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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.
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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.
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.
00-3
SAFETY
00-4
SAFETY NOTICE
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.
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
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.
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
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
Caution
Weight
Tightening
torque
Coat
Oil, water
Drain
4
3
2
5
6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
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
100%
88%
79%
71%
41%
SAD00479
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
00-7
FOREWORD
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
Disassembly
Type 2
Connection
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
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
Polyethylene
container
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
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
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 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
Various
00-11
FOREWORD
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
SAD00483
Thread diameter
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
Thread diameter
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
Thread diameter
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
Thread diameter
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
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
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
103 {10.5}
22
13
- 16UN
16
20.7
05
32
157 {16.0}
24
1 - 14UNS
25.4
06
36
216 {22.0}
30
3
1 - 12UNF
16
30.3
(10)
41
216 {22.0}
33
(12)
46
245 {25.0}
36
(14)
55
294 {30.0}
42
02
03
00-14
FOREWORD
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
0.32
2.09
3.1
20
65
0.32
5.23
4.6
37
15
84
0.45
13.36
7.0
59
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
26
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
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
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
n
n
n
n
RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
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
B
Millimeters to inches
1 mm = 0.03937 in
00-16
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
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
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
Kilogram to Pound
1 kg = 2.2046 lb
0
0
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
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
0.220
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
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
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
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.
1C = 33.8F
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
PC 128US-2
Ol- 2
Ol- 5
01-11
01-15
01-l
GENERAL
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
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
Overall length
A'
mm
1,480
mm
3,480
mm
2,750
H Cab height
mm
2,810
mm
390
km/h
3.2/5.1
rpm
11.0
PC128US-2
01-4-3
(15)
GENERAL
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
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
Overall length
A'
mm
1,480
mm
3,610
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
Item
PC138USLC-2
Unit
Standard specification
Machine weight
Blade specification
0.50
Engine type
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
14,000
kg
Bucket capacity
A'
1001 1500
2,850
2,590
2,515
mm
Blade specification
600
500
mm
1,480
mm
3,880
mm
3,140
Cab height
mm
2,815
mm
395
km/h
2.9/4.7
rpm
11.0
PC128US-2
01-4-5
(15)
GENERAL
Item
PC138USLC-2
Unit
Standard specification
Machine weight
Blade specification
0.50
Engine type
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
mm
Blade specification
Overall height
C'
14,370
m3
14,000
kg
Bucket capacity
A'
1501 and up
2,850
2,590
2,515
mm
Blade specification
600
500
mm
1,480
mm
3,870
mm
3,140
Cab height
mm
2,815
mm
395
km/h
2.9/5.1
rpm
11.0
01-4-6
(15)
PC128US-2
GENERAL
PC128US-2
Working range (mm)
7731 and up
8,230
5,405
9,260
4,860
6,910
1,980
8,110
470
530
PC128US-2
01-4-7
(15)
GENERAL
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
PC138US-2
PC138USLC-2
4501 and up
1001 and up
8,300
5,480
9,340
4,900
6,840
1,980
8,180
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
m3
0.45
0.45
Operating weight
kg
12,950
13,450
mm
5,445
5,445
mm
5,235
5,235
Working ranges
Performance
With blade
mm
4,900
4,900
mm
mm
8,230
8,110
8,230
8,110
mm
mm
9,220
6,870
9,220
6,870
mm
mm
470 [535]
530 [465]
KN {kg}
93.2 {9,500}
93.2 {9,500}
rpm
11.0
11.0
rpm
12
12
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
2,490
2,490
mm
2,490
2,490
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]
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 [ ] 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
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}
rpm
2,400
rpm
950
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type
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 system
12V, 64 Ah x 2
Type x no.
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
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
Hydraulic cooler
01-6
(15)
With blade
PC128US-2
SPECIFICATIONS
GENERAL
PC128US-2
Machine model
Serial No.
5001 7730
Boom cylinder
Type
105
105
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
mm
115
115
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
mm
95
95
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
Blade cylinder
mm
Type
Bucket cylinder
Hydraulic system
Type
PC128US-2
mm
115
mm
75
Stroke
mm
181
mm
870
mm
689
01-7
A
SPECIFICATIONS
GENERAL
Serial No.
5001 7730
m3
0.45
0.45
Operating weight
kg
13,100
13,600
mm
5,445
5,445
mm
5,235
5,235
Working ranges
Performance
mm
4,900
4,900
mm
8,230
8,230
mm
8,110
8,110
mm
9,220
9,220
mm
6,870
6,870
mm
470 [535]
mm
530 [465]
KN {kg}
93.2 {9,500}
93.2 {9,500}
rpm
11.0
11.0
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]
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
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
S4D102E-1
4-cycle, water-cooled, in-line, vertical,
direct injection, with turbochatger
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}
rpm
2,400
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
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
/min
MPa {kg/cm2}
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
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
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
PC128US-2
01-9
(15)
GENERAL
SPECIFICATIONS
PC128US-2
Machine model
Without blade
Serial No.
5001 7730
Boom cylinder
Type
105
105
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
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
95
95
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
mm
75
Stroke
mm
181
mm
870
mm
689
PC128US-2
SPECIFICATIONS
GENERAL
Without blade
Serial No.
5001 7730
m3
0.36
0.36
Operating weight
kg
12,750
13,250
mm
5,945
5,945
mm
5,760
5,760
mm
5,385
5,385
mm
8,720
8,720
mm
8,600
8,600
Working ranges
Performance
With blade
mm
9,655
9,655
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
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]
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
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
S4D102E-1
4-cycle, water-cooled, in-line, vertical,
direct injection, with turbochatger
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}
rpm
2,400
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
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
/min
MPa {kg/cm2}
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
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
01-10-2
(15)
] are those for the machines when the road liner shoe is equipped.
PC128US-2
GENERAL
SPECIFICATIONS
PC128US-2
Machine model
Serial No.
5001 7730
Boom cylinder
Type
105
105
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
mm
115
115
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
mm
95
95
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
Blade cylinder
Type
Bucket cylinder
Hydraulic system
Type
PC128US-2
mm
115
mm
75
Stroke
mm
181
mm
870
mm
689
01-10-3
A
SPECIFICATIONS
GENERAL
m3
0.45
0.45
Operating weight
kg
12,950
13,450
mm
5,405
5,405
mm
5,195
5,195
mm
4,860
4,860
mm
8,230
8,230
mm
8,110
8,110
mm
9,260
9,260
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]
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.
Ground pressure
Dimension
01-10-4
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.
7731 and up
Model
S4D102E-1
4-cycle, water-cooled, in-line, vertical,
direct injection, with turbochatger
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}
rpm
2,400
rpm
950
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type
24V, 4.5 kw
Alternator
24V, 25A
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
(road liner)
Hydraulic motor
Control
valve
Hydraulic pump
Undercarriage
Hydraulic system
With blade
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
/min
MPa {kg/cm2}
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
Hydraulic filter
Hydraulic cooler
PC128US-2
Box-shaped, open
Tank return side
Air cooled (CF40-1)
01-10-5
(15)
GENERAL
SPECIFICATIONS
PC128US-2
Machine model
Without blade
Serial No.
7731 and up
Boom cylinder
Type
105
105
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
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
95
95
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
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
mm
5,480
5,480
mm
5,265
5,265
mm
4,900
4,900
mm
8,300
8,300
mm
8,180
8,180
mm
9,340
9,340
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]
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
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
PC128US-2
01-10-7
(15)
SPECIFICATIONS
GENERAL
PC138US-2
Machine model
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}
rpm
2,400
rpm
1,100
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type
24V, 3.0 kw
Alternator
24V, 25A
24V, 35A
Battery
12V, 64 Ah x 2
12V, 72 Ah x 2
Radiator type
Carrier roller
1 on each side
Track roller
7 on each side
(road liner)
Hydraulic motor
Control
valve
Hydraulic pump
Undercarriage
Hydraulic system
With blade
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
/min
MPa {kg/cm2}
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM20VL2-P
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
Hydraulic cooler
01-10-8
(15)
PC128US-2
GENERAL
SPECIFICATIONS
PC138US-2
Machine model
Without blade
Serial No.
4501 and up
Boom cylinder
Type
105
105
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
115
115
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
mm
100
100
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
Blade cylinder
Type
Bucket cylinder
Hydraulic system
Type
PC128US-2
With blade
mm
115
mm
75
Stroke
mm
181
mm
870
mm
689
01-10-9
(15)
SPECIFICATIONS
GENERAL
Without blade
m3
0.50
0.50
Operating weight
kg
14,000
14,370
mm
5,480
5,480
mm
5,265
5,265
mm
4,900
4,900
mm
8,300
8,300
mm
8,180
8,180
mm
9,340
9,340
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
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)
PC128US-2
SPECIFICATIONS
GENERAL
PC138USLC-2
Machine model
Without blade
Serial No.
1001 1500
Model
S4D102E-1
4-cycle, water-cooled, in-line, vertical,
direct injection, with turbochatger
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}
rpm
2,400
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
Hydraulic motor
Undercarriage
Battery
Hydraulic system
With blade
Type x no.
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
MPa {kg/cm }
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM20VL-P
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
Hydraulic cooler
PC128US-2
01-10-11
(15)
GENERAL
SPECIFICATIONS
PC138USLC-2
Machine model
Without blade
Serial No.
1001 1500
Boom cylinder
Type
105
105
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
mm
115
115
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
100
100
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
mm
75
Stroke
mm
181
mm
870
mm
689
PC128US-2
SPECIFICATIONS
GENERAL
Without blade
m3
0.50
0.50
Operating weight
kg
14,000
14,370
mm
5,480
5,480
mm
5,265
5,265
mm
4,900
4,900
mm
8,300
8,300
mm
8,180
8,180
mm
9,340
9,340
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
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
01-10-13
(15)
SPECIFICATIONS
GENERAL
PC138USLC-2
Machine model
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}
rpm
2,400
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
Carrier roller
2 on each side
Track roller
8 on each side
Hydraulic motor
Undercarriage
Battery
Hydraulic system
With blade
Type x no.
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
MPa {kg/cm }
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM20VL2-P
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
Hydraulic cooler
01-10-14
(15)
PC128US-2
GENERAL
SPECIFICATIONS
PC138USLC-2
Machine model
Without blade
Serial No.
1501 and up
Boom cylinder
Type
105
105
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
mm
115
115
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
100
100
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
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.
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
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
Operators cab
228
228
Operators seat
12.6
12.6
98
98
92
92
Control valve
80
96
4.8
4.8
3,020
2,460
26
26
Swing circle
155
155
Swing machinery
72.2
72.2
28.6
43.6
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
144 x 2
144 x 2
Sprocket
33.7 x 2
33.7 x 2
Revolving frame
Counterweight
PC128US-2
01-11
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
740 x 2
740 x 2
830 x 2
830 x 2
765 x 2
765 x 2
Boom assembly
820
820
Arm assembly
356
356
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
01-12
(15)
PC128US-2
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
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
Operators cab
228
228
Operators 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
155
155
Swing machinery
72.2
72.2
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
PC128US-2
01-13
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
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
(15)
PC128US-2
WEIGHT TABLE
GENERAL
Without blade
Serial No.
With blade
5001 7730
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
Operators cab
228
228
Operators seat
35
35
98
98
92
92
Control valve
96
106
4.8
4.8
5.1
5.1
3,020
2,460
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
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
PC128US-2
01-14-1
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
Boom assembly
820
820
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
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
Operators cab
245
245
Operators seat
35
35
98
98
92
92
Control valve
80
96
96
106
4.8
4.8
3,020
2,460
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
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
01-14-3
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
7731 and up
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.
With blade
4501 and up
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
Operators cab
245
245
Operators seat
35
35
98
98
92
92
Control valve
80
96
96
106
4.8
4.8
3,400
3,000
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
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
PC128US-2
01-14-5
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC138US-2
Machine model
Without blade
Serial No.
With blade
4501 and up
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
Without blade
Serial No.
With blade
1001 1500
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
Operators cab
245
245
Operators 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
28.6
43.6
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
*1
*2
*1
*2
01-14-7
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC138USLC-2
Machine model
Without blade
Serial No.
Boom cylinder assembly
With blade
1001 1500
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
Without blade
Serial No.
With blade
1501 and up
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
Operators cab
245
245
Operators 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
28.6
43.6
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
With blade
1501 and up
116.2 x 2
116.2 x 2
135
135
95
95
61.7 x 2
01-14-10
(15)
PC128US-2
GENERAL
KIND OF
FLUID 22
4
20
30
14
10
32
0
50
10
68
20
86
30
104
40
122F
50C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
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
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
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%.
0.5 to 1.0%
Above 1.0%
01-16
A
PC128US-2
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
PC128US-2
10-3
(15)
STRUCTURE
AND FUNCTION
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
Specification
Radiator
Oil cooler
Aluminum wave
(4-line)
CF40
3.5/2
3.5/2
4.0/2
18.81
11.83
6.17
49.0 14.7
{0.5 0.15}
-4.9 0
{-0.05 0}
Core type
10-4-2
(15)
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.
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
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
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
pedal LOCK
pedal HALF stroke position
pedal FULL stroket position
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
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
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)
PC128US-2
HYDRAULIC PUMP
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
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
(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.
!i
B
l
SLPOOl63
lo-18
PUMP
E
SLPOO164
/
4
9JUOOOBO
PC1 28US-2
STRUCTURE
2.
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 pistons (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
PC Valve
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
:
:
:
:
:
PC1 28US-2
STdUCTURE
AND FUNCTION
HYDRAULIC
PUMP
PO,UT
P,
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
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
PC1 28US-2
1 O-23
STRUCTURE
1 O-24
AND FUNCTION
HYDRAULIC
A-A
PUMP
9JUOOOB9
PC1 28US-2
HYDRAULIC PUMP
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
10-26
(15)
PC128US-2
HYDRAULIC PUMP
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
10-27-1
(15)
PC128US-2
HYDRAULIC PUMP
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
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
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
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
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
n..__
SVPO7609
b.
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).
lo-29
STRUCTURE
1O-30
AND FUNCTION
HYDRAULIC
PUMP
PC1 28US-2
STRUCTURE
HYDRAULIC
AND FUNCTION
Pi lot
PUMP
Pressure
0 main
valve
-
connected
Direction
to
small
diameter
PC-EPC
valve
SVPO7610
2)
PC1 28US-2
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
1 O-32
HYDRAULIC
AND FUNCTION
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.
Pump discharoe
pressure
PP
SLIP02559
Pump discharoe
orassure
PP
SDP02560
D
Z
2
5
:
L
PC1 28U.S2
PC128US-2
HYDRAULIC PUMP
10-33
(18)
STRUCTURE
AND FUNCTION
HYDRAULIC
Pi lot
PUMP
Pressure
To main
va I ve
31C
--*I*
~/,~1,,,,,,,,,,,,,,,,,,
+
Direction
to
small
diameter
Emergency
PUTID
drive
switch
SVPO76 12
b.
l
1o-34
PC1 28US-2
STRUCTURE
HYDRAULIC
AND FUNCTION
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)
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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)
PC128US-2
CONTROL VALVE
(2/8)
1.
2.
3.
4.
5.
6.
7.
8.
PC128US-2
10-39
CONTROL VALVE
(3/8)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
10-40
(15)
PC128US-2
CONTROL VALVE
(4/8)
1.
2.
3.
4.
5.
6.
7.
PC128US-2
10-41
CONTROL VALVE
(5/8)
1.
2.
3.
4.
5.
6.
10-42
(15)
PC128US-2
CONTROL VALVE
(6/8)
1.
2.
3.
4.
5.
6.
7.
PC128US-2
8.
9.
10.
11.
10-43
(15)
CONTROL VALVE
(7/8)
1.
2.
3.
4.
5.
6.
7.
8.
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.
PC128US-2
9.
10.
11.
12.
13.
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.
PC128US-2
CONTROL VALVE
(2/9)
1.
2.
3.
4.
5.
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.
10-45-5
(15)
12.
13.
14.
15.
16.
17.
18.
19.
PC128US-2
CONTROL VALVE
(4/9)
1.
2.
3.
4.
5.
6.
7.
PC128US-2
10-45-6
5
CONTROL VALVE
(5/9)
1.
2.
3.
4.
5.
6.
7.
8.
10-45-7
(15)
PC128US-2
CONTROL VALVE
(6/9)
1.
2.
3.
4.
5.
6.
7.
PC128US-2
8.
9.
10.
11.
10-45-8
(15)
CONTROL VALVE
(7/9)
1.
2.
3.
4.
5.
6.
7.
8.
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.
PC128US-2
9.
10.
11.
12.
10-45-10
(15)
CONTROL VALVE
(9/9)
1.
2.
3.
4.
5.
6.
10-45-11
(15)
PC128US-2
STRUCTURE
SUCTION
AND FUNCTION
SAFETY VALVE
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
709-70-74700
lo-46
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
on spool opening
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
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
1
Control
valve
-_-_-- __
-----__ I
II
I II
Pump
Passage
PLSf
I
[I
L-l
, L__-------,
I_--_--_---.
I
I I
I
Main
DumD
M i n.
-
Max.
I 1
Servo
piston
SEP02562
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
Max.
LS valve
set pressure
Min.
z
0
LS differential
Dressure
APLS
SOP02563
PC 128US-2
STRUCTURE
2.
.
CLSS
AND FUNCTION
Load
I\
I lcomensationl
Actuator
II
I\
Actua
I cobwensa~
SEP02564
PC1 28US-2
1o-49
STRUCTURE
CLSS
AND FUNCTION
EACH FUNCTION
Pressure
ion
port
LS
pressure
ion
PP
x
Al
E^-..:^^
II
Service
107
T-l
[=1,
CYI .inder
..
i!T----_--_-__-- 1 j+j+
; :---
. Left
travel
motor
itl
III
/
Swing
motor
9:
31.9/34.8HPa
(325/355ko/cml
Ma
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
1 O-52
PC1 28US-2
STRUCTURE
CLSS
AND FUNCTION
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.
Unload valve
Sleeve
Spring
Spool
PC1 28US-2
1o-53
STRUCTURE
CLSS
AND FUNCTION
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
1.
2.
3.
4.
Unload valve
Sleeve
Spring
Spool
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
1.
Work equipment
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
PC128US-2
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
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
PC128US-2
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
\
(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
..
PC1 28US-2
1o-59
STRUCTURE
AND FUNCTION
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
9JUOOl26
1 O-60
PC1 28US-2
STRUCTURE
AND FUNCTION
CLSS
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
9JUOO128
Operation
0. When the control lever is returned to NEUTRALwhile 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
PC1 28US-2
1O-63
STRUCTURE
AND FUNCTION
BOOM REGENERATION
CLSS
CIRCUIT
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.
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
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
lo-65
STRUCTURE
CLSS
AND FUNCTION
ARM REGENERATION
CIRCUIT
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
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
1O-67
STRUCTURE
TRAVEL JUNCTION
VALVE
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
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
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
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
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
AND FUNCTION
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
PC128US-2
7.
8.
9.
10.
11.
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
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
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.
1O-88
FC128US-2
STRUCTURE
3.
AND FUNCTION
VALVE
-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
fC128US-2
lo-89
STRUCTURE
4.
AND FUNCTION
At occurrence
of abnormal
VALVE
high pressure
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
1.
2.
3.
4.
5.
Cover
Body
Slipper seal
O-ring
Shaft
PC128US-2
10-91
A
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
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
Safetyvalve
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}
0.68
{6.94}
2.94
{30}
31.5 {31.5}
55.8 {55.8}
72
75.7
OUTLINE
Travel speed selection
PC128US-2
10-95
(18)
TRAVEL MOTOR
OPERATION
Operation of motor
At slow speed (the motor swash plate angle is maximized.)
10-96
2
PC128US-2
TRAVEL MOTOR
PC128US-2
10-97
2
TRAVEL MOTOR
10-98
(18)
PC128US-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
SJP07629
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
32
SJP07632
10-100
PC128US-2
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
SJPO7633
5i?
