PC128US-2 SEBM018419.PDF

SEBM018419

Shop Manual

PC128US-2 PC138US-2 PC138USLC-2E0 HYDRAULIC EXCAVATOR SERIAL NUMBERS

PC128US-2 5001 - 7730 avance PC128US-2 7731 and up GALEO PC138US-2 4501 and up GALEO PC138USLC-2E0 1001 and up GALEO

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

Copyright 2007 Komatsu Printed in U.S.A. Komatsu America Corp. January 2005

CONTENTS No. of page

01

GENERAL ............................................................................................................ 01-1

10

STRUCTURE AND FUNCTION

20

TESTING AND ADJUSTING

30

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

40

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

90

OTHERS

00-2 4

........................................................... 10-1

................................................................ 20-1

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

PC128US-2

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00-2-5 (19)

SAFETY

SAFETY NOTICE

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

¤

To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS 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 precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two 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 signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. 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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety 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. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.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 machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places. Replace any damaged parts 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 being operated. 20.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. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.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.

FOREWORD

GENERAL

FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

00-6

123

Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

¤

Safety

Special safety precautions are necessary when performing the work.

Caution

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

Weight

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

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.

s

4 3 2 5 6

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING

¤ •

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol

4

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

★

Allowable load

mm

kN

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one 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.

¤

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER


¤ ¤

Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from 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.

Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD


Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

•

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS ★ ★

The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.

Category

Komatsu code

Part No.

Q'ty

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

LT-2

09940-00030

50 g


LT-3

790-129-9060 (Set of adhesive and hardening agent)

Adhesive: 1 kg Hardenin g agent: 500 g

Can

LT-4

790-129-9040

250 g


Holtz MH 705

790-126-9120

75 g

Tube

Three bond 1735

790-129-9140

50 g


2g


Adhesives

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

50 cc


LG-1

790-129-9010

200 g

Tube

LG-5

790-129-9070

1 kg

Can

Main applications, featuresr •

Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

•

Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride), rubber, metal and non-metal.

• •

Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.

•

Used as adhesive or sealant for metal, glass and plastic.

•

Used as sealant for machined holes.

•

Used as heat-resisting sealant for repairing engine.

• • •

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.

• •

Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.

• • •

Resistance to heat, chemicals Used at joint portions subject to high temperatures.

•

Used as adhesive or sealant for gaskets and packing of power train case, etc.

•

Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

•

Gasket sealant • LG-6

790-129-9020

200 g

Tube

• •

00-10

Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.

FOREWORD

Category

COATING MATERIALS

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr •

LG-7

790-129-9070

1g

Tube

Three bond 1211

790-129-9090

100 g

Tube

LM-G

09940-00051

60 g

Can

•

Adhesives

Molybdenum disulphide lubricant

LM-P

09940-00040

200 g

•

Used as heat-resisting sealant for repairing engine.

•

Used as lubricant for sliding portion (to prevent from squeaking).

•

Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.

Tube •

G2-LI

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI

G2-CA

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Various

Various

Molybdenum disulphide lubricant

SYG2-400M

400 g (10 per case)

Belows type

Grease

Various

Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

•

General purpose type

•

Used for normal temperature, light load bearing at places in contact with water or steam.

•

Used for places with heavy load

Various

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter of bolt

Width across flats

mm

mm

6 8 10 12 14

10 13 17 19 22

16 18 20 22 24

24 27 30 32 36

27 30 33 36 39

41 46 50 55 60

Thread diameter of bolt

Width across flats

mm

mm

Nm

6 8 10 12

10 13 14 27

7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85

Nm

kgm

0 0.15 0 0.3 0 0.7 01 02 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35

0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340

1.35 3.2 6.7 11.5 18

13.2 31 66 113 177

kgm

0 0 0 0

0.8 1.9 4.1 8.4

0 0.2 0 0.5 0 0.6 0 0.8

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49

2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5

00-12

Tightening torque

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

FOREWORD


TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

10 12 16

14 17 22

65.7 6.8 112 9.8 279 29

0 0 0

6.7 0.7 11.5 1 28.5 3

0

0 0

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

14 20 24 33 42

Varies depending on type of connector.

34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3

Norminal No.

02 03, 04 05, 06 10, 12 14

kgm

0 0 0 0 0

0 0.5 01 02 06 0 13.5

3.5 9.5 14.5 43 89.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 n 36 n n

7.35 1.47 11.27 1.47 17.64 1.96 22.54 1.96 29.4 4.9 39.2 4.9 49 4.9 68.6 9.8 107.8 14.7 127.4 19.6 151.9 24.5 210.7 29.4 323.4 44.1

0 0 0 0 0 0 0 0 0 0 0 0 0

0.75 0.15 1.15 0.15 1.8 0.2 2.3 0.2 3 0.5 4 0.5 5 0.5 7 1 11 1.5 13 2 15.5 2.5 21.5 3 33 4.5

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

0 0 0 0 0 0 0 0 0 0 0 0 0

00-13

FOREWORD


TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

6 8 10 12

10 2 24 4 43 6 77 12

kgm

0 0 0 0

1.02 2.45 4.38 7.85

0 0.20 0 0.41 0 0.61 0 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

6 8 10 12 14

8 2 10 2 12 2 24 4 36 5

kgm

0 0 0 0 0

0.81 1.02 1.22 2.45 3.67

0 0.20 0 0.20 0 0.20 0 0.41 0 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

Nm

1 / 16 1/8 1/4 3/8 1/2 3/4 1

3 1 8 2 12 2 15 2 24 4 36 5 60 9

kgm

0 0 0 0 0 0 0

0.31 0.81 1.22 1.53 2.45 3.67 6.12

0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats

Taper seal type

Face seal type

Nominal thread Root diameter Thread size size - Threads per (mm) (Reference) (mm) inch, Thread series

Range

Target

19

35 - 63 {3.5 - 6.5}

44 {4.5}

14

9 – - 18UNF 16

14.3

22

54 - 93 {5.5 - 9.5}

74 {4.5}

–

11 – - 16UN 16

17.5

24

59 - 98 {6.0 - 10.0}

78 {8.0}

18

–

–

04

27

84 - 132 {8.5 - 13.5}

103 {10.5}

22

13 – - 16UN 16

20.7

05

32

128 - 186 {13.0 - 19.0}

157 {16.0}

24

1 - 14UNS

25.4

06

36

177 - 245 {18.0 - 25.0}

216 {22.0}

30

3 1 – - 12UNF 16

30.3

(10)

41

177 - 245 {18.0 - 25.0}

216 {22.0}

33

–

–

(12)

46

197 - 294 {20.0 - 30.0}

245 {25.0}

36

–

–

(14)

55

246 - 343 {25.0 - 35.0}

294 {30.0}

42

–

–

02

03

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm 2)

0.85

11

0.32

2

26

5

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

1

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

W

B

B

R

Y

G

L

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

BW

RW

YR

GW

LW

2 Color White & Red Code

WB

3 Color White & Black Code 4

Auxiliary

WL

Color White & Blue Code

WG

5 Color White & Green Code 6 Color

n n

n n n n n n n n n n

White & Black Red & White Rellow & Red Green & White Blue & White BY

RB

YB

GR

LR

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

RY

Black & Red Red & Yellow

n n n n

RG

YG

GY

LY

Yellow & Green

Green & Yellow

Blue & Yellow

YL

GB

LB

Red & Green Yellow & Blue Green & Black Blue & Black RL

YW

GL

Red & Blue Yellow & White Green & Blue

n n 00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE 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 , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point 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 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.

A B

C

C

A

B

B Millimeters to inches 1 mm = 0.03937 in

A

00-16

0

1

2

3

4

5

6

7

8

9

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197 0.591 0.984 1.378 1.772

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 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

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

C

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0

1

2

3

4

5

6

7

8

9

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

0

Kilogram to Pound 1 kg = 2.2046 lb

0 0

0

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0

1

2

3

4

5

6

7

8

9

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

0

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0

1

2

3

4

5

6

7

8

9

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

0

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2

0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–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

117.8 179.6 181.4 183.2 185.0

–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 0

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

00-21

FOREWORD

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

}.

01

GENERAL

General assembly drawing .......................... Specifications ....... ;. ...................................... Weight table .................................................. List of lubricants and water.. .......................

PC 128US-2

Ol- 2 Ol- 5 01-11 01-15

01-l

GENERAL ASSEMBLY DRAWING

GENERAL

SPECIFICATION DIMENSIONAL DRAWING PC128US-2 Serial No.: 7731 and up

Item

Machine weight

PC128US-2 Unit

12,950

Standard specification Blade specification

7731 and up

kg

13,450

Bucket capacity

m3

0.45

Engine type

—

Komatsu S4D102E-1 Diesel engine

kW{HP}/rpm

64 {85.8}/2,200

Standard specification

mm

7,220

Blade specification

mm

7,955

B Overall height

mm

2,850

C Overall width

mm

2,515

D Shoe width

mm

500

Engine rated output A

Overall length

A'

E

Trail swing radius

mm

1,480

F

Crawler overall length

mm

3,480

G Distance between tambler center

mm

2,750

H Cab height

mm

2,810

Minimum ground clearance

mm

390

Traveling speed (Low/High)

km/h

3.2/5.1

Continuous swing speed

rpm

11.0

PC128US-2

01-4-3 (15)


GENERAL

PC138US-2 Serial No.: 4501 and up

Item

Machine weight

PC138US-2 Unit

Standard specification Blade specification

4501 and up 13,400

kg

14,050

Bucket capacity

m3

0.50

Engine type

—

Komatsu SAA4D95LE-3-A Diesel engine

kW{HP}/rpm

66.2 {88.7}/2,200

Standard specification

mm

7,220

Blade specification

mm

7,955

B Overall height

mm

2,850

C Overall width

mm

2,515

D Shoe width

mm

500

Engine rated output A

Overall length

A'

E

Trail swing radius

mm

1,480

F


mm

3,610

G Distance between tambler center

mm

2,880

H Cab height

mm

2,815


mm

395


km/h

2.9/5.1


rpm

11.0

01-4-4 (15)

PC128US-2

GENERAL


PC138USLC-2 Serial No.: 1001 – 1500

Item

PC138USLC-2 Unit

Standard specification Machine weight

Blade specification

0.50

Engine type

—

Komatsu S4D102E-1 Diesel engine

kW{HP}/rpm

64 {85.8}/2,200

Standard specification Overall length

D Shoe width

mm

Blade specification Standard specification

7,395 8,035

mm Standard specification

Overall width

mm

Blade specification

Overall height

C C'

14,370

m3

A

B

14,000 kg

Bucket capacity

Engine rated output

A'

1001 – 1500

2,850 2,590 2,515

mm

Blade specification

600 500

E

Trail swing radius

mm

1,480

F


mm

3,880

mm

3,140

Cab height

mm

2,815


mm

395


km/h

2.9/4.7


rpm

11.0

G Distance between tambler center H

PC128US-2

01-4-5 (15)

GENERAL


PC138USLC-2 Serial No.: 1501 and up

Item

PC138USLC-2 Unit

Standard specification Machine weight

Blade specification

0.50

Engine type

—

Komatsu SAA4D95LE-3-E Diesel engine

kW{HP}/rpm

66.2 {88.7}/2,200

Standard specification Overall length

Overall width

D Shoe width

mm

Blade specification Standard specification

7,390 8,035

mm Standard specification

C

mm

Blade specification

Overall height

C'

14,370

m3

A

B

14,000 kg

Bucket capacity

Engine rated output

A'

1501 and up

2,850 2,590 2,515

mm

Blade specification

600 500

E

Trail swing radius

mm

1,480

F


mm

3,870

mm

3,140

Cab height

mm

2,815


mm

395


km/h

2.9/5.1


rpm

11.0

G Distance between tambler center H

01-4-6 (15)

PC128US-2


GENERAL

WORKING RANGE DRAWING PC128US-2

Serial No.: 7731 and up

PC128US-2 Working range (mm)

7731 and up

A

Maximum digging radius

8,230

B

Maximum digging depth

5,405

C

Maximum digging height

9,260

D

Maximum vertical wall digging depth

4,860

E

Maximum dumping height

6,910

F

Minimum swing radius of work equipment

1,980

G

Maximum reach at ground level

8,110

H

Maximum raising distance of blade

470

I

Maximum lowering distance of blade

530

PC128US-2

01-4-7 (15)


GENERAL

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

Working range (mm)

PC138US-2

PC138USLC-2

4501 and up

1001 and up

A

Maximum digging radius

8,300

B

Maximum digging depth

5,480

C

Maximum digging height

9,340

D

Maximum vertical wall digging depth

4,900

E

Maximum dumping height

6,840

F

Minimum swing radius of work equipment

1,980

G

Maximum reach at ground level

8,180

H

Maximum raising distance of blade

I

Maximum lowering distance of blade

01-4-8 (15)

470 525

490

PC128US-2

SPECIFICATIONS

GENERAL

SPECIFICATIONS FOR STD SPEC. PC128US-2 Serial No.: 5001 – 7730 PC128US-2 Machine model

Without blade

Serial No.

5001 – 7730

Bucket capacity (SAE)

m3

0.45

0.45

Operating weight

kg

12,950

13,450

Max. digging depth

mm

5,445

5,445

Max. digging depth of cut for 2,440 mm 8' level

mm

5,235

5,235

Working ranges Performance

With blade

Max. vertical wall depth

mm

4,900

4,900

Max. digging reach Max. reach st ground level

mm mm

8,230 8,110

8,230 8,110

Max. digging height Max. dumping height

mm mm

9,220 6,870

9,220 6,870

Max. blade lifting amount Max. blade lowering amount

mm mm

— —

470 [535] 530 [465]

KN {kg}

93.2 {9,500}

93.2 {9,500}

Serial No. 6457 and up

rpm

11.0

11.0

Serial No. 5001 – 6456

rpm

12

12

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm2}

42.2 {0.43}

43.1 {0.44}

Overall length (for transport)

mm

7,220

7,955

Overall width

mm

2,490

2,490

Overall width of undercarrige

mm

2,490

2,490

Overall height (for transport)

mm

2,850 [2,890]

2,850 [ 2,890]

Overall height to top of cab

mm

2,730 [2,795]

2,730 [2,795]

Ground clearance of counterweight

mm

855 [920]

855 [920]

Min. ground clearance

mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

1,980

1,980

Height of work equipment at min. swing radius

mm

6,725 [6,790]

6,725 [6,790]

Length of track on ground

mm

2,750

2,750

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,935 [2,000]

1,935 [2,000]

Blade width x height

mm

—

2,490 x 590

Max. digging force (bucket) Swing speed

Dimension

Ground pressure

fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped. PC128US-2

01-5 (15)

SPECIFICATIONS

GENERAL

PC128US-2 Machine model

Without blade

Serial No.

5001 – 7730

Model

S4D102E-1 4-cycle, water-cooled, in-line, vertical, direct injection, with turbochatger

No. of cylinders-bore x stroke

mm

4 – 102 x 120

Piston displacement

¬ {cc}

3.920 {3,920}

Rated horsepower

kW/rpm{HP/rpm}

64/2,200 {87/2,200}

Max. torpue

Nm/rpm{kgm/rpm}

329/1,300 {33.5/1,300}

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio Starting motor

24V, 4.5 kw

Alternator

24V, 25A

Undercarriage

Battery Radiator type

CF19-4

Carrier roller

1 on each side

Track roller

7 on each side Asembly-type triple grouster, 42 on each side

Hydraulic pump

(road liner)

Hydraulic motor control valve

Hydraulic system

12V, 64 Ah x 2

Track shoe (iron shoe)

Road liner, 42 on each side HPV95 (for 105cc/rev.)

Type x no.

Variable displacement piston type x 1 ¬ /min

Discharge Set pressure (at operation) (at traveling) Type x no. Control method

226 (at 2,200rpm) 2

MPa {kg/cm }

31.9 {325} 34.8 {355} 6-spool type x 1 Hydraulic type

Travel motor

GM18VL-J Variable displacement piston type (with brake valve, holding brake) x 2

Swing motor

KMF40ABE-3 Fixed displacement piston type (with shockless safety valve, holding brake) x 1

Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic cooler

01-6 (15)

With blade

Air cooled (CF40-1)

PC128US-2

SPECIFICATIONS

GENERAL


STD (without blade)

Serial No.

5001 – 7730

Boom cylinder

Type

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Reciprocating piston tipe


Arm cylinder

Cylinder inner diameter

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,877

2,877


mm

1,702

1,702




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


mm

Type Bucket cylinder

Work equipment cylinder

Hydraulic system



Type

PC128US-2

OPT (with blade)


mm

—

115

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

01-7 A

SPECIFICATIONS

GENERAL

FOR NORTH AMERICA SPEC. PC128US-2 Serial No.: 5001 – 7730 PC128US-2 Machine model

STD (without blade)

Serial No.

5001 – 7730


m3

0.45

0.45

Operating weight

kg

13,100

13,600

Max. digging depth

mm

5,445

5,445


mm

5,235

5,235


OPT (with blade)


mm

4,900

4,900

Max. digging reach

mm

8,230

8,230

Max. reach st ground level

mm

8,110

8,110

Max. digging height

mm

9,220

9,220

Max. dumping height

mm

6,870

6,870

Max. blade lifting amount

mm

—

470 [535]

Max. blade lowering amount

mm

—

530 [465]

KN {kg}

93.2 {9,500}

93.2 {9,500}


rpm

11.0

11.0

Serial No. 5001 – 6456

rpm

12

12


deg.

19

19


km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm2}

35.6 {0.36}

37.0 {0.38}


mm

7,220

7,955

Overall width

mm

2,590

2,590


mm

2,590

2,590


mm

2,850 [2,890]

2,850 [2,890]


mm

2,730 [2,795]

2,730 [2,795]


mm

855 [920]

855 [920]


mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480


mm

1,980

1,980


mm

6,725 [6,790]

6,725 [6,790]


mm

2,750

2,750

Track gauge

mm

1,990

1,990


mm

1,935 [2,000]

1,935 [2,000]


mm

—

2,490 x 590


Dimension

Ground pressure

fl The values shown in the [

01-8 A

] are those for the machines when the road liner shoe is equipped. PC128US-2

SPECIFICATIONS

GENERAL

PC128US-2 Machine model Without blade Serial No.

5001 – 7730

Model



mm

4 – 102 x 120

Piston displacement

¬ {cc}

3.92 {3,920}

Flywheel horsepower

kW/rpm{HP/rpm}

64/2,200 {87/2,200}

Maximum torpue

Nm/rpm{kgm/rpm}

329/1,300 {33.5/1,300}

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type


24V, 4.5 kw

Alternator

24V, 25A 12V, 72Ah x 2

Radiator type

CF19-4

Carrier roller

1 on each side

Track roller

7 on each side Asembly-type triple grouster, 42 on each side [Road liner, 42 on each side]

Track shoe

Hydraulic motor

control valve

Hydraulic pump

Undercarriage

Battery

Hydraulic system

With blade

HPV95 (for 105cc/rev.) Type x no.

Variable displacement piston type x 1


¬ /min

226 (at 2,200rpm)

MPa {kg/cm2}


Travel motor

GM18VL-J Variable displacement piston type (with brake valve, parking brake) x 2

Swing motor

KMF40ABE-3 Fixed displacement piston type (with shockless safety valve, parking brake) x 1

Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic oil filter

Air cooled (CF40-1)


01-9 (15)

GENERAL

SPECIFICATIONS


Without blade

Serial No.

5001 – 7730

Boom cylinder

Type

Reciprocating piston tipe mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055


mm

2,555

2,555


mm

1,500

1,500

Arm cylinder Blade cylinder



mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,877

2,877


mm

1,702

1,702



Hydraulic system





mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885


mm

2,263

2,263


mm

1,378

1,378

Type

(15)



Type

01-10

With blade

—



mm

—

115

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

PC128US-2

SPECIFICATIONS

GENERAL

FOR KUK SPEC. PC128US-2 Serial No.: 5001 – 7730 PC128US-2 Machine model

Without blade

Serial No.

5001 – 7730


m3

0.36

0.36

Operating weight

kg

12,750

13,250

Max. digging depth

mm

5,945

5,945


mm

5,760

5,760


mm

5,385

5,385

Max. digging reach

mm

8,720

8,720


mm

8,600

8,600


With blade

Max. digging height

mm

9,655

9,655

Max. dumping height

mm

7,305

7,305


mm

—

470 [535]


mm

—

530 [465]

KN {kg}

88.3 {9,000}

88.3 {9,000}


rpm

11.0

11.0

Serial No. 5001 – 6456

rpm

12

12


deg.

19

19


km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm }

42.2 {0.43}

43.1 {0.44}


mm

7,120

7,855

Overall width

mm

2,490

2,490


mm

2,490

2,490


mm

3,190 [3,230]

3,190 [3,230]


mm

2,730 [2,795]

2,730 [2,795]


mm

855 [920]

855 [920]


mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480


mm

2,250

2,250


mm

6,725 [6,790]

6,725 [6,790]


mm

2,750

2,750

Track gauge

mm

1,990

1,990


mm

1,935 [2,000]

1,935 [2,000]


mm

—

2,490 x 590


Dimension

Ground pressure

2

fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped. fl The above values are for the machines equipped with the long arm and 0.36 m3 bucket.

PC128US-2

01-10-1 (15)

GENERAL

SPECIFICATIONS

PC128US-2 Machine model Without blade Serial No.

5001 – 7730

Model



mm

4 – 102 x 120

Piston displacement

¬ {cc}

3.92 {3,920}

Flywheel horsepower

kW/rpm{HP/rpm}

64/2,200 {87/2,200}

Maximum torpue

Nm/rpm{kgm/rpm}

329/1,300 {33.5/1,300}

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type


24V, 4.5 kw

Alternator

24V, 35A 12V, 64Ah x 2

Radiator type

CF19-4

Carrier roller

1 on each side

Track roller

7 on each side Asembly-type triple grouster, 42 on each side [Road liner, 42 on each side]

Track shoe

Hydraulic motor

control valve

Hydraulic pump

Undercarriage

Battery

Hydraulic system

With blade




¬ /min

226 (at 2,200rpm)

MPa {kg/cm2}


Travel motor

GM18VL-J Variable displacement piston type (with brake valve, parking brake) x 2

Swing motor

KMF40ABE-3 Fixed displacement piston type (with shockless safety valve, parking brake) x 1

Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic oil filter


01-10-2 (15)

Air cooled (CF40-1)


GENERAL

SPECIFICATIONS


STD (without blade)

Serial No.

5001 – 7730

Boom cylinder

Type


105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055


mm

2,555

2,555


mm

1,500

1,500

Arm cylinder


mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,877

2,877


mm

1,702

1,702




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





Hydraulic system



Type

PC128US-2

OPT (with blade)

—



mm

—

115

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

01-10-3 A

SPECIFICATIONS

GENERAL

PC128US-2 Serial No.: 7731 and up PC128US-2 Machine model

STD (without blade) 7731 and up


m3

0.45

0.45

Operating weight

kg

12,950

13,450

Max. digging depth

mm

5,405

5,405


mm

5,195

5,195


mm

4,860

4,860

Max. digging reach

mm

8,230

8,230


mm

8,110

8,110

Max. digging height

mm

9,260

9,260

Max. dumping height

mm

6,910

6,910


mm

—

470 [535]


mm

—

530 [465]

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0


deg.

19

19


km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm2}

42.2 {0.43}

43.1 {0.44}


mm

7,220

7,955

Overall width

mm

2,515

2,515


mm

2,490

2,490


mm

2,850 [2,890]

2,850 [ 2,890]


mm

2,810 [2,875]

2,810 [2,875]


mm

895 [960]

895 [960]


mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480


mm

1,980

1,980


mm

6,765 [6,830]

6,765 [6,830]


mm

2,750

2,750

Track gauge

mm

1,990

1,990


mm

1,975 [2,040]

1,975 [2,040]


mm

—

2,490 x 590

Working ranges

Persormance

Serial No.

Max. digging force (bucket)

Ground pressure

Dimension

OPT (with blade)


01-10-4 A


SPECIFICATIONS

GENERAL


Without blade

Serial No.

7731 and up

Model



mm

4 – 102 x 120

Piston displacement

¬ {cc}

3.920 {3,920}

Rated horsepower

kW/rpm{HP/rpm}

64/2,200 {87/2,200}

Max. torpue

Nm/rpm{kgm/rpm}

329/1,300 {33.5/1,300}

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type


24V, 4.5 kw

Alternator

24V, 25A

(For KUK spec.)

24V, 35A

Battery

12V, 64 Ah x 2 12V, 72 Ah x 2

Radiator type

CF19-4

Carrier roller

1 on each side

Track roller

7 on each side


Asembly-type triple grouster, 42 on each side Road liner, 42 on each side

(road liner)

Hydraulic motor

Control valve

Hydraulic pump

Undercarriage

(For North America spec.)

Hydraulic system

With blade




¬ /min

226 (at 2,200rpm)

MPa {kg/cm2}


Travel motor

GM18VL-J Variable displacement piston type (with brake valve, holding brake) x 2

Swing motor


Hydraulic tank Hydraulic filter Hydraulic cooler

PC128US-2

Box-shaped, open Tank return side Air cooled (CF40-1)

01-10-5 (15)

GENERAL

SPECIFICATIONS


Without blade

Serial No.

7731 and up

Boom cylinder

Type


105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055


mm

2,555

2,555


mm

1,500

1,500

Arm cylinder Blade cylinder



mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,877

2,877


mm

1,702

1,702



Hydraulic system





mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885


mm

2,263

2,263


mm

1,378

1,378

Type

(15)



Type

01-10-6

With blade

—



mm

—

115

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

PC128US-2

SPECIFICATIONS

GENERAL


Without blade

m3

0.50

0.50

Operating weight

kg

13,400

14,050

Max. digging depth

mm

5,480

5,480


mm

5,265

5,265


mm

4,900

4,900

Max. digging reach

mm

8,300

8,300


mm

8,180

8,180

Max. digging height

mm

9,340

9,340

Max. dumping height

mm

6,840

6,840


mm

—

470 [535]


mm

—

525 [460]

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0


deg.

19

19


km/h

5.1/2.9

5.1/2.9

Gradeability

deg.

35

35

kPa {kg/cm2}

42.2 {0.43}

44.1 {0.45}


mm

7,260

7,955

Overall width

mm

2,515

2,515


mm

2,490

2,490


mm

2,850 [2,890]

2,850 [ 2,890]


mm

2,815 [2,880]

2,815 [2,880]


mm

900 [965]

900 [965]


mm

395 [460]

395 [460]

Tail swing radius

mm

1,480

1,480


mm

1,980

1,980


mm

6,770 [6,835]

6,770 [6,835]


mm

2,880

2,880

Track gauge

mm

1,990

1,990


mm

1,980 [2,045]

1,980 [2,045]


mm

—

2,490 x 590


Ground pressure

Dimension

4501 and up


Working ranges

Persormance

Serial No.

With blade


01-10-7 (15)

SPECIFICATIONS

GENERAL


Without blade

Serial No.

4501 and up

Model

SAA4D95LE-3-A 4-cycle, water-cooled, in-line, vertical, direct injection, with turbochatger, after cooler


mm

4 – 95 x 115

Piston displacement

¬ {cc}

3.260 {3,260}

Rated horsepower

kW/rpm{HP/rpm}

66.2/2,200 {88.7/2,200}

Max. torpue

Nm/rpm{kgm/rpm}

353/1,500 {36.0/1,500}

High idling speed

rpm

2,400

Low idling speed

rpm

1,100

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type


24V, 3.0 kw

Alternator

24V, 25A

(For KUK spec.)

24V, 35A

Battery

12V, 64 Ah x 2 12V, 72 Ah x 2

Radiator type

Corrugated aluminum (4-line)

Carrier roller

1 on each side

Track roller

7 on each side


Asembly-type triple grouster, 43 on each side Road liner, 43 on each side

(road liner)

Hydraulic motor

Control valve

Hydraulic pump

Undercarriage

(For North America spec.)

Hydraulic system

With blade




¬ /min

226 (at 2,200rpm)

MPa {kg/cm2}


Travel motor

GM20VL2-P Variable displacement piston type (with brake valve, holding brake) x 2

Swing motor


Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic cooler

Air cooled (CF40)

01-10-8 (15)

PC128US-2

GENERAL

SPECIFICATIONS


Without blade

Serial No.

4501 and up

Boom cylinder

Type


105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055


mm

2,555

2,555


mm

1,500

1,500

Arm cylinder


115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,877

2,877


mm

1,702

1,702




mm

100

100

Piston rod diameter

mm

65

65

Stroke

mm

885

885


mm

2,263

2,263


mm

1,378

1,378

Type Blade cylinder





Hydraulic system



Type

PC128US-2

With blade

—



mm

—

115

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

01-10-9 (15)

SPECIFICATIONS

GENERAL

PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Machine model

Without blade

m3

0.50

0.50

Operating weight

kg

14,000

14,370

Max. digging depth

mm

5,480

5,480


mm

5,265

5,265


mm

4,900

4,900

Max. digging reach

mm

8,300

8,300


mm

8,180

8,180

Max. digging height

mm

9,340

9,340

Max. dumping height

mm

6,840

6,840


mm

—

470


mm

—

490

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0


deg.

19

19


km/h

4.7/2.9

4.7/2.9

Gradeability

deg.

35

35

kPa {kg/cm }

33.6 {0.35}

42.2 {0.43}


mm

7,395

8,035

Overall width

mm

2,590

2,515


mm

2,590

2,490


mm

2,850

2,850


mm

2,815

2,815


mm

900

900


mm

395

395

Tail swing radius

mm

1,480

1,480


mm

1,980

1,980


mm

6,770

6,770


mm

3,140

3,140

Track gauge

mm

1,990

1,990


mm

1,980

1,980


mm

—

2,490 x 590


Ground pressure

Dimension

1001 – 1500


Working ranges

Performance

Serial No.

With blade

01-10-10 (15)

2

PC128US-2

SPECIFICATIONS

GENERAL

PC138USLC-2 Machine model

Without blade

Serial No.

1001 – 1500

Model



mm

4 – 102 x 120

Piston displacement

¬ {cc}

3.920 {3,920}

Rated horsepower

kW/rpm{HP/rpm}

64/2,200 {87/2,200}

Max. torpue

Nm/rpm{kgm/rpm}

329/1,300 {33.5/1,300}

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type


24V, 4.5 kw

Alternator

24V, 25A 12V, 72 Ah x 2

Radiator type

CF19-4

Carrier roller

2 on each side

Track roller

8 on each side

Control Hydraulic pump valve


Hydraulic motor

Undercarriage

Battery

Hydraulic system

With blade

Asembly-type triple grouster, 46 on each side HPV95 (for 105cc/rev.)

Type x no.



226 (at 2,200rpm) 2

MPa {kg/cm }


Travel motor

GM20VL-P Variable displacement piston type (with brake valve, holding brake) x 2

Swing motor


Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic cooler

PC128US-2

Air cooled (CF40-1)

01-10-11 (15)

GENERAL

SPECIFICATIONS


Without blade

Serial No.

1001 – 1500

Boom cylinder

Type


105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055


mm

2,555

2,555


mm

1,500

1,500



Arm cylinder

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,877

2,877


mm

1,702

1,702





Hydraulic system



mm

100

100

Piston rod diameter

mm

65

65

Stroke

mm

885

885


mm

2,263

2,263


mm

1,378

1,378

—


Blade cylinder

Type

(15)



Type

01-10-12

With blade


mm

—

115

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

PC128US-2

SPECIFICATIONS

GENERAL

PC138USLC-2 Serial No.: 1501 and up PC138USLC-2 Machine model

Without blade

m3

0.50

0.50

Operating weight

kg

14,000

14,370

Max. digging depth

mm

5,480

5,480


mm

5,265

5,265


mm

4,900

4,900

Max. digging reach

mm

8,300

8,300


mm

8,180

8,180

Max. digging height

mm

9,340

9,340

Max. dumping height

mm

6,840

6,840


mm

—

470


mm

—

490

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0


deg.

19

19


km/h

5.1/2.9

5.1/2.9

Gradeability

deg.

35

35

kPa {kg/cm }

33.6 {0.35}

42.2 {0.43}


mm

7,390

8,035

Overall width

mm

2,590

2,515


mm

2,590

2,490


mm

2,850

2,850


mm

2,815

2,815


mm

900

900


mm

395

395

Tail swing radius

mm

1,480

1,480


mm

1,980

1,980


mm

6,770

6,770


mm

3,140

3,140

Track gauge

mm

1,990

1,990


mm

1,980

1,980


mm

—

2,490 x 590


Ground pressure

Dimension

1501 and up


Working ranges

Performance

Serial No.

With blade

PC128US-2

2

01-10-13 (15)

SPECIFICATIONS

GENERAL


Without blade

Serial No.

1501 and up

Model

SAA4D95LE-3-A 4-cycle, water-cooled, in-line, vertical, direct injection, with turbochatger, after cooler


mm

4 – 95 x 115

Piston displacement

¬ {cc}

3.260 {3,260}

Rated horsepower

kW/rpm{HP/rpm}

66.2/2,200 {88.7/2,200}

Max. torpue

Nm/rpm{kgm/rpm}

353/1,500 {36.0/1,500}

High idling speed

rpm

2,400

Low idling speed

rpm

1,100

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type


24V, 3.0 kw

Alternator

24V, 25A 12V, 72 Ah x 2

Radiator type

Corrugated aluminum (4-line)

Carrier roller

2 on each side

Track roller

8 on each side

Control Hydraulic pump valve


Hydraulic motor

Undercarriage

Battery

Hydraulic system

With blade

Asembly-type triple grouster, 46 on each side HPV95 (for 105cc/rev.)

Type x no.



226 (at 2,200rpm) 2

MPa {kg/cm }


Travel motor

GM20VL2-P Variable displacement piston type (with brake valve, holding brake) x 2

Swing motor


Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic cooler

Air cooled (CF40)

01-10-14 (15)

PC128US-2

GENERAL

SPECIFICATIONS


Without blade

Serial No.

1501 and up

Boom cylinder

Type


105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055


mm

2,555

2,555


mm

1,500

1,500



Arm cylinder


mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175


mm

2,877

2,877


mm

1,702

1,702





Hydraulic system


mm

100

100

Piston rod diameter

mm

65

65

Stroke

mm

885

885


mm

2,263

2,263


mm

1,378

1,378

—


Type Blade cylinder



Type

PC128US-2

With blade


mm

—

115

Piston rod diameter

mm

—

75

Stroke

mm

—

181


mm

—

870


mm

—

689

01-10-15 (15)

GENERAL

WEIGHT TABLE

WEIGHT TABLE ¤

This weight table is a guide for use when transporting or handling component.

FOR STD SPEC. PC128US-2 Serial No.: 5001 – 7730

Unit: kg PC128US-2

Machine model

Without blade

Serial No.

With blade 5001 – 7730

Engine assembly (excl. water, oil)

491

491

• Engine (excl. water, oil)

385

385

• Engine mount

21.6

21.6

• PTO

4.1

4.1

• Hydraulic pump

80

80

Radiator, oil cooler assembly

54

54

1,500

1,500

Operator’s cab

228

228

Operator’s seat

12.6

12.6

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

80

96

Self pressure reducing valve

4.8

4.8

3,020

2,460

Swing motor (with brake valve)

26

26

Swing circle

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly

2,275

2,445

• Track frame

1,280

1,438

• Idler assembly

81 x 2

81 x 2

72.9 x 2

72.9 x 2

• Carrier roller

11 x 2

11 x 2

• Track roller

21 x 14

21 x 14

• Travel motor, final drive assembly

144 x 2

144 x 2

• Sprocket

33.7 x 2

33.7 x 2

Revolving frame

Counterweight

• Recoil spring assembly

PC128US-2

01-11 (15)

WEIGHT TABLE

GENERAL

Unit: kg PC128US-2 Machine model

Without blade

Serial No.


Track shoe assembly • Triple grouser shoe (500mm)

740 x 2

740 x 2

• Triple grouser shoe (600mm)

830 x 2

830 x 2

• Road liner (500mm)

765 x 2

765 x 2

Boom assembly

820

820

Arm assembly

356

356

Bucket link assembly

85.6

85.6

Bucket assembly

369

369

Blade assembly

—

641

113.3 x 2

113.3 x 2

Arm cylinder assembly

140.9

140.9

Bucket cylinder assembly

86.3

86.3

Blade cylinder assembly

—

67.2 x 2

Boom cylinder assembly

01-12 (15)

PC128US-2

WEIGHT TABLE

GENERAL

FOR NORTH AMERICA SPEC. PC128US-2 Serial No.: 5001 – 7730

Unit: kg PC128US-2

Machine model

Without blade

Serial No.



491

491


385

385

• Engine mount

21.6

21.6

• PTO

4.1

4.1

• Hydraulic pump

80

80


54

54

1,500

1,500

Operator’s cab

228

228

Operator’s seat

12.6

12.6


98

98


92

92

Control valve

80

96


4.8

4.8

3,020

2,460

Swing motor

26

26

Swing circle assembly

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6


2,275

2,445

• Track frame

1,280

1,438

• Idler

81 x 2

81 x 2

• Idler cushion

72.9 x 2

72.9 x 2

• Carrier roller

11 x 2

11 x 2

• Track roller

21 x 14

21 x 14

Revolving frame assembly

Counterweight


144 x 2

144 x 2

• Sprocket

33.7 x 2

33.7 x 2


740 x 2

740 x 2


830 x 2

830 x 2


925 x 2

925 x 2

• Road liner (rubber pad type) (500mm)

765 x 2

765 x 2

Track shoe assembly

PC128US-2

01-13 (15)

WEIGHT TABLE

GENERAL


Without blade

Serial No.


Boom assembly

820

820

Arm assembly

356

356

Link assembly

85.6

85.6

Bucket assembly

369

369

Blade assembly

—

641

113.3 x 2

113.3 x 2

140.9

140.9


86.3

86.3


—

67.2 x 2

Boom cylinder assembly Arm cylinder assembly

01-14 (15)

PC128US-2

WEIGHT TABLE

GENERAL

FOR KUK SPEC. Unit: kg

PC128US-2 Serial No.: 5001 – 7730 PC128US-2 Machine model

Without blade

Serial No.



491

491


385

385

• Engine mount

21.6

21.6

• PTO

4.1

4.1

• Hydraulic pump

80

80


54

54

1,500

1,500

Operator’s cab

228

228

Operator’s seat

35

35


98

98


92

92

Control valve

96

106


4.8

4.8

Boom hydraulic drift prevention valve

5.1

5.1

3,020

2,460

Swing motor

26

26


155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6


2,275

2,445

• Track frame

1,280

1,438

• Idler

81 x 2

81 x 2

• Idler cushion

72.9 x 2

72.9 x 2

• Carrier roller

11 x 2

11 x 2

• Track roller

21 x 14

21 x 14


Counterweight


144 x 2

144 x 2

• Sprocket

33.7 x 2

33.7 x 2


740 x 2

740 x 2


830 x 2

830 x 2


925 x 2

925 x 2


765 x 2

765 x 2

Track shoe assembly

PC128US-2

01-14-1 (15)

WEIGHT TABLE

GENERAL


Without blade

Serial No.


Boom assembly

820

820

Arm assembly (long arm)

480

480

Link assembly

85.6

85.6

376

376

—

641

113.3 x 2

113.3 x 2

140.9

140.9


86.3

86.3


—

67.2 x 2

3

Bucket assembly (0.36 m ) Blade assembly Boom cylinder assembly Arm cylinder assembly

01-14-2 (15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg


Without blade

Serial No.

With blade 7731 and up


491

491


385

385

• Engine mount

21.6

21.6

• PTO

4.1

4.1

• Hydraulic pump

80

80


54

54

1,500

1,500

Operator’s cab

245

245

Operator’s seat

35

35


98

98


92

92

Control valve

80

96

(For KUK spec.)

96

106


4.8

4.8

3,020

2,460

Swing motor

26

26


155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6


2,275

2,445

• Track frame

1,280

1,438

• Idler

81 x 2

81 x 2

• Idler cushion

72.9 x 2

72.9 x 2

• Carrier roller

11 x 2

11 x 2

• Track roller

21 x 14

21 x 14


144 x 2

144 x 2

• Sprocket

33.7 x 2

33.7 x 2


Counterweight


*1

740 x 2

740 x 2


*2 *1

710 x 2 830 x 2

710 x 2 830 x 2

*2

795 x 2

795 x 2

765 x 2

765 x 2


*1. Serial No.: 7731 – 9000 *2. Serial No.: 9001 and up PC128US-2

01-14-3 (15)

WEIGHT TABLE

GENERAL


Without blade

Serial No.


Boom assembly

820

820

Arm assembly

356

356

Link assembly

85.6

85.6

Bucket assembly

369

369

Blade assembly

—

641

113.3 x 2

113.3 x 2

140.9

140.9


86.3

86.3


—

67.2 x 2


01-14-4 (15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg


Without blade

Serial No.



491

491


360

360

• Engine mount

19.6

19.6

• PTO

4.1

4.1

• Hydraulic pump

80

80


62

62

1,425

1,425

Operator’s cab

245

245

Operator’s seat

35

35


98

98


92

92

Control valve

80

96

(For KUK spec.)

96

106


4.8

4.8

3,400

3,000

Swing motor

26

26


155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6


2,315

2,470

• Track frame

1,280

1,438

• Idler

78 x 2

78 x 2

• Idler cushion

69 x 2

69 x 2

• Carrier roller

11 x 2

11 x 2

• Track roller

21 x 14

21 x 14


Counterweight


144 x 2

144 x 2

• Sprocket

33.7 x 2

33.7 x 2


755 x 2

755 x 2


845 x 2

845 x 2


935 x 2

935 x 2


815 x 2

815 x 2

Track shoe assembly

PC128US-2

01-14-5 (15)

WEIGHT TABLE

GENERAL


Without blade

Serial No.


Boom assembly

820

820

Arm assembly

356

356

Link assembly

85.6

85.6

Bucket assembly

399

399

Blade assembly

—

641

116.2 x 2

116.2 x 2

135

135


95

95


—

61.7 x 2


01-14-6 (15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg

PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Machine model

Without blade

Serial No.



491

491


385

385

• Engine mount

21.6

21.6

• PTO

4.1

4.1

• Hydraulic pump

80

80


54

54

1,500

1,500

Operator’s cab

245

245

Operator’s seat

35

35


98

98


92

92

Control valve

80

96


4.8

4.8

3,420

3,020

Swing motor

26

26


155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly • Track frame

2,610 1,544

2,750 1,680


Counterweight

• Idler • Idler cushion

81 x 2

81 x 2

72.9 x 2

72.9 x 2

• Carrier roller

11 x 4

11 x 4

• Track roller

21 x 16

21 x 16


144 x 2

144 x 2

• Sprocket

33.1 x 2

33.1 x 2

940 x 2 895 x 2 840 x 2 805 x 2

940 x 2 895 x 2 840 x 2 805 x 2

Boom assembly

820

820

Arm assembly

356

356

Link assembly

85.6

85.6

Bucket assembly

399

399

Blade assembly

—

641

Track shoe assembly • Triple grouser shoe (600mm) • Triple grouser shoe (500mm)

*1. Serial No.: 1001 – 1300 *2. Serial No.: 1301 and up PC128US-2

*1 *2 *1 *2

01-14-7 (15)

WEIGHT TABLE

GENERAL

Unit: kg PC138USLC-2 Machine model

Without blade

Serial No. Boom cylinder assembly


113.3 x 2

113.3 x 2

140.9

140.9


95.8

95.8


—

67.2 x 2


01-14-8 (15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg

PC138USLC-2 Serial No.: 1501 and up PC138USLC-2 Machine model

Without blade

Serial No.



464

464


360

360

• Engine mount

19.6

19.6

• PTO

4.1

4.1

• Hydraulic pump

80

80


62

62

1,425

1,425

Operator’s cab

245

245

Operator’s seat

35

35


98

98


92

92

Control valve

80

96


4.8

4.8

3,400

3,000

Swing motor

26

26


155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly • Track frame

2,595 1,544

2,735 1,680

• Idler

78 x 2

78 x 2

• Idler cushion

69 x 2

69 x 2

• Carrier roller

11 x 4

11 x 4

• Track roller

21 x 16

21 x 16


144 x 2

144 x 2

• Sprocket

33.1 x 2

33.1 x 2


895 x 2

895 x 2


805 x 2

805 x 2

Boom assembly

820

820

Arm assembly

356

356

Link assembly

85.6

85.6

Bucket assembly

399

399

Blade assembly

—

641


Counterweight

PC128US-2

01-14-9 (15)

WEIGHT TABLE

GENERAL

Unit: kg PC138USLC-2 Machine model

Without blade

Serial No. Boom cylinder assembly


116.2 x 2

116.2 x 2

135

135


95

95


—

61.7 x 2


01-14-10 (15)

PC128US-2

GENERAL

LIST OF LUBRICANTS AND WATER

LIST OF LUBRICANTS AND WATER PROPER SELECTION AMBIENT TEMPERATURE RESERVOIR

KIND OF FLUID –22

–4 –20

–30

14 –10

32 0

50 10

68 20

86 30

104 40

122°F 50°C

SAE 30 SAE 10W Engine oil pan

SAE 10W-30 SAE 15W-40

Swing machinery case Final drive case PTO gear case

Engine oil SAE 30

SAE 30 SAE 10W-30

Hydraulic system

SAE 15W-40 ASTM D975 No.2 Fuel tank

Diesel fuel

Greasing system

Grease

Cooling system

Water

*1 NLGI No.2 Add antifreeze

*1: ASTM D975 No.1

PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

Specified capacity

Refill capacity

Engine oil pan

Swing machinery case

Final drive case (each)

PTO gear case

Hydraulic system

Fuel tank

Cooling system

liter

17.5

2.5

2.5

0.75

120

195

18.2

US gal

4.62

0.66

0.66

0.20

31.68

51.48

4.80

16

2.5

2.5

0.75

69

—

—

4.23

0.66

0.66

0.20

18.22

—

—

liter US gal


Specified capacity

Refill capacity

PC128US-2

Engine oil pan

Swing machinery case

Final drive case (each)

PTO gear case

Hydraulic system

Fuel tank

Cooling system

liter

11.5

2.5

2.5

0.75

120

195

14.2

US gal

3.04

0.66

0.66

0.20

31.68

51.48

3.75

11

2.5

2.5

0.75

69

—

—

2.91

0.66

0.66

0.20

18.22

—

—

liter US gal

01-15 (15)

GENERAL

LIST OF LUBRICANTS AND WATER

REMARK • When fuel sulphur content is less than 0.5%, change oil in the oil pan according to every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. •

When starting the engine in an atmospheric temperature of lower than 0˚C(32˚F), be sure to use engine oil of SAE 10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10˚C(50˚F) more or less during the day.

•

Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.

•

There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W40), but be sure to add single grade oil that matches the temperature range in the table.

•

We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity:

Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API:

American Petroleum Institute

Fuel sulphur content

Change interval of oil in engine oil pan

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

01-16 A

PC128US-2

10 STRUCTURE AND FUNCTION PTO .............................................................. 10- 2 Radiator and oil cooler ............................... 10- 3 Power train .................................................. 10- 5 Swing circle ................................................ 10- 6 Swing machinery ....................................... 10- 7 Track frame ................................................. 10- 8 Idler cushion ............................................... 10- 9 Hydraulic component layout ..................... 10- 10 Valve control ............................................... 10- 12 Hydraulic tank and filter ............................. 10- 14 Hydraulic pump (Piston pump) ................. 10- 15 Control valve ............................................... 10- 36 Suction safety valve ................................... 10- 46 CLSS ............................................................ 10- 47 Self pressure reducing valve ..................... 10- 84 Center swivel joint ...................................... 10- 91 Travel motor (Final drive) .......................... 10- 93 Swing motor ............................................... 10-102 Solenoid valve ............................................ 10-108 PPC accumulator ........................................ 10-110 Accumulator for breaker (If equipped) ..... 10-111 PPC valve .................................................... 10-112 Boom hydraulic drift prevention valve ... 10-122-1 Arm hydraulic drift prevention valve ...... 10-122-6 Air-conditioner piping ................................ 10-123 Electric component layout ......................... 10-124 Engine control ............................................ 10-128 Electric control system ............................... 10-136 Monitor System .......................................... 10-149

PC128US-2

10-1 (15)

PTO


PTO

1. 2. 3. 4.

Coupling Shaft Breather Gauge

10-2

5. Hydraulic pump 6. Oil filler plug 7. Level plug

PC128US-2


RADIATOR AND OIL COOLER

RADIATOR AND OIL COOLER PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

PC128US-2

10-3 (15)

STRUCTURE

AND FUNCTION


5

Y 9JAOl328

1. Oil cooler 2. Radiator 3. Shroud 4. Reservoir tank 5. Oil cooler outlet 6. Oil cooler inlet 7. Radiator cap 8. Radiator inlet hose 9. Radiator outlet hose 10. Drain,valve 11. Fan

1o-4

SPECIFICATION Radiator Core type : CF19-4 Fin pitch : 3.5/2 mm Total heat dissipation surface : 34.06 m2 Pressure valve cracking pressure : 49.0 + 14.7 kPa IO.5 ? 0.15 kg/cm21 Vacuum valve cracking pressure : -4.9 - 0 kPa GO.05 - 0 kg/cm21 Oil cooler Core type : CF40-1 Fin pitch : 4.512 mm Total heat dissipation

surface : 8.79 m2

PC1 28US-2




PC128US-2

10-4-1 (15)



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

8. 9. 10. 11. 12. 13.

Shroud Reservoir tank Oil cooler Charge air cooler Radiator cap Radiator Radiator inlet hose

Chage air cooler outlet hose Oil cooler inlet Oil cooler outlet Charge air inlet hose Radiator outlet hose Drain valve

Specification Radiator

Oil cooler

Aluminum wave (4-line)

CF40

Fin pitch (min)

3.5/2

3.5/2

4.0/2

Total heat dissipation surfase (m2)

18.81

11.83

6.17

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

10-4-2 (15)

Charge air cooler

PC128US-2

STRUCTURE

AND FUNCTION

POWER TRAIN

POWER TRAIN

9JA01329

1. Idler’ 2. Control valve 3. Self pressure reducing valve 4. PPC lock solenoid valve 5. 2-speed travel changeover solenoid valve 6:‘Swing hold brake solenoid valve 7. 2-stage relief solenoid valve

PC1 28US-2

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

Travel motor Hydraulic pump Engine Swing motor Center swivel joint Swing machinen/ Swing circle

1o-5

STRUCTURE

SWING

AND FUNCTION

CIRCLE

SWING CIRCLE

-

6 .\

A-A

m B-B

m c-c

9JA01330

1. 2. 4. 5. 6.

Greasing to swing Greasing to swing Seal Ball Inner &e

a. b.

Inner race soft zone position Outer race soft zone position

1O-6

circle bearing circle pinion

Specification Reduction ratio : 90/l 1 = 8.182 Grease : G2-LI Amount of filled grease : 9.1 e

PC1 28US-2


SWING MACHINERY

SWING MACHINERY PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

1. Swing pinion (number of teeth : 11) 2. Case 3. No. 2 sun gear (number of teeth : 17) 4. No. 2 planetary carrier (number of teeth : 17) 5. Ring gear (number of teeth : 61) 6. No. 1 planetary carrier (number of teeth : 17) 7. No. 1 sun gear (number of teeth : 14) 8. Oil filler port 9. Swing motor 10. Level gauge 11. No. 1 planetary gear (number of teeth : 24) 12. No. 2 planetary gear (number of teeth : 22) 13. Drain plug 14. Swing circle (number of teeth : 90)

PC128US-2

Specification Reduction ratio : (14 + 61)/14 × (17 + 61)/17 = 24.58 Swing reduction ratio : 201.11 Swing speed : 12 rpm(PC128US-2 Serial No.: 5001 – 6456) : 11 rpm(PC128US-2 Serial No.: 6457 and up) : 11 rpm(PC138USLC-2 Serial No.: 1001 – 1500) Lubricating oil : SAE30CD Lubricating oil amount : 2.5 ¬

10-7 (15)


SWING MACHINERY


1. Swing pinion (number of teeth : 11) 2. Case 3. No. 2 sun gear (number of teeth : 17) 4. No. 2 planetary carrier (number of teeth : 17) 5. Ring gear (number of teeth : 61) 6. No. 1 planetary carrier (number of teeth : 17) 7. No. 1 sun gear (number of teeth : 14) 8. Oil filler port 9. Swing motor 10. Level gauge 11. No. 1 planetary gear (number of teeth : 24) 12. No. 2 planetary gear (number of teeth : 22) 13. Drain plug 14. Swing circle (number of teeth : 90)

10-7-1 (15)

Specification Reduction ratio : (14 + 61)/14 × (17 + 61)/17 = 24.58 Swing reduction ratio : 201.11 Swing speed : 11 rpm Lubricating oil : SAE30CD Lubricating oil amount : 2.5 ¬

PC128US-2


TRACK FRAME

TRACK FRAME PC128US-2 PC138US-2

1. 2. 3. 4.

Idler Track frame Carrier roller Travel motor

10-8 (15)

5. 6. 7. 8.

Sprocket Track roller Idler cushion Track shoe

PC128US-2

STRUCTURE

IDLER CUSHION

AND FUNCTION

IDLER CUSHION

___-__--_--__-__-_--__---~---~~~~-_____-_--__-__-__

_____-__

_____----__-_--mm

_________-__-__-__ ______-__-__-__-__---

__-

____

_____

-__-

-(r_-z-r”=

9JA01333

1. Idler 2. support 3. Yoke: 4. Cylinder 5. Recoil spring G.“U-packing 7. Pilot 8. Nut 9. Valve 10. Grease fitting

PC128US-2

Specification Grease : G2-LI Amount of filled grease : 140 cc

1o-9


HYDRAULIC COMPONENT LAYOUT

HYDRAULIC COMPONENT LAYOUT

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

14. 15. 16.

17. 18. 19. 20.

Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Swing motor Hydraulic pump Oil cooler L.H. travel motor L. H. PPC valve Blade PPC valve (Blade specification) R. H. PPC valve Center swivel joint 2-actuator attachment PPC valve (Option for PC128US-2 KUK only) (Option for PC138US-2 KUK only) Travel PPC valve 1-actuator attachment PPC valve (When with attachment) Boom hydraulic anti-burst valve (For PC128US-2 KUK only) (For PC138US-2 KUK only) Blade cylinder (Blade specification) Self pressure reducing valve Control valve 4-spool solenoid valve • PPC lock • 2-speed travel speed selection • Swing holding brake • 2-stage relief

10-10 (15)

PC128US-2

STRUCTURE

AND FUNCTION

1. Control valve 2. R.H. work equipment PPC valve 3. Blade PPC valve (When with blade specification) 4. 4-spool solenoid valve 5. R.H. work equipment control lever (Boom, Bucket) 6. Blade control lever (When with blade specification) 7. L.H. work equipment control lever (Arm, Swing) 8. L.H. work equipment PPC valve 9. Safety lock lever (for L.H. & R.H. work equipment) IO. Travel speed boost pedal (When with blade specitication) 11. L.H. travel pedal 12. 2-actuator attachment pedal (When with 2-actuator attachment) 13. R.H. travel pedal 14. 2-actuator attachment PPC valve (When with 2-actuator attachment) 15. Travel PPC valve 16. L.H. travel lever 17. R.H. travel lever 18. l-actuator attachment PPC valve (When with l-actuator attachment) 19. l-actuator attachment pedal (When with l-actuator attachment) 20. Lock pin (When with attachment)

VALVE CONTROL

@

l-actuator side @ l-actuator @ 2-actuator side @ 2-actuator side @ Attachment @ Attachment @I Attachment

attachment

outlet for arm RIGHT

attachment outlet for arm LEFT side attachment outlet for boom RIGHT attachment

outlet for boom LEFT

pedal LOCK pedal HALF stroke position pedal FULL stroket position

Lever and pedal position @ Neutral @ Boom RAISE @ Boom LOWER @ Bucket CURL @ Bucket DUMP @ Neutral @ Arm OUT @ Arm IN @ Swing LEFT @I Swing RIGHT @I L.H. travel FORWARD @I L.H. travel REVERSE @ R.H. travel FORWARD @ R.H. travel REVERSE @ PPC FREE @ PPC LOCK @ Blade RAISE (When with blade specification) @ Blade LOWER (When with blade specification) @ Travel Lo (When with blade specification) @ Travel Hi (When with blade specification)

PC 128US-2

10-13 0


VALVE CONTROL

PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

10-13-1 (15)

PC128US-2


VALVE CONTROL

1. Control valve 2. R.H. work equipment PPC valve 3. R.H. work equipment control lever (for boom and bucket operation) 4. Blade control lever (Blade specification) 5. 4-spool solenoid valve 6. L.H. work equipment control lever (for arm, swing operation) 7. Blade PPC valve (Blade specification) 8. L.H. work equipment PPC valve 9. Safety lock lever 10. L.H. travel pedal 11. R.H. travel pedal 12. L.H. travel lever 13. R.H. travel lever 14. Travel PPC valve 15. Attachment PPC valve (Attachment installable machine) 16. Attachment pedal (Attachment installable machine) 17. Lock pin (Attachment installable machine) Lever and Pedal Positions 1 HOLD 2 Boom LOWER 3 Boom RAISE 4 Bucket CURL 5 Bucket DUMP 6 HOLD 7 Arm OUT 8 Arm IN 9 Swing LEFT 0 Swing RIGHT A L.H. travel FORWARD B L.H. travel REVERSE C R.H. travel FORWARD D R.H. travel REVERSE E PPC FREE F PPC LOCK G Blade RAISE (Blade specification) H Blade LOWER (Blade specification) I Attachment discharge from arm RIGHT side (Attachment installable machine) J Attachment discharge from arm LEFT side (Attachment installable machine) K Attachment pedal LOCK (Attachment installable machine) L Attachment pedal HALF stroke (Attachment installable machine) M Attachment pedal FULL stroke (Attachment installable machine)

PC128US-2

10-13-2 A


HYDRAULIC TANK AND FILTER

HYDRAULIC TANK AND FILTER PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

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

Hydraulic tank Filter element Bypass valve Bypass strainer Suction strainer Drain plug Sight gauge Oil filler cap Pressure valve Vacuum valve

10-14 (15)

Specification Tank capacity : 99 ¬ Hydraulic oil amount in tank : 69 ¬ Pressure valve cracking pressure : 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Vacuum valve cracking pressure : -0.49 – 0 kPa {-0.005 – 0 kg/cm2} Bypass valve set pressure : 103 ± 19.6 kPa {1.05 ± 0.2 kg/cm2}

PC128US-2


HYDRAULIC TANK AND FILTER


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

Hydraulic tank Filter element Bypass valve Suction strainer Drain plug Sight gauge Oil filler cap Pressure valve Vacuum valve

PC128US-2

Specification Tank capacity : 99 ¬ Hydraulic oil amount in tank : 69 ¬ Pressure valve cracking pressure : 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Vacuum valve cracking pressure : -0.49 – 0 kPa {-0.005 – 0 kg/cm2} Bypass valve set pressure : 147 ± 29.4 kPa {1.5 ± 0.3 kg/cm2}

10-14-1 (15)


HYDRAULIC PUMP


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

Main pump LS valve PC valve Fixed choke valve PC-EPC valve (for PC mode selection) LS-EPC valve (for LS set selection)

10-15-1 (15)

PLS : Control valve LS pressure inlet PA : Main pump delivery PB : Main pump pressure input PO : Main pump drain IM : PC mode change current PEPC : EPC valve basic pressure inlet PS : Main pump absorption

PC128US-2


HYDRAULIC PUMP


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

Main pump LS valve PC valve Fixed choke valve PC-EPC valve (for PC mode selection) LS-EPC valve (for LS set selection)

PC128US-2

IM : PC mode change current PA : Main pump delivery PB : Main pump pressure input PS : Main pump absorption PD1 : Case drain PLS : Control valve LS pressure inlet PEPC : EPC valve basic pressure inlet

10-15-2 (15)


HYDRAULIC PUMP


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

Shaft Cradle Case Rocker cam Shoe Piston Cylinder block

10-16 (15)

8. 9. 10. 11. 12. 13.

Valve plate End cap Spring Servo last chance filter Servo piston Slider

PC128US-2

HYDRAULIC PUMP



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

Shaft Cradle Case Rocker cam Shoe Piston Cylinder block

PC128US-2

8. 9. 10. 11. 12. 13.

Valve plate End cap Spring Servo last chance filter Servo piston Slider

10-16-1 (15)

HYDRAULIC


PUMP

Function This pump converts engine rotation and torque transmitted to the pump shaft into hydraulic energy and discharges pressurized oil according to load. This pump can change delivery when the swash plate angle is changed. l

l

I

/

B

f!

\

IO A-A

9JUOOO77

Structure The cylinder block (7) is supported to the shaft (1) with the spline a, and the shaft (1) is supported with the front and rear bearings. The shoe (5) is punched to the tip of the piston (6) with a concave ball so that the piston (6) and the shoe (5) form a spherical bearing. The shoe (5) is always pressed to the plane A of the rocker cam (4) and slides in a circle. The rocker cam (4) leads highly pressurized oil together with the cylindrical plane B with the cradle (2) fixed to the case, forms a static pressure bearing and slides. Thepiston (6) moves in the axial direction relatively in each cylinder of the cylinder block l

l

l

l

l

l

(7). The cylinder block (7) rotates relatively while sealing pressurized oil against the valve plate (81, and the plane is designed to balance the oil pressure properly. Oil in each cylinder of the cylinder block (7) is absorbed and discharged through the valve plate (8).

PC128U.S2

10-17

STRUCTURE

AND FUNCTION

HYDRAULIC

Operation 1. Pump Operation The shaft (1) rotates together with the cylinder block (7), and the shoe (5) slides on the plate A. When the rocker arm (4) moves along the cylindrical plane B, the inclination ato the centerline X of the rocker cam (4) and the axial direction of the cylinder block (7) changes. The inclination a_.is called “swash plate angle.”

1

l

!i

A

B l

-

l

l

l

SLPOOl63

When the swash plate angle of the center line X of the rocker cam (4) is a to the axial direction of the cylinder block (7), the plane A works like the cam against the shoe (5). Therefore, the piston (6) slides inside the cylinder block (7), and the capacities E and F of the cylinder block (7) come to change differently. Then, the pump absorbs and discharges the difference E-F. When the capacity in the E chamber contracts as the cylinder block (7) rotates, the pump discharges oil during the process. On the other ..k#et, _ +h n..--n:hr :n ,hq..cl ,a,,“, .yyI &I te b,oyabtry II,+h LI $2F chamber Increases, the pump absorbs oil during the process. (The figure shows the end of the absorbing process in the Chamber F and the end of the discharging process in the Chamber E. When the centerline X of the rocker cam (4) comes to the axial direction of the cylinder block (7) (when the swash plate angle is 0), the difference between the capacities E and F in the cylinder block (7) comes to 0. And the pump comes to stop absorbing or discharging oil, i.e., the pump stops. (However, the swash plate angle never comes to 0 practically.) In the other words, the swash plate angle a and the pump delivery are in the proportional relations.

lo-18

PUMP

7

E SLPOO164

F

X

/ 4

7

9JUOOOBO

PC1 28US-2

STRUCTURE

2. l

-

l

l

.

HYDRAULIC

AND FUNCTION

PUMP

Delivery Control When the swash plate angle a increases, the difference between the capacities E and F becomes larger and the delivery Q increases. The servo piston (12) changes the swash plate angle a. The servo piston moves in the direction of straight reciprocation according to signal pressures of the PC and LS valves. This straight motion 7s transmitted to the rocker arm (4) through the slider (131, and the rocker cam (41, which is supported with the cylindrical plane to the cradle (21, slides in the direction of rotation.

The servo piston’s (12) area receiving the pressure is different on the right and left sides, and the discharge (self) pressure PP from the main pump is always led to the pressure chamber of the small diameter piston. The output pressure Pen of the LS valve is led to the pressure chamber of the large diameter piston. Motions of the servo piston are controlled according to the relations between the small diameter piston pressure PP and the large diameter piston pressure Pen and the rate of area receiving pressure of the small diameter piston to that of the large diameter piston.

.

PC128US-2

12

13

9Juoooa2

10-19

STRUCTURE

HYDRAULIC

AND FUNCTION

PUMP

LS AND PC VALVES LS Valve

PA

PLS

PLP

PPL

PD

PS IG

PA 9JUOOO84

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

Plug Lock nut Sleeve Spring Seat Spool Piston Sleeve

A PD PLP PLS PPL PSIG

: Pump discharge pressure inlet : Drain pressure outlet : LS valve signal pressure outlet : Control valve LS pressure inlet : PC valve signal pressure inlet : EPC valve output pressure inlet of LS control

PC Valve

1

9JUOOO85

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

Piston’ Spring Seat t Spring Seat Spool Piston Sleeve Lock nut Plug Lock nut

1O-20

PA PA2 PD PN PPL

: : : : :

Pump discharge pressure inlet Pump discharge pressure inlet Drain pressure outlet PC mode switching pressure inlet PC valve’signal pressure outlet

PC1 28US-2

STdUCTURE

AND FUNCTION

HYDRAULIC

PUMP

FIXED THROTTLE VALVE

PO,UT

P,’

N

9JUOOO66

1. 2.

Plug Plug

PA : Drain pressure outlet POUT : Control pressure outlet PIN : LS valve signal pressure inlet

PC1 28US-2

10-21

HYDRAULIC

STRUCTURE AND WNCTlON

PUMP

Operation

To ma in va

Direction to small diameter

1.

I ve

SVPO7604

LS Valve 1) When the control valve is at the center value position The LS valve is a 3-way selector valve, and the pressure PLS (LS pressure) from the control valve inlet is being led to the kpring chamber B and the pump discharge pressure PP is being led to the H port of the sleeve (8). The spool (6) position is determined depending on the force of the LS pressure PLS + the force of spring (4) Z and the force ofthe pump discharge pressure (self-pressure) PP. l

l

PC1 28US-2

1 O-23

STRUCTURE

l

l

l

1 O-24

AND FUNCTION

Before the engine starts, the servo piston (12) is pressed to the right side. (See the right figure.) If the control lever is atthe “center value” position when the engine starts, the LS pressure PLS will be 0 MPa (0 kg/cm*). (The LS valve interconnects to the drain circuit through the control valve spool.) At the time, the spool (6) is pressed to the left side and the. C port is connected to the D port. The pump discharge pressure enters from the K port to the piston large diameter side and from the J port to the piston small diameter side respectively. So, the area difference of the servo piston (12) minimizes the swash plate angle.

HYDRAULIC

A-A

PUMP

9JUOOOB9

PC1 28US-2


HYDRAULIC PUMP


2) Operation in direction for maximum pump delivery • When the LS differential pressure ∆PLS between the pump discharge pressure PP and the LS pressure PLS reduces (when the control valve is large and the discharge pressure PP drops, for example), the combined force of the LS pressure PLS and the spring (4) pushes the spool (6) to the right side. • When the spool (6) moves, port D is connected to port E to bring the PC valve in line. At the time, the PC valve is connected to the drain port, and the circuit D – K is applied with the drain pressure PT. (The operation of the PC valve will be explained later.) • Therefore, the pressure on the piston large diameter side of the servo piston

10-26 (15)

•

•

(12) comes to the drain pressure PT, and since the pump discharge pressure PP is applied to port J on the small diameter side, the servo piston (12) is pushed to the right side and the swash plate is moved to the delivery increasing direction. When port G is applied with the output pressure of the EPC valve for the LS valve, the piston (7) is pushed to the left side. This is effective to reduce the spring (4) set force, and the differential pressure between the oil pressure PP when ports D and E of the spool (6) are connected and PP changes.

PC128US-2

HYDRAULIC PUMP



3) Operation in direction for minimum pump delivery • The following explains move of the servo piston (12) to the left side (in the direction for minimum pump delivery). When the LS differential pressure ∆PLS increases (when the control valve opening area becomes small and the pump discharge pressure PP increases, for example), the force of the discharge pressure PP pushes the spool (6) to the left side. • As the spool (6) moves, the pump discharge pressure PP flows from port C to port D and comes from port K to the piston large diameter side.

10-27-1 (15)

•

•

Though the pump discharge pressure PP comes to port J of the piston small diameter side, the servo piston (12) is pushed to the left side due to the area difference between the piston large diameter side and the piston small diameter side of the servo piston (12) and the swash plate is moved in the delivery reducing direction. When port G is applied with the LS selection pressure, it is effective to reduce the spring (4) set force.

PC128US-2

HYDRAULIC PUMP


PC128US-2 Serial No.: 5001 – 7730

4) When the servo piston balances • Suppose that the area receiving pressure on the piston large diameter side is A1, the area on the piston small diameter side is A0 and the pressure applied to the piston large diameter side is PEN. • When the pump discharge pressure PP of the LS valve balances with the combined force of the LS pressure PLS and the spring (4) force Z and the relations A0 x PP = A1 x PEN hold, the servo piston (12) will stop at the position and the swash plate angle will be held at the intermediate position. (The openings of the D port to the E port and of the C port to the D port of the spool (6) stop almost at the same position.)

PC128US-2

•

•

At the time, the relations of the areas receiving pressure at the both ends of the servo piston are A0 : A1 = 1 : 1.75. When they balance with each other, the pressures applied to the both ends of the piston are related as follows: PP : PEN .=. 1.75 : 1. The spring (4) force has been adjusted so that the spool (6) balance stop position is determined at the center of the standard when PP – PLS = 2.21 MPa (22.5kg/cm2).

10-27-2 0


HYDRAULIC PUMP


4) When the servo piston balances • The area receiving the pressure on the piston large diameter side is supposed to be A1, the one on the small diameter side is supposed to be A0 and the pressure flowing to the piston large diameter side is supposed to be PEN. • When the pump discharge pressure PP of the LS valve balances with the combined force of the LS pressure PLS and the spring (4) force Z and the relations of A0 x PP = A1 x PEN are satisfied, the servo piston (12) stops at the position and the swash plate is held at the intermediate position (stops where the opening from port D to port E of the spool (6) is almost equal to the one from port C to port D).

10-27-3 (18)

•

•

•

At the time, the relations of areas receiving the pressure on the both ends of the servo piston (12) are A0 : A1 = 1 : 1.75, and the ones of pressures applied on the . . ends at the balancing time are piston both PP : PEN = 1.75 : 1 approximately. The spring (4) force has been adjusted so that the balance stop position of the spool (6) is determined when PP – PLS = 2.21 Mpa {22.5 kg/cm2} is satisfied at the standard center. When port G is applied with PSIG (EPC valve output pressure for LS valve of 0 – 2.9 Mpa {10 – 30 kg/cm2}), however, the balance stop position changes proportionally to the PSIG pressure in the range of PP – PLS from 2.1 to 0.6 Mpa {21.5 to 6.5 kg/cm2}. PC128US-2

STRUCTURE

AND FUNCTION

HYDRAULIC

Pilot

PUMP

Pressure To main

LS valve : :

.-f

Emergency PC-EPC

Direction to small diameter oumD

valve

‘: ‘Fixed throttle

Direction to large diameter Pump controller

I’

,I

_

’

I

SVPO7608

2.

PC Valve 1) When the pump controller is normal, the load to the actuator is small and the pump discharge pressure PP is low a. Function of PC-EPC Valve Solenoid (7) The pump controller provides a com’ mand current to the PC-EPC valve solenoid (1). This command current actuates the PC-EPC valve and outputs a signal pressure. When receiving the signal pressure, the PC valve changes the force given to the piston (2). The spool (3) stops where the force to the piston (2) balances with the combined force of the spring setting force of the springs (4) and (6) on the opposite side and the force given to the spool (3) by the pump discharge presl

l

sure PP. And the pressure output from the PC valve (the pressure at the C port) varies with the spool position. The value of the command current X is determined depending on type of work (lever control), selection of working mode, set point of engine speed and actual speed.

l

lo-28

PC1 28US-2

STRUCTURE

HYDRAULIC

AND FUNCTION

Pi lot

PUMP

pressure

To main

;j .I,,,,,,,,,,,,;;;;;,.,: “I~IIIc-Lel

c3 Emergency DU~D drive switch n c c

JIUC

Direction to large diameter

1

n..__

SVPO7609

b. l

l

l

PC1 28US-2

Function of Spring The loads to the springs (4) and (6) of the PC valve are determined depending on swash plate position. As the servo piston (9) moves, the piston (7) connected to the slider (8) moves to the right or the left. When the piston (7) moves to the left, the spring (6) will be contracted. If the piston moves further to the left, the spring will be brought to the seat (5) and be fixed there. Thereafter, the spring (4) will only move. This means that the spring load changes as the piston (7) extends or contracts the springs (4) and (6).

l

Also, since the pressing force of the piston (2) changes as the command current input to the PC-EPC valve solenoid (1) changes, the load to the springs (4) and (6) changes depending on the value of the command current.

lo-29

STRUCTURE

l

l

l

l

1O-30

AND FUNCTION

HYDRAULIC

PUMP

The C port of the PC valve is connected to the E port of the LS valve. The self pressure PP is provided to the A port, the small diameter side of the servo piston (9) and the B port. When the pump discharge pressure PP is small, the spool is located at a position in the left direction. At the time, the C port is connected to the D port, and the pressure to the LS valve becomes the drain pressure PT. If the E port of the LS valve is connected to the G port at the time, the pressure from the J port to the large diameter side of the piston will become the drain pressure PT. And the servo piston will moves to the right side. Then, the pump delivery will come to increase. Also, as the servo piston (9) operates, the slider (8) moves the piston (7) to the right side, and the spring force becomes weak because the springs (4) and (6) ei
PC1 28US-2

STRUCTURE

HYDRAULIC

AND FUNCTION

Pi lot

PUMP

Pressure ‘0 main valve -

outa6 andC rad

connected

Direction to small diameter PC-EPC

valve

SVPO7610

2)

l

l

When the pump controller is normal, the load to actuator is large and the pump discharge pressure PP is high When the load is large and the pump discharge pressure is high, the force pushing the spool (3) to the left side increases ‘and the spool (3) comes to the position shown in the above figure. Then, the pressure flowing from the C port to the LS valve becomes about 3/5 of the pump discharge pressure PP because the pressure from the A port partly flows from the C port to the D port through the LS valve as shown in the above figure.

PC1 28US-2

l

l

When the E port of the LS valve is connected to the G port, this pressure is led from the J port to the large diameter side of the servo piston (9) and the servo piston comes to stop. When the pump discharge pressure PP increase and the spool (3) moves further to the left side, the discharge pressure PP will flow to the C port so as to minimize the pump delivery.

10-31

STRUCTURE

l

l

l

l

1 O-32

HYDRAULIC

AND FUNCTION

When the servo piston (9) moves to the left side, the piston (7) will move to the left. Then, the springs (4) and (6) will be compressed and will push the spool (3) back. If the piston (7) moves further to the left, the ports C and D will open wide. As a result, the pressure at the port C (= J) will drop, and the servo piston (9) will move to the left a_ndwill stop. At the time, the servo piston (9) is located further to the left than where it is when the pump discharge pressure PP is low.

PUMP

_

The positional relations between the pump discharge pressure PP and the servo piston (9) are shown by a broken line because the springs (4) and (6) are 2stage ones. And the relations between the discharge pressure PP and the pump delivery 0 are as shown in the right figure.

Also, when the command current X to the PC-EPC valve solenoid increases, the relations between the pump discharge pressure PP and the pump delivery 0 will move in parallel in relation to the pushing force of the PC-EPC valve solenoid. Therefore, the force of the PC-EPC valve solenoid (1) will be added to the leftward pressing force of the discharge pressure PP to the spool (3), and the relations between PP and Q will move from @ to @ as X increases.

Pump discharoe

pressure

PP

SLIP02559

Pump discharoe

orassure

PP

SDP02560

D Z 2 5 : L

PC1 28U.S2


3) When the pump controller is out of order and the PC redundant switch is set to ON a. In case of light load to main pump • When the pump controller is out of order, set the PC redundant switch to ON to change the circuit to the resistor side. In this case, since the current is too large when the power is directly taken from the battery, the resistor is connected to control the current to the PC-EPC valve solenoid. • At the time, the current becomes constant and the piston (2) pressing force becomes constant as well. • When the pump discharge pressure is low, the combined force of the force of the PC-EPC valve solenoid (1) and the discharge pressure PP is smaller

PC128US-2

HYDRAULIC PUMP

•

than the spring set force. So, the spool (3) balances at a position in the left side. At the time, the C port has the same pressure as the drain pressure at the D port, and the drain pressure PT is led to the large diameter side of the servo piston (9) through the LS valve. Then, the servo piston (9) moves in the direction where the delivery increases because the pressure on the small diameter side of the piston is large.

10-33 (18)

STRUCTURE

AND FUNCTION

HYDRAULIC

Pi lot

PUMP

Pressure To main va I ve

31°C --*I*

~/,~1,,,,,,,,,,,,,,,,,, +

:

-

Direction to small diameter Emergency PUTID drive switch

-

SVPO76 12

b. l

l

l

1o-34

In case of heavy load to main pump When the PC redundant switch is set to ON just like in the previous paragraph, a constant command current is sent to the PC-EPC valve solenoid (1). So, the piston (2) pushes the spool (3) ‘with a constant force. When the pump discharge pressure -PP rises, the spool will moves further to the left side than when the main pump is lightly loaded and will balante at the position shown in the above figure. In this case, since the pressure from the A port is led to the C port, the servo piston (9) will move to the left side (small delivery) and will stop at a position further to the left than when the pump is lightly loaded.

PC1 28US-2

STRUCTURE

l

l

HYDRAULIC

AND FUNCTION

This means that the current, which is sent to the PC-EPC valve solenoid through the resistor when the PC redundant switch is set to On, determines the curve between the pump discharge pressure PP and the delivery 0 as shown in the figure. When the PC redundant switch is set to ON, the curve @ is further to the left than the curve @ drawn when the pump controller is normal.

0 x .-: Q1 -0 z z

Pump

PC1 28US-2

PUMP

discharge

Pressure

PP

SJpO7fj13

1o-35


CONTROL VALVE

CONTROL VALVE OUTLINE There are the following 2 types of contral valve. • 6-spool valve (without service valve) • 7-spool valve (with service valve) • 7-spool valve (with blade) • 8-spool valve (with blade and service valve) • 8-spool valve (with 2 service valve) • 9-spool valve (with blade and 2 service valve) fl Each service valve is a single add-on type, so it is possible to add or remove the extra valve at any time. Extermal oppearance and cross section is given only for the 7 spool valve. AA : Pressure sensor port (pressure sensor is intalled) A1 : To swing motor MB A2 : To L.H. travel motor A A3 : To R.H. travel motor A A4 : To boom cylinder bottom A5 : To arm cylinder head A6 : To bucket cylinder head A7 : To attachment 1 B1 : To swing motor MA B2 : To L.H. travel motor B B3 : To R.H. travel motor B B4 : To boom cylinder head B5 : To arm cylinder bottom B6 : To bucket cylinder bottom B7 : To attachment 1 BP : From boom RAISE PPC/EPC valve LS : To pump LS valve PA1 : From swing L.H. PPC/EPC valve PA2 : From L.H. travel forward PPC valve PA3 : From R.H. travel reverse PPC valve PA4 : From boom RAISE PPC/EPC valve PA5 : From arm OUT PPC/EPC valve PA6 : From bucket DUMP PPC/EPC valve PA7 : From service 1 PPC valve PB1 : From swing R.H. PPC/EPC valve PB2 : From L.H. travel reverse PPC valve PB3 : From R.H. travel forward PPC valve PB4 : From boom LOWER PPC/EPC valve PB5 : From arm IN PPC/EPC valve PB6 : From bucket CURL PPC/EPC valve PB7 : From service 1 PPC valve P : From main pump PP : To main pump PX : From 2-stage relief solenoid valve SA : From swing stroke contral solenoid valve SB : From swing stroke contral solenoid valve TS1 : To tank TS2 : To tank TB : To tank TC : To oil cooler TSW : To swing motor

10-36 (15)

1. Swing bleed valve 2. Travel junction valve 3. Arm regeneration valve 4. Boom drift prevention valve 5. Cover 6. Service valve 7. Bucket valve 8. Arm valve 9. Boom valve 10. R.H. travel valve 11. L.H. travel valve 12. Swing valve 13. PT port block 14. Safety-suction valve

PC128US-2


CONTROL VALVE

7 spool valve (6 spool valve + service valve) PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

PC128US-2

10-37 (15)


CONTROL VALVE


10-37-1 (15)

PC128US-2


CONTROL VALVE

CROSS-SECTIONAL DRAWING fl Cross-sectional drawing shows 7-spool valve (6-spool + service valve). (1/8)

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

Safety-suction valve Suction valve (L.H. travel A) Suction valve (R.H. travel A) Suction valve (Boom bottom) Suction valve (Arm head) Suction valve (Bucket head) Safety-suction valve mount (service A)

10-38 (15)

8 Safety-suction valve mount (service B) 9. Suction valve (Bucket bottom) 10. Suction valve (Arm bottom) 11. Suction valve (Boom head) 12. Suction valve (R.H. travel B) 13. Suction valve (L.H. travel B) 14. Lift check valve

PC128US-2


CONTROL VALVE

(2/8)

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

Main relief valve Spool (swing) Spool (L.H. travel) Spool (R.H. ravel) Spool (boom) Spool (arm) Spool (bucket) Spool (service)

PC128US-2

10-39


CONTROL VALVE

(3/8)

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

Pressure compensation valve F (swing) Pressure compensation valve F (L.H. travel) Pressure compensation valve F (R.H. travel) Pressure compensation valve F (boom) Pressure compensation valve F (arm) Pressure compensation valve F (bucket) Pressure compensation valve F (service) Unload valve

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

Pressure compensation valve R (service) Variable pressure compensation valve Pressure compensation valve R (bucket) Pressure compensation valve R (arm) Pressure compensation valve R (boom) Pressure compensation valve R (R.H. travel) Pressure compensation valve R (L.H. travel) Pressure compensation valve R (swing)

fl The above F and R means the following valves : F : Flow control valve R : Pressure reducing valve

10-40 (15)

PC128US-2


CONTROL VALVE

(4/8)

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

LS pressure detection plug LS bypass plug Pump pressure detection plug Check valve (bucket head) Check valve (arm head) Check valve (boom bottom) LS selection valve

PC128US-2

10-41


CONTROL VALVE

(5/8)

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

Main relief valve Cooler bypass valve Lift check valve LS selection valve Spool (swing) Pressure compensation valve R

10-42 (15)

7. Swing bleed valve 8. Pressure compensation valve F F : Flow control valve R : Pressure reducing valve

PC128US-2


CONTROL VALVE

(6/8)

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

Suction valve (A) Suction valve (B) Spool (L.H. travel) Pressure compensation valve R Travel junction valve Pressure compensation valve F Suction valve (A)

PC128US-2

8. 9. 10. 11.

Suction valve (B) Spool (R.H. travel) Pressure compensation valve R Pressure compensation valve F

F : Flow control valve R : Pressure reducing valve

10-43 (15)


CONTROL VALVE

(7/8)

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

Suction valve (A) Boom drift prevention valve Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Suction valve (A) Suction valve (B)

10-44 (15)

9. 10. 11. 12.

Spool Pressure compensation valve R Arm regemeration valve Pressure compensation valve F


PC128US-2


CONTROL VALVE

(8/8)

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

Suction valve (A) Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Safty-suction valve mount (A) Safty-suction valve mount (B) Spool

PC128US-2

9. 10. 11. 12. 13.

Variable pressure compensation valve Pressure compensation valve R Pressure compensation valve F Pressure relief plug Unload valve


10-45 (15)


CONTROL VALVE

9 spool valve (6-spool valve + Blade valve + Full-flow service valve + Half-flow service valve)

PC128US-2

10-45-2 5


CONTROL VALVE

CROSS-SECTIONAL DRAWING ¡ Cross-sectional drawing shows 9-spool valve (6-spool + service valve). (1/9)

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

Safety-suction valve Suction valve (Left travel A) Suction valve (Right travel A) Suction valve (Boom bottom) Safety-suction valve (Blade bottom) Suction valve (Arm head) Suction valve (Bucket head) Safety-suction valve (Service 1-A) Safety-suction valve (Service 2-A)

10-45-3 5

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

Safety-suction valve (Service 2-B) Safety-suction valve (Service 1-B) Suction valve (Bucket bottom) Suction valve (Arm bottom) Suction valve (Boom head) Suction valve (Right travel B) Suction valve (Left travel B) Lift check valve

PC128US-2


CONTROL VALVE

(2/9)

1. 2. 3. 4. 5.

Main relief valve Spool (Swing) Spool (L.H. travel) Spool (R.H. travel) Spool (Boom)

PC128US-2

6. 7. 8. 9. 10.

Spool (Blade) Spool (Arm) Spool (Bucket) Spool (Service 1) Spool (Service 2)

10-45-4 (15)


CONTROL VALVE

(3/9)

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

Pressure compensation valve F (Swing) Pressure compensation valve F (L.H. travel) Pressure compensation valve F (R.H. travel) Pressure compensation valve F (Boom) Pressure compensation valve F (Blade) Pressure compensation valve F (Arm) Pressure compensation valve F (Bucket) Pressure compensation valve F (Service 1) Pressure compensation valve F (Service 2) Unload valve Variable pressure compensation valve (Service 2)

10-45-5 (15)

12. 13. 14. 15. 16. 17. 18. 19.

Pressure compensation valve (Service 1) Pressure compensation valve R (Bucket) Pressure compensation valve R (Arm) Pressure compensation valve R (Blade) Pressure compensation valve R (Boom) Pressure compensation valve R (R.H. travel) Pressure compensation valve R (L.H. travel) Pressure compensation valve R (Swing)

F : Flow control valve R : Pressure control valve

PC128US-2


CONTROL VALVE

(4/9)

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

LS pressure pickup plug LS bypass plug Pump pressure pickup plug Check valve (Bucket head) Check valve (Arm head) Check valve (Boom bottom) LS selector valve

PC128US-2

10-45-6 5


CONTROL VALVE

(5/9)

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

Main relief valve Cooler bypass valve Lift check valve LS selection valve Spool Pressure compensation valve R Swing bleed valve Pressure compensation valve F

10-45-7 (15)


PC128US-2


CONTROL VALVE

(6/9)

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

Suction valve (A) Suction valve (B) Spool Pressure compensation valve R Travel junction valve Pressure compensation valve F Suction valve (A)

PC128US-2

8. 9. 10. 11.

Suction valve (B) Spool (R.H. travel) Pressure compensation valve R Pressure compensation valve F


10-45-8 (15)


CONTROL VALVE

(7/9)

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

Suction valve (A) Boom drift prevention valve Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Suction valve (A) Suction valve (B)

10-45-9 (15)

9. 10. 11. 12.

Spool Pressure compensation valve R Arm regemeration valve Pressure compensation valve F


PC128US-2


CONTROL VALVE

(8/9)

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

Suction valve (A) Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Safty-suction valve (A) Safty-suction valve mount (B) Spool

PC128US-2

9. 10. 11. 12.

