KOMTRAX communications module (9).

Removal k

1.

Disconnect the negative (–) terminal of the battery beforehand. Remove cover (1).

Installation q

2.

Remove cover (2).

3.

Remove duct (3).

4.

Remove cover (4).

10


PC138US, USLC-8


PC138US, USLC-8

SEN02716-00

11

SEN02716-00




12

PC138US, USLC-8

SEN01980-00



Machine model

Serial number



90 Diagrams and drawings

1

Hydraulic circuit diagram Hydraulic circuit diagram................................................................................................................................. 3

PC138US, USLC-8

1

Hydraulic circuit diagram

Hydraulic circuit diagram PC138US-8

PC138US-8

SEN01980-00 PC138US, USLC-8

3

Hydraulic circuit diagram PC138US-8 (Blade specification and machine ready for attachment)

Hydraulic circuit diagram PC138US-8 (Blade specification and machine ready for attachment)


5

Hydraulic circuit diagram PC138USLC-8 (KA specification) (Blade specification and machine ready for attachment)

Hydraulic circuit diagram PC138USLC-8 (KA specification) (Blade specification and machine ready for attachment)


7

Hydraulic circuit diagram PC138US-8 (KUK specification) (Blade specification and machine ready for attachment)

Hydraulic circuit diagram PC138US-8 (KUK specification) (Blade specification and machine ready for attachment)


9

SEN01980-00




12

PC138US, USLC-8

SEN01981-01



Machine model

Serial number




1

Electrical diagrams and drawings Electrical circuit diagram ................................................................................................................................. 3 Connectors table and arrangement drawing................................................................................................... 5

PC138US, USLC-8

1

SEN01981-01

2


PC138US, USLC-8

Electrical circuit diagram

PC138US, USLC-8

Electrical circuit diagram PC138US, USLC-8


3

Connectors table and arrangement drawing

PC138US, USLC-8

Connectors table and arrangement drawing PC138US, USLC-8

Connector No.

Model

Type of connector

A08

DT-T

6

A13

DT-T

Address

Connector No.

Model

Type of connector

Intermediate connector

F-9

P32

YAZAKI

2

Air conditioner daylight sensor

H-1

2


F-9

P44

DT-T

2

Engine oil level sensor

H-9

Component name

Component name

Address

H-9

P61

X

2

Pressure switch(Buket dump)

-

AB-4

P62

X

2

-

-

J-9

P63

X

2

-

-

-

P64

X

2

-

-

H-9

P65

X

2

-

-

-

P66

X

2

-

-

Orbcomm

-

P67

X

2

-

-

Starter switch

-

PAMB

AMP

3

Ambient pressure sensor

AF-5

AB

Terminal

1

Alternator (Terminal B)

AC01

YAZAKI

10


AC02

X

1

Air conditioner compressor electromagnetic clutch

ACC

Terminal

1

Starter switch

AR

SUMITOMO

3

Alternator

B

Terminal

1

Starter switch

BNC

-

1

BR

Terminal

1

BR

Terminal

1

Battery relay

L-7

PFUEL

BOSCH

3

Common rall pressure sensor

AG-5

C

Terminal

1

Starter switch

-

POIL

FRAMA TOME

1

Engine oil pressure switch (Low pressure)

AD-6

C01

AMP

81

CH700 controller

Z-4

PREG

BOSCH

2

Supply pump solenoid (IMV)

AD-7

C02

AMP

39

CH700 controller

Z-5

PTIM

BOSCH

4

Boost pressur/temp.

AD-8

CAN

FRAMA TOME

3

Engine Bkup speed sensor

AF-1

R1

Terminal

1

Starter switch

-

CE01

DRC

60

Engine controller

AE-9

R05

RELAY

5

Relay for light

X-9

CE02

DRC

60

Engine controller

K-9

R06

RELAY

5

Relay for Starter cut(Ppc lock)

Z-5

CE03

DTP

4

Engine controller

L-8

R07

RELAY

5

Relay for Starter cut(Personal cood)

Z-4

CK01

AMP

14

KOMTRAX communication module

AB-7

R10

RELAY

5

Relay for OPT. light

Y-8

CK02

AMP

10

KOMTRAX communication module

AA-7

R14

Terminal

1

Ribon heater relay

M-5

CM01

070

18

Machine monitor

O-6

R15

Terminal

1

Ribon heater relay

N-5

CM02

070

12

Machine monitor

O-6

R16

Terminal

1

Ribon heater relay

N-5

CM03

070

18

Machine monitor

O-5

R17

X

2

-

H-1

CM05

B60

8

Machine monitor

-

R18

Terminal

1

-

J-1

CN1

DT

2

Injector #1

AF-9

R19

Terminal

1

-

J-1

CN2

DT

2

Injector #2

AF-9

R20

RELAY

4

Blower relay

AB-4

CN3

DT

2

Injector #3

AG-9

R21

RELAY

4

Compressor relay

AB-5

CN4

DT

2

Injector #4

AG-9

R23

RELAY

5

Relay for CM2100(1)

AB-4

D01

SWP

8

Battery relay

AA-7

R24

RELAY

5

Relay for CM2100(2)