Control
valve
PC1 28US-2
SJP07634
10-101
STRUCTURE
AND FUNCTION
SWING MOTOR
SWING MOTOR
TYPE : KMF40ABE-3
9JUOOO70
B
S
T
MA
MB
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, thebrake 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
SJP07636
SJPO7636
10-104
PC1 28US-2
SWING MOTOR
REVERSE PREVENTION
VALVE
II
0
--I_-_-
_-J
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
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
Notch
SJP07777
SOP02036
PC1 28US-2
I-L
II/
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
B-B
9JA01353
1.
2.
3.
4.
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
#ztiva
t
SJPO7636
Exe it
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 80C
Maximum operating pressure :
6.86 MPa (70 kg/cm*)
10-l10
PC1 28US-2
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 C)
Max. actuating pressure : 6.86 MPa {70 kg/cm2}
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 C)
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.
.
10-l 14
(Fio
1)
SEP02569
SEP02570
PC 128US-2
STRUCTURE
3.
.
AND FUNCTION
PPC VALVE
3)
SEP0257
4.
.
(Fio
41
SEP02572
FC128US-2
10-115
PPC VALVE
FOR TRAVEL
10-116
(15)
P3 : R.H reverse
P4 : R.H forward
P5 : Travel signal
PC128US-2
PPC VALVE
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).
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.
PC128US-2
10-119
(15)
PPC VALVE
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 :
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
PC1 28US-2
SJP07646
SJP07647
10-121
STRUCTURE
3.
.
AND FUNCTION
PPC VALVE
4.
l
SJPO7649
10-122
PC1 28US-2
1.
2.
3.
4.
5.
Poppet
Check valve spring
Pilot spool
Pilot spring
Safety-suction valve
PC128US-2
10-122-1
C
1.
2.
3.
4.
5.
Poppet
Check valve spring
Pilot spool
Pilot spring
Safety-suction valve
10-122-2
(15)
PC128US-2
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
10-122-8
(18)
PC128US-2
PC128US-2
10-122-9
C
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
10-123-1
(18)
5.
6.
7.
8.
Receiver tank
Condenser
Air conditioner unit
Duct
PC128US-2
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
A:
B:
C:
D:
1.
2.
3.
4.
PC128US-2
5.
6.
7.
8.
Receiver tank
Condenser
Air conditioner unit
Duct
10-123-2
(18)
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.
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
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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).
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
10-132-4
(15)
A:
B:
C:
t:
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
e.
f.
g.
h.
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)
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
10-132-7
(15)
ENGINE CONTROL
SYSTEM COMPONENTS
FUEL ADJUST DIAL
PC128US-2 Serial No.: 5001 7730
1.
2.
3.
4.
PC128US-2
5.
6.
7.
8.
Shaft
Joint
Bracket
Fuel adjust motor
10-133
(14)
ENGINE CONTROL
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.
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
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.
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)
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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)
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.
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.
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.
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
PC128US-2
Mode A
10-138-3
(15)
10-138-4
(15)
Model
PC128US-2
PC138USLC-2
E mode
B mode
PC128US-2
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.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
2-stage relief solenoid valve
PPC lock solenoid valve
9.
10.
11.
12.
13.
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}
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
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 brake
Swing
lock
operates
Swing
lock
released
OFF
(When controlleris
safe)
ON
OFF
Swing
lock
operates
Swing
holding
breake
operates
10-142
(18)
PC128US-2
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.
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.
10-142-1
(15)
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.
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.
e.
f.
g.
h.
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
PC128US-2
Travel speed
selector switch
Travel accelerator pedal
Step on
Release
LOW
HIGH
(low speed) (high speed)
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)
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)
LOW
HIGH
(low speed) (high speed)
PC128US-2
PC128US-2
10-143-4
(15)
10-143-5
(15)
PC128US-2
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.
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.
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)
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
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.
g.
h.
i.
j.
k.
Throttle signal
Potentiometer signal
Fuel control motor driving signal
Acceleration signal
Deceleration signal
10-144-3
(15)
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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.
PC128US-2
Operation
Engine speed: 1,200 rpm or less
Release
Automatic
Manual
Fuel control dial: Holded in 70% or more of full for 3 seconds or more
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Operational conditions (both required)
Operation
Engine speed: 1,300 rpm or less
Release
Automatic
Manual
Fuel control dial: Holded in 70% or more of full for 3 seconds or more
Coolant temperature:
105C or higher
Operational conditions
Coolant temperature:
102C or higher
Operational conditions
Coolant temperature:
100C or higher
PC128US-2
Release conditions
Coolant temperature: Less than 105C
Fuel control dial: To be returned to the
Release conditions
Release conditions
Coolant temperature: Less than 100C
10-144-5
(15)
Operation
Protection of turbocharger
(See above figure)
10-144-6
(15)
Operation
PC128US-2
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)
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
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
c
c
c : GND
: OPEN
10-147-3
(15)
PC128US-2
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
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
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)
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.
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
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
10-148
(15)
PC128US-2
MONITOR SYSTEM
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.
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.
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
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
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
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
Pilot
[*2]
7
Coolant
temperature
Display Remarks
color
3b
Blue
LCD
Red
LED
Blue
LCD
Red
LED
Fuel level
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
Oil
maintenance
When specified
oil-maintenance
periods elapsed
Lamp
Display method
0 99999.9 h
Gauge
Display area
Service meter
3a
4b
Display item
Caution
[*3]
10
Engine oil
pressure
Overload
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
Lo Hi
Auto-deceleration switch
ON OFF
(Lit)
Wiper switch
OFF INT
ON
(Not lit) (Intermittent) (Continuous)
Name
switch
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
Sensor type
Sensing__approach
When normal
When failed
Caution
Contact
OFF (open)
ON (closed)
Resistance
Resistance
Coolant
temperature
Gauge
Fuel level
69 @
Structure
of
circuit
SBD01537
1.
2.
Plug
Contact
ring
3.
4.
5.
6.
Contact
Diaphragm
Spring
Terminal
@=I3
Structure
7.
2.
3.
of
circuit
SBDOl538
Connector
Plug
Thermistor
10-152
PC1 28US-2
STRUCTURE
AND FUNCTION
F
Structure
fL
EMPTY
E
Y
of
circuit
1.
2.
3.
4.
SEP02590
Float
Connector
Cover
Variable resistor
PC128US-2
10-153
20
STANDADRD
VALUE TABLE
Standard
Standard
Standard
TESTING
AND ADJUSTING
TROUBLESHOOTING
*
1.
2.
3.
A
A
A
. . . . .. . . . .. . . . . . . . . . 20-2
. . . .. . .. . . . . .. .. . . . .. .. . . . 20-101
. . .. . . . .. . .. . .. . .. . . . . . .. . . . .. .. . . . . . 20-201
PC1 28U.S2
20-l
0
PC128US-2, 138USLC-2
Engine
S4D102E-1
Item
Engine speed
Measurement conditions
Unit
Standard value
for new machine
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
980 {100}
245 {2.5}
69 {0.7}
Min. 78 {0.8}
69 {0.7}
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}
Oil temperature
deg
14 1
mm
9.5 12.7
20-2
(17)
PC128US-2
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
Measurement conditions
Unit
Standard value
for new machine
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
980 {100}
245 {2.5}
196 {2.0}
147 {1.5}
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}
Oil temperature
deg
6 0.75
mm
6 10
PC128US-2
20-2-1
(17)
Applicable model
Operating effort of
control lever
Category
PC128US-2
Measurement conditions
Item
Unit
Serial No.
5001 7730
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
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 C
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 C
Engine at full
throttle
+ 1.96
Control levers at
HOLD
7731 and up
PC128US-2
Applicable model
Category
Item
PC128US-2
Measurement conditions
Unit
Serial No.
fl See Fig. A
Overrun when
stopping swing
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
Sec.
Swing
180
fl See Fig. A
Engine at full throttle
Hydraulic oil temperature: 45 55C
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 55C
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.
PC128US-2
20-5
(14)
Applicable model
Category
Measurement conditions
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 55C
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 55C
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 55C
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
Max. 23
2.3 0.2
Max. 2.9
RAISE
Bucket
Cylinder fully
retracted
Max. 15
Sec
fl See Fig. J
Max. 700
OUT
Max. 500
1.3 0.3
Max. 2.5
LOWER
fl See Fig. I
Arm
Cylinder fully
retracted
LOWER
Boom
fl See Fig. H
Bucket teeth in
Engine at full throttle
contact with
Hydraulic oil temperature
ground
: 45 55C
Work equipment
Unit
RAISE
Item
PC128US-2
1.3 0.3
Max. 2.5
20-7
(18)
Engine speed
Category
Unit
Standard value
for new machine
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
N CURL, DUMP
85 10
Min.75 Max.95
N LEFT, RIGHT
85 10
Min.75 Max.95
Item
At 1-pump relief
PC138USLC-2
Measurement conditions
Hydraulic oil temperature : 45 55 C
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
35
58
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}
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}
Travel
Boom control lever Engine at full throttle
Oil temperature: 45 55 C
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)
Applicable model
Category
PC138USLC-2
Measurement conditions
Item
Unit
Standard value
for new machine
+ 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
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}
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}
{}
Max. 65
(Max. 610)
Max. 75
(Max. 720)
Control
LS differential
pressure
+ 1.96
31.87 0.98
20
{325 + 10
}
34.81 0.98
{355 10}
Target
value
(Range)
Travel
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
flLS differential
pressure =
pump outlet
port pressure
LS pressure
+ 1.47
32.36 2.45
{330 25}
MPa
{kg/cm2}
Servo piston
input pressure
+ 1.96
32.36 1.47
{330 15}
Blade LOWER
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
+ 1.96
Swing
fl See Fig. A
Overrun when
stopping swing
20-8-2
(17)
Deg.
(mm)
PC128US-2
Applicable model
Category
Item
PC138USLC-2
Standard value
for new machine
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
Measurement conditions
Unit
fl See Fig. A
Time taken to
start swing
90
Engine at full throttle
Hydraulic oil temperature
: 45 55C
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
Hydraulic drift of
swing
Engine stopped
Hydraulic oil temperature: 45 55C
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.
fl See Fig. C
Travel
Lo
Sec.
fl See Fig. D
PC128US-2
Sec.
Hi
20-8-3
(19)
Applicable model
Category
Item
Measurement conditions
PC138USLC-2
Unit
Standard value
for new machine
Max. 200
220
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
Travel
fl See Fig. F
Hydraulic drift of
travel
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)
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 55C
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)
Blade
(hydraulic drift
at tip of blade)
20-8-4
Engine stopped
Hydraulic oil temperature: 45 55C
Stop machine on 12 slope with
sprocket facing straight up the
slope.
Measure the distance the machine
moves in 5 minutes.
Engine stopped
Hydraulic oil temperature: 45 55C
Set blade at maximum lifting height
and measure downward movement
at edge of blade for 15 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 55C
Unit
Cylinder fully
extended
(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)
Max. 4.4
(Until touching
cushion)
Max. 4.2
Max. 4.0
(Until touching
cushion)
Max. 3.7
(Until touching
cushion)
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 55C
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
Bucket
Cylinder fully
retracted
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
Sec.
20-8-5
(18)
Applicable model
Category
PC138USLC-2
Standard value
for new machine
Max. 2
Max. 2
Max. 2
Max. 2
Blade
Max. 2
Max. 2
Eachcylinder
Max. 3.5
Max. 15
Max. 10
Max. 50
Item
Measurement conditions
Unit
fl See Fig. M
Arm
Bucket
Work equipment
Time lag
fl See Fig. N
Engine at low idling
Hydraulic oil temperature
: 45 55C
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
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
Standard value
for new machine
rpm
Min. 2,100
Min. 2,000
N RAISE, LOWER
100 11
100 21
N IN, OUT
100 11
100 21
N CURL, DUMP
100 11
100 21
N LEFT, RIGHT
100 11
100 21
Item
At 1-pump relief
PC138USLC-2
Measurement conditions
Hydraulic oil temperature : 45 55 C
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
35
58
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}
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}
Travel
Boom control lever Engine at full throttle
Oil temperature: 45 55 C
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)
Applicable model
Category
Item
PC138USLC-2
Measurement conditions
Unit
Standard value
for new machine
+ 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
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}
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}
{}
Max. 65
(Max. 610)
Max. 75
(Max. 720)
Control
LS differential
pressure
+ 1.96
31.87 0.98
20
{325 + 10
}
34.81 0.98
{355 10}
Target
value
(Range)
Travel
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
flLS differential
pressure =
pump outlet
port pressure
LS pressure
+ 1.47
32.36 2.45
{330 25}
MPa
{kg/cm}
Servo piston
input pressure
+ 1.96
32.36 1.47
{330 15}
Blade LOWER
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
+ 1.96
Swing
fl See Fig. A
Overrun when
stopping swing
20-8-8
(17)
Deg.
(mm)
PC128US-2
Applicable model
Category
Item
PC138USLC-2
Standard value
for new machine
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
Measurement conditions
Unit
fl See Fig. A
Time taken to
start swing
90
Engine at full throttle
Hydraulic oil temperature
: 45 55C
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
Hydraulic drift of
swing
Engine stopped
Hydraulic oil temperature: 45 55C
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.
fl See Fig. C
Travel
Lo
Sec.
fl See Fig. D
PC128US-2
Sec.
Hi
20-8-9
(19)
Applicable model
Category
Item
Measurement conditions
PC138USLC-2
Unit
Standard value
for new machine
Max. 200
220
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
Travel
fl See Fig. F
Hydraulic drift of
travel
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)
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 55C
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)
Blade
(hydraulic drift
at tip of blade)
20-8-10
(19)
Engine stopped
Hydraulic oil temperature: 45 55C
Stop machine on 12 slope with
sprocket facing straight up the
slope.
Measure the distance the machine
moves in 5 minutes.
Engine stopped
Hydraulic oil temperature: 45 55C
Set blade at maximum lifting height
and measure downward movement
at edge of blade for 15 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 55C
Unit
RAISE
Item
LOWER
Category
PC138USLC-2
Cylinder fully
extended
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
Max. 4.0
(Untill touching
chshion)
Max. 3.7
(Untill touching
chshion)
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 55C
RAISE
fl See Fig. J
1.3 0.3
Blade fully
raised
LOWER
Work equipment
3.1 0.3
fl See Fig. I
Arm
Cylinder fully
retracted
Standard value
for new machine
1.3 0.3
Bucket
Cylinder fully
retracted
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
Sec.
20-8-11
(17)
Applicable model
Category
PC138USLC-2
Standard value
for new machine
Max. 2
Max. 2
Max. 2
Max. 2
Blade
Max. 2
Max. 2
Eachcylinder
Max. 3.5
Max. 15
Max. 10
Max. 50
Item
Measurement conditions
Unit
fl See Fig. M
Arm
Bucket
Work equipment
Time lag
fl See Fig. N
Engine at low idling
Hydraulic oil temperature
: 45 55C
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
fl See Fig. O
cc/
min
Center swivel
joint
20-8-12
(17)
PC128US-2
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.
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
Measurement
conditions
table
method
3
r
.2-stage
1) Turn starting
switch OFF.
2) Disconnect
connector.
1 MQ
;
.-?
_s
If the condition
is as shown
below, it is normal
in the table
P
(I
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
l/6 turns.
2) It must work
as above.
PC1 28US-2
normally
1) Turn starting
switch OFF.
2) Disconnect
connector.
when
1+
adjusted
20-13
0
TESTING
j
n1
STANDARD
AND ADJUSTING
Name of
component
l-
Inspec-
Cloyector
I.
tion
I method
Judament
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
conditions
table
Measurement
conditions
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.
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
0 - 15.7
T151
CN6 (female)
(7) - (3)
20-14
0
PC1 28US-2
TESTING
STANDARD
AND ADJUSTING
sys-
Name of
component
tern
Con;Ector
$~p-
judgment
Measurement
conditions
table
method
If the condition
is as shown
1) Disconnect
in the table
S7
(male)
Coolant
sensor
If the condition
is as shown
in the table
If the condition
is as shown
in the table
temperature
po6
Fuel level sensor
1.1
:~~$%Zng
1 )Start engine.
(male)
Alternator
ii
Between
alternator
terminal R chassis
z
>
E
:
f
PC1 28US-2
20-15
0
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Kerosene mode
Model selection
Chassis control
Attachment selection
20-16
(17)
CR2
CR1
CR2
CR1
CR2
V07
(male)
V04
(male)
Measure voltage
Measure voltage
CR3
Measurement
conditions
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
Kerosene mode
05V
6 13 V
At standard
mode
At kerosene
mode
Between
(6)
chassis
46V
Attachment
1) Turn starting
switch ON.
2) Insert T-adapter.
01V
1) Turn starting
switch ON.
2) Insert T-adapter.
07V
Controller
PC-EPC solenoid
CR3
Judgment table
Measure resistance
Connector Inspection
No.
method
Measure
resistance
Name of
component
Measure
resistance
System
Max. 1 V
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.
PC128US-2
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Name of
component
Connector Inspection
No.
method
CR3
Measure voltage
System
Judgment table
Measurement
conditions
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
PC-EPC solenoid
CR3
Measure voltage
CR3
Measure voltage
Controller
1) Turn starting
switch ON.
2) Insert T-adapter.
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
Bit ON
Bit ON
Bit ON
Attachment selection
PC128US-2
Monitoring
Bit OFF
Bit OFF
Long arm
Bit ON
Bit OFF
Bit OFF
20-19
(17)
Name of
component
Model selection
Attachment selection
Connector Inspection
No.
method
Monitoring
System
Measurement
conditions
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.
20-20
(17)
Monitoring
Monitoring
Monitoring
Monitoring
Controller
Monitoring
Service
adjustment
310
Kerosene mode
311
1) Turn starting
switch ON.
Bit ON
Neutral position
Bit OFF
Bit ON
Neutral position
Bit OFF
Bit ON
Neutral position
Bit OFF
1) Start engine.
2) Reset safety
lock lever.
3) Operate work
equipment.
1) Start engine.
2) Reset safety
lock lever.
3) Operate work
equipment.
1) Start engine.
2) Reset safety
lock lever.
3) Operate work
equipment.
Bit ON
Neutral position
Bit OFF
PC128US-2
Chassis control
Travel acceleration
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
Connector Inspection
No.
method
Measure
resistance
Name of
component
Measure
resistance
System
Measurement
conditions
Judgment table
If the condition is as shown in the table
below, it is normal
Between (1) (2)
37 60
37 60
PC128US-2
Measure
resistance
C05
(male)
1) Turn starting
switch OFF.
2) Disconnect
connector.
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.
8 15
1) Turn starting
switch OFF.
2) Disconnect
connector.
8 15
1) Turn starting
switch OFF.
2) Disconnect
connector.
Pressure sensor
1) Turn starting
switch OFF.
2) Disconnect
connector.
4.5 5.5 V
0.5 4.5 V
1) Start engine.
2) Insert T-adapter.
20-21
(17)
Name of
component
Connector Inspection
No.
method
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
Min. 1 M
E07
(male)
Measure
voltage
Adjustment
Chassis control
Measure
resistance
System
20-22
(17)
0.5 3.0 V
Measurement
conditions
1) Turn starting
switch OFF.
2) Disconnect
connector.
1) Start engine.
2) Insert T-adapter.