Pressure compensation valve R Pressure compensation valve F Pressure relief plug Unload valve


10-45-10 (15)


CONTROL VALVE

(9/9)

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

Safety-suction valve (A) Safety-suction valve (B) Variable pressure compensation valve Spool Pressure compensation valve R Pressure compensation valve F


10-45-11 (15)

PC128US-2

STRUCTURE

SUCTION

AND FUNCTION

SAFETY VALVE

SUCTION SAFETY VALVE (SAFETY VALVE WITH SUCTION FOR SERVICE PORT) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Suction valve Main valve Piston Piston spring Poppet Poppet spring Suction valve Sleeve Adjustment screw Lock nut

Specification Part No. (Reference)

Set pressure

709-70-74600

24.5 MPa (250 kg/cm21 (at the time of Wmin.)

709-70-74700

17.2 MPa (175 kg/cm21 (at the time of 5f?/min.)

lo-46

I

Use For crusher

PC1 28U.S-2


CLSS

CLSS OUTLINE OF CLSS Features CLSS stands for Closed Center Load Sensing System and is featured as follows : Fine controllability without affect of load Controllability that allows digging even in the fine control mode. Ease of compound operation in which the flow distribution performance depends area duiing compound operation. Saving of energy-by variable pump control l

l

l

on spool opening

l

Configuration The CLSS consists of a variable displacement piston pump, a control valve and actuators. The pump body consists of a main pump, a PC valve and an LS valve. l

l

PLS r________________-------_ I I I i I I I I I

Control

valve

I ______( f

Servo valve

PC128US-2

SDPD2661

1o-47

STRUCTURE

AND FUNCTION

CLSS

Basic principle 1. Control of pump swash plate angle The pump swash plate angle (pump delivery) is controlled so that the LS differential pressure APLS, which is the difference between the pump discharge pressure PP and the LS pressure PLS (actuator load pressure) at the control valve outlet, becomes constant. (LS differential pressure APLS = Pump pressure PP - LS pressuFe PLS)

Actuator

l

I

@

1 Control valve

-_-_-- __ -----__ I II I II

Pump Passage

PLSf

I [I L-l , L__-------, I_--_--_---.

I I I I

Main

I

DumD

M i n. -

Max.

I 1 Servo piston

i

SEP02562

l

*

When the LS differential pressure APLS reduces below the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate angle will move in the direction of maximum. When the set pressure is raised (when the actuator load pressure is low), the pump swash plate angle will move in the direction of minimum. For the detail of the operation, see the paragraph of “Hydraulic Pump.”

0 -a, z m

=

z

Max.

LS valve set pressure Min.

z 0

LS differential

Dressure

APLS SOP02563

PC 128US-2

STRUCTURE

2. .

CLSS

AND FUNCTION

Pressure compensation control A valve (pressure compensation valve) is mounted on the outlet side of the control valve. In case of compound operation of the actuator with this valve, the differential pressure AP between the spool upstream (inlet) and the downstream (outlet) of each valve becomes constant irrespective of load (pressure). So, the flow from the pump is distributed (compensated) in proportion to the opening areas Sl and S2 of each valve being operated.

Load

1

I\

I lcomensationl

1

Actuator

I

II

I\

Actua

I cobwensa~

SEP02564

PC1 28US-2

1o-49

STRUCTURE

CLSS

AND FUNCTION

EACH FUNCTION

AND OPERATION OF EACH VALVE

Hydraulic circuit diagram and valve names Pump detect Pressure detect port

Pressure ion port

LS

pressure

ion PP

x Al

E^-..:^^

I

II

I

Service

107

T-l

[=1,

CYI “.inder .‘.

i!T----_--_-__--’ ’ ’ ’ 1’ j+j+

; :---

. Left travel motor

/

itl

III’

/ Swing motor

9:

I

31.9/34.8HPa

(325/355ko/cm’l

Ma

0’

in Dump

O- 250

L ___-__

__-

_____-__

I SWPO7804

PC1 281

STRUCTURE

AND FUNCTION

CLSS

1. Unload valve Set pressure : 3.38 MPa (34.5 kg/cm? 2. Safety-suction valve Set pressure : 35.8 MPa (365 kg/cm21 3. Pressure compensation valve 4. Suction valve 5. Main relief valve Set pressure : normal : 31.9 MPa (325 kg/cm*) High pressyre : 34.8 MPa (355 kg/cm*} 6. Lift check valve 7. Cooler bypass valve 8. LS selection valve 9. Swing bleeding valve 70. Travel junction valve 11. Boom drift prevention valve 12. Arm regeneration valve

PC1 28US-2

1o-51

STRUCTURE

CLSS

AND FUNCTION

UNLOAD VALVE 1. When the control valve is neutral Function When the control valve is neutral, the delivery Q equivalent to the pump minimum swash plate angle is released to the tankcircuit. At the time, the pump discharge pressure PP is set to 2.45 MPa {25.Okg/ cm21 with the spring (3) inside the vale. (The LS pressure PLS is 0 MPa {Okg/cm2).) l

SDP03735

Operation The pump discharge pressure PP is applied to the left end face of the spool (4) and the LS pressure PLS is applied to the right end face. . Since the LS pressure PLS is 0 when the control valve is neutral, the pump discharge pressure PP is only applied and is set with the lead to the spring (3). . When the pump discharge pressure PP rises to the spring (31 load (2.45 MPa (25.0 kg/cm2H, the spool (4) will move toward the right side and the pump circuit PP will interconnect to the tank circuit T through the drill hole. Therefore, the pump discharge pressure PP is set to 2.45 MPa (25.0 kg/cm21. l

1. 2. 3. 4.

Unload valve Sleeve Spring Spool

PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit

l

1 O-52

PC1 28US-2

STRUCTURE

CLSS

AND FUNCTION

2. When the control valve is in the fine control mode Function When the control valve is in the fine control mode and the requested flow of the actuator is less than the pump minimum swash plate angle, the pump discharge pressure PP is set to the LS pressure PLS + 2.45 MPa (25.0 kglcm2). When the differential pressure between the discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45 MPa (25.0 kg/cm21), the unload valve will open and the LS differential pressure APLS will come to 2.45 MPa (25.0 kg/cm2}. l

SOP03736

Operation When the control valve is operated in the fine control mode, the LS pressure PLS will occur and will be applied to the right end face of the spool (4). At the time the differential pressure between the LS pressure PLS and the pump discharge pressure PP increases because the opening area of the control valve spool is small. When the differential pressure between the pump discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45 ‘.MPa (25.0 kg/cm2)), the spool (4) will move to the right side and the pump circuit PP will interconnect to the tank circuit T. This means that the pump discharge pressure PP is set to the spring force (2.45 MPa (25.0 kg/cm2} + LS pressure PLS, and the LS differential pressure APLS comes to 2.45 MPa (25.0 kg/cm21. l

1. 2. 3. 4.


PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit

l

l

PC1 28US-2

1o-53

STRUCTURE

CLSS

AND FUNCTION

3. When the control valve is operated Function If the required flow of the actuator increases over the pump minimum swash plate angle when the control valve is operated, the flow to the tank circuit T will be interrupted and the pump delivery 0 will be completely flown to the actuator circuit.. l

SDP03737

Operation When the control valve is operated with large stroke, the LS pressure PLS will occur and will be applied to the right end face of the spool (4). At the time, the opening areas of the control valve spool is large and the difference between the LS pressure PLS and the pump discharge pressure PP is small. So, the differential pressure between the pump discharge pressure PP and the LS pressure PLS does not reach the spring (3) load (2.45 MPa (25.0 kg/cm2)) and the spring (3) pushes the spool (4) to the left side. Then, the pump circuit PP and the tank circuit Tare interrupted, and the pump delivery Q is completely flown to the actuator circuit. l

l

1. 2. 3. 4.


PLS : LS circuit (pressure) PP : Pump circuit (pressure) T :Tankcircuit

l

1o-54

PC1 28US-2

STRUCTURE

CLSS

AND FUNCTION

LEADING OF LS PRESSURE Function The LS pressure is load pressure to the actuator on the outlet side of the control valve. In case of a work equipment valve, the pressure reducing valve (3) of the pressure compensation valve reduces the pump discharge pressure PP to the same level as the actuator circuit pressure A and leads the pressure to l

l

1.

Work equipment

l

the LS circuit PLS. Also, the orifice C is mounted on the piston (5) halfway from the pump circuit PP to the pressure reducing valve (31, and the orifice has the damper function. The travel valves leads the actuator circuit pressure A directly to the LS circuit PLS.

valve (boom, arm, bucket, swing)

SOP03738

Operation When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator circuit A through the bridge passage b from the flow control valve (2) and the spool notch a. Since the pressure reducing valve (3) moves to the right at the same time, the pump discharge pressure PP led from the orifice c is reduced due to pressure loss at the notch d and is led to the LS circuit PLS and to the spring chamber PLSl. At the time, the LS circuit PLS is connected to the tank circuit T from the LS bypass plug (4). l

l

l

l

PC128US-2

l

The both end face areas of the pressure reducing valve (3) are the same (SA = SLS), and the actuator circuit pressure PA (= A) is applied to the SA side and the reduced pump discharge pressure PP is applied to the SLS side on the opposite side. Therefore, the pressure reducing valve balances at the position where the actuator circuit pressure PA becomes equal to the pressure of the spring chamber PLSl. The pump discharge pressure PP reduced at the notch d comes to the actuator circuit pressure A and is led to the LS circuit PLS.

1o-55

STRUCTURE

2.

AND FUNCTION

CLSS

Travel valve

Operation When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator circuit A through the bridge passage b from the flow control valve (2) and the spool notch a. At the same time, the actuator circuit pressure PA moves the pressure reducing valve (3) to the right side, and the notches c and d interconnect to the travel junction circuit e and the LS circuit PLS respectively. So, the actuator circuit pressure PA (= A) is led from the notch c to the LS circuit PLS through the notch d. J, The travel circuit is different from the work equipment circuit, the actuator circuit pressure PA is directly led to the LS circuit PLS. l

l

l

lo-56

PC1 28US-2

STRUCTURE

AND FUNCTION

CLSS

LS BYPASS PLUG Function This plug released residual pressure of the LS pressure PLS. - This plug slows the rising speed of the LS pressure PLS, causes pressure losses at the spool and the throttle of the shuttle valve by the discarded throttled flow and reduces the effective LS differential pressure for higher safety. l

PL

SDP03740

Operation Pressurized oil in the LS circuit PLS flows from the clearance filter a in the space between the LS bypass plug (1) and the valve body to the tank circuit T through the orifice b.

1.

LS bypass plug

l

PC128US-2

PLS : LS circuit (pressure) T : Tank circuit (pressure)

1o-57

STRUCTURE

AND FUNCTION

PRESSURE COMPENSATION

CLSS

VALVE

Function 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 oper$ion (the upper side) is higher than that of the actuator on this side (the lower side). l

Aa \

t

(Comensaed

PP

1 O-58

PC128US-2

STRUCTURE

AND FUNCTION

CLSS

Operation When the load pressure of another actuator side (the upper side) rises during a compound operation, the flow in the actuator circuit A on this side (the lower side) is apt to increase.. In this case, the LS pressure PLS of another actuator is applied to the spring chamber PLSl and pushes the pressure reducing valve (1) and the flow cont;ol valve (2) to the left side. 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. 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 and PPA. 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. l

l

l

l

l

‘..

PC1 28US-2

1o-59

STRUCTURE

AND FUNCTION

AREA RATIO OF PRESSURE COMPENSATION

CLSS

VALVE

Function The pressure compensation valve slightly adjust the ratio (S2/Sl) of the area Sl 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. Sl : 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) l

T

T

9JUOOl26

Area ratio (Sl:S2) and compensation characteristics When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pres_ sure PPBI k [LS circuit pressure PLS - Actuator circuit pressure PA (= A)] can be held, and the flow is distributed as per the spool opening area ratio. 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. 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. l

l

l

1 O-60

PC1 28US-2

STRUCTURE

AND FUNCTION

CLSS

BOOM HYDRAULIC DRIFT PREVENTION VALVE Function . This valve prevents boom bottom oil from leading from the spool (1) and prevents the boom from falling naturally when the boom lever is out of operation. 1.

At boom raise

9JUOOl27

Operation l. When the boom is raised, the main pressure from the control valve will push the poppet (5) upward. And the main pressurized oil from the control valve will flow to the boom cylinder bottom through the valve inside.

PC128US-2

lo-61

STRUCTURE

2.

CLSS

AND FUNCTION

Boom lever at neutral

9JUOO128

Operation 0. When the control lever is returned to NEUTRAL’while the boom is raised, the holding pressure on the boom cylinder bottom is confined with the poppet (5). At the same time, the pressurized oil flown in the inside through the orifice a is confined with the pilot spool (3). Then, the boom is held neutral.

1O-62

PC1 28US-2

STRUCTURE

3.

CLSS

AND FUNCTION

At boom lower

9JUOOl29

Operation When the boom is lowered, the pilot pressure Pl from the PPC valve will push the pilot spool (3) and drain pressurized oil from the b chamber inside the poppet. The pressurized oil from the boom cylinder “bottom raises the oil pressure in the Ab port but reduces the pressurized oil in the b chamber through the orifice a. When the pressure in the b chamber drops below the pressure in the Aa port, the poppet (5) will open, and the pressurized oil from the Ab port will be led to the Aa port and flow in the control valve. l

l

l

PC1 28US-2

1O-63

STRUCTURE

AND FUNCTION

BOOM REGENERATION

CLSS

CIRCUIT

1. At boom lower and own weight fall Function 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:l

9JUOOl30

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.

l

l

l

1O-64

At the time, part of the return flow on the bottom side passes through the regeneration passage a of the boom spool (21, pushes the checkvalve (3) to open it and flows to the head side. This increases the boom lower speed.

PC1 28US-2

STRUCTURE

CLSS

AND FUNCTION

2. At boom lower load process Function 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.

9JUOOlJI

Operation 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. l

PC128US-2

l

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.

lo-65

STRUCTURE

CLSS

AND FUNCTION

ARM REGENERATION

CIRCUIT

1. At arm in and own weight fall Function 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. l

T

PLS

9JUOO132

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. At the time, part of the return flow on the head side passes through the regeneration passage a of the arm spool (21, pushes the checkvalve (3) to open it and flows to the bottom side. This increases the arm digging speed. l

1. 2. 3.

Arm cvlinder Arm spool Check valve

l

A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)

l

1O-66

PC1 28US-2

STRUCTURE

CLSS

AND FUNCTION

2. At arm in process Function 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. l

9JUOO133

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. l

PC1 28US-2

1. 2. 3.

Arm cylinder Arm spool Check valve

A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)

1O-67

STRUCTURE

TRAVEL JUNCTION

VALVE

(L.H. and R.H. travel junction 1.

CLSS

AND FUNCTION

When traveling

circuit)

straight

SJPO7615

1O-68

PC1 28US-2

STRUCTURE

AND FUNCTION

CLSS

Function When the L.H. and R.H. travel spool is operated to compensate flow errors in the L.H. and R.H. travel circuits during straight travel, the junction circuit will open. Then, the flows to the L.H. and R.H. travel motors will become the same during the straight travel, and travel deviation will decrease. At the time of steering, load pressure difference brings back the pressure reducing valve. of the travel valve inside the steering and closes the spool notch opening of the travel junction valve to close the junction circuit for steering. l

l

l

Operation When the L.H. and R.H. travel spool (1) is operated, the pump delivery will flow from the pump circuit PP to A through the actuator circuit PA. When traveling straight, the actuator circuit PA will be equalized and the L.H. and R.H. pressure reducing valves (2) will be pressed the same stroke to the right. Then, the notch a and the junction circuit will open. * The L.H. travel forward oil pressure P7 and the R.H. travel forward oil pressure P2 are led to the spring chamber on the both end of the travel junction valve spool (4) through the respective shuttle valves (5). So, PI = P2, and the spool is at the neutral position, and the notch d is ?open?. Then, the L.H. and R.H. travel actuator circuits are interconnected with the junction circuit. When any difference occurs in the flows to the L.H and R.H. travel motors, this valve will compensate them and will reduce occurrence of travel deviations. l

l

l

PC1 28US-2

lo-69

STRUCTURE

2.

AND FUNCTION

When operating

CLSS

travel steering

SJPO7616

1O-70

PC1 28US-2

STRUCTURE

AND FUNCTION

CLSS

Operation l- When the L.H. travel spool (L.H. 1) is returned to the neutral side from the straight traveling state and the steering is operated, there will occur any difference in the load pressures in the L.H. and RH. travel actuator circuits PA (R.H. A > L.H. A).. The LS pressure PLS will become the same as the R.H. A on the higher load pressure side. Therefore, the flow control valve on the L.H.. travel side is pressed to the left side with the LS pressure PLS, i.e., the load pressure on the R.H. travel side, and the notch a closes to interrupt the L.H. and R.H. travel circuits. Also, since the pressures in the spring chambers on the both ends of the travel junction valve spool (4) become different and Pl becomes higher than P2, the spool (4) moves to the Pl side and the notch d closes. Then, the steering can be operated. - The damper is provided to relax the transition characteristics of the junction circuit at the time of abrupt operation. l

PC1 28US-2

1o-71

STRUCTURE

AND FUNCTION

CLSS

TRAVEL LS BYPASS CIRCUIT 1.

At normal operation

1 O-72

PC1 28US-2


CLSS

Function • When an actuator is operated during travel, this circuit will increase the discarded throttled flow of the LS circuit PLS, lessens the pressure compensation accuracy of the travel circuit and limits reduction of the travel speed to small extent. • The bypass circuit is closed in case of independent travel or independent operation of an actuator. Operation • When the boom spool (1) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure A1. • At the same time, the LS circuit pressure PLS is led to the spring chamber PLS1 of the pressure reducing valve (2) of the travel valve. • Since the travel spool is not operated, the travel actuator circuit PA is closed and the check valve (4) inside the flow control valve (3) is also closed. • Therefore, the travel LS bypass circuit is closed in case of independent operation of the boom.

PC128US-2

10-73 (18)

STRUCTURE

AND FUNCTION

2. -At operation

CLSS

of travel + other actuator

9JYOOO2

STRUCTURE

AND FUNCTION

CLSS

Operation When the boom spool (1) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure Al. Since the actuator circuit pressure is generally higher at boom RAISE than during travel (Al > A2), the pressure in the spring chamber PLSl of the flow control valve (3) on the travel side is higher than the travel circuit pressure PA. 4. So, the pressure reducing valve (2) moves to the left side, and the LS pressure of the spring chamber PLSl pushes the check valve (4) from the orifice a to open it and flows, to the travel circuit PA through the passages b and c. Therefore, when the LS circuit pressure PLS, which has been as high as the boom circuit pressure Al, flows to the travel circuit AZ, the pressure will drop.

PC1 28US-2

1o-75

STRUCTURE

SELF PRESSURE REDUCING

AND FUNCTION

VALVE

SELF PRESSURE REDUCING VALVE

PR

I:

I:

Pl

kla

I--

A-4

9JUOOO62

Pl : From pump PR : Supply to solenoid valve, PPC valve and EPC valve, . T : To hydraulic tank

1O-84

PC1 28US-2

STRUCTURE


AND FUNCTION

A-A

9JUOOO63

1. Control valve block 2. Valve (sequence valve) 3. Spring 4. Screw 5. Poppet 6...Spring (pressure reducing valve pilot)

PC128US-2

7. 8. 9. 10. 11.

Spring (pressure reducing valve main) Valve (pressure reducing valve) Spring (safety valve) Ball Filter

1 O-85

STRUCTURE


AND FUNCTION

Function The self pressure reducing valves reduces the discharge pressure of the main pump and supplies it to the solenoid valve, the PPC valve, etc. as the control pressure. l

VALVE

---__-_____-_ MIN3. PI Pork

66MPa

I-

I I 8 I

PI Port

I I I

P, Port

T Port

Hydraulic

circuit SVP07622

1. ‘At engine stop (total low pressure) Operation The spring (6) pushes the poppet (5) t the seat, and the circuit between the ports PR and T is closed. - The spring (7) pushes the valve (8) to the left side, and the circuit between the ports PI and PR is open. The spring (3) pushes the valve (2) to the left side, and the circuit between the ports Pl and P2 is closed. l

l

lo-86

PC 128W2

STRUCTURE

AND FUNCTION


SVP07623

PC1 28US-2

lo-87

STRUCTURE


AND FUNCTION

2. At neutral and reduction of load pressure P2 (at own weight fall in boom LOWER and arm IN) Note : When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.

SVP07624

Operation The spring (3) and the PR pressure (0 MPa (0 kg/cm2} at the time of engine stop) pushes the valve (2) in the direction to close the circuit between the ports PI and P2. When the hydraulic oil enters the Pl port, the expression (Pl pressure + Spring (7) force + (pld area x PR pressure)) holds, and the self pressure reducing valve will adjust the openings of the ports Pl and P2 so that the Pl pressure can be maintained higher than the PR pressure. When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil flows through the route from the PR port, the hole a in the spool (81, the poppet (5) opening to the tank port T. l

l

Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port Pl and the PR opening. Then, the PI pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.

l

1O-88

F’C128US-2

STRUCTURE

3.


AND FUNCTION

VALVE

At raise of load pressure P2

-Q

Servo

SVPO7626

Operation When the load pressure P2 rises due to digging*or other operations, the pump delivery will increase and the Pl pressure will rise. Then, the expression (PI pressure > Spring (7) force + ($d area x PR pressure)) will hold, and the valve (2) will move to the right side ..till the stroke end. As a result, the opening between the ports Pl and P2 will increase, the passage resistance will become smaller to reduce engine loss horsepower. l

f’C128US-2

l

l

When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil will flow through the route from the PR port, the hole a in the spool (81, the poppet (5) opening to the tank port T. Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port P1 and the PR opening. Then, the Pl pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.

lo-89

STRUCTURE

4.


AND FUNCTION

At occurrence

of abnormal

VALVE

high pressure

I”

9 SVP07626

Operation When the PR pressure of the self pressure reducing valve rises abnormally high, the ball (10) will separate from the seat against the spring (9) force to flow the hydraulic oil to the output ports PR + T so as to reduce the PR Then, the equipment (PPC valve, pressure. solenoid valve, etc.), to which the oil pressure is supplied, is protected from the abnormal high pressure. l

1O-90

PC1 28US-2


CENTER SWIVEL JOINT

CENTER SWIVEL JOINT STD (WITHOUT BLADE)

1. 2. 3. 4. 5.

Cover Body Slipper seal O-ring Shaft

PC128US-2

A1 : From control valve (R.H. travel Forward) A2 : To R.H. travel motor B B1 : From control valve (L.H. travel Forward) B2 : To L.H. travel motor A C1 : From control valve (R.H. travel Reverse) C2 : To R.H. travel motor A D1 : From control valve (L.H. travel Reverse) D2 : To L.H. travel motor B E1 : 2-stage travel selection solenoid valve E2 : To L.H./R.H. travel motor D DR1 : To hydraulic tank DR2 : From L.H. travel motor C1 and R.H. travel motor C2

10-91 A


CENTER SWIVEL JOINT

OPT (WITH BLADE)

1. 2. 3. 4. 5. A1 A2 B1 B2 C1 C2 D1

Cover Body Slipper seal Dust seal Shaft : From control valve (R.H. travel “Forward”) : To R.H. travel motor B : From control valve (L.H. travel “Forward”) : To L.H. travel motor A : From control valve (R.H. travel “Reverse”) : To R.H. travel motor A : From control valve (L.H. travel “Reverse”)

10-92 A

D2 : To L.H. travel motor B E1 : From travel 2nd speed selector solenoid valve E2 : To L.H./R.H. travel motor D F1 : From control valve (Blade “LOWER”) F2 : To L.H./R.H. blade cylinder bottom G1 : From control valve (Blade “RAISE”) G2 : To L.H./R.H. blade cylinder head DR1 : To hydraulic tank DR2 : From L.H. travel motor C1, R.H. travel motor C2

PC128US-2

STRUCTURE

TRAVEL MOTOR

AND FUNCTION

34 B-B 9JA01339

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

Plug Check valve spring Check valve Return spring Counterbalance valve Safety’valve Safety valve spring End cover Regulator valve Spring Biake piston Cylinder Spring Swash plate Pivot Crankshaft RV gear A

1o-94

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

RV gear B Cover Driven gear Drive gear Drain plug Hub Regulator piston Spindle Piston Floating seal Plate Disc Valve plate Spring Piston Plug Check valve

PC1 28US-2


TRAVEL MOTOR

Specification Type PC128US-2

Serial No. Spec.

PC138US-2 PC138USLC-2

GM18VL-J

GM20VL-J

GM20VL-P

GM20VL2-P

5001 and up

5001 – 6072

6073 and up

—

STD

OPT(traction up)

—

Serial No.

—

—

—

4501 and up

Spec.

—

—

—

STD

Serial No.

—

—

1001 – 1500

1501 and up

Spec.

—

—

STD

STD

Theoretical delivery (cm3/rev{cc/rev}) Rated speed (rpm)

Hi

33.2 {33.2}

Lo

52.7 {52.7}

Hi

3,267.7

3,191

3,035

3,444

Lo

2,147.3

2,028

1,929

2,025

34.0 {34.0}

Brake releasing pressure (MPa{kg/cm2})

0.68 {6.94}

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

2.94 {30}

Final drive reduction ratio

31.5 {31.5}

55.8 {55.8}

72

75.7

OUTLINE Travel speed selection

• •

Swash plate (14) has 2 faces (x, y) behind it, and is supported by pivot(15). When pressure of control chamber a rises, it pushes regulator piston (24), then swash plate angle becomes minimum, then travel speed goes high.

PC128US-2

10-95 (18)


TRAVEL MOTOR

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

•

• •

•

•

Since the travel 2nd speed selector solenoid valve is demagnetized, the pressurized oil from the main pump does not flow to the D port. Therefore, the spring (10) has pressed the regulator valve (9) to the left side. So, the regulator valve (9) stops the main pressurized oil led from the control valve to the end cover by pushing the check valve (34). The pressurized oil in the control chamber drains in the motor case through the passage b of the regulator valve (9). Then, the main pressurized oil from the cylinder c chamber pushes the swash plate (14) in the direction to maximize the swash plate angle and the motor capacity is increased to the maximum for slow speed travel.

10-96 2

PC128US-2


TRAVEL MOTOR

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

•

•

•

When the travel 2nd speed selector solenoid valve is energized, the pilot pressure from the main pump will flow in the D port and push the regulator valve (9) in the right direction. Therefore, the main pressurized oil from the control valve passes through the passage b of the regulator valve (9), flows in the control chamber a and pushed the regulator piston (24) in the left direction. Then, the swash plate (14) is pressed in the direction to minimize the swash plate angle, and the motor capacity is minimized for high speed travel.

PC128US-2

10-97 2


TRAVEL MOTOR

Operation of brake valve • The brake valve consists of the check valves (3a) and (3b), the counterbalance valve (5) and the safety valve (6), and the circuit configuration is as per the right figure. • Functions and operations of these components are as follows :

Counterbalance valve, check valve Function • When traveling down a slope, the machine weight falling force will make the machine travel faster than the motor rotation. So, traveling with reduced engine speed is very dangerous because the motor idles and runs away. These valves let the machine travel at a speed appropriate for the engine speed (pump delivery) to prevent this danger. Operation at oil supply • When the travel lever is operated, the pressurized oil from the control valve will be supplied to the PA port, push and open the check valve (3a) and flow from the MA port on the motor inlet side to the MB port on the motor outlet side. Since the motor outlet circuit is closed with the check valve (3b) and the counterbalance valve (5), however, the supply-side pressure will rise.

10-98 (18)

PC128US-2

STRUCTURE

l

AND FUNCTION

TRAVEL MOTOR

The pressurized oil on the supply side flows in the Sl chamber from the orifice El of the counterbalance valve (5). When the pressure in the Sl chamber rises above the switching pressure of the counterbalance valve, the counterbalance valve (5) will be pressed in the right direction. So, the circuit between the outlet side MB port and the PB port will open, the motor outlet circuit will open, and the motor will start rotating.

SJP07629

Brake cperaticn at travehg dcwnhi!! If the machine is going to run away when traveling downhill, the motor will idle to reduce the oil pressure on the motor inlet side and the pressure in the Sl chamber through the orifice El. When the pressure in the Sl chamber drops below the switching pressure of the counterbalance valve, the counterbalance valve (5) will be returned in the left direction with the return spring (4), and the outlet side MB port will be throttled. Then, the pressure on the outlet side will rise and rotation resistance will occur to the motor to prevent the machine from running away. This.means that the counterbalance valve (5) moves to a position where the machine own .-weight and the inlet side pressure balance with the pressure at the outlet side MB port, and the outlet circuit is throttled to control the speed to the pump delivery. l

PC1 28US-2

El-

sr

SJPO7630

1o-99

STRUCTURE

TRAVEL MOTOR

AND FUNCTION

Safety valve Function When stopping a travel (or traveling downhill), the counterbalance valve (5) will close the inlet and outlet circuits of the motor. Since the motor keeps rotating by inertia, however, the pressure on the outlet side of the motor will rise abnormally and the motor and pipes’ may be damaged. Then, the safety valve leads the abnormally high-pressure to the inlet side of the motor to prevent the equipment from being damaged. l

Operation When the pressurized oil being supplied from the PA port is stopped flowing at the time of travel stop, the return spring (4) will return the counterbalance valve (5) from the right side to the left side (the neutral position). Though the counterbalance valve (5) closes the a chamber on th:e outlet side circuit, the inertia lets the motor rotate and the pressure in the a chamber rises. The highly pressurized oil in the a chamber passes through the throttle b of the safety valve (6a) and enters in the d chamber from the c chamber. The pressurized oil entered in the d chamber moves the piston (32) to the left side. Meantime, the safety valve (6a) is pushed to open by the pressurized oil in the a chamber, and the pressurized oil in the a chamber flows in the f chamber through the e port. Therefore, the pressurized oil in the a chamber flows in the f chamber at a comparatively slow speed to control the pressure in the a chamber and also to prevent cavitation in the f chamber at the same time. When the piston (32) reaches the stroke end, the pressures in the d and c chambers will rise, the safety valve (6a) will be closed again and the pressure in the a chamber will rise further. Then, the safety valve (6b) will open and the pressurized oil in the a chamber will flow in the f chamber from the g chamber. The pressure in the a chamber can be controlled in two stage as mentioned above, and the hydraulic motor can be smoothly braked to stop.

SJPO7631

d

32

SJP07632

10-100

PC128US-2

STRUCTURE

TRAVEL MOTOR

AND FUNCTION

Operation of parking brake When operating travel When the travel lever is operated, the pressurized oil from the pump will work on the counterbalance valve (5), open the circuit a to the parking’brake and flow in the b chamber of the brake piston (11). - The pressure in the b chamber overcomesthe spring (31) and pushed the brake piston (1 I) in the lefi direction’. This will eliminate the press force to the plate (28) and the disc (29), and the plate (28) and the disc (29) will separate, and the brake force will be released. l

l

SJPO7633

When positioning travel neutral When the travel lever is brought to the neutral position, the counterbalance valve (5) will return td the neutral position and the circuit a to the parking brake will be closed. The pressurized oil in the b chamber of the brake piston (11) will be drained in the case, and the spring (31) will push the brake piston in the right direction. Therefore, the plate (28) and the disc (19) will be pushed to each other, and the brake will come to work. l

l

l

5i? Control

valve

M

PC1 28US-2

SJP07634

10-101

STRUCTURE

AND FUNCTION

SWING MOTOR

SWING MOTOR TYPE : KMF40ABE-3

9JUOOO70

B S T MA MB

: From-iswing brake solenoid valve : From control valve : To tank : From control valve : From control valve

10-102

Specification Type : KMF40ABE-3 Theoretical delivery : 40.2 cc/rev Safety valve set pressure : 27.5 MPa (280 kg/cm2) Rated speed : 2,413 rpm Brake releasing pressure :1.77 MPaIl8.0 kg/cm2}

PC1 28U.52

STRUCTURE

SWING MOTOR

AND FUNCTION

16

c-c

1. Drive shaft 2. Spacer 3. Case 4. Disc 5.,,Plate 6. Brake ring 7. Brake piston 8. Housing 9. Reverse prevention 10. Center spring

PC1 28US-2

valve

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

17

ii is 9JUOO102

Cylinder Valve plate Piston Center shaft Safety valve Check valve Check valve spring Shuttle valve Shuttle valve spring Brake spring

10-103

SWING MOTOR


SWING BRAKE 1. When solenoid valve is demagnetized Operation When the solenoid valve of the swing brake is demagnetized, the pressurized oil from the control pump will be interrupted and the B port will be connected to the tank circuit. Then, the’brake piston (7) will be pressed downward with the_.brake spring (8) and will push the disc (4) and the plate (5) to work the brake. l

l

SJP07636

2. When solenoid valve is energized Operation When the solenoid valve of the swing brake is energized, the valve will be changed over and the pressurized oil from the control pump will enterthe 6 port and will flow in the brake chamber A. The pressurized oil in the A chamber will push the brake spring (8) and the brake piston (7) will move upward. Then, the disc (4) and the plate (5) will separate to release the brake. l

l

I

SJPO7636

10-104

PC1 28US-2

SWING MOTOR


REVERSE PREVENTION

VALVE

II 0 --I_-_-

_-J

1

2

3

4

Tl

MA

MB

T2 Z

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

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

MA MB Tl T2

: Port : Port : Port : P&t

PC128US-2

:____

9JUOOO72

10-105

STRUCTURE

SWING MOTOR

AND FUNCTION

Effect explanation

drawing

,With reversal rotation Prevention valve _ _.

,Without reversal Prevention valve

rotation

MA pr ‘essure

ME pr essure

Motor

ro tat

ion

Time

t

SJPO7637

10-106

PC1 28US-2

STRUCTURE

SWING MOTOR

AND FUNCTION

Function This function is used for reducing swjng back generated on a swing body that can result from factors such as inertia of the swing body, backlash and rigidity of the machinery systern and compressibility of hydraulic oil. This function helps preventing loose loads at the end of swing or cutting lead time (better positioning performance allows you to proceed to the next-operation within a shorter time). l

l

Notch

SJP07777

1. When MB port pressure is generated Operation MB pressure is conducted to d room via the cutout. Utilizing difference of space (Dl>D2), the pressure compresses the spring (6) and drives the spool (5) leftward to interconnect MB+e. Since MA pressure at this time is lower than the pressure set on the spring (31, the spool (2) is not moved and pressurized oil remains closed. Thus, the braking force is maintained. l

l

SOP02036

2. When the motor is once stopped Operation The motor is reverse rotated by charging pressure generated on the MB port (1st reverse rotation). At this time, reversing pressure is generated on the MA port. MA pressure conducted to a room interconnects MA + b by compressing the spring (3) and driving the spool (2) rightward. - The pressure is then conducted through drilled hole on the spool (5) to interconnect b + f.’ Reversing pressure on the MA port is bypassed to the T port to disable the 2nd reverse rotation.

a

l

l

PC1 28US-2

I-L

2

3

II/

0

5

SDP02037

10-107

STRUCTURE

SOLENOID

AND FUNCTION

VALVE

SOLENOID VALVE FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND 2-STAGE RELIEF SOLENOID VALVE.

Al

A4

A3

7i2

A-A

to

i

B-B

9JA01353

1. 2. 3. 4.

PPC lock solenoid valve 2nd travel speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve

Solenoid valve 5. Push spin 6. Coil 7. Gauge 8. .Spool 9. Block 10. Spring

Al A2 A3 A4 ACC Pl T

: To PPC valve : To 2-stage relief valve : To swing hold brake : To 2nd travel speed select valve : To accumulator : From self-pressure reducing valve : To hydraulic oil tank

Check valve 11. Plug 12. Spring 13. Plunger

lo-108

PC1 28US-2

STRUCTURE

SOLENOID

AND FUNCTION

Operation When solenoid is “demagnetized” The coil (6) remains demagnetized as long as signal current to it is stopped.. Thus, the spool (8) is pushed leftward by the spring (IO). Since ports P to A are closed by this spool, flow of. pilot.oil pressure to the actuator is blocked. At the same time, oil from the actuator is lead from A port to T port, then: drained to the hydraulic oil tank.

VALVE

l

l

l

#ztiva t

SJPO7636

When solenoid is “magnetized” - The coil (6) is magnetized by signal current conducted to it. Thus, the spool (8) is pushed rightward by the push pin (5). As the result, pilot oil pressure is conducted from P port through the cage (7) and A port up the actuator. At the same time, T port is closed, thereby blocking flow of oil to the hydraulic oil tank. l

l

Exe i‘t

I)

SJPO7639

PC1 28US-2

10-109

PPC ACCUMULATOR


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

‘\

Gas plug Shell Poppet Holder Bladder Oil port

SBPOO290

Specifications Gas used : Nitrogen gas Gas capacity : 0.3 e Charged gas pressure : 1.18 MPa (12 kg/cm*) at 80°C Maximum operating pressure : 6.86 MPa (70 kg/cm*)

10-l10

PC1 28US-2


ACCUMULATOR FOR BREAKER (IF EQUIPPED)

ACCUMULATOR FOR BREAKER (If equipped) FOR LOW PRESSURE 1. 2. 3. 4. 5. 6.

Cap Core Guard rubber Lid Plug Shell

Specification Type of gas : Nitrogen gas Gas valume : 0.48 ¬ Sealed gas pressure : 0.1 MPa {1 kg/cm2}(at 80 ºC) Max. actuating pressure : 6.86 MPa {70 kg/cm2}

FOR HIGH PRESSURE 1. 2. 3. 4.

Cap Gas plug Plug Shell

Specification Type of gas : Nitrogen gas Gas valume : 0.5 ¬ Sealed gas pressure : 5.88 MPa {60 kg/cm2}(at 80 ºC) Max. actuating pressure : 20.6 MPa {210 kg/cm2}

PC128US-2

10-111 C

STRUCTURE

PPC VALVE

AND FUNCTION

Operation 1. In the neutral mode Pl and P2 ports of the operation valves A and Band the PPCvalve are connected to the drain room D via the fine control hole on the spool l

(1).

2. .

.

.

.

.

.

In the fine control mode (neutral + fine control) When the piston (4) is pushed by the disk (51, the retainer (9) is also pushed, thereby driving the metering spring (2) down via the spool (1). As the result, the fine control hole f is isolated from the drain room D and, almost at the same time, it is connected to the pump pressure PP. Then, pilot pressurized oil for the main pump is conducted from PI port to A port via the fine control hole f. As pressure on PI port is increased, the spool (1) is pushed back thereby disconnecting the fine control hole f from the pump pressure room PP. The disconnected spool (1) is in no time connected to the drain room D, resulting in relieving pressure on Pl port. Thus, the spool (1) is moved up and down so that force of the metering spring (2) and pressure on Pl port may be balanced. Positional relationship between the spool (1) and body (10) (fine control holef is situated at mid point betwe.en the drain room D and pump pressure room PP) remains unchanged until the retainer (9) is contacted against the spool (1). Therefore, the metering spring (2) is compressed in proportion to strokes of the operation lever. So, pressure on PI port is also increased in proportion to strokes of the operation lever. As the result, the operation valve spool is moved up to the position where pressure in A room (the same pressure level as that on Pl port) and force of the operation valve spool return spring is balanced.

10-l 14

(Fio

1) SEP02569

SEP02570

PC 128US-2

STRUCTURE

3. .

.

.

.

AND FUNCTION

PPC VALVE

In the fine control modetoperating lever shifted back to its original position) As the disk (5) starts returning, the spool (1) is push up by force of the centering spring (3) and pressure of,Pl port. Thus, passage between the fine control hole f and drain room D becomes, thereby relieving pressurized oil of Pl port. If Pl port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control hole f and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the PI port pressure is recovered to the level equivalent to the lever position. When the operation valve returns, oil in the drain room D flows in through the fine control hole f’ on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up. (Fig

3) SEP0257

4. .

.

.

I

In the full stroke mode When the disk (51 pushes down the piston (4) and the retainer (91 pushes down the spool (l), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via PI port to push the operation valve spool. Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f’.

(Fio

41 SEP02572

F’C128US-2

10-115

PPC VALVE


FOR TRAVEL

P : From main pump T : To tank P1 : L.H reverse P2 : L.H forward

10-116 (15)

P3 : R.H reverse P4 : R.H forward P5 : Travel signal

PC128US-2


PPC VALVE

PC128US-2 Serial No. 5001 – 6300

1. 2. 3. 4.

Plate Body Piston Collar

PC128US-2

5. Metering spring 6. Centering spring 7. Valve

10-117 (15)


PPC VALVE

PC128US-2 Serial No. 6301 and up PC138US-2 Serial No. 4501 and up PC138USLC-2 Serial No. 1001 and up

1. 2. 3. 4.

Plate Body Piston Collar

10-117-1 (15)

5. 6. 7. 8.

Metering spring Centering spring Valve Pin

PC128US-2


PPC VALVE

Operation 1. In the neutral mode • P1 and P2 ports of the operation valves A, B and PPC valve are connected to the drain room D via the fine control hole f on the spool (1).

2. In the fine control mode (neutral → fine control) • As the piston (4) is pushed by the disk (5), the retainer (9) is pushed, too. At the same time, the spool (1) is also pushed down via the metering spring (2). • By this move, connection of the fine control hole f is switched from the drain room D to the pump pressure room PP, and pilot pressurized oil for the main pump is conducted from P1 port to A port. • As P1 port pressure increases, the spool (1) is pushed back. By this move, connection of the fine control hole f is switched from the pump pressure room PP to the drain room D, thereby relieving P1 port pressure. • As the result, the spool (1) moves up and down so that force of the metering spring (2) and P1 port pressure may be balanced. Positional relationship between the spool (1) and body (10) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (9) is contacted against the spool (1). • The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the P1 port pressure, too, increases in proportion to strokes of the operation lever. • As the result, the operation valve spool moves to the position where pressure of A room (the same as P1 port pressure) is balanced against force of the operation valve spool return spring.

10-118

PC128US-2


PPC VALVE

3. In the fine control mode (when operation lever is shifted back to its original position) • As the disk (5) starts returning, the spool (1) is pushed up by force of the centering spring (3) and P1 port pressure. • By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of P1 port to it. • If P1 port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control hole f and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the P1 port pressure is recovered to the level equivalent to the lever position. • When the operation valve spool returns, oil in the drain room D flows in through the fine control hole f’ on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up.

4. In the full stroke mode • When the disk (5) pushes down the piston (4) and the retainer (9) pushes down the spool (1), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. • Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via P1 port to push the operation valve spool. • Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f’.

PC128US-2

10-119 (15)


PPC VALVE

FOR BLADE, SERVICE

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

Spool Metering spring Centering spring Piston Lever Plate Retainer Body Filter

10-120 (15)

P : T : P1 : P2 :

From self pressure reducing valve To tank To blade or service valve To blade or service valve

PC128US-2

STRUCTURE

AND FUNCTION

PPC VALVE

Operation 1. In the neutral mode PI and P2 ports of the operation valves A, B and PPC valve are connected to the drain room D via the fine control hole f on the spool l

(1).

2. l

.

l

l

l

l

l

In the fine control mode (Neutral + fine control) As the piston (4) is pushed by the disk (5), the retainer (7) is pushed, too. At the same time, the spool (7) is also pushed down via the metering spring (2). By this move, connection of the fine control hole f is switched from the drain room D to the pump pressure room PP, and pilot pressurized oil for the control pump is conducted from Pl port to A port. As PI port pressure increases, the spool (1) is pushed back. By this move, connection of the fine control hole f is switched from the pump pressure room PPto the drain room D, thereby relieving Pl port pressure. As the result, the spool (1) moves up and down so that force of the metering spring (2) and Pl port pressure may be balanced. Positional relationship between the spool (1) and body (8) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (7) is contacted against the spool (1). The’metering spring (2) is, therefore, compressed in proportion to strokes of the opera...tion lever. Thus, the Pl port pressure, too, increases in proportion to strokes of the operation lever. As the result, the operation valve spool moves to the position where pressure of A room (the same as Pl port pressure) is balanced against force of the operation valve spool return spring.

PC1 28US-2

SJP07646

SJP07647

10-121

STRUCTURE

3. .

.

.

AND FUNCTION

PPC VALVE

In the fine control mode (when the operation lever is shifted back to its original position) As the lever (5) starts returning, the spool (1) is pushed up by force of the centering spring (3) and Pl port pressure. By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of Pl port to it. If PI port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control hole f and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the PI port pressure is recovered to the level equivalent to the lever position. When the operation valve spool returns, oil in the drain room D flows in through the fine control hole f’ on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up. SJPO7648

4. l

l

.

l

In the full stroke mode When the disk (5) pushes down the piston (4) and the retainer (7) pushes down the spool (I), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via Pl port to push the operation valve spool. Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f’.

SJPO7649

10-122

PC1 28US-2


BOOM HYDRAULI DRIFT PREVENTION T VALVE

BOOM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC.) PC128US-2 Serial No.: 5001 – 7730

1. 2. 3. 4. 5.

Poppet Check valve spring Pilot spool Pilot spring Safety-suction valve

PC128US-2

CY : To boom cylinder bottom PI : From PPC valve (pilot pressure) T : To hydraulic tank V : From control valve

10-122-1 C


BOOM HYDRAULIC DRIFT PREVENTION VALVE

PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up

1. 2. 3. 4. 5.

Poppet Check valve spring Pilot spool Pilot spring Safety-suction valve

10-122-2 (15)

CY : To boom cylinder bottom PI : From PPC valve (pilot pressure) T : To hydraulic tank V : From control valve

PC128US-2


ARM HYDRAULIC DRIFT PREVENTION VALVE

ARM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC.) (If equipped) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up

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

Pilot spool Spring (1st stage of spool) Spring (2nd stage of spool) Safety valve Check valve Spring

10-122-6 (15)

V : From control valve T : To hydraulic tank CY : To hydraulic cylinder PI : From PPC valve PCV : From pressure pickup and equalizer circuits

PC128US-2



Function If the piping between the main valve and a work equipment cylinder bursts, this valve prevents the oil from flowing back from the work equipment cylinder to prevent sudden fall of the work equipment. Operation 1. When work equipment is in neutral [When piping is normal] • Check valve (5) is closed by the work equipment cylinder holding prssure applied through port CY to chamber b. • When the work equipment is in neutral, no pilot pressure is applied from the PPC valve to port Pi. Accordingly, pilot spool (1) is moved to the left end by the force of springs (2) and (3), then chambers a and b are shut off from each other. • By this operation, oil does not flow between the main valve and the work equipment cylinder, thus the work equipment cylinder is held. • If the pressure in the work equipment cylinder rises high abnormally, work equipment cylinder holding pressure operates safety valve (4). [When piping bursts] • Even if piping A between the main valve and work equipment cylinder bursts, chamber a is shut off from chamber b as in the case where the piping is normal. Accordingly, the work equipment cylinder is held.

PC128US-2

10-122-7 C



2. When oil is sent from main valve to cylinder [When piping is normal] • If pressure of the oil sent from the main valve to chamber a is higher than the total of pressure in chamber b connected to the work equipment cylinder and the force of spring (6), check valve (5) opens and chambers a and b are connected to each other and the oil flows from the main valve to the work equipment cylinder. [When piping bursts] • If piping A between the main valve and work equipment cylinder bursts, the oil in chamber a flows out through the burst part and pressure in chamber a lowers. • If pressure lowers below the total of pressure in chamber b and the force of spring (6), check valve (5) closes and chambers a and b are shut off from each other. Accordingly, pressure in the cylinder is held and the work equipment does not fall suddenly.

10-122-8 (18)

PC128US-2



3. When oil is returned from work equipment cylinder to main valve [When piping is normal] • The work equipment cylinder holding pressure is applied to chamber b and check valve (5) closes. • The pilot pressure from the PPC valve is applied port Pi. If it is higher than the force of spring (2) (area of ød), spool (1) moves to the right standby position (1st-stage stroke). • At this time, chambers a and b are not connected to each other. • If the pilot pressure rises higher than the force of spring (3) (area of ød), spool (1) moves further to the right and chambers a and b are connected to each other (2nd-stage stroke). • Accordingly, the oil is returned from the work equipment cylinder to the main valve.

•

[When piping bursts] If piping A between the main valve and work equipment cylinder bursts, the oil in chamber a flows out through the burst part. Since the oil supplied from chamber b to chamber a flows through opening c of spool (1), however, the cylinder does not fall suddenly.

PC128US-2

10-122-9 C

AIR CONDITIONER PIPING



A : Hot air/cold air spurting with outlet port B : Internal air circulation port C : External air inlet 1. 2. 3. 4.

Hot water drain piping Air conditioner compressor Hot water return piping Refrigerant piping

10-123-1 (18)

5. 6. 7. 8.

Receiver tank Condenser Air conditioner unit Duct

PC128US-2


AIR CONDITIONER PIPING


A: B: C: D:

Hot air/cold air spurting with outlet port Internal air circulation port External air inlet Refrigerant checking port

1. 2. 3. 4.

Hot water drain piping Air conditioner compressor Hot water return piping Refrigerant piping

PC128US-2

5. 6. 7. 8.

Receiver tank Condenser Air conditioner unit Duct

10-123-2 (18)


ELECTRIC COMPONENT LAYOUT

1. Additional light (Standard for KUK and North America) 2. Fuel level sensor 3. L.H. working light 4. PC-EPC solenoid valve 5. Safety relay 6. Starting motor 7. Engine speed sensor 8. Coolant temperature sensor 9. Alternator 10. Electric intale heater 11. Engine oil pressure sensor 12. Air conditioner compressor 13. Heater relay 14. Engine stop solenoid valve 15. Condenser 16. Washer tank 17. Battery relay 18. Battery 19. Fusible link 20. Swing holding brake contraller 21. Deceleration controller 22. Pump controller 23. Air conditioner unit 24. Swing holding breke release switch 25. Travel speed boost pedal 26. Emergency pump drive switch 27. Travel pressure switch 28. Overload alarm pressure switch (Standard for KUK only) 29. Horn 30. Swing RIGHT switch 31. Swing LEFT switch 32. Arm IN pressure switch 33. 2-stage relief solenoid valve 34. Swing holding solenoid valve 35. 2-stage travel speed selection solenoid vaolve 36. PPC lock solenoid valve 37. R.H. working light 38. Travel alarm (Standard for KUK and North America) 65. Automatic travel speed change controller (Serial No.: 6301 and up ) 66. Pump pressure sensor (Serial No.: 6301 and up) PC128US-2 Serial No. : 7731 and up PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1001 and up fl For the layout drawings of electrical equipment of serial numbers later than the above, refer to the paragraph of "CONNECTOR TYPES AND MOUNTING LOCATIONS" in the "TROUBLESHOOTING."

PC128US-2

10-125 (15)


39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64.

ELECTRIC COMPONENT LAYOUT

Temperature control switch Wind volume selection switch Air conditioner switch Horn switch Monitor panel Light switch Car heater switch (Model with heater) One touch deceralation pilot lamp Starting switch Fuse box Throttle control motor Overload alarm buzzer reset switch (Standard for KUK only) Additional light switch (Standard for North America) Wiper switch Wiper controller Swing lock switch Travel speed selection switch PPC lock switch One touch deceralation switch Additional light relay Alarm buzzer Room light Antenna (Standard for North America only) Car radio (Standard for North America only) Speaker (Standard for North America only) Waper motor

PC128US-2 Serial No. : 7731 and up PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1001 and up fl For the layout drawings of electrical equipment of serial numbers later than the above, refer to the paragraph of "CONNECTOR TYPES AND MOUNTING LOCATIONS" in the "TROUBLESHOOTING."

PC128US-2

10-127 (15)


ENGINE CONTROL


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

Starting switch Fuel control dial Safety relay Starting motor Engine stop solenoid Controller Battery relay

PC128US-2

8. 9. 10. 11. 12. 13.

Battery Fuel control motor Fuel control motor relay Engine stop solenoid relay Governor lever Fuel injection pump

10-128-1 (15)


ENGINE CONTROL


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

Starting switch Fuel control dial Safety relay Starting motor Engine stop solenoid Controller Battery relay

10-128-2 (15)

8. 9. 10. 11. 12. 13.

Battery Fuel control motor Fuel control motor relay Engine stop solenoid relay Governor lever Fuel injection pump

PC128US-2

ENGINE CONTROL



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

Battery Battery relay Fusible link Starting switch Fuse box Controller Safety lock lever PPC lock switch Starting motor cut relay

PC128US-2

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

Safety relay Fuel control dial Fuel control motor Fuel control motor relay (for driving) Fuel control motor relay (for acceleration) Fuel control motor relay (for deceleration) Engine stop solenoid Starting motor

10-132-1 (15)

ENGINE CONTROL



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

Battery Battery relay Fusible link Starting switch Fuse box Controller Safety lock lever PPC lock switch Starting motor cut relay

PC128US-2

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

Safety relay Fuel control dial Fuel control motor Engine stop solenoid relay Fuel control motor relay (for acceleration) Fuel control motor relay (for deceleration) Engine stop solenoid Starting motor

10-132-3 (15)


ENGINE CONTROL

START OF ENGINE •

•

•

When the starting switch comes to the ON position, the engine stop solenoid (16) drives the governor stop lever to the "RUN" side. A failsafe mechanism has been adopted that stops the engine when an abnormality occurs in the electrical system. When the safety lock lever (7) comes to the "LOCK" position and the starting switch (4) comes to the START position, a start signal flows to the starting motor and the engine starts. When the safety lock lever is set to the "FREE" position, the starting motor cut relay (9) interrupts the start signal to the starting motor (7) and the engine cannot start. At the time, the fuel control dial (11) is linked to the fuel control motor (12), and the engine speed comes to the speed set with the fuel control dial (11).

CONTROL OF ENGINE SPEED •

•

•

The fuel control motor (12) outputs an acceleration (engine speed increases) signal or a deceleration (engine speed drops) signal to the controller (6) depending on the rotational position of the fuel control dial (11). After receiving the signal, the controller (6) outputs a drive signal to the fuel control motor (12) through the fuel control motor relays (13), (14) and (15). The fuel control motor (12) shortens or extends the cable and controls the engine speed according to the drive signal.

STOP OF ENGINE •

When the starting switch (4) comes to the OFF position, the engine stop solenoid (18) drive the governor stop lever to the "STOP" side and the engine stops.

FUNCTION OF PREVENTING ENGINE STOP SOLENOID FROM BURNING •

•

Engine stop solenoid relay (13) is installed to prevent engine stop solenoid (16) from burning. The time to supply the suction current is limited to 3 seconds after starting switch (4) is turned to the ON position by replacing the 2wire engine stop solenoid (16) (which uses the same wire for the suction and holding currents) with the 3-wire one (which uses independent wires for the suction and holding currents) and adding a timer function and engine stop solenoid relay (13) to controller (6).

10-132-4 (15)

A: B: C: t:

Operation of starting switch Suction coil current Holding coil current 3 seconds PC128US-2


ENGINE CONTROL

AUTO-DECELERATOR PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

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

Battery Battery relay Fusible link Starting switch Fuse box Controller Fuel control dial Fuel control motor Monitor panel Fuel injection pump Boom RAISE PPC oil pressure switch Arm IN PPC oil pressure switch Swing PPC oil pressure switch

I/O Signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal

PC128US-2

14. Travel PPC oil pressure switch 15. Work equipment control lever PPC oil pressure switch 16. Hydraulic pump 17. Control valve 17a. Self pressure reducing valve 17b. Main relief valve 18. PPC lock solenoid valve 19. L.H. work equipment PPC valve 20. R.H. work equipment PPC valve 21. Travel PPC valve 22. Blade PPC valve (Blade specification)

e. f. g. h.

PPC oil pressure switch signal Throttle signal Fuel control motor drive signal Potentiometer signal

10-132-5 (15)


ENGINE CONTROL

FUNCTION • When the all control levers are set to NEUTRAL for waiting for a dump track or work, the engine speed is automatically reduced to a medium speed, and fuel consumption and noise are lowered. • When the control lever is operated, engine speed returns immediately to the speed that is set with the fuel control dial (7). OPERATION PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 When the control lever is set to NEUTRAL, • If the all control levers are set to NEUTRAL while the engine is running at faster speed than the decelerator operating speed (1,400rpm approx.), the engine speed lowers immediately to the 1st deceleration speed, about 200rpm slower than the speed that is set with the fuel control dial. • When 4 sec. elapses, the engine speed lowers again to the 2nd deceleration speed (about 1,400rpm) and the speed that is kept until the control lever is operated next time. WHEN THE CONTROL LEVER IS OPERATED, • If any control lever is operated while the engine speed is kept for the 2nd deceleration speed, the engine speed rises immediately to the speed that is set with the fuel dial. A: B: C: D: E: F : G: H: J : K:

10-132-6 (15)

All work equipment levers at "NEUTRAL" Work equipment lever at "OPERATION" Speed that is set with fuel control dial 1st deceleration speed 2nd deceleration speed (1,400 rpm) 200 ± 50 rpm 0.2 sec. 4 sec. Max. 2 sec. Max. 1 sec.

PC128US-2

ENGINE CONTROL


PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up When the control lever is set to NEUTRAL, • If the all control levers are set to NEUTRAL while the engine is running at faster speed than the decelerator operating speed (1,300rpm approx.), the engine speed lowers immediately to the 1st deceleration speed, about 100rpm slower than the speed that is set with the fuel control dial. • When 4 sec. elapses, the engine speed lowers again to the 2nd deceleration speed (about 1,300rpm) and the speed that is kept until the control lever is operated next time. WHEN THE CONTROL LEVER IS OPERATED, • If any control lever is operated while the engine speed is kept for the 2nd deceleration speed, the engine speed rises immediately to the speed that is set with the fuel dial. A: B: C: D: E: F : G: H: J : K:

PC128US-2

All work equipment levers at "NEUTRAL" Work equipment lever at "OPERATION" Speed that is set with fuel control dial 1st deceleration speed 2nd deceleration speed (1,300 rpm) 100 ± 50 rpm 0.2 sec. 4 sec. Max. 2 sec. Max. 1 sec.

10-132-7 (15)


ENGINE CONTROL

SYSTEM COMPONENTS FUEL ADJUST DIAL PC128US-2 Serial No.: 5001 – 7730

ª1 : PC128US-2 Serial No. 6301 and up

1. 2. 3. 4.

One-touch deceleration pilot lamp Fuel adjust dial Boss Boss

PC128US-2

5. 6. 7. 8.

Shaft Joint Bracket Fuel adjust motor

10-133 (14)


ENGINE CONTROL


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

Knob Dial Spring Ball Potentiometer Connector

Function • The potentiometer (5) is installed under the knob (1) below the monitor panel. When the knob is turned, the shaft of the potentiometer (5) rotates. • When the shaft rotates, the resistance value of the variable resistor in the potentiometer (5) changes and any throttle signal is sent to the controller.

10-133-1 (15)

PC128US-2

ENGINE CONTROL



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

Cable Connector Potentiometer Pulley Gear unit Motor

Input/Output signal DEUTSCH-6P [CN-M48] Pin No. 1 2 3 4 5 6

Signal name Potentiometer input Potentiometer output Potentiometer GND NC Motor (+) Motor (–)

PC128US-2

I/O signal Input Output — — Input Input

10-134-1 (15)


ELECTRIC CONTROL SYSTEM


10-136-2 (15)

PC128US-2


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. 41. 42.

43.

44. 45.


Battery Battery relay Fusible link Starting switch Fuse box Controller Resistor (for driving pump in an emergency) Emergency pump drive switch Swing holding brake release switch Swing lock switch Safety lock lever PPC lock witch Starting motor cut relay Safety relay Fuel control motor relay (for driving) Fuel control motor relay (for acceleration) Fuel control motor relay (for deceleration) Fuel control dial Fuel control motor Monitor panel Hydraulic pump pressure sensor Travel/swing alarm (option) PPC lock solenoid valve Travel speed selector solenoid valve Swing holding brake solenoid valve 2-stage relief solenoid valve LS-EPC valve PC-EPC valve R.H. work equipment PPC valve Travel PPC valve L.H. work equipment PPC valve Blade PPC valve (Blade specification) Boom RAISE PPC oil pressure switch Travel PPC oil pressure switch Arm IN PPC oil pressure switch Swing PPC oil pressure switch Work equipment control lever PPC oil pressure switch Engine stop solenoid Starting motor Engine speed sensor Coolant temperature sensor Hydraulic pump 42a. Servo piston 42b. LS valve 42c. PC valve Control valve 43a. Self pressure reducing valve 43b. Main relief valve Travel motor Swing motor

PC128US-2

10-136-3 A




10-136-4 (15)

PC128US-2


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. 41. 42.

43.

44. 45. 46. 47.


Battery Battery relay Fusible link Starting switch Fuse box Controller Resistor (for driving pump in an emergency) Emergency pump drive switch Swing holding brake release switch Swing lock switch Safety lock lever PPC lock witch Starting motor cut relay Safety relay Engine stop solenoid relay Fuel control motor relay (for acceleration) Fuel control motor relay (for deceleration) Fuel control dial Fuel control motor Monitor panel Hydraulic pump pressure sensor Travel/swing alarm (option) PPC lock solenoid valve Travel speed selector solenoid valve Swing holding brake solenoid valve 2-stage relief solenoid valve LS-EPC valve PC-EPC valve R.H. work equipment PPC valve Travel PPC valve L.H. work equipment PPC valve Blade PPC valve (Blade specification) Boom RAISE PPC oil pressure switch Travel PPC oil pressure switch Arm IN PPC oil pressure switch Swing PPC oil pressure switch Work equipment control lever PPC oil pressure switch Engine stop solenoid Starting motor Engine speed sensor Coolant temperature sensor Hydraulic pump 42a. Servo piston 42b. LS valve 42c. PC valve Control valve 43a. Self pressure reducing valve 43b. Main relief valve Travel motor Swing motor Heater relay Air heater

PC128US-2

10-136-5 (15)




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

Battery Battery relay Fusible link Starting switch Fuse box Controller Resistor (for driving pump in an emergency) Emergency pump drive switch Monitor panel PC-EPC valve

Input/Output signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal

PC128US-2

11. 12. 13. 14.

LS-EPC valve Engine speed sensor Coolant temperature sensor Control valve 14a. Self pressure reducing valve 14b. Main relief valve 15. Hydraulic pump 15a. Servo valve 15b. LS valve 15c. PC valve

e. f. g. h.

PC-FPC valve drive signal LS-FPC valve drive signal Coolant temperature signal Engine speed signal

10-138-1 (15)



Function • This function is for selecting any of the three working modes "A," "B" and "E" with the working mode selector switch on the monitor panel. The controller can select optimum engine torques or pump absorption torques for works to be expected. •

The controller detects the engine governor speed set with the fuel control dial depending on the pump absorption torques set in each mode and detects actual engine speeds. Then, the controller controls all torques at each output point of the engine so that the pump can absorb them.

•

When an engine speed was lowered, the controller prevents the engine from stopping by throttling the pump absorption torque.

10-138-2 (18)

PC128US-2



CONTROL METHOD IN EACH MODE Mode A • Matching point in Mode A PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up • When a load to the pump increases and the pressure rises and the engine speed lowers. At the time, the controller reduces the pump delivery so that the speed lowers to the speed at the full output point or so. If the pressure drops on the contrary, the controller increases the pump delivery so that the speed comes to the speed at the full output point or so. The controller repeats these controls so that the engine can always be used at speeds at the full output point or so.

PC128US-2

Mode A

66.2 kW/2,200 rpm {88.7 HP/2,200 rpm}

10-138-3 (15)


Mode E and Mode B • Matching point in Mode E : 85% partial output point in Mode A • Matching point in Mode B : 75% partial output point in Mode A • At the time, the controller lowers the engine speed by keeping the pump absorption torque constant along the equal horsepower curve with the compound control both on the engine side and on the pump side. Therefore, the engine is used in high fuel efficient ranges.

10-138-4 (15)


Model

PC128US-2 PC138USLC-2

E mode

54.4 kW/2,000 rpm {72.9 HP/2,000 rpm}

B mode

47.8 kW/1,800 rpm {64.1 HP/1,800 rpm}

PC128US-2




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

Battery Battery relay Fusible link Starting switch Fuse box Controller 2-stage relief solenoid valve PPC lock solenoid valve

9. 10. 11. 12. 13.

Travel PPC valve Travel PPC oil pressure switch Engine Hydraulic pump Control valve 13a. Self pressure reducing valve 13b. Main relief valve

Input/Output Signals a. Controller power supply b. Solenoid power supply c. Solenoid valve drive signal d. Travel PPC oil pressure switch signal Function 2-stage relief • The relief pressure in the normal operation is 31.9 MPa {325 kg/cm2}, and the relief pressure rises to 34.8 MPa {355 kg/cm2} when the 2stage relief function is operated. Therefore, the oil pressure will rise more.

10-139-1 (15)

Condition During travel

Relief pressure 31.9 MPa {325 kg/cm2} ↓ 34.8 MPa {355 kg/cm2}

PC128US-2



FUNCTION Swing lock, swing holding brake • Swing lock holds swing at any position, and swing holding brake works to prevent swing drift. fl Be careful when using the machine in this condition. When the swing holding brake is released, the swing is held only by a brake operated hydraulically by the swing safety valve, so therre may be hydraulic drift when the swing is stopped on a slope. fl Release the swing holding brake also during arm IN operations. Swing lock switch

ON

OFF

PC128US-2

Swing lock lamp

Function

Operation

Gose out

• When the swing control lever is returned to the neutral position, the swing holding Swing brake is actuated after approx. 4 seconds. holding • When the swing control lever is operated, brake the swing holding brake is released, and it is possible to operate the swing freely.

Lights up

• If abnormality occurs in the swing holding brake system and OFF, the swing holding brake is canceled and it becomes possible to operate the swing. • However, even when the swing control level is returned to the nertral position, the swing holding brake is not actuated.

Swing lock

10-141 (18)



Swing holding brake release • When there is a problem in the controller and swing holding brake dosn't work properly, swing holding brake can be released and then swing can be operated by operating swing holding brake release switch to ON. (1) OFF position : Release (2) ON position : Automatic fl When swing lock switch is turned ON, even it swing holding brake switch is turned ON, swing holding brake is not released. Swing holding ON breake release (When abnormality) switch Swing lock ON OFF switch

Swing brake

Swing lock operates

Swing lock released

OFF (When controlleris safe) ON

OFF

Swing lock operates

Swing holding breake operates

Input/Output Signal time chart

10-142 (18)

PC128US-2




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

Battery Battery relay Fusible link Starting switch Fuse box Controller Swing holding brake release switch Swing lock switch Monitor panel Swing holding brake solenoid valve PPC lock solenoid valve

Input/Output Signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal

PC128US-2

12. 13. 14. 15. 16. 17. 18.

Swing motor L.H. work equipment PPC valve Arm IN PPC oil pressure switch Swing PPC oil pressure switch Engine Hydraulic pump Control valve 18a. Self pressure reducing valve 18b. Main relief valve 19. Travel/swing alarm (option)

e. f. g. h.

Solenoid valve drive signal Swing PPC oil pressure switch signal Arm IN PPC oil pressure switch signal Alarm operation signal

10-142-1 (15)




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

Battery Battery relay Fusible link Starting switch Fuse box Controller Monitor panel Travel speed selector solenoid valve L.H. travel motor

Input/Output signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal

10-143-1 (15)

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

R.H. travel motor Engine speed sensor Pump pressure sensor Engine Hydraulic pump Control valve 15a. Self pressure reducing valve 15b. Main relief valve 16. Travel/swing alarm (option)

e. f. g. h.

Solenoid valve drive signal Engine speed signal Pump pressure signal Alarm operation signal

PC128US-2



FUNCTION Travel Speed Selection 1. Travel Speed "Manual" Change Standard Specification and Blade Specification (option) PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Standard Specification PC128US-2 Serial No.: 5001 – 7730 • When the travel speed selector switch is set to LOW or HIGH, the motor capacity changes and travel speeds can be selected.

Travel speed selector switch Motor capacity (cc/rev)

52.7

33.2

Travel speed (km/h)

3.2

5.1

Maximum

Minimum

Travel motor swash plate angle

PC128US-2

Travel speed selector switch Travel accelerator pedal Step on Release

Blade Specification (Option) PC128US-2 Serial No. : 5001 – 7730 • When the travel speed selector switch or the travel accelerator pedal is operated, the motor capacity changes and travel speeds can be selected. fl The travel accelerator pedal works when the travel speed selector switch is set to the LOW position. When the switch is set to the HIGH position, the travel speed does not change even if the pedal is stepped on.

LOW HIGH (low speed) (high speed)


Motor capacity (cc/rev)

52.7

33.2

Travel speed (km/h)

3.2

5.1

Maximum

Minimum

Motor capacity (cc/rev)

33.2

33.2

Travel speed (km/h)

5.1

5.1

Minimum

Minimum



10-143-2 (15)


Standard Specification and Blade Specification (option) PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up


Travel speed selector switch Motor capacity (cc/rev)

55.8

31.5

Travel speed (km/h)

2.9

5.1

Maximum

Minimum


10-143-3 (15)


PC128US-2



2. "Automatic"change of travel speed PC128US-2 Serial No.: 6301 and up PC138USLC-2 Serial No.: 1001 – 1500 1) Automatic selection corresponding to engine speed • If engine speed drops to 1,500 rpm or less when travel speed selector switch is in HIGH and travel speed is HIGH, travel speed changes to LOW automatically. • If engine speed becomes 1,700 rpm or less when travel speed selector switch is in HIGH and travel speed is LOW, travel speed changes to HIGH automatically. fl If travel speed selector switch is in LOW, travel speed is not changed automatically. 2) Automatic selection corresponding to discharge pressure of pump • If travel pressure of 27.5MPa {280 kg/ cm2} or higher continues for 0.02 seconds or more when travel speed selector switch is in HIGH, travel speed changes to LOW automatically. • If travel pressure of 15.7MPa {160 kg/ cm2} or lower continues for 0.20 seconds or more when travel speed selector switch is in HIGH, travel speed changes to HIGH automatically. fl If travel speed selector switch is in LOW, travel speed is not changed automatically.

PC128US-2

10-143-4 (15)



2. "Automatic"change of travel speed PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up 1) Automatic selection corresponding to engine speed • If engine speed drops to 1,500 rpm or less when travel speed selector switch is in HIGH and travel speed is HIGH, travel speed changes to LOW automatically. • If engine speed becomes 1,700 rpm or less when travel speed selector switch is in HIGH and travel speed is LOW, travel speed changes to HIGH automatically. fl If travel speed selector switch is in LOW, travel speed is not changed automatically. 2) Automatic selection corresponding to discharge pressure of pump • If travel pressure of 30.4MPa {310 kg/ cm2} or higher continues for 0.02 seconds or more when travel speed selector switch is in HIGH, travel speed changes to LOW automatically. • If travel pressure of 15.7MPa {160 kg/ cm2} or lower continues for 0.20 seconds or more when travel speed selector switch is in HIGH, travel speed changes to HIGH automatically. fl If travel speed selector switch is in LOW, travel speed is not changed automatically.

10-143-5 (15)

PC128US-2




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

Battery Battery relay Fusible link Starting switch Fuse box Controller Safety lock lever PPC lock switch PPC lock solenoid valve

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

Left work equipment PPC valve Right work equipment PPC valve Traveling PPC valve Blade PPC valve (Blade specification) Engine Hydraulic pump Operation valve 16a. Self pressure reducing valve 16b. Man relief valve

Input/Output signals a. Power supply of controller b. Power supply of solenoids c. Solenoid valve driving signals Function • PPC lock switch works with safety lock lever. Setting safety lock lever to "Lock", PPC lock switch turns to "OFF". • Turning PPC lock switch to "OFF" shuts off current to PPC lock solenoid valve, making operation lever on the work equipment disabled.

PC128US-2

10-144-1 (15)



OVERLOAD ALARM FUNCTION (For KUK spec.) PC128US-2 Serial No.: 5001 – 7730


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

Battery Battery relay Fusible link Starting switch Fuse box Controller Monitor panel Overload alarm actuation switch Overload alarm pressure switch

Input/Output signals a. Power supply of controller b. Power supply of solenoids c. Power supply of monitor panel d. S-NET signal e. Overload alarm actuation signal f. Overload alarm pressure signal

Function • If the pressure in the boom cylinder bottom circuit rises above the set value, the caution lamp lights up and the buzzer sounds to notify the operator of possibility of tipping over of the machine by an overload.

10-144-2 (15)

PC128US-2



ENGINE CONTROL FUNCTION PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500

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

Battery Battery relay Fusible link Starting switch Fuse box Controller Monitor panel Fuel control dial Fuel control motor Fuel control motor relay (for driving) Fuel control motor relay (for acceleration)

Input/Output signals a. Power supply of controller b. Power supply of solenoids c. Power supply of monitor panel d. S-NET signal e. EPC valve driving signal f. Coolant-temperature signal

PC128US-2

12. 13. 14. 15. 16.

Fuel control motor relay (for deceleration) PC-EPC valve Governor lever Coolant temperature sensor Hydraulic pump 16a. Servo valve 16b. LS valve 16c. PC valve 17. Operation valve 17a. Self-pressure reduction valve 17b. Main relief valve

g. h. i. j. k.

Throttle signal Potentiometer signal Fuel control motor driving signal Acceleration signal Deceleration signal

10-144-3 (15)




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

Battery Battery relay Fusible link Starting switch Fuse box Controller Monitor panel Fuel control dial Fuel control motor Fuel control motor relay (for acceleration) Fuel control motor relay (for deceleration) PC-EPC valve

Input/Output signals a. Power supply of controller b. Power supply of solenoids c. Power supply of monitor panel d. S-NET signal e. EPC valve driving signal f. Heater drive signal g. Coolant-temperature signal

10-144-4 (15)

13. 14. 15. 16. 17. 18.

Heater relay Air heater Governor lever Engine speed sensor Coolant temperature sensor Hydraulic pump 18a. Servo valve 18b. LS valve 18c. PC valve 19. Operation valve 19a. Self-pressure reduction valve 19b. Main relief valve

h. i. j. k. l. m. n.

Engine speed signal Throttle signal Potentiometer signal Acceleration signal Deceleration signal Starting switch C signal Preheating pilot signal

PC128US-2



1. Automatic engine warming-up function • Raises engine speed automatically to warm up engine if coolant temperature was low after start-up of engine. PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 Operational conditions (both required)

←

Coolant temperature: Less than 30°C Engine speed: 1,200 rpm or less

Operation Engine speed: 1,200 rpm or less

Release conditions (either one required)

Release

←

Coolant temperature: 30°C or higher

Automatic

Duration of automatic warming-up: 10 minutes or more

Manual

Fuel control dial: Holded in 70% or more of full for 3 seconds or more

Engine speed: Any

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Operational conditions (both required)

←

Coolant temperature: Less than 30°C Engine speed: 1,300 rpm or less

Operation Engine speed: 1,300 rpm or less

Release conditions (either one required)

Release

←

Coolant temperature: 30°C or higher

Automatic

Duration of automatic warming-up: 10 minutes or more

Manual

Fuel control dial: Holded in 70% or more of full for 3 seconds or more

Engine speed: Any

2. Overheat prevention function • Prevents overheat to protect engine by reducing load on pump if coolant temperature rised too much. Operational conditions

← Coolant temperature: 105°C or higher

Operational conditions


Operational conditions


PC128US-2

Operation and actions taken Operational mode: All modes Engine speed: Low idling Engine coolant monitor : Turns ON Alarm buzzer: Sounds

Release conditions Coolant temperature: Less than 105°C Fuel control dial: To be returned to the ← low idling position • The original conditions are restored if two requirements above were obtained (manual restoration).

Operation and actions taken Operational mode: A mode, E mode Engine speed: To be held as it is Engine coolant monitor: Turns ON Delivery of pump: To be reduced

Operation and actions taken Operational mode: A mode Engine speed: To be held as it is Engine coolant monitor: Turns ON Delivery of pump: To be reduced

Release conditions

←

Coolant temperature: Less than 102°C • The original conditions are restored if the requirement above was obtained (automatic restoration).

Release conditions Coolant temperature: Less than 100°C

← • The original conditions are restored if the requirement above was obtained (automatic restoration).

10-144-5 (15)



3. Turbocharger protection function PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up • When the engine is started at low temperature, if the engine speed is increased sharply, the turbocharger may be seized. This trouble is prevented by controlling the engine speed properly. A: Start of engine B: Turbocharger protection time (Approx. 1.1 sec) C: Modulation time (Approx. 1.5 sec) D: 1,200 rpm E: 1,300 rpm F: 2,400 rpm Operating condition Coolant temperature: Max. 30°C Engine speed: Min. 1,300 rpm

Operation

←

Protection of turbocharger (See above figure)

4. Function of preventing production of white smoke when engine is started at low voltage high current tester PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up • When the engine is started at low temperature, the intake air is warmed automatically to improve the combustion efficiency and prevent production of white smoke caused by incomplete combustion. Operating condition Coolant temperature: Max. 30°C Engine speed: Min. 1,000 rpm

10-144-6 (15)

Operation

←

Air heater: Preheating time is selectable (Select preheating time in service adjustment mode: 0/30/60/ 100 sec)

PC128US-2



SELF DIAGNOSIS FUNCTION PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up 1. Error code display/Alarm functions • Controller always watches electronic devices which constitutes the system, including controller itself, each potentiometer which issues input signals, each solenoid valve which receives output signals, and EPC valves, to check for they normal operation. • If problem occurred in any of these devices, the controller diagnoses it and display the results on display (1) of monitor panel as a "USER CODE" or "Service code", sounding alarm buzzer at the same time to notify the problem to operator. fl Refer to the "TROUBLESHOOTING" section as for the details of display and measures to be taken. 2. Error code memory function • Controller takes in memory the error code diagnosed about problem which occurred in advanced system. fl Refer to the "TESTING AND ADJUSTING" section as for the details of display and how to reset.

PC128US-2

10-144-7 (18)



SYSTEM COMPONENTS ENGINE SPEED SENSOR

Function PC128US-2 Serial No.: 5001 – 7730 • The engine speed sensor is installed on the ring gear of the engine flywheel. It electrically counts number of gear teeth that pass its front side and sends the counting to the pump controller.

1. 2. 3. 4. 5.

Wire Magnet Terminal Housing Connector

PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up • The engine speed sensor is installed on the ring gear of the engine flywheel. It electrically counts number of gear teeth that pass its front side and sends the counting to the controller. Remarks : Number of ring gear teeth is 127. •

For the count, a magnet is used which generates current every time a gear tooth passes its front side.

PC128US-2

10-145 (15)



PPC HYDRAULIC SWITCH

Specification Contact structre : Normally opened Operating (ON) pressure : 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) pressure : 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}

1. Plug 2. Switch 3. Connector

Function PC128US-2 Serial No.: 5001 – 7730 • 3 switches installed to control valve sense operating condetion of each actuator, and send it to swing holding brake controller. • 1 switch installed to travel PPC valve sense travel operating condition, and operates 2stage relief solenoid valve. PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up • 8 switches installed to control valve sense operating condition of each actuator, and send it to controller. • 1 switch installed to travel PPC valve sense travel operating condition, and send it to controller.

10-146 (18)

PC128US-2



OVERLOAD ALARM PRESSURE SWITCH (For KUK spec.) PC128US-2 Serial No.: 5001 – 7730

Specifications Composition of contacts: Normally open contacts Operating (ON) pressure: 14.7 ± 0.98 MPa {150 ± 10 kg/cm2} Function • One pressure switch is installed to the boom cylinder bottom circuit to sense the hydraulic pressure on the boom cylinder bottom side.

PC128US-2

10-146-1 A




1. Plug 2. Sensor 3. Connector

Function • One pressure switch is installed to the boom cylinder bottom circuit to sense the hydraulic pressure on the boom cylinder bottom side.

10-146-2 (15)

PC128US-2



CONTROLLER PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500

Model selection table PC128US-2

CN-CR2, 37P CN-CR2, 27P CN-CR2, 7P CN-CR2, 16P × × c c

Attachment selection table Standard arm Long arm Standard arm, X-counterweight long arm, X-counterweight Slide arm Multi changer arm

CN-CR1, 17P CN-CR1, 11P CN-CR2, 17P c × × × c × c

×

c

×

c

c

c

c

× ×

×

×

c : GND × : OPEN

10-147-3 (15)

PC128US-2




10-147-5 (15)

PC128US-2



Input/Output signals DEUTSCH-24P [CN-CR1] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Signal name Fuel control motor feedback potentiometer Boom cylinder bottom pressure sensor Boom angle GND (signal) Air conditioner compressor signal PPC hydraulic pressure switch for Arm IN Fuel control dial Swing boom angle sensor NC GND (signal) Preheating signal PPC hydraulic pressure switch for Arm out Pump pressure sensor

I/O signal Input Input Input — Input Input Input Input — — Input Input Input

Pin No. 14 15 16 17 18

Signal name I/O signal Off-set angle (For PC128UU) Input NC — NC — C-terminal signal Input PPC hydraulic pressure switch for boom Input LOWER

19 20 21 22 23 24

NC Arm angle (For arm crame) GND (analog) Power supply for sensor (+5V) ACC terminal signal PPC hydraulic switch for boom RAISE

I/O signal

Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Signal name S-NET CAN0-L CAN1-L Flash memory write permission signal Exterior parts interference prevention reset switch Reset 2 Alarm switch NC GND (pulse) NC GND (S-NET) CAN0-H CAN1-H GND (232C) NC Reset 1 NC Clear GND (pulse) Engine speed sensor (+)

Pin No.

Signal name Power supply of solenoids GND (common to all solenoids) Key signal (ACC) Fuel control motor relay (for acceleration) Boom-RAISE EPC valve

— Input — Output Input Input

DEUTSCH-40P (1) [CN-CR2] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Signal name NC Set Mode selection 2 232C_RxD NC NC Swing lock switch Electric system Data NC NC CAN shield Mode selection 1 232C_TxD NC Working lamp switch Swing holding brake release switch Strobe Clock NC

— Input Input Input — — Input Output Output — — — Input Output — Input Input Output Output —

I/O signal Input/Output Input/Output Input/Output

Input Input Input Input — — — — Input/Output Input/Output

— — Input — Input — Input

DEUTSCH-40P (2) [CN-CR3] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Signal name Power supply of controller Power supply of solenoids GND (common to all solenoids) Engine stop solenoid relay drive signal Arm IN EPC valve LS-EPC valve Swing holding brake solenoid valve Swing/Travel alarm buzzer Service PPC oil pressure switch Bucket pull-in oil pressure switch Power supply of controller Power supply of solenoids GND (common to all solenoids) Key signal (ACC) Left off set stop EPC valve (For PC128UU) PC-EPC valve Right offset stop solenoid valve Heater relay start signal Left offset PPC oil pressure switch Bucket push-out oil pressure switch GND (controller)

PC128US-2

I/O signal Input Input — Output Output Output Output Output Input Input Input Input — Input Output Output Output Output Input Input —

22 23 24 25 26 27 28 29

30 31 32 33 34 35 36 37 38 39 40

I/O signal Input — Input Output Output Output Solenoid valve for travel speed selection Output 2-stage relief solenoid valve Input Right offset PPC oil pressure switch Input Swing PPC oil pressure switch (Right and left) — GND (controller) — GND (controller) — GND (controller) — NC Output Fuel control motor relay (for deceleration) Output Boom-LOWER EPC valve Output Arm crane relay Output PPC lock solenoid valve — NC Travel PPC oil pressure switch Input (Right, left, front, and rear)

10-147-6 (15)



PUMP PRESSURE SENSOR PC128US-2 Serial No.: 6301 – 7730

1. Sensor 2. Connector Function • Mounted on the inlet circuit of control valve, this sensor changes discharging pressure of pump into voltage, and send it to automatic travel speed change controller.


1. Plug 2. Sensor 3. Connector Function • Mounted on the inlet circuit of control valve, this sensor changes discharging pressure of pump into voltage, and send it to automatic travel speed change controller.

10-147-7 (15)

PC128US-2



Monitor panel fl Refer to the section describing the “Monitor System”. PC valve LS valve PC-EPC valve fl Refer to the section describing the “Hydraulic Pump (Piston pump)”. LS-EPC valve PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

fl Refer to the section describing the “Hydraulic Pump (Piston pump)”. PPC lock solenoid valve 2nd speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve fl Refer to the section describing the “Solenoid Valve”.

10-148 (15)

PC128US-2


MONITOR SYSTEM


1. 2. 3. 4. 5.

Monitor panel Battery Controller Sensors and switches Wiper motor, window washer motor

Description • The monitor system monitors conditions of the machine with sensors mounted on its each section, processes promptly the information obtained, and displays it on panel to let operator know the conditions of the machine.

Input/Output signals a. Power supply b. Switch signal c. Caution signal d. Sensor/switch signal e. Sensor/switch signal f. Output for driving

10-149-1 (15)

PC128US-2

MONITOR SYSTEM


MONITOR PANEL PC128US-2 Serial No.: 5001 – 7730

Outline • Monitor panel has monitoring function, gauge display function, service meter function and switching function. • CPU (Central Processing Unit) is installed in it.

• •

It has LCD display in gauge display position. It has lamps in monitor display position.

Input and output signals AMP040-16P [CN-P01] Pin No. Signal name 1 Power source (24V) 2 Power source (24V) 3 GND 4 GND 5 Starting signal 6 Coolant temperature 7 Fuel level 8 — KES-4P(1) [CX-P02] Pin No. Signal name 1 — 2 Work light 3 Lighting 4 Power source (24V)

10-150 (18)

I/O signal — — — — Input Input Input —

Pin No. 9 10 11 12 13 14 15 16

Signal name Engine oil pressure Battery charging level Spare caution Swing lock Preheating — Alarm buzzer Lighting

I/O signal Input Input — Input Input — Output Input

I/O signal — Output Output —

KES-3P [CN-C12] Pin No. Signal name 1 — 2 Car heater Hi 3 Car heater Lo 4 Car heater Hi

I/O signal — Output Output —

PC128US-2


MONITOR SYSTEM


Outline • The monitor panel has the functions to display a monitor, gauge, service meter and electric system. It has also an alarm buzzer built in. • A CPU (Central Processing Unit) mounted inside processes, displays and outputs information. • The monitor's switch section consists of three Input/Output signals AMP070-12P [CN-P01] Pin No. Signal name 1 Starting switch (battery) 2 Starting switch (battery) 3 Window washer motor output 4 Starting switch (C-terminal) 5 Wiper W-contact 6 GND 7 GND 8 VB + (24V) 9 Wiper motor (+) 10 Wiper motor (–) 11 Alarm buzzer ON signal 12 Wiper P-contact

10-151-1 (15)

I/O signal Input Input Output Input Input — — Input Output Output Input Input

•

flat type sheet switches. Pressing any of these switches changes the conditions of the machine, which are shown by LEDs located above the switches turned ON. The monitor does not give correct display if any of the monitor panel unit, controller, or the wiring between monitor-panel and controller is in abnormal condition.

