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SEBM018419

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Manual

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

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

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

Copyright 2007 Komatsu


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

CONTENTS
No. of page

01

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

10

STRUCTURE AND FUNCTION

20

TESTING AND ADJUSTING

30

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

40

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

90

OTHERS

00-2
4

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

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

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

PC128US-2

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SAFETY

SAFETY NOTICE

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

To prevent injury to workers, the symbol


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

GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.

Always wear safety glasses when hitting


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

3. If welding repairs are needed, always have a


trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.

6. Decide a place in the repair workshop to keep


tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK


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

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places.


Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.

FOREWORD

GENERAL

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

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

STRUCTURE AND FUNCTION


This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

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

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

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

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

Chassis volume: Issued for every machine model


Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models

REVISIONS

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

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

00-6

123

Revised pages are shown in the LIST OF REVISED


PAGES next to the CONTENTS page.

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

Symbol

Item

Remarks

Safety

Special safety precautions


are necessary when performing the work.

Caution

Special technical precautions or other precautions


for preserving standards
are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary


when selecting hoisting
wire, or when working posture is important, etc.

Tightening
torque

Places that require special


attention for the tightening
torque during assembly.

Coat

Places to be coated with


adhesives and lubricants,
etc.

Oil, water

Places where oil, water or


fuel must be added, and
the capacity.

Drain

Places where oil or water


m u s t b e d r a i n e d , a nd
quantity to be drained.

4
3
2
5
6

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS
HOISTING

Heavy parts (25 kg or more) must be lifted


with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol

If a part cannot be smoothly removed from the


machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.

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

Allowable load

mm

kN

tons

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

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

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

Slinging near the edge of the hook may cause


the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41%
SAD00479

3) Do not sling a heavy load with one rope alone,


but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a


wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.

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

2) Sling wire ropes from the middle portion of the


hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release


the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.

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

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion


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

1) Hold the mouthpiece of the tightening portion


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

2) Hold in the condition in Step 1), and turn


lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push


until cover (3) contacts contact surface a of
the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and


pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and


pull out whole body (2) to disconnect it.

Disassembly

Type 2

Hold the mouthpiece of the tightening portion


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

Connection

Hold the mouthpiece of the tightening portion


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

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS

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

Category

Komatsu code

Part No.

Q'ty

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g
(2 pcs.)

Polyethylene
container

LT-2

09940-00030

50 g

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

Main applications, featuresr

Used to prevent rubber gaskets,


rubber cushions, and cock plug
from coming out.

Used in places requiring an immediately effective, strong adhesive.


Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride),
rubber, metal and non-metal.

Features: Resistance to heat and


chemicals
Used for anti-loosening and sealant purpose for bolts and plugs.

Used as adhesive or sealant for


metal, glass and plastic.

Used as sealant for machined


holes.

Used as heat-resisting sealant for


repairing engine.

Quick hardening type adhesive


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

Quick hardening type adhesive


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

Resistance to heat, chemicals


Used at joint portions subject to
high temperatures.

Used as adhesive or sealant for


gaskets and packing of power
train case, etc.

Used as sealant for various


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

Gasket
sealant

LG-6

790-129-9020

200 g

Tube

00-10

Features: Silicon based, resistance to heat, cold


Used as sealant for flange surface, tread.
mab Used as sealant for oil pan,
final drive case, etc.

FOREWORD

Category

COATING MATERIALS

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr

LG-7

790-129-9070

1g

Tube

Three bond
1211

790-129-9090

100 g

Tube

LM-G

09940-00051

60 g

Can

Adhesives

Molybdenum
disulphide
lubricant

LM-P

09940-00040

200 g

Used as heat-resisting sealant for


repairing engine.

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

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

Tube

G2-LI

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

G2-CA

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

Various

Various

Molybdenum
disulphide
lubricant

SYG2-400M

400 g
(10 per
case)

Belows type

Grease

Various

Ftures: Silicon based, quick hardening type


Used as sealant for flywheel
housing, intake manifold, oil an,
thermostat housing, etc.

General purpose type

Used for normal temperature,


light load bearing at places in contact with water or steam.

Used for places with heavy load

Various

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE


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

Width across
flats

mm

mm

6
8
10
12
14

10
13
17
19
22

16
18
20
22
24

24
27
30
32
36

27
30
33
36
39

41
46
50
55
60

Thread diameter
of bolt

Width across
flats

mm

mm

Nm

6
8
10
12

10
13
14
27

7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85

Nm

kgm

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

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

1.35
3.2
6.7
11.5
18

13.2
31
66
113
177

kgm

0
0
0
0

0.8
1.9
4.1
8.4

0 0.2
0 0.5
0 0.6
0 0.8

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS


In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14
18
22
24
30
33
36
42

19
24
27
32
36
41
46
55

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

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

00-12

Tightening torque

0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS


In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

10
12
16

14
17
22

65.7 6.8
112 9.8
279 29

0
0
0

6.7 0.7
11.5 1
28.5 3

0
0

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS


Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

14
20
24
33
42

Varies depending
on type of
connector.

34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3

Norminal No.

02
03, 04
05, 06
10, 12
14

kgm

0
0
0
0
0

0 0.5
01
02
06
0 13.5

3.5
9.5
14.5
43
89.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS


Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

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

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

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

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

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

Norminal No.

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

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

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES


1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter

Tightening torque

mm

Nm

6
8
10
12

10 2
24 4
43 6
77 12

kgm

0
0
0
0

1.02
2.45
4.38
7.85

0 0.20
0 0.41
0 0.61
0 1.22

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

Tightening torque

mm

Nm

6
8
10
12
14

8 2
10 2
12 2
24 4
36 5

kgm

0
0
0
0
0

0.81
1.02
1.22
2.45
3.67

0 0.20
0 0.20
0 0.20
0 0.41
0 0.51

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

Tightening torque

inch

Nm

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

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

kgm

0
0
0
0
0
0
0

0.31
0.81
1.22
1.53
2.45
3.67
6.12

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

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

Taper seal
type

Face seal type

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

Range

Target

19

35 - 63 {3.5 - 6.5}

44 {4.5}

14

9
- 18UNF
16

14.3

22

54 - 93 {5.5 - 9.5}

74 {4.5}

11
- 16UN
16

17.5

24

59 - 98 {6.0 - 10.0}

78 {8.0}

18

04

27

84 - 132 {8.5 - 13.5}

103 {10.5}

22

13
- 16UN
16

20.7

05

32

128 - 186 {13.0 - 19.0}

157 {16.0}

24

1 - 14UNS

25.4

06

36

177 - 245 {18.0 - 25.0}

216 {22.0}

30

3
1 - 12UNF
16

30.3

(10)

41

177 - 245 {18.0 - 25.0}

216 {22.0}

33

(12)

46

197 - 294 {20.0 - 30.0}

245 {25.0}

36

(14)

55

246 - 343 {25.0 - 35.0}

294 {30.0}

42

02

03

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE


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

CLASSIFICATION BY THICKNESS

Copper wire
Cable O.D.
(mm)

Current
rating
(A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal


etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal
number

Number of
strands

Dia. of
strands
(mm2)

Cross
section
(mm 2)

0.85

11

0.32

26

CLASSIFICATION BY COLOR AND CODE


Circuits
Priority
Classification

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

Color White & Blue


Code

WG

5
Color White & Green
Code
6
Color

n
n

n
n
n
n
n
n
n
n
n
n

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

RB

YB

GR

LR

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

RY

Black & Red Red & Yellow

n
n
n
n

RG

YG

GY

LY

Yellow &
Green

Green &
Yellow

Blue & Yellow

YL

GB

LB

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

YW

GL

Red & Blue Yellow & White Green & Blue

n
n
00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.

EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

A
B

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

Liter to U.S. Gallon


1l = 0.2642 U.S. Gal

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

Liter to U.K. Gallon


1l = 0.21997 U.K. Gal

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

General assembly drawing ..........................


Specifications ....... ;. ......................................
Weight table ..................................................
List of lubricants and water.. .......................

PC 128US-2

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

01-l

GENERAL ASSEMBLY DRAWING

GENERAL

SPECIFICATION DIMENSIONAL DRAWING


PC128US-2 Serial No.: 7731 and up

Item

Machine weight

PC128US-2
Unit

12,950

Standard specification
Blade specification

7731 and up

kg

13,450

Bucket capacity

m3

0.45

Engine type

Komatsu S4D102E-1 Diesel engine

kW{HP}/rpm

64 {85.8}/2,200

Standard specification

mm

7,220

Blade specification

mm

7,955

B Overall height

mm

2,850

C Overall width

mm

2,515

D Shoe width

mm

500

Engine rated output


A

Overall length

A'

Trail swing radius

mm

1,480

Crawler overall length

mm

3,480

G Distance between tambler center

mm

2,750

H Cab height

mm

2,810

Minimum ground clearance

mm

390

Traveling speed (Low/High)

km/h

3.2/5.1

Continuous swing speed

rpm

11.0

PC128US-2

01-4-3
(15)

GENERAL ASSEMBLY DRAWING

GENERAL

PC138US-2 Serial No.: 4501 and up

Item

Machine weight

PC138US-2
Unit

Standard specification
Blade specification

4501 and up
13,400

kg

14,050

Bucket capacity

m3

0.50

Engine type

Komatsu SAA4D95LE-3-A Diesel engine

kW{HP}/rpm

66.2 {88.7}/2,200

Standard specification

mm

7,220

Blade specification

mm

7,955

B Overall height

mm

2,850

C Overall width

mm

2,515

D Shoe width

mm

500

Engine rated output


A

Overall length

A'

Trail swing radius

mm

1,480

Crawler overall length

mm

3,610

G Distance between tambler center

mm

2,880

H Cab height

mm

2,815

Minimum ground clearance

mm

395

Traveling speed (Low/High)

km/h

2.9/5.1

Continuous swing speed

rpm

11.0

01-4-4
(15)

PC128US-2

GENERAL

GENERAL ASSEMBLY DRAWING

PC138USLC-2 Serial No.: 1001 1500

Item

PC138USLC-2
Unit

Standard specification
Machine weight

Blade specification

0.50

Engine type

Komatsu S4D102E-1 Diesel engine

kW{HP}/rpm

64 {85.8}/2,200

Standard specification
Overall length

D Shoe width

mm

Blade specification
Standard specification

7,395
8,035

mm
Standard specification

Overall width

mm

Blade specification

Overall height

C
C'

14,370

m3

14,000
kg

Bucket capacity

Engine rated output

A'

1001 1500

2,850
2,590
2,515

mm

Blade specification

600
500

Trail swing radius

mm

1,480

Crawler overall length

mm

3,880

mm

3,140

Cab height

mm

2,815

Minimum ground clearance

mm

395

Traveling speed (Low/High)

km/h

2.9/4.7

Continuous swing speed

rpm

11.0

G Distance between tambler center


H

PC128US-2

01-4-5
(15)

GENERAL

GENERAL ASSEMBLY DRAWING

PC138USLC-2 Serial No.: 1501 and up

Item

PC138USLC-2
Unit

Standard specification
Machine weight

Blade specification

0.50

Engine type

Komatsu SAA4D95LE-3-E Diesel engine

kW{HP}/rpm

66.2 {88.7}/2,200

Standard specification
Overall length

Overall width

D Shoe width

mm

Blade specification
Standard specification

7,390
8,035

mm
Standard specification

mm

Blade specification

Overall height

C'

14,370

m3

14,000
kg

Bucket capacity

Engine rated output

A'

1501 and up

2,850
2,590
2,515

mm

Blade specification

600
500

Trail swing radius

mm

1,480

Crawler overall length

mm

3,870

mm

3,140

Cab height

mm

2,815

Minimum ground clearance

mm

395

Traveling speed (Low/High)

km/h

2.9/5.1

Continuous swing speed

rpm

11.0

G Distance between tambler center


H

01-4-6
(15)

PC128US-2

GENERAL ASSEMBLY DRAWING

GENERAL

WORKING RANGE DRAWING


PC128US-2

Serial No.: 7731 and up

PC128US-2
Working range (mm)

7731 and up

Maximum digging radius

8,230

Maximum digging depth

5,405

Maximum digging height

9,260

Maximum vertical wall digging depth

4,860

Maximum dumping height

6,910

Minimum swing radius of work equipment

1,980

Maximum reach at ground level

8,110

Maximum raising distance of blade

470

Maximum lowering distance of blade

530

PC128US-2

01-4-7
(15)

GENERAL ASSEMBLY DRAWING

GENERAL

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

Working range (mm)

PC138US-2

PC138USLC-2

4501 and up

1001 and up

Maximum digging radius

8,300

Maximum digging depth

5,480

Maximum digging height

9,340

Maximum vertical wall digging depth

4,900

Maximum dumping height

6,840

Minimum swing radius of work equipment

1,980

Maximum reach at ground level

8,180

Maximum raising distance of blade

Maximum lowering distance of blade

01-4-8
(15)

470
525

490

PC128US-2

SPECIFICATIONS

GENERAL

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

Without blade

Serial No.

5001 7730

Bucket capacity (SAE)

m3

0.45

0.45

Operating weight

kg

12,950

13,450

Max. digging depth

mm

5,445

5,445

Max. digging depth of cut for


2,440 mm 8' level

mm

5,235

5,235

Working ranges
Performance

With blade

Max. vertical wall depth

mm

4,900

4,900

Max. digging reach


Max. reach st ground level

mm
mm

8,230
8,110

8,230
8,110

Max. digging height


Max. dumping height

mm
mm

9,220
6,870

9,220
6,870

Max. blade lifting amount


Max. blade lowering amount

mm
mm

470 [535]
530 [465]

KN {kg}

93.2 {9,500}

93.2 {9,500}

Serial No. 6457 and up

rpm

11.0

11.0

Serial No. 5001 6456

rpm

12

12

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm2}

42.2 {0.43}

43.1 {0.44}

Overall length (for transport)

mm

7,220

7,955

Overall width

mm

2,490

2,490

Overall width of undercarrige

mm

2,490

2,490

Overall height (for transport)

mm

2,850 [2,890]

2,850 [ 2,890]

Overall height to top of cab

mm

2,730 [2,795]

2,730 [2,795]

Ground clearance of counterweight

mm

855 [920]

855 [920]

Min. ground clearance

mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

1,980

1,980

Height of work equipment at


min. swing radius

mm

6,725 [6,790]

6,725 [6,790]

Length of track on ground

mm

2,750

2,750

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,935 [2,000]

1,935 [2,000]

Blade width x height

mm

2,490 x 590

Max. digging force (bucket)


Swing speed

Dimension

Ground pressure

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

01-5
(15)

SPECIFICATIONS

GENERAL

PC128US-2
Machine model

Without blade

Serial No.

5001 7730

Model

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

No. of cylinders-bore x stroke

mm

4 102 x 120

Piston displacement

{cc}

3.920 {3,920}

Rated horsepower

kW/rpm{HP/rpm}

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

Max. torpue

Nm/rpm{kgm/rpm}

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

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio


Starting motor

24V, 4.5 kw

Alternator

24V, 25A

Undercarriage

Battery
Radiator type

CF19-4

Carrier roller

1 on each side

Track roller

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

Hydraulic pump

(road liner)

Hydraulic motor control


valve

Hydraulic system

12V, 64 Ah x 2

Track shoe (iron shoe)

Road liner, 42 on each side


HPV95 (for 105cc/rev.)

Type x no.

Variable displacement piston type x 1


/min

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

226 (at 2,200rpm)


2

MPa {kg/cm }

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

Travel motor

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

Swing motor

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

Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic cooler

01-6
(15)

With blade

Air cooled (CF40-1)

PC128US-2

SPECIFICATIONS

GENERAL

PC128US-2
Machine model

STD (without blade)

Serial No.

5001 7730

Boom cylinder

Type

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Reciprocating piston tipe

Reciprocating piston tipe

Arm cylinder

Cylinder inner diameter

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

Reciprocating piston tipe

Type
Blade cylinder

Reciprocating piston tipe

mm

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Reciprocating piston tipe

Cylinder inner diameter

Type

PC128US-2

OPT (with blade)

Cylinder inner diameter

mm

115

Piston rod diameter

mm

75

Stroke

mm

181

Max. length betwiin pins

mm

870

Min. length betwiin pins

mm

689

01-7
A

SPECIFICATIONS

GENERAL

FOR NORTH AMERICA SPEC.


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

STD (without blade)

Serial No.

5001 7730

Bucket capacity (SAE)

m3

0.45

0.45

Operating weight

kg

13,100

13,600

Max. digging depth

mm

5,445

5,445

Max. digging depth of cut for


2,440 mm 8' level

mm

5,235

5,235

Working ranges
Performance

OPT (with blade)

Max. vertical wall depth

mm

4,900

4,900

Max. digging reach

mm

8,230

8,230

Max. reach st ground level

mm

8,110

8,110

Max. digging height

mm

9,220

9,220

Max. dumping height

mm

6,870

6,870

Max. blade lifting amount

mm

470 [535]

Max. blade lowering amount

mm

530 [465]

KN {kg}

93.2 {9,500}

93.2 {9,500}

Serial No. 6457 and up

rpm

11.0

11.0

Serial No. 5001 6456

rpm

12

12

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm2}

35.6 {0.36}

37.0 {0.38}

Overall length (for transport)

mm

7,220

7,955

Overall width

mm

2,590

2,590

Overall width of undercarrige

mm

2,590

2,590

Overall height (for transport)

mm

2,850 [2,890]

2,850 [2,890]

Overall height to top of cab

mm

2,730 [2,795]

2,730 [2,795]

Ground clearance of counterweight

mm

855 [920]

855 [920]

Min. ground clearance

mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

1,980

1,980

Height of work equipment at


min. swing radius

mm

6,725 [6,790]

6,725 [6,790]

Length of track on ground

mm

2,750

2,750

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,935 [2,000]

1,935 [2,000]

Blade width x height

mm

2,490 x 590

Max. digging force (bucket)


Swing speed

Dimension

Ground pressure

fl The values shown in the [

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

No. of cylinders-bore x stroke

mm

4 102 x 120

Piston displacement

{cc}

3.92 {3,920}

Flywheel horsepower

kW/rpm{HP/rpm}

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

Maximum torpue

Nm/rpm{kgm/rpm}

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

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio


Starting motor

24V, 4.5 kw

Alternator

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

Radiator type

CF19-4

Carrier roller

1 on each side

Track roller

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

Track shoe

Hydraulic motor

control
valve

Hydraulic pump

Undercarriage

Battery

Hydraulic system

With blade

HPV95 (for 105cc/rev.)


Type x no.

Variable displacement piston type x 1

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

/min

226 (at 2,200rpm)

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

Tank return side

Hydraulic oil filter

Air cooled (CF40-1)

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

01-9
(15)

GENERAL

SPECIFICATIONS

PC128US-2
Machine model

Without blade

Serial No.

5001 7730

Boom cylinder

Type

Reciprocating piston tipe


mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Arm cylinder
Blade cylinder

Reciprocating piston tipe

Cylinder inner diameter

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Reciprocating piston tipe

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

Type

(15)

Reciprocating piston tipe

Cylinder inner diameter

Type

01-10

With blade

Reciprocating piston tipe

Cylinder inner diameter

mm

115

Piston rod diameter

mm

75

Stroke

mm

181

Max. length betwiin pins

mm

870

Min. length betwiin pins

mm

689

PC128US-2

SPECIFICATIONS

GENERAL

FOR KUK SPEC.


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

Without blade

Serial No.

5001 7730

Bucket capacity (SAE)

m3

0.36

0.36

Operating weight

kg

12,750

13,250

Max. digging depth

mm

5,945

5,945

Max. digging depth of cut for


2,440 mm 8' level

mm

5,760

5,760

Max. vertical wall depth

mm

5,385

5,385

Max. digging reach

mm

8,720

8,720

Max. reach st ground level

mm

8,600

8,600

Working ranges
Performance

With blade

Max. digging height

mm

9,655

9,655

Max. dumping height

mm

7,305

7,305

Max. blade lifting amount

mm

470 [535]

Max. blade lowering amount

mm

530 [465]

KN {kg}

88.3 {9,000}

88.3 {9,000}

Serial No. 6457 and up

rpm

11.0

11.0

Serial No. 5001 6456

rpm

12

12

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm }

42.2 {0.43}

43.1 {0.44}

Overall length (for transport)

mm

7,120

7,855

Overall width

mm

2,490

2,490

Overall width of undercarrige

mm

2,490

2,490

Overall height (for transport)

mm

3,190 [3,230]

3,190 [3,230]

Overall height to top of cab

mm

2,730 [2,795]

2,730 [2,795]

Ground clearance of counterweight

mm

855 [920]

855 [920]

Min. ground clearance

mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

2,250

2,250

Height of work equipment at


min. swing radius

mm

6,725 [6,790]

6,725 [6,790]

Length of track on ground

mm

2,750

2,750

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,935 [2,000]

1,935 [2,000]

Blade width x height

mm

2,490 x 590

Max. digging force (bucket)


Swing speed

Dimension

Ground pressure

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

No. of cylinders-bore x stroke

mm

4 102 x 120

Piston displacement

{cc}

3.92 {3,920}

Flywheel horsepower

kW/rpm{HP/rpm}

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

Maximum torpue

Nm/rpm{kgm/rpm}

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

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio


Starting motor

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

HPV95 (for 105cc/rev.)


Type x no.

Variable displacement piston type x 1

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

/min

226 (at 2,200rpm)

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

Tank return side

Hydraulic oil filter

fl The values shown in the [

01-10-2
(15)

Air cooled (CF40-1)

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

GENERAL

SPECIFICATIONS

PC128US-2
Machine model

STD (without blade)

Serial No.

5001 7730

Boom cylinder

Type

Reciprocating piston tipe


mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Arm cylinder

Reciprocating piston tipe

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

Type
Blade cylinder

Reciprocating piston tipe

Cylinder inner diameter

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Reciprocating piston tipe

Cylinder inner diameter

Type

PC128US-2

OPT (with blade)

Reciprocating piston tipe

Cylinder inner diameter

mm

115

Piston rod diameter

mm

75

Stroke

mm

181

Max. length betwiin pins

mm

870

Min. length betwiin pins

mm

689

01-10-3
A

SPECIFICATIONS

GENERAL

PC128US-2 Serial No.: 7731 and up


PC128US-2
Machine model

STD (without blade)


7731 and up

Bucket capacity (SAE)

m3

0.45

0.45

Operating weight

kg

12,950

13,450

Max. digging depth

mm

5,405

5,405

Max. digging depth of cut for


2,440 mm 8' level

mm

5,195

5,195

Max. vertical wall depth

mm

4,860

4,860

Max. digging reach

mm

8,230

8,230

Max. reach st ground level

mm

8,110

8,110

Max. digging height

mm

9,260

9,260

Max. dumping height

mm

6,910

6,910

Max. blade lifting amount

mm

470 [535]

Max. blade lowering amount

mm

530 [465]

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

km/h

5.1/3.2

5.1/3.2

Gradeability

deg.

35

35

kPa {kg/cm2}

42.2 {0.43}

43.1 {0.44}

Overall length (for transport)

mm

7,220

7,955

Overall width

mm

2,515

2,515

Overall width of undercarrige

mm

2,490

2,490

Overall height (for transport)

mm

2,850 [2,890]

2,850 [ 2,890]

Overall height to top of cab

mm

2,810 [2,875]

2,810 [2,875]

Ground clearance of counterweight

mm

895 [960]

895 [960]

Min. ground clearance

mm

390 [455]

390 [455]

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

1,980

1,980

Height of work equipment at


min. swing radius

mm

6,765 [6,830]

6,765 [6,830]

Length of track on ground

mm

2,750

2,750

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,975 [2,040]

1,975 [2,040]

Blade width x height

mm

2,490 x 590

Working ranges

Persormance

Serial No.

Max. digging force (bucket)

Ground pressure

Dimension

OPT (with blade)

fl The values shown in the [

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

No. of cylinders-bore x stroke

mm

4 102 x 120

Piston displacement

{cc}

3.920 {3,920}

Rated horsepower

kW/rpm{HP/rpm}

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

Max. torpue

Nm/rpm{kgm/rpm}

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

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio


Starting motor

24V, 4.5 kw

Alternator

24V, 25A

(For KUK spec.)

24V, 35A

Battery

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

Radiator type

CF19-4

Carrier roller

1 on each side

Track roller

7 on each side

Track shoe (iron shoe)

Asembly-type triple grouster, 42 on each side


Road liner, 42 on each side

(road liner)

Hydraulic motor

Control
valve

Hydraulic pump

Undercarriage

(For North America spec.)

Hydraulic system

With blade

HPV95 (for 105cc/rev.)


Type x no.

Variable displacement piston type x 1

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

/min

226 (at 2,200rpm)

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

Reciprocating piston tipe


mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Arm cylinder
Blade cylinder

Reciprocating piston tipe

Cylinder inner diameter

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Reciprocating piston tipe

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

Type

(15)

Reciprocating piston tipe

Cylinder inner diameter

Type

01-10-6

With blade

Reciprocating piston tipe

Cylinder inner diameter

mm

115

Piston rod diameter

mm

75

Stroke

mm

181

Max. length betwiin pins

mm

870

Min. length betwiin pins

mm

689

PC128US-2

SPECIFICATIONS

GENERAL

PC138US-2 Serial No.: 4501 and up


PC138US-2
Machine model

Without blade

m3

0.50

0.50

Operating weight

kg

13,400

14,050

Max. digging depth

mm

5,480

5,480

Max. digging depth of cut for


2,440 mm 8' level

mm

5,265

5,265

Max. vertical wall depth

mm

4,900

4,900

Max. digging reach

mm

8,300

8,300

Max. reach st ground level

mm

8,180

8,180

Max. digging height

mm

9,340

9,340

Max. dumping height

mm

6,840

6,840

Max. blade lifting amount

mm

470 [535]

Max. blade lowering amount

mm

525 [460]

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

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}

Overall length (for transport)

mm

7,260

7,955

Overall width

mm

2,515

2,515

Overall width of undercarrige

mm

2,490

2,490

Overall height (for transport)

mm

2,850 [2,890]

2,850 [ 2,890]

Overall height to top of cab

mm

2,815 [2,880]

2,815 [2,880]

Ground clearance of counterweight

mm

900 [965]

900 [965]

Min. ground clearance

mm

395 [460]

395 [460]

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

1,980

1,980

Height of work equipment at


min. swing radius

mm

6,770 [6,835]

6,770 [6,835]

Length of track on ground

mm

2,880

2,880

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,980 [2,045]

1,980 [2,045]

Blade width x height

mm

2,490 x 590

Max. digging force (bucket)

Ground pressure

Dimension

4501 and up

Bucket capacity (SAE)

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

No. of cylinders-bore x stroke

mm

4 95 x 115

Piston displacement

{cc}

3.260 {3,260}

Rated horsepower

kW/rpm{HP/rpm}

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

Max. torpue

Nm/rpm{kgm/rpm}

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

High idling speed

rpm

2,400

Low idling speed

rpm

1,100

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio


Starting motor

24V, 3.0 kw

Alternator

24V, 25A

(For KUK spec.)

24V, 35A

Battery

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

Radiator type

Corrugated aluminum (4-line)

Carrier roller

1 on each side

Track roller

7 on each side

Track shoe (iron shoe)

Asembly-type triple grouster, 43 on each side


Road liner, 43 on each side

(road liner)

Hydraulic motor

Control
valve

Hydraulic pump

Undercarriage

(For North America spec.)

Hydraulic system

With blade

HPV95 (for 105cc/rev.)