PC128US-2
PC128US-2
20-101
(17)
Engine speed
Part Name
799-205-1100
Tachometer kit
795-790-2500
Take-off drive
6090-02-9190
Gear box
799-101-1502
- 99.9 +1,299 C
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
799-101-5160
Nipple
PT1/8
799-101-5220
Nipple
10 x 1.25
07002-11023
O-ring
Adapter
1.0 MPa{10kg/cm2}
790-261-1321
790-261-1331
790-261-1340
Blow-by pressure
799-401-2320
Hydraulic gauge
799-401-2701
795-799-1131
Gear
799-201-1504
Blow-by checker
D
1
795-790-1950
Tool
Commercially
available
Feeler gauge
790-201-9001
Commercially
available
Smoke meter
79A-264-0021
2
Valve clearance
Exhaust color
Operating effort
F
G
20-102
(19)
Bosch index: 0 9
0 294N{0 30kg}
Push-pull scale
Troubleshooting of wiring
harnesses and sensors
Digital display :
6.0 99,999.9rpm
790-261-1311
3
Remarks
Oil pressure
Part No.
0 490N{0 50kg}
79A-264-0091
Commercially
available
Commercially
available
Commercially
available
Scale
790-601-8000
T-adapter kit
799-601-7370
799-601-7050
SW-6P
799-601-7080
Stop watch
Tester
M-1P
Adapter
799-601-7310
SW-12P
799-601-7320
SW-16P
799-601-7340
M-16P
799-601-7540
070-18P
796-127-1140
Wear gauge
PC128US-2
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 and up
Measurement of engine speed
The measuring method is identical with the
method described above.
The engine speed can be displayed in monitoring
mode "1010".
PC128US-2
20-103
(19)
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 C
1. Remove the cover for setting the injection timing of the injection pump from the timing gear
case and install tool A3.
20-104
(19)
PC128US-2
PC128US-2
20-105
(17)
3. When the No.1 cylinder is at top dead center, adjust the valves marked . Next, rotate the crankshaft one turn (360) 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 360.
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.
PC128US-2
20-107
(17)
20-108
(17)
PC128US-2
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
PC128US-2
20-108-1
(17)
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
20-108-3
(17)
20-108-4
(17)
PC128US-2
(Deg)
6 0.75
mm
0.42 0.08
PC128US-2
20-108-5
(17)
0 0.08
20-108-6
(17)
PC128US-2
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
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
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-108-7
(17)
20-108-8
(17)
PC128US-2
PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
PC138US-2
Serial No.: 1405 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-108-9
(17)
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
ENGINE
STOP SOLENOID
LINKAGE
BEP01424
Testing
1. Turn the starting switch ON, set to the operating
condition, then adjust so that the clearance 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
-Revo
01
rame
Dial gauge
2.
3.
TXP02404
BLP01317
4.
5.
6.
150-200mm
BLPOl3
PC1 28US-2
20-111
0
limit
line
TXP02405
1.
2.
3.
20-112
0
PC128US-2
TESTING
TESTlNG
AND ADJUSTING
AND ADJUSTING
HYDRAULIC PRESSURE IN
WORK EQUIPMENT,
SWING, TRAVEL CIRCUIT
when
measuring:
45 - 55 C
20-114
0
BLPO1284
-1
PC1 28US2
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}
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
PC128US-2
20-117
(18)
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
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
AND ADJUSTING
measuring
: 45 - 55 C
j,
Oil temperature
1.
pisand
and
{400
kg/cm%
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
PRESSURE
PRESSURE
pressure
1)
9JFOOl20
-1
BLP01284
20-120
0
PC128US-2
TESTING
3.
AND ADJUSTING
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
when measuring
: 45 - 55 C
3.
Adjusting
2.
After adjusting,
tighten
locknut (2).
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
: 45 - 55 C
Oil temperature
1.
2.
3.
conditions
PC1 28US-2
20-123
0
TESTING
MEASURING
AND ADJUSTING
PRESSURE
- 55 C
PPC
BLP01302
20-124
0
PC1 28US-2
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
TRAVEL DEVIATION
Posture
Testing
*
Travel on flat ground.
1.
2.
TDP00328
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
Oil temperature
1.
Work equipment
when measuring : 45 - 55 C
cylinder
2.
End
of
stroke
~p~connect
zi
TLP00652
PC1 28US-2
ZO-127
0
TESTING
MEASURING
MEASURING
AND ADJUSTING
Oil temperature
when measuring
: 45 - 55 C
3.
4.
II
20- 128
0
9JFOOO95
PC1 28US-2
BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
Air bleeding procedure
Nature of work
Change hydraulic oil
Clean strainer
Bleed air
from
pump
Start
engine
(Note)
(Note)
Replace cylinder
Remove cylinder piping
Note : Bleed the air from the swing and travel motors only when the oil inside the motor case has been
drained.
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.
4.
Bleeding
20-130
0
BLEEDING
AIR
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.
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.
2.
PC1 28US-2
20-131
0
TESTING
PROCEDURE
AND ADJUSTING
FOR CHECKING
DIODE
1.
Diode
as
individual
Diode
included
Part
in
wiring
harness
I-
TLP00664
BLPO1357
20-132
0
PC128US-2
HOUR INSPECTION
Work instruction No.
Date of execution
Day:
Year:
Month:
S4D102E-1
Service meter
hours
Inspector
....................................................................................................................
....................................................................................................................
....................................................................................................................
Outside temperature
Max.
Min.
Height
Revolving frame
Good
Bad
Good
Bad
Good
Bad
Other parts
Engine oil
Display of self-diagnosis
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
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
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
Bad
Blade raised
sec
Left
5-turn swing
Right
High speed
Engine at full
throttle
Left
Right
5-turn travel
Left
Low speed
Right
Hydraulic drift of
work equipment
PC128US-2
mm/15min
20-133
(14)
Oil
pressure
Item
Low idling
Engine at full
throttle
Serial No.
5001 7730
Engine at full
Serial No.
Main oil pressure
7731 and up throttle
PC
Bucket-CURL circuit relieved
Control lever in neutral
20-134
(14)
Engine at full
throttle
LS differential
pressure
{<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
HOUR INSPECTION
Work instruction No.
Date of execution
Day:
Year:
Month:
S4D102E-1
Service meter
hours
Inspector
....................................................................................................................
....................................................................................................................
....................................................................................................................
Outside temperature
Max.
Min.
Height
Revolving frame
Good
Bad
Good
Bad
Good
Bad
Other parts
Engine oil
Display of self-diagnosis
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
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
2.9 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
Low idling
Engine speed
Engine
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
Bad
Blade raised
sec
Left
5-turn swing
Right
High speed
Engine at full
throttle
Left
Right
5-turn travel
Left
Low speed
Right
Hydraulic drift of
work equipment
PC128US-2
mm/15min
20-135
(17)
Oil
pressure
Item
Low idling
Engine at full
throttle
Engine at full
throttle
PC
Bucket-CURL circuit
relieved
Control lever in neutral
20-136
(17)
Engine at full
throttle
LS differential
pressure
{<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
HOUR INSPECTION
Work instruction No.
Date of execution
Day:
Year:
Month:
SAA4D95LE-3-A
Service meter
hours
Inspector
....................................................................................................................
....................................................................................................................
....................................................................................................................
Outside temperature
Max.
Min.
Height
Revolving frame
Good
Bad
Good
Bad
Good
Bad
Other parts
Engine oil
Display of self-diagnosis
Hydraulic oil
Monitor (
Monitor panel
Condition
Unit
Low idling
Engine speed
1,050 1,150
rpm
Engine
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
Standard
MeasureService limit
value for
ment
Good
value
new machine
result
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
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
2.9 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
Hydraulic drift of
work equipment
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
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
{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
in a level place, and check that the safety pin, blocks, and parking
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.,
Be extremely
When disconnecting
careful not to touch any hot parts or to get caught in any rotating
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.
1.
2.
3.
20-202
0
2)
4.
5.
6.
SEQUENCE
TROUBLESHOOTING
SEQUENCE
OF EVENTS
IN TROUBLESHOOTING
OF EVENTS IN TROUBLESHOOTING
TEWOO180
TEW00181
\
step 1
Examination,
1)
When
confirmation
a request
for repairs
2)
of symptoms
Name
of customer
Type,
serial number
Details
of jobsite,
Ask questions
is received,
II
-------
first
points.
Ring 1 Ring
__-----
of machine
etc.
to gain an outline
of the prob-
lem.
.
Condition
of failure
TEWM)182
failure
jtep
Operating
Past history,
environment
details
of maintenance,
etc.
2
Determining
1)
location
of cause
section
shop
probable
manual
to find
locations
TEWO0183
of the
of possible
causes.
step 3
Preparation
1)
of troubleshooting
tools
and prepare
=tools in
oa
/step
the necessaw
2)
Hydraulic
7
1.
tools.
.
T-adapter
=z
pressure
gauge
kit, etc.
the nec-
essary replacement
Pinpoint
locations
of failure
(carry out
troubleshooting)
Decide
action to take
1)
Before
starting
repair simple
2)
troubleshooting,
Check before
starting
locate
and
failures.
select
matches
items
Section
of the shop
a troubleshooting
the symptoms,
flowchart
troubleshooting.
TEWOO187
Drive
and
operate
the condition
the
and judge
machine
to confirm
if there
is really
Step 4
(Go]
Was there
anything
chine before
strange
the failure
about
the ma-
occurred?
occur suddenly?
been carried
TEwoo188
PC128US-2
20-203
0
TROUBLESHOOTING
20-204
(17)
PC128US-2
TROUBLESHOOTING
TEW00194
PC128US-2
TEW00195
TEW00196
20-205
(17)
TROUBLESHOOTING
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
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.
PC128US-2
20-207
(17)
TROUBLESHOOTING
TEW00196
TEW00202
20-208
(17)
PC128US-2
TROUBLESHOOTING
TEW00204
TEW00205
TEW00206
PC128US-2
20-209
(17)
TROUBLESHOOTING
3.
POINTS
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.
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)
20-210
0
PC I 2aus-2
TROUBLESHOOTING
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
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
TROUBLESHOOTING
Electrical
equipment
Item
Judgment value
Action
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add coolant
Clean or replace
Replace
Tighten or replace
Tighten or replace
Tighten or replace
Repair
Repair
Bleed air
24 30V
Replace
Add or replace
Replace
Repair
Disconnect
connector and dry
20-212
(17)
Replace
Replace
PC128US-2
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.
ConnecNo. of
tor
pins
type
Place of use
Address
F-5
A01
Intermediate connector
A-2
D23
KES
A02
Intermediate connector
B-2
D24
KES
F-5
R-5
A03
SWP
16
Intermediate connector
A-2
E11
Body ground
(Ribbon heater relay)
A04
SWP
16
Intermediate connector
A-2
E13
Starting motor
N-3
A05
DT
Intermediate connector
B-2
E14
R-6
A06
DT
Intermediate connector
A-1
E15
Intermediate connector
N-7
A07
DT
Intermediate connector
A-2
E16
M-6
A08
SWP
Intermediate connector
B-2
E17
Alternator
O-3
A09
SWP
16
A10
DT
Intermediate connector
(Arm crane)
Intermediate connector
(Arm crane)
A20
16
Intermediate connector
D-9
F01
H-2
A21
16
Intermediate connector
D-4
F02
K-8
A22
12
Intermediate connector
D-4
FB1
Fuse box
F-6
A23
SWP
12
Intermediate connector
H-5
H08
Intermediate connector
F-6
C09
DT
E-8
H09
Intermediate connector
F-6
C06 SUMITOMO 16
Prolix switch
D-8
H16
A-6
C05
DT
Pressure sensor
G-6
K19
F-8
C10
F-8
M02
Safety relay
O-3
C13
I-8
M10 DEUTSCH
Intermediate connector
G-6
C14
J-8
M11
Fusible link
L-3
CR1
DT
24
CR700 Controller
F-7
M13
DT
G-7
CR2
DT
40
CR700 Controller
F-7
M13
Speaker (Right)
K-8
CR3
CT
40
CR700 Controller
F-7
M14
Fusible link
L-3
D01
KES
F-5
M15
Fusible link
L-3
D05
KES
M16
Horn
I-2
D06
KES
F-5
X
YAZAKI
M22
090
Horn switch
B-7
E07
N-6
M26
SWP
12
A/C unit
E-9
D08
KES
E-5
M28
Window washer
L-5
D14
SWP
L-4
M30
G-3
D15
O-7
M31
D-9
D17
KES
E-4
M34
D20
KES
F-5
M36F
Kerosene mode
F-8
D22
SWP
L-4
M36M
Kerosene mode
F-8
20-218-2
(17)
C-2
E20
SWP
Intermediate connector
M-5
A-1
E30
Safety relay
N-3
PC128US-2
TROUBLESHOOTING
Connector No.
M38
ConnecNo. of
tor
pins
type
Place of use
Address
Connector No.
ConnecNo. of
tor
pins
type
Address
Place of use
Light switch
C-8
S17
R-4
M40 YAZAKI
Cigar lighter
A-5
S30
G-4
M40
I-8
S31
M41
SWP
A-7
S32
G-5
M41
J-8
S33
G-4
M47
090
20
Intermediate connector
B-7
S34
M48
DT
L-4
S35
M49
PA
Radio
F-7
S36
Intermediate connector
G-6
M50
Wiper motor
A-6
S37
Intermediate connector
L-4
M51
Fuel dial
B-7
S50
M71
Room lamp
L-7
S51
M73
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
F-6
V04
G-7
M84
SWP
14
E-9
V05
G-8
M85
SWP
16
Intermediate connector
(Airconditioner unit)
Intermediate connector
(Airconditioner unit)
E-9
V06
M87
12
A/C unit
C-4
V07
M88 YAZAKI
10
B-5
W03
K-8
M92
DT
X05
D-8
P01
AMP
12
Monitor panel
A-7
P02
AMP
20
Monitor panel
A-6
P03
C-8
P06
I-8
O-7
P07
P15
AMP
F-6
R06 SINAGAWA
B-8
R07 SINAGAWA
B-3
R08 SINAGAWA
Decelerator relay
B-3
R09 SINAGAWA
Accelerator relay
B-3
R10 SINAGAWA
B-7
S01
B-4
S05
G-5
S08
S10
PC128US-2
E-4
20-218-3
7
TROUBLESHOOTING
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
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.
ConnecNo. of
tor
pins
type
Address
Place of use
Connector No.
A01
Intermediate connector
L-4
A02
SWP
14
Intermediate connector
L-4
H08
A03
SWP
14
Intermediate connector
K-4
ConnecNo. of
tor
pins
type
HOLD Terminal
Address
Place of use
Q-2
Intermediate connector
F-4
H09
Intermediate connector
F-4
A-6
H16
A-4
A06
DT
Intermediate connector
(Arm crane)
A20
16
Intermediate connector
C-7
J1
SUMITOMO
20
Junction connector
F-7
A21
16
Intermediate connector
D-4
J2
SUMITOMO
20
Junction connector
F-6
AR
DT
Alternator
M-5
J3
SUMITOMO
20
Junction connector
F-6
C05
DT
Pressure sensor
G-8
K19
F-7
C06 SUMITOMO
16
Prolix switch
C-7
M02
Safety relay
H-1
C13
J-9
M10
DT
Intermediate connector
G-7
C14
I-9
M11
Fusible link
L-4
CR1
DT
24
CR 700 controller
F-6
M13
G-9
CR2
DT
40
CR 700 controller
F-6
M13
Speaker (Right)
K-9
CR3
DT
40
CR 700 controller
F-6
M14
Fusible link
L-4
M16
SWP
Horn
A-3
M22
090
Horn switch
B-5
M26
SWP
12
E-7
M28
KES
Window washer
L-6
M30
F-4
D01
SWP
D02
SWP
D03
SWP
E07
M-5
M31
D-7
E11 Terminal
H-1
M34
Q-8
E12 Terminal
Relay ground
H-1
M38
Light switch
B-7
E14 Terminal
G-2
M40 YAZAKI
Cigarette lighter
A-4
E17
Alternator
N-3
M40
H-9
E30 Terminal
Safety relay
H-3
M41
SWP
A-6
E50 Terminal
Starting motor
Q-4
M41
J-9
E51 Terminal
G-2
M47
090
20
Intermediate connector
B-6
E52 Terminal
P-9
M48
DT
Auto-decelation motor
L-5
EU1
F-5
M49
PA
Radio
F-5
F01
DT
H-9
M50
Wiper motor
A-5
F02
K-9
M51
Fuel dial
B-6
I-3
L-9
FB1
DT
H-3
GND Terminal
20-218-8
(17)
Fuse box
F-5
M52
DT
Intermediate connector
(Engine stop solenoid relay)
Q-2
M71
Room lamp
PC128US-2
TROUBLESHOOTING
Connector No.
ConnecNo. of
tor
pins
type
Place of use
Address
Connector No.
ConnecNo. of
tor
pins
type
Address
Place of use
M73
Speaker (Left)
L-8
T01 Terminal
Battery
L-6
M80
20
F-4
T02 Terminal
Revolving ground
L-5
M81
16
F-5
T03 Terminal
Revolving ground
L-5
F-6
T04
Radio ground
F-5
F-5
T05 Terminal
Floor ground
C-3
F-7
T06 Terminal
B-3
D-3
T21 Terminal
I-1
B-3
T22 Terminal
I-3
M83 SUMITOMO
M84
SWP
14
M85
SWP
16
Intermediate connector
(Air conditioner unit)
Intermediate connector
(Air conditioner unit)
M87
12
M88 YAZAKI
10
PULL Terminal
Q-2
V03 SHINAGAWA
B-6
P01
AMP
12
Monitor panel
A-5
V4
DT
G-8
P02
AMP
20
Monitor panel
A-5
V5
DT
G-9
P03
C-7
V6
DT
G-8
P06
I-9
V7
DT
H-9
P07
V06
Intermediate connector
E-7
Airconditioner outsideair
temperature sensor
E-3
V07
Intermediate connector
E-7
A-5
V08
Intermediate connector
E-7
P09
SWP
P15
AMP
R06 SHINAGAWA
B-6
V09
Intermediate connector
E-7
R08 SHINAGAWA
Deceleration relay
J-3
W03
K-9
R09 SHINAGAWA
Accelerator relay
J-3
X05
C-7
R10 SHINAGAWA
B-6
S01
C-3
S05
G-6
S08
G-5
S10
E-3
S17 Terminal
N-4
S30
G-5
S31
G-6
S32
G-6
S33
G-6
S34
G-6
S35
G-7
S36
Intermediate connector
G-7
S37
Intermediate connector
G-7
S50
D-7
S51
D-7
PC128US-2
20-218-9
(17)
TROUBLESHOOTING
20-218-10
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-218-11
(17)
TROUBLESHOOTING
20-218-12
(17)
PC128US-2
Number of
Pins
T-adapter Part
Number
799-601-7010
BWP04702
799-601-7020
BWP04703
BWP04704
BWP04705
799-601-7030
BWP04706
799-601-7040
PC128US-2
20-219
(17)
Number of
Pins
BWP04707
BWP04708
799-601-7050
BWP04709
BWP04711
12
BWP04713
BWP04710
799-601-7060
BWP04712
BWP04714
799-601-7070
(17)
799-601-7310
14
20-220
T-adapter Part
Number
PC128US-2
Number of
Pins
BWP04715
16
BWP04716
T-adapter Part
Number
799-601-7320
PC128US-2
20-221
(17)
M Type Connector
Number of
Pins
T-adapter Part
Number
799-601-7080
BWP04717
BWP04719
BWP04721
BWP04723
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
S Type Connector
Male (Female housing)
BWP04727
10
(white)
BWP04729
12
(white)
BWP04731
16
(white)
BWP04733
PC128US-2
T-adapter
Part Number
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)
T-adapter Part
Number
BWP04736
BWP04738
799-601-7160
BWP04740
799-601-7170
PC128US-2
Number of
Pins
T-adapter Part
Number
11
BWP04741
BWP04742
799-601-2710
BWP04743
BWP04744
799-601-2950
BWP04745
BWP04746
13
799-601-2720
PC128US-2
20-225
(17)
Number of
Pins
BWP04747
BWP04748
17
799-601-2730
BWP04749
BWP04750
21
20-226
(17)
T-adapter Part
Number
799-601-2740
PC128US-2
Number of
Pins
BWP04751
T-adapter Part
Number
BWP04752
799-601-7180
BWP04753
BWP047544
12
799-601-7190
BWP04755
BWP04756
16
799-601-7210
BWP04757
BWP04758
20
799-601-7220
PC128US-2
20-227
(17)
Number of
Pins
10
799-601-7510
12
BWP04761
14
BWP04763
18
BWP04765
20
BWP04767
20-228
(19)
T-adapter Part
Number
BWP04762
799-601-7520
BWP04764
799-601-7530
BWP04766
799-601-7540
BWP04768
799-601-7550
PC128US-2
Number of
Pins
L Type Connector
Male (Female housing)
BWP04769
BWP04770
Number of
Pins
10
BWP04771
T-adapter
Part Number
BWP04772
BWP04773
PC128US-2
PA Type Connector
Number of
Pins
T-adapter
Part Number
T-adapter Part
Number
BWP04774
799-601-3460
20-229
(17)
Number of
Pins
BWP04775
BWP04776
BWP04777
BWP04779
BWP04778
BWP04780
BWP04781
BWP04782
(17)
20-230
T-adapter
Part Number
PC128US-2
Number of
Pins
T-adapter
Part Number
BWP04784
BWP04783
Number of
Pins
BWP04785
BWP04786
799-601-7360
BWP04787
BWP04788
799-601-7370
Type
(shell
size
code)
F Type Connector
T-adapter
Part Number
PC128US-2
T-adapter Part
Number
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)
T-adapter Part
Number
799-601-9210
18-8
(1)
799-601-9210
799-601-9220
18-14
(2)
799-601-9220
20-230-2
(17)
PC128US-2
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector
Type
(shell size
code)
Body (plug)
Body (receptacle)
T-adapter Part
Number
799-601-9230
18-20
(3)
799-601-9230
799-601-9240
18-21
(4)
799-601-9240
PC128US-2
20-230-3
(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)
T-adapter Part
Number
799-601-9250
24-9
(5)
799-601-9250
799-601-9260
24-16
(6)
799-601-9260
20-230-4
(17)
PC128US-2
[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell size
code)
Body (receptacle)
T-adapter Part
Number
799-601-9270
24-21
(7)
799-601-9270
799-601-9280
24-23
(8)
799-601-9280
PC128US-2
20-230-5
(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)
T-adapter Part
Number
799-601-9290
24-31
(9)
799-601-9290
20-230-6
(17)
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)
T-adapter Part
Number
799-601-9020
799-601-9030
799-601-9040
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
12GR:
799-601-9110
12B:
799-601-9120
12G:
799-601-9130
12BR:
799-601-9140
12
20-230-8
(17)
T-adapter Part
Number
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)
T-adapter Part
Number
799-601-9010
Number
of Pins
Body (plug)
Body (receptacle)
T-adapter Part
Number
PC128US-2
20-230-9
(17)
[The pin No. is also marked on the connector (electric wire insertion end)]
No. of
pins
Body (receptacle)
24
799-601-9360
40
(A)
799-601-9350
40
(B)
799-601-9350
20-230-10
(19)
T-adapter
Part No.