AMP040-20P [CN-P02] Pin No. Signal name 1 Engine coolant temperature 2 Fuel level 3 Radiator coolant level 4 NC 5 Air cleaner clogging 6 NC 7 Engine oil pressure 8 Engine oil level 9 S-NET signal 10 S-NET signal 11 Battery charge level 12 NC 13 GND (analog signal) 14 NC 15 Pull-up window limit switch 16 Alarm buzzer cancel 17 Swing lock 18 Preheating 19 Lamp switch 20 GND (S-NET)

I/O signal Input Input Input Input Input Input Input Input Input/Output Input/Output Input — — — Input Input Input Input Input —

PC128US-2


MONITOR SYSTEM

METER DISPLAY

Display No. category 1

[*1] 2

Display

Caution

4a

Gauge Caution

5

Pilot

[*2] 7

Coolant temperature

Display Remarks color

Time counting while engine is in operation (alternator is generating) (Always lit even if starting switch is OFF)

Count time during engine operates. Alphanumerics in Displays 2 digit alphanumerics (user code or service code) if electric control system is in 2 digits abnormal condition.

3b

See picture above All the segments of the corresponding level and lower are turned ON. Specified tempera- (Level 8 (102°C or higher):Monitor lamp blinks. Level 9: Monitor lamp blinks and ture (102°C) or alarm buzzer sounds.) higher

Blue

LCD

Red

LED

Blue

LCD

Red

LED

Fuel level

See picture above All the segments of the corresponding level and lower are turned on. (Level 1 (42 ¬ or Specified level less): Monitor lamp blinks.) (42 ¬) or lower

Preheating

Turned on for about 30 seconds after starting switch was turned to "HEAT". It blinks During preheating (for about 10 seconds) after preheating was over to notify it to operator, and then it is turned off.

Swing lock

When swing-lock is in operation

• Turned on when the swing lock function is active. • Blinks when swing holding brake release Green switch was turn on.

Oil maintenance

When specified oil-maintenance periods elapsed

• Turned ON when specified oil maintenance periods (125h, 250, and 500h) elapsed. (Also, elapsed time and telephone No. of your dealer are shown on service meter.) • Not turned on if no oil maintenance period has been specified.

Lamp

Battery charge Charge in fault (charge voltage < level battery voltage)

8

9

Display method

0 – 99999.9 h

Gauge

6

Display area

Service meter

3a

4b

Display item

Caution

[*3] 10

Engine oil pressure

Overload

Turned ON when starting switch was turned on; turned off after engine started running. In normal condition : turned OFF Lower than the specified pressure In abnormal condition : turned ON 49 kPa {0.5 kg/cm2} (As for engine oil pressure only, alarm buzzer sounds if the pressure became abnormal Lower than the when engine was running.) specified pressure 14.7 MPa {150 kg/ cm2}

Red

[*1] As for display and operation, refer to the "Self Diagnosis Function" section. [*2] As for display and operation, refer to the "TROUBLESHOOTING" chapter. [*3] For PC128US-2 & PC138US-2 KUK specification only.

PC128US-2

10-151-2 (15)

MONITOR SYSTEM


MONITOR SWITCH

No.

Function

Operation

Travel speed selector switch

Used to select a travel speed from two of them. "Lo" is lit : Travel in low speed. "Hi" is lit : Travel in high speed.

Lo ←→ Hi

2

Auto-deceleration switch

Activates the function to reduce fuel consumption. Turned ON : The function is active. Turned OFF : The function is not active.

ON ←→ OFF (Lit)

3

Wiper switch

Activates wiper of front glass. "ON" is lit : Wiper works continuously. "INT" is lit: Wiper works intermittently. Not lit : Wiper is not working.

OFF → INT → ON (Not lit) (Intermittent) (Continuous)

Sprays washer fluid onto front glass.

[When wiper is not working] ON : Washer fluid is sprayed and wiper works continuously. OFF : Wiper works twice and stops after the switch was released. [When wiper is working intermittently] ON : Washer fluid is sprayed and wiper works continuously. OFF : Wiper works twice and returns to intermittent operation after the switch was released.

1

4

Name

Wind washer switch

* Operation mode selector 5

switch

Sets the movement and force of the working equipment. "A" is lit : A mode (for heavy duty work) "E" is lit : E mode (for fuel economical operation) "B" is lit : B mode (for breaker work)

A ←→ E ←→B

* You can change the default settings which become active when starting switch is turned on. Refer to the "TROUBLE-

SHOOTING" chapter. fl Signs written in bold fonts in the "Operation" column above represent the positions switches default to when starting switched is turned on.

10-151-3 A

PC128US-2


MONITOR

SYSTEM

SENSORS l

l

l

Signal from a sensor is directly entered to the panel. There are two types of sensors, contact type and resistance type. One end of a contacttype sensor is connected to the ground on the machine body. Display class

Sensor type

Sensing__approach

When normal

When failed

Caution

Engine oil pressure

Contact

OFF (open)

ON (closed)

Resistance

-

-

Resistance

-

-

Coolant

temperature

Gauge Fuel level

ENGINE OIL PRESSURE SENSOR

0

69 @ Structure

of

circuit

SBD01537

1. 2.

Plug Contact

ring

3. 4.

5. 6.

Contact Diaphragm

Spring Terminal

COOLANT TEMPERATURE SENSOR

@=I3 Structure

7. 2. 3.

of

circuit

SBDOl538

Connector Plug Thermistor

10-152

PC1 28US-2

STRUCTURE

AND FUNCTION

FUEL LEVEL SENSOR

F Structure

fL

EMPTY

E Y

of

circuit

3

1. 2. 3. 4.

4

SEP02590

Float Connector Cover Variable resistor

PC128US-2

10-153

20


STANDADRD

VALUE TABLE

Standard

value table for engine

Standard

value table for chassis . . . . . . .. . .. . .. . . . . . . 20-3

Standard

value table for electrical

TESTING

AND ADJUSTING

TROUBLESHOOTING

* 1.

2.

3. A A A

A

. . . . .. . . . .. . . . . . . . . . 20-2

parts .._.. 20-12

. . . .. . .. . . . . .. .. . . . .. .. . . . 20-101

. . .. . . . .. . .. . .. . .. . . . . . .. . . . .. .. . . . . . 20-201

Note the following.when making judgments using the standard value tables for testing, adjusting, or troubleshooting. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. These standard values are not the standards used in dealing with claims. When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.

PC1 28U.S2

20-l 0

STANDARD VALUE TABLE FOR ENGINE


STANDARD VALUE TABLE FOR ENGINE PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 Applicable model

PC128US-2, 138USLC-2

Engine

S4D102E-1

Item

Engine speed

Measurement conditions

Unit

Standard value for new machine

Service limit value

High idling

rpm

2,400 ± 60

—

Low idling

rpm

925 + 050

—

Rated speed

rpm

2,200

—

Bosch index

Max. 5.5

7.5

Max. 1.0

2.0

0.25

—

0.51

—

Max. 490 {50}

980 {100}

343 – 588 {3.5 – 6.0}

245 {2.5}

Min. 9.8 {1.0}

69 {0.7}

Min. 78 {0.8}

69 {0.7}

°C

80 – 110

120

At sudden acceleration Exhaust gas color At high idling

Valve clearance (normal temperature)

Blow-by pressure (SAE 30 oil)

Oil pressure (SAE 30 oil)

Intake valve mm Exhaust valve

(Water temperature: Pa Operating range) {mm H2O} At high idling

(Water temperature: Operating range) At high idling At low idling (SAE30)

KPa {kg/cm2}

At low idling (SAE10W)

Oil temperature

Whole speed range (inside oil pan)

Fuel injection timing

Before top dead center

deg

14 ± 1

—

Fan belt tension (alternator)

Deflection when pressed with finger force of approx. 58.8 N {6 kg.}

mm

9.5 – 12.7

—

20-2 (17)

PC128US-2


STANDARD VALUE TABLE FOR ENGINE

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Applicable model

PC138US-2, 138USLC-2

Engine

SAA4D95LE-3-A

Item

Engine speed


Unit


Service limit value

High idling

rpm

2,400 ± 60

—

Low idling

rpm

1,100 ± 50

—

Rated speed

rpm

2,200

—

Bosch index

Max. 4.5

5.5

Max. 1.0

2.0

0.35

—

0.50

—

Max. 490 {50}

980 {100}

343 – 588 {3.5 – 6.0}

245 {2.5}

Min. 294 {3.0}

196 {2.0}

Min. 245 {2.5}

147 {1.5}

°C

80 – 115

120

At sudden acceleration Exhaust gas color At high idling

Valve clearance (normal temperature)

Blow-by pressure (SAE 30 oil)

Oil pressure (SAE 30 oil)

Intake valve mm Exhaust valve

(Water temperature: Pa Operating range) {mm H2O} At high idling

(Water temperature: Operating range) At high idling At low idling (SAE30)

KPa {kg/cm2}

At low idling (SAE10W)

Oil temperature

Whole speed range (inside oil pan)

Fuel injection timing

Before top dead center

deg

6 ± 0.75

—

Fan belt tension (alternator)

Deflection when pressed with finger force of approx. 58.8 N {6 kg.}

mm

6 – 10

—

PC128US-2

20-2-1 (17)

STANDARD VALUE TABLE FOR CHASSIS


Applicable model

Operating effort of control lever

Category

PC128US-2


Item

• Engine at full throttle • Oil temperature: 45 – 55 ºC • Fit push-pull scale to center of control lever knob to measure • Fit push-pull scale to tip of control Travel control lever pedal to measure • Measure max. value to end of travel

Unit

Serial No. 5001 – 7730

Blade control lever

7731 and up N {kg}

5001 – 7730 7731 and up 5001 – 7730

—

—

7731 and up

74.5 ± 18.6 {7.6 ± 1.9}

Max.107.6 {Max.11}

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 20 {325 +– 10 }

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 20 {325 +– 10 }

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 20 {325 +– 10 }

5001 – 7730

31.38 ± 0.98 {320 ± 10}

31.38 – 2.45 15 {320 +– 25 }

7731 and up

27.46 ± 0.98 {280 ± 10}

27.46 – 2.45 15 {280 +– 25 }

Travel pedal

Boom Arm

• • • •

Hydraulic oil temperature: 45 – 55 ºC Engine at full throttle Pump discharge pressure Relieve only circuit to be measured

Standard value Service limit for new value machine Max.24.5 Max.31.4 {Max.2.5} {Max.3.2} 25.50 ± 6.86 Max.32.36 {2.6 ± 0.7} {Max.3.3} Max.27.5 Max.36.3 {Max.2.8} {Max.3.7} 24.52 ± 5.88 Max.39.23 {2.5 ± 0.6} {Max.4.0}

5001 and up

Bucket

Swing

+ 1.96

31.87 0 {325 + 20 0 }

Hydraulic pressure

Blade RAISE

20-4 (14)

+ 1.47

+ 1.96

31.87 – 0.98 20 {325 +– 10 }

34.81 ± 1.96 {355 ± 20}

3.24 ± 0.20 {33 ± 2}

3.24 ± 0.49 {33 ± 5}

3.43 ± 0.98 {35 ± 10}

3.43 ± 0.98 {35 ± 10}

At pump relief (normal actuation)

15.98 ± 1.47 {163 ± 15}

15.98 ± 2.45 {163 ± 25}

All levers at HOLD

2.75 ± 0.98 {28 ± 10}

— {—}

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

2.21 ± 0.1 {22.5 ± 1}

— {—}

Control

LS differential pressure

+ 1.47

34.81 ± 0.98 {355 ± 10}

Target value (Range)

• Hydraulic oil temperature : 45 – 55 ºC • Engine at full throttle flLS differential pressure = pump outlet port pressure – LS pressure

+ 1.96

32.36 ± 2.45 {330 ± 25}

MPa {kg/cm}

Travel

Servo piston input pressure

+ 1.96

32.36 ± 1.47 {330 ± 15}

Blade LOWER

• Hydraulic oil temperature : 45 – 55 ºC • Engine at full throttle

+ 1.96

Control levers at HOLD 7731 and up

PC128US-2



Applicable model Category

Item

PC128US-2


Unit

Serial No.

Standard value Service limit for new value machine

fl See Fig. A

Overrun when stopping swing

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Stop after swinging one turn and measure distance that swing circle Deg. 5001 and up (mm) moves • Figure in ( ) shows movement at outside of swing circle

Max. 60 (Max. 580)

Max. 70 (Max. 676)

5001 – 6462

2.8 ± 0.3 (3.4 ± 0.3)

Max. 3.5 (Max. 4.0)

6463 and up

3.2 ± 0.3 (3.9 ± 0.3)

Max. 4.0 (Max. 4.6)

5001 – 6462

3.3 ± 0.4 (4.8 ± 0.5)

Max. 5.2 (Max. 6.3)

6463 and up

3.8 ± 0.4 (5.5 ± 0.5)

Max. 5.9 (Max. 7.2)

5001 – 6462

25 ± 2

25 ± 4

6463 and up

28.6 ± 2

28.6 ± 4

0 (0)

0 (0)

Max. 3

Max. 6

fl See Fig. A

Time taken to start swing

• Engine at full throttle • Hydraulic oil temperature : 45 – 55°C 90° • Time taken to swing 90° and 180° from starting position • Figure in ( ) shows time when bucket is at rated load

Sec.

Swing

180°

fl See Fig. A • Engine at full throttle • Hydraulic oil temperature: 45 – 55°C Time taken to swing • Swing one turn, and measure time taken to swing next 5 turns

Sec.

fl See Fig. B

Hydraulic drift of swing

• Engine stopped • Hydraulic oil temperature: 45 – 55°C • Bucket at rated load (450 kg) or full of soil. • Set machine on 15° slope, and set upper structure at an uphill angle of 45°. Deg. • Make match marks on swing circle (mm) 5001 and up outer race and track frame. • Measure distance that match marks move apart after 15 minutes. • Figure in ( ) shows at rated load.

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C Leakage from swing • Relieve swing circuit. ¬/min 5001 and up motor

PC128US-2

20-5 (14)





Total work fl See Fig. G equipment (hydraulic drift • Place in above posture and measure at tip of bucket extension or retraction of each cylteeth) inder and downward movement at tip of bucket teeth. Boom cylinder • Horizontal, flat ground (amount of • Bucket: Rated load (450 kg) retraction of • Levers at HOLD cylinder) • Engine stopped • Hydraulic oil temperature: 45 – 55°C Arm cylinder • Start measuring immediately after (amount of setting. extension of • Measure hydraulic drift every 5 mincylinder) utes, and judge from results for 15 minutes. Bucket cylinder (amount of retraction of cylinder)

Blade (hydraulic drift at tip of blade)

mm

Serial No.

5001 and up

• Engine stopped • Hydraulic oil temperature: 45 – 55°C • Set blade at maximum lifting height and measure downward movement at edge of blade for 15 minutes.

Cylinder fully extended

Fully extended

fl See Fig. K Blade Blade in contact • Engine at full throttle with ground • Hydraulic oil temperature : 45 – 55°C

Blade fully raised

PC128US-2

Max. 75

Max. 40

Max. 60

Max. 31

Max. 47

3.8 ± 0.3

Max. 4.4

IN

3.1 ± 0.3

Max. 4.2

3.2 ± 0.3

Max. 4.0

3.1 ± 0.3

Max. 3.7

5001 and up

CURL

Fully extended

Max. 50

2.9 ± 0.3

Max. 3.7

DUMP

• Engine at full throttle • Hydraulic oil temperature : 45 – 55°C

Max. 23

2.3 ± 0.2

Max. 2.9

RAISE

Bucket Cylinder fully retracted

Max. 15

(Until touching (Until touching cushion) cushion)

Sec fl See Fig. J

Max. 700


OUT


Max. 500

1.3 ± 0.3

Max. 2.5

LOWER

Work equipment speed

fl See Fig. I

Arm Cylinder fully retracted

Standard value Service limit for new value machine


LOWER

Boom fl See Fig. H Bucket teeth in • Engine at full throttle contact with • Hydraulic oil temperature ground : 45 – 55°C

Work equipment

Unit

RAISE

Hydraulic drift of work equipment

Item

PC128US-2

1.3 ± 0.3

Max. 2.5

20-7 (18)



PC138USLC-2 Serial No.: 1001 – 1500 Applicable model

Engine speed

Category

Unit


Service limit value

rpm

Min. 2,100

Min. 2,000

N → RAISE, LOWER

85 ± 10

Min.75 Max.95

N → IN, OUT

85 ± 10

Min.75 Max.95

Bucket control lever

N → CURL, DUMP

85 ± 10

Min.75 Max.95

Swing control lever

N → LEFT, RIGHT

85 ± 10

Min.75 Max.95

Item

At 1-pump relief

Boom control lever

Arm control lever

Travel of control levers

PC138USLC-2

Measurement conditions • Hydraulic oil temperature : 45 – 55 ºC • Engine oil pressure : Within operating range • Engine coolant temperature : Within operating range • 1 pump relief: Bucket relief

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

mm Blade control lever

N → RAISE, LOWER

53 ± 6

Min.47 Max.59

Travel control lever

N → FORWARD, REVERSE (LEFT, RIGHT)

115 ± 12

Min.103 Max.127

Work equipment, swing

3–5

5–8

10 ± 3

10 ± 5

15.7 ± 3.9 {1.6 ± 0.4}

Max.24.5 {Max.2.5}

15.7 ± 3.9 {1.6 ± 0.4}

Max.24.5 {Max.2.5}

12.7 ± 2.9 {1.3 ± 0.3}

Max.21.6 {Max.2.2}

12.7 ± 2.9 {1.3 ± 0.3}

Max.21.6 {Max.2.2}

Blade control lever

25.50 ± 6.86 {2.6 ± 0.7}

Max.32.32 {Max.3.3}


24.52 ± 5.88 {2.5 ± 0.6}

Max.39.23 {Max.4.0}

Travel pedal

74.5 ± 18.6 {7.6 ± 1.9}

Max.107.6 {Max.11}

Play of control lever


Travel Boom control lever • Engine at full throttle • Oil temperature: 45 – 55 ºC • Fit push-pull scale to center of control lever knob to measure Arm control lever • Fit push-pull scale to tip of control pedal to measure Bucket control lever • Measure max. value to end of travel Swing control lever

PC128US-2

N {kg}

20-8-1 (17)




PC138USLC-2


Item • • • •

Unit



+ 1.96

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 20 {325 +– 10 }

Arm

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 20 {325 +– 10 }

Bucket

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 + 20 {325 – 10 }

Swing

27.46 ± 0.98 {280 ± 10}

27.46 – 2.45 15 {280 +– 25 }

Blade RAISE

31.87 0 + 20 {325 0 }

Boom

+ 1.96

Hydraulic pressure

Service limit value

34.81 ± 1.96 {355 ± 20}

3.24 ± 0.20 {33 ± 2}

3.24 ± 0.49 {33 ± 5}

Control levers at HOLD

3.43 ± 0.98 {35 ± 10}

3.43 ± 0.98 {35 ± 10}


15.98 ± 1.47 {163 ± 15}

15.98 ± 2.45 {163 ± 25}

All levers at HOLD

2.75 ± 0.98 {28 ± 10}

— {—}


2.21 ± 0.1 {22.5 ± 1}

— {—}

Max. 65 (Max. 610)

Max. 75 (Max. 720)

Control


+ 1.96

31.87 – 0.98 20 {325 +– 10 }

34.81 ± 0.98 {355 ± 10}


Travel


+ 1.47

32.36 ± 2.45 {330 ± 25}

MPa {kg/cm2}


+ 1.96

32.36 ± 1.47 {330 ± 15}

Blade LOWER


+ 1.96

Swing

fl See Fig. A Overrun when stopping swing

20-8-2 (17)

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Stop after swinging one turn and measure distance that swing circle moves • Figure in ( ) shows movement at outside of swing circle

Deg. (mm)

PC128US-2




Item

PC138USLC-2 Standard value for new machine

Service limit value

2.9 ± 0.3 (3.6 ± 0.3)

Max. 3.6 (Max. 4.2)

4.0 ± 0.4 (5.0 ± 0.5)

Max. 6.0 (Max. 6.5)

25 ± 2

25 ± 4

0 (0)

0 (0)

Max. 3

Max. 6

Max. 41.6

50.6

Hi

Max. 26.5

32.6

Lo

Max. 25.3

Max. 30.6

Max. 15.2

Max. 18.3


Unit

fl See Fig. A


90° • Engine at full throttle • Hydraulic oil temperature : 45 – 55°C Sec. • Time taken to swing 90° and 180° from starting position • Figure in ( ) shows time when 180° bucket is at rated load

fl See Fig. A

Swing

• Engine at full throttle Time taken to swing • Hydraulic oil temperature: 45 – 55°C Sec. • Swing one turn, and measure time taken to swing next 5 turns fl See Fig. B


• Engine stopped • Hydraulic oil temperature: 45 – 55°C • Bucket at rated load (450 kg) or full of soil. • Set machine on 15° slope, and set upper structure at an uphill angle of Deg. (mm) 45°. • Make match marks on swing circle outer race and track frame. • Measure distance that match marks move apart after 15 minutes. • Figure in ( ) shows at rated load.

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C Leakage from swing • Relieve swing circuit. ¬/min motor

fl See Fig. C

Travel

Travel speed (1)

• Engine at full throttle • Hydraulic oil temperature : 45 – 55°C • Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.

Lo Sec.

fl See Fig. D

Travel speed (2)

PC128US-2

• Engine at full throttle • Hydraulic oil temperature : 45 – 55°C • Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.

Sec. Hi

20-8-3 (19)




Item


PC138USLC-2 Unit


Service limit value

Max. 200

220

0

0

Max. 1.1

Max. 1.65

Max. 500

Max. 700

Max. 15

Max. 23

Max. 50

Max. 75

Max. 40

Max. 60

Max. 31

Max. 47

fl See Fig. D fl See Fig. E

Travel deviation

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Run up for at least 10 m, and measure deviation when traveling next 20 m on flat ground. fl Use a hard horizontal surface. mm

Travel

fl See Fig. F

Hydraulic drift of travel

Leakage from travel motor


Work equipment

Total work equipment (hydraulic drift at tip of bucket teeth) Boom cylinder (amount of retraction of cylinder) Arm cylinder (amount of extension of cylinder)

(19)

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Lock shoes and relieve travel circuit. ¬/min

fl See Fig. G • Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. • Horizontal, flat ground • Bucket: Rated load (450 kg) • Levers at HOLD • Engine stopped • Hydraulic oil temperature: 45 – 55°C • Start measuring immediately after setting. • Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes. mm

Bucket cylinder (amount of retraction of cylinder)


20-8-4

• Engine stopped • Hydraulic oil temperature: 45 – 55°C • Stop machine on 12° slope with sprocket facing straight up the slope. • Measure the distance the machine moves in 5 minutes.


PC128US-2



Applicable model

Boom Bucket teeth in contact with ground

Measurement conditions fl See Fig. H • Engine at full throttle • Hydraulic oil temperature : 45 – 55°C

Unit


(Until touching cushion)

3.1 ± 0.3

fl See Fig. I IN

3.2 ± 0.3 (Until touching cushion)

3.1 ± 0.3

OUT


Fully extended

(Until touching cushion)

Service limit value

Max. 4.4 (Until touching cushion)

Max. 4.2



Sec. CURL

3.2 ± 0.3

Fully extended

DUMP

2.6 ± 0.2

fl See Fig. K Blade • Engine at full throttle Blade in contact • Hydraulic oil temperature with ground : 45 – 55°C

RAISE

fl See Fig. J

1.3 ± 0.3

Blade fully raised

LOWER


Work equipment

Arm Cylinder fully retracted

Standard value for new machine 3.8 ± 0.3

RAISE

Item

LOWER

Category

PC138USLC-2

1.3 ± 0.3



Max. 4.0

Max. 3.2

Max. 2.5

Max. 2.5

Max. 3

Max. 3

Time lag

fl See Fig. L

Boom

PC128US-2

• Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Fully retract arm and bucket cylinders, then lower boom from maximum height and measure time taken from point where bucket contacts ground to point where chassis rises from ground

Sec.

20-8-5 (18)





Service limit value

Max. 2

Max. 2

Max. 2

Max. 2

Blade

• Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Lower blade from maximum height and measure time taken from point where blade contacts ground to point where chassis rises from ground.

Max. 2

Max. 2

Eachcylinder

• Hydraulic oil temperature : 45 – 55 ºC • Engine full • Circuit to be measured is relieved.

Max. 3.5

Max. 15

Max. 10

Max. 50

Item


Unit

fl See Fig. M

Arm

• Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Set top surface of boom horizontal, retract bucket cylinder fully, then extend arm cylinder and measure time taken for arm to start moving again after stopping at bottom.

Bucket

Work equipment

Time lag

fl See Fig. N • Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Set top surface of boom horizontal, retract arm cylinder fully, then extend bucket cylinder and measure time taken for bucket to start moving again after stopping at bottom.

Sec

Internal leakage level

fl See Fig. O

cc/ min Center swivel joint

20-8-6 (17)

PC128US-2



PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Applicable model

Engine speed

Category

Unit


Service limit value

rpm

Min. 2,100

Min. 2,000

N → RAISE, LOWER

100 ± 11

100 ± 21

N → IN, OUT

100 ± 11

100 ± 21

Bucket control lever

N → CURL, DUMP

100 ± 11

100 ± 21

Swing control lever

N → LEFT, RIGHT

100 ± 11

100 ± 21

Item

At 1-pump relief

Boom control lever

Arm control lever

Travel of control levers

PC138USLC-2

Measurement conditions • Hydraulic oil temperature : 45 – 55 ºC • Engine oil pressure : Within operating range • Engine coolant temperature : Within operating range • 1 pump relief: Bucket relief

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

mm Blade control lever

N → RAISE, LOWER

53 ± 6

Min.47 Max.59


N → FORWARD, REVERSE (LEFT, RIGHT)

115 ± 12

Min.103 Max.127

Work equipment, swing

3–5

5–8

10 ± 3

10 ± 5

16.67 ± 3.92 {1.7 ± 0.4}

Max.25.5 {Max.2.6}

16.67 ± 3.92 {1.7 ± 0.4}

Max.25.5 {Max.2.6}

13.73 ± 2.94 {1.4 ± 0.3}

Max.22.56 {Max.2.3}

13.73 ± 2.94 {1.4 ± 0.3}

Max.22.56 {Max.2.3}

Blade control lever

25.51 ± 6.86 {2.6 ± 0.7}

Max.32.36 {Max.3.3}


24.52 ± 5.88 {2.5 ± 0.6}

Max.39.23 {Max.4.0}

Travel pedal

74.5 ± 18.6 {7.6 ± 1.9}

Max.107.6 {Max.11}

Play of control lever


Travel Boom control lever • Engine at full throttle • Oil temperature: 45 – 55 ºC • Fit push-pull scale to center of control lever knob to measure Arm control lever • Fit push-pull scale to tip of control pedal to measure Bucket control lever • Measure max. value to end of travel Swing control lever

PC128US-2

N {kg}

20-8-7 (17)




Item

PC138USLC-2

Measurement conditions • • • •

Unit



+ 1.96

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 20 {325 +– 10 }

Arm

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 + 20 {325 – 10 }

Bucket

31.87 ± 0.49 {325 ± 5}

31.87 – 0.98 + 20 {325 – 10 }

Swing

27.46 ± 0.98 {280 ± 10}

27.46 – 2.45 15 {280 +– 25 }

Blade RAISE

31.87 0 + 20 {325 0 }

Boom

+ 1.96

Hydraulic pressure

Service limit value

34.81 ± 1.96 {355 ± 20}

3.24 ± 0.20 {33 ± 2}

3.24 ± 0.49 {33 ± 5}

Control levers at HOLD

3.43 ± 0.98 {35 ± 10}

3.43 ± 0.98 {35 ± 10}


15.98 ± 1.47 {163 ± 15}

15.98 ± 2.45 {163 ± 25}

All levers at HOLD

2.75 ± 0.98 {28 ± 10}

— {—}


2.21 ± 0.1 {22.5 ± 1}

— {—}

Max. 65 (Max. 610)

Max. 75 (Max. 720)

Control


+ 1.96

31.87 – 0.98 20 {325 +– 10 }

34.81 ± 0.98 {355 ± 10}


Travel


+ 1.47

32.36 ± 2.45 {330 ± 25}

MPa {kg/cm}


+ 1.96

32.36 ± 1.47 {330 ± 15}

Blade LOWER


+ 1.96

Swing

fl See Fig. A Overrun when stopping swing

20-8-8 (17)

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Stop after swinging one turn and measure distance that swing circle moves • Figure in ( ) shows movement at outside of swing circle

Deg. (mm)

PC128US-2




Item


Service limit value

3.3 ± 0.3 (4.1 ± 0.3)

Max. 4.1 (Max. 4.8)

4.6 ± 0.5 (5.8 ± 0.5)

Max. 6.4 (Max. 7.5)

28.6 ± 2

28.6 ± 4

0 (0)

0 (0)

Max. 3

Max. 6

Max. 45

54

Hi

Max. 26.9

32.3

Lo

Max. 26.1

Max. 31.4

Max. 14.9

Max. 18


Unit

fl See Fig. A


90° • Engine at full throttle • Hydraulic oil temperature : 45 – 55°C Sec. • Time taken to swing 90° and 180° from starting position • Figure in ( ) shows time when 180° bucket is at rated load

fl See Fig. A

Swing

• Engine at full throttle Time taken to swing • Hydraulic oil temperature: 45 – 55°C Sec. • Swing one turn, and measure time taken to swing next 5 turns fl See Fig. B


• Engine stopped • Hydraulic oil temperature: 45 – 55°C • Bucket at rated load (450 kg) or full of soil. • Set machine on 15° slope, and set upper structure at an uphill angle of Deg. (mm) 45°. • Make match marks on swing circle outer race and track frame. • Measure distance that match marks move apart after 15 minutes. • Figure in ( ) shows at rated load.

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C Leakage from swing • Relieve swing circuit. ¬/min motor

fl See Fig. C

Travel

Travel speed (1)

• Engine at full throttle • Hydraulic oil temperature : 45 – 55°C • Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.

Lo Sec.

fl See Fig. D

Travel speed (2)

PC128US-2

• Engine at full throttle • Hydraulic oil temperature : 45 – 55°C • Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.

Sec. Hi

20-8-9 (19)




Item


PC138USLC-2 Unit


Service limit value

Max. 200

220

0

0

Max. 1.1

Max. 1.65

Max. 500

Max. 700

Max. 15

Max. 23

Max. 50

Max. 75

Max. 40

Max. 60

Max. 31

Max. 47

fl See Fig. D fl See Fig. E

Travel deviation

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Run up for at least 10 m, and measure deviation when traveling next 20 m on flat ground. fl Use a hard horizontal surface. mm

Travel

fl See Fig. F

Hydraulic drift of travel

Leakage from travel motor


Work equipment

Total work equipment (hydraulic drift at tip of bucket teeth) Boom cylinder (amount of retraction of cylinder) Arm cylinder (amount of extension of cylinder)

• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Lock shoes and relieve travel circuit. ¬/min

fl See Fig. G • Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. • Horizontal, flat ground • Bucket: Rated load (450 kg) • Levers at HOLD • Engine stopped • Hydraulic oil temperature: 45 – 55°C • Start measuring immediately after setting. • Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes. mm

Bucket cylinder (amount of retraction of cylinder)


20-8-10 (19)

• Engine stopped • Hydraulic oil temperature: 45 – 55°C • Stop machine on 12° slope with sprocket facing straight up the slope. • Measure the distance the machine moves in 5 minutes.


PC128US-2



Applicable model

Boom Bucket teeth in contact with ground

Measurement conditions fl See Fig. H • Engine at full throttle • Hydraulic oil temperature : 45 – 55°C

Unit RAISE

Item

LOWER

Category

PC138USLC-2


Max. 4.4 (Untill touching chshion)

IN

3.2 ± 0.3 (Untill touching chshion)

3.1 ± 0.3

OUT

Fully extended

3.8 ± 0.3 (Untill touching chshion)

(Untill touching chshion)

Max. 4.2



Sec. CURL

3.2 ± 0.3

Fully extended

DUMP

2.5 ± 0.3

fl See Fig. K Blade • Engine at full throttle Blade in contact • Hydraulic oil temperature with ground : 45 – 55°C

RAISE

fl See Fig. J

1.3 ± 0.3

Blade fully raised

LOWER


Work equipment


Service limit value

3.1 ± 0.3

fl See Fig. I Arm Cylinder fully retracted


1.3 ± 0.3



Max. 4.0

Max. 3.1

Max. 2.5

Max. 2.5

Max. 3

Max. 3

Time lag

fl See Fig. L

Boom

PC128US-2

• Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Fully retract arm and bucket cylinders, then lower boom from maximum height and measure time taken from point where bucket contacts ground to point where chassis rises from ground

Sec.

20-8-11 (17)





Service limit value

Max. 2

Max. 2

Max. 2

Max. 2

Blade

• Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Lower blade from maximum height and measure time taken from point where blade contacts ground to point where chassis rises from ground.

Max. 2

Max. 2

Eachcylinder

• Hydraulic oil temperature : 45 – 55 ºC • Engine full • Circuit to be measured is relieved.

Max. 3.5

Max. 15

Max. 10

Max. 50

Item


Unit

fl See Fig. M

Arm

• Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Set top surface of boom horizontal, retract bucket cylinder fully, then extend arm cylinder and measure time taken for arm to start moving again after stopping at bottom.

Bucket

Work equipment

Time lag

fl See Fig. N • Engine at low idling • Hydraulic oil temperature : 45 – 55°C • Set top surface of boom horizontal, retract arm cylinder fully, then extend bucket cylinder and measure time taken for bucket to start moving again after stopping at bottom.

Sec

Internal leakage level

fl See Fig. O

cc/ min Center swivel joint

20-8-12 (17)

PC128US-2



Pump performance curve

• •

TVC current: 0.4 A Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)

Check point

As desired

Test pump discharge pressure (MPa {kg/cm2})

Discharge pressure of other pump (MPa {kg/cm2})

P1

P2

Average pressure (MPa {kg/cm2}) P1 + P2 2

Standard value Judgement for discharge standard lower amount limit Q (¬/min) Q (¬/min) See graph

See graph

fl As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. fl When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed. PC128US-2

20-11 (18)

TESTING

STANDARD

AND ADJUSTING

Name of component

SYS

tern

Travel

boost

solenoid

Con;Ftor

‘“t$~-

vo5 (male)

.9 8 :g 25

.$

relief

solenoid

Judgment

V06 (male)

Ecu eg ;z!

If the condition is as shown below, it is normal Between

(I) - (2)

Between

(I),

Min.

If the condition is as shown below, it is normal Between

(1) - (2)

Between

(I),

(2) -chassis

Cl3 (male)

z ti

Between

(1)

Between

(I),

1 M.Q

in the table

Min.

Min.

t

1 M.Q

8-15Q

(2) -chassis

1) Turn starting switch OFF 2) Disconnec connector.

in the table

- (2)

1) Turn starting switch OFF. 2) Disconnect connector.

37-6OQ

If the condition is as shown below, it is normal PC-EPC solenoid

in the table

37-60.Q

(2) -chassis

PARTS


table

method

3 r

.2-stage

VALUE TABLE FOR ELECTRICAL


1 MQ

; .-? _s

If the condition is as shown below, it is normal

in the table

P (I

(I), (2) -chassis

Measure

Engine

speed

sensor

E07 (male)

I- (2)

Between Between

with

Between

500 - 1000 sz Min.

1 MQ

AC range

(I) - (2)

1) Start engine. 2) Insert T-adapter. 0.5 - 3.0 Q

1) Screw in rotation sensor until it contacts ring gear, then turn back

5

l/6 turns. 2) It must work

a

as above.

‘n’

PC1 28US-2

normally


when

1+

adjusted

20-13 0

TESTING

j n1

STANDARD

AND ADJUSTING

Name of component

l-

Inspec-

Cloyector I”“.


tion

I method

Judament

I

the condition is as shown in Table mel is normal. ble 1 (CHECK, CAUTION section)

Monitor item (input connector) .ngin;;if6

;;pssure

Engine

Battery charge CN6 (IO)

Engine

Sensor signal input

Display

started

:HECK, CAUTION ection

Measurement con’ditions

table

1 and Table 2, the monitor


ON

Max.

OFF

20-30V

1V

started

lble 2 (Gauges) Position of gauge display \

Starting

switch

Iisplay level resistance (Monitor panel input resistance) Starting

ON

switch

Min.

-

OFF

I 1 ) Connect adapter.

T

I)Turn starting switch OFF, and insert dummy resistance, or measure resistance of sensor. !)Turn starting switch ON, and check display. 3)Connect socket.

Max. (kQ)

Measure resistance between coolant temperature gauge CN6 (female) (6) - (3)

PARTS PARTS

Right side T

6.36 - 10.05

Sauges

9.47 - Disconnection Min.

-

Max. (Q)

Measure resistance between fuel level gauge

Right side

I

0 - 15.7

I

T151

CN6 (female) (7) - (3)

20-14 0

PC1 28US-2

TESTING

STANDARD

AND ADJUSTING

sys-

Name of component

tern

Con;Ector


$~p-

judgment


table

method If the condition

Engine oil pressure sensor

is as shown

1) Disconnect

in the table

S’7 (male)

I

Coolant sensor

RELATED PARTS PARTS

I

I’

I

If the condition

is as shown

in the table

If the condition

is as shown

in the table

temperature

po6 Fuel level sensor

1.1

:~~$%Zng

When engine is running (l/2 throttle or above) + 27.5 - 29.5 V % If the battery is old, or after starting in cold areas, the voltage may not rise-for some time.

1 )Start engine.

(male)

%

Alternator

‘ii

Between alternator terminal R chassis

z > E : f

PC1 28US-2

20-15 0

STANDARD VALUE TABLE FOR ELECTRICAL PARTS



Kerosene mode

Model selection

Chassis control

Attachment selection

PPC hydraulic lock solenoid

Swing holding brake solenoid

20-16 (17)

CR2

CR1 CR2

CR1 CR2

V07 (male)

V04 (male)

Measure voltage Measure voltage

CR3


If the condition is as shown in the table below, it is normal

1) Turn starting switch OFF. 2) Insert T-adapter. 3) Turn starting switch ON.

Because normal power supply is used between CR3 (1), (21) and chassis, voltage is applied even in 20 – 30 V starting motor switch OFF state. Between CR3 (2), (12), (22) and chassis If the condition is as shown in the table below, it is normal Diesel fuel mode Engine Between full Kerosene mode (16) – Engine chassis Diesel fuel mode slow

Kerosene mode

0–5V

6 – 13 V



At standard mode At kerosene mode

Between (6) – chassis

4–6V

Attachment

1) Turn starting switch ON. 2) Insert T-adapter.

0–1V

If the condition is as shown in the table below, it is normal CR2 (27) – CR1 (4)


0–7V

Measure voltage Measure voltage

Controller

PC-EPC solenoid

CR3

Judgment table

Measure resistance

Power supply voltage

Connector Inspection No. method

Measure resistance

Name of component

Measure resistance

System

Max. 1 V

STD arm Long arm

CR (17) – CR1 (10) Max. 1 V Min. 7 V



CR (11) – CR1 (10) Min. 7 V Max. 1 V CR (17) – CR1 (10) Min. 7 V Min. 7 V If the condition is as shown in the table below, it is normal Between (1) – (2)

37 – 60 Ω


Between (1), (2) – chassis Min. 1 MΩ

If the condition is as shown in the table below, it is normal Between (1) – (2)

37 – 60 Ω



PC128US-2



PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Name of component

Power supply voltage


CR3

Measure voltage

System

Judgment table




Because normal power supply is used between CR3 [1], [21] and chassis, voltage is applied even in 20 – 30 V starting motor switch OFF state. Between CR3 [2], [12], [22] and chassis

PC-EPC solenoid

CR3

Measure voltage

* The voltage can be checked in monitoring mode "1036". If the condition is as shown in the table below, it is normal Diesel fuel mode 0 – 5 V Engine Between full Kerosene mode 0 – 7 V [16] – Engine chassis Diesel fuel mode 6 – 13 V slow Kerosene mode * The controller output current can be checked in monitoring mode "1050".

CR3

Measure voltage

Controller


Swing holding brake release solenoid


At swing brake cancel switch OFF (at release) At swing brake cancel switch ON (at normal time)

Max. 1 V Between CR3 [7] – CR3 [3]

1) Turn starting switch OFF. 2) Disconnect connector. 3) Insert T-adapter.

20 – 30 V

Model selection

—

Monitoring

If the condition is as shown in the table 1) Turn starting below, it is normal. switch ON. Monitoring mode: "1020", "1021" Model selec- Model selec- UU/US selec- Tire 2 signal tion 1 (1020, tion 2 (1020, tion (1020, (1021 bit(5)) bit (5)) bit (6)) bit (3)) Bit OFF

Bit ON

Bit ON

Bit ON

Attachment selection

PC128US-2

—

Monitoring

If the condition is as shown in the table 1) Turn starting below, it is normal. switch ON. Monitoring mode: "1020" Attachment Attachment Attachment selection 1 selection 2 selection 3 (1020, bit (2)) (1020, bit (1)) (1020, bit (4)) Standard Bit ON arm

Bit OFF

Bit OFF

Long arm

Bit ON

Bit OFF

Bit OFF

20-19 (17)



Name of component

Model selection Attachment selection


—

Monitoring

System


Judgment table If the condition is as shown in the table below, it is normal. Monitoring mode: "1001" Model/Attachment code Standard arm

020

Long arm

021

1) Turn starting switch ON.

Swing pressure switch

Travel pressure switch

Other work equipment pressure switches  Arm OUT, bucket   CURL, bucket DUMP,   blade, attachment 

20-20 (17)

—

—

—

Monitoring Monitoring

—

Monitoring

Arm IN pressure switch

—

Monitoring

Controller

Boom RAISE pressure sensor

—

Monitoring

Select in service adjustment mode

Service adjustment

* The model and attachment codes do not make difference in performance. If the condition is as shown in the table below, it is normal. Diesel fuel/Kerosene mode "31" Standard mode

310

Kerosene mode

311

1) Turn starting switch ON.

If the condition is as shown in the table 1) Start engine. below, it is normal. 2) Reset safety Monitoring mode: "1023", bit (6) lock lever. 3) Operate work Boom RAISE position Bit ON equipment. Neutral position Bit OFF If the condition is as shown in the table below, it is normal. Monitoring mode: "1023", bit (5) Arm IN position

Bit ON

Neutral position

Bit OFF

If the condition is as shown in the table below, it is normal. Monitoring mode: "1023", bit (4) Swing (Right or left) position

Bit ON

Neutral position

Bit OFF

If the condition is as shown in the table below, it is normal. Monitoring mode: "1023", bit (3) Travel (Forward, reverse, right, or left) position

Bit ON

Neutral position

Bit OFF

1) Start engine. 2) Reset safety lock lever. 3) Operate work equipment.



If the condition is as shown in the table below, it is normal. Monitoring mode • Arm OUT "1028" (1) • Blade, attachment "1028" (2) • Bucket CURL "1028" (3) • Bucket DUMP "1028" (4) Other work equipment operation

Bit ON

Neutral position

Bit OFF

PC128US-2



Chassis control

Travel acceleration solenoid

2-stage relief solenoid

PC-EPC solenoid

LS-EPC solenoid

V05 (male)

V06 (male)

C13 (male)

C14 (male)

Measure resistance Measure resistance

V04 (male)

Measure resistance


V07 (male)

Measure resistance

PPC hydraulic lock solenoid


Measure resistance

Name of component

Measure resistance

System


Judgment table If the condition is as shown in the table below, it is normal Between (1) – (2)

37 – 60 Ω


If the condition is as shown in the table below, it is normal Between (1) – (2)

37 – 60 Ω


PC128US-2

Measure resistance

C05 (male)


* The controller output can be checked in monitoring mode "1060", bit (1). If the condition is as shown in the table below, it is normal Between (1) – (2)

37 – 60 Ω




37 – 60 Ω




8 – 15 Ω



* The controller output can be checked in monitoring mode "1050". If the condition is as shown in the table below, it is normal Between (1) – (2)

8 – 15 Ω



* The controller output can be checked in monitoring mode "1054". If the condition is as shown in the table below, it is normal

Pressure sensor


Between (A) – (B)

4.5 – 5.5 V

Between (e) – (P)

0.5 – 4.5 V

1) Start engine. 2) Insert T-adapter.

* The controller output can be checked in monitoring mode "1042".

20-21 (17)



Name of component


Judgment table If the condition is as shown in the table below, it is normal Between (1) – (2) Between (1), (2) – chassis

500 – 1,000 Ω Min. 1 MΩ

Engine speed sensor

E07 (male)

Measure voltage

Measurement in the AC range

Adjustment

Chassis control

Measure resistance

System

20-22 (17)

Between (1) – (2)

0.5 – 3.0 V

Measurement conditions 1) Turn starting switch OFF. 2) Disconnect connector.

1) Start engine. 2) Insert T-adapter.

* The controller output can be checked in monitoring mode "1010".

1) Thread the speed sensor until it touches the ring gear and return it by 1 ± 1/6 rotations. 2) Perform normal operation according to the above adjustment.

PC128US-2

TESTING AND ADJUSTING Tools for testing, adjusting and troubleshooting ................................................................................. 20-102 Measuring engine speed ........................................................................................................................ 20-103 Measuring exhaust color ........................................................................................................................ 20-105 Adjusting valve clearance ....................................................................................................................... 20-106 Measuring blow-by pressure ................................................................................................................. 20-108 Measuring engine oil pressure ........................................................................................................... 20-108-1 Testing and adjusting fuel injection timing ........................................................................................ 20-108-2 Testing and adjusting belt tension for air conditioner compressor ................................................. 20-108-7 Testing and adjusting fan belt tension ............................................................................................... 20-108-8 Adjusting engine speed sensor ........................................................................................................... 20-108-9 Adjusting fuel control cable ................................................................................................................... 20-109 Adjusting engine stop solenoid linkage ................................................................................................ 20-110 Testing clearance of swing circle bearing ............................................................................................. 20-111 Checking wear of sprocket ..................................................................................................................... 20-112 Testing and adjusting track shoe tension .............................................................................................. 20-113 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ......................... 20-114 Testing and adjusting output pressure of PC valve (servo piston input pressure) ............................ 20-117 Testing and adjusting LS valve output pressure (servo piston input pressure)and LS differential pressure .................................................................. 20-119 Testing and adjusting control circuit oil pressure ................................................................................ 20-122 Measuring solenoid valve output pressure .......................................................................................... 20-123 Measuring PPC valve output pressure .................................................................................................. 20-124 Adjusting PPC valve ................................................................................................................................ 20-125 Testing and adjusting travel deviation .................................................................................................. 20-126 Checking location of cause of hydraulic drift of work equipment ...................................................... 20-127 Measuring oil leakage in swing motor .................................................................................................. 20-128 Measuring oil leakage in travel motor ................................................................................................... 20-128 Bleeding air .............................................................................................................................................. 20-129 Releasing remaining pressure in hydraulic circuit ............................................................................... 20-131 Releasing remaining pressure in hydraulic tank .................................................................................. 20-131 Procedure for checking diode ................................................................................................................ 20-132 Pm clinic inspection table ....................................................................................................................... 20-133

PC128US-2

20-101 (17)


TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING Check or measurement item Symbol

Engine speed

A

Coolant and oil temperatures

Part Name

799-205-1100

Tachometer kit

2

795-790-2500

Take-off drive

3

6090-02-9190

Gear box

799-101-1502

Digital temperature gauge

- 99.9 – +1,299 ºC

799-101-5002

Hydraulic tester

Pressure gauge : 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic tester

• 799-101-5160

Nipple

PT1/8

799-101-5220

Nipple

10 x 1.25

07002-11023

O-ring

B

2

C

Adapter

1.0 MPa{10kg/cm2}

• 790-261-1321 • 790-261-1331 • 790-261-1340

Blow-by pressure

4

799-401-2320

Hydraulic gauge

5

799-401-2701

Differential pressure gauge

795-799-1131

Gear

799-201-1504

Blow-by checker

D 1

E

795-790-1950

Tool

Commercially available

Feeler gauge

1

790-201-9001

Handy Smoke Checker

2

Commercially available

Smoke meter

1

79A-264-0021

2 Valve clearance Exhaust color

Operating effort

F G

H

Stroke, hydraulic drift

I


J

Measuring voltage and resistance values

K

Measuring wear of sprocket

20-102 (19)

Bosch index: 0 – 9 0 – 294N{0 – 30kg} Push-pull scale

2

Troubleshooting of wiring harnesses and sensors

Digital display : 6.0 – 99,999.9rpm

Male, female both 14 x 1.5 (female PT 1/8) Male, female both 18 x 1.5 (female PT 1/8) Male, female both 22 x 1.5 (female PT 1/8) Male, female both 10 x 1.25 (female PT 1/8)

• 790-261-1311 3

Adjusting fuel injection timing

Remarks

1

1

Oil pressure

Part No.

L

0 – 490N{0 – 50kg}

79A-264-0091 Commercially available Commercially available Commercially available

Scale

1

790-601-8000

T-adapter kit

2

799-601-7370

For 6-pin relay

3

799-601-7050

SW-6P

4

799-601-7080

Stop watch Tester

M-1P Adapter

M

5

799-601-7310

SW-12P

6

799-601-7320

SW-16P

7

799-601-7340

M-16P

8

799-601-7540

070-18P

796-127-1140

Wear gauge

PC128US-2


MEASURING ENGINE SPEED

MEASURING ENGINE SPEED PC128US-2 Serial No.: 5001 – 7730 fl Measure the engine speed under the following conditions. • Coolant temperature: Within operating range • Hydraulic oil temperature : 45 – 55 ºC 1. Remove air conditioner compressor top cover. 2. Remove air conditioner compressor belt. 3. Remove cover (1) at timing gear case end. 4. Install tool A2 to speed pick-up port. 5. Connect bracket of tool A1, probe and tachometer to tool A2. 6. Start the engine, and measure the engine speed when it is set to the conditions for measuring. 1) Measuring at low idling and high idling : Measure the engine speed with the fuel control lever set to low idling and high idling. 2) Measuring speed at pump relief : Run the engine at full throttle and measure the engine speed when the main pump is relieved. 3) Measuring speed at near rated speed : Run the engine at full throttle, operate the arm lever, and measure the engine speed when the arm is relieved.

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 and up Measurement of engine speed ª The measuring method is identical with the method described above. ª The engine speed can be displayed in monitoring mode "1010".

PC128US-2

20-103 (19)


MEASURING ENGINE SPEED

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl Measure the engine speed under the following condition. • Coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55 ºC 1. Remove the cover for setting the injection timing of the injection pump from the timing gear case and install tool A3.

2. Connect bracket [1], probe [2] and tachometer to tool A3. 3. Start the engine and measure the following revolving speeds. 1) Measure the low idling speed and high idling speed. 2) Set the fuel control lever to the low idling and high idling positions and measure the revolving speeds at the respective positions. 3) Revolving speed when pump is relieved Relieve the pump and run engine at full throttle and measure its revolving speed.

20-104 (19)

PC128US-2


MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR •

When measuring in the field when there is no air or electric power supply, use smoker checker G1; when recording official data, use smoke meter G2. fl Raise the coolant temperature to the operating range before measuring. ¤ When removing or installing the measuring equipment, be careful not to touch any high temperature part. 1. Measuring with handy smoke checker G1 1) Fit filter paper in tool G1. 2) Insert the exhaust gas intake port into the exhaust pipe. 3) Accelerate the engine suddenly, and at the same time operate the handle of tool G1 to catch the exhaust gas on the filter paper. 4) Remove the filter paper and compare it with the scale provided to judge the condition. 2. Measuring with smoke meter G2 1) Insert probe of smoke meter G2 into the outlet port of exhaust the pipe, then tighten the clip to secure it to the exhaust pipe. 2) Connect the probe hose, accelerator switch plug, and air hose to smoke meter G2. fl The pressure of the air supply should be less than 1.47 MPa {15 kg/cm2}. 3) Connect the power cord to the AC100V outlet. fl When connecting the port, check first that the power switch of the smoke meter is OFF. 4) Loosen the cap nut of the suction pump, then fit the filter paper. fl Fit the filter paper securely so that the exhaust gas does not leak. 5) Turn the power switch of smoke meter G2 ON. 6) Accelerate the engine suddenly, and at the same time, depress the accelerator pedal of smoke meter G2 and catch the exhaust gas color on the filter paper. 7) Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (10 sheets or more) inside the filter paper holder, and read the indicated value.

PC128US-2

20-105 (17)


ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 1. Remove the cylinder head cover. 2. Using cranking tool D, rotate the crankshaft in the normal direction until timing pin (1) enters the hole in the gear. fl In this position, the No.1 cylinder is at compression top dead center.

3. When the No.1 cylinder is at top dead center, adjust the valves marked . Next, rotate the crankshaft one turn (360º) in the normal direction and adjust the valve clearance of the remaining valves marked . fl Make a counter mark on the crankshakft pulley or damper, then rotate 360º.

4. To adjust the valve clearance, loosen locknut (7), then insert feeler gauge F between rocker lever (4) and valve stem (5), and turn adjustment screw (6) until the clearance is a sliding fit. Then tighten locknut (7) to hold the adjustment screw in position. 9 Locknut : 23.5 Nm {2.4 kgm} fl After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn the crankshaft 180º each time and adjust the valve clearance of each cylinder according to the firing order. • Firing order : 1 – 3 – 4 – 2 fl Note that there is no timing mark on the front pulley, so set to compression top dead center as follows. 1) If the firing order is followed, No. 3 cylinder comes after No. 1 cylinder, so watch the movement of the valves of No. 2 cylinder when rotating. 2) When the clearance is 0 for both the intake and exhaust valves of the No. 2 cylinder, the No. 3 cylinder is at compression top dead center. (When setting No. 2 cylinder, watch No. 3 cylinder.)

20-106 (17)

PC128US-2


PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Method of adjusting valve clearance 1. Remove the cylinder head cover. 2. Turn the crankshaft forward and bring cylinder No. 1 to the compression top dead center and match the TOP mark line of crank pulley (1) to pointer (2), watching the movement of the air intake valve of cylinder No. 4 (4 cylinders). a The air intake valve of cylinder No. 4 (4 cylinders) moves (opens) when cylinder No. 1 comes near the compression top dead center.

ADJUSTING VALVE CLEARANCE

a Adjust the valve clearance according to the following procedure. Loosen locknut (8) of adjustment screw (7). Insert filler gauge of the specified thickness between valve stem (6) and rocker arm (5) and adjust the valve clearance so that the filler gauge will move lightly.

5. Tighten the locknut to secure the adjustment screw. Locknut: 39.2 – 49 Nm {4 – 5 kgm}

3. Adjust the clearance of the valves marked with q in the valve arrangement. 4. Turn the crankshaft forward by 1 turn and adjust the clearance on the valves marked with Q.

a You may adjust the valve clearances of each cylinder in the firing order, rotating the crankshaft by 180° each time.

PC128US-2

20-107 (17)


MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE fl Measure the blow-by pressure under the following conditions. • Coolant temperature : Within operating range • Hydraulic oil temperature: 50 – 80 ºC 1. Install the nozzle of blow-by checker E to the blowby hose. 2. Connect the nozzle and gauge with the hose. 3. Run the engine at full throttle and relieve the arm circuit. 4. Measure the blow-by pressure at the point where the gauge indicator remains steady.

20-108 (17)

PC128US-2

MEASURING ENGINE OIL PRESSURE


MEASURING ENGINE OIL PRESSURE fl Measure the engine oil pressure under the following conditions. • Coolant temperature : Within operating range


1. Remove engine oil pressure switch (1). 2. Fit a nipple C3 and install oil pressure gauge C2 (0.981 MPa {10 kg/cm2}). 3. Start the engine, and measure the engine oil pressure with the engine at low idling and at high idling.


PC128US-2

20-108-1 (17)


TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 Testing 1. Using cranking tool D, rotate the crankshaft in the normal direction until timing pin (1) enters the hole in the gear. 2. Remove plug (2), reverse timing pin (3), and check that pin (3) is meshed with timing pointer (4) at the fuel injection pump end. Adjusting fl If the timing pin does not mesh with the pointer, adjust as follows. 1. Remove the fuel injection pump. For details, see REMOVAL OF FUEL INJECTION PUMP. 2. Rotate the camshaft of the fuel injection pump and timing pin (3) with timing pointer (4). 3. Install the fuel injection pump. For details, see INSTALLATION OF FUEL INJECTION PUMP.

20-108-2 (17)

PC128US-2


PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Adjustment by use of match marks a Apply this method usually. (Then installing the fuel injection pump to the original engine without repairing it, when checking only the injection timing, etc.) 1. Bring cylinder No. 1 to the compression top dead center. 1) Turn the crankshaft forward and match 1.4Top line (1) on the crank pulley to pointer (2).

2) Check that cylinder No. 1 is at the compression top dead center by the following method. If the following condition is not obtained, turn the crankshaft one more turn. a If the fuel injection pump is removed: Check that C is seen at the tooth tip of the idler gear. a If the fuel injection pump is installed to the engine: Remove the head cover and check that (both air intake valve and exhaust valve of cylinder No. 1 have the valve clearance).

PC128US-2


2. Remove front cover (3) of the fuel injection pump. 3. Install the fuel injection pump holder and drive gear as one unit to the engine. 4. Insert the timing check pin 4.0 – 4.5 mm in diameter and 80 mm in length on hole a of the front gear cover and match it to the hole of the drive gear. a Check that the timing check pin enters straight and the hole of the fuel injection pump holder is aligned with the mounting hole of the front gear cover (in which the mounting bolt will be inserted). a If the holes are deviated from each other, remove the fuel injection pump and check its engagement with the drive gear.

5. Remove the timing check pin and tighten each bolt.

20-108-3 (17)


Adjustment by delivery valve method (When installing a repaired or replaced fuel injection pump, when checking after disassembling or replacing the gear train)


4. Using spring pusher O2, compress the valve spring and remove valve cotter (5). 5. Loosen spring pusher O2 and remove spring seat (6) and valve spring (7).

1. Remove the cylinder head cover. 2. Bring cylinder No. 1 to the compression top dead center. 1) Turn the crankshaft forward and match injection timing line (1) on the crank pulley to pointer (2). 2) Check that both air intake valve and exhaust valve of cylinder No. 1 have the valve clearance. a If either or both of the valves do not have the valve clearance, turn the crankshaft one more turn. 6. Turn the stem of air intake valve (8) with the fingers while it is in contact with the top of piston (9) to fit it securely.

3. Remove snap ring (3) from the front end of the rocker shaft, then remove air intake rocker arm (4) of cylinder No. 1.

20-108-4 (17)

PC128US-2



7. Apply dial gauge O3 to the valve stem end and turn the crankshaft forward or in reverse to set the dial gauge to 0 when its pointer starts turning in reverse. 8. Turn the crankshaft about 45 degrees in reverse from the compression top dead center of cylinder No. 1. 9. Turn the crankshaft forward so that the dial gauge indicates standard dimension a. BTDC

°(Deg)

6 ± 0.75

a

mm

0.42 ± 0.08

12. Set the fuel injection lever to the FULL position. 13. Loosen the nut at the oblong hole of the injection pump mounting flange, then loosen the injection pump mounting bolts (14).

10. Disconnect fuel injection pipe (10) of cylinder No. 1. 11. Remove delivery valve holder (11), and remove delivery valve (12) and spring (13) from its inside. Then, install delivery valve holder (11) again. 14. Turning the injection pump outward and operating the priming pump, move the injection pump toward the cylinder block little by little and stop when the fuel stops flowing out of the delivery valve holder. a If the injection pump is slanted out, the injection timing is delayed. If the former is slanted toward the cylinder block, the latter is advanced. 15. Tighten injection pump mounting bolts (14) alternately. 16. Tighten the nut at the oblong hole of the injection pump mounting flange.

PC128US-2

20-108-5 (17)



17. Turn the crankshaft forward and check that the pointer of the dial gauge is in the standard range shown in the following table when cylinder No. 1 is at the top dead center (when the pointer of the dial gauge starts moving in reverse). If the pointer of the dial gauge is out of this range, repeat the above steps from 7. Dimension when cylinder is at top dead center (mm)

0 ± 0.08

18. Remove the delivery valve holder (11) and install delivery valve (12) and spring (13) to it, then install delivery valve holder (14) again. a Replace the o-ring and copper gasket of the delivery valve. WARNING! Tighten the delivery valve 3 times to secure it. (If it is not tightened sufficiently, the gasket may be broken.) Delivery valve holder: 39.2 – 44.1 Nm {4 – 4.5 kgm} 19. Connect fuel injection pipe (3). Sleeve nut: 19.6 – 24.5 Nm {2 – 2.5 kgm} 20. Install valve spring (7) and valve seat (6). 21. Compress the valve spring with spring pusher O2 and install valve cotter (5). 22. Install air intake rocker arm (4) of cylinder No. 1, then install snap ring (3). a Install the snap ring securely. 23. Install the cylinder head cover. Sleeve nut: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}

20-108-6 (17)

PC128US-2


TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

PC128US-2 Serial No.: 5001 – 7730

PC128US-2 Serial No.: 5001 – 7730 fl If the deflection of the belt when it is pressed at a point midway between the crankshaft pulley and the compressor pulley is not within the standard value, or when carrying out maintenance after replacing the belt, adjust the belt tension as follows. 1. Loosen 2 mounting bolts (2) and 2 adjustment plate bolts (3) of compressor assembly (1). 2. Move the position of compressor assembly (1) to adjust the belt tension. 3. When the position of compressor assembly (1) is fixed, tighten 2 adjustment plate bolts (3) and 2 mounting bolts (2) to secure in position. 4. After adjusting the belt tension, repeat the above testing procedure to check that the belt tension is within the standard value.


PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up fl If the deflection of the belt when it is pressed at a point midway between the crankshaft pulley and the compressor pulley is not within the standard value, or when carrying out maintenance after replacing the belt, adjust the belt tension as follows: 1. Loosen two mounting bolts (2) and (3) of compressor assembly (1). 2. Loosen nut (4) and thread and adjust adjustment bolt (5) so that the deflection of the belt can be set to 12 to 15 (about 58.8 N {about 6 kgf}). 3. When the position of compressor assembly (1) is fixed, tighten two mounting bolts (2) and (3) to secure them in position. 4. After tightening adjustment bolt (5) two or three rotations, tighten nut (4) and secure adjusting bolt (5). 5. After adjusting the belt tension, repeat the above testing procedure to check that the belt tension is within the standard value.

PC128US-2


20-108-7 (17)


TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl When deflection a made by pressing the intermediate point of the belt between the alternator pulley and drive pulley is out of the standard range or when the belt was replaced, adjust the belt tension according to the following procedure. 1. Open the engine hood and remove the cover between the hydraulic tank and operator's cab. 2. Loosen mounting bolt (2) and fixing bolt (3) of alternator assembly (1). 3. Loosen locknut (4), and then loosen tension bolt (5) to adjust the belt tension. Tighten fixing bolt (3) first, and then tighten alternator mounting bolt (2) and locknut (4). fl Do not touch the double nut (6). 4. After adjusting the belt tension, check that it is in the standard range according to the check procedure shown above.

20-108-8 (17)

PC128US-2

ADJUSTING ENGINE SPEED SENSOR


ADJUSTING ENGINE SPEED SENSOR 1. Screw in until the tip of sensor (1) contacts gear (2). 2. When gear (2) contacts sensor (1), turn back 1±1/ 6 turn. 3. Tighten locknut (3). fl Be careful not to let the tip of the sensor be scratched or to let any iron particles stick to the sensor tip. fl Be particularly careful when securing the sensor wiring to ensure that no excessive force is brought to bear on the wiring.



PC128US-2

20-108-9 (17)

TESTING

AND ADJUSTING

ADJUSTING

ADJUSTING

ENGINE

STOP SOLENOID

LINKAGE

ENGINE STOP SOLENOID LINKAGE

‘

BEP01424

Testing 1. Turn the starting switch ON, set to the operating condition, then adjust so that the clearance between lever (I) and stopper (2) is 1 - 2 mm. Adjusting 1. Loosen the mounting bolts of solenoid assembly (31, move solenoid assembly (3) to adjust the clearance between lever (I) and stopper (21, then tighten the mounting bolts. * There is an oblong hole at the bracket end.

20-110 0

PC1 28US-2

TESTING

TESTING

AND ADJUSTING

CLEARANCE

OF SWING

CIRCLE BEARING

TESTING CLEARANCE OF SWING CIRCLE BEARING Method of testing clearance of swing circle bearing when mounted on machine 1. Fix a magnet-type dial gauge to the outer circle (or inner circle) of the swing circle, and put the tip of the probe in contact with the inner circle (or outer circle). Set the dial gauge at the front or rear.

-Revo

01

rame

Dial gauge

2.

Extend the work equipment to the maximum reach, and set the tip of the bucket to the same height as the bottom of the revolving frame. When this is done, the front of the upper structure will go down and the rear will rise.

3.

Set the dial gauge to the zero point.

TXP02404

BLP01317

4.

5.

Set the arm more or less at ground surface, then lowerthe dercarriage at the front of the the ground. When this is done, the front ture will rise and the rear will

of the upper strucgo down.

Read the value on the dial gauge at this point. The value on the dial gauge is the clearance of the swing.circle bearing. g

6.

right angles to the boom until the unmachine comes off

When carrying out the measurement, do not put your hand or feet under the undercarriage.

150-200mm

BLPOl3

Return to the condition in Step 2, and check that the dial gauge has returned to the zero point. If it has not returned to the zero point, repeat Steps 2 to 5.

PC1 28US-2

20-111 0

CHECKING WEAR OF SPROCKET


CHECKING WEAR OF SPROCKET Wear

limit

line

TXP02405

1.

Remove the track shoe assembly. * For details, see DISASSEMBLYAND ASSEMBLY, REMOVAL OF STEEL SHOE ASSEMBLY.

2.

Align wear gauge M with the sprocket. * Align the datum line, then align the wave shape of the sprocket with the wave shape of the wear gauge.

3.

Judge the sprocket wear. Sr If the wave shape of the sprocket is above the wear limit line : It is possible to continue to use the sprocket. * If the wave shape of the sprocket has reached the wear limit line : Replace the sprocket with a new part.

20-112 0

PC128US-2

TESTING TESTlNG

AND ADJUSTING

AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT Measuring Sr Oil temperature a

.

when

measuring:

45 - 55 “C

Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then put the safety lock lever in the LOCK position. Remove pressure pick-up plug (I) (Thread dia.=lOmm, Pitch=l.25mm) from the circuit to be measured, then install oil pressure gauge Cl (58.8 MPa {SO0 kg/cm*}).

Measuring unload hydraulic pressure l Start the engine, run at full throttle, and measure the hydraulic pressure when the control levers are at HOLD.

Measuring main relief (pump relief) oil pressure 1. Run the engine at full throttle and measure the oil pressure when each actuator is relieved. l The condition for each actuator is as follows: 1) For the work equipment, operate the cylinder to the end of its stroke. 2) Forthe swing, dig a hole and lowerthe bucket. 3) For the travel, fit block (1) under the grouser of the track shoe, or fit block (2) between the sprocket and frame to lock the track, and measure one side at a time. * The set pressure of the safety valve of the swing motor is lower than the main relief valve set pressure, so when the swing is relieved, the set pressure of the safety valve is measured.

20-114 0

BLPO1284 -1

PC1 28US2


TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

Adjusting 1. Adjusting main relief valve • Disconnect high pressure hose. 1) Adjusting high pressure setting • Loosen locknut (2) of main relief valve (1), then turn holder (3) to adjust. fl Turn the holder to adjust as follows. • To INCREASE pressure, turn CLOCKWISE. • To DECREASE pressure, turn COUNTERCLOCKWISE. fl After adjusting, use the measurement procedure above to check the oil pressure again. fl Amount of adjustment for one turn of holder : Approx. 12.6 MPa {128 kg/cm2} 9 Locknut : 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm} fl When the high pressure setting is adjusted, the low pressure setting will also change, so adjust the low pressure setting also. 2) Adjusting low pressure setting • Loosen locknut (4) of main relief valve (1), then turn holder (5) to adjust. fl Turn the holder to adjust as follows. • To INCREASE pressure, turn CLOCKWISE. • To DECREASE pressure, turn COUNTERCLOCKWISE. fl After adjusting, use the measurement procedure above to check the oil pressure again. fl Amount of adjustment for one turn of holder : Approx. 12.6 MPa {128 kg/cm2} 9 Locknut : 39.2 – 49.0 Nm {4 – 5 kgm}

2. Adjusting swing motor safety valve fl If the swing relief pressure is not normal, adjust the swing motor safety valve as follows. 1) Loosen locknut (7) of swing motor safety valve (6), then turn adjustment screw (8) to adjust. fl Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Amount of adjustment for one turn of adjustment screw : 14.0 MPa {143 kg/cm2}

PC128US-2

20-115 (18)

TESTING TESTING

2)

AND ADJUSTING

After adjusting, m &

tighten

AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

locknut (7).

Locknut : 53.9 + 4.9 Nm (5.5 + 0.5 kgm1 .n.fer comnletinn of adiustment. ,-------~ -, use the r’--.-.. measurement procedure the oil pressure again.

above to check

9JFOO253

20-116 0

PC1 28US-2


TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)

TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE) Measuring fl Oil temperature when measuring : 45 – 55 ºC 1. Remove pressure measurement plugs (1) and (2) (Thread dia.= 10 mm, Pitch=1.25 mm), and install oil pressure gauge C1 (39.2 MPa {400 kg/cm2}). 2. Turn the swing lock switch ON. 3. Run the engine at full throttle and measure the oil pressure when the arm IN circuit is relieved. [Reference] If there is any abnormality with problem in the LS valve or servo piston, the servo piston input pressure becomes a value close to 0 or the same pressure as the pump discharge pressure.

PC128US-2

20-117 (18)

TESTING TESTING

AND ADJUSTING

AND ADJUSTING

OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)

Adjusting If the load increases and the engine speed drops, or if the engine speed is normal but the work equipment speed is slow, adjust PC valve (6) as follows if the pump discharge pressure and LS differential pressure are normal. 1) Loosen iocknut (41, and if the work equipment speed is slow, turn screw (5) clockwise; if the engine speed drops, turn the screw counterclockwise. 2) Remove pressure measurement plugs (1) and (2) (Thread dia.= IO mm, Pitch=1.25 mm), and install oil pressure gauge Cl (39.2 MPa (400 kg/cm*}). 3) Turn the swing lock switch ON. Run the engine at full throttle and measure the oil pressure when the arm IN circuit is relieved. [Reference] If there is any abnormality in the LS valve or servo piston, the servo piston input pressure becomes a value close to 0 or the same pressure as the pump discharge pressure.

BKPOIOI5

20-118 0

PC1 28US-2

TESTING

TESTING AND ADJUSTING LS VALVE OUTPUT (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE when

measuring

: 45 - 55 “C

j,

Oil temperature

1.

Measuring LS valve output pressure (servo ton input pressure) plugs (I) 1) Remove pressure measurement (2) (Thread dia.= 10 mm, Pitch=1.25 mm), install oil pressure gauge Cl (39.2 MPa

pisand and {400

kg/cm%

2) Use the work equipment 3)

to raise the track assembly on one side. Run the engine at full throttle, operate under the conditions shown in Table 1, rotate the track under no load, and measure the oil pressure (the oil pressure when the travel is operated on one side under no load).

Travel lever

Pump pressure MPaIkg/cmZI

Servo inlet pressure APaIkg/cm*)

About same pressure

Neutral

t Full

/

PC1 28U.S2

Remarks

7.85f0.49 {80+20)

4.41f0.98 (45flOI

Pressure of about 315

PRESSURE PRESSURE

TESTING

2.

AND ADJUSTING

Measuring

LS differential

TESTING AND ADJUSTING LS VALVE OUTPUT (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

PRESSURE PRESSURE

pressure

1)

Measuring with.differential pressure gauge i) Remove oil pressure measurement plugs (1) and (2) (Thread dia.=lOmm, Pitch=l.25mm), and install differential pressure gauge Cl. * Connect pump discharge pressure side (1) to the high- pressure side of the differential gauge and LS pressure side (2) to the low-pressure side. ii) Use the work equipment to raise the track on one side. iii) Run the engine at full throttle, set to the conditions below, and measure the LS differential pressure. LS differential pressure when travel lever is at.Neutral : 2.75 f 0.98 MPa 128 k 10 kg/cm*) * The LS differential pressure when the travel lever is at Neutral is the same as the unload pressure. LS differential pressure when travel lever is at half-way position (track rotating under no load) : 1.57 f 0.1 MPa I16 f lkg/cm*) 2) Measuring with oil pressure gauge * The maximum differentialpressure is less than 1.96 MPa (20 kg/cm*), so measure with the same gauge. i) Remove oil pressure measurement plugs (I) and (2) (thread dia.=lOmm, pitch=l.25mm), and install oil pressure gauge Cl. ii) Install oil pressure gauge Cl (39.23 MPa (400 kg/cm*}) to the plug for measuring the pump discharge pressure. * Use a gauge with a scale in units of 0.98 MPa {IO kg/cm*). iii) Use the work equipment to raise the track on one side. iv) Run the engine at high idling, set to the conditions in Step 1) - iii), and measure the pump discharge pressure. * Stand directly in front of the indicator and be sure to read it correctly. v) Run the engine at high idling, set to the conditions in Step 1) - iii), and measure the LS pressure. * Stand directly in front of the indicator and be sure to read it correctly. vi) Calculate the LS differential pressure from the pump discharge pressure and the LS pressure. (Differential pressure) = (Pump discharge pressure) - (LS pressure) l

l

9JFOOl20

-1

BLP01284

20-120 0

PC128US-2

TESTING

3.

AND ADJUSTING

TESTING AND ADJUSTlNG LS VALVE OUTPUT (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

Adjusting LS valve * If the results show that the LS differential pressure is not within the standard value, adjust the LS valve as follows. 1) Disconnect hose (8) from LS valve (7). 2) Loosen locknut (9) and turn adjustment screw (IO) to adjust the differential pressure. * Turn the adjustment screw to adjust as follows. l To INCREASE pressure, turn CLOCKWISE l To DECREASE pressure, turn COUNTERCLOCKWISE * Amount of adjustmentfor one turn of adjustment screw: 1.30 MPa i13.3 kg/cm*} (LS differential pressure) 3) After adjusting, tighten locknut (8). w *

PC1 28US-2

PRESSURE PRESSURE

BKP01016

Locknut : 59 f IO Nm (6 f 1 kgml After completion of adjustment, repeat the procedure above to check the LS differential pressure again.

20-121 0

TESTING

TESTING

AND ADJUSTING

AND ADJUSTING

CONTROL

CIRCUIT OIL PRESSURE

TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE : Measuring * Oil temperature a

when measuring

: 45 - 55 “C

Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then put the safety lock lever in the LOCK position.

1. Remove the cover at the top of the valve. 2.

Disconnect hose (I) going to the solenoid valve, then install adapter C3 and oil pressure gauge Cl (5.9 MPa {SO kg/cm*)).

3.

Start the engine and measure full throttle.

with the engine at

Adjusting

*

If the pressure in the control circuit is not normal, adjust the control relief valve as follows.

1

Loosen locknut (2) and turn adjustment.screw (3) to adjust. * Turn the adjustment screw as follows. l To INCREASE pressure, turn CLOCKWISE l To DECREASE pressure, turn COUNTERCLOCKWISE * Amount of adjustment for one turn of adjustment screw : 0.98 MPa {IO kg/cm*}

2.

After adjusting,

tighten

locknut (2).

w

Locknut : 19.6 - 24.5 Nm (2.0 - 2.5 kgm}

*

After completion of adjustment, repeat the procedure above to check the oil pressure again.

20-122 0

9JFOO266

PC1 28US-2

TESTING

TESTING

AND ADJUSTING

SOLENOID

VALVE OUTPUT

PRESSURE

TESTING SOLENOID VALVE OUTPUT PRESSURE when measuring

: 45 - 55 “C

*

Oil temperature

1.

Disconnect the output hose of the solenoid valve to be measured, then install adapter C3 between the hose and the measurement point.

2.

Install oil pressure gauge Cl (5.9 MPa {SO kg/cm211 to adapter C3.

3.

Measure the output pressure underthe in the table below.

lock lever: LOCK

conditions

PPC lock actuated

Swing lock switch: LOCK

PC1 28US-2

20-123 0

TESTING

MEASURING PPC VALVE OUTPUT PRESSURE * Oil temperature when measuring : 45 1.

MEASURING

AND ADJUSTING

PPC VALVE OUTPUT

PRESSURE

- 55 “C

Measuring PPC valve output pressure 1) Disconnect PPC hose (I) of the circuit to be measured. 2) install adapter C3 between the hose and elbow. 3) Install oil pressure gauge Cl (5.88 MPa I60 kg/cm211 to adapter C3. 4) Run the engine at full throttle, operate the control lever of the circuit to be measured, and measure the oil pressure.

PPC

BLP01302

20-124 0

PC1 28US-2

TESTING

TESTING

AND ADJUSTING

AND ADJUSTING

TRAVEL DEVIATION

TESTING AND ADJUSTING TRAVEL DEVIATION Travel

Posture

’

Testing * Travel on flat ground. 1.

Set the machine in the travel posture. Ir When setting the machine in the travel posture, extend the bucket and arm cylinder rods fully, and hold the boom at an angle of 45”.

2.

Travel for IOm, then measure the deviation when traveling the next 20m . J, Measure with the engine at full throttle. * Install an oil pressure gauge and measure the pump discharge pressure at the same time.

TDP00328

0

20m

Make

Make a mark 10m midway

a mark

MIyarin;,J,

at Point

1Om

the

Make

Run

UP

for

IOm

a mark:

midwAark

Mark Measure distance

the

amount A at this

of point TEP00329

20-126 0

PC1 28US-2

CHECKING TESTING

AND ADJUSTING

LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT

CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT *

Oil temperature

1.

Work equipment

when measuring : 45 - 55 “C cylinder

*

If the hydraulic drift of the work equipment is not within the standard value, measure the internal leakage of the cylinder as follows and judge if the cause of the hydraulic drift is in the cylinder or the control valve. . If the leakage is within the standard value, the problem is in the control valve. . If the leakage is more than the standard value, the problem is in the cylinder. 1) Fully extend the rod of the cylinder to be measured, then stop the engine.

2) Disconnect the hose at the head end and block the hose at the chassis end with a blind plug. Boom cylinder: Hose (I 1 Arm cylinder: Hose (2) Bucket cylinder: Hose (3) Be careful not to disconnect the hose at g the bottom end. 3) Start the engine, run the engine at full throttle, and apply the relief pressure to the bottom end of the cylinder. * Boom cylinder: Operate to RAISE Arm cylinder: Operate to IN Bucket cylinder: Operate to CURL 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. l

l

l

2.

Checking_ PPC valve If there is a difference in the hydraulic drift when the safety lock lever is at the LOCK or FREE position (with the engine running), the PPC valve is defective.

End

of

stroke

~p~connect

zi

l

TLP00652

PC1 28US-2

ZO-127 0

TESTING

MEASURING MEASURING

AND ADJUSTING

OIL LEAKAGE OF SWING MOTOR, OIL LEAKAGE OF TRAVEL MOTOR

MEASURING OIL LEAKAGE OF SWING MOTOR *

Oil temperature

when measuring

: 45 - 55 “C

1. Disconnect drain hose (I) from the swing motor, then install a blind plug at the tank end. 2. Dig the bucket into the ground and lock the swing. 3. Start the engine and relieve the swing circuit with the engine at full throttle. 4. Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. f After measuring, swing 180” and measure again.

MEASURING OIL LEAKAGE OF TRAVEL MOTOR * Oil temperature when measuring : 45 - 55 “C 1. 2.

3.

4.

Disconnect drain hose (2) from the travel motor, then fit a blind plug at the hose end. Fit block @ under the track shoe grouser, or fit block @ between the sprocket and frame to lock the track. Start the engine and relieve the travel circuit with the engine at full throttle. a When measuring the oil leakage from the travel motor, there is a serious risk that mistaken operation of the control lever may lead to an accident, so always use signals and check carefully when carrying out this operation. Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. * When measuring, move the motor slightly (to change the position between the valve plate and cylinder, and the piston and cylinder), and measure several times.

II

20- 128 0

9JFOOO95

PC1 28US-2

BLEEDING AIR


BLEEDING AIR Order for operations and procedure for bleeding air Air bleeding procedure

Air bleeding item

Nature of work • Change hydraulic oil • Clean strainer

1

2

Bleed air from pump

Start engine

→

3

4

5

6

7

Bleed air Bleed air Bleed air Pressurize Start from from from hydraulic operation cylinder swing travel tank motor motor

→

→

→ (Note)

→

→

(Note)

→

→

→

→

→

• Replace, repair control valve

→

→

→

• Replace cylinder • Remove cylinder piping

→

→

→

• Replace, repair swing motor • Remove swing motor piping

→

• Replace, repair travel motor, swivel • Remove travel motor, swivel piping

→

• Replace return filter element • Replace, repair pump

→

→ →

→ →

Note : Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained. 1. Bleeding air from pump 1) Loosen air bleed plug (1), and bleed the air from the plug. fl WHen no more air comes out with the oil, the bleeding is completed. 2) When oil oozes out, tighten plug (1). 9 Air bleed plug : 17.16 ± 2.45 Nm {1.75 ± 0.25 kgm} fl Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low idling for 10 minutes. 2. Bleeding air from cylinders 1) Start the engine and run at idling for approx. 5 minutes. 2) Run the engine at low idling, and raise and lower the boom 4 – 5 times in succession. fl Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat Step 2). After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat Steps 2) and 3) to bleed the air from the arm, bucket, swing, and blade cylinders. PC128US-2

20-129 (17)

TESTING

AND ADJUSTING

3.

Bleeding air from swing motor 1) Turn the swing lock switch ON and run at idling for 5 minutes. * Use the S port pressure to bleed the air from the swing motor. 2) Disconnect hose (1) from the swing motor, then fit a blind plug in the hose end. 3) Run the engine at low idling and check that oil oozes out from elbow (2). Jr If oil does not flow out from the elbow, repeat Step 1). 4) Connect hose (I).

4.

Bleeding

20-130 0

BLEEDING

AIR

air from travel motor

PC1 28US-2

TESTING

AND ADJUSTING

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT, RELEASING REMAINING PRESSURE IN HYDRAULIC TANK

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT Jr If the piping between the hydraulic cylinder

and the control valve is to be disconnected, release the remaining pressure from the circuit as follows. The travel circuit is an open circuit, so there is no remaining pressure. In this case, it is enough just to the oil filler cap.

1.

Loosen the oil filler cap slowly to release the pressure inside the tank.

2.

Operate the control levers. * When the levers are operated 2 - 3 times, the pressure stored in the accumulator is removed.

3. Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. Jr Repeat the above operation 2 - 3 times to release all the remaining pressure.

RELEASING REMAINING PRESSURE IN HYDRAULIC TANK a The hydraulic tank is sealed and pressurized. When removing the hoses or plugs connected to the hydraulic tank, do as follows to release the remaining pressure in the hydraulic tank. 1.

Lower the work equipment the engine.

2.

Loosen the oil filler cap or oil filler plug slowly to release the pressure inside the hydraulic tank.

PC1 28US-2

to the ground and stop

.

20-131 0

TESTING

PROCEDURE

AND ADJUSTING

FOR CHECKING

DIODE

PROCEDURE FOR CHECKING DIODE l

l

1.

Diode

as

individual

Diode

included

Part

Use the following procedure to check the diode as individual part and the diode included in the wiring harness. Use a digital tester with a range for measuring diodes. Put the red (+) end of the test pin in contact with the anode (P) of the diode, and the black (-) end in contact with the cathode (N). * There is a mark showing the direction of continuity on the surface of the diode. * With a normal tester, if it is switched to the diode range, the voltage of the internal battery is displayed. The value indicates the following. l No change : No continuity l Changes: There is continuity (normal) (Note) 0 Value is 0 or near 0: Short circuit inside diode Note : In the case of silicon diodes, a value beDependtween 400 and 600 is displayed. ing on the type of tester, 0.4 - 0.6 may also be displayed.

in

wiring

harness

I-

TLP00664

BLPO1357

20-132 0

PC128US-2


Pm CLINIC INSPECTION TABLE


PC128US-2 # 5001 and up Machine Serial No. Mounted engine

HOUR INSPECTION Work instruction No.

Date of execution Day: Year:

Month:

S4D102E-1

Service meter hours

Inspector

INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK Is there abnormality before starting inspection?

What is maximum level of coolant temperature? (During operation)

.................................................................................................................... ....................................................................................................................

White Green Green Green Green Red Red 1 2 3 4 5 6 7

....................................................................................................................

Outside temperature Max. Min.

˚C

Height

m

Check of work equipment for damage Boom foot

Lower part of boom

Arm cylinder bracket

Revolving frame

˚C

Good

Bad

Good

Bad

Good

Bad

Other parts

Check of coolant level, oil level, and monitor Engine coolant

Engine oil

Display of self-diagnosis

Hydraulic oil

Monitor (

)

Monitor panel

fl If machine is cold, warm it up. Item

Condition

Unit

Standard MeasureService limit value for ment Good value new machine result 925 – 975

—

rpm

2,340 – 2,460

—

Min. 2,100

Min. 2,000

Max. 0.49 {Max. 50} 0.34 – 0.59 {3.5 – 6.0} Min. 0.10 {Min. 1.0} 0.34 – 0.59 {3.5 – 6.0} Min. 0.08 {Min. 0.8}

Max. 0.98 {Max. 100} Min. 0.25 {Min. 2.5} Min. 0.07 {Min. 0.7} Min. 0.25 {Min. 2.5} Min. 0.07 {Min. 0.7}

—

—

3.5 – 4.1

Max. 4.4

2.8 – 3.4

Max. 3.7

2.9 – 3.5

Max. 4.0

2.6 – 3.2

Max. 3.7

1.0 – 1.6

Max. 2.5

25 ± 2

25 ± 4

Max. 26

Max. 32

Max. 39

Max. 48

Max. 500

Max. 700

Low idling Engine speed

Engine at full throttle

Engine

Bucket CURL relief Blow-by pressure

kPa {mmAq}

Arm IN relief High idling SAE30 Low idling

Lubricating oil pressure

MPa {kg/cm2}

High idling SAE10W


Low idling Hydraulic oil temperature Boom raised (to just before cushion) Arm out (to just before cushion) Arm in (to just before cushion) Bucket curled

45 – 55 ˚C

˚C

No load applied and extended to end Boom in horizontal position

Bad


Boom and arm in horizontal positions

Blade raised

sec Left

5-turn swing Right High speed


Left Right

5-turn travel Left Low speed Right Hydraulic drift of work equipment

PC128US-2

Rated load applied and engine stopped

mm/15min

20-133 (14)



Oil pressure

PC128US-2 # 5001 and up Condition

Item Low idling

Pc All levers in neutral


Control oil pressure

All levers in neutral Boom-RAISE circuit relieved Arm-IN circuit relieved

Main relief valve and safety valve

Bucket-CURL circuit relieved Left-swing circuit relieved Right-swing circuit relieved Right-swing circuit relieved Left-swing circuit relieved

Serial No. 5001 – 7730

Engine at full Serial No. Main oil pressure 7731 and up throttle

Blade-RAISE circuit relieved Blade-LOWER circuit relieved Right-travel-forward circuit relieved Right-travel-reverse circuit relieved Left-travel-forward circuit relieved Left-travel-reverse circuit relieved All levers in neutral


PC Bucket-CURL circuit relieved Control lever in neutral

LS 1-side track running idle Travel speed: Hi Travel lever in half position

20-134 (14)

Engine at full throttle LS differential pressure

< >: Reference value Standard MeasureService limit value for ment Unit Good value new machine result <2.45 – 3.43> <2.45 – 3.43> {<25 – 35>} {<25 – 35>} 3.04 – 3.43 2.75 – 3.73 {31 – 35} {28 – 38} <2.45 – 3.43> — {<25 – 35>} — 31.4 – 32.4 30.9 – 33.8 {320 – 330} {315 – 345} 31.4 – 32.4 30.9 – 33.8 {320 – 330} {315 – 345} 31.4 – 32.4 30.9 – 33.8 {320 – 330} {315 – 345} 30.4 – 32.4 28.9 – 32.9 {310 – 330} {295 – 335} 30.4 – 32.4 28.9 – 32.9 {310 – 330} {295 – 335} 26.5 – 28.4 25.0 – 28.9 {270 – 290} {255 – 295} 26.5 – 28.4 25.0 – 28.9 {270 – 290} {255 – 295} MPa 31.9 – 33.8 30.9 – 33.8 {kg/cm2} {325 – 345} {315 – 345} 30.9 – 33.8 29.9 – 34.8 {315 – 345} {305 – 355} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 2.45 – 4.41 2.45 – 4.41 {25.0 – 45.0} {25.0 – 45.0} 14.5 – 17.5 13.5 – 18.4 {148 – 178} {138 – 188} 1.77 – 3.73 — {18.0 – 38.0} 2.11 – 2.30 {21.5 – 23.5}

Bad

—

PC128US-2




PC138USLC-2 # 1001 – 1500 Machine Serial No. Mounted engine



Month:

S4D102E-1

Service meter hours

Inspector



.................................................................................................................... ....................................................................................................................