Type x no.

Variable displacement piston type x 1

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

/min

226 (at 2,200rpm)

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

Tank return side

Hydraulic cooler

Air cooled (CF40)

01-10-8
(15)

PC128US-2

GENERAL

SPECIFICATIONS

PC138US-2
Machine model

Without blade

Serial No.

4501 and up

Boom cylinder

Type

Reciprocating piston tipe


mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Arm cylinder

Reciprocating piston tipe


mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

100

100

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

Type
Blade cylinder

Reciprocating piston tipe

Cylinder inner diameter

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Reciprocating piston tipe

Cylinder inner diameter

Type

PC128US-2

With blade

Reciprocating piston tipe

Cylinder inner diameter

mm

115

Piston rod diameter

mm

75

Stroke

mm

181

Max. length betwiin pins

mm

870

Min. length betwiin pins

mm

689

01-10-9
(15)

SPECIFICATIONS

GENERAL

PC138USLC-2 Serial No.: 1001 1500


PC138USLC-2
Machine model

Without blade

m3

0.50

0.50

Operating weight

kg

14,000

14,370

Max. digging depth

mm

5,480

5,480

Max. digging depth of cut for


2,440 mm 8' level

mm

5,265

5,265

Max. vertical wall depth

mm

4,900

4,900

Max. digging reach

mm

8,300

8,300

Max. reach st ground level

mm

8,180

8,180

Max. digging height

mm

9,340

9,340

Max. dumping height

mm

6,840

6,840

Max. blade lifting amount

mm

470

Max. blade lowering amount

mm

490

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

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}

Overall length (for transport)

mm

7,395

8,035

Overall width

mm

2,590

2,515

Overall width of undercarrige

mm

2,590

2,490

Overall height (for transport)

mm

2,850

2,850

Overall height to top of cab

mm

2,815

2,815

Ground clearance of counterweight

mm

900

900

Min. ground clearance

mm

395

395

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

1,980

1,980

Height of work equipment at


min. swing radius

mm

6,770

6,770

Length of track on ground

mm

3,140

3,140

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,980

1,980

Blade width x height

mm

2,490 x 590

Max. digging force (bucket)

Ground pressure

Dimension

1001 1500

Bucket capacity (SAE)

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

No. of cylinders-bore x stroke

mm

4 102 x 120

Piston displacement

{cc}

3.920 {3,920}

Rated horsepower

kW/rpm{HP/rpm}

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

Max. torpue

Nm/rpm{kgm/rpm}

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

High idling speed

rpm

2,400

Low idling speed

rpm

950

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio


Starting motor

24V, 4.5 kw

Alternator

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

Radiator type

CF19-4

Carrier roller

2 on each side

Track roller

8 on each side

Control Hydraulic pump


valve

Track shoe (iron shoe)

Hydraulic motor

Undercarriage

Battery

Hydraulic system

With blade

Asembly-type triple grouster, 46 on each side


HPV95 (for 105cc/rev.)

Type x no.

Variable displacement piston type x 1


/min

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

226 (at 2,200rpm)


2

MPa {kg/cm }

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

Travel motor

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

Tank return side

Hydraulic cooler

PC128US-2

Air cooled (CF40-1)

01-10-11
(15)

GENERAL

SPECIFICATIONS

PC138USLC-2
Machine model

Without blade

Serial No.

1001 1500

Boom cylinder

Type

Reciprocating piston tipe


mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Reciprocating piston tipe

Reciprocating piston tipe

Arm cylinder

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

Reciprocating piston tipe

Reciprocating piston tipe

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Cylinder inner diameter

Cylinder inner diameter

mm

100

100

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

Reciprocating piston tipe

Blade cylinder

Type

(15)

Reciprocating piston tipe

Cylinder inner diameter

Type

01-10-12

With blade

Cylinder inner diameter

mm

115

Piston rod diameter

mm

75

Stroke

mm

181

Max. length betwiin pins

mm

870

Min. length betwiin pins

mm

689

PC128US-2

SPECIFICATIONS

GENERAL

PC138USLC-2 Serial No.: 1501 and up


PC138USLC-2
Machine model

Without blade

m3

0.50

0.50

Operating weight

kg

14,000

14,370

Max. digging depth

mm

5,480

5,480

Max. digging depth of cut for


2,440 mm 8' level

mm

5,265

5,265

Max. vertical wall depth

mm

4,900

4,900

Max. digging reach

mm

8,300

8,300

Max. reach st ground level

mm

8,180

8,180

Max. digging height

mm

9,340

9,340

Max. dumping height

mm

6,840

6,840

Max. blade lifting amount

mm

470

Max. blade lowering amount

mm

490

KN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0

Swing max. slope angle

deg.

19

19

Travel speed (Hi/Lo)

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}

Overall length (for transport)

mm

7,390

8,035

Overall width

mm

2,590

2,515

Overall width of undercarrige

mm

2,590

2,490

Overall height (for transport)

mm

2,850

2,850

Overall height to top of cab

mm

2,815

2,815

Ground clearance of counterweight

mm

900

900

Min. ground clearance

mm

395

395

Tail swing radius

mm

1,480

1,480

Min. swing radius of work euipment

mm

1,980

1,980

Height of work equipment at


min. swing radius

mm

6,770

6,770

Length of track on ground

mm

3,140

3,140

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,980

1,980

Blade width x height

mm

2,490 x 590

Max. digging force (bucket)

Ground pressure

Dimension

1501 and up

Bucket capacity (SAE)

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

No. of cylinders-bore x stroke

mm

4 95 x 115

Piston displacement

{cc}

3.260 {3,260}

Rated horsepower

kW/rpm{HP/rpm}

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

Max. torpue

Nm/rpm{kgm/rpm}

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

High idling speed

rpm

2,400

Low idling speed

rpm

1,100

g/kWh{g/HPh}

224 {165}

Performance

Engine

Type

Min. fuel consumption ratio


Starting motor

24V, 3.0 kw

Alternator

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

Radiator type

Corrugated aluminum (4-line)

Carrier roller

2 on each side

Track roller

8 on each side

Control Hydraulic pump


valve

Track shoe (iron shoe)

Hydraulic motor

Undercarriage

Battery

Hydraulic system

With blade

Asembly-type triple grouster, 46 on each side


HPV95 (for 105cc/rev.)

Type x no.

Variable displacement piston type x 1


/min

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

226 (at 2,200rpm)


2

MPa {kg/cm }

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

Travel motor

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

Tank return side

Hydraulic cooler

Air cooled (CF40)

01-10-14
(15)

PC128US-2

GENERAL

SPECIFICATIONS

PC138USLC-2
Machine model

Without blade

Serial No.

1501 and up

Boom cylinder

Type

Reciprocating piston tipe


mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

1,055

1,055

Max. length betwiin pins

mm

2,555

2,555

Min. length betwiin pins

mm

1,500

1,500

Reciprocating piston tipe

Reciprocating piston tipe

Arm cylinder

Cylinder inner diameter

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

Reciprocating piston tipe

Reciprocating piston tipe

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Cylinder inner diameter

mm

100

100

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

Reciprocating piston tipe

Type
Blade cylinder

Reciprocating piston tipe

Cylinder inner diameter

Type

PC128US-2

With blade

Cylinder inner diameter

mm

115

Piston rod diameter

mm

75

Stroke

mm

181

Max. length betwiin pins

mm

870

Min. length betwiin pins

mm

689

01-10-15
(15)

GENERAL

WEIGHT TABLE

WEIGHT TABLE

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

FOR STD SPEC.


PC128US-2 Serial No.: 5001 7730

Unit: kg
PC128US-2

Machine model

Without blade

Serial No.

With blade
5001 7730

Engine assembly (excl. water, oil)

491

491

Engine (excl. water, oil)

385

385

Engine mount

21.6

21.6

PTO

4.1

4.1

Hydraulic pump

80

80

Radiator, oil cooler assembly

54

54

1,500

1,500

Operators cab

228

228

Operators seat

12.6

12.6

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

80

96

Self pressure reducing valve

4.8

4.8

3,020

2,460

Swing motor (with brake valve)

26

26

Swing circle

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly

2,275

2,445

Track frame

1,280

1,438

Idler assembly

81 x 2

81 x 2

72.9 x 2

72.9 x 2

Carrier roller

11 x 2

11 x 2

Track roller

21 x 14

21 x 14

Travel motor, final drive assembly

144 x 2

144 x 2

Sprocket

33.7 x 2

33.7 x 2

Revolving frame

Counterweight

Recoil spring assembly

PC128US-2

01-11
(15)

WEIGHT TABLE

GENERAL

Unit: kg
PC128US-2
Machine model

Without blade

Serial No.

With blade
5001 7730

Track shoe assembly


Triple grouser shoe (500mm)

740 x 2

740 x 2

Triple grouser shoe (600mm)

830 x 2

830 x 2

Road liner (500mm)

765 x 2

765 x 2

Boom assembly

820

820

Arm assembly

356

356

Bucket link assembly

85.6

85.6

Bucket assembly

369

369

Blade assembly

641

113.3 x 2

113.3 x 2

Arm cylinder assembly

140.9

140.9

Bucket cylinder assembly

86.3

86.3

Blade cylinder assembly

67.2 x 2

Boom cylinder assembly

01-12
(15)

PC128US-2

WEIGHT TABLE

GENERAL

FOR NORTH AMERICA SPEC.


PC128US-2 Serial No.: 5001 7730

Unit: kg
PC128US-2

Machine model

Without blade

Serial No.

With blade
5001 7730

Engine assembly (excl. water, oil)

491

491

Engine (excl. water, oil)

385

385

Engine mount

21.6

21.6

PTO

4.1

4.1

Hydraulic pump

80

80

Radiator, oil cooler assembly

54

54

1,500

1,500

Operators cab

228

228

Operators seat

12.6

12.6

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

80

96

Self pressure reducing valve

4.8

4.8

3,020

2,460

Swing motor

26

26

Swing circle assembly

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly

2,275

2,445

Track frame

1,280

1,438

Idler

81 x 2

81 x 2

Idler cushion

72.9 x 2

72.9 x 2

Carrier roller

11 x 2

11 x 2

Track roller

21 x 14

21 x 14

Revolving frame assembly

Counterweight

Travel motor, final drive assembly

144 x 2

144 x 2

Sprocket

33.7 x 2

33.7 x 2

Triple grouser shoe (500mm)

740 x 2

740 x 2

Triple grouser shoe (600mm)

830 x 2

830 x 2

Triple grouser shoe (700mm)

925 x 2

925 x 2

Road liner (rubber pad type) (500mm)

765 x 2

765 x 2

Track shoe assembly

PC128US-2

01-13
(15)

WEIGHT TABLE

GENERAL

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

Bucket cylinder assembly

86.3

86.3

Blade cylinder assembly

67.2 x 2

Boom cylinder assembly


Arm cylinder assembly

01-14
(15)

PC128US-2

WEIGHT TABLE

GENERAL

FOR KUK SPEC.


Unit: kg

PC128US-2 Serial No.: 5001 7730


PC128US-2
Machine model

Without blade

Serial No.

With blade
5001 7730

Engine assembly (excl. water, oil)

491

491

Engine (excl. water, oil)

385

385

Engine mount

21.6

21.6

PTO

4.1

4.1

Hydraulic pump

80

80

Radiator, oil cooler assembly

54

54

1,500

1,500

Operators cab

228

228

Operators seat

35

35

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

96

106

Self pressure reducing valve

4.8

4.8

Boom hydraulic drift prevention valve

5.1

5.1

3,020

2,460

Swing motor

26

26

Swing circle assembly

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly

2,275

2,445

Track frame

1,280

1,438

Idler

81 x 2

81 x 2

Idler cushion

72.9 x 2

72.9 x 2

Carrier roller

11 x 2

11 x 2

Track roller

21 x 14

21 x 14

Revolving frame assembly

Counterweight

Travel motor, final drive assembly

144 x 2

144 x 2

Sprocket

33.7 x 2

33.7 x 2

Triple grouser shoe (500mm)

740 x 2

740 x 2

Triple grouser shoe (600mm)

830 x 2

830 x 2

Triple grouser shoe (700mm)

925 x 2

925 x 2

Road liner (rubber pad type) (500mm)

765 x 2

765 x 2

Track shoe assembly

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

Arm assembly (long arm)

480

480

Link assembly

85.6

85.6

376

376

641

113.3 x 2

113.3 x 2

140.9

140.9

Bucket cylinder assembly

86.3

86.3

Blade cylinder assembly

67.2 x 2

Bucket assembly (0.36 m )


Blade assembly
Boom cylinder assembly
Arm cylinder assembly

01-14-2
(15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg

PC128US-2 Serial No.: 7731 and up


PC128US-2
Machine model

Without blade

Serial No.

With blade
7731 and up

Engine assembly (excl. water, oil)

491

491

Engine (excl. water, oil)

385

385

Engine mount

21.6

21.6

PTO

4.1

4.1

Hydraulic pump

80

80

Radiator, oil cooler assembly

54

54

1,500

1,500

Operators cab

245

245

Operators seat

35

35

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

80

96

(For KUK spec.)

96

106

Self pressure reducing valve

4.8

4.8

3,020

2,460

Swing motor

26

26

Swing circle assembly

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly

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

Travel motor, final drive assembly

144 x 2

144 x 2

Sprocket

33.7 x 2

33.7 x 2

Revolving frame assembly

Counterweight

Track shoe assembly


Triple grouser shoe (500mm)

*1

740 x 2

740 x 2

Triple grouser shoe (600mm)

*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

Road liner (rubber pad type) (500mm)

*1. Serial No.: 7731 9000


*2. Serial No.: 9001 and up
PC128US-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

Bucket cylinder assembly

86.3

86.3

Blade cylinder assembly

67.2 x 2

Boom cylinder assembly


Arm cylinder assembly

01-14-4
(15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg

PC138US-2 Serial No.: 4501 and up


PC138US-2
Machine model

Without blade

Serial No.

With blade
4501 and up

Engine assembly (excl. water, oil)

491

491

Engine (excl. water, oil)

360

360

Engine mount

19.6

19.6

PTO

4.1

4.1

Hydraulic pump

80

80

Radiator, oil cooler assembly

62

62

1,425

1,425

Operators cab

245

245

Operators seat

35

35

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

80

96

(For KUK spec.)

96

106

Self pressure reducing valve

4.8

4.8

3,400

3,000

Swing motor

26

26

Swing circle assembly

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly

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

Revolving frame assembly

Counterweight

Travel motor, final drive assembly

144 x 2

144 x 2

Sprocket

33.7 x 2

33.7 x 2

Triple grouser shoe (500mm)

755 x 2

755 x 2

Triple grouser shoe (600mm)

845 x 2

845 x 2

Triple grouser shoe (700mm)

935 x 2

935 x 2

Road liner (rubber pad type) (500mm)

815 x 2

815 x 2

Track shoe assembly

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

Bucket cylinder assembly

95

95

Blade cylinder assembly

61.7 x 2

Boom cylinder assembly


Arm cylinder assembly

01-14-6
(15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg

PC138USLC-2 Serial No.: 1001 1500


PC138USLC-2
Machine model

Without blade

Serial No.

With blade
1001 1500

Engine assembly (excl. water, oil)

491

491

Engine (excl. water, oil)

385

385

Engine mount

21.6

21.6

PTO

4.1

4.1

Hydraulic pump

80

80

Radiator, oil cooler assembly

54

54

1,500

1,500

Operators cab

245

245

Operators seat

35

35

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

80

96

Self pressure reducing valve

4.8

4.8

3,420

3,020

Swing motor

26

26

Swing circle assembly

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly


Track frame

2,610
1,544

2,750
1,680

Revolving frame assembly

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

Travel motor, final drive assembly

144 x 2

144 x 2

Sprocket

33.1 x 2

33.1 x 2

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

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

Boom assembly

820

820

Arm assembly

356

356

Link assembly

85.6

85.6

Bucket assembly

399

399

Blade assembly

641

Track shoe assembly


Triple grouser shoe (600mm)
Triple grouser shoe (500mm)

*1. Serial No.: 1001 1300


*2. Serial No.: 1301 and up
PC128US-2

*1
*2
*1
*2

01-14-7
(15)

WEIGHT TABLE

GENERAL

Unit: kg
PC138USLC-2
Machine model

Without blade

Serial No.
Boom cylinder assembly

With blade
1001 1500

113.3 x 2

113.3 x 2

140.9

140.9

Bucket cylinder assembly

95.8

95.8

Blade cylinder assembly

67.2 x 2

Arm cylinder assembly

01-14-8
(15)

PC128US-2

WEIGHT TABLE

GENERAL

Unit: kg

PC138USLC-2 Serial No.: 1501 and up


PC138USLC-2
Machine model

Without blade

Serial No.

With blade
1501 and up

Engine assembly (excl. water, oil)

464

464

Engine (excl. water, oil)

360

360

Engine mount

19.6

19.6

PTO

4.1

4.1

Hydraulic pump

80

80

Radiator, oil cooler assembly

62

62

1,425

1,425

Operators cab

245

245

Operators seat

35

35

Fuel tank (excl. fuel)

98

98

Hydraulic tank (excl. hydraulic oil)

92

92

Control valve

80

96

Self pressure reducing valve

4.8

4.8

3,400

3,000

Swing motor

26

26

Swing circle assembly

155

155

Swing machinery

72.2

72.2

Center swivel joint

28.6

43.6

Track frame assembly


Track frame

2,595
1,544

2,735
1,680

Idler

78 x 2

78 x 2

Idler cushion

69 x 2

69 x 2

Carrier roller

11 x 4

11 x 4

Track roller

21 x 16

21 x 16

Travel motor, final drive assembly

144 x 2

144 x 2

Sprocket

33.1 x 2

33.1 x 2

Track shoe assembly


Triple grouser shoe (600mm)

895 x 2

895 x 2

Triple grouser shoe (500mm)

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

Revolving frame assembly

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

Bucket cylinder assembly

95

95

Blade cylinder assembly

61.7 x 2

Arm cylinder assembly

01-14-10
(15)

PC128US-2

GENERAL

LIST OF LUBRICANTS AND WATER

LIST OF LUBRICANTS AND WATER


PROPER SELECTION
AMBIENT TEMPERATURE
RESERVOIR

KIND OF
FLUID 22

4
20

30

14
10

32
0

50
10

68
20

86
30

104
40

122F
50C

SAE 30
SAE 10W
Engine oil pan

SAE 10W-30
SAE 15W-40

Swing machinery case


Final drive case
PTO gear case

Engine oil
SAE 30

SAE 30
SAE 10W-30

Hydraulic system

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

Diesel fuel

Greasing system

Grease

Cooling system

Water

*1
NLGI No.2
Add antifreeze

*1: ASTM D975 No.1

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

Specified
capacity

Refill
capacity

Engine oil
pan

Swing
machinery
case

Final drive
case
(each)

PTO gear
case

Hydraulic
system

Fuel tank

Cooling
system

liter

17.5

2.5

2.5

0.75

120

195

18.2

US gal

4.62

0.66

0.66

0.20

31.68

51.48

4.80

16

2.5

2.5

0.75

69

4.23

0.66

0.66

0.20

18.22

liter
US gal

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

LIST OF LUBRICANTS AND WATER

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

When starting the engine in an atmospheric


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

Use API classification CD as engine oil and if


API classification CC, reduce the engine oil
change interval to half.

There is no problem if single grade oil is


mixed with multigrade oil (SAE10W-30, 15W40), but be sure to add single grade oil that
matches the temperature range in the table.

We recommend Komatsu genuine oil which


has been specifically formulated and approved for use in engine and hydraulic work
equipment applications.

Specified capacity: Total amount of oil including


oil for components and oil in
piping.
Refill capacity:

Amount of oil needed to refill


system during normal inspection and maintenance.

ASTM: American Society of Testing and Material


SAE: Society of Automotive Engineers
API:

American Petroleum Institute

Fuel sulphur content

Change interval of oil in


engine oil pan

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

01-16
A

PC128US-2

10 STRUCTURE AND FUNCTION


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

PC128US-2

10-1
(15)

PTO

STRUCTURE AND FUNCTION

PTO

1.
2.
3.
4.

Coupling
Shaft
Breather
Gauge

10-2

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

PC128US-2

STRUCTURE AND FUNCTION

RADIATOR AND OIL COOLER

RADIATOR AND OIL COOLER


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

PC128US-2

10-3
(15)

STRUCTURE

AND FUNCTION

RADIATOR AND OIL COOLER

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

STRUCTURE AND FUNCTION

RADIATOR AND OIL COOLER

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

PC128US-2

10-4-1
(15)

RADIATOR AND OIL COOLER

STRUCTURE AND FUNCTION

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

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

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

Chage air cooler outlet hose


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

Specification
Radiator

Oil cooler

Aluminum wave
(4-line)

CF40

Fin pitch (min)

3.5/2

3.5/2

4.0/2

Total heat dissipation surfase (m2)

18.81

11.83

6.17

Pressure valve cracking pressure


(kPa {kg/cm2})

49.0 14.7
{0.5 0.15}

Vacuum valve cracking pressure


(kPa {kg/cm2})

-4.9 0
{-0.05 0}

Core type

10-4-2
(15)

Charge air cooler

PC128US-2

STRUCTURE

AND FUNCTION

POWER TRAIN

POWER TRAIN

9JA01329

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

PC1 28US-2

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

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

1o-5

STRUCTURE

SWING

AND FUNCTION

CIRCLE

SWING CIRCLE

6
.\

A-A

m
B-B

m
c-c

9JA01330

1.
2.
4.
5.
6.

Greasing to swing
Greasing to swing
Seal
Ball
Inner &e

a.
b.

Inner race soft zone position


Outer race soft zone position

1O-6

circle bearing
circle pinion

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

PC1 28US-2

STRUCTURE AND FUNCTION

SWING MACHINERY

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

1. Swing pinion (number of teeth : 11)


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

PC128US-2

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

10-7
(15)

STRUCTURE AND FUNCTION

SWING MACHINERY

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

1. Swing pinion (number of teeth : 11)


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

10-7-1
(15)

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

PC128US-2

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

HYDRAULIC COMPONENT LAYOUT

HYDRAULIC COMPONENT LAYOUT

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

14.
15.
16.

17.
18.
19.
20.

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

10-10
(15)

PC128US-2

STRUCTURE

AND FUNCTION

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

VALVE CONTROL

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

attachment

outlet for arm RIGHT

attachment outlet for arm LEFT side


attachment outlet for boom RIGHT
attachment

outlet for boom LEFT

pedal LOCK
pedal HALF stroke position
pedal FULL stroket position

Lever and pedal position


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

PC 128US-2

10-13
0

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

VALVE CONTROL

1. Control valve
2. R.H. work equipment PPC valve
3. R.H. work equipment control lever
(for boom and bucket operation)
4. Blade control lever (Blade specification)
5. 4-spool solenoid valve
6. L.H. work equipment control lever
(for arm, swing operation)
7. Blade PPC valve (Blade specification)
8. L.H. work equipment PPC valve
9. Safety lock lever
10. L.H. travel pedal
11. R.H. travel pedal
12. L.H. travel lever
13. R.H. travel lever
14. Travel PPC valve
15. Attachment PPC valve
(Attachment installable machine)
16. Attachment pedal
(Attachment installable machine)
17. Lock pin (Attachment installable machine)
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

STRUCTURE AND FUNCTION

HYDRAULIC TANK AND FILTER

HYDRAULIC TANK AND FILTER


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

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

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

10-14
(15)

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

PC128US-2

STRUCTURE AND FUNCTION

HYDRAULIC TANK AND FILTER

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)

STRUCTURE AND FUNCTION

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)

PLS : Control valve LS pressure inlet


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

PC128US-2

STRUCTURE AND FUNCTION

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)

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

When the swash plate angle of the center line


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

lo-18

PUMP

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

: Pump discharge pressure inlet


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

PC Valve

9JUOOO85

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

Piston
Spring
Seat
t
Spring
Seat
Spool
Piston
Sleeve
Lock nut
Plug
Lock nut

1O-20

PA
PA2
PD
PN
PPL

:
:
:
:
:

Pump discharge pressure inlet


Pump discharge pressure inlet
Drain pressure outlet
PC mode switching pressure inlet
PC valvesignal pressure outlet

PC1 28US-2

STdUCTURE

AND FUNCTION

HYDRAULIC

PUMP

FIXED THROTTLE VALVE

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

STRUCTURE AND WNCTlON

PUMP

Operation

To ma in
va

Direction
to
small
diameter

1.

I ve

SVPO7604

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

PC1 28US-2

1 O-23

STRUCTURE

1 O-24

AND FUNCTION

Before the engine starts, the servo piston


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

HYDRAULIC

A-A

PUMP

9JUOOOB9

PC1 28US-2

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

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

2) Operation in direction for maximum


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

10-26
(15)

(12) comes to the drain pressure PT, and


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

PC128US-2

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

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

3) Operation in direction for minimum


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

10-27-1
(15)

Though the pump discharge pressure PP


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

PC128US-2

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

PC128US-2 Serial No.: 5001 7730

4) When the servo piston balances


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

PC128US-2

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

10-27-2
0

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

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

4) When the servo piston balances


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

10-27-3
(18)

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

STRUCTURE

AND FUNCTION

HYDRAULIC

Pilot

PUMP

Pressure
To main

LS valve
:
:

.-f

Emergency
PC-EPC

Direction
to
small
diameter
oumD

valve

:
Fixed
throttle

Direction
to
large
diameter
Pump
controller

,I

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

sure PP. And the pressure output from


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

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).

Also, since the pressing force of the


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

lo-29

STRUCTURE

1O-30

AND FUNCTION

HYDRAULIC

PUMP

The C port of the PC valve is connected


to the E port of the LS valve. The self
pressure PP is provided to the A port,
the small diameter side of the servo
piston (9) and the B port.
When the pump discharge pressure
PP is small, the spool is located at a
position in the left direction.
At the
time, the C port is connected to the D
port, and the pressure to the LS valve
becomes the drain pressure PT. If the
E port of the LS valve is connected to
the G port at the time, the pressure
from the J port to the large diameter
side of the piston will become the
drain pressure PT. And the servo piston will moves to the right side. Then,
the pump delivery will come to increase.
Also, as the servo piston (9) operates,
the slider (8) moves the piston (7) to
the right side, and the spring force
becomes weak because the springs (4)
and (6) ei<pand. As the spring force
becomes weak, the spool (3) moves
to the right side to disconnect the C
port from the D port. Then, the pump
discharge pressure ports B and C are
connected.
As a result, the pressure at the C port
rises and the pressure on the large
diameter side of the piston rises as
well, and the servo piston (9) stops
moving to the right side. This means
that the stop position of the servo piston (9) (= pump delivery)
is determined where the pressing
force
caused the pressure PP to the spool
(3), the pressing force of the PC-EPC
valve solenoid and the forces of the
springs (4) and (6) balance with each
other.