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
799-601-2600
Econo-21P
799-601-3100
MS-37P
799-601-3200
MS-37P
799-601-3300
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
799-601-2720
MIC
13P
Q Q
799-601-2730
MIC
17P
Q Q Q Q
Q Q
799-601-2740
MIC
21P
Q Q Q Q
Q Q
799-601-2950
MIC
9P
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
799-601-7010
1P
799-601-7020
2P
Q Q Q
799-601-7030
3P
Q Q Q
799-601-7040
4P
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
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
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
1P
799-601-7090
2P
Q Q Q
799-601-7110
3P
Q Q Q
799-601-7120
4P
Q Q Q
799-601-7130
6P
Q Q Q
799-601-7340
8P
799-601-7140
8P
Q Q Q
799-601-7150
10P-White
Q Q Q
799-601-7160
12P-Blue
Q Q Q
799-601-7170
16P-Blue
Q Q Q
799-601-7330
16P-White
799-601-7350
12P-White
799-601-7180
AMP040
8P
799-601-7190
AMP040
12P
799-601-7210
AMP040
16P
Q Q Q
Q
Q
Q
799-601-7220
AMP040
20P
Q Q Q
799-601-7230
Short connector
X-2
Q Q Q
799-601-7240
Case
799-601-7270
Cace
799-601-7510
070
10P
799-601-7520
070
12P
799-601-7530
070
14P
799-601-7540
070
18P
799-601-7550
070
20P
799-601-7360
Relay connector
5P
799-601-7370
Relay connector
6P
799-601-7380
JFC connector
2P
799-601-9010
DTM
2P
799-601-9020
DT
2P
799-601-9030
DT
3P
799-601-9040
DT
4P
799-601-9050
DT
6P
799-601-9060
DT
8P-Gray
799-601-9070
DT
8P-Black
799-601-9080
DT
8P-Green
Q Q
Q
799-601-9090
DT
8P-Blown
799-601-9110
DT
12P-Gray
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
799-601-9130
DT
12P-Green
799-601-9140
DT
12P-Blown
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
799-601-9320
For DT, HD
Q Q
799-601-9330
Case
799-601-9340
Case
799-601-9350
DRC26
40P
799-601-9360
DRC26
24P
799-601-9410
2P
799-601-9420
3P
799-601-9430
PVC socket
2P
799-601-9710
AMP 2-963215-1
AMP 2-963217-1
for HST controller
16P
799-601-9720
AMP 1-963215-1
AMP 1-963217-1
for HST controller
16P
799-601-9730
AMP 2-1437285-2
AMP 2-1437285-8
for HST controller
26P
PC128US-2
Q
Q
20-230-13
(19)
TROUBLESHOOTING
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
20-231
(17)
TROUBLESHOOTING
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)
TROUBLESHOOTING
PC128US-2
Abnormal system
E02
PC-EPC system
E03
E05
20-233
(17)
TROUBLESHOOTING
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
20-234
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
Abnormality system
User code
E101
E108
E112
E113
E114
E115
E116
E203
E205
E206
E213
E215
E216
E218
E222
E02
E223
E02
E03
E03
20-235
(17)
TROUBLESHOOTING
Service code
20-236
(17)
Abnormality system
User code
E224
E226
E227
E232
E02
E233
E02
E241
E242
E255
E256
Checksum error
E306
E308
E315
E316
E317
E05
E318
E05
E05
PC128US-2
TROUBLESHOOTING
(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:
PC128US-2
20-237
(17)
TROUBLESHOOTING
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
20-238
(17)
PC128US-2
TROUBLESHOOTING
Code No.
Item
0008
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]
Charge level
Buzzer output
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)
20-239
(17)
TROUBLESHOOTING
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
1025
1026
20-240
(17)
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]
(*1)
(*1)
ATT selection 2
ATT selection 1
Model selection 1
ATT selection 3
UU/US selection
Model selection 2
Kerosene mode
Travel selector switch (Panel)
Working mode selector switch
Back lamp
SET/CLEAR switch
Mode selector () switch
Mode selector () switch
(*1)
Motor relay ()
Motor relay (+)
Crane mode switch [monitor]
Display selector switch [monitor]
Arm ground angle warning cancel switch (At connector connection)
(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]
Preheating signal
(*1)
C-terminal signal
(*1)
(*1)
(*1)
(*1)
(*1)
Heater relay
(*1)
20-241
(17)
TROUBLESHOOTING
(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.
20-242
(17)
PC128US-2
TROUBLESHOOTING
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
PC128US-2
20-243
(17)
TROUBLESHOOTING
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
20-244
(17)
PC128US-2
TROUBLESHOOTING
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
PC128US-2
20-245
(17)
TROUBLESHOOTING
20-246
(19)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-246-1
(19)
TROUBLESHOOTING
20-246-2
(17)
(1)
(2)
(3)
(4)
(5)
(6)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-246-3
(17)
TROUBLESHOOTING
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
Model
ATT
Remarks
10
PC128US
Standard arm
Controller default
11
PC128US
Long arm
20
PC138US
Standard arm
21
PC138US
Long arm
Display
20-246-4
(19)
PC128US-2
TROUBLESHOOTING
Travel/Swing
alarm output
(If travel alarm is
installed)
210
Set to 211.
Adjustment of
LS-EPC valve
current
264
310
Change fuel.
When kerosene is
used, engine speed
lower largely.
Set to () side.
Type of fuel
Adjustment of
low idling speed
*
324
Adjustment of
arm crane mode
speed
*
334
344
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.
354
810
400
E-idling speed is
remarkably high.
Set to () side.
E-idling speed is
remarkably low.
B-idling speed is
remarkably high.
Set to () side.
B-idling speed is
remarkably low.
If 401 is selected, all service adjustment items are set to initial values.
PC128US-2
20-246-5
(19)
TROUBLESHOOTING
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700
controller (decelerator control) system E3:
.
2) When a service code is not displayed on the monitor panel and ENGINE DOES NOT START:
When the starting motor rotates:
Check the rotation
.... Advance to MECHANICAL SYSTEM TROUBLESHOOTING S-2.
of a starting motor.
When the starting motor does not rotate:
.... Advance to ELECTRICAL SYSTEM TROUBLESHOOTING E-8.
20-252
(17)
PC128US-2
TROUBLESHOOTING
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.
<Example> 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
20-253
7
TROUBLESHOOTING
Troubleshooting device
Service code
N-cc
E-cc
C-cc
CR700 controller (pump control system) electrical system troubleshooting E2-cc system
F-cc
H-cc
M-cc
E3-cc system
E1-cc system
20-254
(17)
PC128US-2
TROUBLESHOOTING
<Example>
[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.
NO
Defective alternator
Replace
Repair or
replace
Replace
YES
2
Disconnect P02.
Set the starting switch to ON.
1V max.
NO
YES
PC128US-2
20-255
(17)
TROUBLESHOOTING
To item 2
1
Is service code of
monitor panel
displayed?
YES
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 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
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.
Working mode
E mode
E mode
Throttle signal
E mode or equivalent
E mode or equivalent
Auto decelerator
ON (Decelerator mode)
ON (Decelerator mode)
Immersion signal
Travel speed
Lo
Automatic warm-up
Table 1
Working mode
A
Arm crane
PC128US-2
Operation
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
Operating condition
Travel Hi/Lo
2-stage relief
Note 1: Perform the lever operation slightly in such degree that the machine cannot move.
20-258
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-259
(17)
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
20-302
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-303
(17)
TROUBLESHOOTING
20-304
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-305
(17)
TROUBLESHOOTING
PC-EPC SYSTEM
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-306
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-307
(17)
TROUBLESHOOTING
20-308
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-309
(17)
TROUBLESHOOTING
E-1
(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
between C01
Between C13
YES (female) (3) - (4),
(female) (1)(2) - chassis ground :
between (3)(4) Min. 1 M
chassis ground
Turn starting switch OFF.
normal?
Disconnect C01.
Between C01
5 YES
(female) (3) - (4) :
Is resistance
500 - 1000
between E07
Between C01
(female) (1) - (2),
(female) (3)(4) chassis ground : NO between (1)(2) chassis ground
Min. 1 M
normal?
1 Turn starting
switch OFF.
Between C01
NO
Disconnect C01.
(female) (3) - (4) :
Does LED of pump
500 - 1000
controller flash?
Between C01 (female)
(3)(4) - chassis ground :
Min. 1 M
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 M
NO
Turn starting switch OFF.
Disconnect C05.
PC128US-2
Remedy
4 YES
To A
Repair or replace
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
Replace
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
Replace
Repair or replace
Replace
20-311
(17)
TROUBLESHOOTING
E-1
Cause
2 YES
Is voltage between
YES C01 (1) and chassis
ground normal?
5 YES
Is pump controller
LED off?
Is resistance
7 14
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?
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
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.
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
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 operators 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
chassis ground
Turn starting switch OFF
normal?
Disconnect C06
Between C13
2
(male) (1) - (2) :
NO
Is resistance
8 - 15
between CR2
Between C13
YES (female) (39) - (40),
(male) (1)(2) - chassis ground :
between (39)(40) Min. 1 M
chassis ground
Turn starting switch OFF.
normal?
Disconnect CR3.
Between CR2
5 YES
(female) (39) - (40) :
Is resistance
500 - 1000
between E07
Between CR2
(female) (2) - (1),
(female) (39) - (40)
1
chassis ground : NO between (2)(1) chassis ground
Min. 1 M
normal?
Turn starting
Does LED of pump
switch OFF.
Between CR2
NO
Disconnect CR2.
controller flash?
(female) (39) - (40) :
500 - 1000
Between CR2 (female)
Start engine.
(39)(40) - chassis ground : Min. 1 M
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 M
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
Reset up
Repair or replace
20-315
(17)
TROUBLESHOOTING
E-1
Cause
2 YES
Is voltage between
YES CR3 (2) (12) (22)
and chassis
ground normal?
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
NO (1), or defective contact or
disconnection in wiring
Turn starting switch
harness between C06
OFF.
(female) (23) and C13 (female)
Disconnect C06.
(6)
Turn starting
switch ON.
3
Does pump
controller LED
NO flash?
8 15
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
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.
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
PC128US-2
20-317
(17)
TROUBLESHOOTING
E-2
Remedy
Defective contact or
Is resistance
YES between S12 and
S13 (wiring
harness end)
2
normal?
Is resistance
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
Turn starting switch OFF. chassis ground
Disconnect S13.
Max. 1
Turn starting
NO
switch OFF.
Remove S12 and S13.
Safety lock lever: FREE
20 30 V
Turn starting switch
ON.
NO
Repair or replace
Repair or replace
Replace
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 M
[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
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
Defective contact or
disconnection in wiring
NO harness between S10
Max. 1
Turn starting switch OFF. (female) (1) - fuse (14)
Disconnect S13.
37 - 60
Turn starting
NO
switch OFF.
Remove S10.
Safety lock lever: FREE
Between V7 (male)
(2) - (1) :37 - 60
Between V7
NO
(male) (2) - chassis ground :
Min. 1 M
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
YES
1
Is voltage between
V7 (1) and (2)
normal?
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 M
[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
Repair or replace
Replace
PC128US-2
TROUBLESHOOTING
E-2
PC128US-2
20-321
(17)
TROUBLESHOOTING
E-3
4 YES
resistance
YES Is
between S08
3
(female) (2), S30
Disconnect
S08,
(male) (1) and (2)
NO
S30, and S05.
normal?
Start engine.
Operate swing or arm control
20 60
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
Min. 1
NO
Turn starting switch
OFF.
Disconnect C03 and V04.
Min. 1
Turn starting switch
NO
OFF.
Disconnect C03.
NO
Is resistance
YES between X05
(female) (4) and
9
V04 (female) (2)
normal?
NO
Max. 1
Turn starting switch OFF.
Disconnect X05 and V04.
Min. 1
Turn starting switch NO
OFF.
Disconnect X05.
20-322
(17)
Repair or replace
Repair or replace
Replace
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?
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
YES chassis, is
NO
resistance between
Turn starting switch
C03 (female) (4) and
6
OFF.
chassis ground
Disconnect X05.
normal?
Remedy
Replace
Defective contact or
disconnection in wiring
harness between X05
(female) (4) and C03
(female) (3)
Repair or replace
Repair or replace
PC128US-2
TROUBLESHOOTING
E-3
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause
YES
1
Is voltage between
V04 (1) and (2)
normal?
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 M
[FREE] (solenoid
Turn starting switch OFF.
ON) : 20 30 V
Turn starting switch Disconnect X05.
Swing lock switch: [LOCK]
ON.
Remedy
Replace
Defective contact or
disconnection in wiring
harness between V04
(female) (2) and X05
(female) (4)
Repair or 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
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
NO
S05 (male) (1) - (2)
1
Turn starting switch OFF.
normal?
Disconnect C03, S08, and
Min. 1
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
lever slightly (but do not move
work equipment).
Turn starting switch
OFF.
NO
Disconnect V4.
Go to A
Is resistance
Min. 1
NO
Turn starting switch
OFF.
Disconnect C03 and V4.
Min. 1
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
Replace
Replace
NO
Is resistance
YES between X05
(female) (4) and V4
9
(female) (2)
normal?
NO
Max. 1
Turn starting switch OFF.
Disconnect X05 and V4.
Min. 1
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
YES chassis, is
NO
resistance between
Turn starting switch
CR3 (female) (3)
6
OFF.
and chassis ground
Disconnect X05.
normal?
Remedy
Replace
Defective contact or
disconnection in wiring
harness between X05
(female) (4) and V4 (female)
(2)
Repair or replace
Repair or replace
PC128US-2
E-3
TROUBLESHOOTING
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause
YES
1
Is voltage between
V4 (1) and (2)
normal?
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 M
[FREE] (solenoid
Turn starting switch OFF.
ON) : 20 30 V
Turn starting switch Disconnect X05.
Swing lock switch: [LOCK]
ON.
Remedy
Replace
Defective contact or
disconnection in wiring
harness between V4
(female) (2) and X05
(female) (4)
Repair or replace
PC128US-2
20-325
(17)
TROUBLESHOOTING
E-4
Remedy
Defective contact or
1
Is voltage between
V05 (female) (1)
and chassis
ground normal?
(1)(2) - chassis
ground normal?
Defective contact or
disconnection in wiring
harness between M39
Max. 1 . Turn
NO (female) (1) and chassis
Starting switch OFF.
ground
Disconnect S13.
20 - 30 V
Turn starting switch
ON.
NO
Repair or replace
Repair or replace
Replace
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
YES
1
Is voltage between
V05 (1) and (2)
normal?
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 M
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
Repair or replace
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
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?
Between V5 (male)
(2) - (1): 37 - 60
Between V5 (male) NO
(1)(2) - chassis ground : Min. 1 M
Turn starting switch OFF.
Disconnect V5.
20 - 30 V
Turn starting switch
NO
ON.
20-328
(17)
PC128US-2
TROUBLESHOOTING
E-5
2 YES
YES Is voltage between
C05 (5) and (10)
normal?
Is voltage between
C05 (2) and (1)
normal?
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
Remedy
YES
3
Is voltage between
C05 (2) and chassis
NO ground normal?
Disconnect C05
Turn starting switch NO
ON.
18 28V
2 YES
Is resistance beYES tween C02 (female) (6) and (11)
normal?
1
Is resistance between E07 (male)
(1) and (2) normal?
PC128US-2
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?
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
Remedy
YES
3
Is voltage between
C05 (B) and
NO chassis ground
normal?
Disconnect C05
Turn starting switch NO
ON.
4.5 5.5V
2 YES
Is resistance beYES tween CR3 (female) (39) and (40)
normal?
1
Is resistance between E07 (male)
(1) and (2) normal?
PC128US-2
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
5
Is voltage between
battery relay
terminal M and
NO chassis ground
normal?
20 30 V
Turn starting
switch ON.
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
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?
20 30 V
Turn starting switch
ON.
2
YES Is sound heard
from battery relay?
Turn starting
switch ON OFF.
20 30 V
Turn starting switch
ON.
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.
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?
NO
20 30 V
Turn starting switch
ON.
20-334
(17)
PC128US-2
E-6
TROUBLESHOOTING
Cause
YES
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 (+)
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
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
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
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
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
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?
20 30 V
Turn starting
switch ON.
YES
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.
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?
NO
20 30 V
Turn starting switch
ON.
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
Replace
11
Is voltage between
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
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
20
Is voltage between
S10 (1) and chassis
Is voltage between
starting switch T12
NO and chassis
ground normal?
Repair or replace
Replace
NO (between B - ACC)
Is voltage between
starting switch T9
and chassis
ground normal?