....................................................................................................................

Outside temperature Max. Min.

˚C

Height

m


Lower part of boom


Revolving frame

˚C

Good

Bad

Good

Bad

Good

Bad

Other parts


Engine oil


Hydraulic oil

Monitor (

)

Monitor panel


Condition

Unit

Standard MeasureService limit value for ment Good value new machine result 925 – 975

—

rpm

2,340 – 2,460

—

Min. 2,100

Min. 2,000



—

—

3.5 – 4.1

Max. 4.4

2.8 – 3.4

Max. 3.7

2.9 – 3.5

Max. 4.0

2.9 – 3.5

Max. 4.0

1.0 – 1.6

Max. 2.5

23.0 – 27.0

21.0 – 29.0

Max. 26.5

Max. 32.6

Max. 41.6

Max. 50.6

Max. 500

Max. 700



Engine


kPa {mmAq}



MPa {kg/cm2}

High idling SAE10W


Low idling Hydraulic oil temperature Boom raised (to just before cushion) Arm out (to just before cushion) Arm in (to just before cushion) Bucket curled

45 – 55 ˚C

˚C

No load applied and extended to end Boom in horizontal position

Bad



Blade raised

sec Left

5-turn swing Right High speed


Left Right

5-turn travel Left Low speed Right Hydraulic drift of work equipment

PC128US-2


mm/15min

20-135 (17)



Oil pressure

PC138USLC-2 # 1001 – 1500 Condition

Item

Low idling

Pc All levers in neutral


Control oil pressure

All levers in neutral Boom-RAISE circuit relieved


Arm-IN circuit relieved Bucket-CURL circuit relieved Right-swing circuit relieved Left-swing circuit relieved Blade-RAISE circuit relieved Blade-LOWER circuit relieved Right-travel-forward circuit relieved Right-travel-reverse circuit relieved Left-travel-forward circuit relieved Left-travel-reverse circuit relieved


All levers in neutral

PC


Bucket-CURL circuit relieved Control lever in neutral

LS 1-side track running idle Travel speed: Hi Travel lever in half position

20-136 (17)

Main oil pressure

Engine at full throttle LS differential pressure

< >: Reference value Standard MeasureService limit value for ment Unit Good value new machine result <2.45 – 3.43> <2.45 – 3.43> {<25 – 35>} {<25 – 35>} 3.04 – 3.43 2.75 – 3.73 {31 – 35} {28 – 38} <2.45 – 3.43> — {<25 – 35>} — 31.4 – 32.4 30.9 – 33.8 {320 – 330} {315 – 345} 31.4 – 32.4 30.9 – 33.8 {320 – 330} {315 – 345} 31.4 – 32.4 30.9 – 33.8 {320 – 330} {315 – 345} 26.5 – 28.4 25.0 – 28.9 {270 – 290} {255 – 295} 26.5 – 28.4 25.0 – 28.9 {270 – 290} {255 – 295} 31.9 – 33.8 30.9 – 33.8 {325 – 345} {315 – 345} MPa 30.9 – 33.8 29.9 – 34.8 {kg/cm2} {315 – 345} {305 – 355} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 2.45 – 4.41 2.45 – 4.41 {25.0 – 45.0} {25.0 – 45.0} 14.5 – 17.5 13.5 – 18.4 {148 – 178} {138 – 188} 1.77 – 3.73 — {18.0 – 38.0} 2.11 – 2.30 {21.5 – 23.5}

Bad

—

PC128US-2



PC138US-2 # 4501 and up PC138USLC-2 # 1501 and up Machine Serial No. Mounted engine



Month:

SAA4D95LE-3-A

Service meter hours

Inspector



.................................................................................................................... ....................................................................................................................


....................................................................................................................

Outside temperature Max.

˚C

Min. Height

˚C


Lower part of boom


Revolving frame

m

Good

Bad

Good

Bad

Good

Bad

Other parts


Engine oil


Hydraulic oil

Monitor (

)

Monitor panel


Condition

Unit


1,050 – 1,150 rpm


Engine


kPa {mmAq}



MPa {kg/cm2}

High idling SAE10W Low idling


Hydraulic oil temperature Boom raised (to just before cushion) Arm out (to just before cushion) Arm in (to just before cushion) Bucket curled

Standard MeasureService limit value for ment Good value new machine result

˚C

45 – 55 ˚C No load applied and extended to end Boom in horizontal position

Bad

—

2,340 – 2,460

—

Min. 2,100

Min. 2,000



—

—

3.5 – 4.1

Max. 4.4

2.8 – 3.4

Max. 3.7

2.9 – 3.5

Max. 4.0

2.9 – 3.5

Max. 4.0

1.0 – 1.6

Max. 2.5

23.0 – 27.0

21.0 – 29.0



Blade raised

sec Left

5-turn swing

5-turn travel


PC128US-2

Right Left/Right #1001 – 2599 High #2600 – 4500 Engine at Left/Right speed #4501 and up full throttle Left/Right

Max. 26

Max. 32

Max. 26.9

Max. 32.3

Max. 27

Max. 33

#1001 – 2599

Left/Right

Max. 39

Max. 48

Low speed #2600 – 4500

Left/Right

Max. 43.5

Max. 52.2

#4501 and up

Left/Right

Max. 45

Max. 54

Max. 500

Max. 700


mm/15min

20-137 (17)



PC138US-2 # 4501 and up PC138USLC-2 # 1501 and up Bad


Oil pressure

< >: Reference value Standard MeasureService limit value for ment Condition Item Unit Good value new machine result <2.45 – 3.43> <2.45 – 3.43> Low idling {<25 – 35>} {<25 – 35>} Pc All levers in neutral Control oil pressure 3.04 – 3.43 2.75 – 3.73 Engine at full {31 – 35} {28 – 38} throttle <2.45 – 3.43> — All levers in neutral {<25 – 35>} — 31.4 – 32.4 30.9 – 33.8 Boom-RAISE circuit relieved {320 – 330} {315 – 345} 31.4 – 32.4 30.9 – 33.8 Arm-IN circuit relieved {320 – 330} {315 – 345} 31.4 – 32.4 30.9 – 33.8 Bucket-CURL circuit relieved {320 – 330} {315 – 345} 26.5 – 28.4 25.0 – 28.9 Left-swing {270 – 290} {255 – 295} circuit relieved 31.9 – 33.8 30.9 – 33.8 Blade-RAISE circuit relieved Engine at full {325 – 345} {315 – 345} Main oil pressure throttle 30.9 – 33.8 29.9 – 34.8 Blade-LOWER circuit MPa {315 – 345} {305 – 355} relieved {kg/cm2} 33.8 – 35.8 32.9 – 36.8 Right-travel-forward circuit {345 – 365} {335 – 375} relieved 33.8 – 35.8 32.9 – 36.8 Right-travel-reverse circuit {345 – 365} {335 – 375} relieved 33.8 – 35.8 32.9 – 36.8 Left-travel-forward circuit {345 – 365} {335 – 375} relieved 33.8 – 35.8 32.9 – 36.8 Left-travel-reverse circuit {345 – 365} {335 – 375} relieved 2.45 – 4.41 2.45 – 4.41 All levers in neutral {25.0 – 45.0} {25.0 – 45.0} PC 14.5 – 17.5 13.5 – 18.4 Bucket-CURL circuit relieved {148 – 178} {138 – 188} Servo piston input pressure 1.77 – 3.73 — Control lever in neutral Engine at full {18.0 – 38.0} throttle LS 1-side track running idle LS differential 2.11 – 2.30 Travel speed: Hi — {21.5 – 23.5} pressure Travel lever in half position

20-138 (17)

PC128US-2

TROUBLESHOOTING Points to remember when trobleshooting ............................................................................................ 20-202 Sequence of events in troubleshooting ................................................................................................ 20-203 Points to rememver when carrying out maintenance .......................................................................... 20-204 Checks before troubleshooting .............................................................................................................. 20-212 Connector types and mounting locations ............................................................................................. 20-214 Connector arrangement diagram .......................................................................................................... 20-216 Connection table for connector pin numbers ....................................................................................... 20-219 Functional description of electrical system mechanism (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) .... 20-231 Monitor panel display and special functions (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) ................... 20-232 Method of using troubleshooting charts (PC128US-2 Serial No.: 5001 – 7730) ................................ 20-247 Judgment table for electricl system, hydraulic and mechanical system (PC128US-2 Serial No.: 5001 – 7730) ............................... 20-250 How to read decision list (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up).................................................... 20-252 Method of using troubleshooting charts (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) .......................... 20-254 Diagnostic contents and diagnostic procedure at troubleshooting (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) .......................... 20-256 Troubleshooting of electrical system (E mode) (PC128US-2 Serial No.: 5001 – 7730) ..................... 20-301 Troubleshooting of hydraulic, mechanical systems (H mode) ............................................................ 20-401 Troubleshooting of machine monitor system (M mode) (PC128US-2 Serial No.: 5001 – 7730) ........ 20-501 Troubleshooting of machine monitor system (M mode) (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) ... 20-551 Troubleshooting of communication system (N mode) (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) ... 20-601 Troubleshooting of controller CR700 [deceleration control system] (E mode) (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) ... 20-701 Troubleshooting of controller CR700 [pump control system] (C mode) (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) ... 20-801 Troubleshooting of controller CR700 [input signal system] (F mode) (PC128US-2 Serial No.: 7731 and up) (PC138USLC-2 Serial No.: 1001 and up) ... 20-901 Troubleshooting of engine (S mode) ..................................................................................................... 20-951

PC128US-2

20-201 (14)

POINTS

TROUBLESHOOTING

POINTS TO REMEMBER

TO REMEMBER

WHEN

TROUBLESHOOTING

WHEN TROUBLESHOOTING

a

Stop: the machine curely fitted.

in a level place, and check that the safety pin, blocks, and parking

brake are se-

g

When carrying out the operation with two or more workers, do not allow any unauthorized person to come near.

a

If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.,

keep strictly to the agreed signals, and

g

Be extremely

a

When disconnecting

careful not to touch any hot parts or to get caught in any rotating

a

When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

wiring,

always disconnect

the negative

(-1 terminal

parts.

of the battery first.

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.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: . Parts that have no connection with the failure or other unnecessary parts will be disassembled. . 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 through prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occured apart from the problem that had been reported? 2) Was there anything strange about the machine before tha 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? Check before troubleshooting 1) Check the oil level.

20-202 0

2)

4.

5.

6.

Checkfor any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. 4) Check the stroke of the control valve spool. 5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 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. * When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. Ir 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. Measures to remove root cause of failure Even if the dailure 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 occureed. Then, remove the root cause. PC1 28US-2

SEQUENCE

TROUBLESHOOTING

SEQUENCE

OF EVENTS

IN TROUBLESHOOTING

OF EVENTS IN TROUBLESHOOTING

TEWOO180

a

TEW00181

\ step 1 Examination, 1)

When

confirmation

a request

for repairs

ask the following

2)

of symptoms

-

Name

of customer

-

Type,

serial number

-

Details

of jobsite,

Ask questions

is received,

II -------

first

points.

Ring 1 Ring

__-----

I

of machine

etc.

to gain an outline

of the prob-

lem. .

Condition

.

Work being carried out at the time of the

of failure TEWM)182

failure

i

jtep

.

Operating

.

Past history,

environment details

of maintenance,

etc.

2 Determining 1)

location

of cause

Look at the troubleshooting

section

shop

probable

manual

to find

locations

TEWO0183 of the

of possible

causes.

step 3 Preparation 1)

of troubleshooting

tools

Look at the table of troubleshooting the shop manual

and prepare

=tools in

oa /step

the necessaw

2)

Hydraulic

7 1.

tools. . T-adapter

=z pressure

gauge

kit, etc.

Look in the parts book and prepare

the nec-

essary replacement

Pinpoint

V’

locations

of failure

(carry out

1

troubleshooting)

.

Decide

action to take

1)

Before

starting

repair simple

2)

troubleshooting,

.

Check before

-

Other check items

starting

See the Troubleshooting manual, that

locate

and

failures.

select

matches

items Section

of the shop

a troubleshooting the symptoms,

flowchart

and carry out

troubleshooting. TEWOO187

Drive

and

operate

the condition

the

and judge

machine

to confirm

if there

is really

a

Step 4 (Go]

-

Was there

anything

chine before

strange

the failure

Did the failure Had any repairs

about

the ma-

occurred?

occur suddenly? been carried

out before the

TEwoo188

PC128US-2

20-203 0

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 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).

1. 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.

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.

(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.

20-204 (17)

PC128US-2

TROUBLESHOOTING


(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.

TEW00194

(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. As already said, 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 shortcircuited 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. fl When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. fl 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.

PC128US-2

TEW00195

TEW00196

20-205 (17)

TROUBLESHOOTING


2) Removing, installing, and drying connectors and wiring harnesses ‡

Disconnecting connectors (1) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. 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. fl Never pull with one hand. (2) When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. fl If the connector is twisted up and down or to the left or right, the housing may break.

Catches

(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. fl If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-206 (17)

PC128US-2

TROUBLESHOOTING

‡


Connecting connectors (1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. fl If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the 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. fl If there is any damage or breakage, replace the connector. (2) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with 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. fl If the connector cannot be corrected easily, remove the clamp and adjust the position. (4) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

•

Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal) : a, b, d • Incomplete locking state (Diagonal) : c

PC128US-2

20-207 (17)

TROUBLESHOOTING

‡


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. fl 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 oil and water from the compressed air before blowing with air.

TEW00196

(2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. fl 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.

TEW00202

(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. fl After completely drying the connector, blow it with contact restorer and reassemble.

20-208 (17)

PC128US-2

TROUBLESHOOTING


3) Handling control box (1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. (2) Do not open the cover of the control box unless necessary.

TEW00204

(3) Do not place objects on top of the control box. (4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. (5) During rainy weather, do not leave the control box in a place where it is exposed to rain.

TEW00205

(6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). (7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

TEW00206

2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. fl 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. fl If there is any change, there is probably defective contact in that circuit.

PC128US-2

20-209 (17)

TROUBLESHOOTING

3.

POINTS

POINTS TO REMEMBER WHEN HYDRAULIC EQUIPMENT

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

HANDLING

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, repairing the machine in rain or high winds, places where there is a lot of dust.

or or

21 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 confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed 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 on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.

TEWOO208

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.

20-210 0

PC I 2aus-2

TROUBLESHOOTING

POINTS

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

51 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. (Do not 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.

oi I

TEW00710

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 ultrafine (about 3~) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

TEW00211

PC 128US-2

20-211 0

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Hydraulic, mechanical equipment

Electrical equipment

Lubricating oil, coolant

Item

Judgment value

Action

1. Check fuel level, type of fuel

—

Add fuel

2. Check for impurities in fuel

—

Clean, drain

3. Check hydraulic oil level

—

Add oil

4. Check hydraulic strainer

—

Clean, drain

5. Check swing machinery oil level

—

Add oil

6. Check engine oil level

—

Add oil

7. Check coolant level

—

Add coolant

8. Check dust indicator for clogging

—

Clean or replace

9. Check hydraulic filter

—

Replace

1. Check for looseness, corrosion of battery terminal, wiring

—

Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring

—

Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring

—

Tighten or replace

1. Check for abnormal noise, smell

—

Repair

2. Check for oil leakage

—

Repair

3. Carry out air bleeding

—

Bleed air

24 – 30V

Replace

2. Check battery electrolyte level

—

Add or replace

3. Check for discolored, burnt, exposed wiring

—

Replace

4. Check for missing wiring clamps, hanging wiring

—

Repair

5. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals)

—

Disconnect connector and dry

Electrics, electrical equipment

1. Check battery voltage (engine stopped)

6. Check for blown, corroded fuses 7. Check alternator voltage (engine running at 1/2 throttle or above)

20-212 (17)

— After running for several minutes: 27.5 – 29.5 V

Replace Replace

PC128US-2

CONNECTOR TYPES AND MOUNTING LOCATIONS

TROUBLESHOOTING

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 fl The Address column in this table shows the address in the connector pin allocation drawing (3dimensional drawing). Connector No.

ConnecNo. of tor pins type

Place of use

Address

Connector No.


Place of use

Address

PC-EPC valve diode

F-5

A01

L

2

Intermediate connector

A-2

D23

KES

2

A02

X

3


B-2

D24

KES

2

Pumping switch diode

F-5 R-5

A03

SWP

16


A-2

E11

—

—

Body ground (Ribbon heater relay)

A04

SWP

16


A-2

E13

—

—

Starting motor

N-3

A05

DT

3


B-2

E14

—

—

Ribbon heater relay

R-6

A06

DT

8


A-1

E15

X

3


N-7

A07

DT

8


A-2

E16

L

2

Engine air heater relay

M-6

A08

SWP

8


B-2

E17

X

2

Alternator

O-3

A09

SWP

16

A10

DT

8

Intermediate connector (Arm crane) Intermediate connector (Arm crane)

A20

S

16


D-9

F01

X

2

Travel/swing alarm (OPT)

H-2

A21

S

16


D-4

F02

M

2

Arm crane revolving light

K-8

A22

S

12


D-4

FB1

—

—

Fuse box

F-6

A23

SWP

12


H-5

H08

M

6


F-6

C09

DT

4

Attachment selection connector

E-8

H09

S

8


F-6

C06 SUMITOMO 16

Prolix switch

D-8

H16

M

2

Arm crane buzzer

A-6

C05

DT

3

Pressure sensor

G-6

K19

M

2

Pump prolix resistor

F-8

C10

M

2

Arm ground cancel selection

F-8

M02

X

2

Safety relay

O-3

C13

X

2

EPC valve solenoid for PC

I-8

M10 DEUTSCH

2


G-6

C14

X

2

EPC valve solenoid for LS

J-8

M11

L

2

Fusible link

L-3

CR1

DT

24

CR700 Controller

F-7

M13

DT

2

Boom work equipment lamp

G-7

CR2

DT

40

CR700 Controller

F-7

M13

M

2

Speaker (Right)

K-8

CR3

CT

40

CR700 Controller

F-7

M14

L

2

Fusible link

L-3

D01

KES

2

Window washer diode

F-5

M15

L

2

Fusible link

L-3

D05

KES

2

Swing holding brake diode F-5

M16

2

Horn

I-2

D06

KES

2

Travel speed diode

F-5

X YAZAKI M22 090

2

Horn switch

B-7

E07

X

2

Engine speed sensor

N-6

M26

SWP

12

A/C unit

E-9

D08

KES

2

Swing holding brake cancel switch diode

E-5

M28

X

2

Window washer

L-5

D14

SWP

2

Battery relay diode

L-4

M30

M

2

OPT power supply

G-3

D15

—

2

Stop solenoid diode

O-7

M31

M

2

OPT power supply

D-9

D17

KES

2

Heater relay diode

E-4

M34

X

1

Airconditioner compressor Q-7

D20

KES

2

PPC hydraulic lock diode

F-5

M36F

M

1

Kerosene mode

F-8

D22

SWP

2

Battery relay diode

L-4

M36M

M

1

Kerosene mode

F-8

20-218-2 (17)

C-2

E20

SWP

8


M-5

A-1

E30

—

—

Safety relay

N-3

PC128US-2

TROUBLESHOOTING

Connector No. M38


M


Place of use

Address

Connector No.


Address

Place of use

3

Light switch

C-8

S17

—

—

Engine hydraulic switch

R-4

M40 YAZAKI

2

Cigar lighter

A-5

S30

X

2

Right swing pressure switch

G-4

M40

M

2

Cab work equipment lamp (STD)

I-8

S31

X

2

Boom RAISE pressure switch G-5

M41

SWP

6

Arm crane monitor

A-7

S32

X

2

Arm dump pressure switch

G-5

M41

M

2

Cab work equipment lamp (OPT)

J-8

S33

X

2

Boom LOWER pressure switch

G-4

M47

090

20


B-7

S34

X

2

Bucket digging pressure switch G-5

M48

DT

6

Auto decelerator motor

L-4

S35

X

2

Bucket dump pressure switch G-5

M49

PA

9

Radio

F-7

S36

X

2


G-6

M50

M

6

Wiper motor

A-6

S37

X

2


L-4

M51

M

3

Fuel dial

B-7

S50

—

—

Emergency pumping switch D-9 D-9

M71

M

2

Room lamp

L-7

S51

—

—

Swing holding brake cancel switch

M73

M

2

Speaker (Left)

L-7

T01

—

—

Battery

L-5

M80

—

20

Airconditioner panel

F-6

T02

—

—

Revolving ground

L-4

M81

—

16

Airconditioner panel

F-6

T03

—

—

Revolving ground

L-5

M83 SUMITOMO

3

Intake duct (Airconditioner)

F-6

V04

X

2


G-7

M84

SWP

14

E-9

V05

X

2

Travel speed solenoid

G-8

M85

SWP

16

Intermediate connector (Airconditioner unit) Intermediate connector (Airconditioner unit)

E-9

V06

X

2

2-stage relief valve solenoid G-6

M87

S

12

A/C unit

C-4

V07

X

2

PPC hydraulic lock solenoid H-8

M88 YAZAKI

10

B-5

W03

M

2

Rear limit switch

K-8

M92

DT

3

Airconditioner foot spurting servo Boom cylinder bottom pressure sensor

—

X05

M

4

Swing lock switch

D-8

P01

AMP

12

Monitor panel

A-7

P02

AMP

20

Monitor panel

A-6

P03

M

2

Buzzer cancel switch

C-8

P06

X

2

Fuel level sensor

I-8 O-7

P07

X

2

Engine water temperature sensor

P15

AMP

2

Solar radiation center

F-6

R06 SINAGAWA

6

Starting motor cut relay

B-8

R07 SINAGAWA

6

Motor driven relay

B-3

R08 SINAGAWA

6

Decelerator relay

B-3

R09 SINAGAWA

6

Accelerator relay

B-3

R10 SINAGAWA

6

Revolving light driving relay

B-7

S01

X

2

Travel pressure switch

B-4

S05

X

2

Arm digging pressure switch

G-5

S08

X

2

Left swing pressure switch G-4

S10

M

3

Hydraulic lock switch

PC128US-2

E-4

20-218-3 7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DIAGRAM


20-218-4 (17)

PC128US-2


TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl The Address column in this table shows the address in the connector pin allocation drawing (3dimensional drawing). Connector No.


Address

Place of use

Connector No.

A01

L

2


L-4

A02

SWP

14


L-4

H08

A03

SWP

14


K-4


HOLD Terminal

Address

Place of use

1

Engine stop solenoid

Q-2

M

6


F-4

H09

S

8


F-4

A-6

H16

M

2

Arm crane buzzer

A-4

A06

DT

8

Intermediate connector (Arm crane)

A20

S

16


C-7

J1

SUMITOMO

20

Junction connector

F-7

A21

S

16


D-4

J2

SUMITOMO

20

Junction connector

F-6

AR

DT

3

Alternator

M-5

J3

SUMITOMO

20

Junction connector

F-6

C05

DT

3

Pressure sensor

G-8

K19

M

2

Pump prolix resistance

F-7

C06 SUMITOMO

16

Prolix switch

C-7

M02

X

2

Safety relay

H-1

C13

X

2

EPC valve solenoid (PC)

J-9

M10

DT

2


G-7

C14

X

2

EPC valve solenoid (LS)

I-9

M11

L

2

Fusible link

L-4

CR1

DT

24

CR 700 controller

F-6

M13

M

2

Boom working lamp

G-9

CR2

DT

40

CR 700 controller

F-6

M13

M

2

Speaker (Right)

K-9

CR3

DT

40

CR 700 controller

F-6

M14

L

2

Fusible link

L-4

M16

SWP

2

Horn

A-3

M22

090

2

Horn switch

B-5

M26

SWP

12

Air conditioner unit

E-7

M28

KES

2

Window washer

L-6

M30

M

2

Power source (Opt)

F-4

D01

SWP

8

Engine stop solenoid Diode  Heater relay  F-3

D02

SWP

8

Swing holding brake  Diode release, Battery relay,  F-3 Window washer 

8

2-stage ralief, PPC safety lock, Swing Diode holding brake, Travel speed selector

D03

SWP

E07

2

Engine speed sensor

M-5

M31

M

2

Power source (Opt)

D-7

E11 Terminal

1

Electrical intake air heater relay

H-1

M34

X

1

Air conditioner compressor

Q-8

E12 Terminal

1

Relay ground

H-1

M38

M

3

Light switch

B-7

E14 Terminal

1


G-2

M40 YAZAKI

2

Cigarette lighter

A-4

E17

2

Alternator

N-3

M40

M

2

Cab working lamp (STD)

H-9

E30 Terminal

1

Safety relay

H-3

M41

SWP

6

Arm crane monitor

A-6

E50 Terminal

1

Starting motor

Q-4

M41

M

2

Cab working lamp (OPT)

J-9

E51 Terminal

1


G-2

M47

090

20


B-6

E52 Terminal

1


P-9

M48

DT

6

Auto-decelation motor

L-5

EU1

M

2

Overload alarm switch

F-5

M49

PA

9

Radio

F-5

F01

DT

2

Travel and swing alarm (Opt)

H-9

M50

M

6

Wiper motor

A-5

F02

M

2

Arm crane beacon lamp

K-9

M51

M

3

Fuel dial

B-6 I-3 L-9

FB1

DT

  H-3  

X

—

GND Terminal

20-218-8 (17)

—

Fuse box

F-5

M52

DT

2

Intermediate connector (Engine stop solenoid relay)

1


Q-2

M71

M

2

Room lamp

PC128US-2


TROUBLESHOOTING

Connector No.


Place of use

Address

Connector No.


Address

Place of use

M73

M

2

Speaker (Left)

L-8

T01 Terminal

1

Battery

L-6

M80

—

20

Air conditioner panel

F-4

T02 Terminal

1

Revolving ground

L-5

M81

—

16

Air conditioner panel

F-5

T03 Terminal

1

Revolving ground

L-5

Intake duct (Air conditioner)

F-6

T04

1

Radio ground

F-5

F-5

T05 Terminal

1

Floor ground

C-3

F-7

T06 Terminal

1

Floor frame ground

B-3

D-3

T21 Terminal

1

Engine stop solenoid relay

I-1

B-3

T22 Terminal

1

Engine stop solenoid relay

I-3

M83 SUMITOMO

3

M84

SWP

14

M85

SWP

16

Intermediate connector (Air conditioner unit) Intermediate connector (Air conditioner unit)

M87

S

12

Air conditioner unit

M

M88 YAZAKI

10

PULL Terminal

1


Q-2

V03 SHINAGAWA

6

Starting motor relay

B-6

P01

AMP

12

Monitor panel

A-5

V4

DT

2

Swing holding brake solenoid valve

G-8

P02

AMP

20

Monitor panel

A-5

V5

DT

2

Travel speed selector solenoid valve

G-9

P03

M

2

Buzzer cancel switch

C-7

V6

DT

2

2-stage relief solenoid valve

G-8

P06

X

2

Fuel level gauge

I-9

V7

DT

2

PPC hydraulic safety lock solenoid

H-9

P07

X

2

Engine coolant temperature sensor P-8

V06

X

1


E-7

Airconditioner outsideair temperature sensor

E-3

V07

X

1


E-7

A-5

V08

X

1


E-7

P09

SWP

2

P15

AMP

2

R06 SHINAGAWA

6

Starting motor cutout relay

B-6

V09

X

1


E-7

R08 SHINAGAWA

6

Deceleration relay

J-3

W03

M

2

Rear limit switch

K-9

R09 SHINAGAWA

6

Accelerator relay

J-3

X05

M

4

Swing lock switch

C-7

R10 SHINAGAWA

6

Beacon lamp drive relay

B-6

S01

X

2

Drive pressure switch

C-3

S05

X

2

Arm IN pressure switch

G-6

S08

X

2

Left swing pressure switch

G-5

S10

M

3

PPC hydraulic lock switch

E-3

S17 Terminal

1

Engine oil pressure switch

N-4

S30

X

2

Right swing pressure switch

G-5

S31

X

2

Boom RAISE oil pressure switch

G-6

S32

X

2

Boom DUMP oil pressure switch

G-6

S33

X

2

Boom LOWER oil pressure switch

G-6

S34

X

2

Bucket digging pressure switch

G-6

S35

X

2

Bucket DUMP oil pressure switch

G-7

S36

X

2


G-7

S37

X

2


G-7

S50

—

—

Emergency pump drive switch

D-7

S51

—

—

Swing holding brake release switch

D-7

PC128US-2

20-218-9 (17)

TROUBLESHOOTING


CONNECTOR ARRANGEMENT DIAGRAM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

20-218-10 (17)

PC128US-2

TROUBLESHOOTING

PC128US-2


20-218-11 (17)

TROUBLESHOOTING

20-218-12 (17)


PC128US-2


CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS a The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. a Deuscht connector has marks of pin numbers on the wiring harness side. X Type Connector

Number of Pins

Male (Female housing)

Female (Male housing)

T-adapter Part Number

1

Part number: 08055-00181


799-601-7010

BWP04702

2

799-601-7020



BWP04703

3

BWP04704


BWP04705

4


799-601-7030


BWP04706

799-601-7040


—

Terminal part number: 79A-222-3370 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

Terminal part number: 79A-222-3390 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

—

—

Terminal part number: 79A-222-3380 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red

Terminal part number: 79A-222-3410 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red

—

PC128US-2

20-219 (17)


Number of Pins


SWP Type Connector Male (Female housing)

BWP04707


BWP04708

6

799-601-7050


8

BWP04709


BWP04711

12


BWP04713


BWP04710

799-601-7060


BWP04712

BWP04714

799-601-7070


(17)

799-601-7310


14

20-220



PC128US-2



SWP Type Connector

Number of Pins


BWP04715

16



BWP04716


799-601-7320


—

Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

—

—

Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red

Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red

—

PC128US-2

20-221 (17)



M Type Connector

Number of Pins




1



799-601-7080

2

BWP04717


3

BWP04719


4

BWP04721


6

BWP04723


8

BWP04725


20-222 (17)

BWP04718

799-601-7090


BWP04720

799-601-7110


BWP04722

799-601-7120


BWP04724

799-601-7130


BWP04726

799-601-7340


PC128US-2


Number of Pins

8

S Type Connector Male (Female housing)

BWP04727


10 (white)

BWP04729


12 (white)

BWP04731


16 (white)

BWP04733


PC128US-2




BWP04728

799-601-7140


BWP04730

799-601-7150


BWP04732

799-601-7350


BWP04734

799-601-7330


20-223 (17)


Number of Pins

10 (blue)


S Type Connector Male (Female housing)

BWP04735

—

12 (blue)

BWP04737


16 (blue)

BWP04739


20-224 (17)



BWP04736

—

—

BWP04738

799-601-7160


BWP04740

799-601-7170


PC128US-2


Number of Pins


MIC Type Connector Male (Female housing)



7

Body part number: 79A-222-2640 (Quantity: 5 pieces)


—

11



—

BWP04741

BWP04742

5

799-601-2710


BWP04743


BWP04744

9

799-601-2950


BWP04745


BWP04746

13

799-601-2720


PC128US-2


20-225 (17)


Number of Pins


MIC Type Connector Male (Female housing)

BWP04747


BWP04748

17

799-601-2730


BWP04749


BWP04750

21

—

20-226 (17)


799-601-2740





—

PC128US-2


Number of Pins


AMP040 Type Connector Male (Female housing)

BWP04751



BWP04752

8

799-601-7180

—

Housing part number: 79A-222-3430 (Quantity: 5 pieces)

BWP04753

BWP047544

12

799-601-7190

—


BWP04755

BWP04756

16

799-601-7210

—


BWP04757

BWP04758

20

799-601-7220

—


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

PC128US-2

20-227 (17)


Number of Pins


AMP070 Type Connector Male (Female housing)


10

799-601-7510

—

12

BWP04761

—

14

BWP04763

—

18

BWP04765

—

20

BWP04767

—

20-228 (19)


Part number: 7821-92-7330

BWP04762

799-601-7520


BWP04764

799-601-7530


BWP04766

799-601-7540


BWP04768

799-601-7550


PC128US-2


Number of Pins

2


L Type Connector Male (Female housing)

BWP04769


BWP04770

—

—

Number of Pins

9

10


BWP04771



BWP04772

—

— BENDIX (MS) Type Connector


BWP04773

—

PC128US-2

— PA Type Connector

—

Number of Pins




BWP04774

799-601-3460

—

20-229 (17)


Number of Pins


KES1 Automobile Type Connector Male (Female housing)

BWP04775


BWP04776

2

—

Part number: 08027-10210 (Natural color) 08027-10220 (Black)

3

BWP04777


BWP04779


BWP04778

BWP04780

—


BWP04781


BWP04782

6

—


(17)

—


4

20-230



PC128US-2



KES1 Automobile Type Connector

Number of Pins




BWP04784

BWP04783

8

—


Number of Pins

5


Connector for relay (Socket) Male (Female housing)

BWP04785


BWP04786

799-601-7360

—

6

BWP04787

—

BWP04788

799-601-7370

— Type (shell size code)

— F Type Connector

Pin (Male terminal)

Body (Female terminal)

4


—

—

PC128US-2


—

20-230-1 (17)



[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)


799-601-9210

18-8 (1)

Part number: 08191-11201, 08191-11202 08191-11205, 08191-11206 Pin (female terminal)

Part number: 08191-14101, 08191-14102 08191-14105, 08191-14106 Pin (male terminal)

799-601-9210



799-601-9220

18-14 (2)



799-601-9220

Part number: 08191-22201, 08191-22202 08191-22205, 08191-22206

20-230-2 (17)

Part number: 08191-23101, 08191-23102 08191-23105, 08191-23106

PC128US-2





Body (plug)

Body (receptacle)

Pin (male terminal)



799-601-9230

18-20 (3)

Part number: 08191-31201, 08191-31202 Pin (female terminal)

Part number: 08191-34101, 08191-34102 Pin (male terminal)

799-601-9230



799-601-9240

18-21 (4)



799-601-9240

Part number: 08191-42201, 08191-42202

PC128US-2

Part number: 08191-43101, 08191-43102

20-230-3 (17)





Body (plug)

Body (receptacle)

Pin (male terminal)



799-601-9250

24-9 (5)



799-601-9250



799-601-9260

24-16 (6)



799-601-9260

Part number: 08191-62201, 08191-62202 08191-62205, 08191-62206

20-230-4 (17)

Part number: 08191-63101, 08191-63102 08191-63105, 08191-63106

PC128US-2



[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)



799-601-9270

24-21 (7)



799-601-9270



799-601-9280

24-23 (8)

Part number: 08191-81201, 08191-81202, 08191-81203, 08191-81204, 08191-81205, 08191-80206 Pin (female terminal)

Part number: 08191-84101, 08191-84102, 08191-84103, 18191-84104, 08191-84105, 08191-84106 Pin (male terminal)

799-601-9280

Part number: 08191-82201, 08191-82202, 08191-82203, 08191-82204, 08191-82205, 08191-82206

PC128US-2

Part number: 08191-83101, 08191-83102, 08191-83103, 18191-83104, 08191-83105, 08191-83106

20-230-5 (17)





Body (plug)

Body (receptacle)

Pin (male terminal)



799-601-9290

24-31 (9)



799-601-9290

Part number: 08191-92203, 08191-92204 08191-92205, 08191-92206

20-230-6 (17)

Part number: 08191-93103, 08191-93104 08191-93105, 08191-93106

PC128US-2



[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

Number of Pins

Body (plug)

Body (receptacle)

2


799-601-9020

Part number: 08192-12200 (normal type) 08192-22200 (fine wire type)


3

799-601-9030



4

799-601-9040



6

799-601-9050


PC128US-2


20-230-7 (17)



[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

Number of Pins

Body (plug)

Body (receptacle)

8GR: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8BR: 799-601-9080

8

Part number: 08192-1820 T (normal type) 08192-2820 T (fine wire type)


12GR: 799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12BR: 799-601-9140

12


20-230-8 (17)



PC128US-2



[The pin No. is also marked on the connector (electric wire insertion end)] DTM Series connector

Number of Pins

Body (plug)

Body (receptacle)

2


799-601-9010



DTHD Series connector

Number of Pins

Body (plug)

Body (receptacle)

1


—

Part number:08192-31200 (Contact size #12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)

PC128US-2

Part number:08192-31100 (Contact size #12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)

20-230-9 (17)



[The pin No. is also marked on the connector (electric wire insertion end)] No. of pins

DRC26 Series connector Body (plug)

Body (receptacle)

24

799-601-9360

—

Part No.: 7821-93-3110

40 (A)

799-601-9350

—

Part No.: 7821-93-3120

40 (B)

799-601-9350

—

20-230-10 (19)

T-adapter Part No.

Part No.: 7821-93-3130

PC128US-2


T-ADAPTER TABLE

T-ADAPTER TABLE a The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker assemblies are shown in the lines.

Q Q

Q Q

—

799-601-9300

799-601-9200

799-601-9100

Q

799-601-2600

For measuring box

Econo-21P

799-601-3100

For measuring box

MS-37P

Q

799-601-3200

For measuring box

MS-37P

Q

799-601-3300

For measuring box

Econo-24P

799-601-3360

Plate

For MS box

799-601-3370

Plate

For MS box

799-601-3380

Plate

For MS box

799-601-3410

BENDIX(MS)

24P

Q Q

799-601-3420

BENDIX(MS)

24P

Q Q

799-601-3430

BENDIX(MS)

17P

Q Q

799-601-3440

BENDIX(MS)

17P

799-601-3450

BENDIX(MS)

5P

799-601-3460

BENDIX(MS)

10P

799-601-3510

BENDIX(MS)

5P

Q Q

799-601-3520

BENDIX(MS)

14P

Q Q

799-601-3530

BENDIX(MS)

19P

799-601-2910

BENDIX(MS)

14P

799-601-3470

CASE

799-601-2710

MIC

5P

Q Q

Q

Q

799-601-2720

MIC

13P

Q Q

Q

Q

799-601-2730

MIC

17P

Q Q Q Q

Q Q

Q

799-601-2740

MIC

21P

Q Q Q Q

Q Q

Q

799-601-2950

MIC

9P

Q Q Q

Q

799-601-2750

ECONO

2P

Q Q

799-601-2760

ECONO

3P

Q Q

799-601-2770

ECONO

4P

Q Q

799-601-2780

ECONO

8P

Q Q

799-601-2790

ECONO

12P

Q Q

799-601-2810

DLI

8P

Q Q

799-601-2820

DLI

12P

Q Q

799-601-2830

DLI

16P

Q Q

799-601-2840

Extension cable

Q Q

799-601-2850

CASE

Q

799-601-7010

X

1P

Q

Q

799-601-7020

X

2P

Q Q Q

Q

799-601-7030

X

3P

Q Q Q

Q

799-601-7040

X

4P

Q Q Q

Q

PC128US-2

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

Q

799-601-2900

Pin No.

799-601-2800

Connector type

799-601-2700

Port No.

799-601-2500

KIT No.

Q

Q Q Q Q Q Q

Q Q Q Q Q

Q

20-230-11 (19)


T-ADAPTER TABLE

799-601-7050

SWP

6P

Q Q Q

799-601-7060

SWP

8P

Q Q Q

799-601-7310

SWP

12P

799-601-7070

SWP

14P

—

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

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

Pin No.

799-601-2800

Connector type

799-601-2700

Port No.

799-601-2500

KIT No.

Q Q

Q Q

799-601-7320

SWP

16P

799-601-7080

M

1P

Q

Q

799-601-7090

M

2P

Q Q Q

Q

799-601-7110

M

3P

Q Q Q

Q

799-601-7120

M

4P

Q Q Q

Q

799-601-7130

M

6P

Q Q Q

Q

799-601-7340

M

8P

799-601-7140

S

8P

Q Q Q

Q

799-601-7150

S

10P-White

Q Q Q

Q

799-601-7160

S

12P-Blue

Q Q Q

799-601-7170

S

16P-Blue

Q Q Q

799-601-7330

S

16P-White

799-601-7350

S

12P-White

799-601-7180

AMP040

8P

Q

799-601-7190

AMP040

12P

Q

Q

799-601-7210

AMP040

16P

Q Q Q

Q

Q

Q Q Q

799-601-7220

AMP040

20P

Q Q Q

Q

799-601-7230

Short connector

X-2

Q Q Q

Q

799-601-7240

Case

799-601-7270

Cace

799-601-7510

070

10P

Q

799-601-7520

070

12P

Q

799-601-7530

070

14P

Q

799-601-7540

070

18P

Q

799-601-7550

070

20P

Q

799-601-7360

Relay connector

5P

Q

799-601-7370

Relay connector

6P

Q

799-601-7380

JFC connector

2P

Q

799-601-9010

DTM

2P

Q

Q

799-601-9020

DT

2P

Q

Q

799-601-9030

DT

3P

Q

Q

799-601-9040

DT

4P

Q

Q

799-601-9050

DT

6P

Q

Q

799-601-9060

DT

8P-Gray

Q

Q

799-601-9070

DT

8P-Black

Q

Q

799-601-9080

DT

8P-Green

Q

Q

Q Q Q

799-601-9090

DT

8P-Blown

Q

Q

799-601-9110

DT

12P-Gray

Q

Q

20-230-12 (19)

PC128US-2


T-ADAPTER TABLE

—

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

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

Pin No.

799-601-2800

Connector type

799-601-2700

Port No.

799-601-2500

KIT No.

799-601-9120

DT

12P-Black

Q

Q

799-601-9130

DT

12P-Green

Q

Q

799-601-9140

DT

12P-Blown

Q

Q

799-601-9210

HD30

18-8

Q Q

799-601-9220

HD30

18-14

Q Q

799-601-9230

HD30

18-20

Q Q

799-601-9240

HD30

18-21

Q Q

799-601-9250

HD30

24-9

Q Q

799-601-9260

HD30

2-16

Q Q

799-601-9270

HD30

24-21

Q Q

799-601-9280

HD30

24-23

Q Q

799-601-9290

HD30

24-31

Q Q

799-601-9310

Plate

For HD30

Q Q

Q

799-601-9320

For measuring box

For DT, HD

Q Q

Q

799-601-9330

Case

799-601-9340

Case

799-601-9350

DRC26

40P

Q

799-601-9360

DRC26

24P

Q

799-601-9410

For NE, G sensor

2P

Q

799-601-9420

For boost pressure, fuel

3P

Q

799-601-9430

PVC socket

2P

Q

799-601-9710

AMP 2-963215-1 AMP 2-963217-1 for HST controller

16P

Q

799-601-9720


16P

Q

799-601-9730


26P

Q

PC128US-2

Q Q

20-230-13 (19)

TROUBLESHOOTING

FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM

FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 This electrical system control mechanism consists of a monitor panel and a controller. The monitor panel and CR700 controller input signals each requires. On the other hand, the CR700 controller outputs necessary signals or inputs in accordance with the signals selected by the monitor panel and controls the absorption torque of the pump and the engine output.

Network information 1) Work mode (A, E, B) information 2) Auto-decelerator (ON/OFF) signal 3) Travel Hi/Lo signal 4) Coolant temperature (coolant temperature) information 5) Service code (failure code) information PC128US-2

(Monitor panel → CR700 controller) (Monitor panel → CR700 controller) (Monitor panel → CR700 controller) (Monitor panel → CR700 controller) (CR700 controller → Monitor panel)

20-231 (17)

TROUBLESHOOTING

FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up This electrical system control mechanism consists of a monitor panel and a controller. The monitor panel and CR700 controller input signals each requires. On the other hand, the CR700 controller outputs necessary signals or inputs in accordance with the signals selected by the monitor panel and controls the absorption torque of the pump and the engine output.

Network information 1) Work mode (A, E, B) information 2) Auto-decelerator (ON/OFF) signal 3) Travel Hi/Lo signal 4) Coolant temperature (water temperature) information 5) Service code (failure code) information 6) Preheating signal

20-232 (17)

(Monitor panel → CR700 controller) (Monitor panel → CR700 controller) (Monitor panel → CR700 controller) (Monitor panel → CR700 controller) (CR700 controller → Monitor panel) (CR700 controller → Monitor panel) PC128US-2

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up 1. Lamp/Gauge/Buzzer Diagnostic Function When the starting switch is turned ON, all lamps and gauges come on for about three seconds and the warning buzzer sounds for about one second. The diagnosis of the monitor panel itself is performed and normal display is performed subsequently (a burnt-out bulb can be seen in the lamp that does not come on by visual check). 2. “USER CODE” display function The abnormality information of the CR700 controller is all sent to the monitor panel. For this abnormality information having high emergency, a “USER CODE” is automatically displayed on the digital meter display portion (1) of the monitor panel as the “USER CODE” and the operator is urged to take corrective action. fl The portion other than the digital meter display portion (1), service meter display portion (2), and the point where lighting is performed ( portion in the following illustration) come out. 1) User code display (1) Digital meter display portion (2) Service meter display portion (3) Working mode selector (UP) switch (4) Working mode selector (DOWN) switch (5) Setting switch (6) Travel speed switch (7) Auto-decelerator switch (8) Buzzer cancel switch

Example) When user code [E02] is displayed:

2) User code list User code

PC128US-2

Abnormal system

E02

PC-EPC system

E03

Swing holding brake system

E05

Decelerator motor system

20-233 (17)

TROUBLESHOOTING


3. “SERVICE CODE” Display Function The abnormality information of the CR700 controller is all sent to the monitor panel. This abnormality information is all stored in the monitor panel as a “SERVICE CODE” independently of the information that needs to or does not need to display the “SERVICE CODE”). When the following operation is performed, a service code is displayed on the digital display portion of the monitor panel and “E” indicating that an abnormality is currently occurring and an elapsed time (service meter time) are displayed on the service meter display portion. 1) Service code display and cancel method (1) Use the following procedure to switch to a service code. i) Continue pressing “Buzzer cancel switch (8)” + “Auto-decelerator switch (7)” for 2.5 seconds or more. ii) Press “Buzzer cancel switch (8)” + “Working mode selector (UP) switch (3) (or “Working mode selector (DOWN) switch (4)” and set them so that “01” can be displayed on the second or third digit from the left of service meter display portion (2). iii) Press “Setting switch (5)”.

(1) (2) (3) (4) (5) (6) (7) (8)

Digital meter display portion Service meter display portion Working mode selector (UP) switch Working mode selector (DOWN) switch Setting switch Travel speed switch Auto decelerator switch Buzzer cancel switch

Example 1) When [01] is displayed on service meter display portion (2):

Example 2) When [E213] occurred six hours before: fl If it is also occurring currently, “E” is displayed on the third digit from the left of service meter display portion (2). When it is normal currently, “E” is not displayed. fl An elapsed time is displayed on the third digit from the right of service meter display portion (2).

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Example 3) If a service code is not stored, “ – “ is displayed on all digits of digital meter display portion (1) and service meter display portion (2). (2) To advance the display of a service code, press “Buzzer cancel switch (8)” + “Working mode selector (UP) switch (3)”. (3) To return the display of a service code, press “Buzzer cancel switch (8)” + “ Working mode selector (DOWN) switch (4). (4) To terminate the display of a service code, press “Buzzer cancel switch (8)” + “Autodecelerator switch (7)”. (5) To erase storage of a service code, turn “OFF” “Starting switch” once pressing “Buzzer cancel switch (8)”. Turn “ON” the “Starting switch” again and continue pressing “Buzzer cancel switch (8)” for five seconds as is. fl If service codes stored exceed 20, the smallest one is erased sequentially.

2) Service code list Service code

PC128US-2

Abnormality system

User code

E101

Incorrect description contents

—

E108

Detection of engine water temperature exceeding 105˚C

—

E112

Wiper motor driven forward rotation system short circuit

—

E113

Wiper drive reverse rotation system short circuit

—

E114

Window washer drive system short circuit

—

E115

Washing is disabled for 10 seconds

—

E116

Storage is disabled for 10 seconds

—

E203

Swing holding brake solenoid system short circuit

E205

2-stage relief solenoid system short circuit

—

E206

Travel Hi/Lo selector solenoid system short circuit

—

E213

Swing holding brake solenoid relay system disconnection

E215

2-stage relief solenoid system disconnection

—

E216

Travel Hi/Lo selector solenoid system disconnection

—

E218

S-NET communication error

—

E222

LS-EPC system short circuit

E02

E223

LS-EPC system disconnection

E02

E03

E03

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Service code

20-236 (17)

Abnormality system

User code

E224

Pump pressure sensor system error

—

E226

Pressure sensor system power failure

—

E227

Engine speed sensor system error

—

E232

PC-EPC solenoid system short circuit

E02

E233

PC-EPC solenoid system disconnection

E02

E241

Boom angle potentiometer system error (beyond input value range)

—

E242

Arm angle potentiometer system error (beyond input value range)

—

E255

Boom angle potentiometer corrected value error (beyond correction value range)

—

E256

Checksum error

—

E306

Feedback potentiometer system error

—

E308

Fuel dial input value error

E315

Battery relay output short circuit abnormality

—

E316

Decelerator motor out of order abnormality

—

E317

Decelerator motor system disconnection abnormality

E05

E318

Decelerator motor system short circuit abnormality

E05

E05

PC128US-2

TROUBLESHOOTING


4. “MONITORING CODE” Display Function Input signals from sensors into each component and output signals that drive solenoids can be checked in real time using a monitoring code. When the following operation is performed, a 4-digit monitoring code No. is displayed on the second to fifth digit from the left of service meter display portion (2) of the monitor panel and monitoring information is displayed on digital meter display portion (1).

1) Monitoring code display method (1) Use the following procedure to switch to a monitoring code. i) Continue pressing “Buzzer cancel switch (8)” + “Auto decelerator switch (7)” for 2.5 seconds or more. ii) Press “Buzzer cancel switch (8)” + “Working mode selector (UP) switch (3) (or “Working mode selector (DOWN) switch (4))” and set them so that “02” can be displayed on the second or third digit from the left of service meter display portion (2). iii) Press “Setting switch (5)”.

(1) (2) (3) (4) (5) (6) (7) (8)


Example 1) When monitoring code 1010 (engine speed: 2,050 rpm) displayed using a numeral is displayed:

Example 2) When monitoring code 1020 (switch input state (1)) displayed using a bit pattern is displayed:

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(2) To advance the display of a service code, press “Buzzer cancel switch (8)” + “Working mode selector (UP) switch (3)”. (3) To return the display of a service code, press “Buzzer cancel switch (8)” + “ Working mode selector (DOWN) switch (4). (4) To terminate the display of a service code, continue pressing “Buzzer cancel switch (8)” + “Auto-decelerator switch (5) for 2.5 seconds or more”. 2) Monitoring code list fl For details of the code displayed in the unit column as “(6 bits)”, refer to the bit pattern list. Display code 0008 0041 0042 0043 0045 0046 0047 0048 0049 0200 1000 1001 1002 1003 1004 1016 1027 1028 1036 1061 1010 1020 1021 1022 1023 1024 1025 1026 1030 1032 1034 1035 1040 1042 1050 1054 1060

Description S-NET connected state Water temperature sensor voltage Fuel sensor voltage Charge voltage Sensor input 1 Sensor input 2 Output state Wiper state Reserved Program version (Monitor) Software version No. Attachment selection Model selection Attachment code (*1) Option selection state (*1) Second throttle command (*1) ON/OFF input 5 (*1) ON/OFF input 6 (*1) Power supply voltage (*1) ON/OFF output (*1) Engine speed ON/OFF input 1 ON/OFF input 2 ON/OFF input 3 ON/OFF input 4 ON/OFF input and output ON/OFF input and output ON/OFF input and output Work equipment angle sensor voltage First boom Work angle sensor voltage Arm Fuel dial voltage Feedback potentiometer voltage Boom bottom voltage Pump pressure EPC output current PC-EPC EPC output current LS-EPC ON/OFF output

Unit

Component name

(6bit) × 10 mV × 10 mV × 100 mV (6bit) (6bit) (6bit) (6bit) (6bit) — — — — — (6bit) rpm (6bit) (6bit) V (6bit) rpm (6bit) (6bit) (6bit) (6bit) (6bit) (6bit) (6bit) V V V V MPa MPa × 10 mA × 10 mA (6bit)

CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller CR700 controller

(*1) PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

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3) Bit pattern list (The bit of the corresponding No. comes on.) fl [1] to [6] of digital display portion (1) indicate a bit No. fl A monitoring code No. (four digits) is displayed on the second to fifth digit from the left of service meter display portion (2).

Code No.

Item

0008

S-NET connected state

0045

Sensor input 1

0046

Sensor input 2

0047

Output state

0048

Wiper state

0049

Standby

PC128US-2

Bit [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6]

Detailed description (state when a bit comes on) At ID2 connection At ID3 connection At ID4 connection At ID5 connection At ID6 connection At ID7 connection Starting switch “ON” (ON) Starting switch “Start” (Start) (ON) Starting switch “Preheat” (ON) Light switch (ON)

Engine oil pressure Engine oil level

(At OPEN time) (At OPEN time)

Charge level Buzzer output

(At decrease time) (ON)

Washer output Wiper output 1 Wiper output 2 Wiper output 3 Wiper output 4 Swing lock switch Buzzer cancel switch Widow limit switch W contact P contact

(ON) (ON) (ON) (ON) (ON) (ON) (ON) (ON) (ON) (ON)

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Code No.

1004

Item

Option selection

1020

ON/OFF input 1

1021

ON/OFF input 2

1022

ON/OFF input 3

1023

ON/OFF input 4

1024

ON/OFF input and output

1025

1026

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Bit [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6]

Detailed description (state when a bit comes on) Arm crane mounting

(*1)

Arm ground angle warning cancel

(*1)

ATT selection 2 ATT selection 1 Model selection 1 ATT selection 3 UU/US selection Model selection 2

(At GND connection) (At GND connection) (At GND connection) (At GND connection) (At GND connection) (At GND connection)

Arm crane mounting

(At power supply connection)

Kerosene mode Travel selector switch (Panel) Working mode selector switch Back lamp SET/CLEAR switch Mode selector (∆) switch Mode selector (∇) switch

(At GND connection)

Another work equipment mode selector switch (ON) Travel pressure switch (ON) Swing pressure switch (ON) Arm digging pressure switch (ON) Boom RAISE pressure switch (ON)

Motor-driven power supply

(*1)

Motor relay (–) Motor relay (+) Crane mode switch [monitor] Display selector switch [monitor] Arm ground angle warning cancel switch (At connector connection)

Bucket dump inhibition solenoid + Patlight (At relay output) Warning cancel

(For EU)

PC128US-2


TROUBLESHOOTING

Code No.

1027

1028

1060

1061

PC128US-2

Item

ON/OFF input 5

ON/OFF input 6

ON/OFF output

ON/OFF output

Bit [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6]

Detailed description (state when a bit comes on)

Preheating signal

(*1)

C-terminal signal

(*1)

Arm OUT pressure switch Service pressure switch Bucket digging pressure switch Bucket DUMP pressure switch

(*1) (*1) (*1) (*1)

Swing holding brake

(At brake release)

Travel 2nd speed Travel or swing alarm 2-stage relief

(At travel 2nd speed) (At alarm output) (At travel pressure switch ON)

Heater relay

(*1)

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5. “WORKING MODE DEFAULT” Setting Function When the normal starting switch is turned ON, the “WORKING MODE” of the monitor panel is set so that Mode A can come out. If the following procedures are used to use the default setting function, the setting can be changed so that startup can be performed in the “WORKING MODE” in accordance with the choice of the operator.

1) Default setting operation procedures (1) Use the following procedure to switch to the default setting mode. i) Continue pressing “Buzzer cancel switch (8)” + “Auto-decelerator switch (7)” for 2.5 seconds or more. ii) Press “Buzzer cancel switch (8)” + “Working mode selector (UP) switch (3) (or Working mode selector (DOWN) switch (4))” and set them so that “05” can be displayed on the second or third digit from the left of service meter display portion (2). iii) Press “Setting switch (5)”. fl “d SET” is displayed on service meter display portion (2) and indicator (10) of the mode set as a default value flashes. (2) To change (move) the default setting mode, i) press “Working mode selector (UP) switch (3) (or Working mode selector (DOWN) switch (4))”. ii) Press “Setting switch (5)”.

(1) (2) (3) (4) (5) (6) (7) (8)


(3) To terminate the default setting mode (default setting mode completion), continue the “Buzzer cancel switch (8) + “Auto-decelerator switch (7)” for 2.5 seconds or more. fl When the starting switch is turned OFF in the normal mode LED flashing state (default setting mode), the contents of the working mode default are not changed.

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(4) Confirmation method after working default setting i) Check that the LED is changed to normal lighting. ii) Turn OFF the starting switch and turn on the starting switch again. iii) Check that the working mode default is changed to the setting state.

6. Decelerator Motor Adjustment Mode PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 This mode is used to adjust the decelerator motor and the injection pump linkage. fl For details, refer to the “TESTING AND ADJUSTING DECELERATOR MOTOR LEVER STROKE” of Testing and Adjustment Volume. 1) Decelerator motor adjustment mode display method (1) Use the following procedure to switch to the Decelerator motor adjustment mode. i) Continue pressing “Buzzer cancel switch (8)” + “Auto-decelerator switch (7)” for 2.5 seconds or more. ii) Press “Buzzer cancel switch (8)” + “Working mode selector (UP) switch (3) (or Working mode selector (DOWN) switch (4))” and set them so that “03” can be displayed on the second or third digit from the left of service meter display portion (2). iii) Press “Setting switch (5)”. ii) fl “GOV” is displayed on digital display portion (1) and “GSET” is displayed on service meter display portion (2).

(1) (2) (3) (4) (5) (6) (7) (8)

Digital meter display portion Service meter display portion Working mode selector (UP) switch Working mode selector (DOWN) switch Setting switch Travel speed switch Auto-decelerator switch Buzzer cancel switch

(2) To terminate the display of a service code, continue pressing “Buzzer cancel switch (8)” + “Auto-decelerator switch (7) for 2.5 seconds or more”.

PC128US-2

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7. Governor motor adjustment mode PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl Use this mode to set the engine governor lever fully. fl Set the deceleration motor cable to the engine high idling position (to the shortest position). fl When the starting switch is turned ON, if this mode is not selected, the governor motor may not operate. Reference If a short circuit or a grounding fault occurs in the circuit of the governor motor control system, the cable may move out of the normal control range. At this time, even if the cause of the trouble is removed, the governor motor cannot be controlled. If this occurs, operate the panel switch in this mode to return the cable into the normal control range to restore the governor motor control. No. Operation 1 1) Turn the starting switch ON and set the fuel control dial to the FULL position. At this time, turn the automatic decelerator (one-touch decelerator) OFF (reset it).

Display

2) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds. 3) Set the code in the service meter section to "03". (8) + (3): Next code (8) + (4): Previous code

[GOV] is displayed on display portion (1), [GSET] is displayed on service meter portion (2).

4) Press switch (5). * Under this condition, the deceleration motor cable is at the engine high idling position (It becomes shortest). 2 Use this function for only above purpose (2). (Do not use this function usually.) Be sure to remove the cause of the trouble before using this function. 5)-1 When engine speed does not rise from low idling Press switch (3) several times and operate the fuel control dial to check that the governor control is restored. 5)-2 When engine speed does not lower from high idling Press switch (4) several times and operate the fuel control dial to check that the governor control is restored. 3 To finish the governor motor adjustment mode, perform the operation in 1-2), and the monitor panel displays normally.

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8. Boom Angle Potentiometer Correction Mode (Only at Arm Crane) This mode is used to adjust the boom angle potentiometer. 1) Boom Angle Potentiometer Correction Mode display method (1) Use the following procedure to switch to the boom angle potentiometer correction mode. i) Continue pressing “Buzzer cancel switch (8)” + “Auto decelerator switch (7)” for 2.5 seconds or more. ii) Press “Buzzer cancel switch (8)” + “Working mode selector (UP) switch (3) (or Working mode selector (DOWN) switch (4))” and set them so that “06” can be displayed on the second or third digit from the left of service meter display portion (2). iii) Press “Setting switch (5)”. fl Check that “1 SET” is displayed on service meter display portion (1) (the central three segments of digital display portion (1) flash).

(1) (2) (3) (4) (5) (6) (7) (8)


(2) Use the following procedure to adjust the boom angle potentiometer correction mode. i) After switching to the mode of item i), start the engine and operate “Boom” to the RAISE side stroke end. fl “ --” (correctable range) or “---” (uncorrectable range)” flashes on the digital display portion. fl For the correctable range, because incorrect mounting of the boom angle potentiometer is assumed, check it. ii) Press setting switch (5) for three seconds or more. fl The same item as item i) flashes on digital meter display portion (1).

PC128US-2

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iii) When normal adjustment can be made (when the boom angle belongs to a theoretical value, “ ” is displayed on digital meter display portion (2) for five seconds and processing returns to item i) (boom angle potentiometer correction mode). fl When correction was disabled, “---” flashes (buzzer sounds five times) on digital portion (2) and processing returns to item i). fl If correction is impossible, because incorrect mounting of the boom angle potentiometer is assumed, check it.

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

1) Display of oil maintenance function (1) The oil maintenance display mode is automatically displayed when the setting time exceeds “minus 10 hours” as described above. (2) To terminate the oil maintenance function (within 20 seconds after the starting switch is turned ON), pressing setting switch (5) short returns to the normal display mode. Example) When the oil replacement interval setting of 250 hours and the elapsed time of 245 hours after oil is replaced are displayed:

PC128US-2

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

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(1) (2) (3) (4) (5) (6)

Digital meter display portion Service meter display portion Working mode selector (UP) switch Setting switch Travel speed switch Auto-decelerator switch

PC128US-2

TROUBLESHOOTING


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

PC128US-2

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TROUBLESHOOTING

10. Setting model and attachment Set the specification of machine model and attachment. (PC128US with standard arm does not need this setting) No. Operation 1 1) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds. 2) Set the code in the service meter section to "19". (8) + (3): Next code (8) + (4): Previous code 3) Press switch (5).

Display Display section displays "10" and service meter section displays "19SET". (If 19SET has been set, current set value is displayed in display section.) Display

Service meter

2 1) Set the value in the display section to a desired value. Set value

Model

ATT

Remarks

10

PC128US

Standard arm

Controller default

11

PC128US

Long arm

20

PC138US

Standard arm

21

PC138US

Long arm

(8) + (3): Next code (8) + (4): Previous code

When PC138US long arm is selected

Display

After switch (5) is pressed, display section displays "000", and then "---"

2) Press switch (5). Display

3 1) To finish selection of model and attachment Perform the operation in 1-(1), and the monitor panel displays normally. After setting 18SET and 19SET, be sure to turn the starting switch OFF once. This setting becomes effective only after the starting switch is turned OFF once.

B: The buzzer cancel switch is installed on the right console.

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11. Service adjustment This service adjustment is set for adjustment of dispersion of components and parts and for replay to requests of each user. Perform this adjustment for the following phenomena and users' requests. fl Basically, the following items do not need to be adjusted, since they are adjusted when delivered. fl This service adjustment is not effective when a component or a part is broken. 1) Service adjustment items table The phenomena of the machine which need service adjustment, procedure for changing the set values, and precautions are listed. fl Usually, each adjustment value is set to the initial value. Adjustment Phenomenon of machine/ Procedure for changing Precautions code/set value Users' request set value Engine speed lowers Change set value to 204 Adjust to degree that work largely during work. decrease pump absorp- equipment cycle time is not tion torque. lengthened.

Service adjustment item Adjustment of PC-EPC valve current

Work equipment speed is low.

Change set value to increase pump absorption torque.

Adjust to degree that engine speed is not lowered largely. Alarm sounds when machine travels or swings.

Travel/Swing alarm output (If travel alarm is installed)

210

Set for each user who wants to sound alarm during swinging.

Set to 211.

Adjustment of LS-EPC valve current

264

Engine speed lowers largely during work.

Change set value to Adjust to degree that work decrease pump absorp- equipment cycle time is not tion torque. lengthened. fl Perform this when adjustment with PC-EPC valve current is insufficient. fl Even if LS-EPC valve current is not increased even if adjusted toward positive (+) side.

310

• Change fuel. • When kerosene is used, engine speed lower largely.

310: Diesel fuel

Low idling speed is remarkably high.

Set to (–) side.

Low idling speed is remarkably low.

Set to (+) side.

Type of fuel

*

Adjustment of low idling speed *

324

Adjustment of arm crane mode speed *

334

Adjustment of Emode speed *

344

Adjustment of Bmode speed *

White smoke prevention logic (Air heater relay output)

Initialization of set values (Only contents of service adjustment)

311: Kerosene * Since the low idling speed is set by the governor stopper, it does not change under normal condition.

Arm crane idling speed Set to (–) side. is remarkably high. Arm crane idling speed Set to (+) side. is remarkably low.

354

810

400

E-idling speed is remarkably high.

Set to (–) side.

E-idling speed is remarkably low.

Set to (+) side.

B-idling speed is remarkably high.

Set to (–) side.

B-idling speed is remarkably low.

Set to (+) side.

Set for each user who cares white smoke when engine is started at low temperature.

Change set value so that air heater will operate automatically after engine is started.

* If the B-mode speed is heightened, it is set near the high idling speed and the auto-decelerator may not operate normally. fl Since air heater consumes much current, battery can be dead. Teach user to so operate machine that battery will be charged sufficiently.

If 401 is selected, all service adjustment items are set to initial values.

* The engine speed adjustment is an auxiliary adjustment method. (1) Check the installation condition of the governor cable. (2) Check the condition of the governor cable motor.

PC128US-2

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HOW TO READ DECISION LIST

HOW TO READ DECISION LIST PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up This decision list is a tool (decision table) for selecting whether a nature of trouble of a chassis is caused by an electrical system failure or a hydraulic or mechanical failure and advancing to troubleshooting codes (N, E, S, C, F, H, M) that match each event. The decision table identifies that processing should advance to which troubleshooting codes according to the presence of the display of user and service codes. fl The abnormality display (warning) using the monitor panel directly advances to machine monitor troubleshooting code (M). (Refer to the machine monitor system troubleshooting.) 1. CR700 Controller (Decelerator Control System) or Engine Related Decision List • When a service code is displayed on the monitor panel, advance to troubleshooting code (E) of the lowermost step of the decision table. (A is marked to the point where a failure mode and a service code match.) • If a service code is not displayed and a nature of trouble appears in the monitor panel, advance to diagnostic code (Eor S) at the right end which matches the failure mode of the decision list. Failure mode “Engine does not start” [Procedure] Test that a service code is displayed on the monitor panel. Controller (Decelerator Control System) or Engine-Related Decision List

[Decision] 1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700 controller (decelerator control) system “E3: ”. 2) When a service code is not displayed on the monitor panel and “ENGINE DOES NOT START”: When the starting motor rotates: • Check the rotation .... Advance to MECHANICAL SYSTEM TROUBLESHOOTING “S-2”. of a starting motor. When the starting motor does not rotate: .... Advance to ELECTRICAL SYSTEM TROUBLESHOOTING “E-8”.

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HOW TO READ DECISION LIST

2. CR700 Controller (Pump Control System) or Oil Pressure Related Decision Table • When a service code is displayed on the monitor panel, advance to the troubleshooting code (C) of the lowermost step of the decision table. (A is marked to the point where a failure mode and a service code match.) • If a service code is not displayed and a nature of trouble appears in the monitor panel, check the display of an input signal that matches the failure mode of the decision table (display the location marked with a circle ( )) and • When an input signal is displayed normally, advance to the diagnostic code (H) at the right of the decision list. • When an input signal is not displayed, advance to the diagnostic code (F) at the lowermost step of the decision list. Failure mode “Swing is not performed” [Procedure] Test that a service code is displayed on the monitor panel. CR700 Controller (Pump Control System) or Oil Pressure-Related Decision Table

[Decision] 1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700 controller (decelerator control) system “E2: ”. 2) When a service code is not displayed on the monitor panel and “SWING IS NOT PERFORMED”: When the signal is provided: • Check a CR700 controller .... Advance to MECHANICAL SYSTEM TROUBLESHOOTING input signal. “H-25”. (Check it in the monitorWhen the signal is not provided: ing mode.) .... Advance to the CR700 CONTROLLER INPUT SIGNAL SYSTEM TROUBLESHOOTING “F”. PC128US-2

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METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up 1. Classification of Diagnostic Code No. Diagnostic code No.

Troubleshooting device

Service code

N-cc

Communication system troubleshooting

—

E-cc

CR700 controller (decelerator control system) troubleshooting

C-cc

CR700 controller (pump control system) electrical system troubleshooting E2-cc system

F-cc

CR700 controller (input signal system) troubleshooting

—

H-cc

Hydraulic, mechanical system troubleshooting

—

M-cc

Machine monitor system troubleshooting

E3-cc system

E1-cc system

2. How to Read Troubleshooting (Method) Every Failure Mode 1) Title column The title column of troubleshooting describes a troubleshooting code, service code, and failuremode (nature of trouble). 2) Itemization Even for the same nature of trouble, if the method of this diagnosis depends on a model, device, or event, the contents of the nature of trouble is subdivided into a) to ?. ([2] of the example). (This is called itemization.) Select and execute the corresponding troubleshooting. If no itemization is performed, advance troubleshooting from the beginning of the nature of trouble. 3) How to advance troubleshooting YES

•

As a result of testing or measuring YES NO of , advance to the next step by NO advancing one branch of either YES or NO. (Note: The No. described in the upper right-hand is a serial number, but not a No. showing a procedure.) corners of • If the branch of YES or NO as the result of testing or measurement is directly coupled with a cause, the cause is referred to and the corrective action at the right is executed. ([3] of the example) • When the testing or measuring method and decision value in the lower column of matches the decision value and questionnaires in the lower column of described, NO is applied if they deviate from the YES decision value and are not matched. • Regarding the preparatory work and decision value necessary for testing or measurement in the lower column of the nature of trouble, because the preparatory work may be ignored and the operation or handling method be mistaken or equipment be damaged, read them well before testing or measurement starts and advance the work. 4) General precautions To advance the failure mode (nature of trouble), all common precautions ([4] of the example) are marked with a fl next to the title.Because the precautions marked with a fl are omitted in , be sure to execute them at the testing of . 5) Diagnostic tools To advance this diagnosis, prepare the necessary diagnostic tools referring to the TESTING OR ADJUSTING AND TROUBLESHOOTING EQUIPMENT LIST and advance the work.

20-254 (17)

PC128US-2

TROUBLESHOOTING


6) Device locations and pin numbers For the testing or measuring locations of wiring connector CN cc and connector pin numbers shown in the flow of this diagnosis, advance the work referring to the connector type, mounting locations, and connector pin No. table.

[1] M-12 When the starting switch is set to ON (the engine stopped), precautions and emergency stop items flash. (But “Battery” and “Engine oil pressure” do not come on.) [4] fl Inspect both the alternator system and the engine hydraulic system. [2] a) Alternator system

  Itemization of a) and b) b) Oil pressure sensor system 

[3]

Cause

Remedy

1 • Disconnect the terminal R. • Set the starting switch to ON. • 1V max.

Is the voltage between the alternator R and the machine body normal?

NO

Defective alternator

Replace

Hot short-circuit of harness between P02 (female) (11) and alternator R

Repair or replace

Defective monitor panel

Replace

YES

2 • Disconnect P02. • Set the starting switch to ON. • 1V max.

Is the voltage between P02 (11) and the machine body normal?

NO

YES

PC128US-2

20-255 (17)

DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT TROUBLESHOOTING

TROUBLESHOOTING

DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT TROUBLESHOOTING PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up When an abnormality occurred diagnosis advances in accordance with the decision table CR700 controller (decelerator control system) or CR700 controller (pump control system) that correspond to the contents of a failure. However, refer to this flow for the detailed diagnostic contents or procedure. Further, for the diagnosis, ask the operator of detailed questions as much as possible and check the following items previously. [1] connected state of the controller (check using monitoring codes 0200, 1000, 1001, 1002, 1003*, 1004*), [2] fuse blown, [3] power generation (charge input) voltage (monitoring *: PC138US-2 Serial No.: 4501 and up code 0043). PC138USLC-2 Serial No.: 1501 and up Besides, the confirmation procedures of the testing items No. 3 and 4 in the following flow are described on the next page and later pages. YES

E02 (PC-EPC system) E03 (Swing holding brake system) E05 (Governor motor system)

To item 2

1 Is service code of monitor panel displayed?

YES

E2: Troubleshooting (C mode) of CR700 controller (pump control system) at the number level of cc E3: Troubleshooting (E mode) of CR700 controller (decelerator control system) at the number level of cc

5 YES

Is engine electrical YES system without display of failure 4 code normal?

2 Is service code of monitor panel NO displayed?

Engine system or YES hydraulic (mechanical) system?

• Check service code by performing operation

3

Is input and output signal of governor NO pump controller normal?

• Check it by monitoring

Diagnose in the corresponding mode Diagnose engine main unit (S mode)

Diagnose engine electrical system (E mode) (flow without • Flow of part without NO display) decision table abnormality display

Diagnose by hydraulic (mechanical) system • Decide system from engine speed after NO (H mode) hydraulic adjustment • Is all working equipment slow and does engine speed decrease at heavy load? Diagnose by input signal system (F mode)

NO

fl Decide the details in accordance with the CR700 controller (decelerator control system) (pump control system) decision table.

20-256 (17)

PC128US-2


TROUBLESHOOTING

For an output signal of the monitor panel, if there is no abnormality display of a communication system sent by S-NET, it may be decided that the output signal is sent. When there is no abnormality display, perform testing directly, such as an incorrect operation, according to the following points.Besides, whenan abnormality occurred in the S-NET system, note diagnosis because the default mode is automatically switched as shown below.

Default Mode When Communication Between Monitor Panel and Governor Pump Controller is Disabled Setting mode

Pump control side

Governor control side

1

Working mode

E mode

E mode

2

Throttle signal

E mode or equivalent

E mode or equivalent

3

Auto decelerator

ON (Decelerator mode)

ON (Decelerator mode)

4

Immersion signal

Recognized to be below 30˚C

Recognized to be below 30˚C

5

Travel speed

Lo

6

Automatic warm-up

— —

ON (Automatic warm-up mode)

1. Confirmation Points of Monitor Panel Output Signal fl For the monitoring mode operation method, refer to “Monitor Panel Display and Special Function” 1) Component connected state (1) Set the monitoring mode and display monitoring code “08”. (2) The state indicates that the connected component comes on in the clock display portion (bit). fl [1], [2], and [3] come on. 2) Confirmation of working mode signal (1) Set the monitoring mode and display monitoring code “10”. (2) Switch the working mode as shown in Table 1 and check the change of the engine speed.

Table 1 Working mode A

E

B

Arm crane

PC128US-2

Operation

Engine speed (no load maximum speed) (rpm)

Work equipment

About 2,400

Travel

About 2,400

Work equipment

About 2,200

Travel

About 2,200

Work equipment

About 2,000

Travel

About 2,000

Work equipment

About 1,500

Travel

About 1,500

20-257 (17)


TROUBLESHOOTING

3) Confirmation of Travel Speed Selector Signal (1) Set the monitoring mode and display monitoring code “1060”. (2) Check that the travel speed selector switch Hi, engine of 1,500 rpm or more, travel Hi travel bit [4] comes on (or comes out). (ª): The bit is ON (bit (4) comes on) above 27.46 MPa {280 kg/cm2} when the oil pressure rises and is OFF (bit [4] comes out) below 15.69 MPa {160 kg/cm2} when the oil pressure falls. 2. Confirmation of CR700 Controller Input Signal fl Check the input signal of each controller according to the following procedure. • Pump control system 1) Confirmation of input signal (1) Testing of hydraulic switch i) Set the monitoring mode and display monitoring code “1023”. ii) Operate each work equipment lever and check the lighting state of a bit pattern. fl For the bit pattern list, refer to the monitor panel display and special functions. (2) Testing of speed center (test it with an engine speed) i) Set the monitoring mode and display monitoring code “1010”. ii) Change the speed by the fuel dial and measure the engine speed at that time. (3) Testing of pump discharge pressure sensor i) Set the monitoring mode and display monitoring code “1042”. fl When the display is “24.0”, it indicates that the pressure is 24 MPa. ii) Measure the oil pressure of the pump. (4) Testing of kerosene mode input signal i) Set the monitoring mode and display monitoring code “1021”. ii) Ground the CR700 controller connector CR2 [6] to the GND and check that the bit [6] comes on. 2) Confirmation of output signal (1) Testing of LS-EPC solenoid output current i) Set the monitoring mode and display monitoring code “1054”. ii) When all levers are neutral and set in the A mode, measure the engine full current value. fl When all levers are neutral: 900 ± 100 mA ⇒ Refer to the monitor display example. At engine full and lever operation (other than travel): 0 A (2) Confirmation of the ON ←→ OFF solenoid state i) Set the monitoring mode and display monitoring code “1060”. ii) Referring to Table 3, check that the corresponding bit comes on. Table 3 Solenoid Type and Operating Condition Solenoid name

Operating condition

Bit that comes ON

Swing holding brake

Either swing or operating equipment lever operation

Monitor code “1060” [1]

Travel Hi/Lo

Fuel dial above 1,500 rpm and travel speed switch Hi and travel switch ON and travel Hi rotation


2-stage relief

At travel lever operation


Note 1: Perform the lever operation slightly in such degree that the machine cannot move.

20-258 (17)

PC128US-2

TROUBLESHOOTING


• Engine throttle Control System 1) Confirmation of Input Signal (1) Testing of fuel dial input voltage i) Set the monitoring mode and display monitoring code “1034”. ii) Measure the voltage when the fuel dial is rotated from low idle to high idle. fl The voltage is 0.3 to 4.3 V. (2) Testing of decelerator potentiometer voltage i) Set the monitoring mode and display monitoring code “1035”. ii) Measure the potentiometer voltage when the fuel dial is rotated from low idle to high idle. fl The voltage at auto decelerator OFF. : 2.15 – 4.55 V PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 : 2.67 – 4.55 V PC138US-2 Serial No.: 9501 and up PC138USLC-2 Serial No.: 1501 and up 2) Confirmation of Output Signal (1) Confirmation of decelerator motor driving signal i) Set the monitoring mode and display monitoring code “1024”. ii) Check that bit [3] comes on when the fuel dial is rotated to the directions of the engine speed “Acceleration” and “Deceleration”.

PC128US-2

20-259 (17)

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

PC128US-2 Serial No.: 5001 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM ....... 20-301-1 RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM ......................................... 20-302 E-1 Abnormality in PC-EPC system ...................................................................................................... 20-310 a) Speeds of all work equipment, travel, swing are slow or lack power .................................... 20-311 b) There is excessive drop in engine speed, or engine stalls ...................................................... 20-312 E-2 Abnormality in PPC lock solenoid system ..................................................................................... 20-318 a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move .......... 20-318 b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move .............. 20-318 E-3 Abnormality in swing lock solenoid system ................................................................................. 20-322 a) Even when swing lock switch is turned OFF, upper structure does not swing ...................... 20-322 b) Even when swing lock switch is turned to LOCK, upper structure swings ............................ 20-323 E-4 Abnormality in travel speed solenoid system ............................................................................... 20-326 a) Even when travel speed selector switch is turned to Hi, travel speed does not change to high speed .................................................................................................. 20-326 b) Even when travel speed selector switch is turned to Lo, travel speed does not change to low speed ................................................................................................... 20-326 E-5 Trouble in automatic travel speed control system ........................................................................ 20-329 a) Main pump pressure sensor system ......................................................................................... 20-329 b) Engine speed sensor system ...................................................................................................... 20-329 E-6 Abnormality in engine starting system ......................................................................................... 20-334

PC128US-2

20-301 (17)

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM PC-EPC SYSTEM PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

PPC LOCK SOLENOID SYSTEM PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

20-302 (17)

PC128US-2

TROUBLESHOOTING


SWING LOCK SOLENOID SYSTEM PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

TRAVEL SPEED SOLENOID SYSTEM PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

PC128US-2

20-303 (17)

TROUBLESHOOTING


AUTOMATIC TRAVEL SPEED CONTROL SYSTEM PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

20-304 (17)

PC128US-2

TROUBLESHOOTING


ENGINE STARTING SYSTEM PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

PC128US-2

20-305 (17)

TROUBLESHOOTING


PC-EPC SYSTEM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

PPC LOCK SOLENOID SYSTEM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

20-306 (17)

PC128US-2

TROUBLESHOOTING


TRAVEL SPEED SOLENOID SYSTEM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

SWING LOCK SOLENOID SYSTEM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

PC128US-2

20-307 (17)

TROUBLESHOOTING


RELATED ELECTRICAL CIRCUIT DIAGRAM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

20-308 (17)

PC128US-2

TROUBLESHOOTING


ENGINE STARTING SYSTEM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

PC128US-2

20-309 (17)

TROUBLESHOOTING

E-1

E-1 Abnormality in PC-EPC system PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 Items to check on LED display of pump controller when this failure mode occurs • For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps. However, remove the protective cover of the pump controller at the rear of the operator’s compartment, and use a mirror to check. 1. Content of display 1) When normal • LED lights up. 2) When there is abnormality in power supply voltage • Output stops, LED goes out. 3) When PC-EPC solenoid output is short circuited [when C01 (13) - PC-EPC solenoid C13 (1) is short circuited] • Output stops, LED flashes. (See display pattern a). 4) When there is abnormality in machine model selection • LED flashes. (See display pattern c). Note : When kerosene mode selector switch (terminal) is connected, ignore the flashing and carry out troubleshooting. 5) When there is disconnection in speed sensor [when there is abnormal voltage at C01 (2), (3)] . Output is made same as when engine speed is minimum, LED flashes. (See display pattern d). Note : When engine speed becomes abnormally low, LED does not flash. 6) When there is disconnection in PC-EPC solenoid output [when there is disconnection between C01 (13) - PC-EPC solenoid C13 (1)] • LED flashes. (See display pattern b). 2. Display ( : ON, : OFF) 1) Display pattern a (method of re-enaction: pattern below is repeated when starting switch is ON) (ON for 0.5 seconds, then OFF for 2.0 seconds) 2) Display pattern b (method of re-enaction: pattern below is repeated when starting switch is ON) (ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds) 3) Display pattern c (method of re-enaction: pattern below is repeated when starting switch is ON)

(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds) 4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)

(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds) 5) If more than one of the above failures occurs at the same time, the above patterns a to d are repeated. Note : indicates ON for 0.1 second, indicates OFF for 0.1 second.

20-310 (17)

PC128US-2

E-1

TROUBLESHOOTING

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. a) Speeds of all work equipment, travel, swing are slow or lack power

Cause

Is resistance YES between C05 (female) (4) and 3 chassis ground normal?

Is resistance between C13 YES (female) (1) - (2), between (1)(2) chassis ground normal? • Between C13 2 (female) (1) - (2) : NO Is resistance 500 - 1000 Ω between C01 • Between C13 YES (female) (3) - (4), (female) (1)(2) - chassis ground : between (3)(4) Min. 1 MΩ chassis ground • Turn starting switch OFF. normal? • Disconnect C01. • Between C01 5 YES (female) (3) - (4) : Is resistance 500 - 1000 Ω between E07 • Between C01 (female) (1) - (2), (female) (3)(4) chassis ground : NO between (1)(2) chassis ground Min. 1 MΩ normal? 1 • Turn starting switch OFF. • Between C01 NO • Disconnect C01. (female) (3) - (4) : Does LED of pump 500 - 1000 Ω controller flash? • Between C01 (female) (3)(4) - chassis ground : Min. 1 MΩ • Start engine. • Turn starting switch OFF. • Disconnect E07.

7 YES

Is there continuity YES between C01 (female) (5) - (10), 6 between (6) - (10)? Does model selector connector NO match machine model?

• Between C01 NO (female) (5) - (10) :Continuity • Between C01 (female) (6) - (10) : No continuity • Turn starting switch OFF. • Disconnect C01.

NO 8 YES A

Is resistance between C05 (male) (2),(4) chassis ground normal? • Min. 1 MΩ NO • Turn starting switch OFF. • Disconnect C05.

PC128US-2

Remedy

4 YES To A

Short circuit with chassis ground in wiring harness NO between C05 (female) (4) and C03 (female) (2)

Repair or replace

Defective PC-EPC solenoid

Replace

Defective contact, disconnection, or short circuit with chassis ground in wiring harness between C01 (female) (3) - E07 (female) (1) or C01 (4) - E07 (2)

Repair or replace

Defective engine speed sensor

Replace

Defective pump controller

Replace

Defective contact, disconnection, or short circuit with chassis ground in wiring harness between C01 (male) (5) - C09 (male) (1), C05 (female) (6) - C09 (female) (2) or C01 (female) (10) - C09 (male) (3)

Repair or replace

Defective machine model selection connector

Replace

Short circuit with chassis ground in wiring harness between C01 (female) (13) and C05 (female) (2)

Repair or replace

Defective emergency pump drive switch

Replace

20-311 (17)

TROUBLESHOOTING

E-1

b) There is excessive drop in engine speed, or engine stalls fl When fuse 2 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit related to fuse 2.)

Cause

2 YES


Is voltage between YES C01 (1) and chassis ground normal?

5 YES

Is pump controller LED off?

Is resistance

(female) (1) and (2) normal?

3

• 7 – 14 Ω • Turn starting switch OFF. • Disconnect C13.

Does pump controller LED NO flash?

Go to A

Is resistance YES between C05 4 (female) (3) and (4) normal?

YES between C13 • Turn starting switch ON.