AB-4

D02

SWP

8

Ribbon heater relay/washer motor

Z-6

RB

Terminal

1

Battery relay

L-7

D03

SWP

8

Monitor light switch

Z-6

RE

Terminal

1

Battery relay

L-6

D10

-

2

Diode

AB-7

RM

Terminal

1

Battery relay

L-7

D11

-

2

Diode

AB-7

S02

SWP

6

Light switch

R-8

E01

Terminal

1

Ribbon heater

I-9

S04

SWP

6

Swing lock switch

R-8

E10

Terminal

1

Starting motor

I-9

S07

SWP

6

Beacon

S-8

F01

-

20

Fuse

X-9

S10

Y090

2

Right knob switch

Q-7

F02

L

2

Fuse(45A)

L-6

S14

M

3

PPC hydraulic lock switch

W-9

F03

L

2

Fuse(450A)

L-6

S21

-

5


Y-8

F04

Terminal

1

Fuse

L-4

S22

-

5

Emergency swing parking brake release

F05

Terminal

1

Fuse(50A)

K-1

S25

090

16


AA-7

F06

Terminal

1

Fuse(120A)

L-4

T01

Terminal

1

Floor frame

W-1

GT5

-

1

Antenna

F-1

T02

Terminal

1

Cab GND

L-5

H08

M

4


Y-5

T03

Terminal

1

GND

X-2

H09

M

8


Y-5

T04

Terminal

1

Floor frame

G-1

H15

S090

22


T-9

T05

Terminal

1

Revolving frame

G-1

H16

S

12


Y-3

T06

Terminal

1

GND

AF-5

J01

SUMITOMO

20

Junction connector (Pink)

T-9

T07

Terminal

1

GND

AE-5

J02

SUMITOMO

20


U-9

T08

Terminal

1

Revolving frame

I-1

J03

SUMITOMO

20


U-9

T09

Terminal

1

Revolving frame

I-1

J04

SUMITOMO

20

Junction connector (Black)

U-9

T10

Terminal

1

Revolving frame

I-1

J05

SUMITOMO

20

Junction connector (Green)

V-9

T11

Terminal

1

Revolving frame

H-1

J06

SUMITOMO

20

Junction connector (Black)

V-9

T12

Terminal

1

Revolving frame

H-1

J07

SUMITOMO

20


V-9

T14

Terminal

1

Revolving frame

V-1

K01

M

2

Pump resistor

Z-7

TNC

-

1

FOMA

L-5

K02

DT-T

3

CAN terminal resistance

K-9

TWTR

PACKARD

2

Engine water temperature sensor

L01

-

2

Working lamp (Boom)

B-9

V01

DT-T

2

PPC lock solenoid valve

C-9

L03

M

2

Cab light

I-9

V02

DT-T

2

Travel speed shifting solenoid valve

C-9

M01

PA

9

Radio

X-2

V03

DT-T

2

Swing holding brake solenoid valve

C-9

M02

M

2

Speaker(left)

J-9

V04

DT-T

2

Travel junction solenoid valve

B-8

M03

M

2

Speaker(right)

I-9

V05

DT-T

2

Confluece solenoid valve

A-8

M04

-

2

Cigar lighter

O-6

V10

DT-T

2

Bucket dump lock solenoid valve

E-9

M05

M

6

Wiper motor

"E-1,O-5"

V11

DT-T

2

PC-EPC valve

G-9

M06

KES

2

Window washer motor

K-1

V30

DT-T

2

Att current

Q-1

M07

090

2

Horn (High tone)

E-1

W03

M

2

Limit switch

J-9

M09

M

2

Optional power supply connector (1)

S-9

-

TAJIMI

8

Rear view camera

M10

M

2

Optional power supply connector (2)

W-2

M11

M

4

DC/DC converter

-

M12

M

2

12V outlet

-

M13

M

2

Optional power supply connector (12 V)

-

M14

DT-T

2

Travel alarm

D-9

M40

X

2

Head light(STD)

G-9

M41

X

2

Head light(OPT)

E-9

N08

DT-T

12

Service coneeector

X-9

N10

SUMITOMO

4


AB-3 AF-1

NE

FRAMA TOME

3

NE sensor

P01

X

2

Pressure switch(Buket dump)

A-6

P02

X

2

Pressure switch(Arm dump)

A-5

P03

X

2

Pressure switch(Boom UP)

A-5

P04

X

2

Pressure switch(Buket digging)

A-5

P05

X

2

Pressure switch(Arm digging)

A-5

P06

X

2

Pressure switch(Boom down)

A-5

P07

X

2

Pressure switch(Left swing)

A-4

P08

X

2

Pressure switch(Right swing)

A-4

P09

AMP

3

-

C-1

P10

AMP

3

-

D-1

P11

AMP

3

-

D-1

P12

DT-T

6


B-1

P13

X

2


R-1

P14

X

2

Pressure switch(Service)

Q-1

P15

X

2

Pressure switch(Service)

Q-1

P17

S 090

2

A/C HI/LO pressure switch

T-1

P20

M

3

Fuel dial

Q-9

P21

X

1

Fuel level sensor

F-9

P22

DT-T

2

Hydraulic oil temperature sensor

G-9

P25

AMP

3

Pump pressure sensor

A-6

P26

AMP

3

-

A-6

P27

AMP

3

-

A-6

P28

AMP

3

-

A-1

P29

DT-T

6


A-7

P31

YAZAKI

2

Sunshine sensor

O-6

Y-8

AE-9

-

SEN01981-01

PC138US, USLC-8

5


PC138US, USLC-8

SEN01981-01

7

SEN01981-01




8

PC138US, USLC-8

10795750-DKP8P8EM-Download Komatsu Pc138us-8 Pc138uslc-8 Excavator Manual

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