20 30 V
Starting switch:
START
PPC lock switch:
LOCK
Replace
Disconnection or defective
(17)
Repair or replace
Disconnection or defective
contact in wiring harness
20 30 V
Starting switch:
ON
20-340
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
Remedy
NO (Between B - C)
Repair or replace
Replace
PC128US-2
TROUBLESHOOTING
E-6
PC128US-2
20-341
(17)
TROUBLESHOOTING
l. 017tr
\ IVI
-
G
2
T-
Swing motor
T-
l-
Travel motor
a,
2
P
-ii
L
-s
5
-
s
J
4
z
.P
2
.a
.s
t
8
:
-
P
-
s
ST
;5
5
G
s
iz
s
-
PC128US-2
L
b
E
-
rrs-
l
0
l
0
cG
-
Ts
-
i00
s-
l
DO
8
b
t;
v
I
7
8
E
.-
5
7
.-E
i;
e
-
1
?
$
>
$
E
SOIC aid
5
.?
s 6 1
27T 2& s
is 2 z %
E 2
J
i-
al
2 u2 6
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i -
E
F
- - -6
6
- - F
- - - - - - - - - - - - - - - - - - -
2
a
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
Check that there is no abnormal noise from the pump before starting troubleshooting.
abnormal noise, carry out troubleshooting
for H-4.)
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
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.
GotoA
NO
pressure reducing
. Arm relief
pressure) normal?
6
A
YES
Is LS differential
pressure normal?
Defective
valve
20-404
0
For details,
see, TESTING
AND
of
pump LS
ADJUSTING,
Ieplace
Testing and
PC1 28US-2
H-3
TROUBLESHOOTING
3 YES
YE
NO
IO
YES
fiiisz?p
Al
NO
NO
20-406
0
Replace
Repair or replace
Go to Troubleshooting of
Electric System E-3b)
Repair or replace
Repair or replace
Repair or replace
Defective PTO
Repair or replace
p5jiiiJHP
Remedy
PC1 28US-2
H-4, H-5
TROUBLESHOOTING
H-4 Abnormal
noise generated
(around pump)
Cause
3 YES
YE
Go to Item 4
NO
YE
Remedy
:hange
lydraulic oil
Is suction strainer
blocked by
external object?
n
Is hydraulic tank
oil level normal?
Repair or replace
Check again
[according to
change in
symptoms)
Add hydraulic oi
Fine control
ability is poor or
response is poor
% External object:
cloth, etc.
N0
Cause
YES
1
Is pump servo
orifice clogged?
2 YES
Does condition
_ become normal
NO when LS valve is
replaced?
Remedy
Jean
Defective LS valve
Replace
Replace
NO
PC1 28US-2
20-407
0
TROUBLESHOOTING
H-6
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?
$;w.compensation NO
1
Is PPC valve
output pressure
normal?
* 3.24 * 0.49 MPa
133 t 5 kg/cm4
. Engine at full
throttle
- Operate lever fully.
20-408
0
Note
* 15 cclmin
*Engine at full
throttle
NO
6 YES
Is pressure
reducing valve
piston throttle free
of clogging?
NO
be sure to
return the valves to their original
positions after checking.
NO
NO
PC128US-2
ELECTRICAL
TROUBLESHOOTING
panel
CIRCUIT DIAGRAM
FOR MONITOR
Starting
FOR MONITOR
SYSTEM
SYSTEM
Alarm
buzzer
switch
B BRACC C R, Rz
OFF 0
HEAT 0 0 o--o
ON
000
START 0 0 0 O--o
Q
Fuse
Bat terv
308
308
tterv
lay
,301;
h
0
Fuel level
sensor
20-502
0
Alternator
Engine
level
water
sensor
Engine
oil
pressure
switch
Fusible
I ink
TXP0.2417
PC128US-2
TROUBLESHOOTING
M-l
*
*
*
M-l
YES
, I
Is voltage between
PO1 (female) (1)
and (3) normal?
*20-30V
*Turn starting
switch ON.
YES
Is fuse 2 normal?
NO
M-l
Related electrical
inserted.
Replace
Defective contact or
disconnection in wiring
harness between PO1
(female) (1) and fuse 2, or
between PO1 (female) (3)
and chassis ground
Repair or replace
wiring harness
Blown fuse 2
Check cause of
blown fuse, then
repair, and
replace fuse
circuit diagram
Fusible
I ink
Monitor
Panel
nA4
l-v I
I I GND
Ml4
.
.
I
IAAA~C
\vLtv
I u
\
CNll
($WP,l 6)
i%
PC1 28US-2
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
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
Caution
YES
I
Is there
disconnection in
20-504
0
1 Remedy
Replace
Cause
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
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
Defective alternator
NO
Replace
Repair or replace
wrng harness
Replace
circuit diagram
Panel
I
PO1 (04016)
:CN-2
(SWP12)
Alternator
El7 (X2)
3
--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
P=2 YES
Monitor
inserted.
Remedy
Replace
Defective contact or
disconnection in wiring
harness between PO1
(female) (9) and S17 Wiring
harness end)
Repair or replace
wiring harness
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
Cause
YES
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?
Monitor
circuit diagram
Panel
TXP0242
PC1 28US-2
20-507
0
M-7
TROUBLESHOOTING
M-7
*
Ir
*
Remedy
Cause
YES
1
-Disconnect S13.
* Start engine.
2 YES
Is circuit between
_ PO1 (female) (9)
_
NO and chassis
ground insulated?
NO
- Min. 1 MR
* Disconnect PO1 and P13.
-Turn starting switch OFF.
M-7 Related
Monitor
electrical
Replace
inserted.
Replace
Repair or replace
wiring harness
circuit diagram
Panel
PO1 (04016)
w-2
(SWP12)
D
E20
(SWP8)
Engine oil
Pressure switch
TXP02.420
20-508
0
PC1 28US-2
M-8
TROUBLESHOOTING
M-8
*
*
*
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
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
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)
temperature
remains
at bottom
inserted.
RemedY
YES
1
Does level go up
one at a time and
finally go out?
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
Repair or replace
wiring harness
Replace
immediately
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
Repair or replace
wiring harness
circuit diagram
Panel
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
a) No segments
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
-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
Cause
Remedy
YE
inserted.
Remedy
?eplace
Repair or replace
wiring harness
i(eplace
Defective contact or
disconnection in wiring
harness between PO1
(female) (3) and chassis
ground
Repair or replace
wiring harness
20-511
0
TROUBLESHOOTING
c)
M-10
Even when tank is filled, fuel gauge does not give full tank display
2 YES
Is resistance of
fuel level sensor
normal?
- Remove sensor.
.zdv;;;;;rV
hand
* start engie.
- Max. 0.1 V
k
NO
NO
Cause
1 Remedy
Replace
Defective contact or
disconnection in wiring
harness between PO1
(female) (3) and chassis
ground
Repair or replace
wiring harness
Replace
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
of alarm buzzer
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
~~~
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
Replace
when PO1 is
disconnected?
-Disconnect POl.
NO
-Turn starting switch
ON.
M-l 1 Related
electrical
circuit diagram
1 (KESl
PO4 (M2)
2)
@.
Panel
=
-
a
Monitor
Repair or replace
wiring harness
Al arm
buzzer
Fusible
I ink
3
ry
TXP02426
PC1 28U.52
20-513
0
M-12
TROUBLESHOOTING
a)
When battery
charge caution
inserted.
YES
1
Is voltage between
PO1 (female) (10)
and (3) normal?
NO
*Start engine.
.20-30V
b)
When battery
charge caution
Replace
Repair or replace
wiring harness
lamp lights up
Remedy
No. M-9.
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
qepair or replacf
3eolace
No
Monitor
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
Gauge lighting
inserted.
Cause
1
Is voltage between
PO1 (female) (16)
and (3) normal?
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
electrical
Repair or replace
wiring harness
Cause
M-13 Related
Rep,ace
Fusible
I ink
Battery
relay
TXP02428
20-515
0
M-14
TROUBLESHOOTING
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?
NO
* Turn starting
switch OFF.
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
Replace
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
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
c)
Remedy
Go to troubleshooting of
heater
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
20-5 16
0
PC1 28US-2
TROU~~LESHOOTING
M-14
Preheating
switch
~06 (KES~
~12 (KES~
4)
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
20-556
(17)
PC128US-2
TROUBLESHOOTING
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-558
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-559
(17)
TROUBLESHOOTING
M-1
Cause
Remedy
1
After making the "Resetting arrangement," check the situations for a while in the normal
operation. (See Note 1.)
Normal
YES
2
Set the starting switch to
OFF.
20 30V
YES
Defective monitor panel
Replace
Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)
20-560
(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.)
Normal
YES
2
Set the starting switch to
OFF.
20 30V
YES
Defective monitor panel
Replace
Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)
PC128US-2
20-561
(17)
TROUBLESHOOTING
Cause
Remedy
1
Does the coolant temperature gauge NO
on the monitor indicate a red range
and is the caution lamp flashing?
YES
See M-13-c).
2
Set the starting switch to ON.
YES
Defective monitor panel
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 105C so far, remove the factors in the troubleshooting of the engine body.
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
YES
Defective monitor panel.
Replace
2
Set the starting switch to ON.
20 30V
YES
Repair or
replace
3
Set the starting switch to ON.
20 30V
YES
Repair or
replace
Cause
PC128US-2
Remedy
Replace
20-563
(17)
TROUBLESHOOTING
M-8
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
1
Set the starting switch to ON.
20 30V
YES
Defective monitor panel.
Replace
2
Set the starting switch to ON.
20 30V
YES
Repair or
replace
3
Set the starting switch to ON.
20 30V
YES
Repair or
replace
Cause
PC128US-2
Remedy
Replace
20-565
(17)
TROUBLESHOOTING
M-8, M-9
M-9 The starting switch is set to ON, and the whole monitor panel
remains lighted.
Cause
20-566
(17)
Remedy
Replace
PC128US-2
TROUBLESHOOTING
M-10
M-10
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
Replace
YES
2
Set the starting switch to
ON.
Max. 1V
YES
Defective monitor panel
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
Replace
YES
2
Set the starting switch to
ON.
Max. 1V
YES
3
Are the monitoring code [0045] NO
(3) and [1027] (3) ON?
Defective controller
Replace
Defective controller
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
Defective alternator
Replace
YES
2
Engine start, Medium speed
min.
20 30V
YES
Defective monitor panel.
Replace
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-569
(17)
TROUBLESHOOTING
M-11
Cause
Remedy
1
Engine slow
YES
Replace
Replace
2
Set the starting switch to OFF.
Disconnect the sensor harness
and P02.
YES
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-570
(17)
PC128US-2
TROUBLESHOOTING
M-12
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
Defective alternator
Replace
YES
2
Disconnect P02.
Set the starting switch to ON.
Max. 1V
YES
Defective monitor panel
Replace
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-571
(17)
TROUBLESHOOTING
M-12
Cause
Remedy
1
Set the starting switch to OFF.
Disconnect the sensor terminal
S17.
Replace
YES
2
Set the starting switch to ON.
Disconnect P02 and sensor
terminal S17.
YES
Defective monitor panel
Replace
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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)
Cause
See M-12-b).
b)
Cause
See M-12-a).
PC128US-2
Remedy
Remedy
20-573
(17)
TROUBLESHOOTING
c)
M-13
Before diagnosis, make sure that the engine oil pressure is normal.
Cause
Remedy
1
Engine start
Medium speed min.
Replace
YES
2
Engine start
YES
3
Set the starting switch to OFF.
Disconnect P02 and P07.
Max. 1
YES
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-574
(17)
PC128US-2
TROUBLESHOOTING
d)
M-13
Cause
Remedy
1
Engine start
NO
Replace
YES
Engine start
Wait for 2 minutes approx.
(The display of fuel level is
arranged to be slightly delayed because the fuel level
fluctuates.)
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
Replace
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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. 1
Set the buzzer cancel switch
to OFF : Min. 1 M
Remedy
1
Is the resistance value between NO
P03 (female) (1) a d (2) normal?
Replace
YES
2
Disconnect P03.
Set the starting switch to ON.
20 30V
YES
Defective monitor panel
Replace
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-576
(17)
PC128US-2
TROUBLESHOOTING
M-15
Cause
Remedy
1
Set the starting switch to ON.
Set to Monitoring Code
[0045].
NO
YES
Defective monitor panel
Replace
2
Set the starting switch to ON.
Set the lighting switch to ON.
20 30V
YES
Defective monitor panel
Replace
PC128US-2
20-577
(17)
TROUBLESHOOTING
M-16, M-17
When engine water temperature does not rise practically, flashes the engine system.
Cause
Remedy
1
Disconnect P07.
Set the starting switch to ON.
YES
Repair or
replace
Repair or
replace
Replace
2
Set the starting switch to OFF.
Disconnect P02 and P07.
YES
3
Set the starting switch to OFF.
Disconnect P02 and P07.
NO
YES
Remedy
1
Disconnect P07.
Set the starting switch to ON.
YES
2
Set the starting switch to ON.
Disconnect P02 and P07.
YES
20-578
(17)
Replace
Repair or
replace
PC128US-2
TROUBLESHOOTING
M-16, M-17
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
2
Set the starting switch to
OFF.
Disconnect P02 and P06.
YES
Cause
Remedy
1
Disconnect P06.
Set the starting switch to ON.
YES
2
Set the starting switch to OFF.
Disconnect P02 and P06.
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)
Replace
PC128US-2
TROUBLESHOOTING
M-18, M-19
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-581
(17)
TROUBLESHOOTING
M-20, M-21
Remedy
1
Is the voltage between P02 (17) NO
and the machine body as per the
table?
YES
Table
Swing lock switch ON
Swing lock switch OFF
Replace
Max. 1V
20 30V
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
M-21 While the engine is rotating, the service meter does not advance.
Cause
Remedy
1
Start the engine.
Medium speed min.
Replace
YES
20-582
(17)
PC128US-2
TROUBLESHOOTING
M-22
Cause
Remedy
1
Check by raising and lowering
the float if the resistance valve NO
between the connector (1) and
the flange is as per the table.
YES
2
NO
Replace
Clean or
replace the
connector.
Replace the
sensor.
(See Note 2.)
Defective sensor
Replace
YES
YES
4
Is it found in visual check that the NO
harness is cut?
YES
Table
Upper stopper position
(Full)
About Max. 12
About 85 110
PC128US-2
20-583
(17)
TROUBLESHOOTING
M-23
Remedy
1
Is the resistance value between the NO
temperature sensor connectors
(male) (1) and (2) as per the table?
YES
Clean the
connector or
replace the
sensor.
Defective sensor
Replace
2
Is it found in visual check that the NO
harness is cut?
YES
Table
Normal temperature (25C)
About 37 50k
100C
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
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
Replace
YES
3
Set the starting switch to ON.
NO
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
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. 1
YES
Defective monitor panel
Replace
Remedy
1
Front window : Closed position
Set the starting switch to ON.
Set the monitoring code to
[0049]
NO
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
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
Tsa
10 sec
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.
Tia
4 sec
Tsa
10 sec
Tip
1.5 sec
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
Max. 1
20-586
(17)
Min. 1M
PC128US-2
TROUBLESHOOTING
M-24
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
YES
Repair or
replace
Cause
Remedy
1
Set the starting switch to ON.
Disconnect M28.
Max. 20 30V
YES
2
Set the starting switch to OFF.
Disconnect P01 and M28.
Max. 1
Repair or
replace
Replace
Replace
YES
3
Set the starting switch to ON.
Set the washer switch to ON.
Max. 1V
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
YES
Defective monitor panel
20-588
(17)
Replace
PC128US-2
TROUBLESHOOTING
M-25
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
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
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
1
Cause
Remedy
YES
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
Replace
When each controller is not connected to the network, "---" is displayed. When a correct alphanumeric
character is not displayed (when another model is displayed), the model of each controller has not been
selected properly.
20-602
(17)
PC128US-2
TROUBLESHOOTING
N-1
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
1
Cause
Remedy
YES
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
Replace
PC128US-2
20-603
(17)
! 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)
TROUBLESHOOTING
Deceleration-motor
potentiometer
(Controls the process.)
Any rpm
(Follows the throttle
direction.)
2 seconds
Starting switch
turned "ON"
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
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
Cause
Remedy
1
Turn starting switch ON
20 30V
YES
Defective controller CR700
Replace
2
Starting switch ON
20 30V
YES
20-712
(17)
PC128US-2
TROUBLESHOOTING
E-1
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-713
(17)
TROUBLESHOOTING
E-2
E-2
Remedy
1
Is current value normal between NO
CR3 (female) (18) and (23)?
YES
Defective controller
Replace
2
Detach R07 and CR3.
Min. 1 M
YES
Defective relay
Replace
20-714
(17)
PC128US-2
TROUBLESHOOTING
E-3
E-3
Cause
Remedy
1
Turn starting switch ON;
operate dial (up).
1.2A or less
YES
Defective controller
Replace
2
Detach R09 and CR3.
Min. 1 M
YES
Defective relay
Replace
PC128US-2
20-715
(17)
TROUBLESHOOTING
E-3
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-716
(17)
PC128US-2
TROUBLESHOOTING
E-4
E-4
Remedy
1
Turn starting switch ON;
operate dial (down).
1.2A or less.
YES
Defective controller
Replace
Defective harness
Repair or
replace
Defective relay
Replace
2
Detach R08 and CR3.
Min. 1 M
YES
PC128US-2
20-717
(17)
TROUBLESHOOTING
E-4
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-718
(17)
PC128US-2
TROUBLESHOOTING
E-5
E-5
! 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
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
Repair or
replace
2
Do relays of R07, R08 and R09 NO
operate normally?
YES
PC128US-2
20-719
(17)
TROUBLESHOOTING
E-5
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-720
(17)
PC128US-2
E-6
TROUBLESHOOTING
E-6
Remedy
YES
Defective controller
Replace
Replace
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
Remedy
1
NO
YES
Defective controller
Replace
Replace
Defective harness
Replace
motor
Testing and
adjusting
2
Detach E07
500 1,000
NO
YES
3
Detach CR2
500 1,000
YES
(*1) PC128US-2
PC138USLC-2
(*2) PC138US-2
PC138USLC-2
NO
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-722
(17)
PC128US-2
E-8
TROUBLESHOOTING
E-8
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 k
Between (2) (3):
1.4 5.5 k
Between (1) (3): 5 1 k
Between M48 (male) (1), (2),
(3) chassis ground:
Min. 1 M
(*1) PC128US-2
PC138USLC-2
(*2) PC138US-2
PC138USLC-2
Remedy
1
Is feedback potentiometer voltage NO
of monitoring 1035 normal?
YES
Defective controller
Replace
Replace
Repair or
replace
2
Is resistance between M48 (male) NO
(1), (2), and (3) normal?
YES
PC128US-2
20-723
(17)
TROUBLESHOOTING
E-8
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-724
(17)
PC128US-2
E-9
TROUBLESHOOTING
E-9
Disconnect CR1.
Resistance between CR1
(female) (22) chassis
ground: Min. 1 M
Cause
Remedy
YES
Disconnect M48.
Resistance between CR1
(female) (22) chassis
ground: Min. 1 M
Defective controller
Replace
Replace
Repair or
replace
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 M
3
Is resistance between CR1 (female) NO
(22) and chassis ground normal?
YES
PC128US-2
20-725
(17)
TROUBLESHOOTING
E-9
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-726
(17)
PC128US-2
E-10
TROUBLESHOOTING
Remedy
1
Is resistance between CR3 (female)
(4) and chassis ground normal?
NO
YES
Defective controller
Replace
Replace
Repair or
replace
Replace
Disconnect M52.
Resistance between M52
(male) (1) (2): 68 10%
Resistance between M52
(male) (1), (2) chassis
ground: Min. 1 M
Disconnect D32
(with M52 disconnected).
Resistance between CR3
(female) (4) chassis
ground: Min. 1 M
NO
YES
3
NO
YES
PC128US-2
20-727
(17)
TROUBLESHOOTING
E-11
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?