Replace

Defective contact or disconnection in wiring Repair or replace harness between fuse 2 and C01 (female) (1)

NO • 20 – 30 V • Turn starting switch ON. 1

Remedy

Defective contact, disconnection, or short circuit with chassis ground in wiring harness between C05 (female) Repair or replace (3) and C13 (female) (1), or • 7 – 14 Ω NO defective contact or • Turn starting switch disconnection in wiring harness between C05 (female) OFF. (4) and C13 (female) (2) • Disconnect C05. Defective PC-EPC solenoid

Replace


Replace

NO 7 YES Is there continuity YES between C01 (female) (5) - (10), between (6) - (10)?

• Start engine.

6

Does model selection NO connector match machine model?

Defective contact or disconnection in wiring Repair or replace harness between C01 • Between C01 NO (female) (5) and C09 (male) (female) (5) - (10) : (1), or between C01 (female) Continuity (6) and C09 (male) (2) • Between C01 (female) (6) - (10) : No continuity • Turn starting switch OFF. • Disconnect C01. Defective machine model Replace selection connector

NO

8 A

YES

Is there continuity between C05 (female) (1) - (3) and (2) - (4)? • Turn starting switch OFF. • Disconnect C05.

20-312 (17)

NO

Defective contact, disconnection, or short circuit with chassis ground in wiring harness between C01 (female) (7) and C05 (female) Repair or replace (1), or defective contact or disconnection in wiring harness between C01 (female) (13) and C05 (female) (2) Defective emergency pump Replace drive switch

PC128US-2

TROUBLESHOOTING

E-1

E-1 Related electric circuit diagram

PC128US-2

20-313 (17)

TROUBLESHOOTING

E-1

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Items to check on LED display of pump controller when this failure mode occurs • For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps. However, remove the protective cover of the pump controller at the rear of the operator’s compartment, and use a mirror to check. 1. Content of display 1) When normal • LED lights up. 2) When there is abnormality in power supply voltage • Output stops, LED goes out. 3) When PC-EPC solenoid output is short circuited [when CR3 (16) - PC-EPC solenoid C13 (1) is short circuited] • Output stops, LED flashes. (See display pattern a). 4) When there is disconnection in speed sensor [when there is abnormal voltage at CR2 (39), (40)] • Output is made same as when engine speed is minimum, LED flashes. (See display pattern d). Note : When engine speed becomes abnormally low, LED does not flash. 5) When there is disconnection in PC-EPC solenoid output [when there is disconnection between CR3 (16) - PC-EPC solenoid C13 (1)] • LED flashes. (See display pattern b). 2. Display ( : ON, : OFF) 1) Display pattern a (method of re-enaction: pattern below is repeated when starting switch is ON) (ON for 0.5 seconds, then OFF for 2.0 seconds) 2) Display pattern b (method of re-enaction: pattern below is repeated when starting switch is ON) (ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds) 3) Display pattern c (method of re-enaction: pattern below is repeated when starting switch is ON)

(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds) 4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)

(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds) 5) If more than one of the above failures occurs at the same time, the above patterns a to d are repeated. Note : indicates ON for 0.1 second, indicates OFF for 0.1 second.

20-314 (17)

PC128US-2

E-1

TROUBLESHOOTING

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. a) Speeds of all work equipment, travel, swing are slow or lack power PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

Cause

Remedy

4 YES Go to A resistance YES Is between C06 3 (female) (2) - (5) normal? Is resistance between C13 YES (female) (1) - (2), NO • Between C06 between (1)(2) (female) (2) - (5): 8 - 15 Ω chassis ground • Turn starting switch OFF normal? • Disconnect C06 • Between C13 2 (male) (1) - (2) : NO Is resistance 8 - 15 Ω between CR2 • Between C13 YES (female) (39) - (40), (male) (1)(2) - chassis ground : between (39)(40) Min. 1 MΩ chassis ground • Turn starting switch OFF. normal? • Disconnect CR3. • Between CR2 5 YES (female) (39) - (40) : Is resistance 500 - 1000 Ω between E07 • Between CR2 (female) (2) - (1), (female) (39) - (40) 1 chassis ground : NO between (2)(1) chassis ground Min. 1 MΩ normal? • Turn starting Does LED of pump switch OFF. • Between CR2 NO • Disconnect CR2. controller flash? (female) (39) - (40) : 500 - 1000 Ω • Between CR2 (female) • Start engine. (39)(40) - chassis ground : Min. 1 MΩ • Turn starting switch OFF. • Disconnect E07.

6 YES Is machine model and attachment set NO up or arm crane 6 set up correct?

NO

7 YES A

Is resistance between C05 (male) (2),(6) chassis ground normal? • Min. 1 MΩ NO • Turn starting switch OFF. • Disconnect C05.

PC128US-2

Disconnection or Short circuit with chassis ground in wiring harness between C06 (female) (2) (5) and C03 (female) (1) (2)

Repair or replace


Replace

Defective contact, disconnection, or short circuit with chassis ground in wiring harness between CR2 (female) (39) - E07 (female) (2) or CR2 (40) E07 (2)

Repair or replace


Replace


Replace

Defective machine model set up or arm crane set up

Reset up

Short circuit with chassis ground in wiring harness between CR3 (female) (16) and C05 (female) (3)

Repair or replace

Defective emergency pump Replace drive switch

20-315 (17)

TROUBLESHOOTING

E-1

b) There is excessive drop in engine speed, or engine stalls fl When fuse 1 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit related to fuse 2.)

Cause

2 YES


Is voltage between YES CR3 (2) (12) (22) and chassis ground normal?

1

5 YES To A

Is pump controller LED off? Is resistance

Is resistance YES between C06 4 (female) (2) and (5) normal?

Defective contact, disconnection, or short circuit with chassis ground in wiring harness between C06 (female) (5) and C13 (female) Repair or replace • 8 – 15 Ω NO (1), or defective contact or disconnection in wiring • Turn starting switch harness between C06 OFF. (female) (23) and C13 (female) • Disconnect C06. (6)

YES between C13

• Turn starting switch ON.

(male) (1) and (2) normal?

3 Does pump controller LED NO flash?

• 8 – 15 Ω • Turn starting switch OFF. • Disconnect C13.

Is machine model and attachment set NO up or arm crane set up correct?

NO

7 YES Is there continuity between C06 (female) (2) - (3) and (5) - (6)?

20-316 (17)

NO


Replace


Replace

Defective machine model set up or arm crane set up

Reset up

NO 6 YES

• Start engine.

• Turn starting switch OFF. • Disconnect C06.

Replace

Defective contact or disconnection in wiring Repair or replace harness between fuse 1 and CR3 (female) (2) (12) (22)

NO • 20 – 30 V • Turn starting switch ON.

A

Remedy

Defective contact, disconnection, or short circuit with chassis ground in wiring harness between CR3 (female) Repair or replace (16) and C06 (female) (3), or defective contact or disconnection in wiring harness between CR3 (female) (23) and C06 (female) (6) Defective emergency pump Replace drive switch

PC128US-2

TROUBLESHOOTING

E-1

E-1 Related electric circuit diagram PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

PC128US-2

20-317 (17)

TROUBLESHOOTING

E-2

E-2 Abnormality in PPC lock solenoid system PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move Cause

Remedy

Defective contact or

4 YES disconnection in wiring

Is resistance YES between S12 and S13 (wiring harness end) 2 normal? Is resistance

YES between V07 (male) 1 Is voltage between V07 (female) (1) and chassis ground normal?

(1) - (2), between (1)(2) - chassis ground normal?

Is resistance YES between S13 (wiring harness end) and chassis 3 ground normal?

Defective contact or disconnection in wiring NO harness between S13 and • Max. 1 Ω • Turn starting switch OFF. chassis ground • Disconnect S13.

• Max. 1 Ω • Turn starting NO switch OFF. • Remove S12 and S13. • Safety lock lever: FREE

• Between V07 (male) (1) - (2) : 500 - 1000 Ω NO • Between V07 (male) (1)(2) chassis ground : Min. 1 MΩ • Turn starting switch OFF. • Disconnect V07.

• 20 – 30 V • Turn starting switch ON. NO

harness between V07 (female) (2) and S12

Repair or replace

Repair or replace

Defective PPC lock switch

Replace

Defective PPC lock solenoid

Replace

Defective contact or disconnection in wiring harness between fuse 3 and V07 (female) (1)

Repair or replace

b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move

Cause

YES 1 Is voltage between V07 (1) and (2) normal?

2 YES

Is resistance • Safety lock lever between S12 and [LOCK] (solenoid NO S13 (switch end) OFF) : Max. 1 V normal? • Safety lock lever NO • Min. 1 MΩ [FREE] (solenoid • Turn starting switch OFF. ON) : 20 – 30 V • Turn starting switch • Disconnect S12 and S13. • Safety lock lever: [LOCK] ON.

20-318 (17)

Remedy


Replace

Defective contact or disconnection in wiring harness between S13 and chassis ground

Repair or replace


Replace

PC128US-2

TROUBLESHOOTING

E-2

E-2 Related electrical circuit diagram

PC128US-2

20-319 (17)

TROUBLESHOOTING

E-2

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move Cause

4 YES Defective contact or Is resistance YES between S10 (female) (1) - fuse 3 (14)normal? Is resistance YES between S10 (female) (2) chassis ground 2 normal? Is resistance

YES between V7 (male) 1

(2) - (1), between (2)(1) - chassis ground normal?

Defective contact or disconnection in wiring NO harness between S10 • Max. 1 Ω • Turn starting switch OFF. (female) (1) - fuse (14) • Disconnect S13.

• 37 - 60 Ω • Turn starting NO switch OFF. • Remove S10. • Safety lock lever: FREE

• Between V7 (male) (2) - (1) :37 - 60 Ω • Between V7 NO (male) (2) - chassis ground : Min. 1 MΩ • Turn starting switch OFF. • Disconnect V7.

Is voltage between V7 (female) (2) and chassis ground normal?

• 20 – 30 V • Turn starting switch ON. NO

disconnection in wiring harness between V7 (female) (1) and chassis ground

Remedy

Repair or replace

Repair or replace


Replace


Replace

Defective contact or disconnection in wiring harness between fuse V7 (female) (2) S10 (female) (2)

Repair or replace

b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move

Cause


2 YES

Is resistance between S10 • Safety lock lever [LOCK] (solenoid NO (male) (1) - (2) normal? OFF) : Max. 1 V • Safety lock lever NO • Min. 1 MΩ [FREE] (solenoid • Turn starting switch OFF. ON) : 20 – 30 V • Turn starting switch • Disconnect S10. • Safety lock lever: [LOCK] ON.

20-320 (17)

Remedy


Replace

Defective contact in wiring harness between S10 (female) (2) - V7 (female) (2)

Repair or replace


Replace

PC128US-2

TROUBLESHOOTING

E-2


PC128US-2

20-321 (17)

TROUBLESHOOTING

E-3

E-3 Abnormality in swing lock solenoid system PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. a) Even when swing lock switch is turned OFF, upper structure does not swing Cause

4 YES resistance YES Is between S08 3 (female) (2), S30

When C03 (female) (female) (2) - chassis is grounded to ground normal? chassis, is • Min. 1 Ω YES resistance between NO S08 (female) (1), • Turn starting switch 2 S30 (female) (1), OFF. S05 (female) (1) Is resistance • Disconnect C03, S08, chassis ground between S08 and S30. normal? YES (male) (1) - (2), S30 (male) (1) - (2) or • Min. 1 Ω NO S05 (male) (1) - (2) 1 • Turn starting switch OFF. normal? Is resistance • Disconnect C03, S08, and • Min. 1 Ω between V04 S30. • Disconnect S08, (male) (1) and (2) NO S30, and S05. normal? • Start engine. • Operate swing or arm control • 20 – 60 Ω lever slightly (but do not move work equipment). • Turn starting switch OFF. NO • Disconnect V04.

Go to A

Defective contact or disconnection in wiring harness between S08 (female) (2), S30 (female) (2) - chassis ground Defective contact or disconnection in wiring harness between C03 (female) (3) - S08 (female) (1), S30 (female) (1)

Is resistance

YES between C03 5 Is voltage between A C03 (female) (1) and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

(female) (2) and chassis ground normal?

• Min. 1 Ω NO • Turn starting switch OFF. • Disconnect C03 and V04.

• Min. 1 Ω • Turn starting switch NO OFF. • Disconnect C03.

NO

Is resistance YES between X05 (female) (4) and 9 V04 (female) (2) normal?

NO • Max. 1 Ω • Turn starting switch OFF. • Disconnect X05 and V04.

• Min. 1 Ω • Turn starting switch NO OFF. • Disconnect X05.

20-322 (17)

Repair or replace

Repair or replace

Replace

Defective swing holding brake solenoid valve

Replace

—

Defective contact or disconnection in wiring harness between X05 (female) (3) and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between V04 (female) (1) and C03 (female) (4)

Repair or replace

Defective contact or disconnection in wiring Repair or replace harness between C03 (female) (2) and chassis ground Defective contact or disconnection in wiring Repair or replace harness between fuse 2 and C03 (female) (1)

10 YES

Is resistance B between X05 (male) (3) and (4) normal?

—

Defective swing or arm IN pressure switch (S08, S30 or S05)

8 YES Go to B Is resistance YES between X05 (female) (3) and 7 chassis ground When V04 (female) normal? is grounded to • Min. 1 Ω YES chassis, is NO resistance between • Turn starting switch C03 (female) (4) and 6 OFF. chassis ground • Disconnect X05. normal?

Remedy

Defective swing holding auto brake controller

Replace

Defective contact or disconnection in wiring harness between X05 (female) (4) and C03 (female) (3)

Repair or replace

Defective swing lock switch

Repair or replace

PC128US-2

TROUBLESHOOTING

E-3

b) Even when swing lock switch is turned to LOCK, upper structure swings

Cause


2 YES

Is resistance between X05 (male) • Swing lock switch (3) and (4), between [LOCK] (solenoid NO (4) and chassis ground normal? OFF) : Max. 1 V • Swing lock switch NO • Min. 1 MΩ [FREE] (solenoid • Turn starting switch OFF. ON) : 20 – 30 V • Turn starting switch • Disconnect X05. • Swing lock switch: [LOCK] ON.

Remedy

Defective swing holding brake solenoid

Replace

Defective contact or disconnection in wiring harness between V04 (female) (2) and X05 (female) (4)

Repair or replace

Defective swing lock switch Replace


PC128US-2

20-323 (17)

TROUBLESHOOTING

E-3

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. a) Even when swing lock switch is turned OFF, upper structure does not swing Cause

4 YES resistance YES Is between S08 3 (female) (2), S30

When CR 1(female) (female) (2) - chassis (12) is grounded to ground normal? chassis, is • Min. 1 Ω YES resistance between NO S08 (female) (1), • Turn starting switch 2 S30 (female) (1), OFF. CR3 (female) (30) Is resistance • Disconnect C03, S08, chassis ground between S08 and S30. normal? YES (male) (1) - (2), S30 (male) (1) - (2) or • Min. 1 Ω NO S05 (male) (1) - (2) 1 • Turn starting switch OFF. normal? • Disconnect C03, S08, and • Min. 1 Ω Is resistance S30. • Disconnect S08, between V4 (male) NO S30, and S05. (1) and (2) normal? • Start engine. • Operate swing or arm control • 37 – 60 Ω lever slightly (but do not move work equipment). • Turn starting switch OFF. NO • Disconnect V4.

Go to A

Is resistance

YES between CR3 5 Is voltage between A CR3 (female) (2) (12) (22) and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

• Min. 1 Ω NO • Turn starting switch OFF. • Disconnect C03 and V4.

(female) (7) - X05 (female) (3) normal?

• Min. 1 Ω • Turn starting switch NO OFF. • Disconnect C03.

Repair or replace

Defective contact or disconnection in wiring harness between CR3 (female) (30) - S08 (female) (1), S30 (female) (1)

Repair or replace

Defective swing or arm IN pressure switch (S08, S30 or S05)

Replace

Defective swing holding brake solenoid valve

Replace

NO

Is resistance YES between X05 (female) (4) and V4 9 (female) (2) normal?

NO • Max. 1 Ω • Turn starting switch OFF. • Disconnect X05 and V4.

• Min. 1 Ω • Turn starting switch NO OFF. • Disconnect X05.

20-324 (17)

—

Defective contact or disconnection in wiring harness between X05 (female) (3) and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between V4 (female) (1) and CR3 (female) (3)

Repair or replace

Defective contact or disconnection in wiring Repair or replace harness between CR3 (female) (7) - X05 (female) (3) Defective contact or disconnection in wiring Repair or replace harness between fuse 8 and CR3 (female) (2) (12) (22)

10 YES

Is resistance B between X05 (male) (3) and (4) normal?

—

Defective contact or disconnection in wiring harness between S08 (female) (2), S30 (female) (2) - chassis ground

8 YES Go to B Is resistance YES between X05 (female) (2) and 7 chassis ground When V4 (female) is normal? grounded to • Min. 1 Ω YES chassis, is NO resistance between • Turn starting switch CR3 (female) (3) 6 OFF. and chassis ground • Disconnect X05. normal?

Remedy

Defective swing holding auto brake controller

Replace

Defective contact or disconnection in wiring harness between X05 (female) (4) and V4 (female) (2)

Repair or replace

Defective swing lock switch

Repair or replace

PC128US-2

E-3

TROUBLESHOOTING

b) Even when swing lock switch is turned to LOCK, upper structure swings Cause


2 YES

Is resistance between X05 (male) • Swing lock switch (4) and (2), between [LOCK] (solenoid NO (4) and chassis ground normal? OFF) : Max. 1 V • Swing lock switch NO • Min. 1 MΩ [FREE] (solenoid • Turn starting switch OFF. ON) : 20 – 30 V • Turn starting switch • Disconnect X05. • Swing lock switch: [LOCK] ON.

Remedy

Defective swing holding brake solenoid

Replace

Defective contact or disconnection in wiring harness between V4 (female) (2) and X05 (female) (4)

Repair or replace

Defective swing lock switch Replace


PC128US-2

20-325 (17)

TROUBLESHOOTING

E-4

E-4 Abnormalty travel speed solenoid system PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. a) Even when travel speed selector switch is turned to Hi, travel speed does not change to high speed fl When fuse 2 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit related to fuse 2.) Cause

Remedy

Defective contact or

4 YES disconnection in wiring Is resistance M39 YES between (female) (1) and chassis ground 3 normal? Is resistance

YES between M39 2 Is resistance V05 (male) YES between (1) - (2), between

1 Is voltage between V05 (female) (1) and chassis ground normal?

(1)(2) - chassis ground normal?

(male) (1) and (2) normal?

Defective contact or disconnection in wiring harness between M39 • Max. 1 Ω . Turn NO (female) (1) and chassis • Starting switch OFF. ground • Disconnect S13.

• Turn starting switch OFF. • Disconnect S12 and NO S13. • Safety lock lever: FREE

• Between V05 (male) (1) - (2): 20 - 60 Ω • Between V06 (male) NO (1)(2) - chassis ground : Min. 1 MΩ • Turn starting switch OFF. • Disconnect V05.

• 20 - 30 V • Turn starting switch ON. NO

harness between V05 (female) (2) and M39 (female) (2)

Repair or replace

Repair or replace

Defective travel speed selector switch

Replace

Defective travel speed solenoid

Replace

Defective contact or disconnection in wiring Repair or replace harness between fuse 3 and V05 (female) (1)

b) Even when travel speed selector switch is turned to Lo, travel speed does not change to low speed

Cause


2 YES

Is resistance between M39 • Travel speed (male) (1) - (2), selector switch NO between (1)(2) [Lo] (solenoid OFF) : chassis ground Max. 1V normal? • Travel speed selector switch [Hi] • Min. 1 MΩ NO (solenoid ON) : • Turn starting switch OFF. 20 – 30 V • Disconnect M39. • Turn starting switch • Travel speed selector ON. switch : [Lo]

20-326 (17)

Remedy


Replace

Short circuit with chassis ground in wiring harness between V05 (female) (2) and M39 (female) (2)

Repair or replace

Defective travel speed selector switch

Replace

PC128US-2

TROUBLESHOOTING

E-4


PC128US-2

20-327 (17)

TROUBLESHOOTING

E-4

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. fl When fuse 1 is normal. (If fuse 1 is blown, check for a short circuit with the ground in the circuit related to fuse 1.) fl Befor carrying out troubleshooting check that main pump pressure sensor system is normal. Cause

YES

Remedy

Defective controller

Replace

Defective contact, disconnect, or short circuit with chassis ground in wiring harness between CR3 (female) (27) (3) - V5 (female) (2) (1)

Repair or replace


Replace

Defective contact or disconnection in wiring harness between fuse 1 and CR3 (female) (2) (12) (22)

Repair or replace

Is resistance

YES between CR3 (female) (27) and 2 3 (3) normal?

Is resistance V5 (male) YES between (2) - (1), between (2) - chassis ground normal? 1 Is voltage between CR3 (female) (2),(12),(22) and chassis ground normal?

• Turn starting switch NO OFF. • Disconnect CR3. • Safety lock lever: FREE

• Between V5 (male) (2) - (1): 37 - 60 Ω • Between V5 (male) NO (1)(2) - chassis ground : Min. 1 MΩ • Turn starting switch OFF. • Disconnect V5.

• 20 - 30 V • Turn starting switch NO ON.


20-328 (17)

PC128US-2

TROUBLESHOOTING

E-5

E-5 Trouble in automatic travel speed control system PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. fl If this failure mode is detected, the travel speed does not change automatically. a) Main pump pressure sensor system Cause

2 YES YES Is voltage between C05 (5) and (10) normal?

Is voltage between C05 (2) and (1) normal?

Defective governor pump controller

Replace

Disconnection, defective contact, or short circuit with power source or chassis ground in wiring harness between C02 (female) (5) – C05 (female) (3)

Repair or replace

Disconnection, defective contact, or short circuit with chassis ground in wiring harness between C02 (female) (10) – C05 (female) (1)

Repair or replace

Disconnection, defective contact, or short circuit with chassis ground in wiring harness between C02 (female) (2) – C05 (female) (2)

Repair or replace

↔

1

• Run engine at full NO throttle • Relieve travel system and set lever in neutral repeatedly

Remedy

• Lever – Neutral return • 0.5 – 4.5V

• Turn starting switch ON. • 18 – 28V

YES 3

Is voltage between C05 (2) and chassis NO ground normal? • Disconnect C05 • Turn starting switch NO ON. • 18 – 28V

b) Engine speed sensor system Cause

2 YES Is resistance beYES tween C02 (female) (6) and (11) normal? 1 Is resistance between E07 (male) (1) and (2) normal?

• Turn starting switch NO OFF. • Disconnect C02. • 500 – 1,000Ω

• Turn starting switch OFF • Disconnect E07 NO • 500 – 1,000Ω

PC128US-2

Defective automatic Lo/Hi travel speed controller

Remedy

Replace

Disconnection, defective contact, or short circuit with power source or chassis Repair or ground in wiring harness between C02 (female) (6) – replace E07 (female) (1) or between C02 (female) (10) – E07 (female) (2) Defective engine speed sensor (Internal disconnection, defective contact, short circuit with chassis ground)

Replace

20-329 (17)

TROUBLESHOOTING

E-5


20-330 (17)

PC128US-2

E-5

TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. fl If this failure mode is detected, the travel speed does not change automatically. a) Main pump pressure sensor system Cause

2 YES YES Is voltage between CR1 (13) and (21) normal?

Is voltage between C05 (B) and (A) normal?

Defective governor pump controller

Replace

Disconnection, defective contact, or short circuit with power source or chassis ground in wiring harness between CR1 (female) (13) – C05 (female) (C)

Repair or replace

Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CR1 (female) (21) – C05 (female) (A)

Repair or replace

Disconnection, defective contact, or short circuit with chassis ground in wiring harness between CR1 (female) (22) – C05 (female) (B)

Repair or replace

↔

1

• Run engine at full NO throttle • Relieve travel system and set lever in neutral repeatedly

Remedy

• Lever – Neutral return • 0.5 – 4.5V

• Turn starting switch ON. • 4.5 – 5.5V

YES 3

Is voltage between C05 (B) and NO chassis ground normal? • Disconnect C05 • Turn starting switch NO ON. • 4.5 – 5.5V

b) Engine speed sensor system Cause

2 YES Is resistance beYES tween CR3 (female) (39) and (40) normal? 1 Is resistance between E07 (male) (1) and (2) normal?

• Turn starting switch NO OFF. • Disconnect CR3. • 500 – 1,000Ω

• Turn starting switch OFF • Disconnect E07 NO • 500 – 1,000Ω

PC128US-2

Defective automatic Lo/Hi travel speed controller

Remedy

Replace

Disconnection, defective contact, or short circuit with power source or chassis Repair or ground in wiring harness between CR3 (female) (39) – replace E07 (female) (2) or between CR3 (female) (40) – E07 (female) (1) Defective engine speed sensor (Internal disconnection, defective contact, short circuit with chassis ground)

Replace

20-331 (17)

TROUBLESHOOTING

E-5


20-332 (17)

PC128US-2

TROUBLESHOOTING

E-6

E-6 Abnormality in engine starting system PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going YES on the next step. 4 fl When fuse 1 is normal. (If fuse 1 is blown, Is voltage between check for a short circuit with the ground YES starting motor YES terminal B and in the circuit related to fuse 1.) chassis ground normal?

5 Is voltage between battery relay terminal M and NO chassis ground normal?

• 20 – 30 V • Turn starting switch ON.


3 Is there sound of YES starting motor pinion engaging?

6 YES Is voltage between battery relay terminal B and NO chassis ground normal? NO • 20 – 30 V • Turn starting switch ON.

YES

• Turn starting switch ON ↔ START.

7 Is voltage between safety relay terminal C and NO chassis ground normal?

YES

9 Is voltage between YES M02 (1) and chassis ground normal? • 20 – 30 V 8 • Turn starting switch ON. Is voltage between safety relay terminal B and NO NO chassis ground normal?


2 YES Is sound heard from battery relay? • Turn starting switch ON ↔ OFF.


NO

14 YES Is there continuity YES between battery relay terminal E and chassis ground?

1 Is specific gravity of battery normal? • Min. 1.24

13

Is voltage between battery relay terminal BR and NO chassis ground normal? • 20 – 30 V • Turn starting switch ON.

• Turn starting switch NO OFF.

YES 15

Is voltage between starting switch terminal BR NO and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

YES 16 Is voltage between starting switch terminal B NO and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

17 YES Is voltage between fuse 1 inlet and NO chassis ground normal?


20-334 (17)

PC128US-2

E-6

TROUBLESHOOTING

Cause

YES

Remedy

Defective starting motor

Replace

Defective contact or disconnection in wiring harness between battery relay terminal M and starting motor terminal B

Repair or replace

Defective battery relay

Replace

Defective contact or disconnection in wiring harness between battery (+) terminal and battery relay terminal B

Repair or replace

Defective contact or disconnection in wiring harness between safety relay terminal C and starting motor terminal S

Repair or replace

Defective safety relay

Replace

Defective contact, disconnection, or short circuit with power source in wiring harness between alternator terminal R and M02 (female) (2)

Repair or replace

10 Is voltage between M02 (2) and chassis ground normal? • Max. 13 V • Turn starting switch ON.

11 YES

Is voltage between alternator terminal NO R and chassis ground normal?

NO • Max. 13 V • Disconnect terminal R. • Turn starting switch ON. 12 YES

Is voltage between starting switch terminal C (T09) and chassis ground normal? • 20 - 30 V NO • Turn starting switch ON.

Defective alternator Defective contact or disconnection in wiring harness between starting switch terminal C (T9) and M02 (female) (1)

Repair or replace

Defective starting switch (circuit C)

Replace

Defective contact or disconnection in wiring harness between starting Repair or replace motor terminal B and safety relay terminal B


Replace

Defective contact or disconnection in wiring harness between battery relay E and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between starting switch terminal BR (T7) and battery relay terminal BR

Repair or replace

Defective starting switch (circuit BR)

Replace

Defective contact or disconnection in wiring harness between fuse 1 outlet and starting switch terminal B (T6)

Repair or replace

Defective contact or disconnection in wiring harness between battery (+) terminal - M11 (1), (2) - fuse 1 inlet Lack of battery capacity

PC128US-2

Replace

Repair or replace

Charge or replace

20-335 (17)

TROUBLESHOOTING

E-6


20-336 (17)

PC128US-2

TROUBLESHOOTING

E-6

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up YES

fl Before carrying out troubleshooting, check that all the 4 related connectors are properly inserted. Is voltage between fl Always connect any disconnected YES starting motor connectors before going on the terminal B and chassis ground next step. normal? fl When fuse 1 is normal. (If fuse 1 is blown, • 20 – 30 V check for a short circuit with the ground • Turn starting NO switch ON. in the circuit related to fuse 1.)

YES 5 Is voltage between battery relay terminal M and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

3 Is there sound of

YES starting motor

pinion engaging? • Turn starting switch ON ↔ START.

6 YES Is voltage between battery relay terminal B and NO chassis ground normal? NO • 20 – 30 V • Turn starting switch ON.

YES

YES

7 Is voltage between safety relay terminal S and NO chassis ground normal? • 20 – 30 V • Turn starting switch ON.

8 Is voltage between safety relay terminal C and NO chassis ground normal?

2


YES Is sound heard from battery relay?

YES

9

• Turn starting switch ON ↔ OFF.

Is voltage between safety relay terminal B and NO chassis ground normal? • 20 – 30 V • Turn starting switch ON.

NO 24 YES

1 Is specific gravity of battery normal? • Min. 1.26

Is there continuity YES between battery relay terminal E and chassis ground?

23

Is voltage between battery relay terminal BR and NO chassis ground normal? • 20 – 30 V • Turn starting switch ON.

• Turn starting switch NO OFF.

YES 25

Is voltage between starting switch terminal BR NO and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

26 Is voltage between starting switch terminal B NO and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

YES

27 YES Is voltage between fuse 20 inlet and NO chassis ground normal?


20-338 (17)

PC128US-2

E-6

TROUBLESHOOTING Cause

Remedy


Replace

Defective contact or disconnection in wiring harness between battery relay terminal M and starting motor terminal B

Repair or replace


Replace

Defective contact or disconnection in wiring harness between battery (+) Repair or replace terminal and battery relay terminal B

YES


Replace

Defective contact or disconnection in wiring harness between safety relay terminal C and starting motor terminal S

Repair or replace

Defective safety relay

Replace

11 Is voltage between

YES M02 (2) and

chassis ground normal?

10 Is voltage between M02 (1) and chassis ground normal? • 20 – 30 V • Turn starting switch ON. • PPC lock switch: LOCK

• Max. 13 V • Turn starting switch ON.

12 YES Is voltage between alternator terminal NO R and chassis ground normal?

NO • Max. 13 V • Disconnect terminal R. • Turn starting switch ON.

Defective contact, disconnection, or short circuit with power source in wiring harness between alternator terminal R and M02 (female) (2) Defective alternator

Replace

Repair or replace

Go to A

NO

Defective contact or disconnection in wiring harness between safety relay terminal B and heater relay terminal B

Replace


Replace

Defective contact or disconnection in wiring harness between battery relay E and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between starting switch terminal BR (T7) and battery relay terminal BR Defective starting switch (circuit BR)

Repair or replace

Replace

Defective contact or disconnection in wiring Repair or replace harness between fuse 1 outlet and starting switch terminal B (T6) Defective contact or disconnection in wiring harness between battery (+) Repair or replace terminal - M11 (1), (2) - fuse 1 inlet Lack of battery capacity

PC128US-2

Charge or replace

20-339 (17)

TROUBLESHOOTING

E-6

Cause

13 YES A

Is voltage between V03 (6) and chassis ground normal? • 20 – 30 V • Starting switch: START • PPC lock switch: LOCK

YES 14

Is voltage between V03 (3) and chassis NO ground normal?

YES 15 Is voltage between R06 (3) and chassis NO ground normal?

• 20 – 30 V • Starting switch: START • PPC lock switch: LOCK

16 YES

NO • 20 – 30 V • Starting switch: START • PPC lock switch:LOCK

Is resistance YES between R06 (female) (2) chassis ground normal? 17 NO • Max. 1 Ω • Starting switch: OFF Is voltage between • Disconnect R06. R06 (1) and chassis YES ground normal?

Is voltage between S10 (3) and chassis NO ground normal? • 20 – 30 V • Starting switch: ON

YES

Defective V3 relay or malfunction of KOMTRAX

Replace relay

Disconnection or defective contact in wiring harness between R06 (female) (3) V3 (female) (3)

Repair or replace

Go to B

Go to C

Defective R06 relay


20 Is voltage between S10 (1) and chassis

Is voltage between starting switch T12 NO and chassis ground normal?

Repair or replace

Replace

(female) (1) (including fuse 14) Defective starting switch

NO (between B - ACC)

C

Is voltage between starting switch T9 and chassis ground normal? • 20 – 30 V • Starting switch: START • PPC lock switch: LOCK

Replace

Disconnection or defective

22 YES contact in wiring harness

(17)

Repair or replace

Disconnection or defective contact in wiring harness

• 20 – 30 V • Starting switch: ON

20-340

Replace

21 YES between T12 - fuse 14 - S10 Repair or replace

NO ground normal? • 20 – 30 V • Starting switch: ON

Repair or replace

Disconnection or defective contact in wiring harness between R06 (female) (2) chassis ground Disconnection or defective contact in wiring harness between S10 (female) (3) R06 (female) (1)

19

• 20 – 30 V • Starting switch: ON

Disconnection or defective contact in wiring harness between V03 (female) (6) M02 (female) (1)

Is voltage between R06 (5) and chassis NO ground normal?

• 20 – 30 V • Starting switch: START • PPC lock switch: LOCK

18 YES

B

Remedy

between T9 - R06 (female) (5) Defective starting switch

NO (Between B - C)

Repair or replace

Replace

PC128US-2

TROUBLESHOOTING

E-6

E-6 ENGINE STARTING SYSTEM PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

PC128US-2

20-341 (17)

TABLE OF FAILURE MODES AND CAUSES

TROUBLESHOOTING

l. 017tr \ IVI -

T

G 2

T-

Swing motor

-

-

T-

l-

Travel motor

-

-

5

z

a, 2

3

E

P -ii L

E

-s 5 -

s

0

s J

4 z

z

.P 2

.a

.s

3

E

z

z

2

t 8

2

h

P

6

‘m

: -

P -

s ST ;5 5 G s iz s -

PC128US-2

-

L b E -

-

*

-

rrs-

l 0

l 0

cG -

0

Ts -

i00

s-

l DO 8

b t; v I

7 8

E .-

5 7

.-E i;

-

e -

u

5

z

5

“2

1” ?

i

$ >

-

$ E

F

SOIC aid

-

5 .?

s 6 1” 27T 2& s is 2 z %

B

Q

z

E 2

J i-

al 2 u2 6 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i -

E F - - -6 6 - - F - - - - - - - - - - - - - - - - - - -

0

0

;

2

2 a

-

-

P

l

Y

6 -

5 -

E uL 0 B ij A H-6

-

H-7

-

H-8

-

H-9

-

H-10

-

H-l 1

-

H-12

-

H-13

-

-

H-14

H-15 H-16

s -

H-17

-

H-18

-

-

H-19

-

H-20

-

H-21

H-22

-

H-23

-

-

H-24

-

20-403 0

H-l

TROUBLESHOOTING

H-l Jr

Speeds of all work equipment,

travel, swing are slow or lack power

Check that there is no abnormal noise from the pump before starting troubleshooting. abnormal noise, carry out troubleshooting for H-4.)

(If there is any

Cause

4 YES

Remedy

main pump

epair or replace

Defective PC valve or PC-EPC valve

epair or replace

Defective valve

main relief

epair or replace

Defective

unload valve

,epair or replace

Defective self pressure reducing valve

lepair or replace

(Pressure reducing valve, LS circuit) Defective operation main valve

tepair or replace

Defective

YES

3r

pressure) normal? -See TESTING AND NO ADJUSTING.

I

I

YEIS Is main pump relief pressure normal?

GotoA

. See TESTING AND ADJUSTING.

NO

pressure reducing . Arm relief

pressure) normal?

* 2.7: i,, MPa NO (28 ? i., kglcms) * Engine at full throttle

* 3.24 f 0.49 MPa (33 + 5 kg/cm?) *Engine at full throttle

6 A

YES

Is LS differential pressure normal?

Defective valve

- 2.2 * 0.1 MPa NO (22.5 * 1 kg/ems) - Engine at full throttle f Operate travel on one side under no load.

Note :Check the control circuit equipment. adjusting control circuit oil pressure.

20-404 0

For details,

see, TESTING

AND

of

pump LS

ADJUSTING,

Ieplace

Testing and

PC1 28US-2

H-3

TROUBLESHOOTING

H-3 No work equipment,

travel, swing move Cause

3 YES YE

NO

IO

YES

fiiisz?p Al

NO

NO

20-406 0

Defective PPC lock solenoid valve

Replace

Defective chassis wiring harness

Repair or replace

Go to Troubleshooting of Electric System E-3b)

Repair or replace

Defective self pressure reducing valve

Repair or replace

Defective main pump

Repair or replace

Defective PTO

Repair or replace

p5jiiiJHP

A

- 3.24 f 0.49 MPa (33 f 5 kg/cm9 - Engine at full throttle

Remedy

PC1 28US-2

H-4, H-5

TROUBLESHOOTING

H-4 Abnormal

noise generated

(around pump) Cause

3 YES YE

Go to Item 4

pi+JHImproper hydraulic oil

NO YE

Remedy

Are there bubbles in hydraulic tank?

:hange lydraulic oil

Suction strainer blocked by external object (cloth, etc.)

I

Is suction strainer blocked by external object?

n Is hydraulic tank oil level normal?

Defect inside main pump

Repair or replace

Operate for a short time and watch for any change in symptoms

Check again [according to change in symptoms)

Improper hydraulic oil

Add hydraulic oi Fine control ability is poor or response is poor

% External object: cloth, etc.

N0

H-5 Fain control ability is poor or response is poor

Cause

YES 1 Is pump servo orifice clogged?

2 YES Does condition _ become normal NO when LS valve is replaced?

Remedy

Clogged orifice for servo pump

Jean

Defective LS valve

Replace

Defective servo piston

Replace

_

NO

PC1 28US-2

20-407 0

TROUBLESHOOTING

H-6

H-6 Boom is slow or lacks power

5 YES YES -

Is leakage from hydraulic cylinder normal?

-

4 YES -

Is main pump relief pressure normal?

-

3 Does pressure * 31237: JJ:;; compensation MPa 1325 T:z kg/cm?) valve (pressure -Engine at full NO YES reducing valve throttle piston, flow control valve + pressure reducing valve) 2 _ move smoothly? YES Does control valve P* It is also possible to - spool move interchange with smoothly? $;w.compensation NO 1 Is PPC valve output pressure normal? * 3.24 * 0.49 MPa 133 t 5 kg/cm4 . Engine at full throttle - Operate lever fully.

20-408 0

Note

* 15 cclmin *Engine at full throttle

NO

6 YES Is pressure reducing valve piston throttle free of clogging? NO

: In this case, always

be sure to return the valves to their original positions after checking.

NO

NO

PC128US-2

ELECTRICAL

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM Monitor

panel

CIRCUIT DIAGRAM

FOR MONITOR

Starting

FOR MONITOR

SYSTEM

SYSTEM

Alarm buzzer

switch

B BRACC C R, Rz

OFF 0 HEAT 0 0 o--o ON

000

START 0 0 0 O--o Q Fuse

Bat terv 308

.

.

308

t

tterv lay

.

,301;

-

t

’

h 0

Fuel level sensor

20-502 0

Alternator

Engine level

water sensor

Engine oil pressure switch

Fusible I ink

TXP0.2417

PC128US-2

TROUBLESHOOTING

M-l * * *

M-l

No display appears when starting switch is turned ON

Before carrying out troubleshooting, check that all the related connectors are properly Alwavs connect any disconnected connectors before going on the next step. Check fuse 2 before starting troubleshooting.

YES , I Is voltage between PO1 (female) (1) and (3) normal? *20-30V *Turn starting switch ON.

YES Is fuse 2 normal?

NO

M-l

Related electrical

inserted.


Replace

Defective contact or disconnection in wiring harness between PO1 (female) (1) and fuse 2, or between PO1 (female) (3) and chassis ground

Repair or replace wiring harness

Blown fuse 2

Check cause of blown fuse, then repair, and replace fuse

circuit diagram

Fusible I ink Monitor

Panel nA4 l-v I

I

I

I I GND

Ml4 . .

I IAAA~C \vLtv

I u \

CNll

($WP,l 6)

i%’

PC1 28US-2

I

I

TXP02418

20-503 0

M-2, M-3

TROUBLESHOOTING

M-Z *

Display does not go out after completion of self check (all lamps light up for 3 seconds) when starting switch is turned ON

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

*

Cause


M-3 * * a)

Remedy

Replace

Some items do not light up during self check (all lamps light up for 3 seconds) when starting switch is turned ON

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. No gauges Preheating

(fuel level, engine water temperature) pilot lamp does not light up


Caution

lamps (engine oil pressure, battery

1

YES I

I

Is there disconnection in

* Check visually for blown bulb.

20-504 0

1 Remedy

Replace

charge) do not light up

Cause

I

inserted.

light up

Cause

b)

inserted.

Llown bulb

Remedy

FXeplace

l-l

NO

;o to M-4

-

PC1 28US-2

M-4

TROUBLESHOOTING

M-4 * *

Charge caution lamp does not light up when starting switch is turned ON (before starting engine) :

Before carrying Always connect

out troubleshooting, any disconnected

check that all’the related connectors are properly connectors before going on the next step.

inserted.

Cause

YES


1 Is voltage between PO1 (female) (10) 2 YES and (3) normal? _ Is voltage between alternator terminal - Start engine. NO R and chassis -27.5- 29.5 V ground normal? * Start engine.

-27.5 - 29.5 V

M-4

Related electrical

Monitor

Remedy

Defective contact or disconnection in wiring harness between PO1 (female) (10) and alternator terminal R


NO

Replace

Repair or replace w’r’ng harness

Replace

circuit diagram

Panel I

PO1 (04016)

:CN-2 (SWP12)

Alternator

El7 (X2) 3

o

--oR 0

TXP02419

PC1 28US-2

20-505 0

M-5

TROUBLESHOOTING

M-5

Engine oil pressure caution lamp does not light up when starting switch is turned ON (before starting engine)

*

Before carrying

out troubleshooting,

Ir

Always

any disconnected

connect

check that all the related connectors are properly connectors before going on the next step.

P=2 YES

(female) (9) and (3) Is continl *Turn stalrting switch NO chassis E normal? - Disconnect POl. -Turn starting switch OFF. NO * Max. 0.5 R -Disconnect sensor (+) terminal 617).

M-5 Related electrical

Monitor

inserted.

Remedy


Replace

Defective contact or disconnection in wiring harness between PO1 (female) (9) and S17 Wiring harness end)


Defective engine oil pressuresensor

Replace

circuit diagram

Panel I

PO1 (04016)

w-2 (SWP12) $iJ

Engine oil Pressure switch

a s17

TXP02420

20-506 0

PC128US-2

M-6

TROUBLESHOOTING

M-6 * *

Preheating HEAT

pilot lamp does not light up when starting switch is at

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

Cause

YES

1

Remedy


Replace

Disconnection in wiring harness between PO1 (female) (13) and starting switch Rl, or defective starting switch

Repair or replace

Is voltage between PO1 (13) and (3) normal?

-

*Turn starting switch NO to HEAT position. .20-30V


Monitor

circuit diagram

Panel

TXP0242

PC1 28US-2

1

20-507 0

M-7

TROUBLESHOOTING

M-7 * Ir *

Engine oil pressure caution lamp lights up when engine is running

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Wheri engine oil pressure is normal.

Remedy

Cause

Defective engine oil pressure sensor

YES 1

-

-Disconnect S13. * Start engine.

2 YES


Is circuit between _ PO1 (female) (9) _ NO and chassis ground insulated?

Contact of chassis ground with wiring harness between PO1 (female) (9) and P13

NO - Min. 1 MR * Disconnect PO1 and P13. -Turn starting switch OFF.

M-7 Related

Monitor

electrical

I

Replace

Does engine oil pressure caution lamp go out?

inserted.

Replace


circuit diagram

Panel

I

PO1 (04016)

w-2 (SWP12) D

E20 (SWP8)

Engine oil Pressure switch

3

TXP02.420

20-508 0

PC1 28US-2

M-8

TROUBLESHOOTING

M-8 * * *

Charge caution lamp lights up when engine is running

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. When charging is being carried out normally.

inserted.

Cause

2 YES Is continuiW YES_ between POI 1 (female) (10) and (3) normal? Is voltage of alternator terminal R normal?

ti NO

* Stan engine. * 27.5 - 29.5 v

. Start engine. * Measure voltage between alternator No terminal R and chassis ground. -27.5 - 29.5 V


Monitor

Remedy


Replace

Contact of chassis ground with wiring harness between PO1 (female) (10) and alternator terminal R

Repair or replace

Defective generation of electricity by alternator

Replace

circuit diagram

Panel I

Alternator

PO 1 (040 16)

TXP02419

PC1 28US-2

20-509 0

M-9

TROUBLESHOOTING

M-9 *

Abnormality

in engine water temperature

gauge

* *

Before carrying out troubl&hooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. When engine water temperature is normal.

a)

After engine is started,

temperature

remains

at bottom

inserted.

level and does not move

RemedY

YES 1

Does level go up one at a time and finally go out?

-

2

YES ~

p Does level go up *Turn starting switch _ one at a time and ON. NO finally go out? * Connect short connector to P07. . Turn starting switch NO -See Note 1. ON. - Short circuit PO6 (6) and (3). * See Note 1.

b)

Defective coolant temperature sensor

Fil?plaCe

Defective contact or disconnection in wiring harness between PO1 (female) (6) - PO7 (female) (i), or defective contact or disconnection in wiring harness between P2 (female) (2) and chassis ground



Replace

Note 1) If the condition is normal, the display goes up one level approx. every 2 sec.

After engine is started, temperature

immediately

goes up (there is no overheating

but gauge enters

red range) Cause

2 YES Is resistance YES between PO7 1 (male) (1) and (2) normal? Is voltage between p PO1 (3) and chassis - * Start engine’ * Min. 4 kQ ground normal? * Disconnect P07. *Start engine. * Max. 0.1 V

Monitor


NO

NO


Remedy

Defective coolant temperature sensor

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (3) and chassis ground


circuit diagram

Panel

I

PO1 (04016)

w-2 (SWP12) @

Alternator

El7 (X2) 3

o *R 0

TXP02419

20-510 0

PC1 28US-2

M-10

TROUBLESHOOTING

M-10 Abnormality * * Jr

in fuel gauge

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. When fuel level is normal.

a) No segments

on fuel gauge light up Cause

Defective fuel level sensor (internal disconnection)

YES

Defective contact or disconnection in wiring harness between PO1 (female) (7) and PO6 (female) (I), or defective contact or disconnection in wiring harness between fuel level sensor f-end) and chassis ground

segments light Does fuel gauge * Ground PO6 (female) - give full tank (1) to chassis. No display? *Turn startina switch ON. * ;;;:3;.ircuit PO1 (7) NO *Wait for approx. 1 minute. . Turn starting switch ON. *Wait for approx. 1 minute.

-1

YES 2 --out? Is resistance of . fuel level SenSOr

3 YES

normal? 1

PO1 (3) and chassis

-Start engine. . Max. 0.1 V

PC128US-2

II

Do all segments on fuel gauge go -1

_

* Disconnect P06. NO -Turnstarting switch ON. *Wait for approx. 1 minute.

p . Remove sensor. * Move float by hand NO and measure resistance behveen PO6 (male) (1) and chassis ground. * F position: Max. 10 L2 * E position: Min. 85 Q * Disconnect P4.

seplace

Iepair or replace viring harness

teplace

at full tank display

Cause

I

Remedy


b) Fuel level has gone down but fuel gauge remains

YE

inserted.

Remedy


?eplace

Short circuit with chassis ground in wiring harness between PO1 (female) (7) and PO6 (female) (1)


Defective fuel level sensor

i(eplace



20-511 0

TROUBLESHOOTING

c)

M-10

Even when tank is filled, fuel gauge does not give full tank display

I

2 YES

Is resistance of fuel level sensor

YES Is voltage between 1 - PO1 (3) and chassis ground normal? -

normal? - Remove sensor. .zdv;;;;;rV hand

* start engi”e. - Max. 0.1 V

k NO

NO

Cause

1 Remedy


Replace



Defective fuel level sensor

Replace

resistance between PO6 (male) (1) and chassis ground. * F position: Max. 10 Q * Disconnect P06.

M-10 Related

Monitor

electrical

circuit diagram

Panel I

PO 1 (040 16)

Fuel level sensor

TXP02425

20-512 a

PC1 28lJ.S2

M-II

TROUBLESHOOTING

M-l 1 Defective operation * Ir a)

of alarm buzzer

Before carrvino out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Buzzer does not sound

inserted.

Remedy

YES


leplace

Defective contact or disconnection in wiring harness between PO4 (female) (1) and PO1 (female) (15). or defective buzzer