PC1 28US-2

STRUCTURE

HYDRAULIC

AND FUNCTION

Pi lot

PUMP

Pressure
0 main
valve
-

outa6 andC rad

connected

Direction
to
small
diameter
PC-EPC

valve

SVPO7610

2)

When the pump controller is normal, the


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

PC1 28US-2

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

When the servo piston (9) moves to the


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

PUMP

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

Also, when the command current X to the


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

Pump discharoe

pressure

PP

SLIP02559

Pump discharoe

orassure

PP

SDP02560

D
Z
2
5
:
L

PC1 28U.S2

STRUCTURE AND FUNCTION

3) When the pump controller is out of order


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

PC128US-2

HYDRAULIC PUMP

than the spring set force. So, the spool


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

10-33
(18)

STRUCTURE

AND FUNCTION

HYDRAULIC

Pi lot

PUMP

Pressure
To main
va I ve

31C
--*I*

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

Direction
to
small
diameter
Emergency
PUTID
drive
switch

SVPO76 12

b.
l

1o-34

In case of heavy load to main pump


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

PC1 28US-2

STRUCTURE

HYDRAULIC

AND FUNCTION

This means that the current, which is


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

0
x
.-:
Q1
-0
z
z

Pump

PC1 28US-2

PUMP

discharge

Pressure

PP

SJpO7fj13

1o-35

STRUCTURE AND FUNCTION

CONTROL VALVE

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

10-36
(15)

1. Swing bleed valve


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

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

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

PC128US-2

10-37
(15)

STRUCTURE AND FUNCTION

CONTROL VALVE

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

10-37-1
(15)

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

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

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

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

10-38
(15)

8 Safety-suction valve mount (service B)


9. Suction valve (Bucket bottom)
10. Suction valve (Arm bottom)
11. Suction valve (Boom head)
12. Suction valve (R.H. travel B)
13. Suction valve (L.H. travel B)
14. Lift check valve

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(2/8)

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

Main relief valve


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

PC128US-2

10-39

STRUCTURE AND FUNCTION

CONTROL VALVE

(3/8)

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

Pressure compensation valve F (swing)


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

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

Pressure compensation valve R (service)


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

fl The above F and R means the following valves :


F : Flow control valve
R : Pressure reducing valve

10-40
(15)

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(4/8)

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

LS pressure detection plug


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

PC128US-2

10-41

STRUCTURE AND FUNCTION

CONTROL VALVE

(5/8)

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

Main relief valve


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

10-42
(15)

7. Swing bleed valve


8. Pressure compensation valve F
F : Flow control valve
R : Pressure reducing valve

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(6/8)

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

Suction valve (A)


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

PC128US-2

8.
9.
10.
11.

Suction valve (B)


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

F : Flow control valve


R : Pressure reducing valve

10-43
(15)

STRUCTURE AND FUNCTION

CONTROL VALVE

(7/8)

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

Suction valve (A)


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

10-44
(15)

9.
10.
11.
12.

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

F : Flow control valve


R : Pressure reducing valve

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(8/8)

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

Suction valve (A)


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

PC128US-2

9.
10.
11.
12.
13.

Variable pressure compensation valve


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

F : Flow control valve


R : Pressure reducing valve

10-45
(15)

STRUCTURE AND FUNCTION

CONTROL VALVE

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

PC128US-2

10-45-2
5

STRUCTURE AND FUNCTION

CONTROL VALVE

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

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

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

10-45-3
5

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

Safety-suction valve (Service 2-B)


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

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(2/9)

1.
2.
3.
4.
5.

Main relief valve


Spool (Swing)
Spool (L.H. travel)
Spool (R.H. travel)
Spool (Boom)

PC128US-2

6.
7.
8.
9.
10.

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

10-45-4
(15)

STRUCTURE AND FUNCTION

CONTROL VALVE

(3/9)

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

Pressure compensation valve F (Swing)


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

10-45-5
(15)

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

Pressure compensation valve (Service 1)


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

F : Flow control valve


R : Pressure control valve

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(4/9)

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

LS pressure pickup plug


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

PC128US-2

10-45-6
5

STRUCTURE AND FUNCTION

CONTROL VALVE

(5/9)

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

Main relief valve


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

10-45-7
(15)

F : Flow control valve


R : Pressure reducing valve

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(6/9)

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

Suction valve (A)


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

PC128US-2

8.
9.
10.
11.

Suction valve (B)


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

F : Flow control valve


R : Pressure reducing valve

10-45-8
(15)

STRUCTURE AND FUNCTION

CONTROL VALVE

(7/9)

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

Suction valve (A)


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

10-45-9
(15)

9.
10.
11.
12.

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

F : Flow control valve


R : Pressure reducing valve

PC128US-2

STRUCTURE AND FUNCTION

CONTROL VALVE

(8/9)

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

Suction valve (A)


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

PC128US-2

9.
10.
11.
12.

Pressure compensation valve R


Pressure compensation valve F
Pressure relief plug
Unload valve

F : Flow control valve


R : Pressure reducing valve

10-45-10
(15)

STRUCTURE AND FUNCTION

CONTROL VALVE

(9/9)

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

Safety-suction valve (A)


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

F : Flow control valve


R : Pressure reducing valve

10-45-11
(15)

PC128US-2

STRUCTURE

SUCTION

AND FUNCTION

SAFETY VALVE

SUCTION SAFETY VALVE


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

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

Specification
Part No. (Reference)

Set pressure

709-70-74600

24.5 MPa (250 kg/cm21


(at the time of Wmin.)

709-70-74700

17.2 MPa (175 kg/cm21


(at the time of 5f?/min.)

lo-46

Use
For crusher

PC1 28U.S-2

STRUCTURE AND FUNCTION

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

Pressure compensation control


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

Load

I\

I lcomensationl

Actuator

II

I\

Actua

I cobwensa~

SEP02564

PC1 28US-2

1o-49

STRUCTURE

CLSS

AND FUNCTION

EACH FUNCTION

AND OPERATION OF EACH VALVE

Hydraulic circuit diagram and valve names


Pump
detect
Pressure
detect
port

Pressure
ion
port

LS

pressure

ion
PP

x
Al

E^-..:^^

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

PLS : LS circuit (pressure)


PP : Pump circuit (pressure)
T
: Tank circuit

1 O-52

PC1 28US-2

STRUCTURE

CLSS

AND FUNCTION

2. When the control valve is in the fine control mode


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

SOP03736

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

1.
2.
3.
4.

Unload valve
Sleeve
Spring
Spool

PLS : LS circuit (pressure)


PP : Pump circuit (pressure)
T
: Tank circuit

PC1 28US-2

1o-53

STRUCTURE

CLSS

AND FUNCTION

3. When the control valve is operated


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

SDP03737

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

1.
2.
3.
4.

Unload valve
Sleeve
Spring
Spool

PLS : LS circuit (pressure)


PP : Pump circuit (pressure)
T
:Tankcircuit

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

the LS circuit PLS. Also, the orifice C is


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

valve (boom, arm, bucket, swing)

SOP03738

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

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

PLS : LS circuit (pressure)


T
: Tank circuit (pressure)

1o-57

STRUCTURE

AND FUNCTION

PRESSURE COMPENSATION

CLSS

VALVE

Function
When the load pressure becomes lower than another actuator and the flow is going to increase
during a compound
operation, this valve compensates
the load pressure. (At the time, the load pressure of another actuator under compound oper$ion
(the upper side) is higher than that of the actuator on this side (the lower side).
l

Aa
\

(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

AREA RATIO OF PRESSURE COMPENSATION

CLSS

VALVE

Function
The pressure compensation
valve slightly adjust the ratio (S2/Sl) of the area Sl on the left side of the
flow control valve (2) and the area S2 on the right side of the pressure reducing valve (1) to suite the
characteristics
of each actuator and determines-the-compensation
characteristics.
Sl : Area of the flow control valve (2) - area of the piston (3)
S2 : Area of the pressure reducing valve (1) - area of the piston (3)
l

9JUOOl26

Area ratio (Sl:S2) and compensation characteristics


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

1 O-60

PC1 28US-2

STRUCTURE

AND FUNCTION

CLSS

BOOM HYDRAULIC DRIFT PREVENTION VALVE


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

At boom raise

9JUOOl27

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

PC128US-2

lo-61

STRUCTURE

2.

CLSS

AND FUNCTION

Boom lever at neutral

9JUOO128

Operation
0. When the control lever is returned to 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

1. At boom lower and own weight fall


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

9JUOOl30

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

1O-64

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

PC1 28US-2

STRUCTURE

CLSS

AND FUNCTION

2. At boom lower load process


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

9JUOOlJI

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

PC128US-2

At the time, the head side pressure B and the


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

lo-65

STRUCTURE

CLSS

AND FUNCTION

ARM REGENERATION

CIRCUIT

1. At arm in and own weight fall


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

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

A : Head circuit (pressure)


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

1O-66

PC1 28US-2

STRUCTURE

CLSS

AND FUNCTION

2. At arm in process
Function
When the bottom pressure B of the cylinder
(1) rises above the head pressure A and the
arm enters the digging
process, the check
valve (3) will be closed and the circuits on the
head side and the bottom side will be interrupted.
l

9JUOO133

Operation
When the arm is in the digging process, the
bottom side pressure B of the arm cylinder
(1) will rise, close the check valve (3) and interrupt the circuits on the head side and the
bottom side.
l

PC1 28US-2

1.
2.
3.

Arm cylinder
Arm spool
Check valve

A : Head circuit (pressure)


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

1O-67

STRUCTURE

TRAVEL JUNCTION

VALVE

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


1.

CLSS

AND FUNCTION

When traveling

circuit)

straight

SJPO7615

1O-68

PC1 28US-2

STRUCTURE

AND FUNCTION

CLSS

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

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

TRAVEL LS BYPASS CIRCUIT


1.

At normal operation

1 O-72

PC1 28US-2

STRUCTURE AND FUNCTION

CLSS

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

PC128US-2

10-73
(18)

STRUCTURE

AND FUNCTION

2. -At operation

CLSS

of travel + other actuator

9JYOOO2

STRUCTURE

AND FUNCTION

CLSS

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

PC1 28US-2

1o-75

STRUCTURE

SELF PRESSURE REDUCING

AND FUNCTION

VALVE

SELF PRESSURE REDUCING VALVE

PR

I:

I:

Pl

kla

I--

A-4

9JUOOO62

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

1O-84

PC1 28US-2

STRUCTURE

SELF PRESSURE REDUCING VALVE

AND FUNCTION

A-A

9JUOOO63

1. Control valve block


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

PC128US-2

7.
8.
9.
10.
11.

Spring (pressure reducing valve main)


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

1 O-85

STRUCTURE

SELF PRESSURE REDUCING

AND FUNCTION

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

VALVE

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

66MPa

I-

I
I
8
I

PI Port

I
I
I

P, Port

T Port

Hydraulic

circuit
SVP07622

1. At engine stop (total low pressure)


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

lo-86

PC 128W2

STRUCTURE

AND FUNCTION

SELF PRESSURE REDUCING VALVE

SVP07623

PC1 28US-2

lo-87

STRUCTURE

SELF PRESSURE REDUCING VALVE

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.

SELF PRESSURE REDUCING

AND FUNCTION

VALVE

At raise of load pressure P2

-Q

Servo

SVPO7626

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

fC128US-2

When the PR pressure rises above the set


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

lo-89

STRUCTURE

4.

SELF PRESSURE REDUCING

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

STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT


STD (WITHOUT BLADE)

1.
2.
3.
4.
5.

Cover
Body
Slipper seal
O-ring
Shaft

PC128US-2

A1 : From control valve (R.H. travel Forward)


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

10-91
A

STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT

OPT (WITH BLADE)

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

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

10-92
A

D2 : To L.H. travel motor B


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

PC128US-2

STRUCTURE

TRAVEL MOTOR

AND FUNCTION

34
B-B
9JA01339

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

Plug
Check valve spring
Check valve
Return spring
Counterbalance valve
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

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Specification
Type
PC128US-2

Serial No.
Spec.

PC138US-2
PC138USLC-2

GM18VL-J

GM20VL-J

GM20VL-P

GM20VL2-P

5001 and up

5001 6072

6073 and up

STD

OPT(traction up)

Serial No.

4501 and up

Spec.

STD

Serial No.

1001 1500

1501 and up

Spec.

STD

STD

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

Hi

33.2 {33.2}

Lo

52.7 {52.7}

Hi

3,267.7

3,191

3,035

3,444

Lo

2,147.3

2,028

1,929

2,025

34.0 {34.0}

Brake releasing pressure


(MPa{kg/cm2})

0.68
{6.94}

Hi-Lo switching pressure


(MPa{kg/cm2})

2.94
{30}

Final drive reduction ratio

31.5 {31.5}

55.8 {55.8}

72

75.7

OUTLINE
Travel speed selection

Swash plate (14) has 2 faces (x, y) behind it,


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

PC128US-2

10-95
(18)

STRUCTURE AND FUNCTION

TRAVEL MOTOR

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

Since the travel 2nd speed selector solenoid


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

10-96
2

PC128US-2

STRUCTURE AND FUNCTION

TRAVEL MOTOR

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

When the travel 2nd speed selector solenoid


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

PC128US-2

10-97
2

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Operation of brake valve


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

Counterbalance valve, check valve


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

10-98
(18)

PC128US-2

STRUCTURE

AND FUNCTION

TRAVEL MOTOR

The pressurized oil on the supply side flows


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

SJP07629

Brake cperaticn at travehg


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

PC1 28US-2

El-

sr

SJPO7630

1o-99

STRUCTURE

TRAVEL MOTOR

AND FUNCTION

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

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

SJPO7631

32

SJP07632

10-100

PC128US-2

STRUCTURE

TRAVEL MOTOR

AND FUNCTION

Operation of parking brake


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

SJPO7633

When positioning travel neutral


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

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

: From-iswing brake solenoid valve


: From control valve
: To tank
: From control valve
: From control valve

10-102

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

PC1 28U.52

STRUCTURE

SWING MOTOR

AND FUNCTION

16

c-c

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

PC1 28US-2

valve

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

17

ii is
9JUOO102

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

10-103

SWING MOTOR

STRUCTURE AND FUNCTION

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

2. When solenoid valve is energized


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

SJPO7636

10-104

PC1 28US-2

SWING MOTOR

STRUCTURE AND FUNCTION

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

1. When MB port pressure is generated


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

SOP02036

2. When the motor is once stopped


Operation
The motor is reverse rotated by charging pressure generated on the MB port (1st reverse
rotation).
At this time, reversing pressure is generated
on the MA port. MA pressure conducted to a
room interconnects MA + b by compressing
the spring (3) and driving the spool (2) rightward.
- The pressure is then conducted
through
drilled hole on the spool (5) to interconnect
b
+ f. Reversing pressure on the MA port is
bypassed to the T port to disable the 2nd reverse rotation.

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.

PPC lock solenoid valve


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

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

Al
A2
A3
A4
ACC
Pl
T

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

Check valve
11. Plug
12. Spring
13. Plunger

lo-108

PC1 28US-2

STRUCTURE

SOLENOID

AND FUNCTION

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

VALVE

#ztiva
t

SJPO7636

When solenoid is magnetized


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

Exe it

I)

SJPO7639

PC1 28US-2

10-109

PPC ACCUMULATOR

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

ACCUMULATOR FOR BREAKER (IF EQUIPPED)

ACCUMULATOR FOR BREAKER


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

Cap
Core
Guard rubber
Lid
Plug
Shell

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

FOR HIGH PRESSURE


1.
2.
3.
4.

Cap
Gas plug
Plug
Shell

Specification
Type of gas : Nitrogen gas
Gas valume : 0.5
Sealed gas pressure :
5.88 MPa {60 kg/cm2}(at 80 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.
.

In the fine control mode


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

10-l 14

(Fio

1)
SEP02569

SEP02570

PC 128US-2

STRUCTURE

3.
.

AND FUNCTION

PPC VALVE

In the fine control modetoperating


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

3)
SEP0257

4.
.

In the full stroke mode


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

(Fio

41
SEP02572

FC128US-2

10-115

PPC VALVE

STRUCTURE AND FUNCTION

FOR TRAVEL

P : From main pump


T : To tank
P1 : L.H reverse
P2 : L.H forward

10-116
(15)

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

PC128US-2

STRUCTURE AND FUNCTION

PPC VALVE

PC128US-2 Serial No. 5001 6300

1.
2.
3.
4.

Plate
Body
Piston
Collar

PC128US-2

5. Metering spring
6. Centering spring
7. Valve

10-117
(15)

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

PPC VALVE

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

2. In the fine control mode


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

10-118

PC128US-2

STRUCTURE AND FUNCTION

PPC VALVE

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

4. In the full stroke mode


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

PC128US-2

10-119
(15)

STRUCTURE AND FUNCTION

PPC VALVE

FOR BLADE, SERVICE

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

Spool
Metering spring
Centering spring
Piston
Lever
Plate
Retainer
Body
Filter

10-120
(15)

P :
T :
P1 :
P2 :

From self pressure reducing valve


To tank
To blade or service valve
To blade or service valve

PC128US-2

STRUCTURE

AND FUNCTION

PPC VALVE

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

(1).

2.
l

In the fine control mode


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

PC1 28US-2

SJP07646

SJP07647

10-121

STRUCTURE

3.
.

AND FUNCTION

PPC VALVE

In the fine control mode (when the operation


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

4.
l

In the full stroke mode


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

SJPO7649

10-122

PC1 28US-2

STRUCTURE AND FUNCTION

BOOM HYDRAULI DRIFT PREVENTION T VALVE

BOOM HYDRAULIC DRIFT PREVENTION VALVE


(FOR KUK SPEC.)
PC128US-2 Serial No.: 5001 7730

1.
2.
3.
4.
5.

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

PC128US-2

CY : To boom cylinder bottom


PI : From PPC valve (pilot pressure)
T : To hydraulic tank
V : From control valve

10-122-1
C

STRUCTURE AND FUNCTION

BOOM HYDRAULIC DRIFT PREVENTION VALVE

PC128US-2 Serial No.: 7731 and up


PC138US-2 Serial No.: 4501 and up

1.
2.
3.
4.
5.

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

10-122-2
(15)

CY : To boom cylinder bottom


PI : From PPC valve (pilot pressure)
T : To hydraulic tank
V : From control valve

PC128US-2

STRUCTURE AND FUNCTION

ARM HYDRAULIC DRIFT PREVENTION VALVE

ARM HYDRAULIC DRIFT PREVENTION VALVE


(FOR KUK SPEC.) (If equipped)
PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up

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

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

10-122-6
(15)

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

PC128US-2

STRUCTURE AND FUNCTION

ARM HYDRAULIC DRIFT PREVENTION VALVE

Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the
oil from flowing back from the work equipment
cylinder to prevent sudden fall of the work 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

STRUCTURE AND FUNCTION

ARM HYDRAULIC DRIFT PREVENTION VALVE

2. When oil is sent from main valve to cylinder


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

10-122-8
(18)

PC128US-2

STRUCTURE AND FUNCTION

ARM HYDRAULIC DRIFT PREVENTION VALVE

3. When oil is returned from work equipment


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

[When piping bursts]


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

PC128US-2

10-122-9
C

AIR CONDITIONER PIPING

STRUCTURE AND FUNCTION

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

A : Hot air/cold air spurting with outlet port


B : Internal air circulation port
C : External air inlet
1.
2.
3.
4.

Hot water drain piping


Air conditioner compressor
Hot water return piping
Refrigerant piping

10-123-1
(18)

5.
6.
7.
8.

Receiver tank
Condenser
Air conditioner unit
Duct

PC128US-2

STRUCTURE AND FUNCTION

AIR CONDITIONER PIPING

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

A:
B:
C:
D:

Hot air/cold air spurting with outlet port


Internal air circulation port
External air inlet
Refrigerant checking port

1.
2.
3.
4.

Hot water drain piping


Air conditioner compressor
Hot water return piping
Refrigerant piping

PC128US-2

5.
6.
7.
8.

Receiver tank
Condenser
Air conditioner unit
Duct

10-123-2
(18)

STRUCTURE AND FUNCTION

ELECTRIC COMPONENT LAYOUT

1. Additional light (Standard for KUK and North


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

PC128US-2

10-125
(15)

STRUCTURE AND FUNCTION

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

ELECTRIC COMPONENT LAYOUT

Temperature control switch


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

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

PC128US-2

10-127
(15)

STRUCTURE AND FUNCTION

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)

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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)

STRUCTURE AND FUNCTION

ENGINE CONTROL

START OF ENGINE

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

CONTROL OF ENGINE SPEED

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

STOP OF ENGINE

When the starting switch (4) comes to the OFF


position, the engine stop solenoid (18) drive
the governor stop lever to the "STOP" side and
the engine stops.

FUNCTION OF PREVENTING ENGINE


STOP SOLENOID FROM BURNING

Engine stop solenoid relay (13) is installed to


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

10-132-4
(15)

A:
B:
C:
t:

Operation of starting switch


Suction coil current
Holding coil current
3 seconds
PC128US-2

STRUCTURE AND FUNCTION

ENGINE CONTROL

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

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

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

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

PC128US-2

14. Travel PPC oil pressure switch


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

e.
f.
g.
h.

PPC oil pressure switch signal


Throttle signal
Fuel control motor drive signal
Potentiometer signal

10-132-5
(15)

STRUCTURE AND FUNCTION

ENGINE CONTROL

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

10-132-6
(15)

All work equipment levers at "NEUTRAL"


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

PC128US-2

ENGINE CONTROL

STRUCTURE AND FUNCTION

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

PC128US-2

All work equipment levers at "NEUTRAL"


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

10-132-7
(15)

STRUCTURE AND FUNCTION

ENGINE CONTROL

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

1 : PC128US-2 Serial No. 6301 and up

1.
2.
3.
4.

One-touch deceleration pilot lamp


Fuel adjust dial
Boss
Boss

PC128US-2

5.
6.
7.
8.

Shaft
Joint
Bracket
Fuel adjust motor

10-133
(14)

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

10-136-2
(15)

PC128US-2

STRUCTURE AND FUNCTION

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.

ELECTRIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

10-136-4
(15)

PC128US-2

STRUCTURE AND FUNCTION

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.

ELECTRIC CONTROL SYSTEM

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)

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

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.

PC-FPC valve drive signal


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

10-138-1
(15)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

The controller detects the engine governor


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

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

10-138-2
(18)

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

CONTROL METHOD IN EACH MODE


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

PC128US-2

Mode A

66.2 kW/2,200 rpm


{88.7 HP/2,200 rpm}

10-138-3
(15)

STRUCTURE AND FUNCTION

Mode E and Mode B


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

10-138-4
(15)

ELECTRIC CONTROL SYSTEM

Model

PC128US-2
PC138USLC-2

E mode

54.4 kW/2,000 rpm


{72.9 HP/2,000 rpm}

B mode

47.8 kW/1,800 rpm


{64.1 HP/1,800 rpm}

PC128US-2

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

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.

Travel PPC valve


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

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

10-139-1
(15)

Condition
During travel

Relief pressure
31.9 MPa {325 kg/cm2}

34.8 MPa {355 kg/cm2}

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

ON

OFF

PC128US-2

Swing
lock
lamp

Function

Operation

Gose out

When the swing control lever is returned


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

Lights up

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

Swing
lock

10-141
(18)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

Swing holding brake release


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

Swing brake

Swing
lock
operates

Swing
lock
released

OFF
(When controlleris
safe)
ON

OFF

Swing
lock
operates

Swing
holding
breake
operates

Input/Output Signal time chart

10-142
(18)

PC128US-2

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

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.

Solenoid valve drive signal


Swing PPC oil pressure switch signal
Arm IN PPC oil pressure switch signal
Alarm operation signal

10-142-1
(15)

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

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.

R.H. travel motor


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

e.
f.
g.
h.

Solenoid valve drive signal


Engine speed signal
Pump pressure signal
Alarm operation signal

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

Travel speed
selector switch
Motor capacity
(cc/rev)

52.7

33.2

Travel speed
(km/h)

3.2

5.1

Maximum

Minimum

Travel motor swash plate


angle

PC128US-2

Travel speed
selector switch
Travel accelerator pedal
Step on
Release

Blade Specification (Option)


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

LOW
HIGH
(low speed) (high speed)

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

Travel motor swash


plate angle

Travel motor swash


plate angle

10-143-2
(15)

STRUCTURE AND FUNCTION

Standard Specification and Blade Specification (option)


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

ELECTRIC CONTROL SYSTEM

Travel speed
selector switch
Motor capacity
(cc/rev)

55.8

31.5

Travel speed
(km/h)

2.9

5.1

Maximum

Minimum

Travel motor swash plate


angle

10-143-3
(15)

LOW
HIGH
(low speed) (high speed)

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

2. "Automatic"change of travel speed


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

PC128US-2

10-143-4
(15)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

2. "Automatic"change of travel speed


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

10-143-5
(15)

PC128US-2

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

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.

Left work equipment PPC valve


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

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

PC128US-2

10-144-1
(15)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

OVERLOAD ALARM FUNCTION


(For KUK spec.)
PC128US-2 Serial No.: 5001 7730

PC128US-2 Serial No.: 7731 and up


PC138US-2 Serial No.: 4501 and up

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

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

ENGINE CONTROL FUNCTION


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

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

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

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

PC128US-2

12.
13.
14.
15.
16.

Fuel control motor relay (for deceleration)


PC-EPC valve
Governor lever
Coolant temperature sensor
Hydraulic pump
16a. Servo valve
16b. LS valve
16c. PC valve
17. Operation valve
17a. Self-pressure reduction valve
17b. Main relief valve

g.
h.
i.
j.
k.

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

10-144-3
(15)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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.

Engine speed signal


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

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1. Automatic engine warming-up function


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

Coolant temperature: Less than 30C


Engine speed: 1,200 rpm or less

Operation
Engine speed: 1,200 rpm or less

Release conditions (either one required)

Release

Coolant temperature: 30C or higher

Automatic

Duration of automatic warming-up: 10 minutes or more

Manual

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

Engine speed: Any

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

Coolant temperature: Less than 30C


Engine speed: 1,300 rpm or less

Operation
Engine speed: 1,300 rpm or less

Release conditions (either one required)

Release

Coolant temperature: 30C or higher

Automatic

Duration of automatic warming-up: 10 minutes or more

Manual

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

Engine speed: Any

2. Overheat prevention function


Prevents overheat to protect engine by reducing load on pump if coolant temperature rised too much.
Operational conditions

Coolant temperature:
105C or higher

Operational conditions

Coolant temperature:
102C or higher

Operational conditions

Coolant temperature:
100C or higher

PC128US-2

Operation and actions taken


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

Release conditions
Coolant temperature: Less than 105C
Fuel control dial: To be returned to the

low idling position


The original conditions are restored
if two requirements above were obtained (manual restoration).

Operation and actions taken


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

Operation and actions taken


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

Release conditions

Coolant temperature: Less than 102C


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

Release conditions
Coolant temperature: Less than 100C

The original conditions are restored


if the requirement above was obtained (automatic restoration).

10-144-5
(15)

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

3. Turbocharger protection function


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

Operation

Protection of turbocharger
(See above figure)

4. Function of preventing production of white


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

10-144-6
(15)

Operation

Air heater: Preheating time is


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

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

SELF DIAGNOSIS FUNCTION


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

PC128US-2

10-144-7
(18)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

PPC HYDRAULIC SWITCH

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

1. Plug
2. Switch
3. Connector

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

10-146
(18)

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

OVERLOAD ALARM PRESSURE SWITCH


(For KUK spec.)
PC128US-2 Serial No.: 5001 7730

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

PC128US-2

10-146-1
A

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

PC128US-2 Serial No.: 7731 and up


PC138US-2 Serial No.: 4501 and up

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

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

Model selection table


PC128US-2

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

c
c

Attachment selection table


Standard arm
Long arm
Standard arm,
X-counterweight
long arm,
X-counterweight
Slide arm
Multi changer arm

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


c

c : GND
: OPEN

10-147-3
(15)

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

10-147-5
(15)

PC128US-2

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

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

I/O signal
Input
Input
Input

Input
Input
Input
Input

Input
Input
Input

Pin No.
14
15
16
17
18

Signal name
I/O signal
Off-set angle (For PC128UU)
Input
NC

NC

C-terminal signal
Input
PPC hydraulic pressure switch for boom
Input
LOWER

19
20
21
22
23
24

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

I/O signal

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

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

Pin No.