Replace
Defective controller
Replace
Replace
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
! 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)
TROUBLESHOOTING
User codes
Traveling system
Compound
operation
Work-equipment
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
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
20-808
(17)
PC128US-2
TROUBLESHOOTING
Monitoring codes
1023
1021
1060
Bit patterns
227
Model code
Traveling
Arm IN (5)
Traveling (3)
224
Status of solenoid in
operation
Oil-pressure switch
Swinging (4)
Abnormality in pump
pressure 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
User codes
Traveling system
Compound
operation
Work-equipment
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
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
20-810
(17)
PC128US-2
TROUBLESHOOTING
1023
Monitoring codes
1028
1021
1060
Bit patterns
227
Model code
Traveling
Arm IN (5)
Traveling (3)
224
Status of solenoid in
operation
Oil-pressure switch
Swinging (4)
Abnormality in pump
pressure 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
20-812
(17)
PC128US-2
TROUBLESHOOTING
(2/2)
PC128US-2
20-813
(17)
TROUBLESHOOTING
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
(1/2)
20-814
(17)
PC128US-2
TROUBLESHOOTING
(2/2)
PC128US-2
20-815
(17)
TROUBLESHOOTING
C-1
C-1
Cause
2 YES
Defective controller
Remedy
Replace
Is voltage normal
(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
20-816
(17)
PC128US-2
TROUBLESHOOTING
C-1
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-817
(17)
TROUBLESHOOTING
C-2
!
C-2
Cause
YES
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
NO
Remedy
Replace
Table 1
Diagnosis No.2
Diagnosis No.3
Diagnosis No.4
Resistance
8 15
Min. 1 M
Table 2
Diagnosis No.5
C06 (male) (2) (3), (5) (6)
C06 (female) (2), (3), (5), (6) body
20-818
(17)
Resistance
Max. 1
Min. 1 M
PC128US-2
TROUBLESHOOTING
C-2
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-819
(17)
TROUBLESHOOTING
C-3
C-3
! 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
NO
Remedy
Replace
Repair or
replace
Replace
Repair or
replace
Replace
Table 1
Diagnosis No.2
Diagnosis No.3
Diagnosis No.4
Resistance
8 15
Min. 1 M
Table 2
Diagnosis No.5
C06 (male) (2) (3), (5) (6)
C06 (female) (2), (3), (5), (6) body
20-820
(17)
Resistance
Max.1
Min. 1 M
PC128US-2
TROUBLESHOOTING
C-3
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-821
(17)
TROUBLESHOOTING
C-4
C-4
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
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).
NO
Replace
to A
Defective swing-holding-brake
solenoid (inner short-circuit or Replace
ground fault)
5 YES
4
Remedy
Table 1
V04 (male)(1) (2)
37 60
Min. 1 M
20-822
(17)
PC128US-2
TROUBLESHOOTING
C-4
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
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).
NO
Replace
to A
Defective swing-holding-brake
solenoid (inner short-circuit or Replace
ground fault)
5 YES
4
Remedy
Table 1
V4 (male)(1) (2)
37 60
V4 (male)(2) body
Min. 1 M
20-824
(17)
PC128US-2
TROUBLESHOOTING
C-4
PC128US-2
20-825
(17)
TROUBLESHOOTING
C-5
C-5
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
ones?
Turn starting switch
OFF.
Replace V04 with NO
another one.
Turn starting switch ON.
Remedy
Replace
to A
Disconnection or defective
contact of harness between Repair or
Turn starting
NO CR3 (female)(7) and D08 (fe- replace
male)(2).
switch OFF.
Disconnect D08, CR3.
Disconnection, defective con Max. 1
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
20 30 V
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
ones?
Turn starting switch
OFF.
Replace V4 with
NO
another one.
Turn starting switch ON.
Remedy
Replace
to A
Disconnection or defective
contact of harness between Repair or
Turn starting
NO CR3 (female)(7) and D02 (fe- replace
male)(8).
switch OFF.
Disconnect D02, CR3.
Disconnection, defective con Max. 1
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
20 30 V
PC128US-2
TROUBLESHOOTING
C-5
PC128US-2
20-829
(17)
TROUBLESHOOTING
C-6
C-6
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
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
Table 1
V05 (male)(1) (2)
37 60
Min. 1 M
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
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
Table 1
V5 (male)(1) (2)
37 60
V5 (male)(2) body
Min. 1 M
PC128US-2
20-831
(17)
TROUBLESHOOTING
C-7
C-7
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
Turn
starting
after replacing the
switch
OFF.
solenoid and conNO
Disconnect V05.
nector with other
37
60
ones?
Turn starting switch
OFF.
Replace V03 with NO
another one.
Turn starting switch
ON.
NO
Remedy
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
Turn
starting
after replacing the
switch
OFF.
solenoid and conNO
Disconnect V5.
nector with other
37
60
ones?
Turn starting switch
OFF.
Replace V5 with
NO
another one.
Turn starting switch
ON.
NO
Remedy
PC128US-2
20-833
(17)
TROUBLESHOOTING
C-8
C-8
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Cause
3 YES
Remedy
Replace
Is resistance nor-
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
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
Table 1
V06 (male)(1) (2)
37 60
Min. 1 M
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
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
Table 1
V6 (male)(1) (2)
37 60
V6 (male)(2) body
Min. 1 M
PC128US-2
20-835
(17)
TROUBLESHOOTING
C-9
C-9
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
Turn starting switch
after replacing the
OFF.
solenoid and conNO
Disconnect V06.
nector with other
37 60
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.
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
Turn starting switch
after replacing the
OFF.
solenoid and conNO
Disconnect V6.
nector with other
37 60
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.
PC128US-2
20-837
(17)
TROUBLESHOOTING
C-10
Cause
2 YES
Remedy
Replace
Replace
Table 1
Diagnosis No.1
Diagnosis No.2
Resistance
8 15
Min. 1 M
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-838
(17)
PC128US-2
TROUBLESHOOTING
C-11
Cause
2 YES
Remedy
Replace
Replace
Table 1
Diagnosis No.1
Diagnosis No.2
Resistance
8 15
Min. 1 M
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-839
(17)
TROUBLESHOOTING
C-12
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
Neutral lever.
Turn starting switch
0.5 4.5 V
OFF.
Attach T-adapter.
NO
Run engine at full
speed.
5V
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
20-840
(17)
PC128US-2
TROUBLESHOOTING
C-13
Remedy
Replace
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-841
(17)
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
20-902
(17)
PC128US-2
TROUBLESHOOTING
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
20-903
(17)
TROUBLESHOOTING
F-1
Turn on swing-lock switch before operating swing lever (even if just for a moment).
If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.
Cause
Detach S08.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for L.H.
swinging: Max. 1
Refer to Note.
Detach S30.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for
R.H. swinging: Max.1
Refer to Note.
Remedy
1
Defective L.H. swing pressure switch
Replace
Replace
YES
YES
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
YES
Defective controller CR700
Replace
[Note] You may diagnose with a short-circuit connector attached.In step 2 of diagnosis,
if the voltage between CR1(24) and body is 20 30 V, go to YES;
if it is 1 V or less, go to NO.
20-904
(17)
PC128US-2
TROUBLESHOOTING
F-1
Turn on swing-lock switch before operating swing lever (even if just for a moment).
If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.
Cause
Detach S08.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for L.H.
swinging: Max. 1
Refer to Note.
Detach S30.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for
R.H. swinging: Max.1
Refer to Note.
Remedy
1
Defective L.H. swing pressure switch
Replace
Replace
YES
YES
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
YES
Defective controller CR700
Replace
[Note] You may diagnose with a short-circuit connector attached.In step 2 of diagnosis,
if the voltage between CR3(30) and body is 20 30 V, go to YES;
if it is 1 V or less, go to NO.
PC128US-2
20-905
(17)
TROUBLESHOOTING
F-2
F-2
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
Operate travel lever:
Max. 1
Refer to Note.
Remedy
1
Is resistance between S01 (male) NO
(1) and (2) normal? Is the connection insulated from body?
Replace
YES
2
Turn starting switch OFF.
Detach S01 from CR1.
Between CR1 and S01:
Max. 1
Between harness and body:
Min. 1 M
YES
3
Start engine.
Put swing lever in Neutral:
20 30 V
Replace
YES
4
Start engine.
Operate travel lever:
Max. 1 V
YES
Defective controller CR700
Replace
[Note] You may diagnose with a short-circuit connector attached.In step 1 of diagnosis,
if the voltage between CR1(18) and body is 20 30 V, go to YES;
if it is 1 V or less, go to NO.
20-906
(17)
PC128US-2
TROUBLESHOOTING
F-2
F-2
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
Operate travel lever:
Max. 1
Refer to Note.
Remedy
1
Is resistance between S01 (male) NO
(1) and (2) normal? Is the connection insulated from body?
Replace
YES
2
Turn starting switch OFF.
Detach S01 from CR3.
Between CR3 and S01:
Max. 1
Between harness and body:
Min. 1 M
YES
3
Start engine.
Put swing lever in Neutral:
20 30 V
Replace
YES
4
Start engine.
Operate travel lever:
Max. 1 V
YES
Defective controller CR700
Replace
[Note] You may diagnose with a short-circuit connector attached.In step 1 of diagnosis,
if the voltage between CR3(40) and body is 20 30 V, go to YES;
if it is 1 V or less, go to NO.
PC128US-2
20-907
(17)
TROUBLESHOOTING
F-3
F-3
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
Replace
Replace
YES
2
Start engine.
Put boom lever in LOWER:
Max. 1 V
YES
Disconnect S33.
Start engine.
Put boom lever in Neutral:
Min. 1 M
Put boom lever in LOWER:
Max. 1
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(5) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
20-908
(17)
PC128US-2
F-3
TROUBLESHOOTING
F-3
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 boom lever in Neutral:
20 30 V
Replace
Replace
YES
2
Start engine.
Put boom lever in LOWER:
Max. 1 V
YES
Disconnect S33.
Start engine.
Put boom lever in Neutral:
Min. 1 M
Put boom lever in LOWER:
Max. 1
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(18) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
PC128US-2
20-909
(17)
TROUBLESHOOTING
F-4
F-4
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
Replace
Replace
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
Put boom lever in RAISE:
Max. 1
Refer to Note.
Turn starting switch OFF.
Disconnect S31 from CR1.
Between CR1 and S31:
Max. 1
Between harness and body:
Min. 1 M
3
Is resistance between S31 (male) NO
(1) and (2) normal? Is the connection insulated from body?
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
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 boom lever in Neutral:
20 30 V
Replace
Replace
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
Put boom lever in RAISE:
Max. 1
Refer to Note.
Turn starting switch OFF.
Disconnect S31 from CR1.
Between CR1 and S31:
Max. 1
Between harness and body:
Min. 1 M
3
Is resistance between S31 (male) NO
(1) and (2) normal? Is the connection insulated from body?
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
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
Replace
Replace
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
Put arm lever in IN:
Max. 1
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(6) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
20-912
(17)
PC128US-2
TROUBLESHOOTING
F-5
F-5
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
Replace
Replace
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
Put arm lever in IN:
Max. 1
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(12) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
PC128US-2
20-913
(17)
F-6
TROUBLESHOOTING
Cause
Remedy
1
Start engine.
Put arm-lever in Neutral:
20 30 V
NO
Replace
Replace
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
Put arm lever in OUT:
Max. 1
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(5) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
20-914
(17)
PC128US-2
F-6
TROUBLESHOOTING
Cause
Remedy
1
Start engine.
Put arm-lever in Neutral:
20 30 V
NO
Replace
Replace
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
Put arm lever in OUT:
Max. 1
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(6) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
PC128US-2
20-915
(17)
TROUBLESHOOTING
F-7
F-7
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 bucket lever in Neutral:
20 30 V
Replace
Replace
YES
2
Start engine.
Put bucket lever in CURL:
Max. 1 V
YES
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
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(5) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
20-916
(17)
PC128US-2
F-7
TROUBLESHOOTING
F-7
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 bucket lever in Neutral:
20 30 V
Replace
Replace
YES
2
Start engine.
Put bucket lever in CURL:
Max. 1 V
YES
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
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR3(10) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
PC128US-2
20-917
(17)
TROUBLESHOOTING
F-8
F-8
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 bucket lever in Neutral:
20 30 V
Replace
Replace
Replace
YES
2
Start engine.
Put bucket lever in Dump:
Max. 1 V
YES
Disconnect S35.
Start engine.
Put bucket lever in Neutral:
Min.1 Mz
Put bucket lever in Dump:
Max. 1 z
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(5) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
20-918
(17)
PC128US-2
F-8
TROUBLESHOOTING
F-8
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 bucket lever in Neutral:
20 30 V
Replace
Replace
Replace
YES
2
Start engine.
Put bucket lever in Dump:
Max. 1 V
YES
Disconnect S35.
Start engine.
Put bucket lever in Neutral:
Min.1 Mz
Put bucket lever in Dump:
Max. 1 z
Refer to Note.
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR3(20) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.
PC128US-2
20-919
(17)
TROUBLESHOOTING
F-9
F-9
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 M
Operate ATT pedal service
(front) pressure switch:
Max. 1
Refer to Note.
Disconnect S41.
Start engine.
Put ATT-pedal in Neutral:
Max.1 M
Operate ATT pedal service
(front) pressure switch:
Max. 1
Refer to Note.
YES
Defective controller CR700
Replace
Replace
Replace
2
Is resistance between S40 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?
YES
3
Is resistance between S41 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?
YES
YES
[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
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
YES
Defective controller CR700
Disconnect S38.
Start engine.
Put blade lever in Neutral:
Min.1 M
Operate blade LOWER
pressure switch:
Max. 1
Refer to Note.
Disconnect S39.
Start engine.
Put blade lever in Neutral:
Max.1 M
Operate blade RAISE (front)
pressure switch:
Max. 1
Refer to Note.
Replace
2
Is resistance between S38 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?
YES
3
Is resistance between S41 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?
Replace
YES
YES
[Note] You may diagnose with a short-circuit connector attached.In this case,
if the voltage between CR3(9) and body is 20 30 V, go to YES;
f it is Max. 1 V, go to NO.
PC128US-2
20-921
(17)
TROUBLESHOOTING
F-10
Cause
Turn starting switch ON.
S Harness for Kerosene mode:
Connected: 20 30 V
Open: Max. 1 V
Max. 1
Remedy
20-922
(17)
PC128US-2
TROUBLESHOOTING OF ENGINE
(S MODE)
PC128US-2
20-951
(14)
TROUBLESHOOTING
Causes
Questions
(a)
w
w
(b)
w
(c)
(d)
c
c
Troubleshooting
Check items
(e)
20-952
(14)
i
ii
iii
b
b
b
PC128US-2
inje
ctio
n)
Causes
Seiz
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
Degree of use
PC128US-2
20-953
(14)
TROUBLESHOOTING
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
Questions
Suddenly
Gradually
Check items
Troubleshooting
20-954
(14)
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
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
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
Charging rate
20C
0C
10C
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
Wor
100 %
Questions
Ease of starting
Check items
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 2630V between alternator terminal B and terminal E
with engine at low idling?
Yes
No
20-956
(14)
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
PC128US-2
PC128US-2
Replace
Replace
Clean
Correct
Replace
Adjust
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
20-958
(14)
Replace
Replace
Remedy
Replace
Replace
Troubleshooting
Replace
Replace
Replace
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
PC128US-2
S-2
TROUBLESHOOTING
KIND
OF FLUID
-4
-20
14
-10
32
0
50
10
68F
20C
Diesel fuel
Bro
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
Troubleshooting
PC128US-2
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
20-959
(14)
TROUBLESHOOTING
S-2
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
Check items
Troubleshooting
20-960
(14)
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
PC128US-2
TROUBLESHOOTING
S-3
Causes
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
Check items
Troubleshooting
PC128US-2
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Clean
20-961
(14)
S-4
TROUBLESHOOTING
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)
Bro
Questions
Check items
20-962
(14)
Replace
Clean
Correct
Replace
Replace
Clean
Clean
Add
Replace
Replace
Replace
Replace
Remedy
Replace
PC128US-2
S-5
TROUBLESHOOTING
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
Questions
Check items
Troubleshooting
PC128US-2
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust
20-963
(14)
TROUBLESHOOTING
S-6
Clog
Seiz
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
Questions
Suddenly
Gradually
Black
Blue under light load
Check items
Troubleshooting
20-964
(14)
Replace
Replace
Clean
Correct
Adjust
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
PC128US-2
S-7
TROUBLESHOOTING
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
Gradually
Check items
PC128US-2
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
20-965
(14)
TROUBLESHOOTING
S-8
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
Questions
Excessive
None
Troubleshooting
20-966
(14)
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
PC128US-2
S-9
TROUBLESHOOTING
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
Check items
Excessive
Amount of blow-by gas
None
PC128US-2
Replace
Clean
Clean
Replace
Replace
Remedy
Clean
Troubleshooting
20-967
(14)
S-10
TROUBLESHOOTING
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
White
Check items
Troubleshooting
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
Causes
Questions
Suddenly increased
Gradually increased
PC128US-2
Replace
Replace
Replace
Remedy
Replace
Replace
Troubleshooting
Check items
20-969
(14)
TROUBLESHOOTING
S-12
Type of oil
10
10
20
30
Causes
40C
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
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
20-970
(14)
Replace
Replace
Correct
Adjust
Adjust
Add
Replace
Correct
Clean
Clean
Remedy
Clean
Troubleshooting
PC128US-2
S-13
TROUBLESHOOTING
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
Causes
Questions
Check items
PC128US-2
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Remedy
Replace
20-971
(14)
TROUBLESHOOTING
S-14
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
Suddenly overheated
Always tends to overheat
Water temperature
gauge
Rises quickly
Does not go down from red range
Check items
Troubleshooting
20-972
(14)
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
PC128US-2
S-15
TROUBLESHOOTING
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
)
Causes
Questions
Gradually occurred
Suddenly occurred
Check items
PC128US-2
Replace
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
20-973
(14)
S-16
TROUBLESHOOTING
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
Suddenly increased
Gradually increased
Check items
20-974
(14)
Adjust
Replace
Correct
Correct
Replace
Replace
Replace
Remedy
Replace
PC128US-2
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)
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
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)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
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.
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
790-331-1110
Wrench
790-101-2501
790-101-2510
Block
790-101-2550
Leg
790-101-2560
Nut
790-101-2570
Plate
790-101-3101
Bearing puller
790-101-4200
Puller
(294 kN {30 ton})
790-101-1102
1 796T-426-1140
Push tool
2 790-201-2680
Plate
1 790-201-2850
Spacer
2 790-201-2750
Spacer
790-101-5401
790-101-5461
Plate
790-101-5441
Plate
For sub-bearing
790-101-5421
Grip
01010-51240
Bolt
790-201-2750
Spacer
796T-226-1210
Wrench assembly
790-101-5401
790-101-5461
Plate
790-101-5421
Grip
01010-51240
Bolt
790-101-5401
790-101-5471
Plate
790-101-5421
Grip
01010-51240
Bolt
790-201-2850
Push tool
Symbol
A
Disassembly, assembly of
swing machinery
PC128US-2
Part No.
Part Name
Sketch
Qty
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
30-5
(16)
10
797T-423-1360
Push tool
11
795-630-1803
Torque wrench
791-675-1510
Installer
791-600-2001
or
791-685-8006
Compressor (A)
791-635-3160
Extension
790-201-2770
Spacer
790-101-1600
Cylinder
(686 kN {70 ton})
790-101-1102
Pump
790-201-1500
790-201-1590
790-201-1610
790-101-5021
Grip
01010-50816
Bolt
790-434-1650
Installer
791-601-1000
Oil pump
791-616-1040
790-105-1100
Cylinder
(297 kN {30 ton})
791-101-1102
Pump
791-616-1110
Frame
791-616-1121
Plate
791-616-1131
Plate
791-616-1150
Guide
791-616-1160
Adapter
791T-616-1280
Adapter
791-620-3530
Push
791-620-3260
Push
791-620-3270
Guide
01011-62260
Bolt
01643-62260
Washer
01011-61455
Bolt
01643-31445
Washer
790-105-1100
Cylinder
(297 kN {30 ton})
790-101-1102
Pump
790-101-2501
Push puller
790-101-2510
Block
Symbol
Disassembly, assembly of
idler recoil spring
Disassembly, assembly of
track roller
Expansion, installation of
track shoe
Disassembly of center
swivel joint
30-6
(16)
Part No.