tepair or replace viring harness

1 Does buzzer sound when PO1 (female) _ VE’ --A ‘=I --^

- YES

_

C

~~~

*Turn starting switch ON.

b)

Buzzer continues

Defective contact or disconnection in wiring harness between battery relay terminal M - Ml4 (1). (2)-CN-4(l)-fuse2-PO4 (female) (2). or blown fuse !5

NO

Iepair or replace wiring harness

to sound and does not stop Remedy

Replace when PO1 is disconnected?

Contact of chassis ground with wiring harness between PO1 (female) (15) and PO4 (female) (1)

-Disconnect POl. NO -Turn starting switch ON.

M-l 1 Related

electrical

circuit diagram

1 (KESl

PO4 (M2)

2) @.

Panel

3

= -

a Monitor


I

Al arm buzzer

Fusible I ink

3 ry

TXP02426

PC1 28U.52

20-513 0

M-12

TROUBLESHOOTING

M-12 Service meter does not advance when engine is running * Ir


a)

When battery

charge caution

inserted.

lamp does not light up Remedy

YES

1 Is voltage between PO1 (female) (10) and (3) normal?

NO

*Start engine. .20-30V

b)

When battery

charge caution

Jc Carry out Troubleshooting


Replace

Contact of chassis ground with wiring harness between PO1 (female) (10) and CN-2 (female) (5)


lamp lights up Remedy

No. M-9.


I

YES

Is continuity between PO1 ?) (10) and

NO

ngine. 29.5 v * Start engine. - Measure voltage between alternator terminal R and chassis ground. -27.5 - 29.5 V

Defective generation of electricity by alternator

I

qepair or replacf

3eolace

No


Monitor

Contact of chassis ground with wiring harness between PO1 (female) (10) and tilternator terminal R

Replace

circuit diagram

Panel I

PO1 (04016)

CN-2 (SWP12) @

Alternator

El7 (X2) -o --OR 0

TXP02419

20-5 14 0

PC1 28US-2

M-13

TROUBLESHOOTING

M-13 Night lighting does not light up J, -Before carrying out troubleshooting, check that all the related connectors are properly -k .Always connect any disconnected connectors before going on the next step. a)

Gauge lighting

inserted.

does not light up Remedy

Cause

1 Is voltage between PO1 (female) (16) and (3) normal?

1

Blown lamp (mslde monitor panel) for night lighting

YES

Defective contact or disconnection in wiring harness between PO1 (female) (16) and PO2 (female) (3)

11

* Disconnect POl. NO . Turn starting switch ON. . Turn light switch ON. .20-30V

b)

Service mefer

lighting

Remedy

Replace

circuit diagram

Lighting

switch

’

,...

PC1 28US-2

I

does not light up


electrical


I

I

Cause

M-13 Related

Rep,ace

Fusible I ink

Battery relay

TXP02428

20-515 0

M-14

TROUBLESHOOTING

M-14 Heater does not work * *


a)

Neither

Hi nor Lo work

Remedy

2 YES Isthere continuity :Es Is continuity (between MO6 male terminals) of _ heater switch as shown in table below?

between MO6 (female) (4) and chassis ground?

1

NO

* Turn starting switch OFF.

* Turn starting switch OFF. NO -Disconnect M06.

b)

inserted.

F Go to troubleshooting of heater Defective contact or disconnection in wiring harness between MO6 (female) (4) and chassis ground

Repair or replace

Defective heater switch

Replace

Only Lo does not work Cause

2 YES Is there continuity YES between Ml 2 (female) (2) and 1 chassis ground? ~ Is there continuity _ - DisconnectM12. between MO6 -Turn starting switch (male) (3) and (4)? -Turn starting switch

j

NO

OFF. to Lo.

- Disconnect M06. - 2;; starting switch NO

1 Remedy

Go to troubleshooting of heater Defective contact or disconnection in wiring harness between MO6 (female) (3) and Ml2 (female) (2)

Repair or replace


Replace

*Turn heater switch to Lo.

c)

Only Hi does not work Cause

Remedy

Go to troubleshooting of heater

I I

I

I

*Disconnect M12. NO -Turn starting switch OFF. -Turn starting switch to Hi

between MO6 (male) (2) and (4)? 4

-Disconnect M06. -2;; starting switch NO

Defective contact or disconnection in wiring harness between MO6 (female) (3) and Ml2 (female) (2)

3epair or replace


Ieplace

-Turn heater switch to Hi.

20-5 16 0

PC1 28US-2

TROU~~LESHOOTING

M-14

M-14 Related electrical circuit diagram

Preheating

switch ~06 (KES~

~12 (KES~

4)

I

PC1 28US-2

3)

Preheating switch

,____

TXP0.2429

20-517 0

TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up Actions to be taken on monitor panel and phenomena on machine body at the time of abnormality occurrence ....................................................................................................... 20-554 Electrical circuit diagram of mode M System .............................................................................................. 20-556 M-1 [E101] (An error history data abnormality) is displayed .................................................................. 20-560 M-2 [E108] (Detection of engine water temperature 105° ) is displayed................................................ 20-562 M-3 [E112] (Short circuit of wiper normal rotation output) is displayed .................................................. 20-562 M-4 [E113] (Short circuit of wiper reverse rotation output) is displayed ................................................. 20-562 M-5 [E114] (Contact of washer output with 24V) is displayed................................................................ 20-562 M-6 [E115] (Impossibility in 10 sec. at the time of wiping away) is displayed ........................................ 20-562 M-7 [E116] (Impossibility in 10 sec. of storage) is displayed.................................................................. 20-562 M-8 When the starting switch is set to ON, the whole monitor panel does not come ON for 3 sec ....... 20-563 a) When the whole monitor panel does not come ON .................................................................... 20-563 b) When part of the monitor panel does not come ON ................................................................... 20-563 M-9 The starting switch is set to ON, and the whole monitor panel remains lighted.............................. 20-566 M-10 (The engine pre-heating monitor) comes ON even without pre-heating arrangement ................... 20-567 M-11 When the starting switch is set to ON, the engine is started, the basic check items flash.............. 20-569 a) Alternator system........................................................................................................................ 20-569 b) Engine oil pressure system ........................................................................................................ 20-570 M-12 When the starting switch is set to ON (the engine stopped), precautions and emergency stop items flash. (But "Battery" and "Engine oil pressure" do not come ON)............... 20-571 a) Alternator system........................................................................................................................ 20-571 b) Oil pressure sensor system ........................................................................................................ 20-572 M-13 When the starting switch is set to ON and the engine is started, precautions and emergency stop items flash. (But when inspection items before diagnosis and engine are normal) ................ 20-573 a) (Engine oil pressure) flashes ...................................................................................................... 20-573 b) (Battery charge level) flashes ..................................................................................................... 20-573 c) (Coolant temperature) flashes .................................................................................................... 20-574 d) (Fuel level) flashes ..................................................................................................................... 20-575 M-14 When the starting switch is set to ON (the engine stops), the buzzer does not sound for 1 sec Though caution items flash, the buzzer does not sound ................................................................ 20-576 M-15 Monitor panel night lighting does not come ON. (The liquid crystal display is normal)................... 20-577 M-16 The coolant temperature gauge does not rise ................................................................................ 20-578 M-17 The coolant temperature gauge does not indicate (During operation, the gauge does not indicate any stage) ............................................................ 20-578

PC128US-2

20-551 (17)

M-18 M-19 M-20 M-21 M-22 M-23 M-24

M-25

The fuel level gauge indicates FULL all the time ............................................................................ 20-580 The fuel level gauge indicates nothing............................................................................................ 20-580 Though the swing lock switch is set to ON (lock), (the swing lock monitor) does not come ON..... 20-582 While the engine is rotating, the service meter does not advance.................................................. 20-582 The fuel level sensor system is defective ....................................................................................... 20-583 The coolant temperature sensor system is defective...................................................................... 20-584 The windshield wiper does not work, or works though the wiper is not switched ON..................... 20-585 a) The windshield wiper does not work........................................................................................... 20-585 b) The windshield wiper works though it is not switched ON .......................................................... 20-585 The washer motor does not work, or works though the washer is not switched ON ...................... 20-588 a) The washer motor does not work ............................................................................................... 20-588 b) The washer motor works though the washer is not switched ON............................................... 20-588

! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and connectors were returned to the original positions, the machine has restored. ! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the service code "E" is displayed. (When the service code is not displayed, the machine has restored.) ! Before diagnosis, check if related connectors are engaged properly. ! Be sure to return disconnected connectors to the original positions before proceeding to the next step.

20-552 (17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500

20-556 (17)

PC128US-2

TROUBLESHOOTING



20-558 (17)

PC128US-2

TROUBLESHOOTING

PC128US-2


20-559 (17)

TROUBLESHOOTING

M-1

M-1 [E101] (An error history data abnormality) is displayed. PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 " This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13 connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the battery terminals are disconnected and connected for troubleshooting. This is not an abnormality. (When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF) " When the service code is displayed again after the resetting arrangement is made, follow the procedures below for diagnosis:

Cause

Remedy

1 • After making the "Resetting arrangement," check the situations for a while in the normal operation. (See Note 1.)

Is the service code displayed NO again after the "Resetting arrangement" is taken?

Normal

—

YES

2 • Set the starting switch to OFF. • 20 – 30V

Is the voltage between P01 (8) NO and the machine body normal?

Disconnection, defective contact or ground fault of harness among the bat- Repair or tery, M13 (1), (2) and P01 (female) (8) replace

YES Defective monitor panel

Replace

Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is. (This deletes all service codes stored in the internal memory.)

M-1 Related Electrical Circuit Diagram

20-560 (17)

PC128US-2

TROUBLESHOOTING

M-1

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up " This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13 connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the battery terminals are disconnected and connected for troubleshooting. This is not an abnormality. (When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF) " When the service code is displayed again after the resetting arrangement is made, follow the procedures below for diagnosis:

Cause

Remedy

1 • After making the "Resetting arrangement," check the situations for a while in the normal operation. (See Note 1.)

Is the service code displayed NO again after the "Resetting arrangement" is taken?

Normal

—

YES

2 • Set the starting switch to OFF. • 20 – 30V


Disconnection, defective contact or ground fault of harness among the bat- Repair or tery, M13 (1), (2) and P01 (female) (8) replace


Replace

Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is. (This deletes all service codes stored in the internal memory.)


PC128US-2

20-561 (17)

TROUBLESHOOTING

M-2, M-3, M-4, M-5, M-6, M-7

M-2 [E108] (Detection of engine water temperature 105°) is displayed.

Cause

Remedy

1 Does the coolant temperature gauge NO on the monitor indicate a red range and is the caution lamp flashing?

YES See M-13-c).

—

Failure of engine body system (See Note 1.)

—

2 • Set the starting switch to ON.

Is "E" shown in front of the serv- NO ice code?


Replace

Note 1 : The monitor panel has returned to normal as far as the display is concerned. Since the coolant temperature sensor detected water temperatures of over 105°C so far, remove the factors in the troubleshooting of the engine body.

M-3 [E112] (Short circuit of wiper normal rotation output) is displayed. " See M-24.

M-4 [E113] (Short circuit of wiper reverse rotation output) is displayed. " See M-24.

M-5 [E114] (Contact of washer output with 24V) is displayed. " See M-25.

M-6 [E115] (Impossibility in 10 sec. at the time of wiping away) is displayed. " See M-24.

M-7 [E116] (Impossibility in 10 sec. of storage) is displayed. " See M-24.

20-562 (17)

PC128US-2

TROUBLESHOOTING

M-8

M-8 When the starting switch is set to ON, the whole monitor panel does not come ON for 3 sec. PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 " Make sure that Fuses 6, 13 and 18 are not blown. a) When the whole monitor panel does not come ON

Cause

Remedy

1 • Set the starting switch to ON. • 20 – 30V

Are the voltages among P01 (8) – NO (6), (7), P02 (1), (2) – (6) and (7) normal?

YES Defective monitor panel.

Replace


Is the voltage between Fuse 13 NO and the machine body normal?

YES

Disconnection, defective contact or Repair or ground fault of harness between Fuse replace 13 and battery relay RM. Disconnection, defective contact or ground fault of harness between P01 (female) (1) (2) and Fuse 13

Repair or replace



YES

Disconnection, defective contact or Repair or ground fault of harness between Fuse replace 18 and Battery B. Disconnection, defective contact or ground fault of harness between P02 (female) (19) and Fuse 6

Repair or replace

b) When part of the monitor panel does not come ON

Cause


PC128US-2

Remedy

Replace

20-563 (17)

TROUBLESHOOTING

M-8

M-8 a) Related Electrical Circuit Diagram

20-564 (17)

PC128US-2

M-8

TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up a Make sure that Fuses 6, 12 and 18 are not blown. a) When the whole monitor panel does not come ON

Cause

Remedy


Are the voltages among P01 (8) – NO (6), (7), P02 (1), (2) – (6) and (7) normal?


Replace



YES

Disconnection, defective contact or Repair or ground fault of harness between Fuse replace 12 and battery relay RM. Disconnection, defective contact or ground fault of harness between P01 (female) (1) (2) and Fuse 12

Repair or replace



YES

Disconnection, defective contact or Repair or ground fault of harness between Fuse replace 18 and Battery B. Disconnection, defective contact or ground fault of harness between P02 (female) (19) and Fuse 6

Repair or replace

b) When part of the monitor panel does not come ON

Cause


PC128US-2

Remedy

Replace

20-565 (17)

TROUBLESHOOTING

M-8, M-9

M-8 a) Related Electrical Circuit Diagram

M-9 The starting switch is set to ON, and the whole monitor panel remains lighted. Cause


20-566 (17)

Remedy

Replace

PC128US-2

TROUBLESHOOTING

M-10

M-10

(The engine pre-heating monitor) comes ON even without pre-heating arrangement.

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Cause

Remedy

1 • Disconnect the terminal R1. • Set the starting switch to ON. • Max. 1V

Is the voltage between the starting NO switch R1 and the machine body normal?

Defective starting switch

Replace

YES

2 • Set the starting switch to ON. • Max. 1V


Hot short circuit of harness between Repair or starting switch R1 and P02 (female) replace (18)


Replace


PC128US-2

20-567 (17)

TROUBLESHOOTING

M-10

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up a Make sure that S-NET is normal Cause

Remedy

1 • Disconnect the terminal R1. • Set the starting switch to ON. • Max. 1V

Is the voltage between the starting NO switch R1 and the machine body normal?

Defective starting switch

Replace

YES

2 • Set the starting switch to ON. • Max. 1V

Is the voltage between CR1 (11) NO and the machine body normal?

Hot short circuit of harness between Repair or starting switch R1 and CR1 (female) replace (11)

YES

3 Are the monitoring code [0045] – NO (3) and [1027] – (3) ON?


Replace


Replace


Replace

YES

4 Is the monitoring code [1061] – NO (2) ON?

YES


20-568 (17)

PC128US-2

TROUBLESHOOTING

M-11

M-11 When the starting switch is set to ON, the engine is started, the basic check items flash. a Inspect both the alternator system and the engine oil pressure system. a) Alternator system a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is defective. Cause

Remedy

1 • Engine start, Medium speed min. • 20 – 30V

Is the voltage between the alter- NO nator R and the machine body normal?


Replace

YES

2 • Engine start, Medium speed min. • 20 – 30V

Is the voltage between P02 (fe- NO male) (11) and the machine body normal?

Disconnection or defective contact of Repair or harness between alternator R and P02 replace (female) (11)


Replace

M-11 a) Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


PC128US-2

20-569 (17)

TROUBLESHOOTING

M-11

b) Engine oil pressure system a When the engine oil pressure is normal a Check Bit (3) of Monitoring Code [0046] When it is ON, the monitor panel is defective.

Cause

Remedy

1 • Engine slow

Does the display disappear when NO the oil pressure sensor terminal S17 is disconnected at engine slow?

YES

The oil pressure sensor is defective (at low pressure).

Replace


Replace

2 • Set the starting switch to OFF. • Disconnect the sensor harness and P02.

Is there continuity between P02 NO (female) (7) and the machine body?

YES

Ground fault of harness between P02 Repair or (female) (7) and sensor terminal S17 replace

M-11 b) Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


20-570 (17)

PC128US-2

TROUBLESHOOTING

M-12

M-12 When the starting switch is set to ON (the engine stopped), precautions and emergency stop items flash. (But "Battery" and "Engine oil pressure" do not come ON.) a

Inspect both the alternator system and the engine hydraulic system.

a) Alternator system a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is defective.

Cause

Remedy

1 • Disconnect the terminal R. • Set the starting switch to ON. • Max. 1V

Is the voltage between the alter- NO nator R and the machine body normal?


Replace

YES

2 • Disconnect P02. • Set the starting switch to ON. • Max. 1V


Hot short-circuit of harness between Repair or P02 (female) (11) and alternator R replace


Replace

M-12 a) Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


PC128US-2

20-571 (17)

TROUBLESHOOTING

M-12

b) Oil pressure sensor system a When the engine oil pressure is normal a Check Bit (3) of Monitoring Code [0046] When it is ON, the monitor panel is defective.

Cause

Remedy

1 • Set the starting switch to OFF. • Disconnect the sensor terminal S17.

Is there continuity between the NO sensor terminal S17 and the machine body?

Defective oil pressure sensor

Replace

YES

2 • Set the starting switch to ON. • Disconnect P02 and sensor terminal S17.

Is there continuity between P02 NO (female) (11) and the sensor terminal S17?

Disconnection or defective contact of harness between P02 (female) (7) and Repair or replace sensor terminal S17


Replace

M-12 b) Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


20-572 (17)

PC128US-2

TROUBLESHOOTING

M-13

M-13 When the starting switch is set to ON and the engine is started, precautions and emergency stop items flash. (but when inspection items before diagnosis and engine are normal) a)

(Engine oil pressure) flashes. ! Before diagnosis, make sure that the engine oil pressure is normal.

Cause

—

See M-12-b).

b)

(Battery charge level) flashes.

Cause

See M-12-a).

PC128US-2

Remedy

Remedy

—

20-573 (17)

TROUBLESHOOTING

c)

M-13

(Coolant temperature) flashes. !

Before diagnosis, make sure that the engine oil pressure is normal.

Cause

Remedy

1 • Engine start • Medium speed min.

Is the coolant temperature gauge NO in the red range?


Replace

YES

2 • Engine start

Is only Level 1 (the lowest level) of the gauge displayed after P07 NO is disconnected?

YES

The coolant temperature sensor system is defective. (See M-25.)

—

3 • Set the starting switch to OFF. • Disconnect P02 and P07. • Max. 1 Ω

Is the resistance value between NO P02 (female) (1) and P07 (female) (1) normal?

Disconnection or defective contact of Repair or harness between P02 (female) (1) and replace P07 (female) (1)

YES

Disconnection or defective contact of Repair or harness between P02 (female) (1) and replace P07 (female) (2)

M-13 c) Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


20-574 (17)

PC128US-2

TROUBLESHOOTING

d)

M-13

(Fuel level) flashes. ! Before diagnosis, make sure that fuel is not empty.

Cause

Remedy

1 • Engine start

Is the fuel gauge in the red range?

NO


Replace

The fuel level sensor system is defective. (See M-22.)

—

YES • Engine start • Wait for 2 minutes approx. (The display of fuel level is arranged to be slightly delayed because the fuel level fluctuates.)

• Connect P06 (female) (1) to the machine body ground. • Set the starting switch to ON. • Max. 0.3V

2 Does the gauge indication come on up to Level 9 (the right end) NO when P06 (female) (1) is connected to the machine body ground?

YES

3 Is the voltage between P02 (2) NO and the machine body normal?

YES

Disconnection or defective contact of harness between P02 (female) (2) and Repair or replace P06 (female) (1) Defective monitor panel

Replace

M-13 d) Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


PC128US-2

20-575 (17)

TROUBLESHOOTING

M-14

M-14 When the starting switch is set to ON (the engine stops), the buzzer does not sound for 1 sec. Though caution items flash, the buzzer does not sound. ! Even when "BATTERY CHARGE LEVEL" or "FUEL" of the caution items becomes abnormal, the buzzer does not sound. ! The buzzer is controlled inside the monitor panel. When a buzzer sound is requested or when the voltage of P01 (11) comes to the range from 20 to 30V, the buzzer will sound.

Cause • Set the starting switch to OFF. • Disconnect P03. • Set the buzzer cancel switch to ON : Max. 1Ω • Set the buzzer cancel switch to OFF : Min. 1 M Ω

Remedy

1 Is the resistance value between NO P03 (female) (1) a d (2) normal?

Defective buzzer cancel switch

Replace

YES

2 • Disconnect P03. • Set the starting switch to ON. • 20 – 30V


Ground fault of harness between P02 Repair or (female) (16) and P03 (female) (2) replace


Replace

M-14 Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


20-576 (17)

PC128US-2

TROUBLESHOOTING

M-15

M-15 Monitor panel night lighting does not come ON. (The liquid crystal display is normal.) ! When the headlamp and the working lamp come ON normally,

Cause

Remedy

1 • Set the starting switch to ON. • Set to Monitoring Code [0045].

NO

Is Bit (4) of Monitoring Code [0045] OFF?


Replace

2 • Set the starting switch to ON. • Set the lighting switch to ON. • 20 – 30V


Disconnection or defective contact of Repair or harness between P02 (female) (19) replace and M47 (male) (14)


Replace


PC128US-2

20-577 (17)

TROUBLESHOOTING

M-16, M-17

M-16 The coolant temperature gauge does not rise. !

When engine water temperature does not rise practically, flashes the engine system.

Cause

Remedy

1 • Disconnect P07. • Set the starting switch to ON.

When a short connector is connected to P07 (female), does the gauge NO level rise step by step and does the gauge go out finally?

YES


—

Disconnection or defective contact of harness between P02 (female) (1) and P07 (female) (1)

Repair or replace

Disconnection or defective contact of harness between P02 (female) (13) (20) and machine body P02 (female) (2) machine body

Repair or replace


Replace

2 • Set the starting switch to OFF. • Disconnect P02 and P07.

Is there continuity between P02 NO (female) (1) and P07 (female) (1)?

YES


Is there continuity between P02 (female) (13) (20) and P07 (female) (2)?

NO

YES

M-17 The coolant temperature gauge does not indicate. (During operation, the gauge does not indicate any stage.) ! When the starting switch is set to ON, the gauge level will rise step by step and the gauge will go out finally or during operation the gauge does not indicate any satage. Cause

Remedy


Does the gauge indication appear NO when P07 is disconnected?

YES


—

2 • Set the starting switch to ON. • Disconnect P02 and P07.

Is there continuity between P02 NO (female) (1) and the machine body?

YES

20-578 (17)


Replace

Ground fault of harness between P02 (female) (1) and P07 (female) (1)

Repair or replace

PC128US-2

TROUBLESHOOTING

M-16, M-17

M-16, M-17 Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


PC128US-2

20-579 (17)

TROUBLESHOOTING

M-18, M-19

M-18 The fuel level gauge indicates FULL all the time. ! Before the diagnosis, make sure that the fuel tank is really filled with fuel.

Cause • Set the starting switch to ON. • Wait for 2 minutes approx. (The display of fuel level is arranged to be slightly delayed because the fuel level fluctuates.)

Remedy

1 When P06 is disconnected, does the NO gauge level fall step by step and does the gauge indication go out finally?

YES


—


Replace


Is there continuity between P02 (fe- NO male) (2) and the machine body?

YES

Ground fault of harness between P02 Repair or (female) (2) and P06 (female) (1) replace

M-19 The fuel level gauge indicates nothing. ! Before the diagnosis, make sure that fuel remains in the fuel tank.

Cause

Remedy


Does the gauge indicate anything NO after P06 (female) (1) is connected to the machine body ground?

YES


—


Is there continuity between P02 (female) (2) and the machine body after NO P06 (female) (1) is connected to the machine body ground?

YES

20-580 (17)

Disconnection or defective contact of harness between P02 (female) (2) and Repair or replace P06 (female) (1) Defective monitor panel

Replace

PC128US-2

TROUBLESHOOTING

M-18, M-19

M-18, M-19 Related Electrical Circuit Diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500


PC128US-2

20-581 (17)

TROUBLESHOOTING

M-20, M-21

M-20 Though the swing lock switch is set to ON (lock), (the swing lock monitor) does not come ON. ! Execute this troubleshooting only when the swing lock is in operation practically. Cause

Remedy

1 Is the voltage between P02 (17) NO and the machine body as per the table?

• Set the starting switch to ON.

Disconnection or defective contact of Repair or harness between P02 (female) (17) replace and X05 (male) (1)

YES Table Swing lock switch ON Swing lock switch OFF


Replace

Max. 1V 20 – 30V



M-21 While the engine is rotating, the service meter does not advance. Cause

Remedy

1 • Start the engine. Medium speed min.

Is the battery charge level caution NO lamp ON?


Replace

See M-12 a).

—

YES

20-582 (17)

PC128US-2

TROUBLESHOOTING

M-22

M-22 The fuel level sensor system is defective. ! Before the diagnosis, remove the fuel level sensor.

Cause

Remedy

1 Check by raising and lowering the float if the resistance valve NO between the connector (1) and the flange is as per the table.

YES

2 NO

Defective sensor (See Note 2.)

Replace

Does the float have large crack, NO chip or flaw?

Defective contact of connector

Clean or replace the connector.

Interference of sensor in tank

Replace the sensor. (See Note 2.)

Defective sensor

Replace

Does the arm move smoothly?

YES

3

YES

4 Is it found in visual check that the NO harness is cut?

Disconnection of harness (See Note 3.) (Defective clamp) (Apply of external force)

YES

Table Upper stopper position (Full)

About Max. 12Ω

Lower stopper position (Empty)

About 85 – 110Ω

Note 1 : Difference between Fuel Level and Gauge Indication When the gauge indication is FULL, the fuel level is indicated as 78~100%, and when the indication is at the lowest position, the fuel level is indicated as 14.5% max. When the machine body is inclined, the actual indication is different from them. Check the gauge 2 or more minutes later than parking the machine body on a level ground. (The gauge is arranged to indicate fuel level slowly because the fuel level fluctuates.) Note 2 : Install the sensor carefully so that it does not interfere inside the tank or that it may be installed improperly. Note 3 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.

PC128US-2

20-583 (17)

TROUBLESHOOTING

M-23

M-23 The coolant temperature sensor system is defective. Cause

Remedy

1 Is the resistance value between the NO temperature sensor connectors (male) (1) and (2) as per the table?

YES

Defective contact of connector (See Note 1.)

Clean the connector or replace the sensor.

Defective sensor

Replace

2 Is it found in visual check that the NO harness is cut?

YES

Disconnection of harness (See Note 2.) Replace the (Defective clamp) sensor. (Apply of external force)

Table Normal temperature (25°C)

About 37 – 50k Ω

100°C

About 3.5 – 4.0k Ω

Note 1 : In case of recurrence, the machine side connector (female side) is supposed to be defective. So, check the machine side connector and harness. Note 2 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.

20-584 (17)

PC128US-2

TROUBLESHOOTING

M-24

M-24 The windshield wiper does not work, or works though the wiper is not switched ON. a) The windshield wiper does not work. ! Make sure that the fuse 18 is normal. ! Execute this diagnosis when the service code [E112] [E113], [E115] or [E116] is displayed. Cause • Front window : Close position • Set the starting switch to ON. • Set the monitoring code to [0049].

Remedy

1 NO

Does Bit (3) of the monitoring code [0049] come on?

YES • Set the starting switch to ON. • Set the wiper switch to "ON" or "INT." • Set the monitoring code to [0049].

2 When the wiper switch is set to "ON" or "INT," do Bits (4) and (5) NO of the monitoring code [0049] go out?


Replace

Defective wiper motor

Replace

YES

3 • Set the starting switch to ON.

NO

Are the voltages between pins of M50 as per Table 1?

YES

4 • Set the starting switch to OFF. • Disconnect P02 and M50.

Are the resistance values between pins from P01 (female) and NO M50 (male) as per Table 2?

YES

• Set the starting switch to OFF. • Disconnect Terminals (1) and (2) of W03. • Max. 1Ω

Disconnection, defective contact, short- Repair or circuit of ground fault of harness of im- replace proper resistance value Defective monitor panel

5 Is the resistance value between NO Terminals (1) and (2) of the rear limit switch W03 normal?

Replace

Check the front window, The rear limit switch is defective, or the or replace the front window is opened. rear limit switch.

YES

6 .• Set the starting switch to OFF. • Disconnect P02 and Terminals (1) and (2) of W03. • Max. 1Ω

Are the resistance values between the rear limit switch W03 terminal NO (1) and P02 (female) (15) and between W03 Terminal (2) and the machine body normal?

Disconnection or defective contact of Repair or harness of improper resistance value replace


Replace

b) The windshield wiper works though it is not switched ON. Cause

Remedy

1 • Front window : Closed position • Set the starting switch to ON. • Set the monitoring code to [0049]

NO

Does Bit (3) of the monitoring code [0049] come ON?


Replace


Replace

YES • Set the starting switch to ON. • Set the wiper switch to "ON" or "INT." • Set the monitoring code to [0049].

PC128US-2

2 When the wiper switch is set to NO "ON" or "INT," do Bits (4) and (5) of the monitoring code [0049] go out?

YES

Hot short circuit of harness between P01 (female) (9) and M50 (female) (3) Repair or or between P01 (female) (10) and M50 replace (female) (1)

20-585 (17)

TROUBLESHOOTING

M-24

Table 1 Timing Chart when the windshield wiper is set to ON Symbol

Set time

Temporary stop time to the next operation

Item

Tia

0.13 sec

Safety circuit during wiper operation (Safety function 1)

Tsa

10 sec

Temporary halt time at wiper blade storage

Tip

1.5 sec

Safety circuit at wiper storage (Safety function 2)

Tsp

10 sec

When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in the range of 20 – 30V.

Timing Chart when the windshield wiper is set to INT. Item

Symbol Set time

Temporary stop time to the next operation

Tia

4 sec

Safety circuit during wiper operation (Safety function 1)

Tsa

10 sec

Temporary halt time at wiper blade storage

Tip

1.5 sec

Safety circuit at wiper storage (Safety function 2)

Tsp

10 sec

When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in the range from 20 – 30V. Table 2 Diagnosis 1

Resistance value

Between P01 (female) (10) and M50 (male) (1) Between P01 (female) (9) and M50 (male) (3) Between P01 (female) (12) and M50 (male) (4)

Max. 1Ω

Between P01 (female) (6), (7) and M50 (male) (5) Between P01 (female) (5) and M50 (male) (6) Between M50 (female) (1), (3), (4), (5), (6) and GND

20-586 (17)

Min. 1MΩ

PC128US-2

TROUBLESHOOTING

M-24



PC128US-2

20-587 (17)

TROUBLESHOOTING

M25

M-25 The washer motor does not work, or works though the washer is not switched ON. a) The washer motor does not work. ! Make sure that Fuse 4 is normal. a-1) When [E114] is displayed.

Cause

Remedy

1 • Set the starting switch to ON. • Disconnect P02 and M28. • Max. 1V

Is the voltage among P01 (fe- NO male) (3), M28 (female) (2) and the machine body normal?

YES

Hot short circuit of harness between Replace P01 (female) (3) and M28 (female) (1). • Defective monitor panel • Defective diode

Repair or replace

a-2) When [E114] is not displayed.

Cause

Remedy

1 • Set the starting switch to ON. • Disconnect M28. • Max. 20 – 30V

Is the voltage among Fuse 4, NO M28 (female) (2) and the machine body normal?

Disconnection or defective contact of Repair or harness between Fuse 4 and M28 (fereplace male) (2).

YES

2 • Set the starting switch to OFF. • Disconnect P01 and M28. • Max. 1Ω

Is the resistance value between NO P01 (female) (3), M28 (female) (1) normal?

Disconnection or defective contact of harness between P01 (female) (3) and M28 (female) (1).

Repair or replace

Defective washer motor

Replace


Replace

YES

3 • Set the starting switch to ON. • Set the washer switch to ON. • Max. 1V

Is the voltage between P01 (fe- NO male) (3) and the machine body normal?

YES

b) The washer motor works though the washer is not switched ON.

Cause

Remedy

1 • Set the starting switch to OFF. • Disconnect P02 and M28. • Min. 1M Ω

Is the resistance value between NO M28 (female) (1) and the machine body normal?

Ground fault of harness between P01 Repair or (female) (3) and M28 (female) (1). replace


20-588 (17)

Replace

PC128US-2

TROUBLESHOOTING

M-25



PC128US-2

20-589 (17)

TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE)

PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up N-1 [E218] Communication abnormality ................................................................................................... 20-602

! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and connectors were returned to the original positions, the machine has restored. ! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the service code "E" is displayed. (When the service code is not displayed, the machine has restored.) ! Before diagnosis, check if related connectors are engaged properly. ! Be sure to return disconnected connectors to the original positions before proceeding to the next step. PC128US-2

20-601 (17)

TROUBLESHOOTING

N-1

N-1

[E218] Communication abnormality

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 1

Cause

Remedy

Are [128] and "US" intermittently NO displayed in the monitoring code 1002?

YES

• Set the starting switch to ON. • 7.5V min. • Disconnect CR2 and measure the voltage on the harness side.

The machine has restored.

—

Defective controller CR700

Replace

2 Is the voltage between CR2 (21) NO and the machine body normal?

YES

3 Is the resistance value among NO P02 (9), (10) and CR2 (21) normal?

YES

•

Disconnection of harness among P02 Replace (9), (10) and CR2 (21) Defective monitor panel

Replace

When each controller is not connected to the network, "---" is displayed. When a correct alphanumeric character is not displayed (when another model is displayed), the model of each controller has not been selected properly.

N-1 Related Electrical Circuit Diagram

20-602 (17)

PC128US-2

TROUBLESHOOTING

N-1

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up 1

Cause

Remedy

Are model code and attachment NO code displayed according to setting in monitoring code 1001?

YES

• Set the starting switch to ON. • 7.5V min. • Disconnect CR2 and measure the voltage on the harness side.

The machine has restored.

—


Replace

2 Is the voltage between CR2 (21) NO and the machine body normal?

YES

3 Is the resistance value among NO P02 (9), (10) and CR2 (21) normal?

YES

Disconnection of harness among P02 Replace (9), (10) and CR2 (21) Defective monitor panel

Replace

N-1 Related Electrical Circuit Diagram

PC128US-2

20-603 (17)

TROUBLESHOOTING OF CONTROLLER CR700 [DECELERATION CONTROL SYSTEM] (E MODE) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up Cautions when troubleshooting controller CR700 [Deceleration control system] ....................................... 20-702 Response of controller and phenomena on machine body when abnormality has occurred...................... 20-704 Table for determining controller (Engine throttle control system) or engine related .................................... 20-706 Electric circuit diagram of E mode system ................................................................................................. 20-708 E-1 Abnormality in power supply of controller CR700 (LED on controller is OFF) ................................ 20-712 E-2 [E321] [E322] "Short circuit/disconnection in motor drive relay system" is displayed .................... 20-714 E-3 [E323] [E324] "Short circuit/disconnection in accelerator relay system" is displayed ..................... 20-715 E-4 [E325] [E326] "Short circuit/disconnection in decelerator relay system" is displayed..................... 20-717 E-5 [E328] "Abnormality in motor stall system" is displayed ................................................................. 20-719 E-6 [E308] "Abnormality in fuel dial input value" is displayed ............................................................... 20-721 E-7 [E227] "Abnormality in engine speed sensor system" is displayed ................................................ 20-722 E-8 [E306] "Abnormality in motor feedback potentiometer input value" is displayed ............................ 20-723 E-9 [E258] "Short circuit in potentiometer power supply" is displayed .................................................. 20-725 E-10 [E304] [E314] "Short circuit/disconnection in engine stop solenoid relay system" is displayed...... 20-727 E-11 Auto-decelerator does not operate ................................................................................................. 20-728

! During troubleshooting after an abnormality occurred, if service code "E" is not displayed when you inserted a T-adapter after detaching a connector, or when you connected the connector after detaching the Tadapter, the normal condition has been restored already. ! If you have turned off starting-switch after an abnormality occurred, turn it on and check to see if service code "E" is displayed. (If it is not displayed, the normal condition has been restored). ! Before starting troubleshooting, check for any faulty engagement of related connectors. ! Before going to next step in the troubleshooting procedure, be sure to connect any connector you have detached.

PC128US-2

20-701 (17)

CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [DECELERATION CONTROL SYSTEM]

TROUBLESHOOTING

CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [DECELERATION CONTROL SYSTEM] 1. The machine has the control function as shown below for starting cold engine to prevent seizure of turbocharger because of cold engine coolant (lower than 30°C).

Deceleration-motor potentiometer (Controls the process.)

Engine is forced to be fixed at the rpm for warming-up. (Any throttle direction is ignored.)

Any rpm (Follows the throttle direction.)

2 seconds Starting switch turned "ON"

A: Turbocharger protection time C: Modulation range

Starting switch turned to "START"

B: Modulation time D: When engine speed does not reach 1,200 rpm

The machine does not allow engine to start when coolant is cold (lower than 30° C) when the deceleration motor was found normal by the check of whether or not the deceleration motor linkage worked. ! To release this control of cold engine start, connect a short-circuit connector to engine-coolant-temperature sensor (CN-P07) connected to CN-P02 ((1)) on monitor panel and cause short circuit between it and GND {or between CN-P07 (female) (1) and GND}, or check operation in the deceleration-adjustment mode. 2. Cautions when an abnormality occurred with no user code displayed The engine is under the control of controller CR700. Problems which may occur in this system include: 1) Higher (lower) idling speed 2) Lower rpm in high idle 3) Higher (lower) rpm in auto-deceleration 4) Higher (lower) engine speed during auto-matic warming-up 5) Hunting 6) Engine does not stop. If an abnormality occurred, and it was alarmed in the clock-display section on monitor panel, look up to the corresponding diagnosis flow of E1 through E10 according to the quick-reference table for troubleshooting. If no abnormality was alarmed on the display though it existed in the machine body, you have to determine whether it occurred in "mechanical system or electric system". The problems listed in 1) - 6) above may also occur due to faulty adjustment of the linkage between deceleration motor and injection pump. If any of 1) - 6) above occurred without no alarm on the display, diagnose it according to the following procedure:

20-702 (17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 (1/2)

20-708 (17)

PC128US-2

TROUBLESHOOTING


(2/2)

PC128US-2

20-709 (17)

TROUBLESHOOTING


PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up (1/2)

20-710 (17)

PC128US-2

TROUBLESHOOTING


(2/2)

PC128US-2

20-711 (17)

TROUBLESHOOTING

E-1

E-1

Abnormality in power supply of controller CR700 (LED on controller is OFF)

! Check that fuse 11 is not blown. ! If starting motor runs normally, follow the procedure below. (Otherwise, refer to E-8.)

Cause

Remedy

1 • Turn starting switch ON • 20 – 30V

Is voltage normal between CR3 NO (1),(11) – (21), (31), (32), (33)?

YES Defective controller CR700

Replace

2 • Starting switch ON • 20 – 30V

Is voltage between fuse 18 and NO body normal?

YES

Disconnection or defective contact of Repair or harness between fuse 18 and battery. replace Disconnection or defective contact of harnesses between fuse 18 and CR3 Repair or replace (female) (1),(11).

E-1 Related electric circuit diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500

20-712 (17)

PC128US-2

TROUBLESHOOTING

E-1


PC128US-2

20-713 (17)

TROUBLESHOOTING

E-2

E-2

[E321] [E322] "Short circuit/Disconnection in motor drive relay system" is displayed Cause

• Turn starting switch ON; operate fuel dial. • 1.2A or less • Temperature of engine coolant: 30°C or higher

Remedy

1 Is current value normal between NO CR3 (female) (18) and (23)?

YES Defective controller

Replace

2 • Detach R07 and CR3. • Min. 1 MΩ

Is resistance value normal between NO CR3 (female) (18) and body?

Defective harness; defective connector Repair or CN-A09 replace

YES Defective relay

Replace


20-714 (17)

PC128US-2

TROUBLESHOOTING

E-3

E-3

[E323] [E324] "Short circuit/Disconnection in accelerator relay system" is displayed

Cause

Remedy

1 • Turn starting switch ON; operate dial (up). • 1.2A or less

Is current value normal between NO CR3 (female) (25) and (23)?


Replace



Defective harness; defective connector Repair or CN-A09 replace

YES Defective relay

Replace


PC128US-2

20-715 (17)

TROUBLESHOOTING

E-3


20-716 (17)

PC128US-2

TROUBLESHOOTING

E-4

E-4

[E325] [E326] "Short circuit/Disconnection in decelerator relay system" is displayed Cause

Remedy

1 • Turn starting switch ON; operate dial (down). • 1.2A or less.

Is current value normal between NO CR3 (female) (35) and (23)?


Replace

Defective harness

Repair or replace

Defective relay

Replace



YES


PC128US-2

20-717 (17)

TROUBLESHOOTING

E-4


20-718 (17)

PC128US-2

TROUBLESHOOTING

E-5

E-5

[E328] "Abnormality in motor stall system" is displayed

! Abnormality in motor stall is alarmed if motor did not follow the operation of dial for 10 seconds after the operation. Check by monitoring whether input signal and relay output are normal while the alarm issued remains on the display. PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 Cause • Turn starting switch ON. • 4A or less if normal When dialed up: (+) on (5) side, (–) on (6) side When dialed down: (–) on (5) side, (+) on (6) side

• Resistance value between (1) and (2) of eachrelay: 290 Ω ± 10% • Operation of each relay (when starting switch is ON) When neutral: (3) and (6) continue. When dialed up: R07, and R09 (3) and (5) continue. When dialed down: R07, and R08 (3) and (5) continue.

Remedy

1 Is current value normal between NO M48 (female) (5) (motor (+)) and (6)(motor (–))?

YES Defective motor (drive system)

Replace motor

Defective relay

Replace

Defective harness; fuse (9) blown

Repair or replace

2 Do relays of R07, R08 and R09 NO operate normally?

YES


PC128US-2

20-719 (17)

TROUBLESHOOTING

E-5


20-720 (17)

PC128US-2

E-6

TROUBLESHOOTING

E-6

[E308] "Abnormality in fuel dial input value" is displayed

! Check that the input value is normal in the monitoring mode. Cause

Remedy

1 –

• Fuel control dial voltage: Fuel control dial FULL: 0.7 V

Is fuel control dial voltage of NO monitoring 1034 normal?

Fuel control dial SLOW: 4.3 V • Disconnect M51. • M51 (male) Between (1) – (2): 0.25 – 5 kΩ Between (2) – (3): 0.25 – 5 kΩ Between (1) – (3): 4 – 6 kΩ • Between M51 (male) (1), (2), (3) – chassis ground: Min. 1 MΩ


Replace

Defective fuel control dial

Replace

Defective wiring harness

Repair or replace

2 Is resistance between M51 (male) NO (1), (2), and (3) normal?

YES


PC128US-2

20-721 (17)

TROUBLESHOOTING

E-7

E-7

[E227] "Abnormality in engine speed sensor system" Is displayed Cause

• Turn starting switch OFF: 0 • Engine slow: 93 +50 (930 rpm) (*1) 110 ± 5 (1,100 rpm) (*2) • Engine full: 240 ± 5 (2,400 rpm)

Remedy

1 NO

Is engine speed (monitoring code 1010) normal?


Replace


Replace

Defective harness

Replace motor

Faulty installation of engine-speed sensor

Testing and adjusting

2 • Detach E07 • 500 – 1,000 Ω

Is resistance value normal between E07 (male) (1) and (2)?

NO

YES 3 • Detach CR2 • 500 – 1,000 Ω

Is resistance value normal between CR2 (female) (39) and (40)?

YES

(*1) PC128US-2 PC138USLC-2 (*2) PC138US-2 PC138USLC-2

NO

Serial No.: 7731 and up Serial No.: 1001 – 1500 Serial No.: 4501 and up Serial No.: 1501 and up



20-722 (17)

PC128US-2

E-8

TROUBLESHOOTING

E-8

[E306] "Abnormality in motor feedback potentiometer input value" is displayed

! Check that the input value is normal in the monitoring mode.

Cause • Reset auto-decelerator. • Feedback potentiometer voltage: Fuel control dial FULL: 4.2 V (*1) 4.6 V (*2) Fuel control dial SLOW: 2.1 V (*1) 2.7 V (*2) • Disconnect M48. • M48 (male) Between (1) – (2): 0.36 – 3.9 kΩ Between (2) – (3): 1.4 – 5.5 kΩ Between (1) – (3): 5 ± 1 kΩ • Between M48 (male) (1), (2), (3) – chassis ground: Min. 1 MΩ

(*1) PC128US-2 PC138USLC-2 (*2) PC138US-2 PC138USLC-2

Remedy

1 Is feedback potentiometer voltage NO of monitoring 1035 normal?


Replace

Defective decelerator motor

Replace

Defective wiring harness

Repair or replace

2 Is resistance between M48 (male) NO (1), (2), and (3) normal?

YES

Serial No.: 7731 and up Serial No.: 1001 – 1500 Serial No.: 4501 and up Serial No.: 1501 and up


PC128US-2

20-723 (17)

TROUBLESHOOTING

E-8


20-724 (17)

PC128US-2

E-9

TROUBLESHOOTING

E-9

[E258] "Short circuit in potentiometer power supply" is displayed

• Disconnect CR1. • Resistance between CR1 (female) (22) – chassis ground: Min. 1 MΩ

1

Cause

Remedy

Is resistance between CR1 (female) NO (22) and chassis ground normal?

YES

• Disconnect M48. • Resistance between CR1 (female) (22) – chassis ground: Min. 1 MΩ


Replace

Defective deceleration motor

Replace

Defective wiring harness (Short circuit in 5-V line)

Repair or replace

Defective fuel control dial

Replace

2 Is resistance between CR1 (female) NO (22) and chassis ground normal?

YES

• Disconnect M51. • Resistance between CR1 (female) (22) – chassis ground: Min. 1 MΩ

3 Is resistance between CR1 (female) NO (22) and chassis ground normal?

YES


PC128US-2

20-725 (17)

TROUBLESHOOTING

E-9


20-726 (17)

PC128US-2

E-10

TROUBLESHOOTING

E-10 [E304] [E314] "Short circuit/Disconnection in engine stop solenoid relay system" is displayed PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Cause • Disconnect CR3. • Resistance between CR3 (female) (4) – chassis ground: 68 Ω ± 10%

Remedy

1 Is resistance between CR3 (female) (4) and chassis ground normal?

NO


Replace

Defective stop solenoid relay

Replace

Defective wiring harness (Grounding fault)

Repair or replace

Defective diode (D03)

Replace

2

• Disconnect M52. • Resistance between M52 (male) (1) – (2): 68 Ω ± 10% • Resistance between M52 (male) (1), (2) – chassis ground: Min. 1 MΩ

Are resistance between stop solenoid relay M52 (male) (1) and (2) and resistance between each pin and chassis ground normal?

• Disconnect D32 (with M52 disconnected). • Resistance between CR3 (female) (4) – chassis ground: Min. 1 MΩ

Is resistance between CR3 (female) (4) and chassis ground normal?

NO

YES 3 NO

YES


PC128US-2

20-727 (17)

TROUBLESHOOTING

E-11

E-11 Auto-decelerator does not operate PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up ! Check the auto-decelerator reset input signal and each pressure switch input signal in the monitoring mode.

Cause When auto-decelerator reset switch is pressed; • Bit (2): ON (Auto-decelerator reset)

Remedy

1 Is auto-decelerator reset switch NO of monitoring 1022 normal?

Defective monitor panel or controller

Replace


Replace

Defective pressure switch (Internal seizure)

Replace

Defective wiring harness (Grounding fault in signal line)

Repair or replace

YES Monitoring code [1023] • Bit (1): OFF (Boom LOWER pressure switch) • Bit (3): OFF (Travel pressure switch) • Bit (4): OFF (Swing pressure switch) • Bit (5): OFF (Arm IN pressure switch) • Bit (6): OFF (Boom RAISE pressure switch) Monitoring code [1028] • Bit (1): OFF (Arm OUT pressure switch) • Bit (2): OFF (Att, blade RAISE/LOWER pressure switch) • Bit (3): OFF (Bucket CURL pressure switch) • Bit (4): OFF (Bucket DUMP pressure switch)

2 Is each pressure switch signal of monitoring 1023 and 1028 nor- NO mal?

YES

3 When pressure switch connector of NO abnormal part is disconnected, does bit keep lighting?

YES


! The pressure switches for the blade and attachments are not shown in this figure.

20-728 (17)

PC128US-2

TROUBLESHOOTING OF CONTROLLER CR700 [PUMP CONTROL SYSTEM] (C MODE) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up Cautions when troubleshooting controller CR700 [Pump control system] .................................................. 20-802 Response of controller and phenomena on machine body when abnormality has occurred...................... 20-804 Table for determining controller CR700 [Pump control system] or oil pressure in ralated .......................... 20-808 Electric circuit diagram of C mode system ................................................................................................. 20-812 Troubleshooting flow chart for each failure mode C-1 Abnormality in power supply of controller (LED on controller is OFF) ............................................ 20-816 C-2 [E232] "Short circuit in PC-EPC solenoid system" is displayed ...................................................... 20-818 C-3 [E233] "Disconnection in PC-EPC solenoid system" is displayed .................................................. 20-820 C-4 [E203] "Short circuit in swing holding brake solenoid system" is displayed.................................... 20-822 C-5 [E213] "Disconnection in swing holding brake solenoid system" is displayed ................................ 20-826 C-6 [E206] "Short circuit in travel Hi/Lo selection solenoid system" is displayed .................................. 20-830 C-7 [E216] "Disconnection in travel Hi/Lo selection solenoid system" is displayed............................... 20-832 C-8 [E205] "Short circuit in 2-stage relief solenoid system" is displayed............................................... 20-834 C-9 [E215] "Disconnection in 2-stage relief solenoid system" is displayed ........................................... 20-836 C-10 [E222] "Short circuit in LS-EPC solenoid system" is displayed ...................................................... 20-838 C-11 [E223] "Disconnection in LS-EPC solenoid system" is displayed ................................................... 20-839 C-12 [E224] "Abnormality in pump pressure sensor system" is displayed .............................................. 20-840 C-13 [E227] "Abnormality in engine speed sensor system" is displayed ................................................ 20-841

! During troubleshooting after an abnormality occurred, if no service code "E" is displayed when you inserted a T-adapter after detaching a connector, or when you connected the connector after detaching the Tadapter, the normal condition has been restored already. ! Before starting troubleshooting, check for any faulty engagement of related connectors. ! Before going to next step in the troubleshooting procedure, be sure to connect the connector you have detached.

PC128US-2

20-801 (17)

TABLE FOR DETERMINING CONTROLLER CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED

TROUBLESHOOTING

TABLE FOR DETERMINING CONTROLLER CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Controller CR700 (E2: XX type) Abnormality in power supply of controller Short circuit in PC-EPC solenoid system Disconnection in PC-EPC solenoid system Short circuit in swing holding brake solenoid system Disconnection in swing holding brake solenoid system Short circuit in travel speed selection solenoid system Disconnection in travel speed selection solenoid system Short circuit in 2-Stage relief solenoid system Disconnection in 2-Stage relief solenoid system Short circuit in LS-EPC solenoid system Disconnection in LS-EPC solenoid system

Results of self-diagnosis displayed

User codes

Traveling system

Compound operation

Work-equipment

Entire work-equipment, traveling, and swinging

Failure mode

Service codes Slower speed or reduced power of entire work equipment, traveling, and swinging Substantial drop of engine speed, or engine stop Entire work equipment, traveling, and swinging are inoperable. Abnormal noise (from around pump) Auto-deceleration inoperable Poor fine control performance, or poor response Slower or less powerful movement of boom Slower or less powerful movement of arm Slower or less powerful movement of bucket Boom inoperable Arm inoperable Bucket inoperable Greater hydraulic drift Greater time lag (engine slow) Independent relief causes other work equipment's movement. Full power cannot be attained when pressure is increased. Worsened or weaker stroke-end cushion of boom RAISE In the case of compound operation, the greater the load, the longer the time of operation. Boom moves slower in the case of the swing + boom (RAISE) operation. Travel speed decreases greatly in the case of the swing + travel operation. Deviation is great during constant traveling Travel deviation Deviation is great at the start of traveling Slower traveling speed Steering is hard or not powerful. Traveling speed is unchangeable, or faster than the set speed. Inoperable (only on one side) Does not swing.

Swinging system

E02 E03 — LED off 232 233 203 213 206 216 205 215 222 223

Worsened acceleration performance or speed of swinging

Both R.H. and L.H. One side only Both R.H. and L.H. One side only

Both R.H. and L.H. One side only Greater shock when swinging is stopped (only on one side) Greater abnormal noise when swinging is stopped Greater hydraulic drift When swing holding brake is released during swinging When swing holding brake is operating Diagnosis codes when service codes are displayed Diagnosis codes when abnormality was found by checking monitoring codes Greater drift when swinging is stopped

C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 —

—

—

—

—

—

—

—

—

—

—

Items checked only by monitoring

20-808 (17)

PC128US-2


TROUBLESHOOTING

! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.

LS-EPC current output

PC-EPC current output

Monitoring codes

1023

1021

1060

1002 1010 1042 1050 1054

Diagnosis codes when no service code is displayed

Bit patterns 227

Engine speed input

Model code

Traveling

2-stage relief (6)

PPC initial pressure (2)

Swing holding brake (1)

Kerosene mode (6)

Service pressure switch (2)

Bucket DUMP (2)

Bucket CURL (2)

Arm OUT (2)

Arm IN (5)

Boom RAISE (6)

Boom LOWER (2)

Traveling (3)

— 224

Status of solenoid in operation

Oil-pressure switch

Pump discharge pressure input

Items to be checked in the monitoring mode

Swinging (4)

Abnormality in pump pressure sensor system

Abnormality in engine speed sensor system

Controller CR700 (E2: XX type) Results of self diagnosis displayed

H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 H-11 H-12 H-13 H-14 — H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23 H-24 H-25 H-26 H-27 H-28 C-12

C-13

—

—

—

—

—

—

—

F-1

F-2

F-3

F-4

F-5

PC128US-2

— F-6

F-7

F-8

F-9 F-10

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

20-809 (17)


TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Controller CR700 (E2: XX type) Abnormality in power supply of controller Short circuit in PC-EPC solenoid system Disconnection in PC-EPC solenoid system Short circuit in swing holding brake solenoid system Disconnection in swing holding brake solenoid system Short circuit in travel speed selection solenoid system Disconnection in travel speed selection solenoid system Short circuit in 2-Stage relief solenoid system Disconnection in 2-Stage relief solenoid system Short circuit in LS-EPC solenoid system Disconnection in LS-EPC solenoid system

Results of self-diagnosis displayed

User codes

Traveling system

Compound operation

Work-equipment

Entire work-equipment, traveling, and swinging

Failure mode

Service codes Slower speed or reduced power of entire work equipment, traveling, and swinging Substantial drop of engine speed, or engine stop Entire work equipment, traveling, and swinging are inoperable. Abnormal noise (from around pump) Auto-deceleration inoperable Poor fine control performance, or poor response Slower or less powerful movement of boom Slower or less powerful movement of arm Slower or less powerful movement of bucket Boom inoperable Arm inoperable Bucket inoperable Greater hydraulic drift Greater time lag (engine slow) Independent relief causes other work equipment's movement. Full power cannot be attained when pressure is increased. Worsened or weaker stroke-end cushion of boom RAISE In the case of compound operation, the greater the load, the longer the time of operation. Boom moves slower in the case of the swing + boom (RAISE) operation. Travel speed decreases greatly in the case of the swing + travel operation. Deviation is great during constant traveling Travel deviation Deviation is great at the start of traveling Slower traveling speed Steering is hard or not powerful. Traveling speed is unchangeable, or faster than the set speed. Inoperable (only on one side) Does not swing.

Swinging system

E02 E03 — LED off 232 233 203 213 206 216 205 215 222 223

Worsened acceleration performance or speed of swinging

Both R.H. and L.H. One side only Both R.H. and L.H. One side only

Both R.H. and L.H. One side only Greater shock when swinging is stopped (only on one side) Greater abnormal noise when swinging is stopped Greater hydraulic drift When swing holding brake is released during swinging When swing holding brake is operating Diagnosis codes when service codes are displayed Diagnosis codes when abnormality was found by checking monitoring codes Greater drift when swinging is stopped

C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 —

—

—

—

—

—

—

—

—

—

—

Items checked only by monitoring

20-810 (17)

PC128US-2


TROUBLESHOOTING

! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.

1023

LS-EPC current output

PC-EPC current output

Monitoring codes 1028

1021

1060

1002 1010 1042 1050 1054

Diagnosis codes when no service code is displayed

Bit patterns 227

Engine speed input

Model code

Traveling

2-stage relief (6)

PPC initial pressure (2)

Swing holding brake (1)

Kerosene mode (6)

Service pressure switch (2)

Bucket DUMP (4)

Bucket CURL (3)

Arm OUT (1)

Arm IN (5)

Boom RAISE (6)

Boom LOWER (1)

Traveling (3)

— 224

Status of solenoid in operation

Oil-pressure switch

Pump discharge pressure input

Items to be checked in the monitoring mode

Swinging (4)

Abnormality in pump pressure sensor system

Abnormality in engine speed sensor system

Controller CR700 (E2: XX type) Results of self diagnosis displayed

H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 H-11 H-12 H-13 H-14 — H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23 H-24 H-25 H-26 H-27 H-28 C-12

C-13

—

—

—

—

—

—

—

F-1

F-2

F-3

F-4

F-5

PC128US-2

— F-6

F-7

F-8

F-9 F-10

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

20-811 (17)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 (1/2)

20-812 (17)

PC128US-2

TROUBLESHOOTING


(2/2)

PC128US-2

20-813 (17)

TROUBLESHOOTING



20-814 (17)

PC128US-2

TROUBLESHOOTING


(2/2)

PC128US-2

20-815 (17)

TROUBLESHOOTING

C-1

C-1

Abnormality in power supply of controller (LED on controller is OFF)

! Check that fuses (1) and (18) are not blown.

Cause 2 YES


Remedy Replace

Is voltage normal

YES between CR3 (14), (24) – (21), (31), 1

(32), (33)? Is voltage normal between CR3 (1), • Turn starting switch NO (11) and each (21), ON (31), (32) and • 20 – 30 V (33)? • Attach T-adapter • Turn starting switch NO OFF: 20 – 30 V

Disconnection or defective con- Repair or tact of harnesses between CR3 replace (14), (24) and CNM47 (3) Disconnection or defective contact between fuse (18) and CR3 (1),(11); Disconnection or Replace defectivecontact between CR3 motor (21),(31),(32),(33) and CN-A04 (12),(14)

C-1 Related electric circuit diagram PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500

20-816 (17)

PC128US-2

TROUBLESHOOTING

C-1


PC128US-2

20-817 (17)

TROUBLESHOOTING

C-2 !

C-2

[E232] "Short circuit in PC-EPC solenoid system" is displayed

Be sure to turn emergency pump drive switch to DOWN (normal).

Cause YES


2

4 YES Do resistance values Do resistance valbetween CR3 (feYES male)(16) and (23), ues between C06 (male) (2) and (3), and between (16) YES between (5) and (6), and body match with and between C06 Table 1? (male) (2), (3), (5), 3 • Turn starting switch (6) and body match Do resistance valOFF. with Table 2? 1 ues between C06 • Disconnect CR3. Do resistance values (female) (2) and (5), NO • Turn starting • Attach directcoupled switch OFF. between C13 (male) connector to NO and between (2) and body match with Ta• Disconnect C06. (1) and (2), and beCN-D23 and D24. ble 1? • Turn emergency tween (1) and body pump drive switch to match with Table 1? • Turn starting switch DOWN (normal). OFF. • Turn starting switch • Disconnect C06. OFF. NO • Disconnect C13.

Replace

Ground fault or hot-short-circuit of harness between CR3 (fe- Repair or male)(16) and C06 (female)(3); or hot short circuit of harness replace between CR3 (female)(23) and C06 (female)(6).

Defective emergency pumpdrive switch (inner ground Replace fault or hot short circuit) Ground fault or hot-short-circuit of harness between C06 (female)(2) and C13 (female); Repair or or hot short circuit of harness between C06 (female)(5) and replace C13 (female)(2). • Defective PC-EPC solenoid (internal short-circuit or ground fault) • Defective diode

NO

Remedy

Replace

Table 1 Diagnosis No.2

Diagnosis No.3

Diagnosis No.4

C13 (male) (1) – (2)

CR3 (female) (16) – (23)

C06 (female) (2) – (5)

C13 (male) (1) – body

CR3 (female) (16) – body

C06 (female) (2) – 2body

Resistance 8 – 15 Ω Min. 1 M Ω

Table 2 Diagnosis No.5 C06 (male) (2) – (3), (5) – (6) C06 (female) (2), (3), (5), (6) – body

20-818 (17)

Resistance Max. 1 Ω Min. 1 M Ω

PC128US-2

TROUBLESHOOTING

C-2



PC128US-2

20-819 (17)

TROUBLESHOOTING

C-3

C-3

[E233] "Disconnection in PC-EPC solenoid system" Is displayed

! If a solenoid or its harness was disconnected, current does not flow through the solenoid. If ground fault occurs on the 2-pin side of the solenoid, current (about 1 A) remains to flow. ! Be sure to turn emergency-pump drive switch to DOWN (normal).

Cause YES


Disconnection or defective contact of harness between CR3 (female)(16) and C06 (fe4 YES Do resistance values male)(3); or disconnection, deDo resistance valbetween CR3 (fefective contact or ground fault of YES male) (16) and (23), ues between C06 harness between CR3 (fe(male) (2) and (3), male)(23) and C06 (female)(6). and between (23) YES between (5) and (6) and body match with and between C06 Table 1? 3 (male) (2), (3), (5), • Turn starting switch (6) and body match Defective emergency pumpDo resistance valOFF. with Table 2? 1 drive switch (inner disconnecues between C06 • Disconnect CR3. Do resistance values (female) (2) and (5), NO tion, defective contact or • Turn starting • Attach directcoupled ground fault). switch OFF. between C13 (male) connector to NO and between (2) and body match with Ta• Disconnect C06. (1) and (2), and beCN-D23 and D24. Disconnection of defective conble 1? • Turn emergency tween (2) and body tact of harness between C06 (fepump drive switch to match with Table 1? • Turn starting switch male)(2) and C13 (female); or DOWN (normal). OFF. disconnection, defective contact • Turn starting switch • Disconnect C06. or ground fault of harness beOFF. NO tween C06 (female)(5) and C06 • Disconnect C13. (female)(2).

2

• Defective PC-EPC solenoid (internal short circuit or ground fault) • Defective diode

NO

Remedy Replace

Repair or replace

Replace

Repair or replace

Replace


Diagnosis No.3

Diagnosis No.4

C13 (male) (1) –(2)

CR3 (female) (16) – (23)

C06 (female) (2) – (5)



C06 (female) (2) – 2body


Table 2 Diagnosis No.5 C06 (male) (2) – (3), (5) – (6) C06 (female) (2), (3), (5), (6) – body

20-820 (17)

Resistance Max.1 Ω Min. 1 M Ω

PC128US-2

TROUBLESHOOTING

C-3



PC128US-2

20-821 (17)

TROUBLESHOOTING

C-4

C-4

[E203] "Short circuit in swing holding brake solenoid system" is displayed

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 ! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that service code "E" is displayed. (If it is not displayed, the normal condition has been restored.) ! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting check. Cause 3 YES Is resistance norYES mal between CR3 (female)(7) and body? 2 Do resistance values

YES between V04 (male)

1

(1) and (2), and between (2) and body match with Table 1? • Turn starting switch OFF. • Disconnect V04.

Is [E203] displayed after replacing the solenoid and connector with other ones? • Turn starting switch OFF. NO • Replace V04 with another one. • Start engine. • Operate swing-lever or a lever of work-equipment (for just a moment).

A

• Turn starting switch NO OFF. • Disconnect CR3. • Turn swing lock switch OFF. • Attach a direct coupled connector to CN-D08. • 37 – 60 Ω

NO

YES Is resistance normal

Is resistance normal between X05 (female) (3), (4) and body?

between X05 (male) (4) and body?

• Turn starting switch NO OFF. • Disconnect X05. • 37 – 60 Ω

• Turn starting switch OFF. NO • Disconnect X05. • Turn swing lock switch OFF. • Min. 1 M Ω

Replace

to A

Defective swing-holding-brake solenoid (inner short-circuit or Replace ground fault)

5 YES 4


Remedy

Ground fault of either harness connecting CR3 (female) (7) – Repair or D08 (2), (1) to M47 (19), or (1) replace to X05 (male)(3). Ground fault of harness connecting X05 (male)(4) – M47 Repair or (3) and then to V04 (female) replace (2). Defective swing-lock switch Replace (inner short circuit)

Table 1 V04 (male)(1) – (2)

37 – 60 Ω

V04 (male)(2) – body

Min. 1 M Ω

20-822 (17)

PC128US-2

TROUBLESHOOTING

C-4

C-4 Related electric circuit diagram

PC128US-2

20-823 (17)

TROUBLESHOOTING

C-4

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up ! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that service code "E" is displayed. (If it is not displayed, the normal condition has been restored.) ! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting check. Cause 3 YES Is resistance norYES mal between CR3 (female)(7) and body? 2 Do resistance values

YES between V4 (male)

1

(1) and (2), and between (2) and body match with Table 1? • Turn starting switch OFF. • Disconnect V4.

Is [E203] displayed after replacing the solenoid and connector with other ones? • Turn starting switch OFF. NO • Replace V4 with another one. • Start engine. • Operate swing-lever or a lever of work-equipment (for just a moment).

A

• Turn starting switch NO OFF. • Disconnect CR3. • Turn swing lock switch OFF. • Attach a direct coupled between D02 (4) – (8). • 37 – 60 Ω

NO

YES Is resistance normal

Is resistance normal between X05 (female) (3), (4) and body?

between X05 (male) (4) and body?

• Turn starting switch NO OFF. • Disconnect X05. • 37 – 60 Ω

• Turn starting switch OFF. NO • Disconnect X05. • Turn swing lock switch OFF. • Min. 1 M Ω

Replace

to A

Defective swing-holding-brake solenoid (inner short-circuit or Replace ground fault)

5 YES 4


Remedy

Ground fault of either harness connecting CR3 (female) (7) – Repair or D02 (8), (4) to M47 (19) to replace X05 (male)(3). Ground fault of harness connecting X05 (male)(4) – M47 Repair or (3) and then to V4 (female) replace (2). Defective swing-lock switch Replace (inner short circuit)

Table 1 V4 (male)(1) – (2)

37 – 60 Ω


Min. 1 M Ω

20-824 (17)

PC128US-2

TROUBLESHOOTING

C-4


PC128US-2

20-825 (17)

TROUBLESHOOTING

C-5

C-5

[E213] "Disconnection in swing holding brake solenoid system" is displayed

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 ! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting check. NOTE: [Note] An error [E213] is detected if swing holding brake release switch was turned OFF (swinging enabled); this is not a failure. NOTE: [Note] If an error [E213] was detected when swing lock switch was turned ON (swinging locked), do troubleshooting (F-9) of the swing lock signal input system.

Cause 3 YES Does resistance YES between CR3 (fe2 male) (7) and body match with Table 1? YES Is resistance nor• Turn starting switch NO mal between V04 ON. 1 (male)(1) and (2)? • Disconnect D08. Is [E213] displayed • Turn starting after replacing the switch OFF. solenoid and conNO • Disconnect V04. nector with other • 37 – 60 Ω ones? • Turn starting switch OFF. • Replace V04 with NO another one. • Turn starting switch ON.


Remedy

Replace

to A

Defective swing holding brake solenoid (inner disconnection Replace or hot short circuit) Disconnection or defective con-

6 YES tact of either harness connect- Repair or Is resistance nor-

YES mal between CR3

5

A

Is resistance norYES mal between X05 (male) (4) and 4 body? Is resistance nor• Turn starting mal between X05 switch OFF. (female) (3) and • Disconnect X05. (4)? • 37 – 60 ohm • Turn starting switch OFF. • Disconnect X05. NO • Max.1 Ω

ing D08 (female)(1) – M47 (19) replace or (1) – X05 (male)(3).

(female) (7) and D08 (female) (2)?

Disconnection or defective contact of harness between Repair or • Turn starting NO CR3 (female)(7) and D08 (fereplace male)(2). switch OFF. • Disconnect D08, CR3. Disconnection, defective con• Max. 1 Ω tact or hot short circuit of ei- Repair or ther harness connecting X05 NO (male)(4) – M47 (20) or M47 replace (20) – V04 (female)(2). Defective swing lock switch (inner disconnection or hot Replace short circuit)

Table 1 Diagnosis No. 3 D08(1) – body

20-826 (17)

Voltage

Measuring conditions

0 – 10 V

4 – 5 seconds after putting all levers to Neutral.

20 – 30 V

When swing-lever or a lever of work equipment is operated (just for a moment)

PC128US-2

TROUBLESHOOTING

C-5


PC128US-2

20-827 (17)

TROUBLESHOOTING

C-5

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up ! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting check. NOTE: [Note] An error [E213] is detected if swing holding brake release switch was turned OFF (swinging enabled); this is not a failure. NOTE: [Note] If an error [E213] was detected when swing lock switch was turned ON (swinging locked), do troubleshooting (F-9) of the swing lock signal input system.

Cause 3 YES Does resistance YES between CR3 (fe2 male) (7) and body match with Table 1? YES Is resistance nor• Turn starting switch NO mal between V4 ON. 1 (male)(1) and (2)? • Disconnect D02. Is [E213] displayed • Turn starting after replacing the switch OFF. solenoid and conNO • Disconnect V4. nector with other • 37 – 60 Ω ones? • Turn starting switch OFF. • Replace V4 with NO another one. • Turn starting switch ON.


Remedy

Replace

to A

Defective swing holding brake solenoid (inner disconnection Replace or hot short circuit) Disconnection or defective con-

6 YES tact of either harness connect- Repair or Is resistance nor-

YES mal between CR3

5

A

Is resistance norYES mal between X05 (male) (4) and 4 body? Is resistance nor• Turn starting mal between X05 switch OFF. (female) (3) and • Disconnect X05. (4)? • 37 – 60 ohm • Turn starting switch OFF. • Disconnect X05. NO • Max.1 Ω

ing D02 (female)(8) – M47 (19) replace – X05 (male)(3).

(female) (7) and D02 (female) (8)?

Disconnection or defective contact of harness between Repair or • Turn starting NO CR3 (female)(7) and D02 (fereplace male)(8). switch OFF. • Disconnect D02, CR3. Disconnection, defective con• Max. 1 Ω tact or hot short circuit of ei- Repair or ther harness connecting X05 NO (male)(4) – M47 (20) or M47 replace (20) – V4 (female)(2). Defective swing lock switch (inner disconnection or hot Replace short circuit)

Table 1 Diagnosis No. 3 D02(8) – body

20-828 (17)

Voltage

Measuring conditions

0 – 10 V

4 – 5 seconds after putting all levers to Neutral.

20 – 30 V

When swing-lever or a lever of work equipment is operated (just for a moment)

PC128US-2

TROUBLESHOOTING

C-5


PC128US-2

20-829 (17)

TROUBLESHOOTING

C-6

C-6

[E206] "Short circuit in travel Hi/Lo selection solenoid system" is displayed

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Cause 3 YES YES Is resistance normal between CR3 2 (female)(27) and Do resistance valbody? ues between V05 YES (male)(1) and (2), • Turn starting and between (2) switch OFF. 1 and body, match • Disconnect CR3. with Table 1? Is [E206] displayed • 37 – 60 Ω • Turn starting after replacing the switch OFF. solenoid and conNO nector with other • Disconnect V05. ones? • Turn starting switch OFF. • Replace V05 with NO another one. • Start engine. • Turn travel-speed switch to "Mi" or "Hi". • Operate travel lever just for a moment.

NO

Remedy

Defective engine throttle and Replace pump controller Ground fault of harness connecting CR3 (female)(27) – Repair or A08 (1) and then to V05 (fereplace male)(2); or continuing diode D07.

Defective travel-Hi/Lo selection solenoid (inner short cir- Replace cuit or ground fault)

Table 1 V05 (male)(1) – (2)

37 – 60 Ω


Min. 1 M Ω


20-830 (17)

PC128US-2

C-6

TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Cause 3 YES YES Is resistance normal between CR3 2 (female)(27) and Do resistance valbody? ues between V5 YES (male)(1) and (2), • Turn starting and between (2) switch OFF. 1 and body, match • Disconnect CR3. with Table 1? Is [E206] displayed • 37 – 60 Ω • Turn starting after replacing the switch OFF. solenoid and conNO nector with other • Disconnect V5. ones? • Turn starting switch OFF. • Replace V5 with NO another one. • Start engine. • Turn travel-speed switch to "Mi" or "Hi". • Operate travel lever just for a moment.

NO

Remedy

Defective engine throttle and Replace pump controller Ground fault of harness connecting CR3 (female)(27) – V5 Repair or (female)(2); or continuing di- replace ode D01(1) – (5).

Defective travel-Hi/Lo selection solenoid (inner short cir- Replace cuit or ground fault)

Table 1 V5 (male)(1) – (2)

37 – 60 Ω


Min. 1 M Ω


PC128US-2

20-831 (17)

TROUBLESHOOTING

C-7

C-7

[E216] "Disconnection in travel Hi/Lo selection solenoid system" is displayed

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Cause 3 YES Is resistance norYES mal between CR3 2 (female) (27) and body? YES Is resistance be• Turn starting tween V05 (male) switch OFF. (1) and (2) normal? 1 • Disconnect CR3. Is [E216] displayed • 37 – 60 Ω • Turn starting after replacing the switch OFF. solenoid and conNO • Disconnect V05. nector with other • 37 – 60 Ω ones? • Turn starting switch OFF. • Replace V03 with NO another one. • Turn starting switch ON.

NO

Remedy

Defective engine throttle and Replace pump-controller Disconnection or defective contact of harness connecting Repair or CR3 (female) (27) – A08 (1) and then – V05 (female) (2), replace or V05 (female) (1) to body.

Defective travel-speed solenoid (inner disconnection or Replace hot short circuit)


20-832 (17)

PC128US-2

C-7

TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Cause 3 YES Is resistance norYES mal between CR3 2 (female) (27) and body? YES Is resistance be• Turn starting tween V5 (male) switch OFF. 1 (1) and (2) normal? • Disconnect CR3. Is [E216] displayed • 37 – 60 Ω • Turn starting after replacing the switch OFF. solenoid and conNO • Disconnect V5. nector with other • 37 – 60 Ω ones? • Turn starting switch OFF. • Replace V5 with NO another one. • Turn starting switch ON.

NO

Remedy

Defective engine throttle and Replace pump-controller Disconnection or defective contact of harness connecting Repair or CR3 (female) (27) – A08 (1) and then – V5 (female) (2), or replace V5 (female) (1) to body.

Defective travel-speed solenoid (inner disconnection or Replace hot short circuit)


PC128US-2

20-833 (17)

TROUBLESHOOTING

C-8

C-8

[E205] "Short circuit in 2-stage relief solenoid system" is displayed

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Cause 3 YES


Remedy

Replace

Is resistance nor-

YES mal between CR3

2 (female) (28) and Do resistance values body? between V06 (male) YES • Turn starting (1) and (2) and beswitch OFF. 1 tween (2) and body • Disconnect CR3. match with Table 1? Is [E205] displayed • Turn starting switch • 37 – 60 Ω after replacing the OFF. solenoid and conNO • Disconnect V06. nector with other ones? • Turn starting switch OFF. • Replace V06 with NO another one. • Start engine. • Turn on swing lock switch.

NO

Ground fault of harness between CR3 (female) (28) and Repair or replace V06 (female) (2)

Defective 2-stage relief solenoid (inner short-circuit or Replace ground fault)

Table 1 V06 (male)(1) – (2)

37 – 60 Ω


Min. 1 M Ω


20-834 (17)

PC128US-2

C-8

TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Cause 3 YES Is resistance norYES mal between CR3 2 (female) (28) and Do resistance values body? YES between V6 (male) • Turn starting (1) and (2) and beswitch OFF. tween (2) and body 1 • Disconnect CR3. match with Table 1? Is [E205] displayed • Turn starting switch • 37 – 60 Ω after replacing the OFF. solenoid and conNO • Disconnect V6. nector with other ones? • Turn starting switch OFF. • Replace V6 with NO another one. • Start engine. • Turn on swing lock switch.

NO


Remedy

Replace

Ground fault of harness between CR3 (female) (28) and Repair or replace V6 (female) (2)

Defective 2-stage relief solenoid (inner short-circuit or Replace ground fault)

Table 1 V6 (male)(1) – (2)

37 – 60 Ω


Min. 1 M Ω


PC128US-2

20-835 (17)

TROUBLESHOOTING

C-9

C-9

[E215] "Disconnection in 2-stage relief solenoid system" is displayed

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Cause 3 YES Is resistance norYES mal between CR3 2 (female) (28) and body? YES Is resistance bet• Turn starting switch NO ween V06 (male) (1) OFF. and (2) normal? 1 • Disconnect CR3. Is [E215] displayed • 37 – 60 Ω • Turn starting switch after replacing the OFF. solenoid and conNO • Disconnect V06. nector with other • 37 – 60 Ω ones? • Turn starting switch OFF. NO • Replace V06 with another one. • Turn starting switch ON.


Remedy

Replace

Disconnection, defective contact or hot short circuit of harness between CR3 (female) Repair or (28) and V06 (female) (2), or replace between V06 (female) (1) and body.

Defective 2-stage relief solenoid (inner disconnection or Replace hot short circuit)


20-836 (17)

PC128US-2

C-9

TROUBLESHOOTING

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Cause 3 YES Is resistance norYES mal between CR3 2 (female) (28) and body? YES Is resistance bet• Turn starting switch NO ween V6 (male) (1) OFF. and (2) normal? 1 • Disconnect CR3. Is [E215] displayed • 37 – 60 Ω • Turn starting switch after replacing the OFF. solenoid and conNO • Disconnect V6. nector with other • 37 – 60 Ω ones? • Turn starting switch OFF. NO • Replace V6 with another one. • Turn starting switch ON.


Remedy

Replace

Disconnection, defective contact or hot short circuit of harness between CR3 (female) Repair or (28) and V6 (female) (2), or be- replace tween V6 (female) (1) and body.

Defective 2-stage relief solenoid (inner disconnection or Replace hot short circuit)


PC128US-2

20-837 (17)

TROUBLESHOOTING

C-10

C-10 [E222] "Short circuit in LS-EPC solenoid system" is displayed

Cause 2 YES


Do resistance values between CR3 YES (female) (6) and (13) and between (6) and 1 body match with Table 1? Do resistance values between C14 (male) • Turn starting switch NO (1) and (2) and beOFF. tween (1) and body • Disconnect CR3. match with Table 1?

Remedy Replace

Ground fault or hot short circuit of harnessbetween CR3 (female) (6) and C14 (female) Repair or (1), or hot short circuit of har- replace ness between CR3 (female) (13) and C14 (female)(2). Defective LS-EPC solenoid (inner ground fault or hot short circuit)

• Turn starting switch OFF. NO • Disconnect C14.

Replace


Diagnosis No.2

Resistance

C14 (male) (1) – (2)

CR3 (female) (6) – (13)

8 – 15 Ω



Min. 1 M Ω



20-838 (17)

PC128US-2

TROUBLESHOOTING

C-11

C-11 [E223] "Disconnection in LS-EPC solenoid system" is displayed ! If a solenoid or its harness was disconnected, current does not flow through the solenoid. If ground fault occurs on the 2-pin side of the solenoid, current (about 1A) remains to flow. ! Be sure to turn emergency-pump drive switch to DOWN (normal).

Cause 2 YES


Do resistance values between CR3 YES (female) (6) and (13) and between (13) 1 and body match with Do resistance valTable 1? ues between C14 • Turn starting switch NO (male) (1) and (2) OFF. and between (2) and body match with Ta• Disconnect CR3. ble 1? • Turn starting switch OFF. NO • Disconnect C14.

Remedy Replace

Disconnection or defective contact of harness between CR3 (female)(6) and C14 (female) Repair or (1); or disconnection, defective replace contact, or ground fault of harness between CR3 (female) (13) and C14 (female) (2). Defective LS-EPC solenoid (inner ground fault or hot short circuit)

Replace


Diagnosis No.2

C14 (male) (1) – (2)

CR3 (female) (6) – (13)






PC128US-2

20-839 (17)

TROUBLESHOOTING

C-12

C-12 [E224] "Abnormality in pump pressure sensor system" is displayed Cause 3 YES YES

2 YES

1 T-adapter (B) – (C) to C05 of pump pressure sensor?

C05 (C) – (A)


Remedy

Replace

CR1 (13) – (21) • Turn starting switch NO OFF. • Attach T-adapter. • Run engine at full speed. • Repeat operations: arm excavation relief

• Run engine at full Neutral lever. speed. • 0.5 – 4.5 V • Repeat operations: arm-excavation relief NO

Neutral lever. • Turn starting switch • 0.5 – 4.5 V OFF. • Attach T-adapter. NO • Run engine at full speed. •5V

Disconnection, ground fault or Repair or hot short circuit between C05 replace (C) and CR1 (13).

Defective pump pressure senReplace sor) • Defective controller CR700 • Disconnection, ground fault or hot short circuit between CR3 Repair or CR3 (22) and C05 (B) replace • Disconnection between CR3 (21) and C05 (C)



20-840 (17)

PC128US-2

TROUBLESHOOTING

C-13

C-13 [E227] "Abnormality in engine speed sensor system" Is displayed Cause 2 YES Is resistance beYES tween CR2 (female) (40) and (39) nor1 mal? Is resistance be• Turn starting switch NO tween E07 (male) OFF. (1) and (2) normal? • Disconnect CR2. • 500 – 1000 Ω • Turn starting switch OFF. NO • Disconnect E07. • 500 – 1000 Ω


Remedy Replace

Disconnection, defective contact or ground fault of harness between CR2(female)(40) and Repair or E07 (female) (1), or between replace CR2 (female)(39) and E07 (female)(2). Defective engine speed sensor (inner disconnection, defective Replace contact or ground fault).



PC128US-2

20-841 (17)

TROUBLESHOOTING OF CONTROLLER CR700 [INPUT SIGNAL SYSTEM] (F MODE) PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Electric circuit diagram for f mode............................................................................................................... 20-902 F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON........................................................ 20-904 F-2 Bit-pattern 1023-(3) Travel pressure switch is not turned ON........................................................ 20-906 F-3 Bit-pattern 1023-(2) Boom LOWER pressure switch is not turned ON .......................................... 20-908 F-4 Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON ............................................ 20-910 F-5 Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON ...................................................... 20-912 F-6 Bit-pattern 1023-(2) Arm OUT pressure switch is not turned ON .................................................. 20-914 F-7 Bit-pattern 1023-(2) Bucket CURL pressure switch is not turned ON............................................ 20-916 F-8 Bit-pattern 1023-(2) Bucket DUMP pressure switch is not turned ON ........................................... 20-918 F-9 Bit-pattern 1023-(2) Service pressure switch is not turned ON...................................................... 20-920 F-10 Bit-pattern 1021-(6) Kerosene mode connection is not turned ON................................................ 20-922

PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Electric circuit diagram for f mode............................................................................................................... 20-903 F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON........................................................ 20-905 F-2 Bit-pattern 1023-(3) Travel pressure switch is not turned ON........................................................ 20-907 F-3 Bit-pattern 1023-(1) Boom LOWER pressure switch is not turned ON .......................................... 20-909 F-4 Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON .............................................20-911 F-5 Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON ...................................................... 20-913 F-6 Bit-pattern 1028-(1) Arm OUT pressure switch is not turned ON .................................................. 20-915 F-7 Bit-pattern 1028-(3) Bucket CURL pressure switch is not turned ON............................................ 20-917 F-8 Bit-pattern 1028-(4) Bucket DUMP pressure switch is not turned ON ........................................... 20-919 F-9 Bit-pattern 1028-(2) Service pressure switch is not turned ON...................................................... 20-921

★ In troubleshooting after an abnormality occurred, if the display in the Monitoring mode is normal after you attached a T-adapter instead of a connector detached, or after you connected the connector instead of the T-adapter detached, the normal condition has been restored. ★ Before starting troubleshooting, check for any faulty engagement in related connectors. ★ Before going to next step in troubleshooting process, be sure to connect the connector you have detached.

PC128US-2

20-901 (17)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500

20-902 (17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM


PC128US-2

20-903 (17)

TROUBLESHOOTING

F-1

F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500

★

Turn on swing-lock switch before operating swing lever (even if just for a moment). If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause • Detach S08. • Start engine. • Put swing lever in Neutral: Min. 1 M Ω • Operate swing lever for L.H. swinging: Max. 1 Ω • Refer to Note.

Is resistance between S08 (male) NO (1) and (2) normal? Is the connection insulated from body?

• Detach S30. • Start engine. • Put swing lever in Neutral: Min. 1 M Ω • Operate swing lever for R.H. swinging: Max.1 Ω • Refer to Note.


• Turn starting switch OFF. • Detach S08 and S30 from CR1. • CR1 – S08/S30: Max.1 Ω • Harness – body: Min. 1 M Ω

Are resistance values between CR1 (female) (24) and each of NO S08 and S30 (female) (2) normal? Are the connections insulated from body?

Remedy

1 Defective L.H. swing pressure switch

Replace

Defective R.H. swing pressure switch

Replace

YES

2

YES

3

Disconnection, defective contact or ground fault of harness between CR1 Repair or (female)(24) and S08 (female)(2) or replace S30 (female)(2).

YES • Start engine. • Put swing-lever in Neutral: 20 – 30 V • Operate swing lever: Max. 1 V

4 Is voltage between CR1(24) and NO body normal?


Replace

YES

5 • Start engine. • Operate swing lever: Max.1 V

Is voltage between CR1(24) and NO body normal?

Disconnection or defective contact of harness between S08 (female)(1) or Repair or replace S30 (female)(1) and body GND.


Replace

[Note] You may diagnose with a short-circuit connector attached.In step 2 of diagnosis, • if the voltage between CR1(24) and body is 20 – 30 V, go to YES; • if it is 1 V or less, go to NO.

F-1 Related electric circuit diagram

20-904 (17)

PC128US-2

TROUBLESHOOTING

F-1

F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

★

Turn on swing-lock switch before operating swing lever (even if just for a moment). If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause • Detach S08. • Start engine. • Put swing lever in Neutral: Min. 1 M Ω • Operate swing lever for L.H. swinging: Max. 1 Ω • Refer to Note.


• Detach S30. • Start engine. • Put swing lever in Neutral: Min. 1 M Ω • Operate swing lever for R.H. swinging: Max.1 Ω • Refer to Note.


• Turn starting switch OFF. • Detach S08 and S30 from CR3. • CR3 – S08/S30: Max.1 Ω • Harness – body: Min. 1 M Ω

Are resistance values between CR3 (female) (30) and each of NO S08 and S30 (female) (2) normal? Are the connections insulated from body?

Remedy

1 Defective L.H. swing pressure switch

Replace

Defective R.H. swing pressure switch

Replace

YES

2

YES

3

Disconnection, defective contact or ground fault of harness between CR3 Repair or (female)(30) and S08 (female)(2) or replace S30 (female)(2).

YES • Start engine. • Put swing-lever in Neutral: 20 – 30 V • Operate swing lever: Max. 1 V

4 Is voltage between CR3(30) and NO body normal?


Replace

YES

5 • Start engine. • Operate swing lever: Max.1 V


Disconnection or defective contact of harness between S08 (female)(1) or Repair or replace S30 (female)(1) and body GND.


Replace



PC128US-2

20-905 (17)

TROUBLESHOOTING

F-2

F-2

Bit-pattern 1023-(3) Travel pressure switch is not turned ON

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 Look around to be sure of safety before operating travel lever (even if just for a moment). ★ If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause • Detach S01. • Start engine. • Put travel lever in Neutral: Min. 1 M Ω • Operate travel lever: Max. 1 Ω • Refer to Note.

Remedy

1 Is resistance between S01 (male) NO (1) and (2) normal? Is the connection insulated from body?

Defective travel pressure switch

Replace

YES

2 • Turn starting switch OFF. • Detach S01 from CR1. • Between CR1 and S01: Max. 1 Ω • Between harness and body: Min. 1 M Ω

Is resistance between CR1 (female)(18) and S01 (female)(2) NO normal? Is the connection insulated from body?

Disconnection, defective contact or ground fault of harness between CR1 Repair or replace (female) (18) and S01 (female) (2)

YES

3 • Start engine. • Put swing lever in Neutral: 20 – 30 V



Replace

YES

4 • Start engine. • Operate travel lever: Max. 1 V


Disconnection or defective contact of harness between S01 (female) (1) and Repair or replace body GND.


Replace



20-906 (17)

PC128US-2

TROUBLESHOOTING

F-2

F-2

Bit-pattern 1023-(3) Travel pressure switch is not turned ON

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up Look around to be sure of safety before operating travel lever (even if just for a moment). ★ If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause • Detach S01. • Start engine. • Put travel lever in Neutral: Min. 1 M Ω • Operate travel lever: Max. 1 Ω • Refer to Note.

Remedy


Defective travel pressure switch

Replace

YES

2 • Turn starting switch OFF. • Detach S01 from CR3. • Between CR3 and S01: Max. 1 Ω • Between harness and body: Min. 1 M Ω

Is resistance between CR3 (female)(40) and S01 (female)(2) NO normal? Is the connection insulated from body?

Disconnection, defective contact or ground fault of harness between CR3 Repair or replace (female) (40) and S01 (female) (2)

YES

3 • Start engine. • Put swing lever in Neutral: 20 – 30 V



Replace

YES

4 • Start engine. • Operate travel lever: Max. 1 V


Disconnection or defective contact of harness between S01 (female) (1) and Repair or replace body GND.


Replace



PC128US-2

20-907 (17)

TROUBLESHOOTING

F-3

F-3

Bit-pattern 1023-(2) Boom LOWER pressure switch is not turned ON

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 If you take some measurement with engine started, operate a lever to such an extent that no movement of work equipment is caused. (If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1 • Start engine. • Put boom lever in Neutral: 20 – 30 V

Is resistance between CR1 (5) NO and body normal?


Replace


Replace

YES

2 • Start engine. • Put boom lever in LOWER: Max. 1 V


YES

3

• Disconnect S33. • Start engine. • Put boom lever in Neutral: Min. 1 M Ω • Put boom lever in LOWER: Max. 1 Ω • Refer to Note.


• Turn starting switch OFF. • Disconnect S33 from CR1. • Between CR1 and S33: Max. 1 Ω • Between harness and body: Min. 1 M Ω

Is resistance between CR1 (female) (5) and S33 (female) (2) NO normal? Is the connection insulated from body?

Defective boom LOWER pressure Replace switch

YES

4

YES

Disconnection, defective contact or ground fault of harness between CR1 Repair or replace (female)(5) and S33 (female)(2). Disconnection or defective contact of Repair or harness between S33 (female)(1) and replace body GND.

[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis, • if the voltage between CR1(5) and body is 20 – 30 V, go to YES; • if it is Max. 1 V, go to NO.


20-908 (17)

PC128US-2

F-3

TROUBLESHOOTING

F-3

Bit-pattern 1023-(1) Boom LOWER pressure switch is not turned ON

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up If you take some measurement with engine started, operate a lever to such an extent that no movement of work equipment is caused. (If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy




Replace


Replace

YES

2 • Start engine. • Put boom lever in LOWER: Max. 1 V


YES

3

• Disconnect S33. • Start engine. • Put boom lever in Neutral: Min. 1 M Ω • Put boom lever in LOWER: Max. 1 Ω • Refer to Note.




Defective boom LOWER pressure Replace switch

YES

4

YES

Disconnection, defective contact or ground fault of harness between CR1 Repair or replace (female)(18 ) and S33 (female)(2). Disconnection or defective contact of Repair or harness between S33 (female)(1) and replace body GND.



PC128US-2

20-909 (17)

TROUBLESHOOTING

F-4

F-4

Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON


Cause

Remedy




Replace


Replace

Defective boom RAISE pressure switch

Replace

YES

2 • Start engine. • Put boom lever in RAISE: Max. 1 V


YES • Disconnect S31. • Start engine. • Put boom lever in Neutral: Min. 1 M Ω • Put boom lever in RAISE: Max. 1 Ω • Refer to Note. • Turn starting switch OFF. • Disconnect S31 from CR1. • Between CR1 and S31: Max. 1 Ω • Between harness and body: Min. 1 M Ω


YES

4 Is resistance between CR1 (female) (12) and S31 (female) (2) NO normal? Is the connection insulated from body?

YES


[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis, • if the voltage between CR1(12) and body is 20 – 30 V, go to YES; • if it is Max.1 V, go to NO.


20-910 (17)

PC128US-2

TROUBLESHOOTING

F-4

F-4

Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON


Cause

Remedy




Replace


Replace

Defective boom RAISE pressure switch

Replace

YES

2 • Start engine. • Put boom lever in RAISE: Max. 1 V


YES • Disconnect S31. • Start engine. • Put boom lever in Neutral: Min. 1 M Ω • Put boom lever in RAISE: Max. 1 Ω • Refer to Note. • Turn starting switch OFF. • Disconnect S31 from CR1. • Between CR1 and S31: Max. 1 Ω • Between harness and body: Min. 1 M Ω


YES

4 Is resistance between CR1 (female) (24) and S31 (female) (2) NO normal? Is the connection insulated from body?

YES


[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis, • if the voltage between CR1(24) and body is 20 – 30 V, go to YES; • if it is Max.1 V, go to NO.


PC128US-2

20-911 (17)

TROUBLESHOOTING

F-5

F-5

Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON


Cause

Remedy

1 • Start engine. • Put arm lever in Neutral: 20 – 30 V



Replace


Replace

Defective arm IN pressure switch

Replace

YES

2 • Start engine. • Put arm lever in IN: Max. 1 V


YES • Disconnect S05. • Start engine. • Put arm lever in Neutral: Min. 1 M Ω • Put arm lever in IN: Max. 1 Ω • Refer to Note.




3

YES

4

YES

Disconnection, defective contact or ground fault of harness between CR1 Repair or replace (female) (6) and S05 (female) (2). Disconnection or defective contact of harness between S05 (female)(1) and Repair or replace body GND.



20-912 (17)

PC128US-2

TROUBLESHOOTING

F-5

F-5

Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON


Cause

Remedy

1 • Start engine. • Put arm lever in Neutral: 20 – 30 V



Replace


Replace

Defective arm IN pressure switch

Replace

YES

2 • Start engine. • Put arm lever in IN: Max. 1 V


YES • Disconnect S05. • Start engine. • Put arm lever in Neutral: Min. 1 M Ω • Put arm lever in IN: Max. 1 Ω • Refer to Note.




3

YES

4

YES

Disconnection, defective contact or ground fault of harness between CR1 Repair or replace (female) (12) and S05 (female) (2). Disconnection or defective contact of harness between S05 (female)(1) and Repair or replace body GND.



PC128US-2

20-913 (17)

F-6

TROUBLESHOOTING

F-6 Bit-pattern 1023-(2) Arm OUT pressure switch is not turned ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 If you take some measurement with engine started, operate a lever to such an extent that no movement of work equipment is caused. (If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1 • Start engine. • Put arm-lever in Neutral: 20 – 30 V

Is resistance between CR1 (5) and body normal?

NO


Replace


Replace

Defective arm OUT pressure switch

Replace

YES

2 • Start engine. • Put arm lever in OUT: Max. 1 V


YES • Disconnect S32. • Start engine. • Put arm lever in Neutral: Min. 1 M Ω • Put arm lever in OUT: Max. 1 Ω • Refer to Note.


• Turn starting switch OFF. • DisconnectS32 from CR1. • Between CR1 and S32: Max. 1 Ω • Between harness and body: Min. 1 M Ω


3

YES

4

YES

Disconnection, defective contact or Repair or ground fault of harness between CR1 replace (female)(5) and S32 (female)(2). Disconnection or defective contact of Repair or harness between S32 (female)(1) and replace body GND.



20-914 (17)

PC128US-2

F-6

TROUBLESHOOTING

F-6 Bit-pattern 1028-(1) Arm OUT pressure switch is not turned ON PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up If you take some measurement with engine started, operate a lever to such an extent that no movement of work equipment is caused. (If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1 • Start engine. • Put arm-lever in Neutral: 20 – 30 V

Is resistance between CR1 (6) and body normal?

NO


Replace


Replace

Defective arm OUT pressure switch

Replace

YES

2 • Start engine. • Put arm lever in OUT: Max. 1 V


YES • Disconnect S32. • Start engine. • Put arm lever in Neutral: Min. 1 M Ω • Put arm lever in OUT: Max. 1 Ω • Refer to Note.


• Turn starting switch OFF. • DisconnectS32 from CR1. • Between CR1 and S32: Max. 1 Ω • Between harness and body: Min. 1 M Ω