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

Input

Output
Input
Input

DEUTSCH-40P (1) [CN-CR2]


Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

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

Input
Input
Input

Input
Output
Output

Input
Output

Input
Input
Output
Output

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

Input
Input
Input
Input

Input/Output
Input/Output

Input

Input

Input

DEUTSCH-40P (2) [CN-CR3]


Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

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

PC128US-2

I/O signal
Input
Input

Output
Output
Output
Output
Output
Input
Input
Input
Input

Input
Output
Output
Output
Output
Input
Input

22
23
24
25
26
27
28
29

30
31
32
33
34
35
36
37
38
39
40

I/O signal
Input

Input
Output
Output
Output
Solenoid valve for travel speed selection
Output
2-stage relief solenoid valve
Input
Right offset PPC oil pressure switch
Input
Swing PPC oil pressure switch (Right and left)

GND (controller)

GND (controller)

GND (controller)

NC
Output
Fuel control motor relay (for deceleration)
Output
Boom-LOWER EPC valve
Output
Arm crane relay
Output
PPC lock solenoid valve

NC
Travel PPC oil pressure switch
Input
(Right, left, front, and rear)

10-147-6
(15)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

PUMP PRESSURE SENSOR


PC128US-2 Serial No.: 6301 7730

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

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

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

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

fl Refer to the section describing the Hydraulic Pump (Piston pump).


PPC lock solenoid valve
2nd speed select solenoid valve
Swing hold brake solenoid valve
2-stage relief solenoid valve
fl Refer to the section describing the Solenoid
Valve.

10-148
(15)

PC128US-2

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

MONITOR PANEL
PC128US-2 Serial No.: 5001 7730

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

It has LCD display in gauge display position.


It has lamps in monitor display position.

Input and output signals


AMP040-16P [CN-P01]
Pin No.
Signal name
1
Power source (24V)
2
Power source (24V)
3
GND
4
GND
5
Starting signal
6
Coolant temperature
7
Fuel level
8

KES-4P(1) [CX-P02]
Pin No.
Signal name
1

2
Work light
3
Lighting
4
Power source (24V)

10-150
(18)

I/O signal

Input
Input
Input

Pin No.
9
10
11
12
13
14
15
16

Signal name
Engine oil pressure
Battery charging level
Spare caution
Swing lock
Preheating

Alarm buzzer
Lighting

I/O signal
Input
Input

Input
Input

Output
Input

I/O signal

Output
Output

KES-3P [CN-C12]
Pin No.
Signal name
1

2
Car heater Hi
3
Car heater Lo
4
Car heater Hi

I/O signal

Output
Output

PC128US-2

STRUCTURE AND FUNCTION

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

flat type sheet switches. Pressing any of


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

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

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

Input
Input
Input
Input
Input

PC128US-2

STRUCTURE AND FUNCTION

MONITOR SYSTEM

METER DISPLAY

Display
No. category
1

[*1]
2

Display

Caution

4a

Gauge
Caution

Pilot

[*2]
7

Coolant
temperature

Display Remarks
color

Time counting while engine is in operation


(alternator is generating) (Always lit even if
starting switch is OFF)

Count time during engine operates.


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

3b

See picture above All the segments of the corresponding level


and lower are turned ON.
Specified tempera- (Level 8 (102C or higher):Monitor lamp
blinks. Level 9: Monitor lamp blinks and
ture (102C) or
alarm buzzer sounds.)
higher

Blue

LCD

Red

LED

Blue

LCD

Red

LED

Fuel level

See picture above All the segments of the corresponding level


and lower are turned on. (Level 1 (42 or
Specified level
less): Monitor lamp blinks.)
(42 ) or lower

Preheating

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

Swing lock

When swing-lock
is in operation

Turned on when the swing lock function is


active.
Blinks when swing holding brake release Green
switch was turn on.

Oil
maintenance

When specified
oil-maintenance
periods elapsed

Turned ON when specified oil maintenance


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

Lamp

Battery charge Charge in fault


(charge voltage <
level
battery voltage)

Display method

0 99999.9 h

Gauge

Display area

Service meter

3a

4b

Display item

Caution

[*3]
10

Engine oil
pressure

Overload

Turned ON when starting switch was turned


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

Red

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

PC128US-2

10-151-2
(15)

MONITOR SYSTEM

STRUCTURE AND FUNCTION

MONITOR SWITCH

No.

Function

Operation

Travel speed selector


switch

Used to select a travel speed from two of them.


"Lo" is lit : Travel in low speed.
"Hi" is lit : Travel in high speed.
<The speed is locked at Lo when arm crane is
used.>

Lo Hi

Auto-deceleration switch

Activates the function to reduce fuel consumption.


Turned ON : The function is active.
Turned OFF : The function is not active.
<The function is made inactive when arm crane
is used.>

ON OFF
(Lit)

Wiper switch

Activates wiper of front glass.


"ON" is lit : Wiper works continuously.
"INT" is lit: Wiper works intermittently.
Not lit
: Wiper is not working.

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

Sprays washer fluid onto front glass.

[When wiper is not working]


ON : Washer fluid is sprayed
and wiper works continuously.
OFF : Wiper works twice and
stops after the switch was
released.
[When wiper is working intermittently]
ON : Washer fluid is sprayed
and wiper works continuously.
OFF : Wiper works twice and returns to intermittent operation after the switch
was released.

Name

Wind washer switch

* Operation mode selector


5

switch

Sets the movement and force of the working


equipment.
"A" is lit : A mode (for heavy duty work)
"E" is lit : E mode (for fuel economical operation)
"B" is lit : B mode (for breaker work)
<All "A, E, and B" are off when arm crane is used.>

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

STRUCTURE AND FUNCTION

MONITOR

SYSTEM

SENSORS
l

Signal from a sensor is directly entered to the


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

Sensor type

Sensing__approach

When normal

When failed

Caution

Engine oil pressure

Contact

OFF (open)

ON (closed)

Resistance

Resistance

Coolant

temperature

Gauge
Fuel level

ENGINE OIL PRESSURE SENSOR

69 @
Structure

of

circuit

SBD01537

1.
2.

Plug
Contact

ring

3.
4.

5.
6.

Contact
Diaphragm

Spring
Terminal

COOLANT TEMPERATURE SENSOR

@=I3
Structure

7.
2.
3.

of

circuit

SBDOl538

Connector
Plug
Thermistor

10-152

PC1 28US-2

STRUCTURE

AND FUNCTION

FUEL LEVEL SENSOR

F
Structure

fL

EMPTY

E
Y

of

circuit

1.
2.
3.
4.

SEP02590

Float
Connector
Cover
Variable resistor

PC128US-2

10-153

20

TESTING AND ADJUSTING

STANDADRD

VALUE TABLE

Standard

value table for engine

Standard

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

Standard

value table for electrical

TESTING

AND ADJUSTING

TROUBLESHOOTING

*
1.

2.

3.
A
A
A

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

parts .._.. 20-12

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

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

Note the following.when


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

PC1 28U.S2

20-l
0

STANDARD VALUE TABLE FOR ENGINE

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE


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

PC128US-2, 138USLC-2

Engine

S4D102E-1

Item

Engine speed

Measurement conditions

Unit

Standard value
for new machine

Service limit value

High idling

rpm

2,400 60

Low idling

rpm

925 + 050

Rated speed

rpm

2,200

Bosch
index

Max. 5.5

7.5

Max. 1.0

2.0

0.25

0.51

Max. 490 {50}

980 {100}

343 588 {3.5 6.0}

245 {2.5}

Min. 9.8 {1.0}

69 {0.7}

Min. 78 {0.8}

69 {0.7}

80 110

120

At sudden acceleration
Exhaust gas color
At high idling

Valve clearance
(normal temperature)

Blow-by pressure
(SAE 30 oil)

Oil pressure
(SAE 30 oil)

Intake valve
mm
Exhaust valve

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

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

KPa
{kg/cm2}

At low idling (SAE10W)

Oil temperature

Whole speed range


(inside oil pan)

Fuel injection timing

Before top dead center

deg

14 1

Fan belt tension


(alternator)

Deflection when pressed


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

mm

9.5 12.7

20-2
(17)

PC128US-2

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

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

PC138US-2, 138USLC-2

Engine

SAA4D95LE-3-A

Item

Engine speed

Measurement conditions

Unit

Standard value
for new machine

Service limit value

High idling

rpm

2,400 60

Low idling

rpm

1,100 50

Rated speed

rpm

2,200

Bosch
index

Max. 4.5

5.5

Max. 1.0

2.0

0.35

0.50

Max. 490 {50}

980 {100}

343 588 {3.5 6.0}

245 {2.5}

Min. 294 {3.0}

196 {2.0}

Min. 245 {2.5}

147 {1.5}

80 115

120

At sudden acceleration
Exhaust gas color
At high idling

Valve clearance
(normal temperature)

Blow-by pressure
(SAE 30 oil)

Oil pressure
(SAE 30 oil)

Intake valve
mm
Exhaust valve

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

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

KPa
{kg/cm2}

At low idling (SAE10W)

Oil temperature

Whole speed range


(inside oil pan)

Fuel injection timing

Before top dead center

deg

6 0.75

Fan belt tension


(alternator)

Deflection when pressed


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

mm

6 10

PC128US-2

20-2-1
(17)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Applicable model

Operating effort of
control lever

Category

PC128US-2

Measurement conditions

Item

Engine at full throttle


Oil temperature: 45 55 C
Fit push-pull scale to center of
control lever knob to measure
Fit push-pull scale to tip of control
Travel control lever
pedal to measure
Measure max. value to end of
travel

Unit

Serial No.
5001 7730

Blade control lever

7731 and up
N
{kg}

5001 7730
7731 and up
5001 7730

7731 and up

74.5 18.6
{7.6 1.9}

Max.107.6
{Max.11}

31.87 0.49
{325 5}

31.87 0.98
20
{325 + 10
}

31.87 0.49
{325 5}

31.87 0.98
20
{325 + 10
}

31.87 0.49
{325 5}

31.87 0.98
20
{325 + 10
}

5001 7730

31.38 0.98
{320 10}

31.38 2.45
15
{320 + 25
}

7731 and up

27.46 0.98
{280 10}

27.46 2.45
15
{280 + 25
}

Travel pedal

Boom
Arm

Hydraulic oil temperature: 45 55 C


Engine at full throttle
Pump discharge pressure
Relieve only circuit to be measured

Standard value Service limit


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

5001 and up

Bucket

Swing

+ 1.96

31.87 0
{325 + 20
0 }

Hydraulic pressure

Blade RAISE

20-4
(14)

+ 1.47

+ 1.96

31.87 0.98
20
{325 + 10
}

34.81 1.96
{355 20}

3.24 0.20
{33 2}

3.24 0.49
{33 5}

3.43 0.98
{35 10}

3.43 0.98
{35 10}

At pump relief
(normal actuation)

15.98 1.47
{163 15}

15.98 2.45
{163 25}

All levers at
HOLD

2.75 0.98
{28 10}

{}

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

2.21 0.1
{22.5 1}

{}

Control

LS differential
pressure

+ 1.47

34.81 0.98
{355 10}

Target
value
(Range)

Hydraulic oil
temperature
: 45 55 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

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Applicable model
Category

Item

PC128US-2

Measurement conditions

Unit

Serial No.

Standard value Service limit


for new
value
machine

fl See Fig. A

Overrun when
stopping swing

Engine at full throttle


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

Max. 60
(Max. 580)

Max. 70
(Max. 676)

5001 6462

2.8 0.3
(3.4 0.3)

Max. 3.5
(Max. 4.0)

6463 and up

3.2 0.3
(3.9 0.3)

Max. 4.0
(Max. 4.6)

5001 6462

3.3 0.4
(4.8 0.5)

Max. 5.2
(Max. 6.3)

6463 and up

3.8 0.4
(5.5 0.5)

Max. 5.9
(Max. 7.2)

5001 6462

25 2

25 4

6463 and up

28.6 2

28.6 4

0
(0)

0
(0)

Max. 3

Max. 6

fl See Fig. A

Time taken to start


swing

Engine at full throttle


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

Sec.

Swing

180

fl See Fig. A
Engine at full throttle
Hydraulic oil temperature: 45 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.

Engine at full throttle


Hydraulic oil temperature: 45 55C
Leakage from swing Relieve swing circuit.
/min 5001 and up
motor

PC128US-2

20-5
(14)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

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

Engine at full throttle


Hydraulic oil temperature
: 45 55C

Max. 23

2.3 0.2

Max. 2.9

RAISE

Bucket
Cylinder fully
retracted

Max. 15

(Until touching (Until touching


cushion)
cushion)

Sec
fl See Fig. J

Max. 700

(Until touching (Until touching


cushion)
cushion)

OUT

Engine at full throttle


Hydraulic oil temperature
: 45 55C

Max. 500

1.3 0.3

Max. 2.5

LOWER

Work equipment speed

fl See Fig. I

Arm
Cylinder fully
retracted

Standard value Service limit


for new
value
machine

(Until touching (Until touching


cushion)
cushion)

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

Hydraulic drift of work equipment

Item

PC128US-2

1.3 0.3

Max. 2.5

20-7
(18)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC138USLC-2 Serial No.: 1001 1500


Applicable model

Engine speed

Category

Unit

Standard value
for new machine

Service limit value

rpm

Min. 2,100

Min. 2,000

N RAISE, LOWER

85 10

Min.75 Max.95

N IN, OUT

85 10

Min.75 Max.95

Bucket control lever

N CURL, DUMP

85 10

Min.75 Max.95

Swing control lever

N LEFT, RIGHT

85 10

Min.75 Max.95

Item

At 1-pump relief

Boom control lever

Arm control lever

Travel of control levers

PC138USLC-2

Measurement conditions
Hydraulic oil temperature : 45 55 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

Travel control lever

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}

Blade control lever

25.50 6.86
{2.6 0.7}

Max.32.32
{Max.3.3}

Travel control lever

24.52 5.88
{2.5 0.6}

Max.39.23
{Max.4.0}

Travel pedal

74.5 18.6
{7.6 1.9}

Max.107.6
{Max.11}

Play of control lever

Operating effort of control lever

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)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model
Category

PC138USLC-2

Measurement conditions

Item

Unit

Hydraulic oil temperature: 45 55 C


Engine at full throttle
Pump discharge pressure
Relieve only circuit to be measured

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

Service limit value

34.81 1.96
{355 20}

3.24 0.20
{33 2}

3.24 0.49
{33 5}

Control levers at
HOLD

3.43 0.98
{35 10}

3.43 0.98
{35 10}

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)

Engine at full throttle


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

Deg.
(mm)

PC128US-2

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Applicable model
Category

Item

PC138USLC-2
Standard value
for new machine

Service limit value

2.9 0.3
(3.6 0.3)

Max. 3.6
(Max. 4.2)

4.0 0.4
(5.0 0.5)

Max. 6.0
(Max. 6.5)

25 2

25 4

0
(0)

0
(0)

Max. 3

Max. 6

Max. 41.6

50.6

Hi

Max. 26.5

32.6

Lo

Max. 25.3

Max. 30.6

Max. 15.2

Max. 18.3

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

Engine at full throttle


Time taken to swing Hydraulic oil temperature: 45 55C Sec.
Swing one turn, and measure time
taken to swing next 5 turns
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 Deg.
(mm)
45.
Make match marks on swing circle
outer race and track frame.
Measure distance that match marks
move apart after 15 minutes.
Figure in ( ) shows at rated load.

Engine at full throttle


Hydraulic oil temperature: 45 55C
Leakage from swing Relieve swing circuit.
/min
motor

fl See Fig. C

Travel

Travel speed (1)

Engine at full throttle


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

Lo
Sec.

fl See Fig. D

Travel speed (2)

PC128US-2

Engine at full throttle


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

Sec.
Hi

20-8-3
(19)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model
Category

Item

Measurement conditions

PC138USLC-2
Unit

Standard value
for new machine

Service limit value

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

Engine at full throttle


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

Travel

fl See Fig. F

Hydraulic drift of
travel

Leakage from travel


motor

Hydraulic drift of work equipment

Work equipment

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

(19)

Engine at full throttle


Hydraulic oil temperature: 45 55C
Lock shoes and relieve travel circuit. /min

fl See Fig. G
Place in above posture and measure
extension or retraction of each cylinder and downward movement at
tip of bucket teeth.
Horizontal, flat ground
Bucket: Rated load (450 kg)
Levers at HOLD
Engine stopped
Hydraulic oil temperature: 45 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

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

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

Engine at full throttle


Hydraulic oil temperature
: 45 55C

Fully extended

(Until touching
cushion)

Service limit value

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 speed

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

Engine at full throttle


Hydraulic oil temperature
: 45 55C

Max. 4.0

Max. 3.2

Max. 2.5

Max. 2.5

Max. 3

Max. 3

Time lag

fl See Fig. L

Boom

PC128US-2

Engine at low idling


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

Sec.

20-8-5
(18)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model
Category

PC138USLC-2
Standard value
for new machine

Service limit value

Max. 2

Max. 2

Max. 2

Max. 2

Blade

Engine at low idling


Hydraulic oil temperature
: 45 55C
Lower blade from maximum
height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.

Max. 2

Max. 2

Eachcylinder

Hydraulic oil temperature


: 45 55 C
Engine full
Circuit to be measured is relieved.

Max. 3.5

Max. 15

Max. 10

Max. 50

Item

Measurement conditions

Unit

fl See Fig. M

Arm

Engine at low idling


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

Bucket

Work equipment

Time lag

fl See Fig. N
Engine at low idling
Hydraulic oil temperature
: 45 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

Internal leakage level

fl See Fig. O

cc/
min
Center swivel
joint

20-8-6
(17)

PC128US-2

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

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

Service limit value

rpm

Min. 2,100

Min. 2,000

N RAISE, LOWER

100 11

100 21

N IN, OUT

100 11

100 21

Bucket control lever

N CURL, DUMP

100 11

100 21

Swing control lever

N LEFT, RIGHT

100 11

100 21

Item

At 1-pump relief

Boom control lever

Arm control lever

Travel of control levers

PC138USLC-2

Measurement conditions
Hydraulic oil temperature : 45 55 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

Travel control lever

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}

Blade control lever

25.51 6.86
{2.6 0.7}

Max.32.36
{Max.3.3}

Travel control lever

24.52 5.88
{2.5 0.6}

Max.39.23
{Max.4.0}

Travel pedal

74.5 18.6
{7.6 1.9}

Max.107.6
{Max.11}

Play of control lever

Operating effort of control lever

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)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Applicable model
Category

Item

PC138USLC-2

Measurement conditions

Unit

Hydraulic oil temperature: 45 55 C


Engine at full throttle
Pump discharge pressure
Relieve only circuit to be measured

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

Service limit value

34.81 1.96
{355 20}

3.24 0.20
{33 2}

3.24 0.49
{33 5}

Control levers at
HOLD

3.43 0.98
{35 10}

3.43 0.98
{35 10}

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)

Engine at full throttle


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

Deg.
(mm)

PC128US-2

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Applicable model
Category

Item

PC138USLC-2
Standard value
for new machine

Service limit value

3.3 0.3
(4.1 0.3)

Max. 4.1
(Max. 4.8)

4.6 0.5
(5.8 0.5)

Max. 6.4
(Max. 7.5)

28.6 2

28.6 4

0
(0)

0
(0)

Max. 3

Max. 6

Max. 45

54

Hi

Max. 26.9

32.3

Lo

Max. 26.1

Max. 31.4

Max. 14.9

Max. 18

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

Engine at full throttle


Time taken to swing Hydraulic oil temperature: 45 55C Sec.
Swing one turn, and measure time
taken to swing next 5 turns
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 Deg.
(mm)
45.
Make match marks on swing circle
outer race and track frame.
Measure distance that match marks
move apart after 15 minutes.
Figure in ( ) shows at rated load.

Engine at full throttle


Hydraulic oil temperature: 45 55C
Leakage from swing Relieve swing circuit.
/min
motor

fl See Fig. C

Travel

Travel speed (1)

Engine at full throttle


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

Lo
Sec.

fl See Fig. D

Travel speed (2)

PC128US-2

Engine at full throttle


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

Sec.
Hi

20-8-9
(19)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Applicable model
Category

Item

Measurement conditions

PC138USLC-2
Unit

Standard value
for new machine

Service limit value

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

Engine at full throttle


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

Travel

fl See Fig. F

Hydraulic drift of
travel

Leakage from travel


motor

Hydraulic drift of work equipment

Work equipment

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

Engine at full throttle


Hydraulic oil temperature: 45 55C
Lock shoes and relieve travel circuit. /min

fl See Fig. G
Place in above posture and measure
extension or retraction of each cylinder and downward movement at
tip of bucket teeth.
Horizontal, flat ground
Bucket: Rated load (450 kg)
Levers at HOLD
Engine stopped
Hydraulic oil temperature: 45 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

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

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 speed

Work equipment

Engine at full throttle


Hydraulic oil temperature
: 45 55C

Service limit value

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

Engine at full throttle


Hydraulic oil temperature
: 45 55C

Max. 4.0

Max. 3.1

Max. 2.5

Max. 2.5

Max. 3

Max. 3

Time lag

fl See Fig. L

Boom

PC128US-2

Engine at low idling


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

Sec.

20-8-11
(17)

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Applicable model
Category

PC138USLC-2
Standard value
for new machine

Service limit value

Max. 2

Max. 2

Max. 2

Max. 2

Blade

Engine at low idling


Hydraulic oil temperature
: 45 55C
Lower blade from maximum
height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.

Max. 2

Max. 2

Eachcylinder

Hydraulic oil temperature


: 45 55 C
Engine full
Circuit to be measured is relieved.

Max. 3.5

Max. 15

Max. 10

Max. 50

Item

Measurement conditions

Unit

fl See Fig. M

Arm

Engine at low idling


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

Bucket

Work equipment

Time lag

fl See Fig. N
Engine at low idling
Hydraulic oil temperature
: 45 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

Internal leakage level

fl See Fig. O

cc/
min
Center swivel
joint

20-8-12
(17)

PC128US-2

STANDARD VALUE TABLE FOR CHASSIS

TESTING AND ADJUSTING

Pump performance curve

TVC current: 0.4 A


Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)

Check point

As desired

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

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

P1

P2

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

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

See graph

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

20-11
(18)

TESTING

STANDARD

AND ADJUSTING

Name of
component

SYS

tern

Travel

boost

solenoid

Con;Ftor

t$~-

vo5
(male)

.9
8
:g
25

.$

relief

solenoid

Judgment

V06
(male)

Ecu
eg
;z!

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

(I) - (2)

Between

(I),

Min.

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

(1) - (2)

Between

(I),

(2) -chassis

Cl3
(male)

z
ti

Between

(1)

Between

(I),

1 M.Q

in the table

Min.

Min.

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

VALUE TABLE FOR ELECTRICAL

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

(I), (2) -chassis

Measure

Engine

speed

sensor

E07
(male)

I- (2)

Between
Between

with

Between

500 - 1000 sz
Min.

1 MQ

AC range

(I) - (2)

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

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

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.

VALUE TABLE FOR ELECTRICAL

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

1 and Table 2, the monitor

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

VALUE TABLE FOR ELECTRICAL

$~p-

judgment

Measurement
conditions

table

method
If the condition

Engine oil pressure


sensor

is as shown

1) Disconnect

in the table

S7
(male)

Coolant
sensor

RELATED PARTS PARTS

If the condition

is as shown

in the table

If the condition

is as shown

in the table

temperature

po6
Fuel level sensor

1.1

:~~$%Zng

When engine is running


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

1 )Start engine.

(male)

Alternator

ii

Between
alternator
terminal R chassis

z
>
E
:
f

PC1 28US-2

20-15
0

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

TESTING AND ADJUSTING

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

Kerosene mode

Model selection

Chassis control

Attachment selection

PPC hydraulic lock


solenoid

Swing holding brake


solenoid

20-16
(17)

CR2

CR1
CR2

CR1
CR2

V07
(male)

V04
(male)

Measure voltage
Measure voltage

CR3

Measurement
conditions

If the condition is as shown in the table


below, it is normal

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

Because normal power


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

Kerosene mode

05V

6 13 V

If the condition is as shown in the table


below, it is normal

If the condition is as shown in the table


below, it is normal

At standard
mode
At kerosene
mode

Between
(6)
chassis

46V

Attachment

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

01V

If the condition is as shown in the table


below, it is normal
CR2 (27) CR1 (4)

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

07V

Measure voltage Measure voltage

Controller

PC-EPC solenoid

CR3

Judgment table

Measure resistance

Power supply voltage

Connector Inspection
No.
method

Measure
resistance

Name of
component

Measure
resistance

System

Max. 1 V

STD arm Long arm

CR (17) CR1 (10) Max. 1 V Min. 7 V

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.

CR (11) CR1 (10) Min. 7 V Max. 1 V


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

37 60

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

Between (1), (2) chassis Min. 1 M

If the condition is as shown in the table


below, it is normal
Between (1) (2)

37 60

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

Between (1), (2) chassis Min. 1 M

PC128US-2

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

TESTING AND ADJUSTING

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

Power supply voltage

Connector Inspection
No.
method

CR3

Measure voltage

System

Judgment table

Measurement
conditions

If the condition is as shown in the table


below, it is normal

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

Because normal power


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

PC-EPC solenoid

CR3

Measure voltage

* The voltage can be checked in monitoring mode "1036".


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

CR3

Measure voltage

Controller

If the condition is as shown in the table


below, it is normal

Swing holding brake


release solenoid

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

If the condition is as shown in the table 1) Turn starting


below, it is normal.
switch ON.
Monitoring mode: "1020", "1021"
Model selec- Model selec- UU/US selec- Tire 2 signal
tion 1 (1020, tion 2 (1020, tion (1020, (1021 bit(5))
bit (5))
bit (6))
bit (3))
Bit OFF

Bit ON

Bit ON

Bit ON

Attachment selection

PC128US-2

Monitoring

If the condition is as shown in the table 1) Turn starting


below, it is normal.
switch ON.
Monitoring mode: "1020"
Attachment Attachment Attachment
selection 1 selection 2 selection 3
(1020, bit (2)) (1020, bit (1)) (1020, bit (4))
Standard
Bit ON
arm

Bit OFF

Bit OFF

Long arm

Bit ON

Bit OFF

Bit OFF

20-19
(17)

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

TESTING AND ADJUSTING

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.

Swing pressure switch

Travel pressure switch

Other work equipment


pressure switches
Arm OUT, bucket

CURL, bucket DUMP,


blade, attachment

20-20
(17)

Monitoring
Monitoring

Monitoring

Arm IN pressure switch

Monitoring

Controller

Boom RAISE pressure


sensor

Monitoring

Select in service adjustment mode

Service
adjustment

* The model and attachment codes do not


make difference in performance.
If the condition is as shown in the table
below, it is normal.
Diesel fuel/Kerosene mode "31"
Standard mode

310

Kerosene mode

311

1) Turn starting
switch ON.

If the condition is as shown in the table 1) Start engine.