Part Name
Compressor (B)
Sketch
Qty
Disassembly, assembly of
swing machinery
Necessity
Component
New/
remodel
1
1
Compression of spring
PC128US-2
Removal,
pressfit of
master pin
Q
Removal,
PC138USLCpressfit of
2
master pin
PC128US-2
Disassembly of center
swivel joint
Disassembly, assembly of
hydraulic cylinder
PC128US-2
Part Name
790-101-2520
Screw
790-101-2540
Washer
791-112-1180
Nut
790-101-2630
Leg
790-101-2570
Washer
790-101-2560
Nut
791-112-2650
Adapter
790-502-1003
Repair stand
790-101-1102
Pump
790-102-4300
Wrench assy
790-201-4310
Pin
790-201-1702
790-201-1791
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1702
790-201-1811
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1702
790-201-1821
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
790-201-1610
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
790-201-1620
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
790-201-1630
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-720-1000
Expander
Sketch
Part No.
Qty
Symbol
New/
remodel
Nature of work
Necessity
Disassembly, assembly of
cylinder
Removal, installation of
piston
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
30-7
(16)
Removal, installation, of
work equipment and boom
(19)
Ring
07281-01029
Clamp
796-720-1660
Ring
07281-01159
Clamp
792-785-1100
Remover
796-270-1110
Adapter
790-101-4000
Puller
(490 kN {50 ton})
790-101-1102
Pump
793-498-1210
20Y-54-13180
Adapter
799-703-1200
799-703-1100
Vacuum pump(100V)
For Japan
799-703-1110
Vacuum pump(220V)
For overseas
790-703-1120
Vacuum pump(240V)
For overseas
799-703-1401
Part No.
Part Name
Sketch
796-720-1650
Symbol
30-8
Qty
Disassembly, assembly of
hydraulic cylinder
Necessity
Nature of work
New/
remodel
Removal,
installation
of piston
ring
Removal,
installation
of piston
ring
Charging of
air-conditioning gas
PC128US-2
PC128US-2
30-9
(16)
R Adapter
30-10
(16)
PC128US-2
CYLINDER HEAD
6 Coolant: 13.2 l
[*2]
[*3]
PC128US-2
30-11
(16)
CYLINDER HEAD
[*4]
30-12
(16)
PC128US-2
CYLINDER HEAD
[*6]
PC128US-2
30-13
(16)
CYLINDER HEAD
INSTALLATION
[*1]
[*2]
[*3]
[*4]
[*5]
[*6]
[*7]
[*8]
[*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
Reference
3 U-clamp nut:
7.8 9.8 Nm {0.8 1.0 kgm}
Supplying coolant
Supply coolant from the cooloant filter port to the
specified level, start the engine to circulate 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
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).
[*1]
30-16
(16)
PC128US-2
INJECTION PUMP
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]
30-18
(16)
PC128US-2
PC128US-2
30-19
(16)
INSTALLATION
[*1]
[*2]
Supplying coolant
a Supply coolant from the water filler port to
the specified level, start the engine to circulate coolant and recheck the level.
Bleeding air
a Bleed air from the main pump. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
30-20
(16)
PC128US-2
6 Hydraulic oil: 69 l
(Oil level in hydraulic tank)
6 Coolant: 17.2 l
30-21
(19)
30-22
(16)
PC128US-2
PC128US-2
30-23
(16)
INSTALLATION
[*1] [*2]
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.
30-24
(16)
PC128US-2
6 Hydraulic oil: 69 l
(Oil level in hydraulic tank)
6 Coolant: 13.2 l
[*2]
PC128US-2
30-25
(16)
30-26
(16)
PC128US-2
PC128US-2
[*5]
30-27
(16)
30-28
(16)
PC128US-2
INSTALLATION
[*1]
[*2]
[*3]
Adjustment to fuel control cable. For details, see
TESTING AND ADJUSTING, testing and adjusting of an accelerator pedal.
[*4]
[*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)
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
6 Cooling : 18.2 l
PC128US-2
30-31
(19)
INSTALLATION
[*1]
30-32
(19)
PC128US-2
RADIATOR
RADIATOR ASSEMBLY
PC128US-2
PC138US-2
REMOVAL
1. Drain cooling water.
6 Coolant : 17.2 l
[*3]
[*1]
[*2]
INSTALLATION
[*1] [*2]
[*3]
[*3]
PC138US-2
Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
Coolant : 13.2 l
PC128US-2
30-33
(16)
6 Hydraulic oil :
69 l (Oil level in hydraulic tank)
100 l (Capacity)
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.
30-34
(16)
PC128US-2
INSTALLATION
5 Hydraulic oil :
69 l (Oil level in hydraulic tank)
100 l (Capacity)
PC128US-2
30-35
(16)
AFTER COOLER
[*1]
[*2]
INSTALLATION
[*1] [*2]
30-36
(16)
PC128US-2
AFTER COOLER
[*1]
INSTALLATION
[*1]
PC128US-2
30-37
(16)
FUEL TANK
FUEL TANK
REMOVAL
INSTALLATION
[*1]
30-38
(16)
PC128US-2
INSTALLATION
[*1]
3 Mounting bolt :
98.1 123.0 Nm {10.0 12.5 kgm}
Bleeding air
Bleed air from the swing motor. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC128US-2
30-39
(16)
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)
30-40
(16)
PC128US-2
SWING MOTOR,
SWING MACHINERY
REMOVAL
INSTALLATION
[*1]
Bleeding air
Bleed air from the swing motor. For details , see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC128US-2
30-41
(16)
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).
30-42
(16)
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).
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).
PC128US-2
30-43
(16)
SWING MACHINERY
30-44
(16)
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.
PC128US-2
30-45
(16)
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).
30-46
(16)
PC128US-2
SWING MACHINERY
6. Ring gear
Assemble O-ring (37) to shaft and case assembly, and install ring gear (14).
PC128US-2
30-47
(16)
SWING MACHINERY
3 Mounting bolt :
110.3 12.3 Nm {11.25 1.25 kgm}
30-48
(16)
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
4. Ring gear
Remove ring gear (14).
PC128US-2
30-49
(16)
SWING MACHINERY
6. Shaft assembly
Using push tool F1, remove bearing (29) and collar (30) from shaft (31).
30-50
(16)
PC128US-2
SWING MACHINERY
PC128US-2
30-51
(16)
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 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}
30-52
(16)
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)
5. Ring gear
Install ring gear (14).
PC128US-2
30-53
(16)
SWING MACHINERY
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.
30-54
(16)
PC128US-2
REVOLVING FRAME
REVOLVING FRAME
REMOVAL
PC128US-2
30-55
(16)
REVOLVING FRAME
INSTALLATION
[*1]
Bleeding air
Bleed the air. For details , see TESTING AND
ADJUSTING, Bleeding air from each part.
30-56
(16)
PC128US-2
SWING CIRCLE
SWING CIRCLE
REMOVAL
[*2]
INSTALLATION
[*1]
PC128US-2
30-57
(16)
4 Sprocket : 40 kg
[*1]
INSTALLATION
[*1]
30-58
(16)
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
PC128US-2
30-59
(16)
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)
30-60
(16)
PC128US-2
RECOIL SPRING
RECOIL SPRING
PC138US-2
Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
DISASSEMBLY
30-61
(16)
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)
30-62
(16)
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
30-63
(16)
IDLER
ASSEMBLY
1. Press fit bushings (9) and (10) to idler (4).
30-64
(16)
PC128US-2
IDLER
PC128US-2
30-65
(16)
IDLER
30-66
(16)
PC128US-2
TRACK ROLLER
TRACK ROLLER
DISASSEMBLY
1. Remove pin (1), then remove collar (2).
5
6
10
4
9
3
1
2
11
CLP00790
PC128US-2
30-67
(16)
TRACK ROLLER
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.
CLP00793
CLP00866
30-68
(16)
PC128US-2
TRACK ROLLER
CLP00867
10. Using tool M2, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil : 75 85 cc (EO30-CD)
PC128US-2
30-69
(16)
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]
INSTALLATION
[*1]
[*2]
[*3]
30-70
(16)
PC128US-2
HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL
PC128US-2
30-71
(16)
HYDRAULIC TANK
INSTALLATION
[*1]
Bleeding air
Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air from each part.
30-72
(16)
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
PC128US-2
30-73
(16)
MAIN PUMP
MAIN PUMP
PC138US-2
Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
REMOVAL
30-74
(16)
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]
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
30-76
(16)
PC128US-2
CONTROL VALVE
INSTALLATION
Bleeding air.
Bleed the air from the circuit between the valve
and the hydraulic cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from each part.
PC128US-2
30-77
(16)
CONTROL VALVE
CONTROL VALVE
PC128US-2
Serial No. : 5001 and up
PC138US-2
Serial No. : 1001 4500
PC138USLC-2 Serial No. : 1001 1500
DISASSEMBLY
30-78
(16)
PC128US-2
PC128US-2
CONTROL VALVE
30-79
(16)
30-80
(16)
CONTROL VALVE
PC128US-2
CONTROL VALVE
PC128US-2
30-81
(16)
CONTROL VALVE
30-82
(16)
PC128US-2
CONTROL VALVE
ASSEMBLY
PC128US-2
30-83
(16)
30-84
(16)
CONTROL VALVE
PC128US-2
PC128US-2
CONTROL VALVE
30-85
(16)
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.
CONTROL VALVE
30-86
(16)
PC128US-2
CONTROL VALVE
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 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}
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
3 Mounting bolt :
30.9 3.4 Nm {3.15 0.35 kgm}
3 Mounting bolt :
30.9 3.4 Nm {3.15 0.35 kgm}
3 Plug :
7.35 1.5 Nm {0.75 0.15 kgm}
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
PC128US-2
30-87
(16)
CONTROL VALVE
CONTROL VALVE
PC138US-2
Serial No. : 4501 and up
PC138USLC-2 Serial No. : 1501 and up
ASSEMBLY
30-88
(16)
PC128US-2
a In this section, only the precautions for assembling the control valve assembly are described.
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).
CONTROL VALVE
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
3 T5
3 T6
3 T9
: 59 78 Nm {6 8 kgm}
: 88.3 107.9 Nm {9 11 kgm}
PC128US-2
30-89
(16)
30-90
(16)
CONTROL VALVE
PC128US-2
PC128US-2
CONTROL VALVE
30-91
(16)
LS SELECTION VALVE
LS SELECTION VALVE
DISASSEMBLY
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}
30-92
(16)
PC128US-2
30-94
(16)
PC128US-2
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
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 :
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).
PC128US-2
30-97
(16)
30-98
(16)
PC128US-2
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.
PC128US-2
30-99
(16)
30-100
(16)
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
P1, P2
44.4mm
P3, P4
42.4mm
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).
3 Mounting bolt :
13.23 1.47 Nm {1.35 0.15 kgm}
30-101
(16)
30-102
(16)
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
PC128US-2
30-103
(16)
DISASSEMBLY
4
5
18
1
10
11
7
12
8
13
14
15
16
17
CEP00533
30-104
(16)
PC128US-2
ASSEMBLY
1. Engage valve (16) with body (17).
4
2
5
18
6
9
10
11
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.
12
8
13
14
15
16
17
CEP00533
3 Mounting bolt :
31.0 3.4 Nm {3.15 0.35 kgm}
PC128US-2
30-105
(16)
30-106
(16)
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.
PC128US-2
30-107
(16)
HYDRAULIC CYLINDER
30-108
(16)
PC128US-2
HYDRAULIC CYLINDER
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 60C) 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).
30-110
(16)
PC128US-2
HYDRAULIC CYLINDER
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
i)
Cylinder
Tap
depth
Boom, arm
and blade
10.3
27
121.75
20
Bucket
8.5
27
101.5
20
iii) Clear it of cut powder and dust and completely wash it after processing.
iv) Tighten screw (3).
2 Screw thread :
30-112
(16)
PC128US-2
HYDRAULIC CYLINDER
Tightening torque
Bucket
Arm
Boom
Blade
PC128US-2
30-113
(16)
WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL
[*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).
30-114
(16)
PC128US-2
WORK EQUIPMENT
INSTALLATION
[*1]
[*2]
Bleeding air
Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
PC128US-2
30-115
(16)
OPERATORS CAB
OPERATORS CAB
PC128US-2
Serial No. : 5001 7299
PC138US-2
Serial No. : 1001 2599
PC138USLC-2 Serial No. :
REMOVAL
30-116
(16)
PC128US-2
OPERATORS CAB
INSTALLATION
PC128US-2
30-117
(16)
OPERATOR'S CAB
OPERATORS CAB
PC128US-2
Serial No. : 7301 and up
PC138US-2
Serial No. : 2601 4500
PC138USLC-2 Serial No. : 1001 1500
REMOVAL
30-118
(16)
PC128US-2
OPERATOR'S CAB
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
INSTALLATION
30-120
(16)
PC128US-2
OPERATOR'S CAB
OPERATORS 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).
PC128US-2
30-121
(16)
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).
INSTALLATION
30-122
(16)
PC128US-2
PC128US-2
(1):
(2):
(3):
(4):
(5):
(6):
30-123
(16)
1 793-498-1210
2 20Y-54-13180 Adapter
Sketch
Lifter
t
(Suction cup)
Part name
New/Removal
Qty
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 operators 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 operators 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 operators cab of a wheel
loader.)
2. Remove the window glass.
30-124
(16)
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 operators 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 operators 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.
PC128US-2
30-125
(16)
30-126
(16)
PC128US-2
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.)
PC128US-2
30-127
(16)
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
30-128
(16)
PC128US-2
PC128US-2
30-129
(16)
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 25C.
a Never heat the adhesive higher than 30C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
30-130
(16)
PC128US-2
PC128US-2
30-131
(16)
30-132
(16)
PC128US-2
2 Adhesive:
Sikaflex 256HV manufactured
by Sika Japan
PC128US-2
30-133
(16)
30-134
(16)
PC128US-2
FRONT WINDOW
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
30-135
(16)
FLOOR FRAME
FLOOR FRAME
PC128US-2
Serial No. : 5001 7300
PC138US-2
Serial No. : 1001 2600
PC138USLC-2 Serial No. : 1001 1500
REMOVAL
30-136
(19)
PC128US-2
FLOOR FRAME
INSTALLATION
PC128US-2
30-137
(19)
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
30-138
(19)
PC128US-2
FLOOR FRAME
11. Remove the cover from under the seat and disconnect air conditioner tubes (18) and (19) from
the air conditioner unit.
[*1]
INSTALLATION
[*1]
PC128US-2
30-139
(19)
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
30-140
(19)
PC128US-2
FLOOR FRAME
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
30-141
(16)
FLOOR FRAME
13. Remove the cover from under the seat and disconnect air conditioner tubes (18) and (19) from
the air conditioner unit.
[*1]
INSTALLATION
[*1]
30-142
(19)
PC128US-2
AIR CONDITIONER
COMPRESSOR
PC128US-2 Serial No. : 5001 7299
PC138US-2 Serial No. : 1001 2599
REMOVAL
INSTALLATION
PC128US-2
30-143
(19)
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
a PC128US-2
Serial No. 9501 and up
PC138US-2
Serial No. 4501 and up
PC138USLC-2 Serial No. 1501 and up
INSTALLATION
30-144
(19)
PC128US-2
AIR CONDITIONER
CONDENSER
PC128US-2 Serial No. : 5001 7299
PC138US-2 Serial No. : 1001 2599
REMOVAL
INSTALLATION
PC128US-2
30-145
(19)
AIR CONDITIONER
CONDENSER
PC128US-2 Serial No. : 7301 and up
PC138US-2 Serial No. : 2601 and up
REMOVAL
INSTALLATION
30-146
(19)
PC128US-2
PC128US-2
30-147
(19)
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
30-148
(19)
PC128US-2
k Remove the negative (-) terminal from the battery before setting to work.
1. Drain coolant.
6 Coolant: 17.2 l
PC128US-2
30-149
(19)
6. Remove the cover (13) and separate the connector (14)(CN-M87). (At the rear right in the
operator cab)
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).
30-150
(16)
PC128US-2
INSTALLATION
PC128US-2
30-151
(19)
[*1]
30-152
(19)
PC128US-2
PC128US-2
30-153
(19)
INSTALLATION
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
30-154
(19)
PC128US-2
COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL
INSTALLATION
[*1]
3 Mounting bolt :
3,850 4,710 Nm (393 480 kgm)
PC128US-2
30-155
(16)
MONITOR PANEL
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.
INSTALLATION
PC128US-2
30-157
(16)
40 MAINTENANCE STANDARD
PC128US-2
40-1
(15)
MAINTENANCE STANDARD
SWING MACHINERY
SWING MACHINERY
PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
40-2
(15)
PC128US-2
MAINTENANCE STANDARD
SWING MACHINERY
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.07 0.18
0.4
0.13 0.31
0.6
0.15 0.34
0.7
0.14 0.34
0.7
0.15 0.34
0.7
0.13 0.31
0.6
0.08 0.19
0.4
0.13 1.16
2.3
PC128US-2
Replace
Standard size
Tolerance
Repair limit
145
0
0.100
144.8
Apply
hardchrome
plating recondition, or replace
40-3
(14)
MAINTENANCE STANDARD
SWING MACHINERY
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
40-3-1
(15)
PC128US-2
MAINTENANCE STANDARD
SWING MACHINERY
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.07 0.18
0.4
0.13 0.32
0.6
0.14 0.40
0.7
0.14 0.34
0.7
0.13 0.39
0.7
0.12 0.31
0.6
0.009 0.117
0.2
0.13 1.16
2.3
PC128US-2
Replace
Standard size
Tolerance
Repair limit
145
0
0.100
144.8
Apply
hardchrome
plating recondition, or replace
40-3-2
(15)
MAINTENANCE STANDARD
SWING CIRCLE
SWING CIRCLE
Unit: mm
No.
Check item
40-4
(14)
Criteria
Remedy
Standard size
Clearance limit
0.5 1.6
2.6
Replace
PC128US-2
MAINTENANCE STANDARD
Unit: mm
No.
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
Standard size
Recoil spring
Remedy
Rebuild or
replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
507
390
78.5 kN
{8,000 kg}
494
69.8 kN
{7,120 kg}
502
390
84.3 kN
{8,600 kg}
490
75.0 kN
{7,650 kg}
Replace
PC128US-2
40-5
(15)
IDLER
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Outer diameter of
protruding portion
527
489
477
Depth of protruding
portion
19
25
Width of protruding
portion
52
42
Total width
115
107
Width of tread
Clearance between
idler shaft and bushing
31.5
Standard
size
54
Standard
size
61
10
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 clearance
Clearance limit
0.18 0.38
1.5
Standard size
Repair limit
15
Replace
Rebuild or
replace
40-6-1
A
MAINTENANCE STANDARD
IDLER
PC128US-2
Serial No.: 5363 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
40-6-2
(15)
PC128US-2
IDLER
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Outer diameter of
protruding portion
Remedy
Standard size
Repair limit
527
489
477
Depth of protruding
portion
19
25
Width of protruding
portion
52
42
Total width
115
107
Width of tread
Clearance between
idler shaft and bushing
31.5
Standard
size
Standard
size
61
10
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
+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
Replace
Rebuild or
replace
40-7
A
MAINTENANCE STANDARD
CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No.