3

YES

4

YES

Disconnection, defective contact or Repair or ground fault of harness between CR1 replace (female)(6) and S32 (female)(2). Disconnection or defective contact of Repair or harness between S32 (female)(1) and replace body GND.



PC128US-2

20-915 (17)

TROUBLESHOOTING

F-7

F-7

Bit-pattern 1023-(2) Bucket CURL pressure switch is not turned ON


Cause

Remedy

1 • Start engine. • Put bucket lever in Neutral: 20 – 30 V

Is voltage between CR1 (5) and NO body normal?


Replace


Replace

YES

2 • Start engine. • Put bucket lever in CURL: Max. 1 V


YES

3

• Disconnect S34. • Start engine. • Put bucket lever in Neutral: Min.1 Mz • Put bucket lever in CURL: Max. 1 z • Refer to Note.

Is resistance between S34 (male) (1) and (2) normal? NO Is the connection insulated from body?

• Turn starting switch OFF. • Disconnect S34 from CR1. • Between CR1 and S34: Max. 1 z • Between harness and body: Min. 1 Mz


Defective switch

bucket

CURL

pressure

Replace

YES

4

YES

Disconnection, defective contact or Repair or ground fault of harness between CR1 replace (female) (5) and S34 (female) (2). Disconnection or defective contact of harness between S34 (female)(1) and Repair or replace body GND.



20-916 (17)

PC128US-2

F-7

TROUBLESHOOTING

F-7

Bit-pattern 1028-(3) Bucket CURL pressure switch is not turned ON


Cause

Remedy




Replace


Replace

YES

2 • Start engine. • Put bucket lever in CURL: Max. 1 V


YES

3

• Disconnect S34. • Start engine. • Put bucket lever in Neutral: Min.1 Mz • Put bucket lever in CURL: Max. 1 z • Refer to Note.




Defective switch

bucket

CURL

pressure

Replace

YES

4

YES

Disconnection, defective contact or Repair or ground fault of harness between CR3 replace (female) (10) and S34 (female) (2). Disconnection or defective contact of harness between S34 (female)(1) and Repair or replace body GND.



PC128US-2

20-917 (17)

TROUBLESHOOTING

F-8

F-8

Bit-pattern 1023-(2) Bucket DUMP pressure switch is not turned ON


Cause

Remedy


Is voltage between CR1 (5) and NO body?


Replace


Replace

Defective bucket Dump pressure switch

Replace

YES

2 • Start engine. • Put bucket lever in Dump: Max. 1 V


YES

3

• Disconnect S35. • Start engine. • Put bucket lever in Neutral: Min.1 Mz • Put bucket lever in Dump: Max. 1 z • Refer to Note.




YES

4

YES

Disconnection, defective contact or ground fault of harness between CR1 Replace motor (female) (5) and S35 (female) (2). Disconnection or defective contact of harness between S35 (female) (2) and Repair or replace body GND.



20-918 (17)

PC128US-2

F-8

TROUBLESHOOTING

F-8

Bit-pattern 1028-(4) Bucket DUMP pressure switch is not turned ON


Cause

Remedy




Replace


Replace

Defective bucket Dump pressure switch

Replace

YES

2 • Start engine. • Put bucket lever in Dump: Max. 1 V


YES

3

• Disconnect S35. • Start engine. • Put bucket lever in Neutral: Min.1 Mz • Put bucket lever in Dump: Max. 1 z • Refer to Note.




YES

4

YES

Disconnection, defective contact or ground fault of harness between CR3 Replace motor (female) (20) and S35 (female) (2). Disconnection or defective contact of harness between S35 (female) (2) and Repair or replace body GND.



PC128US-2

20-919 (17)

TROUBLESHOOTING

F-9

F-9

Bit-pattern 1023-(2) Service pressure switch is not turned ON

PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500 If you take some measurement with engine started, operate a lever to such an extent that no movement of ATT is caused. (If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1 • Start engine. • Put swing lever in Neutral: 20 – 30 V • Operate swing lever: Max. 1 V

• Disconnect S40. • Start engine. • Put ATT-pedal in Neutral: Min.1 MΩ • Operate ATT pedal service (front) pressure switch: Max. 1 Ω • Refer to Note. • Disconnect S41. • Start engine. • Put ATT-pedal in Neutral: Max.1 MΩ • Operate ATT pedal service (front) pressure switch: Max. 1 Ω • Refer to Note.

• Turn starting switch OFF. • Disconnect S40 and S41 from CR1. • Between CR1 and S40, S41: Max. 1 Ω • Harness body: Min. 1 MΩ



Replace

Defective service (front) pressure switch

Replace

Defective service (rear) pressure switch

Replace

2 Is resistance between S40 (male) (1) and (2) normal? NO Is the connection insulated from body?

YES


YES

4

Are resistance values between CR1 (female) (5) and each of S40 and NO S41 (female) (2) normal? Are the connections insulated from body?

YES

Disconnection, defective contact or Replace ground fault of harness between CR1 motor (female) (5) and S40(female)(2) or S41 (female)(2). Disconnection or defective contact of Repair or harness between S40 (female) (1) or replace S41 (female) (1) and body GND.

[Note] You may diagnose with a short-circuit connector attached.In this case, • if the voltage between CR1(5) and body is 20 – 30 V, go to YES; • f it is Max. 1 V, go to NO.


20-920 (17)

PC128US-2

F-9

TROUBLESHOOTING

F-9

Bit-pattern 1028-(2) Service pressure switch is not turned ON

PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up If you take some measurement with engine started, operate a lever to such an extent that no movement of blade is caused. (If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1 • Start engine. • Put swing lever in Neutral: 20 – 30 V • Operate swing lever: Max. 1 V



• Disconnect S38. • Start engine. • Put blade lever in Neutral: Min.1 MΩ • Operate blade LOWER pressure switch: Max. 1 Ω • Refer to Note. • Disconnect S39. • Start engine. • Put blade lever in Neutral: Max.1 MΩ • Operate blade RAISE (front) pressure switch: Max. 1 Ω • Refer to Note.

• Turn starting switch OFF. • Disconnect S38 and S39 from CR3. • Between CR3 and S40, S41: Max. 1 Ω • Harness body: Min. 1 MΩ

Replace


Defective blade LOWER pressure switch Replace

YES


Defective blade RAISE pressure switch

Replace

YES

4

Are resistance values between CR3 (female) (9) and each of S38 and NO S39 (female) (2) normal? Are the connections insulated from body?

YES

Disconnection, defective contact or Replace ground fault of harness between CR3 motor (female) (9) and S38(female)(2) or S39 (female)(2). Disconnection or defective contact of Repair or harness between S38 (female) (1) or replace S39 (female) (1) and body GND.

[Note] You may diagnose with a short-circuit connector attached.In this case, • if the voltage between CR3(9) and body is 20 – 30 V, go to YES; • f it is Max. 1 V, go to NO.


PC128US-2

20-921 (17)

TROUBLESHOOTING

F-10

F-10 Bit-pattern 1021-(6) Kerosene mode connection is not turned ON ★ Shown below is the case where a harness for Kerosene mode is connected (M36M(1) and M36F(1) are connected).

Cause • Turn starting switch ON. • S Harness for Kerosene mode: Connected: 20 – 30 V Open: Max. 1 V • Max. 1

Remedy

1

Disconnection or defective contact of harness between CR2 (female) (6) and Repair or IIs voltage between CR2 (6) and NO body normal? (Max. 1V ) fuse (1) in the harness for kerosene replace mode. YES (20 – 30 V) Replace Defective controller CR700


20-922 (17)

PC128US-2

TROUBLESHOOTING OF ENGINE (S MODE)

Method of using troubleshooting charts ............................................................................................. 20-952 S- 1 Starting performance is poor (Starting always takes time) ...................................................... 20-956 S- 2 Engine does not start ................................................................................................................... 20-958 (1) Engine does not turn ............................................................................................................. 20-958 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .................... 20-959 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ................. 20-960 S- 3 Engine does not pick-up smoothly (Follow-up is poor) ............................................................ 20-961 S- 4 Engine stops during operations .................................................................................................. 20-962 S- 5 Engine does not rotate smoothly (Hunting) ............................................................................... 20-963 S- 6 Engine lacks output (or lacks power) .......................................................................................... 20-964 S- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-965 S- 8 Oil consumption is excessive (or exhaust gas is blue).............................................................. 20-966 S- 9 Oil becomes contaminated quickly ............................................................................................. 20-967 S-10 Fuel consumption is excessive .................................................................................................... 20-968 S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-969 S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ....................................................... 20-970 S-13 Oil level rises (Water, fuel in oil) ................................................................................................. 20-971 S-14 Water temperature becomes too high (Overheating) ............................................................... 20-972 S-15 Abnormal noise is made .............................................................................................................. 20-973 S-16 Vibration is excessive ................................................................................................................... 20-974

PC128US-2

20-951 (14)

TROUBLESHOOTING


METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items that can be obtained from the user, depending on the user’s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under C in the chart on the right correspond to this. The serviceman narrows down the causes from information A that he has obtained from the user and the results of C that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].

Causes

A

Questions

(b) (2) (3)

(a)

w w

(b) w

(c) (d)

c c

B

Troubleshooting

C

Check items

(e)

20-952 (14)

i ii iii

b b b

PC128US-2


inje ctio n)

Causes

Seiz

The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with !, and of these, causes that have a high probability are marked with T. Check each of the [Questions] and [Check items] in turn, and marked the ! or T in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. ª1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with # to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. ª2. Use the # in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.

ed t urbo cha Clog rger ged , int air c erfe lean Wor renc er e n pi e lem ston e n ring Clog t , cyl ged inde , sei r zed Imp inje rope ctio r inj n no e ctio Defe zzle n tim ctiv e in ing ject ion pum p (e xces sive

TROUBLESHOOTING

ª1

Confirm recent repair history

ª2

Degree of use

Operatred for long period

w

PC128US-2

20-953 (14)

TROUBLESHOOTING

Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel

)

Causes

Legend : Possible causes (judging from Questions and check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items to confirm the cause.

Seiz ed t Clog urboch arge ged r, in air Wor terfe n pis cleaner elem rence ton Clog ring ent ged , cyli , se nde Imp r rope ized inje r c tion inje Defe ctio ctiv n tim nozzle e in ing Imp rope jection pum r va Cru lve p (e she c xces le d, c aran sive logg Lea ce inje kag e d ctio muf e of n) fler Defe air b ctiv etw e e e con n tu Deff t a r ectiv boc ct o harg f va e in lve, er a ject valv ion nd h e se pum ead at p (ra ck, p lung er s eize d

•


Confirm recent repair history Degree of use

Operated for long period

Questions

Suddenly became black Color of exhaust gas

Gradually became black Blue under light load

Engine oil must be added more frequently Power was lost

Suddenly Gradually

Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner is inspected directly, it is found to be clogged

Troubleshooting

When compression pressure is measured, it is found to be low Speed of some cylinders does not change when operating on reduced cylinders When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust gas color returns to normal

20-954 (14)

Replace

Repair

Replace

Adjust

Replace

Adjust

Adjust

Replace

Replace

Clean

Remedy

Replace

When control rack is pushed, it is found to be heavy or does not return

PC128US-2

TROUBLESHOOTING


Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.

Three symptoms

Step 2 Add up the total of and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Air leakage between turbocharger and head: (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: (5) Worn piston ring, cylinder: Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

PC128US-2

20-955 (14)

TROUBLESHOOTING

S-1

S-1 Starting performance is poor (Starting always takes time) General causes why exhaust smoke comes out but engine takes time to start Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel (At ambient temperature of -10ºC or below, ASTM D975 No. 2 diesel fuel is used)

Causes

n pi ston Defe ring , cyl ctive inde cont Clog r act o ged f val a i r ve, v clea Clog ner ged elem alve sea fuel t Clog ent filte ged r, st rain feed e Elec r p ump trica gau l int ze fi ake lter air h eate r

• • • •

fl Battery charging rate Ambient temperature

Charging rate

20°C 0°C –10°C

90 %

80 %

75 %

70 %

1.28 1.29 1.30

1.26 1.27 1.28

1.24 1.25 1.26

1.23 1.24 1.25

1.22 1.23 1.24

The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.

•

Wor

•

100 %

Questions

Confirm recent repair history Degree of use of machine

Operated for long period

Ease of starting

Gradually became worse Starts when warm

Indicator lamp does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to operation Manual Non-specified fuel has being used Dust indicator lamp is red Battery charge lamp is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Check items

Engine does not pick up smoothly, and combustion is irregular Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged

Troubleshooting

When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Heater mount does not become warm Is voltage 26–30V between alternator terminal B and terminal E with engine at low idling?

Yes No

Either specific gravity of electrolyte or voltage of battery is low Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy or does not return (check after removing fuel injection pump)

20-956 (14)

Replace

Clean

Clean

Clean

Correct

Remedy

Replace

When fuel tank cap is inspected directly, it is found to be clogged

ª Use a test stand

PC128US-2

PC128US-2

Replace

Replace

Clean

Correct

Replace

ªAdjust

Replace

Replace

Replace

Replace Defe ctive regu Defe lato ctive r a ltern Defe ator ctive or d Defe eter ctive iora ted injec Defe batt tion tive ery nozz injec le Defe tion tive timi injec ng Leak tion age, p ump clog (rac Clog ging k , pl ged , air ung a i i n r er st brea fuel Defe uc k ) ther pipi ctive ng h o f e l e in ed p Defe fuel ump ctive tank boo st co mpe nsat or c ance l

TROUBLESHOOTING S-1

Causes

20-957

(14)

TROUBLESHOOTING

S-2

S-2 Engine does not start (1) Engine does not turn Causes

General causes why engine does not turn

fl If internal parts of the engine are seized, carry out troubleshooting for "Engine stops during operations". Defective electrical system Failure in power train

Confirm recent repair history Degree of use of machine Operated for long period Condition of horn when Horn sounds starting switch is turned Horn volume is low ON Speed of rotation is low When starting switch is Makes grating noise turned to START, pinion Soon disengages pinion again moves out, but Makes rattling noise and does not turn When starting switch is turned to START, pinion does not move out When starting switch is turned to ON, there is no clicking sound

20-958 (14)

Replace

—

Replace

Remedy

Replace

For the following conditions 1) - 5), turn the starting switch OFF, connect the cord, and carry out troubleshooting 1) When terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are connected, engine starts 4) When terminal of safety switch and terminal B of starting motor are connected, engine starts 5) There is no 24V between battery relay terminal b and terminal E When ring gear is inspected directly, tooth surface is found to be chipped Cannot be moved by hand even when linkage of fuel cut solenoid is disconnected

Replace

Troubleshooting

Specific gravity of electrolyte, voltage of battery is low

Replace

When battery is checked, battery electrolyte is found to be low

Replace

When starting switch is turned ON, linkage is not actuated

Replace

Battery terminal is loose

Replace

Check items

Questions

• •

Defe ctiv ew iring Defe ctiv of s e or tarti Defe dete ng c ctiv rior ircu e st ated it artin Bro batt ken gm ery r o i n t or g ge Defe ar ctiv e sa fety Defe rela ctiv y or e ba Defe ttery safe ctiv ty s r e lay e ba witc Defe ttery h ctiv t e rmin e fu el cu al co Defe t so nne ctiv leno e st ctio artin n id g sw itch

Internal parts of engine seized

Troubleshooting of defective wiring in starting circuit

•

PC128US-2

S-2

TROUBLESHOOTING

(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) General causes why engine turns but no exhaust smoke comes out Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly in winter)

★

Standards for use of fuel AMBIENT TEMPRATURE

KIND OF FLUID

-4 -20

14 -10

32 0

50 10

68ºF 20ºC

ASTM D975 No.2

Diesel fuel

Bro

ASTM D975 No.1

ken inje ctio Defe n pu ctiv mp e in driv ject Seiz ion e sh ed, pum aft, brok key p (ra en f Clog ck, p eed ged p lung fuel ump Clog er s filte pist ged eize r, st on d) feed rain Insu e p r u ffici mp ent stra fuel Clog iner in ta ged , lea nk Clog king ged fuel air b pipi Defe reat ng ctiv her e hole fuel Imp in fu cut rope sole el ta r fue noid nk l us ed

• • •

Causes

Questions

Confirm recent repair history Degree of use of machine Operated for long period Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty There is leakage from fuel piping Mud is stuck to fuel tank cap Check items

When starting switch is turned ON, linkage is not actuated When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when injection pump piping sleeve nut is loosened Rust and water are found when fuel tank is drained

Troubleshooting

Inspect injection pump directly When control rack is pushed, it is found to be heavy, or does not return Inspect feed pump directly When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When fuel cap is inspected directly, it is found to be clogged

PC128US-2

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Remedy

Replace

Cannot be moved by hand even when linkage of fuel cut solenoid is disconnected

20-959 (14)

TROUBLESHOOTING

S-2

General causes why exhaust smoke comes out but engine not start •

Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil

Defe

• • •

Causes ctive , bro Defe ke n v a lv ctiv e sy s e in ject tem Wor ion (valv n pi pum e , ro ston p (ra cke r Clog ring le v e ck, p ged , cyl r, etc lung inde fuel Clog .) e r f r i l l stuc i t ner ged er, s k) f t e r a e iner d pu Clog mp ged stra air c Defe iner l e ane ctiv r ele e el men ectr Defe ical t ctiv inta e or ke a Lea dete i kag r he rior e, cl ater ated ogg Clog b a i n ttery ged g, a ir in inje Clog ctio fuel n no ged syst zzle a em i r br Imp , defe eat h rope ctiv er h r fue e ole spra l us in fu y ed el t a nk c ap

(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)

Confirm recent repair history Degree of use of machine Operated for long period Questions

Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Rust and water are found when fuel tank is drained Dust indicator lamp is red Indicator lamp does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cap When fuel lever is placed at FULL position, it does not contact stopper

Check items

When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping

Troubleshooting

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When fuel filter is drained, no fuel comes out Remove head cover and check directly When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When air cleaner element is inspected directly, it is found to be clogged Heater mount does not become warm Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated, there is no response, or operation is too heavy Speed does not change when operation of certain cylinders is stopped

20-960 (14)

Clean

Clean

Correct

Replace

Correct

Clean

Clean

Clean

Replace

Replace

Remedy

Replace


PC128US-2

TROUBLESHOOTING

S-3

S-3 Engine does not pick-up smoothly (Follow-up is poor)

Causes

General causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injction Improper fuel used

Clog ged air c Clog lean ged er e lem f uel Clog ent filte ged r, st feed rain Clog er pum ged p st inje rain Seiz ctio er ed i n no njec zzle tion , de Wor fect pum n pi ive p pl ston spra Seiz ung ring y er ed t , cylin urbo d Imp e c harg r lin rope er er, i r va nter Clog lve fere clea ged nce ranc air b e Clog reat her ged hole , lea Defe king in fu ctiv fuel el t a e co nk c pipi ntac ng ap t of valv e an d va lve seat

• • • •

Questions

Confirm recent repair history Degree of use of machine Operated for long period Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Engine oil must be added more frequently Engine pick-up suddenly became poor Rust and water are found when fuel tank is drained Dust indicator lamp is red Noise of interference is heard from around turbocharger Color of exhaust gas

Blue under light load Black

Check items

Clanging sound is heard from around cylinder head Mud is stuck to fuel tank cap There is leakage from fuel piping High idling speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Troubleshooting

Blow-by gas is excessive When air cleaner element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy When valve clearance is checked directly, it is found to be outside standard value When fuel tank cap is inspected directly, it is found to be clogged

PC128US-2

Replace

Correct

Clean

Adjust

Replace

Replace

Replace

Correct

Clean

Clean

Remedy

Clean

When feed pump is operated, operation is too light or too heavy

20-961 (14)

S-4

TROUBLESHOOTING

S-4 Engine stops during operations General causes why engine stops during operations Seized parts inside engine Insufficient supply of fuel Overheating

Causes ken , sei zed Bro pist ken on, , sei co n zed Brok nec cran en d ting ksha ynam ro d ft be Bro i c va ken a ring lve s , sei yste Bro zed m ( ken gea valv pum r tra e, ro in p au Bro cker ken x leve i l i ary fuel r, et equ Insu pum c.) ipm ffici p driv ent ent e sh fuel Clog aft, in ta ged key nk fuel Clog filte ged r, st rain feed Bro er pum ken p st , sei rain z Clog ed f er eed ged , lea pum king Clog p pi ston fuel ged pipi air b Defe ng r e a ther ctiv e in hole ject Fail in fu ion ure el ta pum in p nk owe p (r a r tra c k , in plun ger stuc k)

• • •

fl If there is overheating and the engine stops, carry out troubleshooting for overheating. •

Failure in power train

Bro

fl If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.

Questions

Confirm recent repair history Degree of use of machine Operated for long period Abnormal noise was heard and engine stopped suddenly Condition when engine Engine overheated and stopped stopped Engine stopped slowly There was hunting and engine stopped Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Fuel level lamp lights up Fuel tank is found to be empty When feed pump is operated, operation is too light or too heavy

Check items

Mud is stuck to fuel tank cap Engine rotates, but stops when power train is operated Does not turn at all When it is attempted to turn by hand using barring tool

Turns in opposite direction Moves amount of backlash Shaft does not turn Troubleshooting of chassis

Rust and water are found when fuel tank is drained Metal particles are found when oil is drained Remove oil pan and inspect directly Troubleshooting

Remove head cover and inspect directly When gear train is inspected, it does not turn Rotates when pump auxiliary equipment is removed When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Inspect feed pump directly

20-962 (14)

Replace

Clean

Correct

Replace

Replace

Clean

Clean

Add

Replace

Replace

Replace

Replace

Remedy

Replace

When control rack is pushed, it is found to be heavy, or does not return —

PC128US-2

S-5

TROUBLESHOOTING

S-5 Engine does not rotate smoothly (Hunting) General causes why engine does not rotate smoothly Air in fuel system Defective governor mechanism Defective electric governor mechanism (engine with electric governor)

Causes

Defe ctiv e op Defe erat ctiv ion e ad of g Defe ove just rn o r men ctiv e op t of gov Low erat erno ion idlin of c r g sp Insu ontr eed ffici o l rac is to ent k o fuel Clog in ta low ged nk feed Clog pum ged p st fuel rain Clog f ilter er ged, , stra air in iner Clog c i rcuit ged, betw air in een Clog circu fuel ged it be tank air b t w and een reat feed feed her pum pum hole p p an in fu d no el t a zzle nk

• • •

fl If hunting stops when electric governor rod is disconnected, carry out troubleshooting for the chassis.

Confirm recent repair history

Questions

Degree of use of machine Operated for long period Occurs at a certain speed range Condition of hunting

Occurs at low idling Occurs even when speed is raised Occurs on slopes

Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Rust, water are found when fuel tank is drained

Check items

Leakage from fuel piping When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes rises too far Engine is sometimes difficult to stop Seal on injection pump has come off

Troubleshooting

When governor lever is moved it is found to be stiff When injection pump is tested, governor is found to be improperly adjusted When control rack is pushed, it is found to be heavy, or does not return When fuel tank cap is inspected directly, it is found to be clogged When feed pump strainer is inspected directly, it is found to be clogged

PC128US-2

Clean

Correct

Correct

Clean

Clean

Add

Adjust

Adjust

Adjust

Remedy

Adjust

When fuel filter, strainer are inspected directly, they are found to be clogged

20-963 (14)

TROUBLESHOOTING

S-6

S-6 Engine lacks output (or lacks power) General causes why engine lacks output

•

Clog

fl If there is overheating and lack of output, carry out troubleshooting for overheating.

Seiz

Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used (if non-specified fuel is used, output drops) Lack of output due to overtaking

ged air c lean ed t er e urbo lem Wor cha ent rger n pi , int ston erfe Clog ring renc ged , cyl e inde fuel Clog r filte ged r , s f t e r a ed p Clog ump iner ged stra inje Seiz iner c tion ed i noz njec zle, Imp tion defe rope pum ctiv r va p pl e sp Defe lve u ray nge clea ctiv r ranc e co e ntac Ben t fue t of valv l lev Clog e an er li ged nka d va ge, , lea lve d k seat Clog efec ing fuel tive ged adju pipi a i r brea Defe ng stm ther ent ctiv e bo hole Defe o s in fu t co ctiv el ta mpe ew estg nk nsa t ate diap or diap hrag hrag m m

Causes

• • • •

Confirm recent repair history Degree of use of machine Operated for long period

Questions

Power was lost

Suddenly Gradually

Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Dust indicator lamp is red Color of exhaust gas

Black Blue under light load

Noise of interference is heard from around turbocharger Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular High idling speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low There is hunting from engine (rotation is irregular) Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping When air cleaner element is inspected directly, it is found to be clogged When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When valve clearance is checked directly, it is found to be outside standard value When lever is placed at FULL position, it does not contact stopper When feed pump is operated, operation is too light or too heavy

20-964 (14)

Replace

Replace

Clean

Correct

Adjust

Replace

Adjust

Replace

Correct

Clean

Clean

Replace

Replace

Remedy

Clean


PC128US-2

S-7

TROUBLESHOOTING

S-7 Exhaust smoke is black (Incomplete combustion) General causes why exhaust smoke is black Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel

Causes Seiz ed t urbo Clog cha rger ged , int air c Wor erfe lean renc n pi er e ston e lem Clog ent ring ged , cyl i i nde njec Imp r tion rope noz r inj zle, Defe ecti o ctiv n tim defecti e in ve s ing Imp ject pray i rope on p r u v m a Cru p l v ( e e she xces clea d, c ranc sive logg Lea e inje ed m kag ctio e of u n) f fler air b Defe e ctiv t we e en t con Defe urbo tact ctiv cha of v e in rger alve ject and and ion hea pum valv d e se p (ra at ck, p lung er s eize d)

• • •


Questions

Suddenly became black Color of exhaust gas

Gradually became black Blue under light load

Engine oil must be added more frequently Power was lost

Suddenly Gradually

Non-specified fuel is being used Noise of interference is heard from around turbocharger Dust indicator lamp is red Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Timing lock on fuel injection pump does not match Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner element is inspected directly, it is found to be clogged Troubleshooting

When compression pressure is measured, it is found to be low Speed does not change when operation of certain cylinders is stopped When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust color returns to normal

PC128US-2

Replace

Replace

Correct

Replace

Adjust

Adjust

Adjust

Replace

Replace

Clean

Remedy

Replace

When control rack is pushed, it is found to be heavy, or does not return

20-965 (14)

TROUBLESHOOTING

S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive Abnormal combustion of oil External leakage of oil Wear of lubrication system

Bro

• • •

Causes

ken pist on r Wor ing n pi ston Clog ring ged , cyl inde brea Lea r (lin ther kag er le or b e fro ss e reat Lea mo ngin her kag il fil h e) e fro ose ter o mo Lea r o il co il pi kag ping e fro oler mo Lea kag il dr e fro ain plug mo Bro ken il pa oil c n or oole Wor cylin r n se der al a hea t tur Wor d bine n se a e l n at b d Wor low n, b er e roke nd n re Dus Turb ar s t su eal, cked och seal arge Wor in fr surf r n va om ace inta lve (ste ke s m, g yste uide m ), br oke n se al

fl Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)


Questions

Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust smoke is blue under light load Amount of blow-by gas

Excessive None

Area around engine is dirty with oil Check items

There is oil in engine cooling water When exhaust pipe is removed, inside is found to be dirty with oil When turbocharger air supply pipe is removed, inside is found to be dirty with oil Oil level in clutch or TORQFLOW transmission damper chamber rises Clamps for intake system are loose

Troubleshooting

When compression pressure is measured, it is found to be low When breather element is inspected, it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Inspect rear seal directly When intake manifold is removed, dust is found inside

20-966 (14)

Correct

Correct

Correct

Replace

Replace

Replace

Correct

Correct

Correct

Correct

Clean

Replace

Remedy

Replace

When intake manifold is removed, inside is found to be dirty with oil

PC128US-2

S-9

TROUBLESHOOTING

S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly Entry of exhaust gas due to internal wear Clogging of lubrication passage Improper fuel Improper oil used Operation under excessive load

Causes

Wor n pi ston Clog ring , cyl ged inde brea Clog r lin ther ged er , b re o athe i l filt Wor r ho er n va se lve, Clog valv ged e gu oil c ide Clog oole ged r turb Defe och ctiv arge e se r oil Exh al a drai aus t tur n tu t sm boc be harg oke is b e r turb lack ine end

• • • • •

Questions

Confirm recent repair history Degree of use of machine Operated for long period Engine oil must be added more frequently Non-specified oil is being used Color of exhaust gas

Blue under light load Black Carry out troubleshooting for “Exhaust smoke is black”.

Check items

Excessive Amount of blow-by gas

None

When oil filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Engine oil temperature rises quickly

When breather element is inspected directly, hose is broken or is found to be clogged with dirty oil When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged Turbocharger oil drain tube is clogged

PC128US-2

Replace

Clean

Clean

Replace

Replace

Remedy

Clean

Excessive play of turbocharger shaft When safety valve is directly inspected, spring is found to be catching or broken Replace

Troubleshooting

When compression pressure is measured, it is found to be low

—

20-967 (14)

S-10

TROUBLESHOOTING

S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Leakage of fuel Improper condition of fuel injection Excessive injection of fuel

Defe ctive injec tion Defe pum ctive p (ex nozz Defe cess le ho ive i ctive lder njec spra i n j e tion Defe ction y ) ctive pum fuel p plu Exte injec n ger rnal tion leak timi age ng Leak from age fuel of fu pipin el in Defe side g, fu ctive el fil h oil s ead ter Defe e c a o l v insid ctive er e fee adju d pu stme mp nt o (pist f fue on) l con trol linka ge

• • •

Causes

Questions

Confirm recent repair history Degree of use of machine Operated for long period Condition of fuel consumption

More than for other machines of same model Gradually increased Suddenly increased Black

Exhaust smoke color

White

Seal on injection pump has come off

Check items

There is irregular combustion When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match mark on injection pump is misaligned There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel Engine low idling and high idling speeds are high Injection pump measurement shows that injection amount is excessive

Troubleshooting

Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When check is made using delivery method, injection timing is found to be incorrect Remove head cover and inspect directly Remove feed pump and inspect directly

20-968 (14)

Adjust

Correct

Correct

Correct

Adjust

Replace

Replace

Remedy

Adjust

When engine speed is measured, low idling and high idling speeds are found to be high

PC128US-2

S-11

TROUBLESHOOTING

S-11 Oil is in cooling water, or water spurts back, or water level goes down

Causes

General causes why oil is in cooling water Internal leakage in lubrication system Internal leakage in cooling system Brok en o il co oler Brok core en c , O-r ylind ing er h Brok e en p ad, h owe e a d r tra Hole gask in oi s ca et l coo used ler by p Inter ittin nal c g rack s in cylin der bloc k

• •

Questions

Confirm recent repair history Degree of use of machine Operated for long period Oil level

Suddenly increased Gradually increased

Hard water is being used as cooling water

Excessive air bubbles inside radiator, spurts back Hydraulic oil, transmission oil is cloudy white When hydraulic oil, transmission oil is drained, water is found Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage

PC128US-2

Replace

Replace

Replace

Remedy

Replace

Remove oil pan and inspect directly

Replace

Troubleshooting

Check items

Engine oil level has risen, oil is cloudy white

20-969 (14)

TROUBLESHOOTING

S-12

S-12 Oil pressure caution lamp lights up (Drop in oil pressure) General causes why oil pressure lamp lights up • • • •

Leakage, clogging, wear of lubricating system Defective oil pressure control Improper oil used (improper viscosity) Deterioration of oil due to overheating

fl Standards for engine oil selection

Type of oil

Selection of SAE No. according to ambient temperature –30 –20

–10

0

10

20

30

Causes

40°C

SAE10WCD SAE10W-30CD

Clog

SAE15W-40CD

Wor

Engine oil

ged oil f ilter n be arin Clog g, jo urna ged stra l Clog iner ged insi d o e oi i l pip Bro l pa ken e in n suct side ion Defe o i l pipe pan ctiv e oi braz Lack l pu ing mp of o i l in Defe oil p ctiv an e re gula Defe tor v ctiv e re alve lief Lea valv king e , cru Defe she d hy ctiv e oi drau l pre Defe lic p ssur ctiv ipin e oi e se g l n leve sor Wat l sen er, f sor uel in o il

SAE30CD

Questions

Confirm recent repair history Degree of use of machine Operated for long period Replacement of filters has not been carried out according to Operation Manual Non-specified oil is being used Caution lamp lights up Lights up at low idling Condition when oil pressure lamp lights up

Lights up at low, high idling Lights up on slopes

Check items

Sometimes lights up There is crushing, leakage from hydraulic piping (external) Oil level sensor lamp lights up When oil level in oil pan is inspected, it is found to be low Metal particles are found when oil is drained Metal particles are stuck to oil filter element

Carry out troubleshooting for “Oil level rises”.

Oil is cloudy white or smells of diesel oil

Remove oil pan and inspect directly Oil pump rotation is heavy, there is play There is catching of relief valve or regulator valve, spring or valve guide is broken When oil level sensor is replaced, oil level sensor lamp goes out

20-970 (14)

Replace

Replace

Correct

Adjust

Adjust

Add

Replace

Correct

Clean

Clean

Remedy

Clean

When oil pressure is measured, it is found to be within standard value Clean

Troubleshooting

When oil filter is inspected, it is found to be clogged

—

PC128US-2

S-13

TROUBLESHOOTING

S-13 Oil level rises (Water, fuel in oil) fl If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”.

Water in oil (milky white) Fuel in oil (diluted, and smells of diesel fuel) Entry of oil from other component

Bro

• • •

ken oil c oole Defe r co ctiv re, O e no Bro -ring zzle ken hold cylin er s Wor der leev n, d hea e ama d, h ead Defe ged gas rear ctiv ket e pu seal Lea mp surf kag aux ace e of i l iary fuel Defe equ from ctiv ipm e pa pipi ent Defe rt in n seal g in ctiv s i d side e e th i n hea j erm ecti Hole d co on p osta sm ver ump t ade Crac by p ks in ittin g side cylin der bloc k

General causes why oil level rises

Causes

Questions

Confirm recent repair history Degree of use of machine Operated for long period There is oil in radiator cooling water Fuel must be added more frequently

Check items

Exhaust smoke is white When engine is first started, drops of water come from muffler Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back Oil level goes down in clutch, TORQFLOW transmission, or damper chamber Oil level goes down in hydraulic tank Engine oil smells of diesel fuel Water temperature is low Pressure-tightness test of oil cooler shows there is leakage Troubleshooting

Pressure-tightness test of cylinder head shows there is leakage When compression pressure is measured, it is found to be low Inspect rear seal directly When pump auxiliary equipment is removed, seal is found to be damaged Remove head cover and inspect directly Remove injection pump and inspect directly Defective contact with thermostat seal valve

PC128US-2

Replace

Replace

Correct

Replace

Correct

Replace

Correct

Replace

Replace

Remedy

Replace

Remove oil pan and check directly

20-971 (14)

TROUBLESHOOTING

S-14

S-14 Water temperature becomes too high (Overheating) General causes why water temperature becomes too high Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature in power train fl Carry out troubleshooting for chassis.

Bro ken wat er p Clog ump ged , cru Clog she d ra ged diat radi or fi Defe ator ns ctiv core e ther Defe mos ctiv tat ( ew doe ater Lack s no tem of c t op pera ooli en) Fan ture n g w belt g a aug t e s r l e i p Clog ping ged , wo , bro rn fa Defe ken n pu ctiv oil c lley e pr oole essu Bro r ken r e va cylin lve Hole der sm h ead ade , hea Rise by p d ga ittin in to sket g rque con vert er o il te mpe ratu re

• • • •

Causes

Confirm recent repair history Questions

Degree of use of machine Operated for long period Condition of overheating

Suddenly overheated Always tends to overheat

Water temperature gauge

Rises quickly Does not go down from red range

Radiator water level sensor lights up Fan belt whines under sudden load Cloudy white oil is floating on cooling water Cooling water flows out from overflow hose

Check items

Excessive air bubbles inside radiator, water spurts back Engine oil level has risen, oil is cloudy white There is play when fan pulley is rotated Radiator shroud, inside of underguard are clogged with dirt or mud When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose

Temperature difference between top and bottom radiator tanks is excessive Temperature difference between top and bottom radiator tanks is slight When water filler port is inspected, core is found to be clogged When function test is carried out on thermostat, it does not open even at cracking temperature

Carry out troubleshooting for chassis.

Troubleshooting

Power train oil temperature enters red range faster than engine water temperature

When water temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low

20-972 (14)

Replace

Replace

Replace

Replace

Correct

Add

Replace

Replace

Correct

Correct

Remedy

Replace

Remove oil pan and inspect directly

—

PC128US-2

S-15

TROUBLESHOOTING

S-15 Abnormal noise is made fl Judge if the noise is an internal noise or an external noise.

• • •

Abnormality due to defective parts Abnormal combustion Air sucked in from intake system

Exce ssive wea Seiz r of ed t pisto urbo n rin Mis c g, cy harg sing linde er, i , sei r (lin n t e z Clog rfer ed b er le enc ged ss en ush e , i n gine s g e Defe ized ) ctiv i n ject e in i on n ject Defe ion ctiv pum ozzle e in p (ra Defo ject ion ck, p rme pum d fa lung Defe p (e n, fa er s x ctiv n be cess eize e ad d) lt in ive Brok just i t n e ject r fere men en d ion) nce ynam t of valv Imp ic va rope e cle lve s r ge aran yste Leak a m (v ce r train age alve of ai b , ackl rock r bet Defe er le ash wee ct in ver, n tu r side etc.) b o ch muf arg e fler ( r an d divid ing b cylin oard d er h out o ead f pos ition )

General causes why abnormal noise is made

Causes

Questions

Confirm recent repair history Degree of use of machine Operated for long period Condition of abnormal noise

Gradually occurred Suddenly occurred

Non-specified fuel is being used Engine oil must be added more frequently Color of exhaust gas

Blue under light load Black

Metal particles are found in oil filter Blow-by gas is excessive

Check items

Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is abnormal When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Seal on injection pump has come off Abnormal noise is loud when accelerating engine Clanging sound is heard from around cylinder head Leakage of air between turbocharger and cylinder head, loose clamp Vibrating noise is heard from around muffler When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy Troubleshooting

Remove gear cover and inspect directly Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return Injection pump test shows that injection amount is incorrect Fan is deformed, belt is loose When valve clearance is checked, it is found to be outside standard value Remove cylinder head cover and inspect directly

PC128US-2

Replace

Replace

Replace

Correct

Replace

Correct

Replace

Correct

Replace

Replace

Replace

Remedy

Replace

When muffler is removed, abnormal noise disappears

20-973 (14)

S-16

TROUBLESHOOTING

S-16 Vibration is excessive

General causes why vibration is excessive • • •

Defective parts (abnormal wear, breakage) Improper alignment Abnormal combustion

Causes Wor n co nne ctin Wor g ro n ca d, m m bus Loo ain hing bea se e ring ngin Bro e mou ken ntin part g bo Cen insi lts, de o ter o brok utpu f en en c Imp gine t s h ush rope a a f t nd p ion (dam r ge owe Defe a per) r train r tra ctive i n d b y ackl mis nam Defe alig ic va ash ctiv ned lve s e in ystem ject (valv ion e, ro pum cker p (e lever xces , etc. sive stuck fuel ) inje ctio n)

fl If there is abnormal noise together with the vibration, carry out troubleshooting also for “Abnormal noise is made”.

Questions

Confirm recent repair history Degree of use of machine Operated for long period Condition of vibration

Suddenly increased Gradually increased

Non-specified oil is being used Metal particles are found in oil filter Metal particles are found when oil is drained

Check items

Oil pressure is low at low idling Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Seal on injection pump has come off Remove oil pan and inspect directly Troubleshooting

Remove side cover and inspect directly Inspect directly for loose engine mounting bolts, broken cushion Inspect inside of output shaft (damper) directly When face runout and radial runout are inspected, they are found to be incorrect Remove front cover and inspect directly Remove head cover and inspect directly

20-974 (14)

Adjust

Replace

Correct

Correct

Replace

Replace

Replace

Remedy

Replace

Injection pump test shows that injection amount is incorrect

PC128US-2

30 DISASSEMBLY AND ASSEMBLY Method of using manual.................................. 30- 2 Precautions when carrying out operation........ 30- 3 Special tool list ................................................ 30- 5 Sketch of special tool .................................... 30- 9 CYLINDER HEAD ASSEMBLY Removal and Installation ........................... 30-11 INJECTION PUMP ASSEMBLY Removal and Installation ........................... 30-16 ENGINE AND MAIN PUMP ASSEMBLY Removal and Installation ........................... 30-19 RADIATOR, HYDRAULIC OIL COOLER Removal and Installation ........................... 30-31 RADIATOR ASSEMBLY Removal and Installation ........................... 30-33 HYDRAULIC OIL COOLER ASSEMBLY Removal and Installation ........................... 30-34 AFTER COOLER ASSEMBLY Removal and Installation ........................... 30-36 FUEL TANK Removal and Installation ........................... 30-38 CENTER SWIVEL JOINT Removal and Installation ........................... 30-39 Disassembly and Assembly ...................... 30-40 SWING MOTOR, SWING MACHINERY Removal and Installation ........................... 30-41 SWING MACHINERY Disassembly and Assembly ...................... 30-42 REVOLVING FRAME Removal and Installation ........................... 30-55 SWING CIRCLE Removal and Installation ........................... 30-57 TRAVEL MOTOR AND FINAL DRIVE Removal and Installation ........................... 30-58 RECOIL SPRING Disassembly and Assembly ...................... 30-59 IDLER Disassembly and Assembly ...................... 30-63 TRACK ROLLER Disassembly and Assembly ...................... 30-67 TRACK SHOE Removal and Installation ........................... 30-70 HYDRAULIC TANK Removal and Installation ........................... 30-71

PC128US-2

MAIN PUMP Removal and Installation..........................30- 73 CONTROL VALVE Removal and Installation..........................30- 76 Disassembly and Assembly .....................30- 78 LS SELECTION VALVE Disassembly and Assembly .....................30- 92 PRESSURE COMPENSATION VALVE Disassembly and Assembly .....................30- 94 MAIN RELIEF VALVE Disassembly and Assembly .....................30- 98 WORK EQUIPMENT PPC VALVE (FOR BOOM, BUCKET, ARM, SWING CONTROL) Disassembly and Assembly .................... 30-100 TRAVEL PPC VALVE Disassembly and Assembly .................... 30-104 HYDRAULIC CYLINDER Disassembly and Assembly .................... 30-107 WORK EQUIPMENT Removal and Installation..........................30-114 OPERATOR'S CAB Removal and Installation..........................30-116 OPERATOR'S CAB GLASS (STUCK GLASS) Removal and Installation......................... 30-123 FRONT WINDOW ASSEMBLY Removal and Installation......................... 30-135 FLOOR FRAME Removal and Installation......................... 30-136 AIR CONDITIONER COMPRESSOR Removal and Installation......................... 30-143 AIR CONDITIONER Condenser Removal and Installation......................... 30-145 AIR CONDITIONER UNIT Removal and Installation......................... 30-147 COUNTERWEIGHT Removal and Installation......................... 30-155 MONITOR PANEL ASSEMBLY Removal and Installation......................... 30-156 CONTROLLER ASSEMBLY Removal and Installation......................... 30-157

30-1 (16)

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

METHOD OF USING MANUAL 1. When removing or installing unit assemblies [1] When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. [2] Any special techniques applying only to the installation procedure are marked [*1], and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF QQQQ ASSEMBLY ........... Title of operation

k ................................................................ Precautions related to safety when carrying out the operation 1.

(1) ............................................ Step in operation a ............................................................ Technique or important point to remember when removing (1). 2. EEEE (2)............................................ [*1] ..........Indicates that a technique is listed for use during installation 3. T T T T assembly (3)

6............................................................. See Lubricant and Coolant Table

INSTALLATION OF QQQQ ASSEMBLY ... Title of operation • Carry out installation in the reverse order to removal. [*1] ................................................................ Technique used during installation a ............................................................ Technique or important point to remember when installing EEEE (2). • Adding water, oil ..................................... Step in operation a ............................................................ Point to remember when adding water or oil 5 ......................................................... Quantity when filling with oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools [1] For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

30-2 (16)

PC128US-2

PRECAUTIONS WHEN CARRYING OUT OPERATION


PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind 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. a Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. Nominal number 02 03 04 05 06 10 12

Plug

Sleeve nut (elbow end) Use the two items below as a set

07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234

07221-20210(Nut), 07221-20315(Nut), 07221-20422(Nut), 07221-20522(Nut), 07221-20628(Nut), 07221-21034(Nut), 07221-21234(Nut),

07222-00210(Plug) 07222-00312(Plug) 07222-00414(Plug) 07222-00515(Plug) 07222-00616(Plug) 07222-01018(Plug) 07222-01219(Plug)

1) Hoses and tubes using sleeve nuts Nominal number 04 05

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

2) Split flange type hoses and tubes 3) 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 27

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734

PC128US-2

D 6 8 10 12 14 16 18 20 22 24 27

Dimensions d L 5 8 6.5 11 8.5 12 10 15 11.5 18 13.5 20 15 22 17 25 18.5 28 20 30 22.5 34

30-3 (16)


2. • • • • • • • • • • • • •

PRECAUTIONS WHEN CARRYING OUT OPERATION

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. 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.

a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the 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. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. • 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. • 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. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-4 (16)

PC128US-2

SPECIAL TOOL LIST


SPECIAL TOOL LIST

790-331-1110

Wrench

t

1

790-101-2501

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

1 796T-426-1140

Push tool

t

1

2 790-201-2680

Plate

q

1

1 790-201-2850

Spacer

t

1

2 790-201-2750

Spacer

t

1

790-101-5401

Push tool KIT (C)

q

1

Press fit of 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

5

790-201-2750

Spacer

t

1

6

796T-226-1210

Wrench assembly

t

1

790-101-5401

Push tool kit (C)

q

1

• 790-101-5461

• Plate

1

• 790-101-5421

• Grip

1

• 01010-51240

• Bolt

1

790-101-5401

Push tool kit (C)

• 790-101-5471

• Plate

1

• 790-101-5421

• Grip

1

• 01010-51240

• Bolt

1

790-201-2850

Push tool

Symbol A

1

1

2

3

Disassembly, assembly of swing machinery

F

4

7

8

9

PC128US-2

Part No.

Part Name

q

t

Sketch

Q’ty

Disassembl, assembly of cylinder head

Necessity

Component

New/ remodel

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity: t : Cannot be substituted, should always be prepared (used) q : Extremely useful if available, can be substituted with commercially available part a New/remodel:N .......... Tools with new part numbers, newly developed for this model R .......... Tools with upgraded part numbers, remodeled from items already available for other models Blank ... Tools already available for other models, used without any modification a Tools marked Q in the Sketch column are tools introduced in special sketches. Nature of work, remarks Tightening of cylinder head

Removal of bearing

Q

Press fit of oil seal

Press fit of bearing inner race

Removal separate caler Q

Removal, installation of nut

Press fitting of main bearing outer race

1

1

Press fitting of sub bearing outer race

Press fitting of main bearing inner race

30-5 (16)

SPECIAL TOOL LIST

10

797T-423-1360

Push tool

t

1

11

795-630-1803

Torque wrench

t

1

Press fitting of sub bearing inner race Measurement of running torque of shaft

1

791-675-1510

Installer

t

1

Application of floating seal

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 74)

1

• 790-201-1610

• Plate (Periphery 79)

1

• 790-101-5021

• Grip

1

• 01010-50816

• Bolt

1

1

790-434-1650

Installer

t

1

2

791-601-1000

Oil pump

q

1

791-616-1040

Remover & installer

t

1

790-105-1100


t

1

791-101-1102

Pump

t

1

791-616-1110

Frame

t

1

791-616-1121

Plate

t

1

791-616-1131

Plate

t

1

791-616-1150

Guide

t

1

791-616-1160

Adapter

t

1

791T-616-1280

Adapter

t

1

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

790-101-2501

Push puller

q

1

• 790-101-2510

• Block

Symbol

F

2

Disassembly, assembly of idler recoil spring

L

3

Disassembly, assembly of track roller

Expansion, installation of track shoe

Disassembly of center swivel joint

30-6 (16)

M

R

T

Part No.

Part Name

Compressor (B)

t

Sketch

Q’ty

Disassembly, assembly of swing machinery

Necessity

Component

New/ remodel


Q

Nature of work, remarks

1 1

1

Compression of spring

Press fit of piston dust seal

Application of floating seal 88 Sealing of oil and checking of air leak

PC128US-2

N

Removal, pressfit of master pin

Q Removal, PC138USLCpressfit of 2 master pin

Disconnection of rotor from shaft

PC128US-2

SPECIAL TOOL LIST

Disassembly of center swivel joint

T

1

2

3

Disassembly, assembly of hydraulic cylinder

U

4

5

PC128US-2

Part Name

• 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

790-502-1003

Repair stand

t

1

790-101-1102

Pump

t

1

790-102-4300

Wrench ass’y

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

t

q

q

q

t

Sketch

Part No.

Q’ty

Symbol

New/ remodel

Nature of work

Necessity


Nature of work, remarks

Disconnection of rotor from shaft

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

1

Application of arm and blade cylinder dust seal

Extension of piston ring

30-7 (16)

SPECIAL TOOL LIST

Removal, installation, of work equipment and boom

U

V

Floor frame assembly airconditioner compressor X assembly airconditioner condenser assembly airconditioner unit assembly

(19)

Ring

t

1

07281-01029

Clamp

t

1

796-720-1660

Ring

t

1

07281-01159

Clamp

t

1

792-785-1100

Remover

t

1

• 796-270-1110

• Adapter

t

1

790-101-4000

Puller (490 kN {50 ton})

t

1

790-101-1102

Pump

t

1

1

793-498-1210

Lifter (Suction cup)

t

2

2

20Y-54-13180

Adapter

t

2

799-703-1200

Service tool KIT

t

1

799-703-1100

Vacuum pump(100V)

t

1

For Japan

799-703-1110

Vacuum pump(220V)

t

1

For overseas

790-703-1120

Vacuum pump(240V)

t

1

For overseas

799-703-1401

Gas leak detector

t

1

Part No.

Part Name

6

1

3

Sketch

796-720-1650

Symbol

Operator’s cab glass (stuck glass)

30-8

Q’ty

Disassembly, assembly of hydraulic cylinder

Necessity

Nature of work

New/ remodel


Nature of work, remarks Bucket cylinder (PC128UU-2) Bucket cylinder (PC138US-2) (PC138USLC-2) Arm, boom, blade cylinder

Removal, installation of piston ring Removal, installation of piston ring

Removal of boom foot pin

Removal and installation operatiors cab glass (stuck glass)

Charging of air-conditioning gas

PC128US-2


SKETCH OF SPECIAL TOOL

SKETCH OF SPECIAL TOOL Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. F2-1 Push tool

a Unless otherwise specified, there shall be on burrs or flushes at the corner. F6 Wrench

PC128US-2

30-9 (16)


SKETCH OF SPECIAL TOOL

F-10 Push tool

R Adapter

30-10 (16)

PC128US-2

CYLINDER HEAD


CYLINDER HEAD ASSEMBLY PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery. 1. Remove the counter weight. For details, See REMOVAL OF COUNTERWEIGHT. 2. Drain the coolant.

6 Coolant: 13.2 l

3. Remove frame (1) and (2). 4. Remove cover (3) 5. Remove connector (M34) (4) and cover (5). 6. Loosen air conditioner compressor (6) mounting bolt (7) and adjustment bolt and remove air conditioner compressor belt (8). 7. Remove air conditioner compressor (6). a Put the air conditioner compressor in front of the turbocharger. 8. Disconnect heater hoses (9). 9. Disconnect air hose (10) and remove aftercooler hose (11). [*1] 10. Disconnect radiator hose (12).

[*2]

11. Remove cover (13). 12. Remove muffler drain tube (14). 13. Remove clamp (15).

[*3]

14. Remove mufler (16) and bracket (17) together. 15. Disconnect water temperature sensor connector (P07) (18).

PC128US-2

30-11 (16)

CYLINDER HEAD


16. Disconnect spill tube (19). 17. Remove the bracket mounting bolts of fuel filter (20). 18. Disconnect clip (21) and boost compensator hose (22). 19. Remove the 4 fuel injection tube (23).

[*4]

20. Remove air conditioner compressor bracket (24). 21. Disconnect blow-by hose (25). 22. Remove nut (26) and bracket (27) and disconnect engine stop solenoid (28). 23. Disconnect heater terminal E52 (29) and clip (30). 24. Disconnect air tube (32) from turbocharger (31).

25. Disconnect turbocharger lubrication tubes (33) and (34) on the engine side. 26. Disconnect clip (35). a There are 2 spacers. 27. Lift off turbocharger, exhaust manifold, and lubrication tube assembly (36). [*5]

28. Loosen mounting bolts (38) and (39) of alternator (37) and adjustment bolt (40) and remove alternator belt (41).

30-12 (16)

PC128US-2

CYLINDER HEAD


29. Remove clamp (42). 30. Disconnect heater hoses (43) and radiator hose (44). [*2] 31. Remove fan guard (45). 32. Remove the 6 mounting bolts (46) of, fan (47), and pully (48). 33. Remove water pump assembly (49).

34. Remove cylinder head cover (50).

[*6]

35. Loosen locknut (51), and then loosen adjustment screw (52) by 2 – 3 turns. a Perform this work for all of the 8 places. [*7] 36. Remove 5 mounting bolts (53), 3 mounting nuts (54), and rocker arm and shaft assembly (55). [*8] 37. Remove the 8 push rods (56). 38. Remove the 17 mounting bolts and lift off exhaust manifold assembly (57). [*9]

4 Clinder head, intake manifold Assembly: 40 kg

PC128US-2

30-13 (16)

CYLINDER HEAD


INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

3 Air hose clamp After cooler hose clamp: 10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}

[*2]

[*3]

2 Apply gasket sealant (ThreeBond TB1208E) to the range of 30 mm from each end of radiator hose adapters (of the radiator and water pump) and connect the radiator hose. 3 Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 3 Mounting bolt of clamp between turbocharger and muffler: 1st time: 39.2 – 49 Nm {4 – 5 kgm} 2nd time: 68.6 – 122.5 Nm {7 – 12.5 kgm}

[*4]

3 Fuel injection pipe sleeve nut: 19.6 – 24.5 Nm {2 – 2.5 kgm}

[*5]

3 Mounting bolt of exhaust manihold and turbocharger: 34.3 – 53.9 Nm {3.5 – 5.5 kgm}

[*6]

a Insert the cylinder head cover O-ring in the O-ring groove, taking care not to expand or contact it, and fit it to the cylinder head. Apply adhesive, if necessary. 3 Head cover mounting bolt: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}

[*7]

3 Rock nut: 39.2 – 49 Nm {4 – 5 kgm}

[*8]

3 Rocker arm shaft mounting bolt and nut: 19.6 – 29.4 Nm {2 – 3 kgm}

[*9] 1. Tighten the cylinder head mounting bolts in the following order. 1) Apply molybdenum disulphide LM-P all over the threads and seating face of each bolt and the seats of the cylinder head holes. 2) Turn the bolts with the fingers until they are screwed in the threaded holes of the cylinder head by 2 – 3 threads in the order of [1] – [17] shown in the figure. 3) Tighten the bolts to 68.6 ± 9.8 Nm {7 ± 1 kgm} in the order of [1] – [17] shown in the figure. 4) Tighten the bolts to 107.8 ± 4.9 Nm {11 ± 0.5 kgm} in the order of [1] – [17] shown in the figure. a (1): Exhaust side, (2): Air intake side, (3): Front, (4): Rear

30-14 (16)

PC128US-2


CYLINDER HEAD

5) Use the tool A1 or make marks f with paint on the Y bolt heads and their seats on the cylinder head, and then tighten the bolts in the order of [1] – [17] so that the mark of each bolt will be at 90º +30º from the mark of 0 the cylinder head. a After tightening the bolts, make 1 punch mark (g) on each bolt head. a If there are 5 or more punch marks on a bolt head, do not use that bolt again but replace it.

Reference

3 U-clamp nut: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

3 Mounting bolt of nozzle holder: 39.2 – 49 Nm {4 – 5 kgm} 3 Turbocharger unit mounting bolt: 27 – 34 Nm {2.8 – 3.5 kgm} a If the exhaust manifold is removed, apply gasket sealant LG-7 in the form of a string 1 mm in diameter as shown below.

•

Supplying coolant Supply coolant from the cooloant filter port to the specified level, start the engine to circulate coolant and recheck the level. 5 Coolant: 13.2 l

•

Bleeding air Bleed air from the fuel system. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC128US-2

30-15 (16)

INJECTION PUMP


INJECTION PUMP ASSEMBLY PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Disconnect the wiring harness from the negative terminal of the battery. 1. Remove the counterweight. (See REMOVAL OF COUNTERWEIGHT.) 2. Remove frame (1). 3. Remove oil gauge guide (2). 4. Remove nut (3), and then remove engine stop solenoid (4) and bracket together. 5. Remove cover (6), loosen the mounting bolts and adjustment bolt of air conditioner compressor (5), and then remove air conditioner compressor belt (7). 6. Remove blow-by tube (8).

7. Disconnect clamp (9). 8. Remove nut (10) and disconnect fuel control cable (12) and bracket (11) together. 9. Disconnect spill hose (13) and fuel feed hoses (14) and (15). 10. Remove fuel filter (16). 11. Disconnect fuel feed hose (17) and fuel return hose (18). 12. Remove 4 fuel injection tubes (19).

[*1]

13. Remove lubrication tube (20). 14. Disconnect boost compensator hose (21). 15. Remove clamp (22) and separate wiring harness (23) from fuel injection pump (24). 16. Remove bracket (25).

30-16 (16)

PC128US-2


INJECTION PUMP

17. Remove cover (26) and set the No. 1 cylinder to the compression top dead center. 1) Rotate bolt B forward to match the stamped line of 1.4TOP to pointer C under pulley A. a If there is not valve clearance in the No. 1 cylinder, the No. 4 is at the compression top dead center. In this case, rotate bolt B forward further to match the stamped line of 1.4TOP to pointer C again. 2) Check that bolt hole D on this side is matched to the hole of the pump gear (that the No. 1 cylinder is at the compression top dead center) by inserting a pin about 8 cm long (a round rod) [2]. 18. Remove 6 mounting bolts (27) on the pulley side, mounting bolts (28) and (29) on the pump side, and fuel injection pump (24). a Do not remove the bolt at part E, since it is used as a plug. (Remove it to fix the pump gear when installing.) a Fuel injection pump (24) is disconnected from F.

PC128US-2

30-17 (16)


INJECTION PUMP

INSTALLATION 1. Before installing fuel injection pump (24), remove the bolt from part E and secure the gear with M6 bolt [3] 35 mm or longer. •


[*1]

3 Fuel injection pipe sleeve nut: 19.6 – 24.5 Nm {2 – 3.5 kgm}

•

Bleed air from the fuel system. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-18 (16)

PC128US-2


ENGINE AND MAIN PUMP

ENGINE AND MAIN PUMP ASSEMBLY PC128US-2 Serial No. : 5001 – 8100 PC138US-2 Serial No. : 1001 – 3200 PC138USLC-2 Serial No. : 1001 – 1500 REMOVAL

k Completely ground the work equipment.

k Disconnect the negative (-) terminal of the battery. 1. Remove the radiator, hydraulic oil cooler assembly by referring to "REMOVAL OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY". 2. Disconnect hose (1) between the radiator upper tanks. 3. Remove bracket (2) from the fuel tank together with the reserve tank. 4. Disconnect bracket (3) from the main pump. a The EPC valve connector is attached to it. 5. Disconnect PPC main pressure hose (4). 6. Disconnect earth cable (5). 7. Disconnect LS pressure input hose (6). 8. Disconnect EPC valve connector (7) (C13). 9. Disconnect suction tube (8) from the main pump. 10. Disconnect main pump output hose (9). 11. Disconnect main pump pressure input hose (10). 12. Disconnect case drain hose (11). 13. Disconnect engine oil filter (12) from the hydraulic oil tank and put it near the main pump. 14. Remove stays (13), (14) and (15). 15. Remove adiabatic cover (16). 16. Remove muffler drain tube (17). 17. Remove muffler (18). a Loosen the turbo charger clamp beforehand. 18. Disconnect heater outlet hose (19). 19. Disconnect airconditioner hose (20). a Fit blind plugs into the hoses to prevent the entry of moisture, dust or dirt.

20. Disconnect accelerator cable (21). [*1] 21. Disconnect fuel inlet hose (22) and return hose (23). 22. Disconnect airconditioner hose clamp (24) at two positions. 23. Disconnect engine connectors (25) (E15), (26) (E20), (27) (E16) and (28) (E07) to remove clamp (29). 24. Disconnect fuel spill hose (30). a Apply the blind plug to the hose.

PC128US-2

30-19 (16)



25. Disconnect clamp (31) to remove hose (32). 26. Remove engine side cover (33). 27. Disconnect engine connectors (34) (M02) and (35) (E17). 28. Disconnect starter wire (36) (E13) and safety relay wire (37) (E30). 29. Disconnect heater return hose (38). 30. Remove three of four engine mounts (39). 31. Temporarily lift engine main pump assembly (40), remove the remaining mounting bolt and carefully lift the assembly to remove it. [*2] 4 Engine main pump assembly : 270 kg

INSTALLATION •

Installation is performed in the opposite way to removal.

[*1]

[*2]

a Adjust the cable length by referring to "ADJUSTMENT OF FUEL CONTROL CABLE". a Install the engine main pump assembly by placing the engine mounting rubber as shown in the figure below.

3 Engine mounting tightening bolt : 277.0 ± 31.9 Nm {28.25 ± 3.25 kgm} •

Supplying coolant a Supply coolant from the water filler port to the specified level, start the engine to circulate coolant and recheck the level.

•

Supplying oil (hydraulic oil tank) a 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.

• Bleeding air a Bleed air from the main pump. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-20 (16)

PC128US-2



ENGINE AND MAIN PUMP ASSEMBLY PC128US-2 Serial No. : 8101 and up PC138US-2 Serial No. : 3201 – 4500 REMOVAL

k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank.

k Disconnect the negative (-) terminal of the battery. 1. Remove the counterweight (See REMOVAL OF COUNTERWEIGHT). 2. Drain hydraulic oil and coolant.

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

6 Coolant: 17.2 l

3. Collect air conditioner gas from air conditioner circuit. 4. Remove battery (1). 5. Disconnect air hose (2), aftercooler inlet hose (3), and radiator inlet hose (4). [*1] 6. Disconnect aftercooler outlet hose (5) and radiator outlet hose (6). [*2]

7. Disconnect reservoir tank hose (7) and remove reservoir tank (8). 8. Disconnect wiring connector (9) (M28) and window washer hose (10) and remove washer tank (11). 9. Remove bracket (12) from the main pump. 10. Disconnect wiring connectors (13) (C13) and (14) (C14). 11. Disconnect suction tube (15) PC128US-2

30-21 (19)



12. Disconnect LS pressure input hose (16). 13. Disconnect main pump output hose (17). 14. Disconnect main pump pressure input hose (18). 15. Disconnect case drain hose (19). 16. Remove engine oil filter (20) from the hydraulic tank and move it toward the main pump.

17. Disconnect engine wiring connectors (21) (E15), (22) (E20), (23) (E16), and (24) (E07) and remove clamp (25).

18. Remove stays (26), (27), and (28). 19. Remove heat insulation cover (29). 20. Remove muffler drain tube (30). 21. Remove muffler (31). a Loosen the turbocharger clamp.

22. Disconnect heater hose (32). 23. Disconnect 2 air conditioner hoses (33). a Take measures to prevent dirt, water, etc. from entering the piping.

30-22 (16)

PC128US-2



24. Disconnect fuel control cable (34). [*3] a Before disconnecting the fuel control cable, measure its installed length. 25. Disconnect fuel inlet hose (35) and outlet hose (36). a Plug the hoses to stop the fuel. 26. Disconnect fuel spill hose (37). a Plug the hose to stop the fuel.

27. Disconnect 2 air conditioner hose clamps (38). 28. Disconnect clamp (39) and hose (40). 29. Remove engine side cover (41).

30. Disconnect alternator wiring connector (42) (M02). 31. Disconnect starting motor wire (43) (E13), and safety relay wires (44) (E30) and (45) (E17). 32. Disconnect heater hose (46). 33. Remove 4 mounting bolts (47) of the radiator, aftercooler, and hydraulic oil cooler assembly.

34. Move radiator, aftercooler, and hydraulic oil cooler assembly (48) toward the battery about 50 mm. 35. Sling engine and main pump assembly (49) temporarily, remove 4 engine mounting bolts (50), and lift off the engine and main pump assembly. [*4] a Check that all the wires and pipes are disconnected. a Take care particularly not to damage the radiator, aftercooler, and hydraulic oil cooler assembly.

PC128US-2

30-23 (16)



INSTALLATION •


[*1] [*2]

2 Apply gasket sealant (ThreeBond TB1208E) to the range of 30 mm from each end of radiator hose adapters (of the radiator and water pump) and connect the radiator hose. 3 Air hose clamp: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}

3 Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

3 Aftercooler hose clamp: 10.8 ± 0.5 Nm {1.1 ± 0.05 kgm} [*3] Adjust the cable length. For details, see TESTING AND ADJUSTING, Adjustment of fuel control cable. [*4]

a Install the engine main pump assembly by placing the engine mounting rubber as shown in the figure below.

3 Engine mounting tightening bolt: 277.0 ± 31.9 Nm {28.25 ± 3.25 kgm} •

Supplying 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. 5 Hydraulic tank: 69 l (Oil level in hydraulic tank)

•

Supplying coolant Supply coolant from the coolant filler port to the specified level, start the engine to circulate coolant and recheck the level. 5 Coolant: 17.2 l

•

Bleeding air Bleed air from the pump. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

•

Charging air conditioner with refrigerant gas Using tool X3, charge the air conditioner circuit with refrigerant gas (R134a).

30-24 (16)

PC128US-2



ENGINE AND MAIN PUMP ASSEMBLY PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove the counterweight. (See REMOVAL OF COUNTERWEIGHT). 2. Drain the hydraulic oil and the coolant.

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

6 Coolant: 13.2 l

3. Remove frames (1) and (2). 4. Remove cover (3). 5. Disconnect connector (M34) (4) and remove cover (5). 6. Loosen mounting bolts (7) and the adjustment bolt of air conditioner compressor (6), and then remove air conditioner compressor belt (8). 7. Remove airconditioner compressor (6). a Put the air conditioner compressor in front of the turbocharger. 8. Disconnect heater hose (9). 9. Disconnect air hose (10) and remove after cooler hose (11). [*1] 10. Disconnect radiator hose (12).

[*2]

11. Disconnect coolant temperature sensor connector (P07) (13). 12. Disconnect heater terminal (E52) (14).

PC128US-2

30-25 (16)



13. Disconnect PULL, GND, and HOLD from the top of engine stop solenoid terminals (15). a If the terminal cover falls from the wiring harness, the signal label of the wiring harness falls, too. Accordingly, take a measure to hold the terminal cover. a Terminal name seal is stuck to the engine stop solenoid. 14. Disconnect clip (16) and (17). 15. Remove nut (19), loosen locknut (20), and disconnect fuel control cable (18). [*3] 16. Disconnect fuel hoses (61) and (62).

17. Disconnect starting motor terminals E13 (21) and E54 (22). [*4] 18. Disconnect clip (23) and separate wiring harnesses (24) and (25) from the engine. 19. Disconnect ground terminal (26). 20. Remove clamp (27). 21. Disconnect heater hose (28) and radiator hose (29). [*2] 22. Remove fan guard (30). 23. Remove the 6 mounting bolts (31) and fan (32). 24. Disconnect air tube (34) from turbocharger (33).

30-26 (16)

PC128US-2



25. Disconnect terminal S17 (35) and connectors E17 (36) and E07 (37) from the bottom of the turbocharger. 26. Remove clip (38).

27. Remove cap (40), and then remove reservoir tank (42) and bracket (41) together. 28. Disconnect connectors C14 (43), C13 (44), and clip (45).

29. Disconnect drain hose (46) and pump pressure input hose (47). 30. Disconnect pump spout tube (48) and suction tube (49). 31. Disconnect LS pressure input hose (50) from A. 32. Remove corrosion resistor (51), oil filter (52), and their brackets together.

33. Remove frame (53). 34. Remove the mounting bolt (54).

PC128US-2

[*5]

30-27 (16)



35. Lift off engine assembly (55). a Use bolt hole B of the exhaust manifold to sling the engine by 3 points stably. 4 Engine ass’y : 480 kg

30-28 (16)

PC128US-2



INSTALLATION •


[*1]

3 Air hose clamp and aftercooler hose clamp: 10.8 ± 0.5 Nm {1.1 ± 0.5 kgm}

[*2]

2 Apply gasket sealant (ThreeBond TB1208E) to the range of 30 mm from each end of radiator hose adapters (of the radiator and water pump) and connect the radiator hose. 3 Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*3] Adjustment to fuel control cable. For details, see TESTING AND ADJUSTING, testing and adjusting of an accelerator pedal. [*4]

3 Starting motor terminal E13 (21) (M10): 15.7 – 19.6 Nm {1.6 – 2 kgm} 3 Starting motor terminal E54 (22) (M5): 2.5 – 3 Nm {0.25 – 0.31 kgm}

[*5] Note that washer B on the inside of the chassis (INSIDE) and that on the outside of the chassis (OUTSIDE) to support bottom rubber A of the engine mount on the chassis are different from each other. 3 Engine mount mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

PC128US-2

30-29 (16)


•


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. 5 Hydraulic tank: 69 l (Oil level) 100 l (Capacity)

•

Supply coolant Supply coolant from the coolant filler port to the specified level, start the engine to circulate coolant and recheck the level. 5 Coolant: 13.2 l

•

Bleeding air Bleed air from the pump and fuel system. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-30 (16)

PC128US-2


RADIATOR, HYDRAULIC OIL COOLER

RADIATOR, HYDRAULIC OIL COOLER PC128US-2 Serial No. : 5001 – 8100 PC138US-2 Serial No. : 1001 – 3200 PC138USLC-2 Serial No. : 1001 – 1500 REMOVAL

kGradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine. 1. Remove the counterweight assembly by referring to "REMOVAL OF COUNTERWEIGHT ASSEMBLY". 2. Drain hydraulic oil and coolant. 6 Hydraulic oil : 69 l

6 Cooling : 18.2 l

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

PC128US-2

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RADIATOR, HYDRAULIC OIL COOLER

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

INSTALLATION •


[*1]

a Check that the O-ring is not damaged or deteriorated, then connect the hoses.

•

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

•

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the water through the system. Then check the coolant level again. 5 Hydraulic oil: 69 l

•

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 5 Coolant: 18.2 l

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PC128US-2

RADIATOR


RADIATOR ASSEMBLY PC128US-2 PC138US-2

Serial No. : 8101 and up Serial No. : 3201 and up

REMOVAL 1. Drain cooling water.

6 Coolant : 17.2 l

[*3]

2. Remove the aftercoolar assembly by referring to "REMOVAL OF AFTER COOLER ASSEMBLY". 3. Remove engine hood stay (1) from radiator assembly. 4. Disconnect radiator inlet hose (2).

[*1]

5. Disconnect radiator outlet hose (3).

[*2]

6. Removethe 2 mounting bolts (4) of radiator. 7. Pull up radiator assembly (5) to remove it. a Raise radiator assembly (5) a little, and then slide it toward the oil cooler. a Take care not to damage the radiator core.

INSTALLATION •


[*1] [*2]

3 Radiator hose clamp: 8.8 ± 0.5 Nm {0.9 – 0.05 kgm}

•

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Coolant: 17.2 l

[*3]

[*3] PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up Coolant : 13.2 l

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HYDRAULIC OIL COOLER

HYDRAULIC OIL COOLER ASSEMBLY PC128US-2 Serial No. : 8101 and up PC138US-2 Serial No. : 3201 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Gradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine. 1. Drain hydraulic oil

6 Hydraulic oil : 69 l (Oil level in hydraulic tank) 100 l (Capacity)

2. Remove the after cooler assembly by referring to "REMOVAL OF AFTER COOLER ASSEMBLY". 3. Remove the engine hood cover assembly (1). 4. Disconnect clamp (2), and then disconnect air intake hose (3) from the air cleaner. a Move the air intake hose toward the engine.

5. Remove the oil cooler undercover and disconnect oil cooler outlet tube (4). a Prepare an oil receiving can to receive the leaking hydraulic oil before disconnecting the tube.

6. Remove 2 mounting bolts of oil cooler inlet tube (5). 7. Loosen U-clamp (6) and disconnect oil cooler inlet tube (5) from the hydraulic oil cooler. a Loosen the U-clamp but do not remove it. 8. Remove 2 oil cooler mounting bolts (7).

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PC128US-2


HYDRAULIC OIL COOLER

9. Raise oil cooler assembly (8) a little, and then slide it toward the radiator. 10. Remove bracket (9).

11. Pull up oil cooler assembly (8) to remove it. a Take care not to damage the oil cooler core.

INSTALLATION •


•

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

5 Hydraulic oil : 69 l (Oil level in hydraulic tank) 100 l (Capacity)

PC128US-2

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AFTER COOLER


AFTER COOLER ASSEMBLY PC128US-2 Serial No. : 8101 and up PC138US-2 Serial No. : 3201 – 4500 PC138USLC-2 Serial No. : 1001 – 1500 REMOVAL

k Completely grounding the work equipment. 1. Open 2 engine hoods (1) and remove cover (2). 2. Remove reservoir tank hose (3). 3. Remove aftercooler inlet hose (4).

[*1]

4. Disconnect aftercooler outlet hose (5).

[*2]

5. Remove 2 aftercooler assembly mounting bolts (6). 6. Pull up aftercooler assembly (7) to remove it. a Take care not to damage the aftercooler core.

INSTALLATION •


[*1] [*2]

3 After cooler hose clamp: 10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}

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PC128US-2

AFTER COOLER


AFTER COOLER ASSEMBLY PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Completely grounding the work equipment. 1. Remove mirror (1). 2. Open engine hood (2) and remove cover (3). 3. Remove the undercover and disconnect aftercooler lower hose (4). [*1] a "A" is the radiator hose. 4. Remove cover (5). 5. Disconnect reservoir tank hose (6). 6. Disconnect aftercooler upper hose (7).

[*1]

7. Remove cover (8). 8. Remove mounting bolt (9) and aftercooler (10).

INSTALLATION •


[*1]

3 After cooler hose clamp: 10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}

PC128US-2

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FUEL TANK

FUEL TANK REMOVAL


k Disconnect the negative (-) terminal of the battery. 1. Drain the fuel.

6 Fuel tank : 195 l

2. Remove two hand rails (1) to remove side covers (2) and (3), and upper covers (4), (5), (6) and (7). 3. Disconnect hose (8) from the radiator, the mounting bolt and bracket (9) together with the reserve tank. 4. Disconnect engine fuel return hoses (10) and (11). 5. Disconnect fuel sensor connector (12) (P06) to remove clamp (13). 6. Remove brackets (14) and (15) on the left side of the fuel tank. 7. Disconnect mounting bolt (16) on the right side. 8. Disconnect hoses (17) (to the fuel pump) and (18) (for draining) from the bottom of the fuel tank. a Lift the fuel tank before disconnection. 9. Temporarily lift fuel tank (19), remove the mounting bolt and then carefully lift the tank to remove it. [*1] 4 Fuel tank assembly : 100 kg

INSTALLATION •


[*1]

2 Fuel tank mounting bolt screw : Liquefied adhesive (LT-2)

3 Fuel tank mounting bolt : 277.0 ± 31.9 Nm {28.25 ± 3.25 kgm} •

Supplying oil (fuel tank) Supply fuel.

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PC128US-2


CENTER SWIVEL JOINT

CENTER SWIVEL JOINT REMOVAL

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

k Disconnect the negative (-) terminal of the battery. 1. Remove cover at rear of boom. For details, see "REMOVAL OF SWING MOTOR AND SWING MACHINERY ASSEMBLY". 2. Disconnect hoses (1) – (6) between travel motor and swivel joint. 3. Remove elbow (7). 4. Disconnect drain hose (8). 5. Disconnect hoses (9) – (12) between control valve and swivel joint. 6. Disconnect hose (13) from solenoid valve. 7. Remove plate (14). 8. Disconnect hoses (for changing the speed) (15) and (16) between both travel motors and swivel joint. 9. Remove mounting bolts and lift off center swivel joint assembly (17). [*1] a Sling the joint assembly temporarily, then remove the bolts. 4 Center swivel joint assembly : 30 kg (Standard specification) : 45 kg (Blade specification)

INSTALLATION •


[*1]

2 Mounting bolt screw : Liquefied adhesive (LT-2)

3 Mounting bolt : 98.1 – 123.0 Nm {10.0 – 12.5 kgm} •

Bleeding air Bleed air from the swing motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

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CENTER SWIVEL JOINT

CENTER SWIVEL JOINT DISASSEMBLY 1. Remove cover (1). 2. Remove snap ring (2). 3. Using tool T, pull out swivel rotor (4) and ring (3) from swivel shaft (5). 4. Remove O-rings (6) and slipper seals (7) from swivel shaft (5).

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. 3. Install ring (3) and secure with snap ring (2). 4. Fit O-ring and install cover (1).

3 Swivel joint mounting bolt : 31.3 ± 2.9 Nm {3.2 ± 0.3 kgm}

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PC128US-2


SWING MOTOR, SWING MACHINERY

SWING MOTOR, SWING MACHINERY REMOVAL

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

k Disconnect the negative (-) terminal of the battery. 1. Remove boom rear covers (1) and (2). 2. Disconnect MB and MA port hoses (3) and (4), S port hose (5), and B and T port hoses (6) and (7). 3. Remove the mounting bolt and tighten forcing screw [1] to disconnect swing motor, swing machinery (8) from the revolving frame. [*1] a Temporarily lift the swing motor/swing machinery assembly and gradually lift it upward according to the amount disconnected by the forcing screw. 4. Lift and remove swing motor/swing machinery assembly (8).

4 Swing motor, swing machinery assembly : 100 kg

INSTALLATION •


[*1]

2 Swing machinery fitting surface : Gasket sealant (LG-4 or LG-6) 3 Mounting bolt : 277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}

•

Bleeding air Bleed air from the swing motor. For details , see TESTING AND ADJUSTING, Bleeding air from each part.

PC128US-2

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SWING MACHINERY

SWING MACHINERY PC128US-2 Serial No. : 5001 and up PC138US-2 Serial No. : 1001 – 4500 PC138USLC-2 Serial No. : 1001 – 1500 DISASSEMBLY 1. Draining oil Loosen drain plug and drain oil from swing machinery. 6 Swing machinery case : Approx. 2.5 l

2. Swing motor Remove swing motor assembly (1).

4 Swing motor assembly : 30 kg

3. No. 1 carrier, No. 2 sun gear assembly 1) Remove No. 1 sun gear (2). 2) Remove No. 1 carrier and No. 2 sun gear assembly (3).

3) Disassemble No. 1 carrier and No. 2 sun gear assembly (3) as follows. i) Remove snap ring (4), then remove thrust washer (5), gear (6), bearing (7), and thrust washer (8).

ii) Knock in pin (9) and knock out shaft (10). a After removing the shaft, remove pin (9). iii) Remove snap ring (11), then remove No. 2 sun gear (12) from carrier (13).

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PC128US-2


SWING MACHINERY

4. Ring gear Remove ring gear (14). 5. No. 2 carrier assembly 1) Remove spacer (15). 2) Remove No. 2 carrier assembly (16).

3) Disassemble No. 2 carrier assembly as follows. i) Push in pin (17), and knock out shaft (18) from carrier (19). a After removing the shaft, remove pin (17). ii) Remove thrust washer (20), gear (21), bearing (22), and thrust washer (23).

6. Retainer, collar 1) Remove retainer (24). 2) Set shaft and case assembly to press, push split collar (25) with push tool F5, and press fit bearing (26). a Operate the press gradually and press fit the bearing to a point where the split collar can be removed. 3) Remove split collar (25).

7. Shaft assembly 1) Set shaft and case assembly (27) to block [2], then using push tool [3], remove shaft assembly (28) with press. 2) Remove bearing (26).

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SWING MACHINERY

3) Using push tool F1, remove bearing (29) and collar (30) from shaft (31).

8. Oil seal, bearing outer race 1) Remove oil seal (32) from case (33).

2) Using puller [5], remove bearing outer races (34) and (35) from case (33).

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PC128US-2


SWING MACHINERY

ASSEMBLY a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Bearing outer races Using push tool F4, press fit outer races (34) and (35) to case (33). 2. Shaft assembly 1) Fit O-ring to inside of collar (30) and install to shaft (31). 2) Using push tool F3-1, press fit bearing (29) with press.

3) Set case assembly (36) to shaft assembly (28). 4) Using push tool F3-2, press fit bearing (26) with a press to a point where split collar (25) enters. a Press-fitting force : 11.760 N {1,200 kg} a Press fit the bearing slowly while rotating the case.

5) Install split collars (25). 6) Screw bolt (12mm, P=1.75mm) into case, then using push- pull scale [8], measure tangential force in direction of rotation. a Tangential force : Max. 176.4 N {18 kg} a The tangential force is the maximum force at the start of rotation.

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SWING MACHINERY

3. Oil seal Using push tool F2, press fit oil seal (32). a Replace the oil seal with a new part. 2 Periphery of oil seal: LG-6 a Do not stick LG-6 to the lip and shaft. 2 Lip of oil seal : Grease (G2-LI)

4. Retainer Install retainer (24).

5. No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. i) Assemble bearing (22) to gear (21). ii) Fit top and bottom thrust washers (20) and (23), then set gear assembly to carrier (19).

iii) Align position of pin holes of shaft and carrier, then tap with plastic hammer and install shaft (18). a When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washers. iv) Insert pin (17). a After inserting the pin, caulk the carrier pin portion.

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PC128US-2


SWING MACHINERY

2) Install No. 2 carrier assembly (16) to shaft and case assembly. 3) Install spacer (15).

6. Ring gear Assemble O-ring (37) to shaft and case assembly, and install ring gear (14).

7. No. 1 carrier, No. 2 sun gear assembly 1) Assemble No. 1 carrier and No. 2 sun gear assembly as follows. i) Assemble No. 1 carrier (13) to No. 2 sun gear (12), and install snap ring (11). ii) Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (10). iii) Insert pin (9). a After inserting the pin, caulk the carrier pin portion. a Check that the stepped difference a between the shaft and carrier is less than 0.2 mm. iv) Assemble thrust washer (8), bearing (7), gear (6), and thrust washer (5), then install snap ring (4).

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SWING MACHINERY

2) Install No. 1 carrier and No. 2 sun gear assembly (3). 3) Install No. 1 sun gear (2).

8. Swing motor assembly Install swing motor assembly (1).

3 Mounting bolt : 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

9. Refilling with oil (swing machinery case) Tighten the drain plug and add engine oil EO30CD through the oil filler. 5 Swing machinery case : Approx. 2.5 l

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PC128US-2


SWING MACHINERY

SWING MACHINERY PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up DISASSEMBLY 1. Draining oil Remove the drain plug and drain the oil from the swing machinery. 6 Swing machinery case: 2.5 l

2. Swing motor assembly Lift off the swing motor assembly (1).

4 Swing motor assembly: 30 kg

3. No. 1 sun gear and No. 1 carrier assembly 1) Remove No. 1 sun gear (2). 2) Remove No. 1 carrier assembly (3).

4) Disassemble No. 1 carrier assembly (3) according to the following procedure. i) Remove snap ring (5), thrust washer (6), gear (7), bearing (8), spacer (11) and thrust washer (9). ii) Remove snap ring (4). iii) Remove No. 2 sun gear (13).

4. Ring gear Remove ring gear (14).

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SWING MACHINERY

5. No. 2 carrier assembly 1) Disassemble No. 2 carrier assembly according to the following procedure. i) Remove snap ring (16), thrust washer (17), gear (18), bearing (19), spacer (23) and thrust washer (20). ii) Using tool F6, remove nut (21). iii) Set shaft and case assembly (27) to block [2]. Using push tool [3] and the press, remove shaft assembly (28) and carrier (22). a Set a wood board, etc. under the press so that the shaft assembly will not be damaged when it comes out and falls. iv) Remove sub bearing (25) from carrier (22).

6. Shaft assembly Using push tool F1, remove bearing (29) and collar (30) from shaft (31).

7. Oil seal, bearing outer race 1) Remove oil seal (32) from case (33).

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PC128US-2


SWING MACHINERY

2) Using puller [4], remove bearing outer races (34) and (35) from case (33).

PC128US-2

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SWING MACHINERY

ASSEMBLY a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Bearing outer races Using push tool F7 and F8, press fit outer races (34) and (35) to case (33).

2. Shaft assembly 1) Fit O-ring to inside of collar (30) and install to shaft (31). 2) Using push tool F9, press fit bearing (29) with press. a Press-fitting force: 11.8 – 31.4 kN {1.2 – 3.2 ton}

3) Using tool F10 [5], press fit sub bearing (25) to the No. 2 carrier (22). 4) Using tool [5] and the press, press fit No. 2 carrier (22) to the shaft spline.

2 Splined : Grease (G2-LI) a Press-fitting force: 7.25 – 31.8 kN {0.74 – 3.24 ton} a Turning the case, press fit the bearing slowly.

5) Using tool F6 and install nut (21). Tighten nut (21) to the specified torque and give the bearing 3 turns clockwise and counterclockwise respectively, and then tighten the nut to the specified torque again. 2 Nut (21) : Thread tightener (LT-2) (Min. 0.5 cc, 10 drops)

3 Nut (21) : 784 – 833 Nm {80 – 85 kgm) 6) Using tool F6 and F11, measure the running torque of the shaft. a Running torque: Max. 19.6 Nm {Max. 2.0 kgm}

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PC128US-2


SWING MACHINERY

3. Oil seal Using push tool F2, press fit oil seal (32). a Replace the oil seal with a new part. 2 Periphery of oil seal: LG-6 a Do not stick LG-6 to the lip and shaft. 2 Lip of oil seal : Grease (G2-LI)

4. No. 2 carrier assembly 1) Assemble No. 2 carrier assembly according to the following procedure. • Install thrust washer (20), spacer (23), bearing (19), gear (18), thrust washer (17), and snap ring (16) to carrier (22).

5. Ring gear Install ring gear (14).

6. No. 1 carrier ass’y 1) Install No. 2 sun gear (13) to carrier (10), and then install snap ring (4). 2) Install thrust washer (9), bearing (8), gear (7), thrust washer (6), and snap ring (5).

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SWING MACHINERY

3) Install No. 1 carrier assembly (3). 4) Install No. 1 sun gear (2).

7. Swing motor assembly Install swing motor assembly (1). 3 Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm} •

Supplying oil and grease Tighten the drain plug and supply engine oil EO30-CD through the oil filler. 5 Swing machinery case: Approx. 2.5 l

a Apply LG-5 to the fitting part of the drain tube.

3 Drain plug: 44.1 – 93.1 Nm {4.5 – 9.5 kgm} a When mounting the assembly on the machine, apply gasket sealant LG-6 to the fitting face of the revolving frame.

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PC128US-2


REVOLVING FRAME

REVOLVING FRAME REMOVAL

k Disconnect the negative (-) terminal of the battery. 1. 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. Remove covers (3) and (4). 4. Temporarily lift the boom cylinder to remove pins (5) on the bottom. a Check the number and position of the shims mounted. [*1] 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". 7. 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. 10. Disconnect plate (14) from revolving frame.

11. Remove mounting bolts (15), leaving one each at front and rear. [*2]

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REVOLVING FRAME

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

INSTALLATION •


[*1]

2 Surface inside bushing during pin assembly : Hyper white grease (G2-T)

2 Greasing after pin assembly : Hyper white grease (G2-T)

kNever put your finger in the pin hole when adjusting the position. a 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 Swing circle contacting face : Liquefied gasket (LG-1) 2 Revolving frame mounting bolt screw : Liquefied adhesive (LT-2)

3 Revolving frame mounting bolt : 277.5 ± 32.4 Nm {28.3 ± 3.3 kgm} •

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.

•

Bleeding air Bleed the air. For details , see TESTING AND ADJUSTING, Bleeding air from each part.

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PC128US-2

SWING CIRCLE


SWING CIRCLE REMOVAL

k Gradually loosen the hydraulic oil tank cap to bleed the air from the tank after grounding the work equipment and stopping the engine and lock the safety lock lever. 1. 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).

4 Swing circle assembly : 155 kg

[*2]

INSTALLATION •


[*1]

2 Swing circle mounting bolt : Liquefied adhesive (LT-2)

3 Swing circle mounting bolt : 245 – 308.9 Nm {25 – 31.5 kgm} [*2]

a Lift swing circle assembly (1) and install it on the track frame with the inner wheel soft zone S symbol of the inner race facing the right side of the body as shown in the figure.

2 Amount of circle grease sealed : 9.1 l (G2-LI grease)

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TRAVEL MOTOR AND FINAL DRIVE


TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY REMOVAL 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.

k 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).

4 Sprocket : 40 kg

[*1]

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

INSTALLATION •


[*1]

2 Thread of travel motor mounting bolt : Thread tightener (LT-2)

3 Sprocket mounting bolt : 323.6 – 362.8 Nm {33 – 37 kgm} [*2]

2 Thread of travel motor and final drive assembly mounting bolt : Thread tightener (LT-2)

3 Travel motor and final drive assembly mounting bolt : 235 – 285 Nm {23.5 – 29.5 kgm} a Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air from travel motor. •

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.

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PC128US-2


RECOIL SPRING

RECOIL SPRING PC128US-2 Serial No. : 5001 and up PC138US-2 Serial No. : 1001 – 4500 PC138USLC-2 Serial No. : 1001– 1500 DISASSEMBLY

1. Remove lock plate (1), then remove seat (2) and 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.

kThe 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 : 78,500 N {8,000 kg} (PC128US-2) : 93,200 N {9,500 kg} (PC138USLC-2) 2) 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. 3) Remove pilot (8), spring (7), cylinder (9), and dust seal (10).

4. Disassembly of yoke piston assembly (5) 1) Remove snap ring (12), then remove Upacking (13). 2) Remove wear ring (14) from yoke piston (11).

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RECOIL SPRING

ASSEMBLY 1. Assembly of yoke piston assembly 1) Assemble wear ring (14) to yoke piston (11). 2) Assemble U-packing (13) and secure with snap ring (14). 2. Assembly of recoil spring assembly 1) Using tool L3, press fit dust seal (10) to cylinder (9). 2) Assemble cylinder (9) and pilot (8) to spring (7), and set to tool L2. 3) 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 4) 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 (15) is to the outside. 5. Fill inside of cylinder with a minimum of 120 cc of grease. 2 Inside cylinder : Grease (G2-LI)

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PC128US-2


RECOIL SPRING

RECOIL SPRING PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up DISASSEMBLY

1. Remove lock plate (1), then remove seat (2) and 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.

kThe 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} 2) 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. 3) Remove pilot (8), and spring (7). 4) Remove snap ring (10), dust seal (11) and bush (12) from cylinder (9).

4. Disassembly of yoke piston (5) assembly 1) Remove snap ring (14), then remove Upacking (15). 2) Remove wear ring (16) from yoke piston (13). PC128US-2

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RECOIL SPRING

ASSEMBLY 1. Assembly of yoke piston assembly 1) Assemble wear ring (16) to yoke piston (13). 2) Assemble U-packing (15) and secure with snap ring (14). 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). 3) Assemble cylinder (9) and pilot (8) to spring (7), and set to tool L2. 4) 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 5) 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)

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PC128US-2


IDLER

IDLER DISASSEMBLY 1. Remove dowel pin (1), then remove support (2). 2. Remove floating seal (3) from support (2) and 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). 5. Remove dowel pin (8), then remove support (7) from shaft (5). 6. Remove bushings (9) and (10) from idler (4).

PC128US-2

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IDLER

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. 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.

4. Assemble shaft (5) and support assembly (7) to idler (4).

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PC128US-2


IDLER

5. Add oil between shaft (5) and idler (4). 5 Oil : 90 – 105 cc (EO30-CD)

6. 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.

PC128US-2

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IDLER

7. Install O-ring, then install support (2) with dowel pin (1).

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PC128US-2

TRACK ROLLER


TRACK ROLLER DISASSEMBLY 1. Remove pin (1), then remove collar (2).

8

5 6 10 4

9 3 1 2 11 CLP00790

2. Remove floating seal (3) from collar (2) and roller (4).

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).

PC128US-2

30-67 (16)

TRACK ROLLER


5. Remove collar (8) from shaft (5). 6. Remove bushings (9) and (10) from roller (4).

5 6 8 CLP00791

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. 4. 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

5. Assemble shaft (5) to roller (4).

4

CLP00793

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.

4

5

CLP00866

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PC128US-2

TRACK ROLLER


8. Assemble collar (2) to shaft (5), and install pin (1).

2

1

5

CLP00867

9. 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.

10. Using tool M2, fill track roller assembly with oil, then tighten plug (11). 5 Track roller oil : 75 – 85 cc (EO30-CD)

PC128US-2

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TRACK SHOE


TRACK SHOE REMOVAL 1. Lower work equipment to ground, then loosen lubricator (1), and relieve track tension. [*1] kThe adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.

2. 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]

INSTALLATION [*1]

[*2]

[*3]

a Adjust the track tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension. 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 a When assembling the dust seal, coat the bushing contact surface with grease (G2-LI).

a 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.

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PC128US-2


HYDRAULIC TANK

HYDRAULIC TANK REMOVAL

k Gradually loosen the hydraulic tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine.

k Disconnect the negative (-) terminal of the battery. 1. Drain the hydraulic oil.

6 Hydraulic oil : 100 l (Capacity) 69 l (Oil level)

2. Remove the fuel tank assembly by referring to "REMOVAL OF FUEL TANK ASSEMBLY". 3. Disconnect the clamp from the swing machinery oil level gauge pipe. 4. Disconnect inter-oil cooler hose (2) and intercontrol valve hose (3) to disconnect hose clamp (4). 5. 6. 7. 8.

Disconnect main pump suction hose (5). Disconnect PPC valve drain hose (6). Disconnect harness clamp (7). Disconnect engine oil filter bracket (8). a Move the filter assembly close to the engine. a Put the reserve tank on the main pump.