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

Bit ON

Neutral position

Bit OFF

If the condition is as shown in the table


below, it is normal.
Monitoring mode: "1023", bit (4)
Swing (Right or left) position

Bit ON

Neutral position

Bit OFF

If the condition is as shown in the table


below, it is normal.
Monitoring mode: "1023", bit (3)
Travel (Forward, reverse,
right, or left) position

Bit ON

Neutral position

Bit OFF

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

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

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

If the condition is as shown in the table


below, it is normal.
Monitoring mode
Arm OUT "1028" (1)
Blade, attachment "1028" (2)
Bucket CURL "1028" (3)
Bucket DUMP "1028" (4)
Other work equipment operation

Bit ON

Neutral position

Bit OFF

PC128US-2

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

TESTING AND ADJUSTING

Chassis control

Travel acceleration
solenoid

2-stage relief solenoid

PC-EPC solenoid

LS-EPC solenoid

V05
(male)

V06
(male)

C13
(male)

C14
(male)

Measure
resistance
Measure
resistance

V04
(male)

Measure
resistance

Swing holding brake


solenoid

V07
(male)

Measure
resistance

PPC hydraulic lock


solenoid

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

Between (1), (2) chassis Min. 1 M

If the condition is as shown in the table


below, it is normal
Between (1) (2)

37 60

Between (1), (2) chassis Min. 1 M

PC128US-2

Measure
resistance

C05
(male)

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

* The controller output can be checked in


monitoring mode "1060", bit (1).
If the condition is as shown in the table
below, it is normal
Between (1) (2)

37 60

Between (1), (2) chassis Min. 1 M

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

* The controller output can be checked in


monitoring mode "1060", bit (4).
If the condition is as shown in the table
below, it is normal
Between (1) (2)

37 60

Between (1), (2) chassis Min. 1 M

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

* The controller output can be checked in


monitoring mode "1060", bit (10).
If the condition is as shown in the table
below, it is normal
Between (1) (2)

8 15

Between (1), (2) chassis Min. 1 M

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

* The controller output can be checked in


monitoring mode "1050".
If the condition is as shown in the table
below, it is normal
Between (1) (2)

8 15

Between (1), (2) chassis Min. 1 M

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

* The controller output can be checked in


monitoring mode "1054".
If the condition is as shown in the table
below, it is normal

Pressure sensor

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

Between (A) (B)

4.5 5.5 V

Between (e) (P)

0.5 4.5 V

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

* The controller output can be checked in


monitoring mode "1042".

20-21
(17)

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

TESTING AND ADJUSTING

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

Engine speed sensor

E07
(male)

Measure
voltage

Measurement in the AC range

Adjustment

Chassis control

Measure
resistance

System

20-22
(17)

Between (1) (2)

0.5 3.0 V

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

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

* The controller output can be checked in


monitoring mode "1010".

1) Thread the speed sensor until it


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

PC128US-2

TESTING AND ADJUSTING


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

PC128US-2

20-101
(17)

TESTING AND ADJUSTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING


Check or measurement item Symbol

Engine speed

Coolant and oil temperatures

Part Name

799-205-1100

Tachometer kit

795-790-2500

Take-off drive

6090-02-9190

Gear box

799-101-1502

Digital temperature gauge

- 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

Digital hydraulic tester

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

Differential pressure gauge

795-799-1131

Gear

799-201-1504

Blow-by checker

D
1

795-790-1950

Tool

Commercially
available

Feeler gauge

790-201-9001

Handy Smoke Checker

Commercially
available

Smoke meter

79A-264-0021

2
Valve clearance
Exhaust color

Operating effort

F
G

Stroke, hydraulic drift

Work equipment speed

Measuring voltage and resistance values

Measuring wear of sprocket

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

Male, female both 14 x 1.5


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

790-261-1311
3

Adjusting fuel injection timing

Remarks

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

For 6-pin relay

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

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

MEASURING ENGINE SPEED


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

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 and up
Measurement of engine speed
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)

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
fl Measure the engine speed under the 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.

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


to tool A3.
3. Start the engine and measure the following revolving speeds.
1) Measure the low idling speed and high
idling speed.
2) Set the fuel control lever to the low idling
and high idling positions and measure the
revolving speeds at the respective positions.
3) Revolving speed when pump is relieved
Relieve the pump and run engine at full
throttle and measure its revolving speed.

20-104
(19)

PC128US-2

TESTING AND ADJUSTING

MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR

When measuring in the field when there is no air


or electric power supply, use smoker checker G1;
when recording official data, use smoke meter G2.
fl Raise the coolant temperature to the operating
range before measuring.
When removing or installing the measuring
equipment, be careful not to touch any high temperature part.
1. Measuring with handy smoke checker G1
1) Fit filter paper in tool G1.
2) Insert the exhaust gas intake port into the exhaust pipe.
3) Accelerate the engine suddenly, and at the
same time operate the handle of tool G1 to
catch the exhaust gas on the filter paper.
4) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter G2
1) Insert probe of smoke meter G2 into the outlet port of exhaust the pipe, then tighten the
clip to secure it to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to smoke meter G2.
fl The pressure of the air supply should be
less than 1.47 MPa {15 kg/cm2}.
3) Connect the power cord to the AC100V outlet.
fl When connecting the port, check first that
the power switch of the smoke meter is
OFF.
4) Loosen the cap nut of the suction pump, then
fit the filter paper.
fl Fit the filter paper securely so that the exhaust gas does not leak.
5) Turn the power switch of smoke meter G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
smoke meter G2 and catch the exhaust gas
color on the filter paper.
7) Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (10
sheets or more) inside the filter paper holder,
and read the indicated value.

PC128US-2

20-105
(17)

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
1. Remove the cylinder head cover.
2. Using cranking tool D, rotate the crankshaft in the
normal direction until timing pin (1) enters the
hole in the gear.
fl In this position, the No.1 cylinder is at compression top dead center.

3. When the No.1 cylinder is at top dead center, adjust the valves marked . Next, rotate the crankshaft one turn (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.

4. To adjust the valve clearance, loosen locknut (7),


then insert feeler gauge F between rocker lever
(4) and valve stem (5), and turn adjustment screw
(6) until the clearance is a sliding fit. Then tighten
locknut (7) to hold the adjustment screw in position.
9 Locknut : 23.5 Nm {2.4 kgm}
fl After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 180 each time and adjust the valve
clearance of each cylinder according to the
firing order.
Firing order : 1 3 4 2
fl Note that there is no timing mark on the front
pulley, so set to compression top dead center
as follows.
1) If the firing order is followed, No. 3 cylinder
comes after No. 1 cylinder, so watch the movement of the valves of No. 2 cylinder when rotating.
2) When the clearance is 0 for both the intake
and exhaust valves of the No. 2 cylinder, the
No. 3 cylinder is at compression top dead center. (When setting No. 2 cylinder, watch No. 3
cylinder.)

20-106
(17)

PC128US-2

TESTING AND ADJUSTING

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Method of adjusting valve clearance
1. Remove the cylinder head cover.
2. Turn the crankshaft forward and bring cylinder
No. 1 to the compression top dead center and
match the TOP mark line of crank pulley (1) to
pointer (2), watching the movement of the air
intake valve of cylinder No. 4 (4 cylinders).
a The air intake valve of cylinder No. 4 (4 cylinders) moves (opens) when cylinder No. 1
comes near the compression top dead center.

ADJUSTING VALVE CLEARANCE

a Adjust the valve clearance according to the


following procedure. Loosen locknut (8) of
adjustment screw (7). Insert filler gauge of
the specified thickness between valve stem
(6) and rocker arm (5) and adjust the valve
clearance so that the filler gauge will move
lightly.

5. Tighten the locknut to secure the adjustment


screw.
Locknut: 39.2 49 Nm {4 5 kgm}

3. Adjust the clearance of the valves marked with


q in the valve arrangement.
4. Turn the crankshaft forward by 1 turn and adjust
the clearance on the valves marked with Q.

a You may adjust the valve clearances of each


cylinder in the firing order, rotating the crankshaft by 180 each time.

PC128US-2

20-107
(17)

TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE


fl Measure the blow-by pressure under the following conditions.
Coolant temperature : Within operating range
Hydraulic oil temperature: 50 80 C
1. Install the nozzle of blow-by checker E to the blowby hose.
2. Connect the nozzle and gauge with the hose.
3. Run the engine at full throttle and relieve the arm
circuit.
4. Measure the blow-by pressure at the point where
the gauge indicator remains steady.

20-108
(17)

PC128US-2

MEASURING ENGINE OIL PRESSURE

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE


fl Measure the engine oil pressure under the following conditions.
Coolant temperature : Within operating range

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

1. Remove engine oil pressure switch (1).


2. Fit a nipple C3 and install oil pressure gauge C2
(0.981 MPa {10 kg/cm2}).
3. Start the engine, and measure the engine oil pressure with the engine at low idling and at high
idling.

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

PC128US-2

20-108-1
(17)

TESTING AND ADJUSTING

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
Testing
1. Using cranking tool D, rotate the crankshaft in the
normal direction until timing pin (1) enters the
hole in the gear.
2. Remove plug (2), reverse timing pin (3), and check
that pin (3) is meshed with timing pointer (4) at
the fuel injection pump end.
Adjusting
fl If the timing pin does not mesh with the pointer,
adjust as follows.
1. Remove the fuel injection pump.
For details, see REMOVAL OF FUEL INJECTION
PUMP.
2. Rotate the camshaft of the fuel injection pump
and timing pin (3) with timing pointer (4).
3. Install the fuel injection pump.
For details, see INSTALLATION OF FUEL INJECTION PUMP.

20-108-2
(17)

PC128US-2

TESTING AND ADJUSTING

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

TESTING AND ADJUSTING FUEL INJECTION TIMING

2. Remove front cover (3) of the fuel injection


pump.
3. Install the fuel injection pump holder and drive
gear as one unit to the engine.
4. Insert the timing check pin 4.0 4.5 mm in diameter and 80 mm in length on hole a of the front
gear cover and match it to the hole of the drive
gear.
a Check that the timing check pin enters
straight and the hole of the fuel injection
pump holder is aligned with the mounting
hole of the front gear cover (in which the
mounting bolt will be inserted).
a If the holes are deviated from each other,
remove the fuel injection pump and check its
engagement with the drive gear.

5. Remove the timing check pin and tighten each


bolt.

20-108-3
(17)

TESTING AND ADJUSTING

Adjustment by delivery valve method


(When installing a repaired or replaced fuel injection
pump, when checking after disassembling or replacing the gear train)

TESTING AND ADJUSTING FUEL INJECTION TIMING

4. Using spring pusher O2, compress the valve


spring and remove valve cotter (5).
5. Loosen spring pusher O2 and remove spring
seat (6) and valve spring (7).

1. Remove the cylinder head cover.


2. Bring cylinder No. 1 to the compression top dead
center.
1) Turn the crankshaft forward and match injection timing line (1) on the crank pulley to
pointer (2).
2) Check that both air intake valve and exhaust
valve of cylinder No. 1 have the valve clearance.
a If either or both of the valves do not
have the valve clearance, turn the
crankshaft one more turn.
6. Turn the stem of air intake valve (8) with the fingers while it is in contact with the top of piston
(9) to fit it securely.

3. Remove snap ring (3) from the front end of the


rocker shaft, then remove air intake rocker arm
(4) of cylinder No. 1.

20-108-4
(17)

PC128US-2

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING

7. Apply dial gauge O3 to the valve stem end and


turn the crankshaft forward or in reverse to set
the dial gauge to 0 when its pointer starts turning
in reverse.
8. Turn the crankshaft about 45 degrees in reverse
from the compression top dead center of cylinder No. 1.
9. Turn the crankshaft forward so that the dial
gauge indicates standard dimension a.
BTDC

(Deg)

6 0.75

mm

0.42 0.08

12. Set the fuel injection lever to the FULL position.


13. Loosen the nut at the oblong hole of the injection
pump mounting flange, then loosen the injection
pump mounting bolts (14).

10. Disconnect fuel injection pipe (10) of cylinder


No. 1.
11. Remove delivery valve holder (11), and remove
delivery valve (12) and spring (13) from its
inside. Then, install delivery valve holder (11)
again.
14. Turning the injection pump outward and operating the priming pump, move the injection pump
toward the cylinder block little by little and stop
when the fuel stops flowing out of the delivery
valve holder.
a If the injection pump is slanted out, the injection timing is delayed. If the former is slanted
toward the cylinder block, the latter is
advanced.
15. Tighten injection pump mounting bolts (14) alternately.
16. Tighten the nut at the oblong hole of the injection
pump mounting flange.

PC128US-2

20-108-5
(17)

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING

17. Turn the crankshaft forward and check that the


pointer of the dial gauge is in the standard range
shown in the following table when cylinder No. 1
is at the top dead center (when the pointer of the
dial gauge starts moving in reverse). If the
pointer of the dial gauge is out of this range,
repeat the above steps from 7.
Dimension when cylinder is at top
dead center (mm)

0 0.08

18. Remove the delivery valve holder (11) and install


delivery valve (12) and spring (13) to it, then
install delivery valve holder (14) again.
a Replace the o-ring and copper gasket of the
delivery valve.
WARNING! Tighten the delivery valve 3
times to secure it. (If it is not tightened sufficiently, the gasket may be broken.)
Delivery valve holder:
39.2 44.1 Nm {4 4.5 kgm}
19. Connect fuel injection pipe (3).
Sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}
20. Install valve spring (7) and valve seat (6).
21. Compress the valve spring with spring pusher
O2 and install valve cotter (5).
22. Install air intake rocker arm (4) of cylinder No. 1,
then install snap ring (3).
a Install the snap ring securely.
23. Install the cylinder head cover.
Sleeve nut:
7.84 9.8 Nm {0.8 1.0 kgm}

20-108-6
(17)

PC128US-2

TESTING AND ADJUSTING

TESTING AND ADJUSTING BELT


TENSION FOR AIR CONDITIONER
COMPRESSOR

TESTING AND ADJUSTING BELT TENSION


FOR AIR CONDITIONER COMPRESSOR

PC128US-2 Serial No.: 5001 7730

PC128US-2 Serial No.: 5001 7730


fl If the deflection of the belt when it is pressed at a
point midway between the crankshaft pulley and
the compressor pulley is not within the standard
value, or when carrying out maintenance after replacing the belt, adjust the belt tension as follows.
1. Loosen 2 mounting bolts (2) and 2 adjustment
plate bolts (3) of compressor assembly (1).
2. Move the position of compressor assembly (1) to
adjust the belt tension.
3. When the position of compressor assembly (1) is
fixed, tighten 2 adjustment plate bolts (3) and 2
mounting bolts (2) to secure in position.
4. After adjusting the belt tension, repeat the above
testing procedure to check that the belt tension is
within the standard value.

PC128US-2
Serial No.: 7731 and up
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)

TESTING AND ADJUSTING

TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION


PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
fl When deflection a made by pressing the intermediate point of the belt between the alternator pulley and drive pulley is out of the standard range
or when the belt was replaced, adjust the belt tension according to the following procedure.
1. Open the engine hood and remove the cover between the hydraulic tank and operator's cab.
2. Loosen mounting bolt (2) and fixing bolt (3) of
alternator assembly (1).
3. Loosen locknut (4), and then loosen tension bolt
(5) to adjust the belt tension.
Tighten fixing bolt (3) first, and then tighten alternator mounting bolt (2) and locknut (4).
fl Do not touch the double nut (6).
4. After adjusting the belt tension, check that it is in
the standard range according to the check procedure shown above.

20-108-8
(17)

PC128US-2

ADJUSTING ENGINE SPEED SENSOR

TESTING AND ADJUSTING

ADJUSTING ENGINE SPEED SENSOR


1. Screw in until the tip of sensor (1) contacts gear
(2).
2. When gear (2) contacts sensor (1), turn back 11/
6 turn.
3. Tighten locknut (3).
fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
fl Be particularly careful when securing the sensor wiring to ensure that no excessive force
is brought to bear on the wiring.

PC128US-2
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

ENGINE STOP SOLENOID LINKAGE

BEP01424

Testing
1. Turn the starting switch ON, set to the operating
condition, then adjust so that the clearance between lever (I) and stopper (2) is 1 - 2 mm.
Adjusting
1. Loosen the mounting bolts of solenoid assembly
(31, move solenoid assembly (3) to adjust the clearance between
lever (I) and stopper (21, then
tighten the mounting bolts.
*
There is an oblong hole at the bracket end.

20-110
0

PC1 28US-2

TESTING

TESTING

AND ADJUSTING

CLEARANCE

OF SWING

CIRCLE BEARING

TESTING CLEARANCE OF SWING CIRCLE BEARING


Method of testing clearance of swing circle bearing
when mounted on machine
1. Fix a magnet-type
dial gauge to the outer circle
(or inner circle) of the swing circle, and put the tip
of the probe in contact with the inner circle (or
outer circle).
Set the dial gauge at the front or rear.

-Revo

01

rame

Dial gauge

2.

Extend the work equipment


to the maximum
reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
When this is done, the front of the upper structure will go down and the rear will rise.

3.

Set the dial gauge to the zero point.

TXP02404

BLP01317

4.

5.

Set the arm more or less at


ground surface, then lowerthe
dercarriage at the front of the
the ground.
When this is done, the front
ture will rise and the rear will

of the upper strucgo down.

Read the value on the dial gauge at this point.


The value on the dial gauge is the clearance of
the swing.circle bearing.
g

6.

right angles to the


boom until the unmachine comes off

When carrying out the measurement,


do not
put your hand or feet under the undercarriage.

150-200mm

BLPOl3

Return to the condition in Step 2, and check that


the dial gauge has returned to the zero point. If it
has not returned to the zero point, repeat Steps 2
to 5.

PC1 28US-2

20-111
0

CHECKING WEAR OF SPROCKET

TESTING AND ADJUSTING

CHECKING WEAR OF SPROCKET


Wear

limit

line

TXP02405

1.

Remove the track shoe assembly.


*
For details, see DISASSEMBLYAND ASSEMBLY, REMOVAL OF STEEL SHOE ASSEMBLY.

2.

Align wear gauge M with the sprocket.


* Align the datum line, then align the wave
shape of the sprocket with the wave shape of
the wear gauge.

3.

Judge the sprocket wear.


Sr If the wave shape of the sprocket is above the
wear limit line :
It is possible to continue to use the sprocket.
*
If the wave shape of the sprocket has reached
the wear limit line :
Replace the sprocket with a new part.

20-112
0

PC128US-2

TESTING
TESTlNG

AND ADJUSTING

AND ADJUSTING
HYDRAULIC PRESSURE IN
WORK EQUIPMENT,
SWING, TRAVEL CIRCUIT

TESTING AND ADJUSTING HYDRAULIC


PRESSURE IN WORK EQUIPMENT,
SWING, TRAVEL CIRCUIT
Measuring
Sr Oil temperature
a

when

measuring:

45 - 55 C

Lower the work equipment


to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK position.
Remove
pressure
pick-up
plug (I) (Thread
dia.=lOmm,
Pitch=l.25mm)
from the circuit to be
measured, then install oil pressure gauge Cl (58.8
MPa {SO0 kg/cm*}).

Measuring unload hydraulic pressure


l
Start the engine, run at full throttle, and measure
the hydraulic pressure when the control levers are
at HOLD.

Measuring main relief (pump relief) oil pressure


1. Run the engine at full throttle and measure the
oil pressure when each actuator is relieved.
l
The condition for each actuator is as follows:
1) For the work equipment, operate the cylinder
to the end of its stroke.
2) Forthe swing, dig a hole and lowerthe bucket.
3) For the travel, fit block (1) under the grouser
of the track shoe, or fit block (2) between the
sprocket and frame to lock the track, and measure one side at a time.
*
The set pressure of the safety valve of the
swing motor is lower than the main relief
valve set pressure, so when the swing is
relieved, the set pressure of the safety
valve is measured.

20-114
0

BLPO1284
-1

PC1 28US2

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN


WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

Adjusting
1. Adjusting main relief valve
Disconnect high pressure hose.
1) Adjusting high pressure setting
Loosen locknut (2) of main relief valve (1),
then turn holder (3) to adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTERCLOCKWISE.
fl After adjusting, use the measurement procedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
53.9 4.9 Nm {5.5 0.5 kgm}
fl When the high pressure setting is adjusted, the low pressure setting will also
change, so adjust the low pressure setting also.
2) Adjusting low pressure setting
Loosen locknut (4) of main relief valve (1),
then turn holder (5) to adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTERCLOCKWISE.
fl After adjusting, use the measurement procedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
39.2 49.0 Nm {4 5 kgm}

2. Adjusting swing motor safety valve


fl If the swing relief pressure is not normal, adjust the swing motor safety valve as follows.
1) Loosen locknut (7) of swing motor safety valve
(6), then turn adjustment screw (8) to adjust.
fl Turn the adjustment screw as follows.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCKWISE
fl Amount of adjustment for one turn of adjustment screw : 14.0 MPa {143 kg/cm2}

PC128US-2

20-115
(18)

TESTING
TESTING

2)

AND ADJUSTING

After adjusting,
m
&

tighten

AND ADJUSTING
HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

locknut (7).

Locknut
: 53.9 + 4.9 Nm (5.5 + 0.5 kgm1
.n.fer comnletinn
of adiustment.
,-------~ -, use the
r--.-..
measurement
procedure
the oil pressure again.

above to check

9JFOO253

20-116
0

PC1 28US-2

TESTING AND ADJUSTING

TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE


(SERVO PISTON INPUT PRESSURE)

TESTING AND ADJUSTING OUTPUT PRESSURE


OF PC VALVE (SERVO PISTON
INPUT PRESSURE)
Measuring
fl Oil temperature when measuring : 45 55 C
1. Remove pressure measurement plugs (1) and (2)
(Thread dia.= 10 mm, Pitch=1.25 mm), and install
oil pressure gauge C1 (39.2 MPa {400 kg/cm2}).
2. Turn the swing lock switch ON.
3. Run the engine at full throttle and measure the
oil pressure when the arm IN circuit is relieved.
[Reference]
If there is any abnormality with problem in the
LS valve or servo piston, the servo piston input
pressure becomes a value close to 0 or the same
pressure as the pump discharge pressure.

PC128US-2

20-117
(18)

TESTING
TESTING

AND ADJUSTING

AND ADJUSTING

OUTPUT PRESSURE OF PC VALVE


(SERVO PISTON INPUT PRESSURE)

Adjusting
If the load increases and the engine speed drops,
or if the engine speed is normal but the work
equipment speed is slow, adjust PC valve (6) as
follows if the pump discharge pressure and LS
differential pressure are normal.
1) Loosen iocknut (41, and if the work equipment
speed is slow, turn screw (5) clockwise; if the
engine speed drops, turn the screw counterclockwise.
2) Remove pressure measurement plugs (1) and
(2) (Thread dia.= IO mm, Pitch=1.25 mm), and
install oil pressure gauge Cl (39.2 MPa (400
kg/cm*}).
3) Turn the swing lock switch ON.
Run the engine at full throttle and measure the
oil pressure when the arm IN circuit is relieved.
[Reference]
If there is any abnormality in the LS valve or servo
piston, the servo piston input pressure becomes
a value close to 0 or the same pressure as the
pump discharge pressure.

BKPOIOI5

20-118
0

PC1 28US-2

TESTING

TESTING AND ADJUSTING


LS VALVE OUTPUT
(SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE


(SERVO PISTON INPUT PRESSURE)
AND LS DIFFERENTIAL PRESSURE
when

measuring

: 45 - 55 C

j,

Oil temperature

1.

Measuring LS valve output pressure (servo


ton input pressure)
plugs (I)
1) Remove pressure measurement
(2) (Thread dia.= 10 mm, Pitch=1.25 mm),
install oil pressure gauge Cl (39.2 MPa

pisand
and
{400

kg/cm%

2) Use the work equipment


3)

to raise the track assembly on one side.


Run the engine at full throttle,
operate under
the conditions
shown in Table 1, rotate the
track under no load, and measure the oil pressure (the oil pressure when the travel is operated on one side under no load).

Travel
lever

Pump
pressure
MPaIkg/cmZI

Servo inlet
pressure
APaIkg/cm*)

About same
pressure

Neutral

t
Full

PC1 28U.S2

Remarks

7.85f0.49
{80+20)

4.41f0.98
(45flOI

Pressure of
about 315

PRESSURE
PRESSURE

TESTING

2.

AND ADJUSTING

Measuring

LS differential

TESTING AND ADJUSTING


LS VALVE OUTPUT
(SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

PRESSURE
PRESSURE

pressure

1)

Measuring with.differential pressure gauge


i) Remove oil pressure measurement plugs (1)
and (2) (Thread dia.=lOmm, Pitch=l.25mm),
and install differential pressure gauge Cl.
* Connect pump discharge pressure
side (1) to the high- pressure side of
the differential gauge and LS pressure
side (2) to the low-pressure side.
ii) Use the work equipment to raise the track
on one side.
iii) Run the engine at full throttle, set to the
conditions below, and measure the LS differential pressure.
LS differential pressure when travel lever is at.Neutral :
2.75 f 0.98 MPa 128 k 10 kg/cm*)
* The LS differential pressure when the
travel lever is at Neutral is the same
as the unload pressure.
LS differential pressure when travel lever is at half-way position (track rotating under no load) :
1.57 f 0.1 MPa I16 f lkg/cm*)
2) Measuring with oil pressure gauge
*
The maximum differentialpressure is less
than 1.96 MPa (20 kg/cm*), so measure
with the same gauge.
i) Remove oil pressure measurement plugs (I)
and (2) (thread dia.=lOmm, pitch=l.25mm),
and install oil pressure gauge Cl.
ii) Install oil pressure gauge Cl (39.23 MPa
(400 kg/cm*}) to the plug for measuring
the pump discharge pressure.
*
Use a gauge with a scale in units of
0.98 MPa {IO kg/cm*).
iii) Use the work equipment to raise the track
on one side.
iv) Run the engine at high idling, set to the
conditions in Step 1) - iii), and measure
the pump discharge pressure.
*
Stand directly in front of the indicator
and be sure to read it correctly.
v) Run the engine at high idling, set to the
conditions in Step 1) - iii), and measure
the LS pressure.
* Stand directly in front of the indicator
and be sure to read it correctly.
vi) Calculate the LS differential pressure from
the pump discharge pressure and the LS
pressure.
(Differential pressure) = (Pump discharge
pressure) - (LS pressure)
l

9JFOOl20

-1

BLP01284

20-120
0

PC128US-2

TESTING

3.

AND ADJUSTING

TESTING AND ADJUSTlNG


LS VALVE OUTPUT
(SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

Adjusting LS valve
*
If the results show that the LS differential pressure is not within the standard value, adjust
the LS valve as follows.
1) Disconnect hose (8) from LS valve (7).
2) Loosen locknut (9) and turn adjustment screw
(IO) to adjust the differential pressure.
*
Turn the adjustment
screw to adjust as
follows.
l
To INCREASE pressure, turn CLOCKWISE
l
To DECREASE pressure, turn COUNTERCLOCKWISE
*
Amount of adjustmentfor
one turn of adjustment screw: 1.30 MPa i13.3 kg/cm*}
(LS differential pressure)
3) After adjusting, tighten locknut (8).
w
*

PC1 28US-2

PRESSURE
PRESSURE

BKP01016

Locknut : 59 f IO Nm (6 f 1 kgml
After completion of adjustment, repeat the
procedure above to check the LS differential pressure again.

20-121
0

TESTING

TESTING

AND ADJUSTING

AND ADJUSTING

CONTROL

CIRCUIT OIL PRESSURE

TESTING AND ADJUSTING CONTROL


CIRCUIT OIL PRESSURE
:
Measuring
*
Oil temperature
a

when measuring

: 45 - 55 C

Lower the work equipment to the ground and


stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK position.