Check item
Width of tread
Criteria
Standard size
Repair limit
116
106
123
Standard
size
40
Standard
size
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
Oil amount
(15)
Remedy
PC128US-2
TRACK ROLLER
MAINTENANCE STANDARD
TRACK ROLLER
PC128US-2 Serial No.: 5001 5362
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Diameter of flange
(outside)
158
130
120
Flange width
Total width
Width of tread
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
MAINTENANCE STANDARD
TRACK ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Diameter of flange
(outside)
158
130
120
Flange width
Total width
Width of tread
Oil amount
40-10
(15)
26.5
Rebuild or
replace
176
35
Tolerance
Rebuild or
replace
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
MAINTENANCE STANDARD
TRACK ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Diameter of flange
(outside)
158
130
120
Flange width
Total width
Width of tread
Oil amount
PC128US-2
26.5
Rebuild or
replace
176
35
Tolerance
Rebuild or
replace
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)
MAINTENANCE STANDARD
SPROCKET
SPROCKET
Unit: mm
No.
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
27
22
42
1.5
39
111.7
+0.465
1.160
105.5
109.4
+0.465
1.160
103
40-12
0
Rebuild or
replace
PC128US-2
MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE
TRIPLE SHOE, ROAD LINER, CITY PAD SHOE
PC128US-2
40-13
7
MAINTENANCE STANDARD
TRACK SHOE
PC128US-2
(1/2)
No.
Unit: mm
Check item
Criteria
Standard size
Repair limit
175.25
178.25
Link pitch
Link height
Reverse or
replace
When turned
Standard size
2
Remedy
Normal load
Impact load
42.3
Standard size
Repair limit
86
81
24
19
Reverse or
replace
102.4
Replace
86.4
57
8
9
Link
10
Inner width
52.4
Total width
35
30.1
Width of tread
11
5.5
12
3.75
13
173
14
15
16
Spacer thickness
Bushing
17
18
Press fitting
Regular pin
force
19
Master pin
Reverse or
replace
Adjust or
replace
86.7
Standard size
Repair limit
7.8
3.8
40-14
(15)
PC128US-2
MAINTENANCE STANDARD
TRACK SHOE
PC128US-2
(2/2)
No.
Unit: mm
Check item
Criteria
Remedy
Triple
City pad
196 20
{20 2}
90 10
Road liner
147 10
{15 1}
50 5
Retighten
Tightening torque
(Nm {kgm})
b. Master link
Number of shoes
(on one side)
42
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
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
Standard
interference
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
PC128US-2
40-15
(15)
MAINTENANCE STANDARD
TRACK SHOE
PC138US-2
(1/2)
No.
Unit: mm
Check item
Criteria
Standard size
Repair limit
175.25
178.25
Link pitch
Link height
Reverse or
replace
When turned
Standard size
2
Remedy
Normal load
Impact load
46.6
Standard size
Repair limit
90
85
24
19
Reverse or
replace
102.4
Replace
86.4
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
173
14
86.7
15
16
Spacer thickness
17
18
Bushing
Press fitting
Regular pin
force
19
Master pin
Reverse or
replace
Adjust or
replace
Standard size
Repair limit
9.0
40-15-1
(15)
PC128US-2
MAINTENANCE STANDARD
TRACK SHOE
PC138US-2
(2/2)
No.
Unit: mm
Check item
Criteria
Remedy
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
24
Interference between
master pin and link
Grouser height
Hole
+0.150
+0.050
+0.830
+0.330
0.180 0.780
Shaft
Hole
Standard
interference
+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
25
Standard
interference
Shaft
Interference between
bushing and link
Interference between
regular pin and link
43
Standard size
22
Retighten
Tightening torque
(Nm {kgm})
Number of shoes
(on one side)
21
90 10
Adjust or
replace
0.530 1.130
Standard size
Repair limit
Replace
PC128US-2
40-15-2
(15)
MAINTENANCE STANDARD
PC138USLC-2
(1/2)
No.
Unit: mm
Check item
Criteria
Standard size
Repair limit
175.25
178.25
Link pitch
Link height
Reverse or
replace
When turned
Standard size
2
Remedy
Normal load
Impact load
46.6
Standard size
Repair limit
90
85
24
19
Reverse or
replace
102.4
Replace
86.4
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
173
14
86.7
15
16
Spacer thickness
17
18
Bushing
Press fitting
Regular pin
force
19
Master pin
Reverse or
replace
Adjust or
replace
Standard size
Repair limit
9.0
40-15-3
(15)
PC128US-2
MAINTENANCE STANDARD
TRACK SHOE
PC138USLC-2
(2/2)
No.
Unit: mm
Check item
Criteria
Remedy
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
24
Interference between
master pin and link
Grouser height
Hole
+0.150
+0.050
+0.830
+0.330
0.180 0.780
Shaft
Hole
Standard
interference
+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
25
Standard
interference
Shaft
Interference between
bushing and link
Interference between
regular pin and link
46
Standard size
22
Retighten
Tightening torque
(Nm {kgm})
Number of shoes
(on one side)
21
90 10
Adjust or
replace
0.530 1.130
Standard size
Repair limit
Replace
PC128US-2
40-15-4
(15)
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm
No.
2
3
Check item
Grouser height
Shoe height
Plate thickness
4
5
Criteria
Remedy
Standard size
Repair limit
25
15
20
10
33
23
29.5
19.5
9.5
18
14
11
13
18
15
Rebuild or
replace
1.: PC128US-2 (Serial No.: 5001 9000), PC138USLC-2 (Serial No.: 1001 1300)
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
MAINTENANCE STANDARD
HYDRAULIC PUMP
PC128US-2
40-17
(15)
MAINTENANCE STANDARD
HYDRAULIC PUMP
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
40-17-1
(15)
PC128US-2
MAINTENANCE STANDARD
HYDRAULIC PUMP
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
PC128US-2
40-17-2
(15)
MAINTENANCE STANDARD
CONTROL VALVE
CONTROL VALVE
7 SPOOL (6 SPOOL + SERVICE VALVE)
PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
(1/9)
40-18
(15)
PC128US-2
MAINTENANCE STANDARD
CONTROL VALVE
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
(1/9)
PC128US-2
40-18-1
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(2/9)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
46.8 7.50
40.6
5.500.40N
{0.560.04kg}
4.40 N
{0.45 kg}
16.0 16.0
12.0
5.70 N
{0.58 kg}
4.50 N
{0.46 kg}
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
B-B
9JYOOO59
Unit: mm
No
-
Check
item
Criteria
Standard
Fryg;gth
. .
lrx;Azd
Remedy
size
Repair limit
Installed
load
Free length
Installed
load
184N
0
45.7
28.0
42.4
26.0
40-20
43.0
222+13.7N
{22.6+1.40kg)
a.8kg)
178N
(la.1 kg}
Replace
spring if any
damages or
deformations
are found
PC1 28U.S2
MAINTENANCE STANDARD
CONTROL VALVE
(4/9)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
36.2 5.30
32.0
9.810.98N
{1.00.10kg}
7.85 N
{0.80 kg}
27.5 14.2
18.0
17.70.98N
{1.800.10kg}
13.7 N
{1.40 kg}
28.2 14.5
26.0
29.42.94N
{3.00.30kg}
23.5 N
{2.40 kg}
24.1 15.0
14.5
9.810.98N
{1.00.10kg}
7.85 N
{0.80 kg}
17.1 9.0
15.5
74.5 N
{7.60 kg}
59.8 N
{6.10 kg}
32.5 14.2
23
17.6 N
{1.8 kg}
14.1 N
{1.44 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-21
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(5/9)
Unit: mm
No.
Check item
Criteria
Standard size
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}
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
CONTROL VALVE
(6/9)
Unit: mm
No.
Check item
Criteria
Standard size
PC128US-2
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
72.7 20.6
42.5
1354.90N
{13.80.50kg}
113 N
{11.5 kg}
23.3 12.5
23.0
3.920.98N
{0.400.10kg}
2.94 N
{0.30 kg}
Replace
spring if any
damages or
deformations
are found
40-23
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(7/9)
Unit: mm
No.
Check item
Criteria
Free length
O.D.
17.7 8.20
40-24
Standard size
Installed
Installed
length
load
13.0
13.70.10N
{1.400.10kg}
Remedy
Repair limit
Installed
Free length
load
10.1 N
{1.10 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
CONTROL VALVE
(8/9)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
26.1 17.0
25.0
26.51.57N
{2.700.16kg}
21.2 N
{2.16 kg}
23.7 7.70
12.0
1.94 N
{0.30 kg}
2.35 N
{0.24 kg}
41.5 8.50
31.5
5.88 N
{0.60 kg}
4.71 N
{0.48 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-25
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(9/9)
40-26
(15)
PC128US-2
MAINTENANCE STANDARD
CONTROL VALVE
40-26-2
(15)
PC128US-2
MAINTENANCE STANDARD
CONTROL VALVE
(1/8)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
46.8 7.50
40.6
5.500.40N
{0.560.04kg}
4.40 N
{0.45 kg}
16.0 16.0
12.0
5.70 N
{0.58 kg}
4.50 N
{0.46 kg}
Piston spring
10.5 7.0
6.8
2N
{0.21 kg}
1.6 N
{0.17 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-26-3
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(2/8)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
45.6 28.0
43.0
23014.7N
{23.51.50kg}
184 N
{18.8 kg}
45.7 28.0
43.0
22213.7N
{22.61.40kg}
178 N
{18.1 kg}
42.4 28.0
39.0
22213.7N
{22.61.40kg}
178 N
{18.1 kg}
40-26-4
(15)
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
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
9.810.98N
36.2 5.30
32.0
{0.80 kg}
{1.00.10kg}
27.5 14.2
18.0
28.2 14.5
26.0
24.1 15.0
14.5
17.1 9.0
15.5
9.810.98N
{1.00.10kg}
74.5 N
{7.60 kg}
32.5 14.2
23.0
33.32N
{3.40.2kg}
PC128US-2
Remedy
17.70.98N
{1.800.10kg}
29.42.94N
{3.00.30kg}
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}
Replace
spring if any
damages or
deformations
are found
40-26-5
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(4/8)
Unit: mm
No.
Check item
Criteria
Standard size
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}
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
CONTROL VALVE
(5/8)
Unit: mm
No.
Check item
Criteria
Standard size
PC128US-2
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
72.7 20.6
42.5
1354.90N
{13.80.50kg}
113 N
{11.5 kg}
23.3 12.5
23.0
3.920.98N
{0.400.10kg}
2.94 N
{0.30 kg}
Replace
spring if any
damages or
deformations
are found
40-26-7
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(6/8)
Unit: mm
No.
Check item
Criteria
Free length
O.D.
17.7 8.20
40-26-8
(15)
Standard size
Installed
Installed
length
load
13.0
13.70.10N
{1.400.10kg}
Remedy
Repair limit
Installed
Free length
load
10.1 N
{1.10 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
CONTROL VALVE
(7/8)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
26.1 17.0
25.0
26.51.57N
{2.700.16kg}
21.2 N
{2.16 kg}
23.7 7.70
12.0
1.94 N
{0.30 kg}
2.35 N
{0.24 kg}
41.5 8.50
31.5
5.88 N
{0.60 kg}
4.71 N
{0.48 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-26-9
(15)
MAINTENANCE STANDARD
CONTROL VALVE
(8/8)
40-26-10
(15)
PC128US-2
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Standard size
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}
Replace
spring if any
damages or
deformations
are found
40-27
(15)
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Standard size
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}
16.5 7.20
12.7
20.6 N
{2.10 kg}
18.6 N
{1.90 kg}
Spring
71.0 18.0
59.0
200 N
{20.4 kg}
186 N
{19.0 kg}
16.1 7.80
13.4
61.7 N
{6.30 kg}
58.8 N
{6.0 kg}
40-28
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
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
40-29
(15)
MAINTENANCE STANDARD
SWING MOTOR
SWING MOTOR
KMF40ABE-3
Unit: mm
No.
Check item
Criteria
Standard size
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}
Replace
spring if any
damages or
deformations
are found
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
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Standard size
40-32
A
Remedy
Standard clearance
clearance limit
0.056 0.105
0.111
Replace
80
PC128US-2
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Standard size
PC128US-2
Remedy
Standard clearance
clearance limit
0.056 0.105
0.111
Replace
80
40-33
A
MAINTENANCE STANDARD
PPC VALVE
PPC VALVE
FOR SWING, WORK EQUIPMENT
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}
Centering spring
(for P1 and P2 ports)
47.93 15.5
34.0
39.22 N
{4.0 kg}
31.4 N
{3.2 kg}
Metering spring
26.53 8.15
24.9
17.0 N
{1.70 kg}
13.3 N
{1.36 kg}
40-34
(15)
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
PC128US-2
PC128US-2
PC138US-2
PC138USLC-2
No.
PPC VALVE
Check item
Centering spring
(for P3 and P4 ports)
Unit: mm
Criteria
Free length
O.D.
Standard size
Installed
Installed
length
load
Remedy
Repair limit
Installed
Free length
load
42.48 15.5
34.0
17.65 N
{1.80 kg}
14.1 N
{1.44 kg}
Centering spring
(for P1 and P2 ports)
47.93 15.5
34.0
39.22 N
{4.0 kg}
31.4 N
{3.2 kg}
Metering spring
26.53 8.15
24.9
17.0 N
{1.70 kg}
13.3 N
{1.36 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-34-1
(15)
MAINTENANCE STANDARD
PPC VALVE
FOR TRAVEL
PC128US-2 Serial No.: 5001 6300
Unit: mm
No.
Check item
Criteria
Standard size
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}
Replace
spring if any
damages or
deformations
are found
40-35
(15)
MAINTENANCE STANDARD
PPC VALVE
PC128US-2
Serial No.: 6301 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
Unit: mm
No.
Check item
Criteria
Standard size
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}
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
PPC VALVE
For blade
No.
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
Criteria
Standard size
Centering spring
Metering spring
40-36
(15)
Replace
spring if any
damages or
deformations
are found
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}
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Standard size
Free length Installed
Installed
O.D.
length
load
Remedy
Repair limit
Installed
Free length
load
31.75 8.5
25.0
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
24.5 11.6
18.0
4.9 N
{0.5 kg}
3.9 N
{0.4 kg}
30.9 20.6
29.0
69.6 N
{7.1 kg}
55.9 N
{5.7 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-37
C
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Standard size
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}
24.5 11.6
18.0
4.9 N
{0.5 kg}
3.9 N
{0.4 kg}
30.9 20.6
29.0
69.6 N
{7.1 kg}
55.9 N
{5.7 kg}
40-37-1
(15)
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE STANDARD
Unit: mm
No.
Check item
Criteria
Standard size
Free length Installed
Installed
O.D.
length
load
Remedy
Repair limit
Installed
Free length
load
25.4 11.6
18
4.9 N
{0.5 kg}
3.9 N
{0.4 kg}
31.8 8.5
25
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
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
9JA01392
ARM CYLINDER
9JA01393
BUCKET CYLINDER
9JA01394
BLADE CYLINDER
9JAOl395
40-38
0
PC128US-2
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
No.
Check item
Cylinder
Boom
Cylinder piston
tightening torque
Cylinder piston
lock screw tightening torque
PC128US-2
70
75
Blade
75
Boom
70
70
65
Blade
70
Boom
70
Clearance beArm
tween cylinder
bottom support
shaft and bushing Bucket
Cylinder head
tightening torque
Standard
size
65
Blade
Criteria
Bucket
Clearance beArm
tween piston rod
support shaft and
Bucket
bushing
Unit: mm
70
65
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
Arm
Bucket
Blade
Boom
Arm
Bucket
Blade
Boom
Arm
Bucket
Blade
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)
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
No.
Check item
Cylinder
Boom
Cylinder piston
tightening torque
Cylinder piston
lock screw tightening torque
40-40
(15)
70
75
Blade
75
Boom
70
70
65
Blade
70
Boom
70
Clearance beArm
tween cylinder
bottom support
shaft and bushing Bucket
Cylinder head
tightening torque
Standard
size
65
Blade
Criteria
Bucket
Clearance beArm
tween piston rod
support shaft and
Bucket
bushing
Unit: mm
70
65
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
Arm
Bucket
Blade
Boom
Arm
Bucket
Blade
Boom
Arm
Bucket
Blade
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
MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm
No.
Check item
2
3
4
5
6
7
PC128US-2
Criteria
Standard
size
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
MAINTENANCE STANDARD
DIMENSION
OF WORK EQUIPMENT
A-A
B-B
c-c
9JA01398
40-44
0
PC128US-2
MAINTENANCE STANDARD
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
70
Tolerance
Shaft
Hole
0.030
0.100
+0.100
0
Arm side
81.5
+1.0
0
80
1.2
Boom side
226
+0.5
0
Arm side
226
0.2
0.7
0.030
0.100
+0.100
0
70
264
2.0
213.5
1.0
640.6
0.5
2,491
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
60
0.030
0.080
+0.200
0
Link side
259
0
0.1
Bucket side
261
1.0
16
17
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
MAINTENANCE STANDARD
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
70
Tolerance
Shaft
Hole
0.030
0.100
+0.100
0
Arm side
81.5
+1.0
0
80
1.2
Boom side
226
+0.5
0
Arm side
226
0.2
0.7
70
0.030
0.100
+0.100
0
284.3
2.0
230.3
1.0
635.8
1.0
2,991.1
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
60
0.030
0.080
+0.200
0
Link side
259
0
1.0
Bucket side
261
1.0
16
17
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
MAINTENANCE STANDARD
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
70
Tolerance
Shaft
Hole
0.030
0.100
+0.100
0
Arm side
81.5
+1.0
0
80
1.2
Boom side
226
+0.5
0
Arm side
226
0.2
0.7
70
0.030
0.100
+0.100
0
280.5
2.0
213.0
1.0
640.7
1.0
2,088.5
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
60
0.030
0.080
+0.200
0
Link side
259
0
1.0
Bucket side
261
1.0
16
17
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
51.6
97.9'
I
-
11
12
73
I--
14
15
~.
374.9
-
Tolerance
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
50
85
380
+l.O
0
16
018
17
0110
0130
0132
0108
19
21
22
23
274
51
34
106.7
124.3
25
26
74
27
65
PC128US-2
40-47
MAINTENANCE STANDARD
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
Tolerance
371.3
0.5
51.6
0.5
97.9
374.9
1,231.6
190.2
60
+0.2
0
10
64
11
80
+0.25
0
12
261
1.0
13
50
14
85
15
380
+1.0
0
16
18
17
110
18
130
19
132
20
108
21
274
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)
90-2
(15)
PC128US-2
HYDRAULIC
OTHERS
CIRCUIT DIAGRAM
SERVICE I
(PPC valve)
Selector valve ~2
__-__--__
Ii
IPl
P2 I
L-_-__*--__-_qL____-_XL__f\
I
A7
!__
-c---i
87
SERVICE I -
I
_!
Bl
I
-f2
-
--Al
71
Control valve
Main Puma
PC1 28US-2
SXPO7808
90-3
HYDRAULIC
OTHERS
CIRCUIT DIAGRAM
(ATTACHMENT)
SERVICE I
(PPC valve)
Lock Din
(Large
amount)
--i
I
I
Ii
I-
!--C
SERVICE
A7
-
To oil
cooler
Crusher
ilOO% amount1
SXPO7809
PC1 28US-2
90-5
OTHERS
PC128US-2
90-5-2
A
*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)
*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)
PC128US-2
90-13-2
(15)
PC128US-2
90-13-6
(15)
PC128US-2
90-13-10
(15)
9JB00694
ELECTRIC CIRCUIT DIAGRAM (1/2)
PC128US-2
PC128US-2
90-17-6
A
PC128US-2
9JB00695
90-17-8
A
PC128US-2
90-17-10
(15)
PC128US-2
90-17-12
(15)
PC128US-2
90-17-14
(15)
PC128US-2
90-17-16
(15)
PC128US-2
90-17-18
(15)
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)