9. Disconnect self pressure reducing valve drain hose (9), swing motor drain hose (10), boom lock valve drain hose (11), solenoid valve drain hose (12), main pump drain hose (13) and travel motor drain hose (14).

10. Temporarily lift hydraulic tank (15) and remove the mounting bolt to slowly lift and remove it. [*1] 4 Hydraulic tank assembly : 95 kg

PC128US-2

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HYDRAULIC TANK

INSTALLATION •


[*1]

2 Thread of hydraulic tank mounting bolt : Thread tightener (LT-2)

3 Hydraulic tank mounting bolt : 277.0 ± 31.9 Nm {28.25 ± 3.25 kgm} •

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 5 Hydraulic tank : 100 l (Capacity) 69 l (Oil level)

•

Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

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PC128US-2


MAIN PUMP

MAIN PUMP PC128US-2 Serial No. : 5001 and up PC138US-2 Serial No. : 1001 – 4500 PC138USLC-2 Serial No. : 1001 – 1500 REMOVAL


k Disconnect the negative (-) terminal of the battery. 1. Drain the hydraulic oil.


2. Remove the counterweight assembly by referring to "REMOVAL OF COUNTERWEIGHT ASSEMBLY". 3. Disconnect hose (1) from the radiator upper tank to remove bracket (2) from the fuel tank together with the reserve tank. 4. Remove bracket (3). a An EPC valve connector is mounted to it. 5. Disconnect PPC main pressure hose (4). 6. Disconnect earth cable (5) from the pump side. 7. Disconnect LS pressure input hose (6). 8. Disconnect EPC valve connector (7) (C13). 9. Disconnect suction tube (8) from the pump. 10. Disconnect pump output hose (9). 11. Disconnect pump pressure input hose (10). 12. Disconnect case drain hose (11). 13. Disconnect muffler drain tube (12). 14. Remove adiabatic cover (13). 15. Disconnect joint (14) between the turbo charger and the muffler and remove muffler assembly (15) by removing the mounting bolt. 16. Drain the oil from the flywheel case. 6 Flywheel case : 0.75 l

17. Temporarily lift the pump to remove the mounting bolt and lift main pump assembly (16) to remove it. [*1] a Carefully remove it to prevent it from coming in contact with the engine oil filter. a It can be removed easier by lifting it at two points to make it parallel using a lever block. 4 Main pump assembly : 95 kg

PC128US-2

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MAIN PUMP

MAIN PUMP PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Completely grounding the work equipment.

k Disconnect the negative (-) terminal of the battery. 1. Remove the counterweight assembly by referring to "REMOVAL OF COUNTERWEIGHT ASSEMBLY". 2. Drain the hydraulic oil.


3. Remove cap (40), and then remove reservoir tank (42) and bracket (41) together. 4. Disconnect connectors C14 (43), C13 (44), and clip (45).

5. Disconnect drain hose (46) and pump pressure input hose (47). 6. Disconnect pump spout tube (48) and suction tube (49). 7. Disconnect LS pressure input hose (50) from A.

8. Remove the mounting bolts and lift off the main pump (51). [*1] 4 Main pump assembly : 90 kg

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PC128US-2


MAIN PUMP

PC128US-2 Serial No. : 5001 and up PC138US-2 Serial No. : 1001 and up PC138USLC-2 Serial No. : 1001 and up INSTALLATION •


[*1]

2 Mating surface of pump case : Gasket sealant (LG-6)

•

Refilling with oil (PTO gear case) a Add engine oil E010-CD through the oil filler to the specified level.

•

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. 5 Hydraulic tank : 100 l (Capacity) 69 l (Oil level)

•

Bleeding air a Bleed the air from main pump. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC128US-2

30-75 (16)


CONTROL VALVE

CONTROL VALVE REMOVAL

k Lower the work equipment to the ground and stop the engine. Turn on the main switch and operate the work equipment control levers on both sides freely to release the PPC pressure, then turn off the main switch. k Disconnect the cable from the negative (-) terminal of the battery. 1. Drain hydraulic oil.

6 Hydraulic oil : 100 l

2. Remove handrail (1), then remove covers (2), (3), and (4). 3. Disconnect solenoid valve outlet hoses (5) (PPC main pressure), (6) (2nd travel speed), (7) (Swing holding brake), and (8) (2nd relief).

4. Disconnect hoses (9) connected to bucket cylinder. 5. Disconnect hoses (10) connected to arm cylinder. 6. Disconnect hoses (11) and (12) connected to boom cylinder.

7. Disconnect boom lock valve drain hose (13). 8. Disconnect hoses (14) connected to right travel motor and hoses (15) connected to left travel motor. 9. Disconnect 2 hoses (16) connected to both swing motors.

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PC128US-2


CONTROL VALVE

10. Disconnect hose (17) connected to main pump. 11. Disconnect hose (18) connected to PC-EPC valve. 12. Disconnect drain hoses (19) and (20). 13. Disconnect hose (21) between main relief valve and solenoid valve (A2). 14. Disconnect hoses (22) and (23) connected to main pump (LS valve). 15. Disconnect right PPC hoses (24) (Bucket), (25) (Arm), (26) (Boom), (27) and (28) (Right and left travel), and (29) (Swing). 16. Disconnect left PPC hoses (30) (Bucket), (31) (Arm), (32) (Boom), (33) (Right and left travel), and (35) (Swing). 17. Disconnect drain hose (36). 18. Sling control valve assembly (38) temporarily and remove mounting bolts (37). 19. Lift off control valve assembly (38).

4 Control valve assembly : 85 kg (Standard specification) :100 kg (Blade specification)

INSTALLATION •


•

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

•

Bleeding air. Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC128US-2

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CONTROL VALVE

CONTROL VALVE PC128US-2 Serial No. : 5001 and up PC138US-2 Serial No. : 1001 – 4500 PC138USLC-2 Serial No. : 1001 – 1500 DISASSEMBLY

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PC128US-2


PC128US-2

CONTROL VALVE

30-79 (16)


30-80 (16)

CONTROL VALVE

PC128US-2


a Pressure is still applied to the safety-suction valve circuit for a while after the machine is stopped. Accordingly, loosen pressure releasing plug (1) gradually to release the internal pressure. a Do not disassemble the safety-suction valve, since its pressure cannot be set while it is installed to the machine. a The spools and pressure compensation valves (flow control valve, pressure reducing valve, and piston) of the valves are not interchangeable with each other and they must be assembled in their own directions. Accordingly, be sure to mark them before removing them. 1. Valve assembly 1) Remove main relief valve assembly (2). 2) Remove safety-suction valve assembly (3). 3) Remove LS select valve assembly (4). 4) Remove 10 suction valve assemblies (5). 5) Remove unload valve assembly (6). 2. Lift check valve and cooler bypass valve 1) Remove case (7), then remove spring (8), piston (9), and sleeve (10). 2) Remove case (11), then remove spring (12), piston (13), and sleeve (14). 3. Swing control valve 1) Remove 2 cases (15), then remove 2 springs (16) and 2 retainers (17). 2) Remove spool assembly (18). a Do not disassemble the spool assembly. 4. Swing bleed valve 1) Remove flange (19). 2) Remove plug (20), then remove spring (21) and spool (22). 3) Remove plug (23), then remove ball (24). 5. Left travel control valve and right travel control valve 1) Remove 2 cases (25), then remove 2 springs (26) and 2 retainers (27). 2) Remove spool assembly (28).

CONTROL VALVE

7. Boom control valve 1) Remove 2 cases (35), then remove 2 springs (36) and 2 retainers (37). 2) Remove spool assembly (38). a Do not disassemble the spool assembly. 8. Boom hydraulic drift prevention valve a When disassembling the boom hydraulic drift prevention valve after removing it from the valve unit, remove 4 bolts (39) and 2 bolts (40). Bolt (41) is used to install plate (42). a When disassembling the boom hydraulic drift prevention valve without removing it from the valve unit, remove 4 bolts (39) and 1 bolt (41). 1) Remove plate (42), then remove spring (43), piston (44), spring (45), and valve (46). 2) Remove spring (47), then piston (48). 3) Remove plug (49), then remove sleeve (50). 9. Arm control valve 1) Remove 2 cases (51), then remove 2 springs (52) and 2 retainers (53). 2) Remove spool assembly (54). a Do not disassemble the spool assembly. 10. Arm regeneration valve Remove plug (55), then remove spring (56) and valve (57). 11. Bucket control valve 1) Remove 2 cases (58), then remove 2 springs (59) and 2 retainers (60). 2) Remove spool assembly (61). a Do not disassemble the spool assembly. 12. Service control valve 1) Remove 2 cases (62), then remove 2 springs (63) and 2 retainers (64). 2) Remove spool assembly (65). a Do not disassemble the spool assembly. 13. Swing pressure compensation valve 1) Remove plug (66), then remove valve (67) and spring (68). 2) Remove plug (69), then remove spring (70), piston (71), and valve (72).

6. Travel interconnection valve 1) Remove 2 plugs (29), then remove 2 springs (30), 2 retainers (31), and 2 spools (32). 2) Remove 2 plugs (33), then remove 2 balls (34).

PC128US-2

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CONTROL VALVE

14. Left travel pressure compensation valve and right travel pressure compensation valve 1) Loosen plug (73) and remove it together with valve (74). 2) Loosen plug (75), then remove spring (76) and valve (77). 15. Boom pressure compensation valve 1) Remove plug (78), then remove valve (79) and spring (80). 2) Remove plug (81), then spring (82), piston (83), and valve (84). 16. Arm pressure compensation valve 1) Remove plug (85), then remove valve (86) and spring (87). 2) Remove plug (88), then spring (89), piston (90), and valve (91). 17. Bucket pressure compensation valve 1) Remove plug (92), then remove valve (93) and spring (94). 2) Remove plug (95), then spring (96), piston (97), and valve (98). 18. Service pressure compensation valve 1) Remove plug (99), then remove valve (100) and spring (101). 2) Remove valve (102), then spring (103), and valve (104). 19. Studs for combination (Addition of service valve) a When adding a service valve, disassemble according to the following procedure. 1) Remove 4 nuts (105), then remove 4 studs. a Remove the studs with a flat-head screwdriver. 2) Remove cover (106).

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PC128US-2


CONTROL VALVE

ASSEMBLY

PC128US-2

30-83 (16)


30-84 (16)

CONTROL VALVE

PC128US-2


PC128US-2

CONTROL VALVE

30-85 (16)


a Before assembling the parts, apply engine oil to their sliding surfaces. 1. Studs for combination (Addition of service valve) a When adding a service valve, assemble according to the following procedure. 1) Tighten 4 studs temporarily. 2) Install service valve assembly. 3) Install cover (106). 4) Install 4 washers and tighten nuts (105). a Tighten the nuts in the diagonal order according to the following procedure.

3 Nut : 1st time : 64 ± 4.9 Nm {6.5 ± 0.5 kgm} At this time, check that the height of the stud top is 0.5 – 3 mm above the nut top. If it is out of this range, loosen the nut and adjust the height of the stud with a flat-head screwdriver. 2nd time : 83.36 ± 4.9 Nm {8.5 ± 0.5 kgm} 3rd time : 105.42 ± 7.4 Nm {10.75 ± 0.75 kgm} Check again that the height of the stud top is 0.5 – 3 mm above the nut top.

2. Service pressure compensation valve 1) Install valve (104) and spring (103), then install valve (102).

3 Valve : 215.6 ± 19.6 Nm {22 ± 2 kgm}

2) Install spring (101) and valve (100), then install plug (99). 3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}

3. Bucket pressure compensation valve 1) Install valve (98), piston (97), and spring (96), then install plug (95). 3 Plug : 166.6 ± 19.6Nm {17 ± 2 kgm}


CONTROL VALVE


5. Boom pressure compensation valve 1) Install valve (84), piston (83), and spring (82), then install plug (81). 3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}


6. Right travel pressure compensation valve and left travel pressure compensation valve 1) Install valve (77) and spring (76), then install plug (75). 3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}

2) Install valve (74) and plug (73) as one unit.

3 Plug : 107.8 ± 9.8 Nm {11 ± 1 kgm}

7. Swing pressure compensation valve 1) Install valve (72), piston (71), and spring (70), then install plug (69). 3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}


8. Service control valve 1) Install spool assembly (65). 2) Install 2 retainers (64) and 2 springs (63), then install 2 cases (62). 3 Mounting bolt : 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}

9. Bucket control valve 1) Install spool assembly (61). 2) Install 2 retainers (60) and 2 springs (59), then install 2 cases (58). 3 Mounting bolt : 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}

10. Arm regeneration valve Install valve (57) and spring (56), then install plug (55).

4. Arm pressure compensation valve 1) Install valve (91), piston (90), and spring (89), then install plug (88). 3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}

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PC128US-2


CONTROL VALVE

11. Arm control valve 1) Install spool assembly (54). 2) Install 2 retainers (53) and 2 springs (52), then install 2 cases (51).

17. Swing control valve 1) Install spool assembly (18). 2) Install 2 retainers (17) and 2 springs (16), then install 2 cases (15).

12. Boom hydraulic drift prevention valve 1) Install sleeve (50), then install plug (49). 2) Install piston (48), then install spring (47). 3) Install valve (46), spring (45), piston (44), and spring (43), then install plate (42).

18. Cooler bypass valve and lift check valve 1) Install sleeve (14), piston (13), and spring (12), then install case (11).


3 Mounting bolts (39), (40) : 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm} Mounting bolt (41) : 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}

13. Boom control valve 1) Install spool assembly (38). 2) Install 2 retainers (37) and 2 springs (36), then install 2 cases (35).


14. Travel interconnection valve 1) Install 2 balls (34), then install 2 plugs (33).

3 Plug : 7.4 ± 1.5 Nm {0.75 ± 0.15 kgm}

2) Install 2 spools (32), 2 retainers (31), and 2 springs (30), then install 2 plugs (29). 3 Plug : 55.9 ± 6.9 Nm {5.7 ± 0.7 kgm}

15. Right travel control valve and left travel control valve 1) Install spool (28). 2) Install 2 retainers (27), 2 springs (26), then install 2 cases (25). 3 Mounting bolt : 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}



2) Install sleeve (10), piston (9), and spring (8), then install case (7).


19. Valve assembly 1) Install unload valve assembly (6).

3 Unload valve assembly : 166.6 ± 19.6 Nm {17 ± 2 kgm}

2) Install 10 suction valve assemblies (5).

3 Suction valve assembly : 147 ± 9.8 Nm {15 ± 1 kgm}

3) Install LS select valve assembly (4).

3 LS select valve assembly: 127.4 ± 19.6 Nm {13 ± 2 kgm}

4) Install safety-suction valve assembly (3).

3 Safety-suction valve assembly : 186.2 ± 9.8 Nm {19 ± 1 kgm}

5) Install main relief valve assembly (2).

3 Main relief valve assembly : 98 ± 9.8 Nm {10 ± 1 kgm}

16. Swing bleed valve 1) Install ball (24), then install plug (23).

3 Plug : 7.35 ± 1.5 Nm {0.75 ± 0.15 kgm}

2) Install spool (22) and spring (21), then install plug (20). 3 Plug : 29.4 ± 4.9 Nm {3 ± 0.5 kgm}

3) Install flange (19).


PC128US-2

30-87 (16)


CONTROL VALVE

CONTROL VALVE PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up ASSEMBLY

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PC128US-2


a In this section, only the precautions for assembling the control valve assembly are described. •

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). •

T (Install cover (1)): Tighten the nuts in the diagonal order according to the following procedure. 1st time : 3 58.8 – 68.6 Nm {6 – 7 kgm}

CONTROL VALVE

a When loosening and tightening plug T1-5L, be sure to keep the spool in the valve chamber. 3 T1-5L:14.7 – 19.6 Nm {1.5 – 2 kgm} See LOCTITE shown below.

3 T1-2L: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} See LOCTITE shown below.

2 T1-2L, T1-5L: Apply 1 drop (about 0.02 g) of LOCTITE No. 638 to each of the points shown below. 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.

2nd time : 3 78.5 – 88.3 Nm {8 – 9 kgm} 3rd time : 3 98.1 – 113 Nm {10 – 11.5 kgm} a The height of the stud top above the nut top: 0.5 – 3 mm 3 T1-2 : 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

3 T2-8 : 27.5 – 34.3 Nm {2.8 – 3.5 kgm}

3 T2

: 19.6 – 27.5 Nm {2 – 2.8 kgm}

3 T5

: 49 – 63.7 Nm {5 – 6.5 kgm}

3 T3-5 : 34 – 44 Nm {3.5 – 4.5 kgm}

3 T6

3 T9

: 59 – 78 Nm {6 – 8 kgm} : 88.3 – 107.9 Nm {9 – 11 kgm}

3 T10 : 98.1 – 123 Nm {10 – 12.5 kgm}

3 T11 : 108 – 147 Nm {11 – 15 kgm}

3 T14 : 137 – 157 Nm {14 – 16 kgm}

3 T15 : 147 – 186 Nm {15 – 19 kgm}

3 T18 : 176.6 – 196.2 Nm {18 – 20 kgm}

3 T20 : 196 – 240 Nm {20 – 24.5 kgm}

PC128US-2

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30-90 (16)

CONTROL VALVE

PC128US-2


PC128US-2

CONTROL VALVE

30-91 (16)


LS SELECTION VALVE

LS SELECTION VALVE DISASSEMBLY

1. Remove valve (2) from sleeve (1). 2. Remove O-rings (4) and (5), and seal (6) from sleeve (1). 3. Remove plug (7), then remove pistons (8) and (9), and spring (10). 4. Remove O-ring (11) from plug (7), then remove seal (12) and O-ring (13) from piston (9). a After disassembling, if there is any abnormality in any part except O-rings (4), (5), (11), or seal (6), replace the whole LS select valve assembly.

ASSEMBLY a Before assembling coat the sliding surface with engine oil. 1. Install O-ring (13) and seal (12) to piston (9), then assemble piston (8) and spring (10), and install in sleeve (1). 2. Assemble O-ring (11) to plug (7) and install to sleeve (1). 3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm}

3. Install valve (2) to sleeve (1). 4. Install O-rings (4) and (5), and seal (6) to sleeve (1).

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PC128US-2

PRESSURE COMPENSATION VALVE


PRESSURE COMPENSATION VALVE DISASSEMBLY Pressure compensation valve A : Bucket (Dump, Curl) B : Arm (Out, In) C : Boom (Raise, Lower) D : Travel (Forward, Reverse) E : Swing (Left, Right)

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PC128US-2



Disassembly of pressure compensation valves A, B, C, D, and E •

Some parts of different part Nos. may have shapes similar to each other. Take care when assembling them.

1. A (Bucket) 1) Remove plug (1), then remove spring (2), piston (3), and valve (4). 2) Remove plug (5), then pull out valve (6) and remove spring (7) from it. 2. B (Arm) 1) Remove plug (8), then remove spring (9), piston (10), and valve (11). 2) Remove plug (12), then pull out valve (13) and remove spring (14) from it. 3. C (Boom) 1) Remove plug (15), then remove spring (16), piston (17), and valve (18). 2) Remove plug (19), then pull out valve (20) and remove spring (21) from it. 4. D (Travel) 1) Remove plug (22), then remove spring (23) and valve (24). 2) Remove plug (25), then remove bolt (26) and washer together. 3) Remove sleeve (27), then remove spring (28) and valve (29). 5. E (Swing) 1) Remove plug (30), then spring (31), piston (32), and valve (33). 2) Remove plug (34), then pull out valve (35) and remove spring (36) from it.

PC128US-2

30-95 (16)



ASSEMBLY Pressure compensation valve A : Bucket (Dump, Curl) B : Arm (Out, In) C : Boom (Raise, Lower) D : Travel (Forward, Reverse) E : Swing (Left, Right)

30-96 (16)

PC128US-2


Assembly of pressure compensation valves A, B, C, D, and E a Before assembling the parts, apply engine oil to their sliding surfaces. a Tightening torque of plug, bolt, and sleeve 3 Plugs 1, 8, 12, 15, 22, 30 : 147.0 – 186.0 Nm {15.0 – 19.0 kgm}


5. E (Swing) 1) Fit spring (36) to valve (35) and insert them in valve body, then install O-ring and plug (34). 2) Install piston (32) and spring (31) to valve (33) and insert them in valve body, then install Oring and plug (30).

3 Plug 25 : 98.1 – 123.0 Nm {10.0 – 12.5 kgm} 3 Plugs 5, 19, 34 : 196.0 – 240.0 Nm {20.0 – 24.5 kgm} 3 Bolt 26 :

11.8 – 14.7 Nm {1.2 – 1.5 kgm}

3 Sleeve 27 : 147.0 – 186.0 Nm {15.0 – 19.0 kgm}

1. A (Bucket) 1) Fit spring (7) to valve (6) and insert them in valve body, then install O-ring and plug (5). 2) Install piston (3) and spring (2) to valve (4) and insert them in valve body, then install Oring and plug (1). 2. B (Arm) 1) Fit spring (14) to valve (13) and insert them in valve body, then install O-ring and plug (12). 2) Install piston (10) and spring (9) to valve (11) and insert them in valve body, then install Oring and plug (8). 3. C (Boom) 1) Fit spring (21) to valve (20) and insert them in valve body, then install O-ring and plug (19). 2) Install piston (17) and spring (16) to valve (18) and insert them in valve body, then install O-ring and plug (15). 4. D (Travel) 1) Install spring (28) and valve (29) to sleeve (27) and insert them in valve body and fix them with washer and bolt (26), then install O-ring and plug (25) to sleeve (27). 2) Fit spring (23) to valve (24) and insert them in valve body, then install O-ring and plug (22).

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30-97 (16)


MAIN RELIEF VALVE

MAIN RELIEF VALVE DISASSEMBLY

1. Remove ring (1) to remove valve (2) and spring (3). 2. Loosen nut (4) to remove plug (5) and remove Oring (6) from plug (5). 3. Loosen nut (7) to remove holder (8) and remove retainer (9), O-ring (10) and nut (7) from holder (8). 4. Remove spring (12) and puppet (13) from sleeve (11) and remove seat (14). 5. Remove ring (15) and O-ring (16) from seat (14). 6. Remove O-ring (17), seal (18), and O-ring (19) from sleeve (11). a If any abnormality is detected on valve (2), holder (8), retainer (9), seat (14), ring (15), O-ring (16) or sleeve (11), replace the entire main relief valve assembly.

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PC128US-2


MAIN RELIEF VALVE

ASSEMBLY a Before assembling the parts, apply engine oil to their sliding surfaces. 1. Fit O-ring (16) and ring (15) to seat (14), then install sleeve (11). 2. Install nut (7) and O-ring (10) to holder (8), then assemble and install retainer (9), puppet (13), and spring (12) to sleeves (1) and (2). a Set contact surfaces of seat (14) and puppet (13) securely. 3. Fit O-ring (6) to plug (5), then install them to holder (8). 4. Install spring (3) and valve (2) to sleeve (11), then fit ring (1). 5. Fit O-rings (19) and (17) and seal (18) to sleeve (11). 6. Tighten nut (7) to specified torque.

3 Nut : 58.8 ± 4.9 Nm {6 ± 0.5 kgm}

7. Tighten nut (4) to specified torque.

3 Nut : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}

a After install the main relief valve assembly to the control valve assembly, adjust the pressure. For details, see TESTING AND ADJUSTING, Testing and adjusting hydraulic pressure in work equipment, swing, and travel circuits.

PC128US-2

30-99 (16)


WORK EQUIPMENT PPC VALVE

WORK EQUIPMENT PPC VALVE (FOR BOOM, BUCKET, ARM, SWING CONTROL) PC128US-2 Serial No. : 5001 and up PC138US-2 Serial No. : 1001 – 4500 PC138USLC-2 Serial No. : 1001 – 1500 DISASSEMBLY 1. Remove nut (1), then remove disc (2) and boot (4). 2. Remove bolts, then remove plate (5). a Do not remove joint (3) unless it is to be replaced. 3. Remove seal (6) and collar (7). 4. Pull out piston (8), and remove retainer (9), springs (10) and (11), and shim (12). a Spring (10), (11) 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 (13) from body (14).

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PC128US-2



ASSEMBLY 1. Assemble valve (13) to body (14). 2. Assemble shim (12) and spring (11) to valve (13). a When assembling spring (11), set the end with the small coil diameter (inside diameter) at shim (12) end. 3. Assemble spring (10), retainer (9), and piston (8). a The number of loops in the coil for spring (10) is different for each of the hydraulic ports below, so be careful when installing. Position of port

Free length of spring

P1, P2

44.4mm

P3, P4

42.4mm

a The position of each port is marked on the bottom of the valve body. 2 Piston : Grease (G2-LI)

a When assembling the piston, coat the outside of the piston and the inside of the hole in the body with grease. 4. Fit O-ring to collar (7) and assemble in body (14), then install seal (6). 5. Install plate (5).


6. Install joint (3).

2 Sliding portion of joint : Grease (G2-LI)

2 Female thread of body : Thread tightener (LT-2)

a Coat two places on the female thread (A) with one drop each of Loctite as shown in the diagram below. 3 Joint : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm} a Keep strictly to the tightening torque. 7. Assemble boot (4) and disc (2), and tighten with nut (1). 3 Nut : 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}

a After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve. PC128US-2

30-101 (16)



WORK EQUIPMENT PPC VALVE (FOR BOOM, BUCKET, ARM, SWING CONTROL) PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up 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 (G2-LI) to its outside and the inside of the body hole. 4. Install spring (5) with its small diameter side on the shim (4) side. • Diameter of spring (Inside diameter) Small diameter side: 4.9, Large diameter side: 5.4 5. When installing springs (6) and (7), note that they are different and they must be installed to different hydraulic ports. • Installed height: 34 mm (Common to both springs) • 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}

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PC128US-2



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 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 degrees) 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}

PC128US-2

30-103 (16)

TRAVEL PPC VALVE


TRAVEL PPC VALVE PC128US-2 Serial No. : 5001 and up PC138US-2 Serial No. : 1001 – 4500 PC138USLC-2 Serial No. : 1001 – 1500

3

1

2

DISASSEMBLY 4

1. Remove screw (1) to remove lever (2).

2

2. Remove mounting bolt (3) to remove case shaft assembly (4). 3. Remove mounting bolt (5) to remove plate (6) together with damper assembly (7). a Check the thickness and the mounting position of washer (18).

5 18 1

6

4. Remove mounting bolt (8) to remove damper assembly (7) from plate (6).

9

5. Remove seal (9) and collar (10).

10

6. Remove piston (11) to remove retainer (12), springs (13) and (14) and shim (15). a Store shim (15) after checking the thickness and the number of shims at each mounting position.

11 7

12

8 13

7. Remove valve (16) from body (17).

14 15 16

17

CEP00533

•

Details of body (17)

30-104 (16)

PC128US-2

TRAVEL PPC VALVE


ASSEMBLY 1. Engage valve (16) with body (17).

3

2. Engage shim (15) and spring (14) with valve (16). a Mount shim (15) on the position which has been checked at the time of disassembly with the proper thickness and number. Standard shim thickness : 0.3mm a Since spring (14) is not symmetric vertically , engage it with the smaller diameter side facing the shim.

1

2

4 2 5 18

3. Mount spring (13), retainer (12) and piston (11).

2 Piston outside perimeter and body hole : Grease (G2-LI)

1

6 9

4. Place the O-ring on collar (10) to engage them with body (17) and mount seal (9) on them.

10

5. Mount damper assembly (7) on plate (6) and tighten mounting bolt (8).

11

2 Mounting bolt : Adhesive (LT-2)

3 Mounting bolt : 4.4 ± 0.5 Nm {0.45 ± 0.05 kgm} 6. Plate (6) together with damper assembly (7) and tighten mounting bolt (5). a Engage washer (18) with a standard washer (1.6 mm) beforehand. After completing assembly, measure the difference in the angles when the left and right levers are at full strokes. If it is larger than 0.7°, change the thickness of the washer (18) to make it 0.7° or less. • Washer thickness : 1.0, 1.3 or 1.6 mm a Reducing the washer thickness by 0.3 mm increases the full stroke angle by 0.39°.

7

12

8 13 14 15 16

17

CEP00533


7. Mount case shaft assembly (4) and tighten mounting bolt (3).

2 Shaft swaying part, and lever and piston contacting part : Grease (G2-LI) 3 Mounting bolt : 28.0 ± 3.4 Nm {2.85 ± 0.35 kgm}

8. Mount lever (2) and tighten screw (1).

2 Lever pin and plate swaying part : Grease (G2-LI) 3 Screw : 8.8 ± 1.0 Nm {0.9 ± 0.1 kgm}

PC128US-2

30-105 (16)


TRAVEL PPC VALVE

TRAVEL PPC VALVE PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up 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 (G2-LI) to its outside and the inside of the body hole. 2. Install spring (2) with its small diameter side on the shim (3) side. • 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°.) • 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} • Bolt (12): 3.9 – 4.9 Nm {0.4 – 0.5 kgm} (Apply LOCTITE #262.) • Screw (13): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} • Plug (14): 4 – 9 Nm {0.4 – 0.9 kgm} • Bolt (15): 25 – 30 Nm {2.5 – 3.2 kgm} • Bolt (16): 27 – 34 Nm {2.8 – 3.5 kgm}

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PC128US-2


HYDRAULIC CYLINDER

HYDRAULIC CYLINDER DISASSEMBLY 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". 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. i) Set piston rod assembly (2) on tool U1.

ii) 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.

PC128US-2

30-107 (16)


HYDRAULIC CYLINDER

iii) Use tool U2 to remove piston assembly (4). • If tool U2 is not used, use the four drill holes (diameter = 10) to loosen the piston assembly. iv) Remove plunger (5). • Arm cylinder and boom cylinder. v) Remove collar (6). • Arm cylinder and boom cylinder.

vi) Remove the head assembly (7).

vii) Remove cap (8) to remove eleven balls (9) and cushion plunger (10). • For the arm cylinder only. a Since cap (8) is made of nylon, tighten a screw into it and pull it out with pliers.

2. 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).

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PC128US-2


HYDRAULIC CYLINDER

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).

PC128US-2

30-109 (16)


HYDRAULIC CYLINDER

ASSEMBLY a Be careful not to damage the packing, the dust seal, the O-ring or the like a Do not forcibly insert the backup ring but make it warm with hot water (50 to 60°C) before insertion. 1. 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).

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) Mount the backup ring and O-ring (14). 4) Engage wear ring (12). 5) Engage ring (11). a Be careful not to expand the ring abutment joint too much. 2 Ring groove : Grease (G2-LI)

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PC128US-2


HYDRAULIC CYLINDER

3. Piston rod assembly 1) Set piston rod assembly (2) on tool U1.

2) Assemble head assembly (7). 3) Fit O-ring and backup ring to collar (6), and assemble. • Arm cylinder and boom cylinder. 4) Assemble plunger (5). • Arm cylinder and boom cylinder. a Check that there is a small amount of play at the tip of the plunger.

5) Set cushion plunger (10) on the piston rod and engage 11 balls (9) and fix them using cap (8). • For the arm cylinder only. 6) Assemble piston assembly (4) in the following procedure. • When the rod and piston assembly (2) are reused a Completely wash them and clear them of cut powder or dust. i) 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. ii) 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}

PC128US-2

30-111 (16)

HYDRAULIC CYLINDER


iii) Caulk the screw at two points through punching. •

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. • For the arm cylinder only.

i)

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 After tightening the piston, make sure that there is some play with plunger. • For the boom and arm cylinders only. ii) 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). • Screw processing dimensions (mm) Tap drill Tap drill Tap used diameter depth

Cylinder

Tap depth

Boom, arm and blade

10.3

27

12×1.75

20

Bucket

8.5

27

10×1.5

20

iii) Clear it of cut powder and dust and completely wash it after processing. iv) 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} v) Caulk the screw at four points through punching.

30-112 (16)

PC128US-2


HYDRAULIC CYLINDER

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 : 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}

9) Mount the piping.

PC128US-2

30-113 (16)

WORK EQUIPMENT


WORK EQUIPMENT REMOVAL

k Fully extend the work equipment and set a block at the arm end and lower the bucket tip to the ground. k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove handrail (1), then remove covers (2), (3), and (4). 2. Remove undercovers (5) and (6) from boom mounting section. 3. Disconnect working lamp wiring connector (7) (M10). 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. 10. Remove plug (17) from boom foot pin (19). 11. Remove mounting bolts to remove lock plate (18). 12. Set tool V to boom foot pin (19).

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PC128US-2


WORK EQUIPMENT

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

INSTALLATION • [*1]

[*2]

Carry out installation in the reverse order to removal. a When tightening the locknut, tighten so that the clearance a between the plate and nut is 0.5 – 1.5 mm. 2 Inside surface of bushing when assembling pin : Molybdenum disulphide lubricant (LM-P) 2 Grease after assembling pin : Grease (LM-G)

kWhen aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust the shim thickness so that clearance b between cylinder rod (21) and plate (22) is less than 1 mm. a Standard shim thickness : 1.0 mm [*3]

2 Inside surface of bushing when assembling pin : Molybdenum disulphide lubricant (LM-P)

2 Grease after assembling pin : Grease (LM-G)

kWhen aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust the shim thickness so that clearance c between boom (23) and bracket (24) is less than 0.5 mm. a Standard shim thickness : 0.5, 1.0, 2.0 mm •

Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

•

Refilling with oil (hydraulic tank) Run the engine to circulate the oil through the system. Then add oil to the specified level.

PC128US-2

30-115 (16)


OPERATOR’S CAB

OPERATOR’S CAB PC128US-2 Serial No. : 5001 – 7299 PC138US-2 Serial No. : 1001 – 2599 PC138USLC-2 Serial No. : REMOVAL


k Disconnect the negative (-) terminal of the battery. 1. Remove louver (1). 2. Remove four screws to remove airconditioner switch panel (2). 3. Remove screw (3) to slide duct (4) forward. 4. Disconnect airconditioner connectors (M12 and M31) (5) and (6) to remove duct (4). 5. Disconnect wiper motor connector (CN-75) (7). 6. Disconnect window washer hose (8). a Bend it to prevent detergent liquid from flowing out of the washer tank. 7. Disconnect radio connector (9)(B3). 8. Remove controller housing panel cover (10).

9. Remove 3 mounting bolts (11) and remove panel assembly (12) from operatorís cab, then shift it to rear of operatorís cab.

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PC128US-2


OPERATOR’S CAB

10. Remove the mounting bolt and lift operator cab assembly (13) to remove it. 4 Operator cab assembly : 240 kg

INSTALLATION •


PC128US-2

30-117 (16)


OPERATOR'S CAB

OPERATOR’S CAB PC128US-2 Serial No. : 7301 and up PC138US-2 Serial No. : 2601 – 4500 PC138USLC-2 Serial No. : 1001 – 1500 REMOVAL

k When removing the floor frame together, swing to the left by 135 degrees. (See REMOVAL OF FLOOR FRAME ASSEMBLY.). k Remove the negative (-) terminal from the battery before setting to work. 1. Remove covers (1) – (4) on the monitor panel. a Be sure to remove in the order of (1), (2), (3), (4). Otherwise, the covers may not be removed. a When removing cover (2), disconnect cigarette lighter connector (CN-M40). 2. Remove cover (5) at the lower front of the operator seat and remove ducts (6), (7), (8).

3. Remove covers (9), (10), (11) and (12) at the rear in the operator cab.

4. Loosen four mounting bolts on the bracket mounting CR700 controller (13) and move the controller forward (toward the operator).

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PC128US-2


OPERATOR'S CAB

5. Remove cover (14) and disconnect connectors (CN-A20)(15), (CN-A21)(16), (CN-A22)(17), and (CN-M87)(18) at the rear in the operator cab.

6. Remove ducts (19), (20), (21).

7. Disconnect connectors (CN-H08)(22) and (CNH09)(23) at the rear left in the operator cab. 8. Disconnect intake duct switching connector (CNM83)(25) and remove duct (26). a Lift the duct (25) to remove.

PC128US-2

30-119 (16)


OPERATOR'S CAB

9. Remove six mounting bolts (8) (marked with ) and four nuts (7)(marked with #). [*1] a Tighten the nuts (7) together with the floor frame.

10. Lift and remove the operator cab assembly (29). 4 Operator cab assembly: 280 kg

INSTALLATION •

Carry out installation in reverse oder to removal.

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PC128US-2


OPERATOR'S CAB

OPERATOR’S CAB PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL a When removing the floor frame together, swing to the left by 135 degrees. (See REMOVAL OF FLOOR FRAME ASSEMBLY.) k Remove the negative (-) terminal from the battery before setting to work. 1. Remove the floor mat. 2. Remove cover (1). 3. Loosen right console (2) and move it inward. 4. Remove cover (3). a There is the cigarette lighter, M40. 5. Lower duct joint A, remove connector M88 (4), and then remove duct (5). 6. Remove covers (6), (7), (8), (9), and (10). 7. Remove ducts (11) and (12).

8. Remove cover (13). 9. Disconnect connectors A20 (14), A21 (15), and M87 (16). 10. Remove duct (17). 11. Remove cover (18). 12. Remove the mounting bolts of controller (19) and place controller (19) on the floor.

PC128US-2

30-121 (16)


OPERATOR'S CAB

13. Disconnect connector (20). 14. Remove the 2 mounting bolts and duct (21). 15. Disconnect connector R19 (22). 16. Disconnect connector H09 (23), H08 (24), and V02 (25). 17. Disconnect antenna connector (26).

18. Remove duct hose (27). 19. Disconnect connectors V06 (28) and V09 (29) from the clip. 20. Disconnect connector V01 (30) (secured with a screw), (31) (press the hook to disconnect), and (32) (turn it to disconnect) from KOMTRAX (33). 21. Disconnect wiring harness (34) from the operator's cab.

22. Take out grommet (35) from the right front of the cab and disconnect windshield washer hose from (36). 23. Remove 4 mounting bolts (37) and 6 mounting bolts (38). 24. Lift off operator's cab assembly (39).

4 Operator's cab assembly: 280 kg

INSTALLATION •

Carry out installation in reverse order to removed.

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PC128US-2

OPERATOR'S CAB GLASS (STUCK GLASS)


OPERATOR’S CAB GLASS (STUCK GLASS)

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.

PC128US-2

(1): (2): (3): (4): (5): (6):

Right side window glass Left side rear window glass Door upper window glass Door lower window glass Front window glass Front window assembly (Front window glass + Front frame) ( 7 ) : Both-sided adhesive tape (16) : Center trim seal

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1 793-498-1210

2

t

2

2 20Y-54-13180 Adapter

Sketch

Lifter t (Suction cup)

Part name

New/Removal

Q’ty

Y

Part No.

Necessity

Symbol

SPECIAL TOOLS

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). a 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.) a If the window glass is broken finaly, it may be removed with knife [4] and a screwdriver. a 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.) 2. Remove the window glass.

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PC128US-2



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 surfaces. (If the painted surfaces are scratched, adhesion will be lowered.) (The figure shows the operator’s cab of a wheel loader.) 2. 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.

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3. 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. (Discard the primer 24 hours after it is 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. 3) 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 Parts to be coated with primer: Apply the primer all over dimension (a). • Dimension to apply primer (a): 25 mm

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PC128US-2



a 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. • Part (b) a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. a Never apply wring primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

4) 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.)

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). a Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. a After applying the primer, leave it for at least 5 minutues (within 8 hours) to dry. a Never apply wring the primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

PC128US-2

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4. Stick both-sided adhesive tape (7) along the inside edge of the glass sticking section. a Do not remove the release tape of the bothsided 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.

a 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. 1) Stick both-sided adhesive tape (7) for right side window glass (1) as shown in the figure.

a 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

2) Stick both-sided adhesive tape (7) for left side rear window glass (2) as shown in the figure.

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PC128US-2



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) 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

•

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).

PC128US-2

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5. 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.

a 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. 6. 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.

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PC128US-2



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. • Dimension (q) : 10 mm • Dimension (r) : 15 mm

3) Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.

4) Remove the release tape of the both-sided adhesive tape on the glass side. 5) Apply adhesive (15) to the outside of bothsided adhesive tape (7) of the operator’s cab.

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a Apply adhesive (15) to dimensions s and t of both-sided adhesive tape (7) of operator’s cab (8). • Dimension (s) : 10 mm • Dimension (t) : 15 mm a Apply adhesive (15) higher than bothsided adhesive tape (7). a Apply the adhesive evenly.

a As for the right side window glass, apply the adhesive to the outside of the bothsided adhesive tape on the periphery of the glass.

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.)

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PC128US-2



a After installing front window glass (5), install the center trim seal to its bottom. Then, apply caulking material all around the glass to fill part 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

8. 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.)

(The figure shows the operator's cab of PC2007.)

PC128US-2

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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. 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.

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PC128US-2


FRONT WINDOW

FRONT WINDOW ASSEMBLY

k Lower the work equipment to the ground and stop the engine. a To replace the front window glass, the front 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.

INSTALLATION •


PC128US-2

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FLOOR FRAME

FLOOR FRAME PC128US-2 Serial No. : 5001 – 7300 PC138US-2 Serial No. : 1001 – 2600 PC138USLC-2 Serial No. : 1001 – 1500 REMOVAL

k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove operator’s cab. (See REMOVAL OF OPERATOR’S CAB) 2. Remove left side cover (1). 3. Disconnect wiring connectors (2) (CN1), (3) (CN2), (4) (CN4), and (5) (CN3). 4. Disconnect ground cable (6).

5. Remove handrail (7). 6. Remove covers (8) and (9). 7. Disconnect PPC hoses (10) (Bucket dump, arm out, boom raise, bucket tilt from above). 8. Disconnect PPC hoses (11) (Arm tilt, boom lower, right swing, and left swing from above). a If the color tapes are broken and cannot be judged correctly, put tags, etc. for correct judgment.

9. Disconnect PPC hoses (12) and (13) for travel (Right). 10. Disconnect PPC hoses (14) and (15) for travel (Left).

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PC128US-2


FLOOR FRAME

11. Disconnect PPC main pressure hose (16) (A1). 12. Disconnect PPC drain hose (17). a Drain hydraulic oil 6 Hydraulic oil : 90 l

13. Lift off floor frame assembly (18). a Take care not to damage the PPC hoses. 4 Floor frame assembly : 65 kg

INSTALLATION •


•

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

PC128US-2

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FLOOR FRAME

FLOOR FRAME PC128US-2 Serial No. : 7301 and up PC138US-2 Serial No. : 2601 – 4500 a Swing the upper structure to the left by 135 degrees. (For step 7)

REMOVAL

k Remove the negative (-) terminal from the battery before setting to work. 1. Drain coolant

6 Coolant: 17.2 l

2. Collect air conditioner gas (R134a) from air conditioner circuit. 3. Remove the operator cab assembly by referring to the "OPERATOR’S CAB ASSEMBLY [REMOVAL]" section. 4. Remove the side cover (1). 5. Disconnect connectors (1)A01, (2)A03, (3)A04, (4)A07, (5)A02, (6)A05, (7)A08 , (8)A010 ,and earth wire(9) and remove tool tray (10).

6. Remove heater hose (11).

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

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PC128US-2


FLOOR FRAME

8. Remove upper cover (15) which covers the control valves. 9. Separate eight work equipment and swing PPC valve hoses (16). a The PPC hoses are identified by the following markings in the order from the top: • For bucket CURL: Red • For boom LOWER: Black • For left swing: White • For arm IN: Green • For bucket DUMP: Red • For boom RAISE: Yellow • For right swing: Brown • For arm OUT: Orange 10. Remove the clamp (17) at the right front of the revolving frame.

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

12. Lift and remove floor frame assembly (20). 4 Floor frame assembly: 270 kg

INSTALLATION •


[*1]

3 Air conditioner tube nut: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

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

PC128US-2

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FLOOR FRAME

FLOOR FRAME PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1001 and up a Swing the upper structure to the left by 135 degrees. (For step 9)

REMOVAL

k Remove the negative (-) terminal from the battery before setting to work. 1. Drain coolant

6 Coolant: 13.2 l

2. Collect air conditioner gas (134a) from air conditioner circuit. 3. Remove the operator cab assembly by referring to the "OPERATOR’S CAB ASSEMBLY [REMOVAL]" section. 4. Remove the side cover (1) and front cover (2).

5. Disconnect connectors (3)A01, (4)A02, (5)A03 and remove from a clip.

6. Disconnect hone connector (6) M18 and earth wire (7) 7. Remove tool tray.

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PC128US-2


FLOOR FRAME

8. Disconnect 2 heater hoses (11), upper and lower ones, from under the rear part of the seat.

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

10. Remove upper cover (15) which covers the control valves. 11. Separate eight work equipment and swing PPC valve hoses (16). a The PPC hoses are identified by the following markings in the order from the top: • For bucket CURL: Red • For boom LOWER: Black • For left swing: White • For arm IN: Green • For bucket DUMP: Red • For boom RAISE: Yellow • For right swing: Brown • For arm OUT: Orange 12. Remove the clamp (17) at the right front of the revolving frame.

PC128US-2

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FLOOR FRAME

13. Remove the cover from under the seat and disconnect air conditioner tubes (18) and (19) from the air conditioner unit. [*1]

14. Lift and remove floor frame assembly (20). 4 Floor frame assembly: 270 kg

INSTALLATION •

Carry out installation in reverse order to removal.

[*1]


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

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PC128US-2


AIR CONDITIONER COMPRESSOR

AIR CONDITIONER COMPRESSOR PC128US-2 Serial No. : 5001 – 7299 PC138US-2 Serial No. : 1001 – 2599 REMOVAL


k Disconnect the negative (-) terminal of the battery. 1. Collect air conditioner gas (R134a) from air conditioner circuit. 2. Open cover (1). 3. Remove cover (2). 4. Disconnect hoses (3) and (4). a Plug the hoses and compressor to prevent dust, water, etc. from entering them.

5. Disconnect wiring connector (5) (M34). 6. Loosen belt tension adjustment bolt (6) and mounting bolt (7) to remove drive belt (8). 7. Remove bolts (6) and (7) to remove air conditioner compressor assembly (9).

INSTALLATION •


•

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

PC128US-2

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AIR CONDITIONER COMPRESSOR

AIR CONDITIONER COMPRESSOR PC128US-2 Serial No. : 7301 and up PC138US-2 Serial No. : 2601 and up PC138USLC-2 Serial No. : 1001 and up REMOVAL

k Lower the work equipment to the ground completely.

k Remove the negative (-) terminal from the battery. 1. Collect air conditioner gas (R134a) from air conditioner circuit. 2. Open the cover (1). 3. Remove bolt (2) and Loosen bolt (4) and remove cover (3). 4. Separate hoses (5) and (7) by loosening bolt (6). a Put blind caps to prevent the entry of dirt or water into hoses and compressor. 5. Disconnect wire and connector (8)(M34). 6. Loosen mounting bolt (9), lock nut (11), and bolt (12) to remove air compressor belt . 7. Remove the bolts (4) and (9) and reomve the air compressor assembly (13).

a PC128US-2 Serial No. 9501 and up PC138US-2 Serial No. 4501 and up PC138USLC-2 Serial No. 1501 and up

INSTALLATION •

Carry out installation in reverse oder to reomval.

•

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

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PC128US-2


AIR CONDITIONER CONDENSER

AIR CONDITIONER CONDENSER PC128US-2 Serial No. : 5001 – 7299 PC138US-2 Serial No. : 1001 – 2599 REMOVAL


k Disconnect the negative (-) terminal of the battery. 1. Remove counterweight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY. 2. Collect air conditioner gas (R134a) from air conditioner circuit. 3. Remove covers (1) and (2). 4. Remove air cleaner assembly (3). 5. Disconnect battery relay (4) from bracket. a Shift the disconnected battery relay forward. 6. Disconnect hose (5) connected to air conditioner compressor and hose (6) connected to receiver tank. a When disconnecting these hoses, be sure to use two spanners. 7. Remove mounting bolts to remove air conditioner compressor (7). a Since the fins are soft, take care when removing the air conditioner compressor.

INSTALLATION •


•


PC128US-2

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AIR CONDITIONER CONDENSER

AIR CONDITIONER CONDENSER PC128US-2 Serial No. : 7301 and up PC138US-2 Serial No. : 2601 and up REMOVAL

k Lower the work equipment to the ground completely.

k Remove the negative (-) terminal from the battery. 1. Collect air conditioner gas (R134a) from air conditioner circuit. 2. Loosen bolts (1) and remove cover (2). 3. Remove air cleaner cover (3) and remove the element. 4. Loosen bolts (4) and remove the wire harness clamp. 5. Loosen bolt (5) and remove the battery relay assembly. (The wire related to the battery relay must not be removed.) 6. Loosen bolt (6) and remove the battery relay mounting plate. 7. Remove battery cover fixing screws (7). 8. Remove hose mounting bolts (8) and (9) and disconnect the hose. a Put blind caps to prevent the entry of dirt or water into hoses and compressor. 9. Remove bolts (10) and remove condenser [11].

INSTALLATION •

Carry out installation in reverse oder to remaval.

•


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PC128US-2


AIR CONDITIONER UNIT

AIR CONDITIONER UNIT PC128US-2 Serial No. : 5001 – 7299 PC138US-2 Serial No. : 1001 – 2599 REMOVAL


k Disconnect the negative (-) terminal of the battery. 1. Collect air conditioner gas (R134a) from air conditioner circuit. 2. Remove floor mat (1). 3. Remove covers (2) and (3). 4. Remove louver (4) and the four screws to remove switch panel (5). 5. Remove screw (6) to slide duct (7) forward.

6. Disconnect airconditioner switch connectors (8) and (9) to remove duct (7). 7. Remove grommet (10). 8. Remove the mounting bolt to disconnect duct (11) from the airconditioner unit. 9. Disconnect airconditioner unit connector (12) (M26). a It is located on the bottom of the centralized harness. 10. Disconnect heater hoses (13) and (14) at the rear of the airconditioner unit. a Since coolant flows out, bend and disconnect the hose and apply the blind plug to it. 11. Disconnect airconditioner hoses (15) and (16). a Make sure to double-engage the wrench before disconnection. 12. Disconnect two relay connectors (17).

PC128US-2

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13. Remove the mounting bolt to remove airconditioner unit assembly (18). a Make sure that duct (11) is completely disconnected and remove it by sliding it forward.

INSTALLATION •


•


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PC128US-2



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

k Remove the negative (-) terminal from the battery before setting to work. 1. Drain coolant.

6 Coolant: 17.2 l

2. Collect air conditioner gas from air conditioner circuit. 3. Remove covers (1), (2), (3), (4) from the monitor panel. a Be sure to remove in the order of (1), (2), (3), (4). Otherwise, the covers may not be removed. a When removing the cover (2), disconnect the cigarette lighter connector (CN-M19). 4. Remove cover in front of the operator seat and remove ducts (6), (7), (8).

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

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6. Remove the cover (13) and separate the connector (14)(CN-M87). (At the rear right in the operator cab)

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

8. Disconnect connectors (CN-M26)(18), (CNM85)(19), and (CN-M84)(20) (at the rear of the operator seat). 9. Disconnect the CR700 controller connector (CN021 – 023)(at three positions) and remove the CR700 controller (21).

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PC128US-2



10. Remove the heater hose (11).

11. Remove five seat stand mounting bolts and lift the seat stand by screwing bolts [1] (M12, L = 100mm) into seat stand lifting nuts (left: 2, right: 1). 12. Disconnect two air conditioning hoses, remove six air conditioning unit mounting bolts and remove air conditioning unit assembly (25) by pulling it out from the downside of the operator seat.

INSTALLATION •


a When installing the hoses of the air conditioning circuit, care should be taken to prevent the entry of dirt, dust, water, etc. into hose. a Check that the pipe couplers of the air conditioning hoses have O-rings in them before installation. a Check the O-rings for flaw, deterioration, etc. a Filling air-conditioning gas Using tool X3, charge air conditioner gas (R134a) to air conditioner circuit.

PC128US-2

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AIR CONDITIONER UNIT ASSEMBLY PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Disconnect negative (-) terminal of the battery. 1. Collect air conditioner gas from air conditioner circuit. 2. Drain engine coolant.

6 Drain 13.2 l of the cooling water.

3. Remove floor mat. 4. Remove cover (1). 5. Loosen right console (2) and move it inward. 6. Remove cover (3). a There is the cigarette lighter, M40. 7. Remove covers (4) and (5). 8. Lower duct joint A, remove connector M88 (6), and then remove duct (7). 9. Remove duct (8). 10. Disconnect 2 air conditioner tubes (9).

[*1]

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

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

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PC128US-2



13. Remove duct (16). 14. Disconnect connector (17). 15. Remove the 2 mounting bolts and duct (18). 16. Remove cover (19).

17. Disconnect clip (20). 18. Disconnect connectors M26 (21), M85 (22), and M84 (23) and remove them from the connector clips. 19. Disconnect 2 heater hoses (24), upper one and lower one. a Do not wet controller B.

20. Remove five seat stand mounting bolts and lift the seat stand by screwing bolts [1] (M12, L = 100mm) into seat stand lifting nuts (left: 2, right: 1). 21. Remove six air conditioning unit mounting bolts and remove air conditioning unit assembly (25) by pulling it out from the downside of the operator seat.

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INSTALLATION •

Carry out installation in reverse order to removal.

a When installing the hoses of the air conditioning circuit, care should be taken to prevent the entry of dirt, dust, water, etc. into hose. a Check that the pipe couplers of the air conditioning hoses have O-rings in them before installation. a Check the O-rings for flaw, deterioration, etc. [*1]


•


•

Supplying coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 13.2 l

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PC128US-2


COUNTERWEIGHT

COUNTERWEIGHT REMOVAL


k Disconnect the negative (-) terminal of the battery. 1. Remove engine upper cover (1). 2. Disconnect flywheel case oil filler hose (2). 3. Remove fuel gauge connector (3) from the clamp. a This is intended to prevent it from coming in contact with the frame when the counterweight is lifted. 4. Sling counterweight assembly temporarily and remove 3 mounting bolts (4). [*1] • Width across flats of mounting bolt: 65 mm 5. Lift off counterweight assembly (5) carefully.

4 Counterweight assembly (PC128US-2) : 3,050 kg (Standard specification) : 2,500 kg (Blade specification) 4 Counterweight assembly (PC138US, PC138USLC-2) : 3,450 kg (Standard specification) : 3,050 kg (Blade specification)

INSTALLATION •


[*1]

3 Mounting bolt : 3,850 – 4,710 Nm (393 – 480 kgm)

PC128US-2

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MONITOR PANEL

MONITOR PANEL ASSEMBLY REMOVAL 1. Pull cover (2) of monitor panel (1) and remove the claw stopper. 2. Remove side cover (3). 3. Remove the stopper of cover (4).

4. Remove the 3 mounting bolts of monitor panel (1) and connectors (5) and (6) on the back side, then remove monitor panel assembly (1).

INSTALLATION •


30-156 (16)

PC128US-2


CONTROLLER

CONTROLLER ASSEMBLY PC138US-2 Serial No. : 4501 and up PC138USLC-2 Serial No. : 1501 and up REMOVAL

k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove cover (1) from under the rear part of the seat.

2. Disconnect controller wiring connectors CR1 (2), CR2 (3) and CR3 (4). 3. Remove the 4 mounting bolts and controller assembly (5).

INSTALLATION •


PC128US-2

30-157 (16)

40 MAINTENANCE STANDARD

Swing machinery ......................................... 40- 2 Swing circle .................................................. 40- 4 Track frame, idler cushion ........................... 40- 5 Idler ................................................................ 40- 6 Carrier roller .................................................. 40- 8 Track roller .................................................... 40- 9 Sprocket ........................................................ 40-12 Track shoe ..................................................... 40-13 Hydraulic pump (piston pump) ................... 40-17 Control valve ................................................. 40-18 Suction safety valve ..................................... 40-27 Self pressure reduction valve ...................... 40-28 Travel motor .................................................. 40-29 Swing motor ................................................. 40-30 Solenoid valve .............................................. 40-31 Center swivel joint ........................................ 40-32 PPC valve ...................................................... 40-34 Boom hydraulic drift prevention valve (FOR KUK SPEC.) .......................................... 40-37 Arm hydraulic drift prevention valve (FOR KUK SPEC.) (If equipped) ................ 40-37-2 Hydraulic cylinder ........................................ 40-38 Work equipment ........................................... 40-41 Dimension of work equipment .................... 40-44

PC128US-2

40-1 (15)

MAINTENANCE STANDARD

SWING MACHINERY

SWING MACHINERY PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500

40-2 (15)

PC128US-2


SWING MACHINERY

Unit: mm

No.

Check item

Criteria

Remedy

Standard clearance

Clearance limit

0.07 – 0.18

0.4

1

Backlash of swing motor shaft and No. 1 sun gear

2

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


0.15 – 0.34

0.7

6


0.13 – 0.31

0.6

7

Backlash between No. 2 planetary carrier and swing pinion

0.08 – 0.19

0.4

8

Backlash between swing pinion and swing circle

0.13 – 1.16

2.3

9

Wear on swing pinion collar’s contact surface against oil seal

PC128US-2

Replace

Standard size

Tolerance

Repair limit

145

0 – 0.100

144.8

Apply hardchrome plating recondition, or replace

40-3 (14)


SWING MACHINERY


40-3-1 (15)

PC128US-2


SWING MACHINERY

Unit: mm

No.

Check item

Criteria

Remedy

Standard clearance

Clearance limit

0.07 – 0.18

0.4

1

Backlash of swing motor shaft and No. 1 sun gear

2


0.13 – 0.32

0.6

3


0.14 – 0.40

0.7

4

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

0.14 – 0.34

0.7

5


0.13 – 0.39

0.7

6


0.12 – 0.31

0.6

7

Backlash between No. 2 planetary carrier and swing pinion

0.009 – 0.117

0.2

8

Backlash between swing pinion and swing circle

0.13 – 1.16

2.3

9

Wear on swing pinion collar’s contact surface against oil seal

PC128US-2

Replace

Standard size

Tolerance

Repair limit

145

0 – 0.100

144.8

Apply hardchrome plating recondition, or replace

40-3-2 (15)


SWING CIRCLE

SWING CIRCLE

Unit: mm

No.

Check item

1

Clearance between bearing and circle

40-4 (14)

Criteria

Remedy

Standard size

Clearance limit

0.5 – 1.6

2.6

Replace

PC128US-2


TRACK FRAME, IDLER CUSHION

TRACK FRAME, IDLER CUSHION PC128US-2 PC138US-2

Unit: mm

No.

1

2

Check item

Criteria Standard size

Clearance limit

84

89

82

77

Track frame

185

193

Rebuild

Idler support

183

175

Rebuild or replace

Rebuild

Track Idler guide top frame and bottom width Idler support

Idler guide left and right width

Standard size

3

Recoil spring

Remedy

Rebuild or replace

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

ª1

507

390

78.5 kN {8,000 kg}

494

69.8 kN {7,120 kg}

ª2

502

390

84.3 kN {8,600 kg}

490

75.0 kN {7,650 kg}

Replace

ª 1. For PC128US-2 Serial No.: 5001 – 5362 ª 2. For PC128US-2 Serial No.: 5363 and up, PC138US-2 Serial No.: 4501 and up

PC128US-2

40-5 (15)

IDLER


Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Repair limit

1

Outer diameter of protruding portion

527

—

2

Outer diameter of tread

489

477

3

Depth of protruding portion

19

25

4

Width of protruding portion

52

42

5

Total width

115

107

6

Width of tread

7

Clearance between idler shaft and bushing

8

Interference between idler and bushing

31.5 Standard size 54 Standard size 61

9

10

—

Side clearance of idler (on one side) Tread wall thickness (at center of tread) Oil amount

PC128US-2

Tolerance Shaft Hole +0.074 – 0.250 0 – 0.280 Tolerance Shaft Hole +0.117 +0.030 +0.087 0

Rebuild or replace

36.5 Standard clearance

Clearance limit

0.250 – 0.354

1.5

Standard in- Interference terference limit 0.057 – 0.117

Standard clearance

Clearance limit

0.18 – 0.38

1.5

Standard size

Repair limit

15

9

90 cc (Engine oil: SAE30CD – Red)

Replace

—

Rebuild or replace —

40-6-1 A


IDLER


40-6-2 (15)

PC128US-2

IDLER


Unit: mm

No.

1

Check item

Criteria

Outer diameter of protruding portion

Remedy

Standard size

Repair limit

527

—

489

477

2


3

Depth of protruding portion

19

25

4

Width of protruding portion

52

42

5

Total width

115

107

6

Width of tread

7

Clearance between idler shaft and bushing

8

Interference between idler and bushing

31.5 Standard size

Standard size 61

9

Side clearance of idler (on one side)

10

Tread wall thickness (at center of tread)

—

Oil amount

PC128US-2

36.5

Tolerance Shaft Hole – 0.250 – 0.280

54

Rebuild or replace

+0.074 0

Standard clearance

Clearance limit

0.250 – 0.354

1.5

Tolerance Shaft Hole

Standard in- Interference terference limit

+0.117 +0.087

0.057 – 0.117

+0.030 0

Standard clearance

Clearance limit

0.200 – 0.405

1.5

Standard size

Repair limit

16.5

10.5

90 – 105 cc (Engine oil: SAE30CD)

Replace

—

Rebuild or replace —

40-7 A


CARRIER ROLLER

CARRIER ROLLER

Unit: mm

No.

Check item

1


2

Width of tread

3

Clearance between shaft and bushing


Repair limit

116

106

123

—

Standard size 40 Standard size

4

Interference between collar and bushing 47

5

6

Play on carrier roller in axial direction Tread wall thickness (at 10 mm away from end face roller)

ª1 —

Tolerance

Rebuild or replace

—

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

Replace Standard in- Interference terference limit 0.011 – 0.061

Standard size

Repair limit

0.363 – 0.537

1.5

17.7

12.7

40-8

—

Rebuild or replace

72 cc (Engine oil: SAE30CD – Red) —

Oil amount

ª2

(15)

Remedy

68 – 76 cc (Engine oil: SAE30CD – Red)

ª 1. For PC128US-2 Serial No.: 5001 – 7138 ª 2. For PC128US-2 Serial No.: 7139 and up For PC138US-2 Serial No.: 4501 and up For PC138USLC-2 Serial No.: 1001 and up

PC128US-2

TRACK ROLLER


TRACK ROLLER PC128US-2 Serial No.: 5001 – 5362

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Repair limit

1

Diameter of flange (outside)

158

—

2


130

120

3

Flange width

4

Total width

5

Width of tread

6

7


Interference between roller and bushing

8

Track roller side clearance (on one side)

9

Tread wall thickness (at center of width)

—

Oil amount

PC128US-2

26.5

Rebuild or replace

—

176

—

35

— Tolerance

— Rebuild or replace

Standard size

Shaft

Hole

Standard clearance

Clearance limit

50

– 0.250 – 0.270

+0.187 – 0.025

0.225 – 0.457

1.5

Tolerance

Standard size

Shaft

Hole

57

+0.190 +0.110

+0.090 +0.060


Standard clearance

Clearance limit

0.155 – 0.345

1.5

Standard size

Repair limit

36.5

31.5


Replace

—

Rebuild or replace

—

40-9 A


TRACK ROLLER

ONE SIDE PIN TYPE PC128US-2 Serial No.: 5363 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Repair limit

1


158

—

2


130

120

3

Flange width

4

Total width

5

Width of tread

6

7



8


9


—

Oil amount

40-10 (15)

26.5

Rebuild or replace

—

176

—

35

— Tolerance


Standard size

Shaft

Hole

Standard clearance

Clearance limit

48

– 0.250 – 0.350

+0.186 – 0.025

0.225 – 0.536

1.5

Tolerance

Standard size

Shaft

Hole

55

+0.190 +0.110

+0.093 +0.063


Standard clearance

Clearance limit

0.160 – 0.345

1.5

Standard size

Repair limit

37.5

32.5


Replace

—

Rebuild or replace

—

PC128US-2


TRACK ROLLER

BOTH SIDE PIN TYPE PC128US-2 Serial No.: 5363 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Repair limit

1


158

—

2


130

120

3

Flange width

4

Total width

5

Width of tread

6

7



8


9


—

Oil amount

PC128US-2

26.5

Rebuild or replace

—

176

—

35

— Tolerance


Standard size

Shaft

Hole

Standard clearance

Clearance limit

48

– 0.250 – 0.350

+0.186 – 0.025

0.225 – 0.536

1.5

Tolerance

Standard size

Shaft

Hole

55

+0.190 +0.110

+0.093 +0.063


Standard clearance

Clearance limit

0.165 – 0.440

1.5

Standard size

Repair limit

37.5

32.5


Replace

—

Rebuild or replace

—

40-11 (15)


SPROCKET

SPROCKET

Unit: mm

No.

1

2

Check item

Remedy

Standard size

Tolerance

Repair limit

547.4

+1.0 – 2.0

535

PC138USLC-2

542.8

+1.0 – 2.0

530

PC128US-2

607

—

595

PC138USLC-2

607.5

—

595

Wear on tooth bottom PC128US-2 diameter

Wear on addendum diameter

Criteria

3

Wear on addendum width

27

—

22

4

Wear on tooth bottom width

42

± 1.5

39

111.7

+0.465 – 1.160

105.5

5

Tooth bottom PC128US-2 wall thickness PC138USLC-2

109.4

+0.465 – 1.160

103

40-12 0

Rebuild or replace

PC128US-2


TRACK SHOE

TRACK SHOE TRIPLE SHOE, ROAD LINER, CITY PAD SHOE

ª1. Triple shoe , city pad shoe ª2. Road liner fl P portion shows the link of bushing press fitting end.

PC128US-2

40-13 7


TRACK SHOE

PC128US-2 (1/2) No.

1

Unit: mm

Check item


Repair limit

175.25

178.25

Link pitch

Bushing outer diameter 46.3

3

Link height

4

Link wall thickness (at the section where bushing is to be press fit)

Reverse or replace

When turned

Standard size 2

Remedy

Normal load

Impact load

—

42.3

Standard size

Repair limit

86

81

24

19

5

Reverse or replace

102.4 Replace

6

Shoe bolt pitch

86.4

7

57

8 9

Link

10

Inner width

52.4

Total width

35 30.1

Width of tread

11

Pin protrusion volume

5.5

12

Regular brush protrusion volume

3.75

13

Total pin length

173

14

Total bushing length (master bushing)

15

Bushing wall thickness

16

Spacer thickness Bushing

17 18

Press fitting Regular pin force

ª 19

Master pin

Reverse or replace

Adjust or replace 86.7 Standard size

Repair limit

7.8

3.8 — 39.2 – 137.3 kN {4 – 14 ton} 78.5 – 186.3 kN {8 – 19 ton}

—

39.2 – 98.1 kN {4 – 10 ton}

Items with ª marking are applicable to the dry type shoe.

40-14 (15)

PC128US-2


TRACK SHOE

PC128US-2 (2/2) No.

Unit: mm

Check item

Criteria

Remedy

Tightening torque (Nm {kgm}) Additional tightening angle (deg) a. Regular link Shoe bolt 20

• Triple • City pad

196 ± 20 {20 ± 2}

90 ± 10

• Road liner

147 ± 10 {15 ± 1}

50 ± 5

Retighten

Tightening torque (Nm {kgm})

Additional tightening angle (deg)

Lower limit torque (Nm {kgm})

—

—

—

b. Master link

Number of shoes (on one side)

ª2

42

ª3

43 Tolerance

Standard size 21

22

Hole

46

+0.387 +0.347

+0.062 0

0.285 –0.387

30

+0.150 0

–0.198 –0.250

0.198 – 0.400

Tolerance

Standard size 23

Clearance between regular pin and bushing 30

ª 1 Interference between 24 master pin and link

26

a. Road liner

Hole

+0.150 0

+0.830 +0.330

0.180 – 0.830

Shaft

Hole

Standard interference

+0.020 –0.020

–0.198 –0.250

0.178 – 0.270

Shaft

Hole

Standard clearance

–0.200 –0.300

+0.630 +0.230

Tolerance

Standard size 30

Grouser height

Standard clearance

Shaft

Tolerance

Standard size 30

ª 1 Clearance between master 25 pin and bushing


Shaft

Interference between bushing and link

Interference between regular pin and link

—

Adjust or replace

0.430 – 0.930

Standard size

Repair limit

58

21

Replace

Items with ª 1. marking are applicable to the dry type shoe. ª 2. Serial No.: 7731 – 9000 ª 3. Serial No.: 9001 and up

PC128US-2

40-15 (15)


TRACK SHOE

PC138US-2 (1/2) No.

1

Unit: mm

Check item


Repair limit

175.25

178.25

Link pitch


3

Link height

4


Reverse or replace

When turned

Standard size 2

Remedy

Normal load

Impact load

—

46.6

Standard size

Repair limit

90

85

24

19

5

Reverse or replace

102.4 Replace

6

Shoe bolt pitch

86.4

7

57

8 9

Link

10

Inner width

52.4

Total width

35 30.1

Width of tread

11


5.5

12

Regular bushing protrusion volume

3.75

13

Total pin length

173

14


86.7

15


16

Spacer thickness

17 18

Bushing Press fitting Regular pin force

ª 19

Master pin

Reverse or replace

Adjust or replace

Standard size

Repair limit

9.0

5 — 58.8 – 176.5 kN {6 – 18 ton} 98.1 – 235.4 kN {10 – 24 ton}

—

98.1 – 235.4 kN {10 – 24 ton}


40-15-1 (15)

PC128US-2


TRACK SHOE

PC138US-2 (2/2) No.

Unit: mm

Check item

Criteria

Remedy

Tightening torque (Nm {kgm}) Additional tightening angle (deg) a. Regular link

196 ± 20 {20 ± 2}

• Triple Shoe bolt 20



—

—

—

b. Master link

Tolerance Hole

50.2

+0.387 +0.347

+0.074 0

0.273 –0.387

32

+0.150 +0.050

–0.188 –0.250

0.238 – 0.400

Tolerance

Standard size 23


ª 24

Interference between master pin and link

Clearance between master pin and bushing

Grouser height

Hole

+0.150 +0.050

+0.830 +0.330

0.180 – 0.780

Shaft

Hole


+0.060 +0.020

–0.188 –0.250

0.208 – 0.310

Shaft

Hole

Standard clearance

–0.200 –0.300

+0.830 +0.330

Tolerance

Standard size 32

26

Standard clearance

Shaft

Tolerance

Standard size 32

ª 25


Shaft



—

43 Standard size

22

Retighten



21

90 ± 10

Adjust or replace

0.530 – 1.130

Standard size

Repair limit

—

—

Replace


PC128US-2

40-15-2 (15)


PC138USLC-2 (1/2) No.

1

Unit: mm

Check item


Repair limit

175.25

178.25

Link pitch


3

Link height

4


Reverse or replace

When turned

Standard size 2

Remedy

Normal load

Impact load

—

46.6

Standard size

Repair limit

90

85

24

19

5

Reverse or replace

102.4 Replace

6

Shoe bolt pitch

86.4

7

57

8 9

Link

10

Inner width

52.4

Total width

35 30.1

Width of tread

11


5.5

12

Regular bushing protrusion volume

3.75

13

Total pin length

173

14


86.7

15


16

Spacer thickness

17 18

Bushing Press fitting Regular pin force

ª 19

Master pin

Reverse or replace

Adjust or replace

Standard size

Repair limit

9.0

5 — 58.8 – 176.5 kN {6 – 18 ton} 98.1 – 235.4 kN {10 – 24 ton}

—

98.1 – 235.4 kN {10 – 24 ton}


40-15-3 (15)

PC128US-2


TRACK SHOE

PC138USLC-2 (2/2) No.

Unit: mm

Check item

Criteria

Remedy

Tightening torque (Nm {kgm}) Additional tightening angle (deg) a. Regular link

196 ± 20 {20 ± 2}

• Triple Shoe bolt 20



—

—

—

b. Master link

Tolerance Hole

50.2

+0.387 +0.347

+0.074 0

0.273 –0.387

32

+0.150 +0.050

–0.188 –0.250

0.238 – 0.400

Tolerance

Standard size 23


ª 24

Interference between master pin and link

Clearance between master pin and bushing

Grouser height

Hole

+0.150 +0.050

+0.830 +0.330

0.180 – 0.780

Shaft

Hole


+0.060 +0.020

–0.188 –0.250

0.208 – 0.310

Shaft

Hole

Standard clearance

–0.200 –0.300

+0.830 +0.330

Tolerance

Standard size 32

26

Standard clearance

Shaft

Tolerance

Standard size 32

ª 25


Shaft



—

46 Standard size

22

Retighten



21

90 ± 10

Adjust or replace

0.530 – 1.130

Standard size

Repair limit

—

—

Replace


PC128US-2

40-15-4 (15)


TRACK SHOE

Triple shoe and city pat shoe

Unit: mm

No.

1

2 3

Check item

Grouser height

Shoe height Plate thickness

4 5

Grouser edge length

6

Criteria

Remedy

Standard size

Repair limit

ª1

25

15

ª2

20

10

ª1

33

23

ª2

29.5

19.5

ª1

8

ª2

9.5

ª1

18

ª2

14

ª1

11

ª2

13

ª1

18

ª2

15

Rebuild or replace

ª 1.: PC128US-2 (Serial No.: 5001 – 9000), PC138USLC-2 (Serial No.: 1001 – 1300) ª 2.: PC128US-2 (Serial No.: 9001 and up), PC138US-2 (Serial No.: 4501 and up), PC138USLC-2 (Serial No.: 1301 and up)

40-16 (15)

PC128US-2


HYDRAULIC PUMP

HYDRAULIC PUMP (PISTON PUMP) TYPE : HPV95 (for 105 cc/rev.) PC128US-2 Serial No.: 5001 – 7730

PC128US-2

40-17 (15)


HYDRAULIC PUMP


40-17-1 (15)

PC128US-2


HYDRAULIC PUMP


PC128US-2

40-17-2 (15)


CONTROL VALVE

CONTROL VALVE 7 SPOOL (6 SPOOL + SERVICE VALVE) PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 (1/9)

40-18 (15)

PC128US-2


CONTROL VALVE


PC128US-2

40-18-1 (15)


CONTROL VALVE

(2/9)

Unit: mm

No.

Check item


1

Suction valve spring

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

46.8 × 7.50

40.6

5.50±0.40N {0.56±0.04kg}

—

4.40 N {0.45 kg}

2


16.0 × 16.0

12.0

5.70 N {0.58 kg}

—

4.50 N {0.46 kg}

3

Piston spring

20.0 × 7.0

14.0

1.20 N {0.12 kg}

—

0.98 N {0.10 kg}

PC128US-2

Replace spring if any damages or deformations are found

40-19 (15)

MAINTENANCE

STANDARD

CONTROL VALVE

2

‘2

B-B

9JYOOO59

Unit: mm

No -

Check

item

Criteria Standard Fryg;gth

1

. .

Spool return spring

lrx;Azd

I

Remedy

size

Repair limit Installed load

Free length

Installed load

184N 0

Spool return spring

45.7

x

28.0

Spool return spring

42.4

X

26.0

40-20

43.0

222+13.7N {22.6+1.40kg)

-

a.8kg)

178N (la.1 kg}


PC1 28U.S2


CONTROL VALVE

(4/9)

Unit: mm

No.

Check item


1

Flow control valve spring

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

36.2 × 5.30

32.0

9.81±0.98N {1.0±0.10kg}

—

7.85 N {0.80 kg}

2

Pressure reduction valve spring

27.5 × 14.2

18.0

17.7±0.98N {1.80±0.10kg}

—

13.7 N {1.40 kg}

3


28.2 × 14.5

26.0

29.4±2.94N {3.0±0.30kg}

—

23.5 N {2.40 kg}

4


24.1 × 15.0

14.5

9.81±0.98N {1.0±0.10kg}

—

7.85 N {0.80 kg}

5

Relief valve spring

17.1 × 9.0

15.5

74.5 N {7.60 kg}

—

59.8 N {6.10 kg}

6


32.5 × 14.2

23

17.6 N {1.8 kg}

—

14.1 N {1.44 kg}

PC128US-2


40-21 (15)


CONTROL VALVE

(5/9)

Unit: mm

No.

Check item


1

2

Check valve spring

Check valve spring

40-22 (15)

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

41.5 × 8.50

31.5

5.88 N {0.60 kg}

—

4.71 N {0.48 kg}

20.3 × 13.7

15.6

3.14 N {0.32 kg}

—

2.25 N {0.26 kg}


PC128US-2


CONTROL VALVE

(6/9)

Unit: mm

No.

Check item


1

2

Lift check valve spring Cooler bypass valve spring

Bleed spool return spring

PC128US-2

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

72.7 × 20.6

42.5

135±4.90N {13.8±0.50kg}

—

113 N {11.5 kg}

23.3 × 12.5

23.0

3.92±0.98N {0.40±0.10kg}

—

2.94 N {0.30 kg}


40-23 (15)


CONTROL VALVE

(7/9)

Unit: mm

No.

1

Check item

Travel junction spool return spring

Criteria

Free length × O.D. 17.7 × 8.20

40-24

Standard size Installed Installed length load 13.0

13.7±0.10N {1.40±0.10kg}

Remedy Repair limit Installed Free length load —

10.1 N {1.10 kg}


PC128US-2


CONTROL VALVE

(8/9)

Unit: mm

No.

Check item


1

Lift check valve spring

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

26.1 × 17.0

25.0

26.5±1.57N {2.70±0.16kg}

—

21.2 N {2.16 kg}

2

Piston return spring

23.7 × 7.70

12.0

1.94 N {0.30 kg}

—

2.35 N {0.24 kg}

3

Check valve spring

41.5 × 8.50

31.5

5.88 N {0.60 kg}

—

4.71 N {0.48 kg}

PC128US-2


40-25 (15)


CONTROL VALVE

(9/9)

40-26 (15)

PC128US-2


CONTROL VALVE

FOR KUK SPEC. PC128US-2 9 spool valve (6-spool valve + Blade valve + Full-flow service valve + Half-flow service valve)

40-26-2 (15)

PC128US-2


CONTROL VALVE

(1/8)

Unit: mm

No.

Check item


1


Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

46.8 × 7.50

40.6

5.50±0.40N {0.56±0.04kg}

—

4.40 N {0.45 kg}

2


16.0 × 16.0

12.0

5.70 N {0.58 kg}

—

4.50 N {0.46 kg}

3

Piston spring

10.5 × 7.0

6.8

2N {0.21 kg}

—

1.6 N {0.17 kg}

PC128US-2


40-26-3 (15)


CONTROL VALVE

(2/8)

Unit: mm

No.

Check item


1

Spool return spring

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

45.6 × 28.0

43.0

230±14.7N {23.5±1.50kg}

—

184 N {18.8 kg}

2

Spool return spring

45.7 × 28.0

43.0

222±13.7N {22.6±1.40kg}

—

178 N {18.1 kg}

3

Spool return spring

42.4 × 28.0

39.0

222±13.7N {22.6±1.40kg}

—

178 N {18.1 kg}

40-26-4 (15)


PC128US-2


CONTROL VALVE

(3/8)

Unit: mm

No.

Check item

Criteria Standard size Repair limit Free length Installed Installed Installed Free length × O.D. length load load 7.85 N 9.81±0.98N 36.2 × 5.30 32.0 — {0.80 kg} {1.0±0.10kg}

1

Flow control valve spring

2


27.5 × 14.2

18.0

28.2 × 14.5

26.0

4

Pressure reduction valve spring Pressure reduction valve spring

24.1 × 15.0

14.5

5

Relief valve spring

17.1 × 9.0

15.5

9.81±0.98N {1.0±0.10kg} 74.5 N {7.60 kg}

6


32.5 × 14.2

23.0

33.3±2N {3.4±0.2kg}

3

PC128US-2

Remedy

17.7±0.98N {1.80±0.10kg} 29.4±2.94N {3.0±0.30kg}

— —

13.7 N {1.40 kg} 23.5 N {2.40 kg}

—

7.85 N {0.80 kg} 59.8 N {6.10 kg}

—

26.6 N {2.7 kg}

—


40-26-5 (15)


CONTROL VALVE

(4/8)

Unit: mm

No.

Check item


1

2

Check valve spring

Check valve spring

40-26-6 (15)

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

41.5 × 8.50

31.5

5.88 N {0.60 kg}

—

4.71 N {0.48 kg}

20.3 × 13.7

15.6

3.14 N {0.32 kg}

—

2.25 N {0.26 kg}


PC128US-2


CONTROL VALVE

(5/8)

Unit: mm

No.

Check item


1

2

Lift check valve spring Cooler bypass valve spring

Bleed spool return spring

PC128US-2

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

72.7 × 20.6

42.5

135±4.90N {13.8±0.50kg}

—

113 N {11.5 kg}

23.3 × 12.5

23.0

3.92±0.98N {0.40±0.10kg}

—

2.94 N {0.30 kg}


40-26-7 (15)


CONTROL VALVE

(6/8)

Unit: mm

No.

1

Check item

Travel junction spool return spring

Criteria

Free length × O.D. 17.7 × 8.20

40-26-8 (15)

Standard size Installed Installed length load 13.0

13.7±0.10N {1.40±0.10kg}

Remedy Repair limit Installed Free length load —

10.1 N {1.10 kg}


PC128US-2


CONTROL VALVE

(7/8)

Unit: mm

No.

Check item


1

Lift check valve spring

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

26.1 × 17.0

25.0

26.5±1.57N {2.70±0.16kg}

—

21.2 N {2.16 kg}

2

Piston return spring

23.7 × 7.70

12.0

1.94 N {0.30 kg}

—

2.35 N {0.24 kg}

3

Check valve spring

41.5 × 8.50

31.5

5.88 N {0.60 kg}

—

4.71 N {0.48 kg}

PC128US-2


40-26-9 (15)


CONTROL VALVE

(8/8)

40-26-10 (15)

PC128US-2


SUCTION SAFETY VALVE

SUCTION SAFETY VALVE FOR SERVICE VALVE

Unit: mm

No.

Check item


1

2


Piston spring

PC128US-2

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

16.3 × 21.3

9.50

2.06 N {0.21 kg}

—

1.57 N {0.16 kg}

20.0 × 7.0

14.0

2.06 N {0.21 kg}

—

1.57 N {0.16 kg}


40-27 (15)


SELF PRESSURE REDUCTION VALVE

SELF PRESSURE REDUCTION VALVE

Unit: mm

No.

Check item


1

Spring (pressure reduction main)

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

19.2 × 7.20

16.1

19.6 N {2.0 kg}

—

17.7 N {1.80 kg}

2

Spring (pressure reduction valve pilot)

16.5 × 7.20

12.7

20.6 N {2.10 kg}

—

18.6 N {1.90 kg}

3

Spring

71.0 × 18.0

59.0

200 N {20.4 kg}

—

186 N {19.0 kg}

4

Spring (safety valve)

16.1 × 7.80

13.4

61.7 N {6.30 kg}

—

58.8 N {6.0 kg}

40-28


PC128US-2


TRAVEL MOTOR

TRAVEL MOTOR GM18VL-J : PC128US-2 GM20VL-J : PC128US-2 GM20VL-P : PC128US-2 PC138USLC-2 GM20VL2-P : PC138US-2 PC138USLC-2

PC128US-2

STD OPT (Traction up) OPT (Traction up) STD STD STD

(Serial No. 5001 and up) (Serial No. 5001 – 6072) (Serial No. 6073 and up) (Serial No. 1001 – 1500) (Serial No. 4501 and up) (Serial No. 1501 and up)

40-29 (15)


SWING MOTOR

SWING MOTOR KMF40ABE-3

Unit: mm

No.

Check item


1

Check valve spring

2

Shuttle valve spring

40-30 2

Free length × O.D.

Remedy Repair limit

Installed length

Installed load

Free length

Installed load

23.0

1.28 N {0.13 kg}

—

0.98 N {0.10 kg}

33.0 × 13.8 16.4 × 8.90

11.5

13.7 N {1.40 kg}

—

10.8 N {1.10 kg}


PC128US-2

MAINTENANCE

STANDARD

SOLENOID

VALVE

SOLENOID VALVE FOR PPC LOCK, 2ND TRAVEL SPEED SELECTOR, SWING AND PARK BRAKE, AND 2STAGE RELIEF SOLENOID VALVE

21.6*2.2Nm (2.2*0.22kPml B-B

PC1 28US-2

40-31


CENTER SWIVEL JOINT

CENTER SWIVEL JOINT STD (WITHOUT BLADE)

Unit: mm

No.

Check item


Clearance between rotor and shaft

1

40-32 A

Remedy

Standard clearance

clearance limit

0.056 – 0.105

0.111

Replace 80

PC128US-2


CENTER SWIVEL JOINT

OPT (WITH BLADE)

Unit: mm

No.

Check item


1

Clearance between rotor and shaft

PC128US-2

Remedy

Standard clearance

clearance limit

0.056 – 0.105

0.111

Replace 80

40-33 A


PPC VALVE

PPC VALVE FOR SWING, WORK EQUIPMENT

PC128US-2 Serial No.: 5001 – 7730 No.

1

Unit: mm

Check item

Centering spring (for P3 and P4 ports)

Criteria Standard size Free length Installed Installed × O.D. length load

Remedy Repair limit Installed Free length load

44.45 × 15.5

34.0

29.42 N {3.0 kg}

—

23.5 N {2.4 kg}

2


47.93 × 15.5

34.0

39.22 N {4.0 kg}

—

31.4 N {3.2 kg}

3

Metering spring

26.53 × 8.15

24.9

17.0 N {1.70 kg}

—

13.3 N {1.36 kg}

40-34 (15)


PC128US-2


PC128US-2 PC128US-2 PC138US-2 PC138USLC-2 No.

1

PPC VALVE

Serial No.: 7731 and up Serial No.: 5001 and up (For KUK spec.) Serial No.: 4501 and up Serial No.: 1001 and up

Check item


Unit: mm

Criteria

Free length × O.D.

Standard size Installed Installed length load


42.48 × 15.5

34.0

17.65 N {1.80 kg}

—

14.1 N {1.44 kg}

2


47.93 × 15.5

34.0

39.22 N {4.0 kg}

—

31.4 N {3.2 kg}

3

Metering spring

26.53 × 8.15

24.9

17.0 N {1.70 kg}

—

13.3 N {1.36 kg}

PC128US-2


40-34-1 (15)


PPC VALVE

FOR TRAVEL PC128US-2 Serial No.: 5001 – 6300

Unit: mm

No.

Check item


1

2

Metering spring

Centering spring

PC128US-2

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

26.5 × 8.15

24.9

16.7 N {1.70 kg}

—

13.7 N {1.40 kg}

48.6 × 15.5

32.5

108 N {11.0 kg}

—

86.3 N {8.80 kg}


40-35 (15)


PPC VALVE


Unit: mm

No.

Check item


1

2

Metering spring

Centering spring

40-35-1 (15)

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

26.5 × 8.15

24.9

16.7 N {1.70 kg}

—

13.7 N {1.40 kg}

48.1 × 15.5

32.5

108 N {11.0 kg}

—

86.3 N {8.80 kg}


PC128US-2


PPC VALVE

FOR BLADE, FOR SERVICE

For blade No.

1

2

Unit: mm

Check item

Centering spring

Metering spring

Criteria

Remedy

Standard size Free length Installed Installed × O.D. length load

Repair limit Installed Free length load —

100 N {10.2 kg}

—

13.3 N {1.36 kg}

33.9 × 15.3

28.4

124.5 N {12.7 kg}

22.7 × 8.10

22.0

16.7 N {1.70 kg}

For service No.

Unit: mm

Check item


1

2

Centering spring

Metering spring

40-36 (15)


Free length × O.D.

Remedy Repair limit

Installed length

Installed load

Free length

Installed load

28.4

207.8 N {21.2 kg}

—

167 N {17.0 kg}

42.4 × 15.5 22.7 × 8.10

22.0

16.7 N {1.70 kg}

—

13.3 N {1.36 kg}


PC128US-2



BOOM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC.) PC128US-2 Serial No.: 5001 – 7730

Unit: mm

No.

1

Check item

Pilot spool spring



31.75 × 8.5

25.0

29.4 N {3.0 kg}

—

23.5 N {2.4 kg}

2

Check valve spring

24.5 × 11.6

18.0

4.9 N {0.5 kg}

—

3.9 N {0.4 kg}

3

Spool return spring

30.9 × 20.6

29.0

69.6 N {7.1 kg}

—

55.9 N {5.7 kg}

PC128US-2


40-37 C




Unit: mm

No.

Check item


1

Pilot spool spring

Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

31.75 × 8.5

25.0

29.4 N {3.0 kg}

—

23.5 N {2.4 kg}

2

Check valve spring

24.5 × 11.6

18.0

4.9 N {0.5 kg}

—

3.9 N {0.4 kg}

3

Spool return spring

30.9 × 20.6

29.0

69.6 N {7.1 kg}

—

55.9 N {5.7 kg}

40-37-1 (15)


PC128US-2



ARM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC.) (If equipped) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up

Unit: mm

No.

1

Check item

Check valve spring



25.4 × 11.6

18

4.9 N {0.5 kg}

—

3.9 N {0.4 kg}

2

Spool return spring

31.8 × 8.5

25

29.4 N {3.0 kg}

—

23.5 N {2.4 kg}

3

Spool return spring

30.9 × 20.6

29

69.6 N {7.1 kg}

—

55.7 N {5.7 kg}

PC128US-2

If damaged or deformed, replace spring

40-37-2 (15)

MAINTENANCE

STANDARD

HYDRAULIC

HYDRAULIC

CYLINDER

CYLINDER

BOOM CYLINDER 2

4

1

5

3

9JA01392

ARM CYLINDER

9JA01393

BUCKET CYLINDER

9JA01394

BLADE CYLINDER

9JAOl395

40-38 0

PC128US-2


HYDRAULIC CYLINDER

PC128US-2 Serial No.: 5001 and up PC138USLC-2 Serial No.: 1001 – 1500 No.

Check item Cylinder Boom

1

2

3

Clearance between piston rod Arm and bushing

5

6

Cylinder piston tightening torque

Cylinder piston lock screw tightening torque

PC128US-2

ø 70 ø 75

Blade

ø 75

Boom

ø 70 ø 70 ø 65

Blade

ø 70

Boom

ø 70

Clearance beArm tween cylinder bottom support shaft and bushing Bucket

Cylinder head tightening torque

Standard size

ø 65

Blade

4

Criteria

Bucket

Clearance beArm tween piston rod support shaft and Bucket bushing

Unit: mm

ø 70 ø 65 ø 70

Tolerance Shaft Hole +0.259 – 0.030 +0.063 – 0.076 +0.279 – 0.030 +0.065 – 0.076 +0.250 – 0.030 +0.055 – 0.076 +0.279 – 0.030 +0.065 – 0.076 +0.198 – 0.030 +0.124 – 0.100 +0.198 – 0.030 +0.124 – 0.100 +0.174 – 0.030 +0.100 – 0.080 +0.198 – 0.030 +0.124 – 0.100 +0.198 – 0.030 +0.124 – 0.100 +0.198 – 0.030 +0.124 – 0.100 +0.174 – 0.030 +0.100 – 0.080 +0.198 – 0.030 +0.124 – 0.100

Remedy Standard clearance

Clearance limit

0.093 – 0.335 0.095 – 0.355 0.085 – 0.326 0.095 – 0.355 0.154 – 0.298 0.154 – 0.298 0.130 – 0.254 0.154 – 0.298 0.154 – 0.298 0.154 – 0.298 0.130 – 0.254 0.154 – 0.298

0.435

Boom

171.6 ± 24.5 Nm {17.5 ± 2.5 kgm}

Arm

269.7 ± 39.2 Nm {27.5 ± 4.0 kgm}

Bucket

171.6 ± 24.5 Nm {17.5 ± 2.5 kgm}

Blade

269.7 ± 39.2 Nm {27.5 ± 4.0 kgm}

Boom

294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}

Arm

294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}

Bucket

294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}

Blade

294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}

Boom

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

Arm

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

Bucket

30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}

Blade

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

0.455 0.426 0.455 1.0 1.0

Replace bushing

1.0 1.0 1.0 1.0 1.0 1.0

Re-tightening

40-39 (15)


HYDRAULIC CYLINDER

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

Check item Cylinder Boom

1

2

3

Clearance between piston rod Arm and bushing

5

6

Cylinder piston tightening torque

Cylinder piston lock screw tightening torque

40-40 (15)

ø 70 ø 75

Blade

ø 75

Boom

ø 70 ø 70 ø 65

Blade

ø 70

Boom

ø 70

Clearance beArm tween cylinder bottom support shaft and bushing Bucket

Cylinder head tightening torque

Standard size

ø 65

Blade

4

Criteria

Bucket

Clearance beArm tween piston rod support shaft and Bucket bushing

Unit: mm

ø 70 ø 65 ø 70

Tolerance Shaft Hole +0.259 – 0.030 +0.063 – 0.076 +0.279 – 0.030 +0.065 – 0.076 +0.250 – 0.030 +0.055 – 0.076 +0.279 – 0.030 +0.065 – 0.076 +0.190 – 0.030 +0.070 – 0.100 +0.190 – 0.030 +0.070 – 0.100 +0.170 – 0.030 +0.070 – 0.080 +0.170 – 0.030 +0.070 – 0.100 +0.190 – 0.030 +0.070 – 0.100 +0.190 – 0.030 +0.070 – 0.100 +0.170 – 0.030 +0.070 – 0.080 +0.170 – 0.030 +0.070 – 0.100

Remedy Standard clearance

Clearance limit

0.093 – 0.335 0.095 – 0.355 0.085 – 0.326 0.095 – 0.355 0.100 – 0.290 0.100 – 0.290 0.100 – 0.250 0.100 – 0.270 0.100 – 0.290 0.100 – 0.290 0.100 – 0.250 0.100 – 0.270

0.435

Boom

172 ± 24.5 Nm {17.5 ± 2.5 kgm}

Arm

270 ± 39 Nm {27.5 ± 4.0 kgm}

Bucket

172 ± 24.5 Nm {17.5 ± 2.5 kgm}

Blade

270 ± 39 Nm {27.5 ± 4.0 kgm}

Boom

294 ± 29.4 Nm {30.0 ± 3.0 kgm}

Arm

294 ± 29.4 Nm {30.0 ± 3.0 kgm}

Bucket

294 ± 29.4 Nm {30.0 ± 3.0 kgm}

Blade

294 ± 29.4 Nm {30.0 ± 3.0 kgm}

Boom

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

Arm

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

Bucket

30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}

Blade

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

0.455 0.426 0.455 1.0 1.0

Replace bushing

1.0 1.0 1.0 1.0 1.0 1.0

Re-tightening

PC128US-2

MAINTENANCE

STANDARD

WORK EQUIPMENT

WORK EQUIPMENT

9JAOI396

PC1 28US-2

40-4 1

MAINTENANCE

WORK EQUIPMENT

STANDARD

c-c

B-B

A-A

M-M

L-L

K-K

J-J

H-H

G-G

F-F

E-E

D-D

N-N

P-P 9JA01397

40-42

PC1 28US-2


WORK EQUIPMENT

Unit: mm

No.

Check item

1

Clearance between connecting pin and bushing of revolving frame and boom.

2 3 4 5 6 7

Clearance between connecting pin and bushing of boom and arm. Clearance between connecting pin and bushing of arm and link. Clearance between connecting pin and bushing of arm and bucket. Clearance between connecting pin and bushing of link and bucket. Clearance between connecting pin and bushing of link and link. Clearance between the blade and track frame mounting pin and bushing

PC128US-2


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

70

– 0.030 – 0.100

+0.130 +0.065

0.095 – 0.230

0.8

70

– 0.030 – 0.100

+0.141 +0.074

0.104 – 0.241

0.8

60

– 0.030 – 0.080

+0.129 +0.074

0.104 – 0.209

0.8

60

– 0.030 – 0.080

+0.135 +0.074

0.104 – 0.215

0.8

65

– 0.030 – 0.080

+0.133 +0.074

0.104 – 0.213

0.8

60

– 0.030 – 0.080

+0.130 +0.074

0.104 – 0.210

0.8

70

– 0.030 – 0.100

+0.198 +0.124

0.154 – 0.298

1.5

Replace

40-43 A


DIMENSION

DIMENSION OF WORK EQUIPMENT

OF WORK EQUIPMENT

FOR STD ARM

A-A

B-B

c-c 9JA01398

40-44 0

PC128US-2



Unit: mm PC138US-2 PC138USLC-2 No. Measuring position

Standard size

—

ø 70

1

Tolerance Shaft

Hole

– 0.030 – 0.100

+0.100 0

Arm side

81.5

+1.0 0

Cylinder head side

80

± 1.2

Boom side

226

+0.5 0

Arm side

226

– 0.2 – 0.7

2

3

– 0.030 – 0.100

+0.100 0

4

—

ø 70

5

—

264

± 2.0

6

—

213.5

± 1.0

7

—

640.6

± 0.5

8

—

2,491

9

—

2,101.9

± 1.5

10

—

290.4

± 0.5

11

—

487

± 0.2

12

—

415

± 0.5

13

—

374.9

—

14

—

1,246.2

—

15

—

ø 60

—

– 0.030 – 0.080

+0.200 0

Link side

259

0 – 0.1

Bucket side

261

± 1.0

16

17

—

ø 60

– 0.030 – 0.080

+0.200 0

Arm side

226

0 – 0.5

Bucket side

274

+2.0 0

18

Min.

1,378

—

Max.

2,263

—

19

40-45-1 (15)

PC128US-2



Unit: mm PC138US-2 PC138USLC-2 No. Measuring position

Standard size

—

ø 70

1

Tolerance Shaft

Hole

– 0.030 – 0.100

+0.100 0

Arm side

81.5

+1.0 0

Cylinder head side

80

± 1.2

Boom side

226

+0.5 0

Arm side

226

– 0.2 – 0.7

2

3

ø 70

– 0.030 – 0.100

+0.100 0

4

—

5

—

284.3

± 2.0

6

—

230.3

± 1.0

7

—

635.8

± 1.0

8

—

2,991.1

—

9

—

2,098.9

± 1.5

10

—

289.8

± 0.5

11

—

487

± 0.2

12

—

415

± 0.5

13

—

374.9

—

14

—

1,246.2

—

15

—

ø 60

– 0.030 – 0.080

+0.200 0

Link side

259

0 – 1.0

Bucket side

261

± 1.0

16

17

—

ø 60

– 0.030 – 0.080

+0.200 0

Arm side

226

0 – 0.5

Bucket side

274

+2.0 0

18

Min.

1,378

—

Max.

2,263

—

19

40-45-5 (15)

PC128US-2



Unit: mm PC138US-2 PC138USLC-2

No. Measuring position

Standard size

—

ø 70

1

Tolerance Shaft

Hole

– 0.030 – 0.100

+0.100 0

Arm side

81.5

+1.0 0

Cylinder head side

80

± 1.2

Boom side

226

+0.5 0

Arm side

226

– 0.2 – 0.7

2

3

ø 70

– 0.030 – 0.100

+0.100 0

4

—

5

—

280.5

± 2.0

6

—

213.0

± 1.0

7

—

640.7

± 1.0

8

—

2,088.5

—

9

—

2,101.7

± 1.5

10

—

290.0

± 0.5

11

—

487

± 0.2

12

—

415

± 0.5

13

—

374.9

—

14

—

1,246.2

—

15

—

ø 60

– 0.030 – 0.080

+0.200 0

Link side

259

0 – 1.0

Bucket side

261

± 1.0

16

17

—

ø 60

– 0.030 – 0.080

+0.200 0

Arm side

226

0 – 0.5

Bucket side

274

+2.0 0

18

Min.

1,378

—

Max.

2,263

—

19

40-45-9 (15)

PC128US-2

MAINTENANCE

STANDARD

DIMENSION

OF WORK EQUIPMENT

Unit:mm PC128US-2

No.

Measuring position

Standard size

I -

371.3

2

-

51.6

3

-

97.9'

-

4

I

I -

6

I

7

I

9

11

12

I

73

I--

14 15

I

~.

374.9 -

Tolerance

I

i 0.5 -

I -

1,I 59.6

-

zk0.5

-

190.5

-

5'

-

-

0'

+0.2 0

-

0 60

-

0 64

-

0 80

+0.25 0

-

261

t 1.0

I

-

-

50

-

-

85

-

-

I

380

I

+l.O 0

16

-

018

-

17

-

0110

-

-

0130

-

0132

-

0108

19

-

I

21 22 23

I

-

274

-

-

51

-

-

34

-

106.7

-

124.3

-

25

-

26

-

74

-

27

-

65

-

PC128US-2

40-47



Unit: mm PC138US-2 PC138USLC-2

No. Measuring position

Standard size

Tolerance

1

—

371.3

± 0.5

2

—

51.6

± 0.5

3

—

97.9˚

—

4

—

374.9

—

5

—

1,231.6

—

6

—

190.2

—

7

—

5˚

—

8

—

0˚

—

9

—

ø 60

+0.2 0

10

—

ø 64

—

11

—

ø 80

+0.25 0

12

—

261

± 1.0

13

—

50

—

14

—

85

—

15

—

380

+1.0 0

16

—

ø 18

—

17

—

ø 110

—

18

—

ø 130

—

19

—

ø 132

—

20

—

ø 108

—

21

—

274

—

22

—

51

—

23

—

34

—

24

—

104.2

—

25

—

119.6

—

26

—

74

—

27

—

65

—

40-47-1 (15)

PC128US-2

90 OTHERS Hydraulic circuit diagram (Attachment) (Breaker : 1 service valve : 50% amount) ..................................................... 90- 3 Hydraulic circuit diagram (Attachment) (Crasher : 1 service valve : 100% amount) ................................................... 90- 5 Hydraulic circuit diagram (Attachment) (Crasher : 2 service valve : 100% amount) .................................................. 90-5-2 Electric circuit diagram (Air conditioner) PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 7 Electric circuit diagram (Air conditioner) PC128US-2 (Serial No.: 7731 and up) PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-7-2 Hydraulic circuit diagram PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 9 Hydraulic circuit diagram PC128US-2 (Serial No.: 7731 and up) PC138US-2 (Serial No.: 4501 and up) PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-9-2 Hydraulic circuit diagram (With 1 actuator attachment) PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 11 Hydraulic circuit diagram PC128US-2 (Serial No.: 7731 and up) PC138US-2 (Serial No.: 4501 and up) PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-11-2 Hydraulic circuit diagram (With blade + 1 actuator attachment) PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 13 Hydraulic circuit diagram (With blade + 1 actuator attachment) PC128US-2 (Serial No.: 7731 and up) PC138US-2 (Serial No.: 4501 and up) PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-13-2 Hydraulic circuit diagram (For KUK spec.) PC128US-2 (Serial No.: 5001 – 7730) ..................................................... 90-13-4 Hydraulic circuit diagram (For KUK spec.) PC128US-2 (Serial No.: 7731 and up) PC138US-2 (Serial No.: 4501 and up) .................................................... 90-13-6 Hydraulic circuit diagram (With 2 actuator attachment) (For KUK spec.) PC128US-2 (Serial No.: 5001 – 7730) ..................................................... 90-13-8 Hydraulic circuit diagram (With 2 actuator attachment) (For KUK spec.) PC128US-2 (Serial No.: 7731 and up) PC138US-2 (Serial No.: 4501 and up) .................................................. 90-13-10 Electric circuit diagram (1/2) PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-15 Electric circuit diagram (2/2) PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-17

PC128US-2

90-1 (15)

Electric circuit diagram (1/2) PC128US-2 (Serial No.: 6301 – 7730) ..................................................... 90-17-2 Electric circuit diagram (2/2) PC128US-2 (Serial No.: 6301 – 7730) ..................................................... 90-17-4 Electric circuit diagram (1/2) PC128US-2 (Serial No.: 7731 – 7874) ..................................................... 90-17-6 Electric circuit diagram (2/2) PC128US-2 (Serial No.: 7731 – 7874) ..................................................... 90-17-8 Electric circuit diagram (1/2) PC128US-2 (Serial No.: 7875 and up) PC138USLC-2 (Serial No.: 1001 – 1500) ................................................... 90-17-10 Electric circuit diagram (2/2) PC128US-2 (Serial No.: 7875 and up) PC138USLC-2 (Serial No.: 1001 – 1500) ................................................... 90-17-12 Electric circuit diagram (1/3) PC138US-2 (Serial No.: 4501 and up) PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-14 Electric circuit diagram (2/3) PC138US-2 (Serial No.: 4501 and up) PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-16 Electric circuit diagram (3/3) PC138US-2 (Serial No.: 4501 and up) PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-18 Electric circuit diagram (For KUK spec.) (1/2) PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-19 Electric circuit diagram (For KUK spec.) (2/2) PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-21 Electric circuit diagram (For KUK spec.) (1/2) PC128US-2 (Serial No.: 6301 – 7730) ........................................................ 90-23 Electric circuit diagram (For KUK spec.) (2/2) PC128US-2 (Serial No.: 6301 – 7730) ........................................................ 90-25 Electric circuit diagram (For KUK spec.) (1/2) PC128US-2 (Serial No.: 7731 and up) ....................................................... 90-27 Electric circuit diagram (For KUK spec.) (2/2) PC128US-2 (Serial No.: 7731 and up) ....................................................... 90-29 Electric circuit diagram (For KUK spec.) (1/3) PC138US-2 (Serial No.: 4501 and up) ....................................................... 90-31 Electric circuit diagram (For KUK spec.) (2/3) PC138US-2 (Serial No.: 4501 and up) ....................................................... 90-33 Electric circuit diagram (For KUK spec.) (3/3) PC138US-2 (Serial No.: 4501 and up) ....................................................... 90-35

90-2 (15)

PC128US-2

HYDRAULIC

OTHERS

CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT) (BREAKER : 1 SERVICE VALVE : 50% AMOUNT)

SERVICE I (PPC valve)

Selector valve ~2 __-__--__

Ii

IPl P2 I L-_-__*--__-_qL____-_XL__f\ I A7 !__

-c---i

87

SERVICE I -

I

I _!

Bl I

-f2 -

--Al

71

Control valve

Main Puma

PC1 28US-2

SXPO7808

90-3

HYDRAULIC

OTHERS

HYDRAULIC CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

(ATTACHMENT)

(CRASHER : 1 SERVICE VALVE : 100% AMOUNT)

SERVICE I (PPC valve) Lock Din (Large amount)

--i I I

Ii

I-

!--C

SERVICE

A7 -

1

To oil

cooler

Crusher ilOO% amount1

SXPO7809

PC1 28US-2

90-5

OTHERS

HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT) (CRASHER : 2 SERVICE VALVE : 100% AMOUNT)

PC128US-2

90-5-2 A

HYDRAULIC CIRCUIT DIAGRAM PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Serial No.: 1501 and up

PC128US-2

90-9-2 (15)

HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACTUATOR ATTACHMENT) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up

*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Serial No.: 1501 and up

PC128US-2

90-11-2 (15)

HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 and up *1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Serial No.: 1501 and up

PC128US-2

90-13-2 (15)

HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up

*1. PC128US-2 Serial No.: 7731 and up

PC128US-2


90-13-6 (15)

HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.) PC128US-2 Serial No.: 7731 and up PC138US-2 Serial No.: 4501 and up


PC128US-2


90-13-10 (15)

9JB00694 ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2

PC128US-2

Serial No.: 7731 – 7874

90-17-6 A

ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2

PC128US-2

9JB00695

Serial No.: 7731 – 7874

90-17-8 A

ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 Serial No.: 7875 and up PC138USLC-2 Serial No.: 1001 – 1500

PC128US-2

90-17-10 (15)

ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 Serial No.: 7875 and up PC138USLC-2 Serial No.: 1001 – 1500

PC128US-2

90-17-12 (15)

ELECTRIC CIRCUIT DIAGRAM (1/3) PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up

PC128US-2

90-17-14 (15)


PC128US-2

90-17-16 (15)


PC128US-2

90-17-18 (15)

ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2) PC128US-2 Serial No.: 7731 and up

PC128US-2

90-27 (15)


PC128US-2

90-29 (15)


PC128US-2

90-31 (15)


PC128US-2

90-33 (15)


PC128US-2

90-35 (15)

PC128US-2 SEBM018419.PDF

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