1. Remove the cover at the top of the valve.


2.

Disconnect hose (I) going to the solenoid valve,


then install adapter C3 and oil pressure gauge Cl
(5.9 MPa {SO kg/cm*)).

3.

Start the engine and measure


full throttle.

with the engine at

Adjusting

If the pressure in the control circuit is not normal,


adjust the control relief valve as follows.

Loosen locknut (2) and turn adjustment.screw


(3)
to adjust.
*
Turn the adjustment screw as follows.
l
To INCREASE pressure, turn CLOCKWISE
l
To DECREASE pressure, turn COUNTERCLOCKWISE
*
Amount of adjustment for one turn of adjustment screw : 0.98 MPa {IO kg/cm*}

2.

After adjusting,

tighten

locknut (2).

Locknut : 19.6 - 24.5 Nm (2.0 - 2.5 kgm}

After completion
of adjustment,
repeat the
procedure above to check the oil pressure
again.

20-122
0

9JFOO266

PC1 28US-2

TESTING

TESTING

AND ADJUSTING

SOLENOID

VALVE OUTPUT

PRESSURE

TESTING SOLENOID VALVE


OUTPUT PRESSURE
when measuring

: 45 - 55 C

Oil temperature

1.

Disconnect the output hose of the solenoid valve


to be measured, then install adapter C3 between
the hose and the measurement
point.

2.

Install oil pressure gauge Cl (5.9 MPa {SO kg/cm211


to adapter C3.

3.

Measure the output pressure underthe


in the table below.

lock lever: LOCK

conditions

PPC lock actuated

Swing lock switch: LOCK

PC1 28US-2

20-123
0

TESTING

MEASURING PPC VALVE


OUTPUT PRESSURE
* Oil temperature when measuring : 45
1.

MEASURING

AND ADJUSTING

PPC VALVE OUTPUT

PRESSURE

- 55 C

Measuring PPC valve output pressure


1) Disconnect PPC hose (I) of the circuit to be
measured.
2) install adapter C3 between the hose and elbow.
3) Install oil pressure gauge Cl (5.88 MPa I60
kg/cm211 to adapter C3.
4) Run the engine at full throttle, operate the control lever of the circuit to be measured, and
measure the oil pressure.

PPC

BLP01302

20-124
0

PC1 28US-2

TESTING

TESTING

AND ADJUSTING

AND ADJUSTING

TRAVEL DEVIATION

TESTING AND ADJUSTING


TRAVEL DEVIATION
Travel

Posture

Testing
*
Travel on flat ground.
1.

Set the machine in the travel posture.


Ir When setting the machine in the travel posture, extend the bucket and arm cylinder rods
fully, and hold the boom at an angle of 45.

2.

Travel for IOm, then measure the deviation when


traveling the next 20m .
J, Measure with the engine at full throttle.
*
Install an oil pressure gauge and measure the
pump discharge pressure at the same time.

TDP00328

20m

Make

Make
a mark
10m midway

a mark

MIyarin;,J,

at
Point

1Om

the

Make

Run

UP

for

IOm

a mark:

midwAark

Mark
Measure
distance

the

amount
A at this

of
point
TEP00329

20-126
0

PC1 28US-2

CHECKING
TESTING

AND ADJUSTING

LOCATION OF CAUSE OF HYDRAULIC


DRIFT OF WORK EQUIPMENT

CHECKING LOCATION OF CAUSE OF HYDRAULIC


DRIFT OF WORK EQUIPMENT
*

Oil temperature

1.

Work equipment

when measuring : 45 - 55 C
cylinder

If the hydraulic drift of the work equipment is


not within the standard value, measure the
internal leakage of the cylinder as follows and
judge if the cause of the hydraulic drift is in
the cylinder or the control valve.
. If the leakage is within the standard value, the
problem is in the control valve.
. If the leakage is more than the standard value,
the problem is in the cylinder.
1) Fully extend the rod of the cylinder to be measured, then stop the engine.

2) Disconnect the hose at the head end and block


the hose at the chassis end with a blind plug.
Boom cylinder: Hose (I 1
Arm cylinder: Hose (2)
Bucket cylinder: Hose (3)
Be careful not to disconnect the hose at
g
the bottom end.
3) Start the engine, run the engine at full throttle,
and apply the relief pressure to the bottom
end of the cylinder.
*
Boom cylinder: Operate to RAISE
Arm cylinder: Operate to IN
Bucket cylinder: Operate to CURL
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
l

2.

Checking_ PPC valve


If there is a difference in the hydraulic drift
when the safety lock lever is at the LOCK or
FREE position (with the engine running), the
PPC valve is defective.

End

of

stroke

~p~connect

zi

TLP00652

PC1 28US-2

ZO-127
0

TESTING

MEASURING
MEASURING

AND ADJUSTING

OIL LEAKAGE OF SWING MOTOR,


OIL LEAKAGE OF TRAVEL MOTOR

MEASURING OIL LEAKAGE OF


SWING MOTOR
*

Oil temperature

when measuring

: 45 - 55 C

1. Disconnect drain hose (I) from the swing motor,


then install a blind plug at the tank end.
2. Dig the bucket into the ground and lock the swing.
3. Start the engine and relieve the swing circuit with
the engine at full throttle.
4. Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.
f
After measuring,
swing 180 and measure
again.

MEASURING OIL LEAKAGE OF


TRAVEL MOTOR
* Oil temperature when measuring : 45 - 55 C
1.
2.

3.

4.

Disconnect drain hose (2) from the travel motor,


then fit a blind plug at the hose end.
Fit block @ under the track shoe grouser, or fit
block @ between the sprocket and frame to lock
the track.
Start the engine and relieve the travel circuit with
the engine at full throttle.
a
When measuring
the oil leakage from the
travel motor, there is a serious risk that mistaken operation of the control lever may lead
to an accident, so always use signals and
check carefully when carrying out this operation.
Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.
*
When measuring, move the motor slightly (to
change the position between the valve plate
and cylinder, and the piston and cylinder), and
measure several times.

II

20- 128
0

9JFOOO95

PC1 28US-2

BLEEDING AIR

TESTING AND ADJUSTING

BLEEDING AIR
Order for operations and procedure for bleeding air
Air bleeding procedure

Air bleeding item

Nature of work
Change hydraulic oil
Clean strainer

Bleed air
from
pump

Start
engine

Bleed air Bleed air Bleed air Pressurize


Start
from
from
from
hydraulic operation
cylinder
swing
travel
tank
motor
motor

(Note)

(Note)

Replace, repair control valve

Replace cylinder
Remove cylinder piping

Replace, repair swing motor


Remove swing motor piping

Replace, repair travel motor, swivel


Remove travel motor, swivel piping

Replace return filter element


Replace, repair pump

Note : Bleed the air from the swing and travel motors only when the oil inside the motor case has been
drained.
1. Bleeding air from pump
1) Loosen air bleed plug (1), and bleed the air
from the plug.
fl WHen no more air comes out with the oil,
the bleeding is completed.
2) When oil oozes out, tighten plug (1).
9 Air bleed plug :
17.16 2.45 Nm {1.75 0.25 kgm}
fl Precautions when starting the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
2. Bleeding air from cylinders
1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, and raise and
lower the boom 4 5 times in succession.
fl Operate the piston rod to approx. 100 mm
before the end of its stroke. Do not relieve the circuit under any circumstances.
3) Run the engine at full throttle and repeat Step
2). After that, run the engine at low idling,
and operate the piston rod to the end of its
stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm, bucket, swing, and blade cylinders.
PC128US-2

20-129
(17)

TESTING

AND ADJUSTING

3.

Bleeding air from swing motor


1) Turn the swing lock switch ON and run at
idling for 5 minutes.
*
Use the S port pressure to bleed the air
from the swing motor.
2) Disconnect hose (1) from the swing motor,
then fit a blind plug in the hose end.
3) Run the engine at low idling and check that
oil oozes out from elbow (2).
Jr If oil does not flow out from the elbow,
repeat Step 1).
4) Connect hose (I).

4.

Bleeding

20-130
0

BLEEDING

AIR

air from travel motor

PC1 28US-2

TESTING

AND ADJUSTING

RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT,
RELEASING REMAINING
PRESSURE IN HYDRAULIC TANK

RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
Jr If the piping between the hydraulic cylinder

and
the control valve is to be disconnected, release
the remaining pressure from the circuit as follows.
The travel circuit is an open circuit, so there is no
remaining pressure. In this case, it is enough just
to the oil filler cap.

1.

Loosen the oil filler cap slowly to release the pressure inside the tank.

2.

Operate the control levers.


*
When the levers are operated 2 - 3 times, the
pressure stored in the accumulator
is removed.

3. Start the engine, run at low idling for approx. 5


minutes, then stop the engine and operate the
control levers.
Jr Repeat the above operation 2 - 3 times to release all the remaining pressure.

RELEASING REMAINING
PRESSURE IN HYDRAULIC
TANK
a The hydraulic tank is sealed and pressurized.
When removing the hoses or plugs connected
to the hydraulic tank, do as follows to release
the remaining pressure in the hydraulic tank.
1.

Lower the work equipment


the engine.

2.

Loosen the oil filler cap or oil filler plug slowly to


release the pressure inside the hydraulic tank.

PC1 28US-2

to the ground and stop

20-131
0

TESTING

PROCEDURE

AND ADJUSTING

FOR CHECKING

DIODE

PROCEDURE FOR CHECKING


DIODE
l

1.

Diode

as

individual

Diode

included

Part

Use the following procedure to check the diode


as individual part and the diode included in the
wiring harness.
Use a digital tester with a range for measuring
diodes.
Put the red (+) end of the test pin in contact with
the anode (P) of the diode, and the black (-) end in
contact with the cathode (N).
* There is a mark showing the direction of continuity on the surface of the diode.
* With a normal tester, if it is switched to the
diode range, the voltage of the internal battery is displayed. The value indicates the following.
l
No change : No continuity
l
Changes:
There is continuity (normal) (Note)
0 Value is 0 or near 0:
Short circuit inside diode
Note : In the case of silicon diodes, a value beDependtween 400 and 600 is displayed.
ing on the type of tester, 0.4 - 0.6 may also
be displayed.

in

wiring

harness

I-

TLP00664

BLPO1357

20-132
0

PC128US-2

TESTING AND ADJUSTING

Pm CLINIC INSPECTION TABLE

Pm CLINIC INSPECTION TABLE

PC128US-2 # 5001 and up


Machine Serial No.
Mounted engine

HOUR INSPECTION
Work instruction No.

Date of execution
Day:
Year:

Month:

S4D102E-1

Service meter
hours

Inspector

INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK


Is there abnormality before starting inspection?

What is maximum level of coolant temperature?


(During operation)

....................................................................................................................
....................................................................................................................

White Green Green Green Green Red Red


1
2
3
4
5
6
7

....................................................................................................................

Outside temperature
Max.
Min.

Height

Check of work equipment for damage


Boom foot

Lower part of boom

Arm cylinder bracket

Revolving frame

Good

Bad

Good

Bad

Good

Bad

Other parts

Check of coolant level, oil level, and monitor


Engine coolant

Engine oil

Display of self-diagnosis

Hydraulic oil

Monitor (

Monitor panel

fl If machine is cold, warm it up.


Item

Condition

Unit

Standard
MeasureService limit
value for
ment
Good
value
new machine
result
925 975

rpm

2,340 2,460

Min. 2,100

Min. 2,000

Max. 0.49
{Max. 50}
0.34 0.59
{3.5 6.0}
Min. 0.10
{Min. 1.0}
0.34 0.59
{3.5 6.0}
Min. 0.08
{Min. 0.8}

Max. 0.98
{Max. 100}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}

3.5 4.1

Max. 4.4

2.8 3.4

Max. 3.7

2.9 3.5

Max. 4.0

2.6 3.2

Max. 3.7

1.0 1.6

Max. 2.5

25 2

25 4

Max. 26

Max. 32

Max. 39

Max. 48

Max. 500

Max. 700

Low idling
Engine speed

Engine at full throttle

Engine

Bucket CURL relief


Blow-by pressure

kPa
{mmAq}

Arm IN relief
High idling
SAE30
Low idling

Lubricating oil
pressure

MPa
{kg/cm2}

High idling
SAE10W

Work equipment speed

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

No load applied and


extended to end
Boom in horizontal
position

Bad

Engine at full throttle

Boom and arm in


horizontal positions

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

Rated load applied and engine stopped

mm/15min

20-133
(14)

TESTING AND ADJUSTING

Pm CLINIC INSPECTION TABLE

Oil
pressure

PC128US-2 # 5001 and up


Condition

Item
Low idling

Pc All levers in neutral

Engine at full
throttle

Control oil pressure

All levers in neutral


Boom-RAISE circuit relieved
Arm-IN circuit relieved

Main relief valve and safety valve

Bucket-CURL circuit relieved


Left-swing
circuit relieved
Right-swing
circuit relieved
Right-swing
circuit relieved
Left-swing
circuit relieved

Serial No.
5001 7730

Engine at full
Serial No.
Main oil pressure
7731 and up throttle

Blade-RAISE circuit relieved


Blade-LOWER circuit
relieved
Right-travel-forward circuit
relieved
Right-travel-reverse circuit
relieved
Left-travel-forward circuit
relieved
Left-travel-reverse circuit
relieved
All levers in neutral

Servo piston input


pressure

PC
Bucket-CURL circuit relieved
Control lever in neutral

LS 1-side track running idle


Travel speed: Hi
Travel lever in half position

20-134
(14)

Engine at full
throttle
LS differential
pressure

< >: Reference value


Standard
MeasureService limit
value for
ment
Unit
Good
value
new machine
result
<2.45 3.43> <2.45 3.43>
{<25 35>}
{<25 35>}
3.04 3.43
2.75 3.73
{31 35}
{28 38}
<2.45 3.43>

{<25 35>}

31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
30.4 32.4
28.9 32.9
{310 330}
{295 335}
30.4 32.4
28.9 32.9
{310 330}
{295 335}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
MPa
31.9 33.8
30.9 33.8
{kg/cm2}
{325 345}
{315 345}
30.9 33.8
29.9 34.8
{315 345}
{305 355}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
2.45 4.41
2.45 4.41
{25.0 45.0} {25.0 45.0}
14.5 17.5
13.5 18.4
{148 178}
{138 188}
1.77 3.73

{18.0 38.0}
2.11 2.30
{21.5 23.5}

Bad

PC128US-2

TESTING AND ADJUSTING

Pm CLINIC INSPECTION TABLE

Pm CLINIC INSPECTION TABLE

PC138USLC-2 # 1001 1500


Machine Serial No.
Mounted engine

HOUR INSPECTION
Work instruction No.

Date of execution
Day:
Year:

Month:

S4D102E-1

Service meter
hours

Inspector

INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK


Is there abnormality before starting inspection?

What is maximum level of coolant temperature?


(During operation)

....................................................................................................................
....................................................................................................................

White Green Green Green Green Red Red


1
2
3
4
5
6
7

....................................................................................................................

Outside temperature
Max.
Min.

Height

Check of work equipment for damage


Boom foot

Lower part of boom

Arm cylinder bracket

Revolving frame

Good

Bad

Good

Bad

Good

Bad

Other parts

Check of coolant level, oil level, and monitor


Engine coolant

Engine oil

Display of self-diagnosis

Hydraulic oil

Monitor (

Monitor panel

fl If machine is cold, warm it up.


Item

Condition

Unit

Standard
MeasureService limit
value for
ment
Good
value
new machine
result
925 975

rpm

2,340 2,460

Min. 2,100

Min. 2,000

Max. 0.49
{Max. 50}
0.34 0.59
{3.5 6.0}
Min. 0.10
{Min. 1.0}
0.34 0.59
{3.5 6.0}
Min. 0.08
{Min. 0.8}

Max. 0.98
{Max. 100}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}

3.5 4.1

Max. 4.4

2.8 3.4

Max. 3.7

2.9 3.5

Max. 4.0

2.9 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 at full throttle

Engine

Bucket CURL relief


Blow-by pressure

kPa
{mmAq}

Arm IN relief
High idling
SAE30
Low idling

Lubricating oil
pressure

MPa
{kg/cm2}

High idling
SAE10W

Work equipment speed

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

No load applied and


extended to end
Boom in horizontal
position

Bad

Engine at full throttle

Boom and arm in


horizontal positions

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

Rated load applied and engine stopped

mm/15min

20-135
(17)

TESTING AND ADJUSTING

Pm CLINIC INSPECTION TABLE

Oil
pressure

PC138USLC-2 # 1001 1500


Condition

Item

Low idling

Pc All levers in neutral

Engine at full
throttle

Control oil pressure

All levers in neutral


Boom-RAISE circuit
relieved

Main relief valve and safety valve

Arm-IN circuit relieved


Bucket-CURL circuit
relieved
Right-swing circuit
relieved
Left-swing circuit
relieved
Blade-RAISE circuit
relieved
Blade-LOWER circuit
relieved
Right-travel-forward
circuit relieved
Right-travel-reverse
circuit relieved
Left-travel-forward
circuit relieved
Left-travel-reverse
circuit relieved

Engine at full
throttle

All levers in neutral

PC

Servo piston input


pressure

Bucket-CURL circuit
relieved
Control lever in neutral

LS 1-side track running idle


Travel speed: Hi
Travel lever in half
position

20-136
(17)

Main oil pressure

Engine at full
throttle
LS differential
pressure

< >: Reference value


Standard
MeasureService limit
value for
ment
Unit
Good
value
new machine
result
<2.45 3.43> <2.45 3.43>
{<25 35>}
{<25 35>}
3.04 3.43
2.75 3.73
{31 35}
{28 38}
<2.45 3.43>

{<25 35>}

31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
31.9 33.8
30.9 33.8
{325 345}
{315 345}
MPa
30.9 33.8
29.9 34.8
{kg/cm2} {315 345}
{305 355}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
2.45 4.41
2.45 4.41
{25.0 45.0} {25.0 45.0}
14.5 17.5
13.5 18.4
{148 178}
{138 188}
1.77 3.73

{18.0 38.0}
2.11 2.30
{21.5 23.5}

Bad

PC128US-2

TESTING AND ADJUSTING

Pm CLINIC INSPECTION TABLE

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

INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK


Is there abnormality before starting inspection?

What is maximum level of coolant temperature?


(During operation)

....................................................................................................................
....................................................................................................................

White Green Green Green Green Red Red


1
2
3
4
5
6
7

....................................................................................................................

Outside temperature
Max.

Min.
Height

Check of work equipment for damage


Boom foot

Lower part of boom

Arm cylinder bracket

Revolving frame

Good

Bad

Good

Bad

Good

Bad

Other parts

Check of coolant level, oil level, and monitor


Engine coolant

Engine oil

Display of self-diagnosis

Hydraulic oil

Monitor (

Monitor panel

fl If machine is cold, warm it up.


Item

Condition

Unit

Low idling
Engine speed

1,050 1,150
rpm

Engine at full throttle

Engine

Bucket CURL relief


Blow-by pressure

kPa
{mmAq}

Arm IN relief
High idling
SAE30
Low idling

Lubricating oil
pressure

MPa
{kg/cm2}

High idling
SAE10W
Low idling

Work equipment speed

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

Engine at full throttle

Boom and arm in


horizontal positions

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

Rated load applied and engine stopped

mm/15min

20-137
(17)

TESTING AND ADJUSTING

Pm CLINIC INSPECTION TABLE

PC138US-2
# 4501 and up
PC138USLC-2 # 1501 and up
Bad

Main relief valve and safety valve

Oil
pressure

< >: Reference value


Standard
MeasureService limit
value for
ment
Condition
Item
Unit
Good
value
new machine
result
<2.45 3.43> <2.45 3.43>
Low idling
{<25 35>}
{<25 35>}
Pc All levers in neutral
Control oil pressure
3.04 3.43
2.75 3.73
Engine at full
{31 35}
{28 38}
throttle
<2.45 3.43>

All levers in neutral


{<25 35>}

31.4 32.4
30.9 33.8
Boom-RAISE circuit relieved
{320 330}
{315 345}
31.4 32.4
30.9 33.8
Arm-IN circuit relieved
{320 330}
{315 345}
31.4 32.4
30.9 33.8
Bucket-CURL circuit relieved
{320 330}
{315 345}
26.5 28.4
25.0 28.9
Left-swing
{270 290}
{255 295}
circuit relieved
31.9 33.8
30.9 33.8
Blade-RAISE circuit relieved Engine at full
{325 345}
{315 345}
Main oil pressure
throttle
30.9 33.8
29.9 34.8
Blade-LOWER circuit
MPa
{315 345}
{305 355}
relieved
{kg/cm2}
33.8 35.8
32.9 36.8
Right-travel-forward circuit
{345 365}
{335 375}
relieved
33.8 35.8
32.9 36.8
Right-travel-reverse circuit
{345 365}
{335 375}
relieved
33.8 35.8
32.9 36.8
Left-travel-forward circuit
{345 365}
{335 375}
relieved
33.8 35.8
32.9 36.8
Left-travel-reverse circuit
{345 365}
{335 375}
relieved
2.45 4.41
2.45 4.41
All levers in neutral
{25.0 45.0} {25.0 45.0}
PC
14.5 17.5
13.5 18.4
Bucket-CURL circuit relieved
{148 178}
{138 188}
Servo piston input
pressure
1.77 3.73

Control lever in neutral


Engine at full
{18.0 38.0}
throttle
LS 1-side track running idle
LS differential
2.11 2.30
Travel speed: Hi

{21.5 23.5}
pressure
Travel lever in half position

20-138
(17)

PC128US-2

TROUBLESHOOTING
Points to remember when trobleshooting ............................................................................................ 20-202
Sequence of events in troubleshooting ................................................................................................ 20-203
Points to rememver when carrying out maintenance .......................................................................... 20-204
Checks before troubleshooting .............................................................................................................. 20-212
Connector types and mounting locations ............................................................................................. 20-214
Connector arrangement diagram .......................................................................................................... 20-216
Connection table for connector pin numbers ....................................................................................... 20-219
Functional description of electrical system mechanism (PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) .... 20-231
Monitor panel display and special functions (PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) ................... 20-232
Method of using troubleshooting charts (PC128US-2 Serial No.: 5001 7730) ................................ 20-247
Judgment table for electricl system, hydraulic and mechanical system
(PC128US-2 Serial No.: 5001 7730) ............................... 20-250
How to read decision list (PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up).................................................... 20-252
Method of using troubleshooting charts (PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) .......................... 20-254
Diagnostic contents and diagnostic procedure at troubleshooting
(PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) .......................... 20-256
Troubleshooting of electrical system (E mode) (PC128US-2 Serial No.: 5001 7730) ..................... 20-301
Troubleshooting of hydraulic, mechanical systems (H mode) ............................................................ 20-401
Troubleshooting of machine monitor system (M mode) (PC128US-2 Serial No.: 5001 7730) ........ 20-501
Troubleshooting of machine monitor system (M mode) (PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) ... 20-551
Troubleshooting of communication system (N mode) (PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) ... 20-601
Troubleshooting of controller CR700 [deceleration control system] (E mode)
(PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) ... 20-701
Troubleshooting of controller CR700 [pump control system] (C mode)
(PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) ... 20-801
Troubleshooting of controller CR700 [input signal system] (F mode)
(PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) ... 20-901
Troubleshooting of engine (S mode) ..................................................................................................... 20-951

PC128US-2

20-201
(14)

POINTS

TROUBLESHOOTING

POINTS TO REMEMBER

TO REMEMBER

WHEN

TROUBLESHOOTING

WHEN TROUBLESHOOTING

Stop: the machine


curely fitted.

in a level place, and check that the safety pin, blocks, and parking

brake are se-

When carrying out the operation with two or more workers,


do not allow any unauthorized person to come near.

If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.,

keep strictly to the agreed signals, and

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.

of the battery first.

The aim of troubleshooting


is to pinpoint the basic cause of the failure, to carry out repairs swiftly,
and to prevent reoccurrence of the failure.
When carrying out troubleshooting,
and important point is of course to understand the structure
and function.
However, a short cut to effective troubleshooting
is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms.

1.

2.

3.

When carrying out troubleshooting,


do not
hurry to disassemble the components.
If components are disassembled
immediately
any failure occurs:
.
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
.
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out through
prior investigation
and to carry out troubleshooting in accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occured apart
from the problem that had been reported?
2) Was there anything strange about the machine before tha failure occurred?
3) Did the failure occur suddenly,
or were
there problems with the machine condition
before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred before?
Check before troubleshooting
1) Check the oil level.

20-202
0

2)

4.

5.

6.

Checkfor any external leakage of oil from


the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve
spool.
5) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
Confirming failure
Confirm the extent of the failure yourself,
and judge whether to handle it as a real failure or as a problem with the method of operation, etc.
*
When operating the machine to reenact
the troubleshooting
symptoms, do not
carry out any investigation or measurement that may make the problem worse.
Troubleshooting
Use the results of the investigation
and inspection in Items 2 - 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the
failure exactly.
Ir The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
Measures to remove root cause of failure
Even if the dailure is repaired, if the root
cause of the failure is not repaired, the same
failure will occur again.
To prevent this, always investigate why the
problem occureed. Then, remove the root
cause.
PC1 28US-2

SEQUENCE

TROUBLESHOOTING

SEQUENCE

OF EVENTS

IN TROUBLESHOOTING

OF EVENTS IN TROUBLESHOOTING

TEWOO180

TEW00181

\
step 1
Examination,
1)

When

confirmation

a request

for repairs

ask the following

2)

of symptoms

Name

of customer

Type,

serial number

Details

of jobsite,

Ask questions

is received,

II
-------

first

points.

Ring 1 Ring

__-----

of machine

etc.

to gain an outline

of the prob-

lem.
.

Condition

Work being carried out at the time of the

of failure
TEWM)182

failure

jtep

Operating

Past history,

environment
details

of maintenance,

etc.

2
Determining
1)

location

of cause

Look at the troubleshooting

section

shop

probable

manual

to find

locations

TEWO0183
of the

of possible

causes.

step 3
Preparation
1)

of troubleshooting

tools

Look at the table of troubleshooting


the shop manual

and prepare

=tools in

oa
/step

the necessaw

2)

Hydraulic

7
1.

tools.
.
T-adapter

=z
pressure

gauge

kit, etc.

Look in the parts book and prepare

the nec-

essary replacement

Pinpoint

locations

of failure

(carry out

troubleshooting)

Decide

action to take

1)

Before

starting

repair simple

2)

troubleshooting,

Check before

Other check items

starting

See the Troubleshooting


manual,
that

locate

and

failures.

select

matches

items
Section

of the shop

a troubleshooting
the symptoms,

flowchart

and carry out

troubleshooting.
TEWOO187

Drive

and

operate

the condition

the

and judge

machine

to confirm

if there

is really

Step 4
(Go]

Was there

anything

chine before

strange

the failure

Did the failure


Had any repairs

about

the ma-

occurred?

occur suddenly?
been carried

out before the

TEwoo188

PC128US-2

20-203
0

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE


To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling
electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil).

1. POINTS TO REMEMBER WHEN HANDLING


ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when handling wiring harnesses.

Main failures occurring in wiring harness


(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.

(2) Defective crimping or soldering of connectors


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

20-204
(17)

PC128US-2

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

(3) Disconnections in wiring


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

TEW00194

(4) High-pressure water entering connector


The connector is designed to make it difficult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the connector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be shortcircuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing electricity through it.
(5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
fl When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before cleaning with compressed air.

PC128US-2

TEW00195

TEW00196

20-205
(17)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and


wiring harnesses

Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the connectors apart.
fl Never pull with one hand.
(2) When removing from clips
When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.

Catches

(3) Action to take after removing connectors


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

20-206
(17)

PC128US-2

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

Connecting connectors (DT type connector)


Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female connector
Normal locking state (Horizontal) : a, b, d
Incomplete locking state (Diagonal) : c

PC128US-2

20-207
(17)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Drying wiring harness


If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure water or steam directly on the wiring harness.
If water gets directly on the connector, do as
follows.
(1) Disconnect the connector and wipe off the
water with a dry cloth.
fl If the connector is blown dry with compressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the compressed air before blowing with air.

TEW00196

(2) Dry the inside of the connector with a dryer.


If water gets inside the connector, use a dryer
to dry the connector.
fl Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connector.

TEW00202

(3) Carry out a continuity test on the connector.


After drying, leave the wiring harness disconnected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reassemble.

20-208
(17)

PC128US-2

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box


(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box
unless necessary.

TEW00204

(3) Do not place objects on top of the control


box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
(5) During rainy weather, do not leave the control box in a place where it is exposed to
rain.

TEW00205

(6) Do not place the control box on oil, water,


or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors connected to the control box. Fit an arc welding
ground close to the welding point.

TEW00206

2. Points to remember when troubleshooting electric circuits


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

PC128US-2

20-209
(17)

TROUBLESHOOTING

3.

POINTS

POINTS TO REMEMBER WHEN


HYDRAULIC EQUIPMENT

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

HANDLING

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

1) Be careful of the operating

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

or
or

21 Disassembly

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

3)

Sealing openings
After any piping or equipment
is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leaking oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

TEWOO208

4)

Do not let any dirt or dust get in during refilling


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

20-210
0

PC I 2aus-2

TROUBLESHOOTING

POINTS

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

51 Change hydraulic oil when the temperature

is
high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as possible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants
and sludge in it will mix with
the new oil and will shorten the life of the hydraulic oil.

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

oi I

TEW00710

7)

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

TEW00211

PC 128US-2

20-211
0

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Hydraulic, mechanical equipment

Electrical
equipment

Lubricating oil, coolant

Item

Judgment value

Action

1. Check fuel level, type of fuel

Add fuel

2. Check for impurities in fuel

Clean, drain

3. Check hydraulic oil level

Add oil

4. Check hydraulic strainer

Clean, drain

5. Check swing machinery oil level

Add oil

6. Check engine oil level

Add oil

7. Check coolant level

Add coolant

8. Check dust indicator for clogging

Clean or replace

9. Check hydraulic filter

Replace

1. Check for looseness, corrosion of battery terminal, wiring

Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring

Tighten or replace

3. Check for looseness, corrosion of starting motor terminal,


wiring

Tighten or replace

1. Check for abnormal noise, smell

Repair

2. Check for oil leakage

Repair

3. Carry out air bleeding

Bleed air

24 30V

Replace

2. Check battery electrolyte level

Add or replace

3. Check for discolored, burnt, exposed wiring

Replace

4. Check for missing wiring clamps, hanging wiring

Repair

5. Check for water leaking on wiring (be particularly careful


attention to water leaking on connectors or terminals)

Disconnect
connector and dry

Electrics, electrical equipment

1. Check battery voltage (engine stopped)

6. Check for blown, corroded fuses


7. Check alternator voltage (engine running at 1/2 throttle or
above)

20-212
(17)

After running for


several minutes:
27.5 29.5 V

Replace
Replace

PC128US-2

CONNECTOR TYPES AND MOUNTING LOCATIONS

TROUBLESHOOTING

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
fl The Address column in this table shows the address in the connector pin allocation drawing (3dimensional drawing).
Connector No.

ConnecNo. of
tor
pins
type

Place of use

Address

Connector No.

ConnecNo. of
tor
pins
type

Place of use

Address

PC-EPC valve diode

F-5

A01

Intermediate connector

A-2

D23

KES

A02

Intermediate connector

B-2

D24

KES

Pumping switch diode

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

Ribbon heater relay

R-6

A06

DT

Intermediate connector

A-1

E15

Intermediate connector

N-7

A07

DT

Intermediate connector

A-2

E16

Engine air heater relay

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

Travel/swing alarm (OPT)

H-2

A21

16

Intermediate connector

D-4

F02

Arm crane revolving light

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

Attachment selection connector

E-8

H09

Intermediate connector

F-6

C06 SUMITOMO 16

Prolix switch

D-8

H16

Arm crane buzzer

A-6

C05

DT

Pressure sensor

G-6

K19

Pump prolix resistor

F-8

C10

Arm ground cancel selection

F-8

M02

Safety relay

O-3

C13

EPC valve solenoid for PC

I-8

M10 DEUTSCH

Intermediate connector

G-6

C14

EPC valve solenoid for LS

J-8

M11

Fusible link

L-3

CR1

DT

24

CR700 Controller

F-7

M13

DT

Boom work equipment lamp

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

Window washer diode

F-5

M15

Fusible link

L-3

D05

KES

Swing holding brake diode F-5

M16

Horn

I-2

D06

KES

Travel speed diode

F-5

X
YAZAKI
M22
090

Horn switch

B-7

E07

Engine speed sensor

N-6

M26

SWP

12

A/C unit

E-9

D08

KES

Swing holding brake cancel


switch diode

E-5

M28

Window washer

L-5

D14

SWP

Battery relay diode

L-4

M30

OPT power supply

G-3

D15

Stop solenoid diode

O-7

M31

OPT power supply

D-9

D17

KES

Heater relay diode

E-4

M34

Airconditioner compressor Q-7

D20

KES

PPC hydraulic lock diode

F-5

M36F

Kerosene mode

F-8

D22

SWP

Battery relay diode

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

CONNECTOR TYPES AND MOUNTING LOCATIONS

Place of use

Address

Connector No.

ConnecNo. of
tor
pins
type

Address

Place of use

Light switch

C-8

S17

Engine hydraulic switch

R-4

M40 YAZAKI

Cigar lighter

A-5

S30

Right swing pressure switch

G-4

M40

Cab work equipment lamp (STD)

I-8

S31

Boom RAISE pressure switch G-5

M41

SWP

Arm crane monitor

A-7

S32

Arm dump pressure switch

G-5

M41

Cab work equipment lamp (OPT)

J-8

S33

Boom LOWER pressure switch

G-4

M47

090

20

Intermediate connector

B-7

S34

Bucket digging pressure switch G-5

M48

DT

Auto decelerator motor

L-4

S35

Bucket dump pressure switch G-5

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

Emergency pumping switch D-9


D-9

M71

Room lamp

L-7

S51

Swing holding brake cancel


switch

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

Intake duct (Airconditioner)

F-6

V04

Swing holding brake solenoid

G-7

M84

SWP

14

E-9

V05

Travel speed solenoid

G-8

M85

SWP

16

Intermediate connector
(Airconditioner unit)
Intermediate connector
(Airconditioner unit)

E-9

V06

2-stage relief valve solenoid G-6

M87

12

A/C unit

C-4

V07

PPC hydraulic lock solenoid H-8

M88 YAZAKI

10

B-5

W03

Rear limit switch

K-8

M92

DT

Airconditioner foot spurting


servo
Boom cylinder bottom
pressure sensor

X05

Swing lock switch

D-8

P01

AMP

12

Monitor panel

A-7

P02

AMP

20

Monitor panel

A-6

P03

Buzzer cancel switch

C-8

P06

Fuel level sensor

I-8
O-7

P07

Engine water temperature


sensor

P15

AMP

Solar radiation center

F-6

R06 SINAGAWA

Starting motor cut relay

B-8

R07 SINAGAWA

Motor driven relay

B-3

R08 SINAGAWA

Decelerator relay

B-3

R09 SINAGAWA

Accelerator relay

B-3

R10 SINAGAWA

Revolving light driving relay

B-7

S01

Travel pressure switch

B-4

S05

Arm digging pressure switch

G-5

S08

Left swing pressure switch G-4

S10

Hydraulic lock switch

PC128US-2

E-4

20-218-3
7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DIAGRAM

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

20-218-4
(17)

PC128US-2

CONNECTOR TYPES AND MOUNTING LOCATIONS

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

Engine stop solenoid

Q-2

Intermediate connector

F-4

H09

Intermediate connector

F-4

A-6

H16

Arm crane buzzer

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

Pump prolix resistance

F-7

C06 SUMITOMO

16

Prolix switch

C-7

M02

Safety relay

H-1

C13

EPC valve solenoid (PC)

J-9

M10

DT

Intermediate connector

G-7

C14

EPC valve solenoid (LS)

I-9

M11

Fusible link

L-4

CR1

DT

24

CR 700 controller

F-6

M13

Boom working lamp

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

Air conditioner unit

E-7

M28

KES

Window washer

L-6

M30

Power source (Opt)

F-4

D01

SWP

Engine stop solenoid


Diode Heater relay
F-3

D02

SWP

Swing holding brake


Diode release, Battery relay, F-3
Window washer

2-stage ralief, PPC


safety lock, Swing
Diode holding brake, Travel
speed selector

D03

SWP

E07

Engine speed sensor

M-5

M31

Power source (Opt)

D-7

E11 Terminal

Electrical intake air heater relay

H-1

M34

Air conditioner compressor

Q-8

E12 Terminal

Relay ground

H-1

M38

Light switch

B-7

E14 Terminal

Electrical intake air heater relay

G-2

M40 YAZAKI

Cigarette lighter

A-4

E17

Alternator

N-3

M40

Cab working lamp (STD)

H-9

E30 Terminal

Safety relay

H-3

M41

SWP

Arm crane monitor

A-6

E50 Terminal

Starting motor

Q-4

M41

Cab working lamp (OPT)

J-9

E51 Terminal

Electrical intake air heater relay

G-2

M47

090

20

Intermediate connector

B-6

E52 Terminal

Electrical intake air heater relay

P-9

M48

DT

Auto-decelation motor

L-5

EU1

Overload alarm switch

F-5

M49

PA

Radio

F-5

F01

DT

Travel and swing alarm (Opt)

H-9

M50

Wiper motor

A-5

F02

Arm crane beacon lamp

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)

Engine stop solenoid

Q-2

M71

Room lamp

PC128US-2

CONNECTOR TYPES AND MOUNTING LOCATIONS

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

Air conditioner panel

F-4

T02 Terminal

Revolving ground

L-5

M81

16

Air conditioner panel

F-5

T03 Terminal

Revolving ground

L-5

Intake duct (Air conditioner)

F-6

T04

Radio ground

F-5

F-5

T05 Terminal

Floor ground

C-3

F-7

T06 Terminal

Floor frame ground

B-3

D-3

T21 Terminal

Engine stop solenoid relay

I-1

B-3

T22 Terminal

Engine stop solenoid relay

I-3

M83 SUMITOMO

M84

SWP

14

M85

SWP

16

Intermediate connector
(Air conditioner unit)
Intermediate connector
(Air conditioner unit)

M87

12

Air conditioner unit

M88 YAZAKI

10

PULL Terminal

Engine stop solenoid

Q-2

V03 SHINAGAWA

Starting motor relay

B-6

P01

AMP

12

Monitor panel

A-5

V4

DT

Swing holding brake solenoid valve

G-8

P02

AMP

20

Monitor panel

A-5

V5

DT

Travel speed selector solenoid valve

G-9

P03

Buzzer cancel switch

C-7

V6

DT

2-stage relief solenoid valve

G-8

P06

Fuel level gauge

I-9

V7

DT

PPC hydraulic safety lock solenoid

H-9

P07

Engine coolant temperature sensor P-8

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

Starting motor cutout relay

B-6

V09

Intermediate connector

E-7

R08 SHINAGAWA

Deceleration relay

J-3

W03

Rear limit switch

K-9

R09 SHINAGAWA

Accelerator relay

J-3

X05

Swing lock switch

C-7

R10 SHINAGAWA

Beacon lamp drive relay

B-6

S01

Drive pressure switch

C-3

S05

Arm IN pressure switch

G-6

S08

Left swing pressure switch

G-5

S10

PPC hydraulic lock switch

E-3

S17 Terminal

Engine oil pressure switch

N-4

S30

Right swing pressure switch

G-5

S31

Boom RAISE oil pressure switch

G-6

S32

Boom DUMP oil pressure switch

G-6

S33

Boom LOWER oil pressure switch

G-6

S34

Bucket digging pressure switch

G-6

S35

Bucket DUMP oil pressure switch

G-7

S36

Intermediate connector

G-7

S37

Intermediate connector

G-7

S50

Emergency pump drive switch

D-7

S51

Swing holding brake release switch

D-7

PC128US-2

20-218-9
(17)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DIAGRAM

CONNECTOR ARRANGEMENT DIAGRAM


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

20-218-10
(17)

PC128US-2

TROUBLESHOOTING

PC128US-2

CONNECTOR ARRANGEMENT DIAGRAM

20-218-11
(17)

TROUBLESHOOTING

20-218-12
(17)

CONNECTOR ARRANGEMENT DIAGRAM

PC128US-2

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS


a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
a Deuscht connector has marks of pin numbers on the wiring harness side.
X Type Connector

Number of
Pins

Male (Female housing)

Female (Male housing)

T-adapter Part
Number

Part number: 08055-00181

Part number: 08055-00191

799-601-7010

BWP04702

799-601-7020

Part number: 08055-00282

Part number: 08055-00292

BWP04703

BWP04704

Part number: 08055-00381

BWP04705

Part number: 08055-00481

799-601-7030

Part number: 08055-00391

BWP04706

799-601-7040

Part number: 08055-00491

Terminal part number: 79A-222-3370


Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Terminal part number: 79A-222-3390


Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Terminal part number: 79A-222-3380


Wire size: 2.0
Quantity: 20 pieces
Grommet: red

Terminal part number: 79A-222-3410


Wire size: 2.0
Quantity: 20 pieces
Grommet: red

PC128US-2

20-219
(17)

TESTING AND ADJUSTING

Number of
Pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP Type Connector


Male (Female housing)

BWP04707

Female (Male housing)

BWP04708

799-601-7050

Part number: 08055-10681

BWP04709

Part number: 08055-10881

BWP04711

12

Part number: 08055-11281

BWP04713

Part number: 08055-10691

BWP04710

799-601-7060

Part number: 08055-10891

BWP04712

BWP04714

799-601-7070

Part number: 08055-11481

(17)

799-601-7310

Part number: 08055-11291

14

20-220

T-adapter Part
Number

Part number: 08055-11491

PC128US-2

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP Type Connector

Number of
Pins

Male (Female housing)

BWP04715

16

Part number: 08055-11681

Female (Male housing)

BWP04716

T-adapter Part
Number

799-601-7320

Part number: 08055-11691

Terminal part number:


Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Terminal part number:


Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Terminal part number:


Wire size: 1.25
Quantity: 20 pieces
Grommet: red

Terminal part number:


Wire size: 1.25
Quantity: 20 pieces
Grommet: red

PC128US-2

20-221
(17)

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M Type Connector

Number of
Pins

Male (Female housing)

Female (Male housing)

T-adapter Part
Number

Part number: 08056-00171

Part number: 08056-00181

799-601-7080

BWP04717

Part number: 08056-00271

BWP04719

Part number: 08056-00371

BWP04721

Part number: 08056-00471

BWP04723

Part number: 08056-00671

BWP04725

Part number: 08056-00871

20-222
(17)

BWP04718

799-601-7090

Part number: 08056-00281

BWP04720

799-601-7110

Part number: 08056-00381

BWP04722

799-601-7120

Part number: 08056-00481

BWP04724

799-601-7130

Part number: 08056-00681

BWP04726

799-601-7340

Part number: 08056-00881

PC128US-2

TESTING AND ADJUSTING

Number of
Pins

S Type Connector
Male (Female housing)

BWP04727

Part number: 08056-10871

10
(white)

BWP04729

Part number: 08056-11071

12
(white)

BWP04731

Part number: 08056-11271

16
(white)

BWP04733

Part number: 08056-11671

PC128US-2

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Female (Male housing)

T-adapter
Part Number

BWP04728

799-601-7140

Part number: 08056-10881

BWP04730

799-601-7150

Part number: 08056-11081

BWP04732

799-601-7350

Part number: 08056-11281

BWP04734

799-601-7330

Part number: 08056-11681

20-223
(17)

TESTING AND ADJUSTING

Number of
Pins

10
(blue)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S Type Connector
Male (Female housing)

BWP04735

12
(blue)

BWP04737

Part number: 08056-11272

16
(blue)

BWP04739

Part number: 08056-11672

20-224
(17)

Female (Male housing)

T-adapter Part
Number

BWP04736

BWP04738

799-601-7160

Part number: 08056-11282

BWP04740

799-601-7170

Part number: 08056-11682

PC128US-2

TESTING AND ADJUSTING

Number of
Pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC Type Connector


Male (Female housing)

Female (Male housing)

T-adapter Part
Number

Body part number: 79A-222-2640


(Quantity: 5 pieces)

Body part number: 79A-222-2630


(Quantity: 5 pieces)

11

Body part number: 79A-222-2680


(Quantity: 5 pieces)

Body part number: 79A-222-2670


(Quantity: 5 pieces)

BWP04741

BWP04742

799-601-2710

Body part number: 79A-222-2620


(Quantity: 5 pieces)

BWP04743

Body part number: 79A-222-2610


(Quantity: 5 pieces)

BWP04744

799-601-2950

Body part number: 79A-222-2660


(Quantity: 5 pieces)

BWP04745

Body part number: 79A-222-2650


(Quantity: 5 pieces)

BWP04746

13

799-601-2720

Body part number: 79A-222-2710


(Quantity: 2 pieces)

PC128US-2

Body part number: 79A-222-2690


(Quantity: 2 pieces)

20-225
(17)

TESTING AND ADJUSTING

Number of
Pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC Type Connector


Male (Female housing)

BWP04747

Female (Male housing)

BWP04748

17

799-601-2730

Body part number: 79A-222-2730


(Quantity: 2 pieces)

BWP04749

Body part number: 79A-222-2720


(Quantity: 2 pieces)

BWP04750

21

20-226
(17)

T-adapter Part
Number

799-601-2740

Body part number: 79A-222-2750


(Quantity: 2 pieces)

Body part number: 79A-222-2740


(Quantity: 2 pieces)

Body part number: 79A-222-2770


(Quantity: 50 pieces)

Body part number: 79A-222-2760


(Quantity: 50 pieces)

PC128US-2

TESTING AND ADJUSTING

Number of
Pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 Type Connector


Male (Female housing)

BWP04751

Female (Male housing)

T-adapter Part
Number

BWP04752

799-601-7180

Housing part number: 79A-222-3430


(Quantity: 5 pieces)

BWP04753

BWP047544

12

799-601-7190

Housing part number: 79A-222-3440


(Quantity: 5 pieces)

BWP04755

BWP04756

16

799-601-7210

Housing part number: 79A-222-3450


(Quantity: 5 pieces)

BWP04757

BWP04758

20

799-601-7220

Housing part number: 79A-222-3460


(Quantity: 5 pieces)

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

PC128US-2

20-227
(17)

TESTING AND ADJUSTING

Number of
Pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 Type Connector


Male (Female housing)

Female (Male housing)

10

799-601-7510

12

BWP04761

14

BWP04763

18

BWP04765

20

BWP04767

20-228
(19)

T-adapter Part
Number

Part number: 7821-92-7330

BWP04762

799-601-7520

Part number: 7891-92-7340

BWP04764

799-601-7530

Part number: 7891-92-7350

BWP04766

799-601-7540

Part number: 7891-92-7360

BWP04768

799-601-7550

Part number: 7891-92-7370

PC128US-2

TESTING AND ADJUSTING

Number of
Pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L Type Connector
Male (Female housing)

BWP04769

Female (Male housing)

BWP04770

Number of
Pins

10

Male (Female housing)

BWP04771

Female (Male housing)

T-adapter
Part Number

BWP04772

BENDIX (MS) Type Connector

Male (Female housing)

BWP04773

PC128US-2

PA Type Connector

Number of
Pins

T-adapter
Part Number

Female (Male housing)

T-adapter Part
Number

BWP04774

799-601-3460

20-229
(17)

TESTING AND ADJUSTING

Number of
Pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES1 Automobile Type Connector


Male (Female housing)

BWP04775

Female (Male housing)

BWP04776

Part number: 08027-10210 (Natural color)


08027-10220 (Black)

BWP04777

Part number: 08027-10310

BWP04779

Part number: 08027-10260 (Natural color)


08027-10270 (Black)

BWP04778

BWP04780

Part number: 08027-10410 (Natural color)


08027-10420 (Black)

BWP04781

Part number: 08027-10460 (Natural color)


08027-10470 (Black)

BWP04782

Part number: 08027-10610 (Natural color)


08027-10620 (Black)

(17)

Part number: 08027-10360

20-230

T-adapter
Part Number

Part number: 08027-10660 (Natural color)


08027-10670 (Black)

PC128US-2

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES1 Automobile Type Connector

Number of
Pins

Male (Female housing)

Female (Male housing)

T-adapter
Part Number

BWP04784

BWP04783

Part number: 08027-10810 (Natural color)


08027-10820 (Black)

Number of
Pins

Part number: 08027-10860 (Natural color)


08027-10870 (Black)

Connector for relay (Socket)


Male (Female housing)

BWP04785

Female (Male housing)

BWP04786

799-601-7360

BWP04787

BWP04788

799-601-7370

Type
(shell
size
code)

F Type Connector

Pin (Male terminal)

Body (Female terminal)

T-adapter
Part Number

PC128US-2

T-adapter Part
Number

20-230-1
(17)

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part
Number

799-601-9210

18-8
(1)

Part number: 08191-11201, 08191-11202


08191-11205, 08191-11206
Pin (female terminal)

Part number: 08191-14101, 08191-14102


08191-14105, 08191-14106
Pin (male terminal)

799-601-9210

Part number: 08191-11201, 08191-12202


08191-11205, 08191-12206
Pin (male terminal)

Part number: 08191-13101, 08191-13102


08191-13105, 08191-13106
Pin (female terminal)

799-601-9220

18-14
(2)

Part number: 08191-21201, 08191-12202


08191-21205, 08191-12206
Pin (female terminal)

Part number: 08191-24101, 08191-24102


08191-24105, 08191-24106
Pin (male terminal)

799-601-9220

Part number: 08191-22201, 08191-22202


08191-22205, 08191-22206

20-230-2
(17)

Part number: 08191-23101, 08191-23102


08191-23105, 08191-23106

PC128US-2

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part
Number

799-601-9230

18-20
(3)

Part number: 08191-31201, 08191-31202


Pin (female terminal)

Part number: 08191-34101, 08191-34102


Pin (male terminal)

799-601-9230

Part number: 08191-32201, 08191-32202


Pin (male terminal)

Part number: 08191-33101, 08191-33102


Pin (female terminal)

799-601-9240

18-21
(4)

Part number: 08191-41201, 08191-42202


Pin (female terminal)

Part number: 08191-44101, 08191-44102


Pin (male terminal)

799-601-9240

Part number: 08191-42201, 08191-42202

PC128US-2

Part number: 08191-43101, 08191-43102

20-230-3
(17)

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part
Number

799-601-9250

24-9
(5)

Part number: 08191-51201, 08191-51202


Pin (female terminal)

Part number: 08191-54101, 08191-54102


Pin (male terminal)

799-601-9250

Part number: 08191-52201, 08191-52202


Pin (male terminal)

Part number: 08191-53101, 08191-53102


Pin (female terminal)

799-601-9260

24-16
(6)

Part number: 08191-61201, 08191-62202


08191-61205, 08191-62206
Pin (female terminal)

Part number: 08191-64101, 08191-64102


08191-64105, 08191-64106
Pin (male terminal)

799-601-9260

Part number: 08191-62201, 08191-62202


08191-62205, 08191-62206

20-230-4
(17)

Part number: 08191-63101, 08191-63102


08191-63105, 08191-63106

PC128US-2

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell size
code)

HD30 Series connector


Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part
Number

799-601-9270

24-21
(7)

Part number: 08191-71201, 08191-71202


08191-71205, 08191-71206
Pin (female terminal)

Part number: 08191-74101, 08191-74102


08191-74105, 08191-74106
Pin (male terminal)

799-601-9270

Part number: 08191-72201, 08191-72202


08191-72205, 08191-72206
Pin (male terminal)

Part number: 08191-73102, 08191-73102


08191-73105, 08191-73106
Pin (female terminal)

799-601-9280

24-23
(8)

Part number: 08191-81201, 08191-81202,


08191-81203, 08191-81204,
08191-81205, 08191-80206
Pin (female terminal)

Part number: 08191-84101, 08191-84102,


08191-84103, 18191-84104,
08191-84105, 08191-84106
Pin (male terminal)

799-601-9280

Part number: 08191-82201, 08191-82202,


08191-82203, 08191-82204,
08191-82205, 08191-82206

PC128US-2

Part number: 08191-83101, 08191-83102,


08191-83103, 18191-83104,
08191-83105, 08191-83106

20-230-5
(17)

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part
Number

799-601-9290

24-31
(9)

Part number: 08191-91203, 08191-91204


08191-91205, 08191-91206
Pin (female terminal)

Part number: 08191-94103, 08191-94104


08191-94105, 08191-94106
Pin (male terminal)

799-601-9290

Part number: 08191-92203, 08191-92204


08191-92205, 08191-92206

20-230-6
(17)

Part number: 08191-93103, 08191-93104


08191-93105, 08191-93106

PC128US-2

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector

Number
of Pins

Body (plug)

Body (receptacle)

T-adapter Part
Number

799-601-9020

Part number: 08192-12200 (normal type)


08192-22200 (fine wire type)

Part number: 08192-12100 (normal type)


08192-22100 (fine wire type)

799-601-9030

Part number: 08192-13200 (normal type)


08192-23200 (fine wire type)

Part number: 08192-13100 (normal type)


08192-23100 (fine wire type)

799-601-9040

Part number: 08192-14200 (normal type)


08192-24200 (fine wire type)

Part number: 08192-14100 (normal type)


08192-24100 (fine wire type)

799-601-9050

Part number: 08192-16200 (normal type)


08192-26200 (fine wire type)

PC128US-2

Part number: 08192-16100 (normal type)


08192-26100 (fine wire type)

20-230-7
(17)

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector

Number
of Pins

Body (plug)

Body (receptacle)

8GR:
799-601-9060
8B:
799-601-9070
8G:
799-601-9080
8BR:
799-601-9080

Part number: 08192-1820 T (normal type)


08192-2820 T (fine wire type)

Part number: 08192-1810 T (normal type)


08192-2810 T (fine wire type)

12GR:
799-601-9110
12B:
799-601-9120
12G:
799-601-9130
12BR:
799-601-9140

12

Part number: 08192-1920 T (normal type)


08192-2920 T (fine wire type)

20-230-8
(17)

T-adapter Part
Number

Part number: 08192-1910 T (normal type)


08192-2910 T (fine wire type)

PC128US-2

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DTM Series connector

Number
of Pins

Body (plug)

Body (receptacle)

T-adapter Part
Number

799-601-9010

Part number: 08192-02200

Part number: 08192-02100

DTHD Series connector

Number
of Pins

Body (plug)

Body (receptacle)

T-adapter Part
Number

Part number:08192-31200 (Contact size #12)


08192-41200 (Contact size #8)
08192-51200 (Contact size #4)

PC128US-2

Part number:08192-31100 (Contact size #12)


08192-41100 (Contact size #8)
08192-51100 (Contact size #4)

20-230-9
(17)

TESTING AND ADJUSTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
No. of
pins

DRC26 Series connector


Body (plug)

Body (receptacle)

24

799-601-9360

Part No.: 7821-93-3110

40
(A)

799-601-9350

Part No.: 7821-93-3120

40
(B)

799-601-9350

20-230-10
(19)

T-adapter
Part No.

Part No.: 7821-93-3130

PC128US-2

TESTING AND ADJUSTING

T-ADAPTER TABLE

T-ADAPTER TABLE
a The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker assemblies are shown in the lines.

Q Q

Q Q

799-601-9300

799-601-9200

799-601-9100

799-601-2600

For measuring box

Econo-21P

799-601-3100

For measuring box

MS-37P

799-601-3200

For measuring box

MS-37P

799-601-3300

For measuring box

Econo-24P

799-601-3360

Plate

For MS box

799-601-3370

Plate

For MS box

799-601-3380

Plate

For MS box

799-601-3410

BENDIX(MS)

24P

Q Q

799-601-3420

BENDIX(MS)

24P

Q Q

799-601-3430

BENDIX(MS)

17P

Q Q

799-601-3440

BENDIX(MS)

17P

799-601-3450

BENDIX(MS)

5P

799-601-3460

BENDIX(MS)

10P

799-601-3510

BENDIX(MS)

5P

Q Q

799-601-3520

BENDIX(MS)

14P

Q Q

799-601-3530

BENDIX(MS)

19P

799-601-2910

BENDIX(MS)

14P

799-601-3470

CASE

799-601-2710

MIC

5P

Q Q

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)

TESTING AND ADJUSTING

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

TESTING AND ADJUSTING

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 measuring box

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

For NE, G sensor

2P

799-601-9420

For boost pressure, fuel

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

FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM

FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM


MECHANISM
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
This electrical system control mechanism consists of a monitor panel and a controller. The monitor
panel and CR700 controller input signals each requires. On the other hand, the CR700 controller outputs
necessary signals or inputs in accordance with the signals selected by the monitor panel and controls the
absorption torque of the pump and the engine output.

Network information
1) Work mode (A, E, B) information
2) Auto-decelerator (ON/OFF) signal
3) Travel Hi/Lo signal
4) Coolant temperature (coolant temperature) information
5) Service code (failure code) information
PC128US-2

(Monitor panel CR700 controller)


(Monitor panel CR700 controller)
(Monitor panel CR700 controller)
(Monitor panel CR700 controller)
(CR700 controller Monitor panel)

20-231
(17)

TROUBLESHOOTING

FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
This electrical system control mechanism consists of a monitor panel and a controller. The monitor
panel and CR700 controller input signals each requires. On the other hand, the CR700 controller outputs
necessary signals or inputs in accordance with the signals selected by the monitor panel and controls the
absorption torque of the pump and the engine output.

Network information
1) Work mode (A, E, B) information
2) Auto-decelerator (ON/OFF) signal
3) Travel Hi/Lo signal
4) Coolant temperature (water temperature) information
5) Service code (failure code) information
6) Preheating signal

20-232
(17)

(Monitor panel CR700 controller)


(Monitor panel CR700 controller)
(Monitor panel CR700 controller)
(Monitor panel CR700 controller)
(CR700 controller Monitor panel)
(CR700 controller Monitor panel)
PC128US-2

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS


PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
1. Lamp/Gauge/Buzzer Diagnostic Function
When the starting switch is turned ON, all lamps and gauges come on for about three seconds and
the warning buzzer sounds for about one second. The diagnosis of the monitor panel itself is performed and normal display is performed subsequently (a burnt-out bulb can be seen in the lamp that
does not come on by visual check).
2. USER CODE display function
The abnormality information of the CR700 controller is all sent to the monitor panel.
For this abnormality information having high emergency, a USER CODE is automatically displayed
on the digital meter display portion (1) of the monitor panel as the USER CODE and the operator is
urged to take corrective action.
fl The portion other than the digital meter display portion (1), service meter display portion (2), and
the point where lighting is performed ( portion in the following illustration) come out.
1) User code display
(1) Digital meter display portion
(2) Service meter display portion
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-decelerator switch
(8) Buzzer cancel switch

Example) When user code [E02] is displayed:

2) User code list


User code

PC128US-2

Abnormal system

E02

PC-EPC system

E03

Swing holding brake system

E05

Decelerator motor system

20-233
(17)

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

3. SERVICE CODE Display Function


The abnormality information of the CR700 controller is all sent to the monitor panel.
This abnormality information is all stored in the monitor panel as a SERVICE CODE independently
of the information that needs to or does not need to display the SERVICE CODE).
When the following operation is performed, a service code is displayed on the digital display portion
of the monitor panel and E indicating that an abnormality is currently occurring and an elapsed
time (service meter time) are displayed on the service meter display portion.
1) Service code display and cancel method
(1) Use the following procedure to switch to
a service code.
i) Continue pressing Buzzer cancel
switch (8) + Auto-decelerator switch
(7) for 2.5 seconds or more.
ii) Press Buzzer cancel switch (8) +
Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4) and set them so
that 01 can be displayed on the second or third digit from the left of service meter display portion (2).
iii) Press Setting switch (5).

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Digital meter display portion


Service meter display portion
Working mode selector (UP) switch
Working mode selector (DOWN) switch
Setting switch
Travel speed switch
Auto decelerator switch
Buzzer cancel switch

Example 1) When [01] is displayed on service meter display portion (2):

Example 2) When [E213] occurred six hours


before:
fl If it is also occurring currently, E is displayed on
the third digit from the left of
service meter display portion
(2). When it is normal currently, E is not displayed.
fl An elapsed time is displayed
on the third digit from the
right of service meter display
portion (2).

20-234
(17)

PC128US-2

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

Example 3) If a service code is not stored,


is displayed on all digits
of digital meter display portion
(1) and service meter display
portion (2).
(2) To advance the display of a service code,
press Buzzer cancel switch (8) + Working mode selector (UP) switch (3).
(3) To return the display of a service code,
press Buzzer cancel switch (8) + Working mode selector (DOWN) switch (4).
(4) To terminate the display of a service code,
press Buzzer cancel switch (8) + Autodecelerator switch (7).
(5) To erase storage of a service code, turn
OFF Starting switch once pressing
Buzzer cancel switch (8). Turn ON the
Starting switch again and continue
pressing Buzzer cancel switch (8) for
five seconds as is.
fl If service codes stored exceed 20, the
smallest one is erased sequentially.

2) Service code list


Service code

PC128US-2

Abnormality system

User code

E101

Incorrect description contents

E108

Detection of engine water temperature exceeding 105C

E112

Wiper motor driven forward rotation system short circuit

E113

Wiper drive reverse rotation system short circuit

E114

Window washer drive system short circuit

E115

Washing is disabled for 10 seconds

E116

Storage is disabled for 10 seconds

E203

Swing holding brake solenoid system short circuit

E205

2-stage relief solenoid system short circuit

E206

Travel Hi/Lo selector solenoid system short circuit

E213

Swing holding brake solenoid relay system disconnection

E215

2-stage relief solenoid system disconnection

E216

Travel Hi/Lo selector solenoid system disconnection

E218

S-NET communication error

E222

LS-EPC system short circuit

E02

E223

LS-EPC system disconnection

E02

E03

E03

20-235
(17)

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

Service code

20-236
(17)

Abnormality system

User code

E224

Pump pressure sensor system error

E226

Pressure sensor system power failure

E227

Engine speed sensor system error

E232

PC-EPC solenoid system short circuit

E02

E233

PC-EPC solenoid system disconnection

E02

E241

Boom angle potentiometer system error (beyond input value range)

E242

Arm angle potentiometer system error (beyond input value range)

E255

Boom angle potentiometer corrected value error


(beyond correction value range)

E256

Checksum error

E306

Feedback potentiometer system error

E308

Fuel dial input value error

E315

Battery relay output short circuit abnormality

E316

Decelerator motor out of order abnormality

E317

Decelerator motor system disconnection abnormality

E05

E318

Decelerator motor system short circuit abnormality

E05

E05

PC128US-2

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

4. MONITORING CODE Display Function


Input signals from sensors into each component and output signals that drive solenoids can be
checked in real time using a monitoring code.
When the following operation is performed, a 4-digit monitoring code No. is displayed on the second
to fifth digit from the left of service meter display portion (2) of the monitor panel and monitoring
information is displayed on digital meter display portion (1).

1) Monitoring code display method


(1) Use the following procedure to switch to
a monitoring code.
i) Continue pressing Buzzer cancel
switch (8) + Auto decelerator switch
(7) for 2.5 seconds or more.
ii) Press Buzzer cancel switch (8) +
Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4)) and set them so
that 02 can be displayed on the second or third digit from the left of service meter display portion (2).
iii) Press Setting switch (5).

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Digital meter display portion


Service meter display portion
Working mode selector (UP) switch
Working mode selector (DOWN) switch
Setting switch
Travel speed switch
Auto decelerator switch
Buzzer cancel switch

Example 1) When monitoring code 1010 (engine speed: 2,050 rpm) displayed
using a numeral is displayed:

Example 2) When monitoring code 1020


(switch input state (1)) displayed
using a bit pattern is displayed:

PC128US-2

20-237
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MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

(2) To advance the display of a service code,


press Buzzer cancel switch (8) + Working mode selector (UP) switch (3).
(3) To return the display of a service code,
press Buzzer cancel switch (8) + Working mode selector (DOWN) switch (4).
(4) To terminate the display of a service code,
continue pressing Buzzer cancel switch
(8) + Auto-decelerator switch (5) for 2.5
seconds or more.
2) Monitoring code list
fl For details of the code displayed in the unit column as (6 bits), refer to the bit pattern list.
Display code
0008
0041
0042
0043
0045
0046
0047
0048
0049
0200
1000
1001
1002
1003
1004
1016
1027
1028
1036
1061
1010
1020
1021
1022
1023
1024
1025
1026
1030
1032
1034
1035
1040
1042
1050
1054
1060

Description
S-NET connected state
Water temperature sensor voltage
Fuel sensor voltage
Charge voltage
Sensor input 1
Sensor input 2
Output state
Wiper state
Reserved
Program version (Monitor)
Software version No.
Attachment selection
Model selection
Attachment code
(*1)
Option selection state
(*1)
Second throttle command
(*1)
ON/OFF input 5
(*1)
ON/OFF input 6
(*1)
Power supply voltage
(*1)
ON/OFF output
(*1)
Engine speed
ON/OFF input 1
ON/OFF input 2
ON/OFF input 3
ON/OFF input 4
ON/OFF input and output
ON/OFF input and output
ON/OFF input and output
Work equipment angle sensor voltage First boom
Work angle sensor voltage Arm
Fuel dial voltage
Feedback potentiometer voltage
Boom bottom voltage
Pump pressure
EPC output current PC-EPC
EPC output current LS-EPC
ON/OFF output

Unit

Component name

(6bit)
10 mV
10 mV
100 mV
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)

(6bit)
rpm
(6bit)
(6bit)
V
(6bit)
rpm
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
V
V
V
V
MPa
MPa
10 mA
10 mA
(6bit)

CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller

(*1) PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up

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PC128US-2

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

3) Bit pattern list (The bit of the corresponding


No. comes on.)
fl [1] to [6] of digital display portion (1) indicate a bit No.
fl A monitoring code No. (four digits) is displayed on the second to fifth digit from
the left of service meter display portion
(2).

Code No.

Item

0008

S-NET connected state

0045

Sensor input 1

0046

Sensor input 2

0047

Output state

0048

Wiper state

0049

Standby

PC128US-2

Bit
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]

Detailed description (state when a bit comes on)


At ID2 connection
At ID3 connection
At ID4 connection
At ID5 connection
At ID6 connection
At ID7 connection
Starting switch ON
(ON)
Starting switch Start
(Start) (ON)
Starting switch Preheat
(ON)
Light switch
(ON)

Engine oil pressure


Engine oil level

(At OPEN time)


(At OPEN time)

Charge level
Buzzer output

(At decrease time)


(ON)

Washer output
Wiper output 1
Wiper output 2
Wiper output 3
Wiper output 4
Swing lock switch
Buzzer cancel switch
Widow limit switch
W contact
P contact

(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)

20-239
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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

ON/OFF input and


output

1025

1026

20-240
(17)

ON/OFF input and


output

ON/OFF input and


output

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

Bit
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]

Detailed description (state when a bit comes on)


Arm crane mounting

(*1)

Arm ground angle warning cancel

(*1)

ATT selection 2
ATT selection 1
Model selection 1
ATT selection 3
UU/US selection
Model selection 2

(At GND connection)


(At GND connection)
(At GND connection)
(At GND connection)
(At GND connection)
(At GND connection)

Arm crane mounting

(At power supply connection)

Kerosene mode
Travel selector switch (Panel)
Working mode selector switch
Back lamp
SET/CLEAR switch
Mode selector () switch
Mode selector () switch

(At GND connection)

Another work equipment mode selector switch (ON)


Travel pressure switch
(ON)
Swing pressure switch
(ON)
Arm digging pressure switch
(ON)
Boom RAISE pressure switch
(ON)

Motor-driven power supply

(*1)

Motor relay ()
Motor relay (+)
Crane mode switch [monitor]
Display selector switch [monitor]
Arm ground angle warning cancel switch (At connector connection)

Bucket dump inhibition solenoid + Patlight (At relay output)


Warning cancel

(For EU)

PC128US-2

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

TROUBLESHOOTING

Code No.

1027

1028

1060

1061

PC128US-2

Item

ON/OFF input 5

ON/OFF input 6

ON/OFF output

ON/OFF output

Bit
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]

Detailed description (state when a bit comes on)

Preheating signal

(*1)

C-terminal signal

(*1)

Arm OUT pressure switch


Service pressure switch
Bucket digging pressure switch
Bucket DUMP pressure switch

(*1)
(*1)
(*1)
(*1)

Swing holding brake

(At brake release)

Travel 2nd speed


Travel or swing alarm
2-stage relief

(At travel 2nd speed)


(At alarm output)
(At travel pressure switch ON)

Heater relay

(*1)

20-241
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TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

5. WORKING MODE DEFAULT Setting Function


When the normal starting switch is turned ON, the WORKING MODE of the monitor panel is set so
that Mode A can come out. If the following procedures are used to use the default setting function,
the setting can be changed so that startup can be performed in the WORKING MODE in accordance with the choice of the operator.

1) Default setting operation procedures


(1) Use the following procedure to switch to
the default setting mode.
i) Continue pressing Buzzer cancel
switch (8) + Auto-decelerator switch
(7) for 2.5 seconds or more.
ii) Press Buzzer cancel switch (8) +
Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4)) and set them so
that 05 can be displayed on the second or third digit from the left of service meter display portion (2).
iii) Press Setting switch (5).
fl d SET is displayed on service
meter display portion (2) and indicator (10) of the mode set as a
default value flashes.
(2) To change (move) the default setting
mode,
i) press Working mode selector (UP)
switch (3) (or Working mode selector
(DOWN) switch (4)).
ii) Press Setting switch (5).

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Digital meter display portion


Service meter display portion
Working mode selector (UP) switch
Working mode selector (DOWN) switch
Setting switch
Travel speed switch
Auto decelerator switch
Buzzer cancel switch

(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
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PC128US-2

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

(4) Confirmation method after working default setting


i) Check that the LED is changed to normal lighting.
ii) Turn OFF the starting switch and turn
on the starting switch again.
iii) Check that the working mode default
is changed to the setting state.

6. Decelerator Motor Adjustment Mode


PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
This mode is used to adjust the decelerator motor and the injection pump linkage.
fl For details, refer to the TESTING AND ADJUSTING DECELERATOR MOTOR LEVER
STROKE of Testing and Adjustment Volume.
1) Decelerator motor adjustment mode display
method
(1) Use the following procedure to switch to
the Decelerator motor adjustment mode.
i) Continue pressing Buzzer cancel
switch (8) + Auto-decelerator switch
(7) for 2.5 seconds or more.
ii) Press Buzzer cancel switch (8) +
Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4)) and set them so
that 03 can be displayed on the second or third digit from the left of service meter display portion (2).
iii) Press Setting switch (5).
ii)
fl GOV is displayed on digital display portion (1) and GSET is displayed on service meter display
portion (2).

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Digital meter display portion


Service meter display portion
Working mode selector (UP) switch
Working mode selector (DOWN) switch
Setting switch
Travel speed switch
Auto-decelerator switch
Buzzer cancel switch

(2) To terminate the display of a service code,


continue pressing Buzzer cancel switch
(8) + Auto-decelerator switch (7) for 2.5
seconds or more.

PC128US-2

20-243
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TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

7. Governor motor adjustment mode


PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
fl Use this mode to set the engine governor lever fully.
fl Set the deceleration motor cable to the engine high idling position (to the shortest position).
fl When the starting switch is turned ON, if this mode is not selected, the governor motor may not
operate.
Reference
If a short circuit or a grounding fault occurs in the circuit of the governor motor control system, the
cable may move out of the normal control range. At this time, even if the cause of the trouble is
removed, the governor motor cannot be controlled.
If this occurs, operate the panel switch in this mode to return the cable into the normal control range
to restore the governor motor control.
No.
Operation
1 1) Turn the starting switch ON and set the fuel control dial to the
FULL position.
At this time, turn the automatic decelerator (one-touch decelerator) OFF (reset it).

Display

2) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds.
3) Set the code in the service meter section to "03".
(8) + (3): Next code
(8) + (4): Previous code

[GOV] is displayed on display portion (1),


[GSET] is displayed on service meter portion
(2).

4) Press switch (5).


* Under this condition, the deceleration motor cable is at the
engine high idling position (It becomes shortest).
2 <Function of restoring governor control>
Use this function for only above purpose (2).
(Do not use this function usually.)
Be sure to remove the cause of the trouble before using this
function.
5)-1 When engine speed does not rise from low idling
Press switch (3) several times and operate the fuel control
dial to check that the governor control is restored.
5)-2 When engine speed does not lower from high idling
Press switch (4) several times and operate the fuel control
dial to check that the governor control is restored.
3 To finish the governor motor adjustment mode, perform the operation in 1-2), and the monitor panel displays normally.

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PC128US-2

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

8. Boom Angle Potentiometer Correction Mode


(Only at Arm Crane)
This mode is used to adjust the boom angle potentiometer.
1) Boom Angle Potentiometer Correction Mode
display method
(1) Use the following procedure to switch to
the boom angle potentiometer correction
mode.
i) Continue pressing Buzzer cancel
switch (8) + Auto decelerator switch
(7) for 2.5 seconds or more.
ii) Press Buzzer cancel switch (8) +
Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4)) and set them so
that 06 can be displayed on the second or third digit from the left of service meter display portion (2).
iii) Press Setting switch (5).
fl Check that 1 SET is displayed
on service meter display portion
(1) (the central three segments of
digital display portion (1) flash).

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Digital meter display portion


Service meter display portion
Working mode selector (UP) switch
Working mode selector (DOWN) switch
Setting switch
Travel speed switch
Auto decelerator switch
Buzzer cancel switch

(2) Use the following procedure to adjust the


boom angle potentiometer correction
mode.
i) After switching to the mode of item
i), start the engine and operate
Boom to the RAISE side stroke end.
fl -- (correctable range) or ---
(uncorrectable range) flashes on
the digital display portion.
fl For the correctable range, because
incorrect mounting of the boom
angle potentiometer is assumed,
check it.
ii) Press setting switch (5) for three seconds or more.
fl The same item as item i) flashes
on digital meter display portion
(1).

PC128US-2

20-245
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MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

iii) When normal adjustment can be


made (when the boom angle belongs
to a theoretical value,
is displayed on digital meter display portion (2) for five seconds and processing returns to item i) (boom angle potentiometer correction mode).
fl When correction was disabled,
--- flashes (buzzer sounds five
times) on digital portion (2) and
processing returns to item i).
fl If correction is impossible, because incorrect mounting of the
boom angle potentiometer is assumed, check it.

20-246
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PC128US-2

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

9. Display and Setting of OIL MAINTENANCE FUNCTION


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

1) Display of oil maintenance function


(1) The oil maintenance display mode is automatically displayed when the setting
time exceeds minus 10 hours as described above.
(2) To terminate the oil maintenance function
(within 20 seconds after the starting
switch is turned ON), pressing setting
switch (5) short returns to the normal display mode.
Example) When the oil replacement interval
setting of 250 hours and the
elapsed time of 245 hours after oil
is replaced are displayed:

PC128US-2

20-246-1
(19)

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

2) Setting of interval time and resetting of


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

20-246-2
(17)

(1)
(2)
(3)
(4)
(5)
(6)

Digital meter display portion


Service meter display portion
Working mode selector (UP) switch
Setting switch
Travel speed switch
Auto-decelerator switch

PC128US-2

TROUBLESHOOTING

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

(2) Confirmation of elapsed time


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

PC128US-2

20-246-3
(17)

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

TROUBLESHOOTING

10. Setting model and attachment


Set the specification of machine model and attachment.
(PC128US with standard arm does not need this setting)
No.
Operation
1 1) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds.
2) Set the code in the service meter section to "19".
(8) + (3): Next code
(8) + (4): Previous code
3) Press switch (5).

Display
Display section displays "10" and service
meter section displays "19SET".
(If 19SET has been set, current set value is
displayed in display section.)
Display

Service
meter

2 1) Set the value in the display section to a desired value.


Set value

Model

ATT

Remarks

10

PC128US

Standard arm

Controller default

11

PC128US

Long arm

20

PC138US

Standard arm

21

PC138US

Long arm

(8) + (3): Next code


(8) + (4): Previous code

When PC138US long arm is selected

Display

After switch (5) is pressed, display section


displays "000", and then "---"

2) Press switch (5).


Display

3 1) To finish selection of model and attachment


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

B: The buzzer cancel switch is installed on the right console.

20-246-4
(19)

PC128US-2

MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

TROUBLESHOOTING

11. Service adjustment


This service adjustment is set for adjustment of dispersion of components and parts and for replay to
requests of each user. Perform this adjustment for the following phenomena and users' requests.
fl Basically, the following items do not need to be adjusted, since they are adjusted when delivered.
fl This service adjustment is not effective when a component or a part is broken.
1) Service adjustment items table
The phenomena of the machine which need service adjustment, procedure for changing the set
values, and precautions are listed.
fl Usually, each adjustment value is set to the initial value.
Adjustment Phenomenon of machine/ Procedure for changing
Precautions
code/set value
Users' request
set value
Engine speed lowers
Change set value to
204
Adjust to degree that work
largely during work.
decrease pump absorp- equipment cycle time is not
tion torque.
lengthened.

Service adjustment item


Adjustment of
PC-EPC valve
current

Work equipment speed


is low.

Change set value to


increase pump absorption torque.

Adjust to degree that engine


speed is not lowered largely.
Alarm sounds when machine
travels or swings.

Travel/Swing
alarm output
(If travel alarm is
installed)

210

Set for each user who


wants to sound alarm
during swinging.

Set to 211.

Adjustment of
LS-EPC valve
current

264

Engine speed lowers


largely during work.

Change set value to


Adjust to degree that work
decrease pump absorp- equipment cycle time is not
tion torque.
lengthened.
fl Perform this when adjustment with PC-EPC valve
current is insufficient.
fl Even if LS-EPC valve
current is not increased
even if adjusted toward
positive (+) side.

310

Change fuel.
When kerosene is
used, engine speed
lower largely.

310: Diesel fuel

Low idling speed is


remarkably high.

Set to () side.

Low idling speed is


remarkably low.

Set to (+) side.

Type of fuel

Adjustment of
low idling speed
*

324

Adjustment of
arm crane mode
speed
*

334

Adjustment of Emode speed


*

344

Adjustment of Bmode speed


*

White smoke
prevention logic
(Air heater relay
output)

Initialization of
set values
(Only contents of
service adjustment)

311: Kerosene
* Since the low idling speed
is set by the governor
stopper, it does not change
under normal condition.

Arm crane idling speed Set to () side.


is remarkably high.
Arm crane idling speed
Set to (+) side.
is remarkably low.

354

810

400

E-idling speed is
remarkably high.

Set to () side.

E-idling speed is
remarkably low.

Set to (+) side.

B-idling speed is
remarkably high.

Set to () side.

B-idling speed is
remarkably low.

Set to (+) side.

Set for each user who


cares white smoke
when engine is started
at low temperature.

Change set value so


that air heater will
operate automatically
after engine is started.

* If the B-mode speed is


heightened, it is set near
the high idling speed and
the auto-decelerator may
not operate normally.
fl Since air heater consumes
much current, battery can
be dead. Teach user to so
operate machine that
battery will be charged
sufficiently.

If 401 is selected, all service adjustment items are set to initial values.

* The engine speed adjustment is an auxiliary adjustment method.


(1) Check the installation condition of the governor cable.
(2) Check the condition of the governor cable motor.

PC128US-2

20-246-5
(19)

TROUBLESHOOTING

HOW TO READ DECISION LIST

HOW TO READ DECISION LIST


PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
This decision list is a tool (decision table) for selecting whether a nature of trouble of a chassis is caused
by an electrical system failure or a hydraulic or mechanical failure and advancing to troubleshooting
codes (N, E, S, C, F, H, M) that match each event.
The decision table identifies that processing should advance to which troubleshooting codes according
to the presence of the display of user and service codes.
fl The abnormality display (warning) using the monitor panel directly advances to machine monitor
troubleshooting code (M). (Refer to the machine monitor system troubleshooting.)
1. CR700 Controller (Decelerator Control System) or Engine Related Decision List
When a service code is displayed on the monitor panel, advance to troubleshooting code (E)
of the lowermost step of the decision table.
(A is marked to the point where a failure mode and a service code match.)
If a service code is not displayed and a nature of trouble appears in the monitor panel, advance to
diagnostic code (Eor S) at the right end which matches the failure mode of the decision
list.
<Example> Failure mode Engine does not start
[Procedure] Test that a service code is displayed on the monitor panel.
Controller (Decelerator Control System) or Engine-Related Decision List

[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700
controller (decelerator control) system E3:
.
2) When a service code is not displayed on the monitor panel and ENGINE DOES NOT START:
When the starting motor rotates:
Check the rotation
.... Advance to MECHANICAL SYSTEM TROUBLESHOOTING S-2.
of a starting motor.
When the starting motor does not rotate:
.... Advance to ELECTRICAL SYSTEM TROUBLESHOOTING E-8.

20-252
(17)

PC128US-2

TROUBLESHOOTING

HOW TO READ DECISION LIST

2. CR700 Controller (Pump Control System) or Oil Pressure Related Decision Table
When a service code is displayed on the monitor panel, advance to the troubleshooting
code (C) of the lowermost step of the decision table.
(A is marked to the point where a failure mode and a service code match.)
If a service code is not displayed and a nature of trouble appears in the monitor panel, check the
display of an input signal that matches the failure mode of the decision table (display the location
marked with a circle ( )) and
When an input signal is displayed normally, advance to the diagnostic code (H) at the
right of the decision list.
When an input signal is not displayed, advance to the diagnostic code (F) at the 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

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS


PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
1. Classification of Diagnostic Code No.
Diagnostic code No.

Troubleshooting device

Service code

N-cc

Communication system troubleshooting

E-cc

CR700 controller (decelerator control system) troubleshooting

C-cc

CR700 controller (pump control system) electrical system troubleshooting E2-cc system

F-cc

CR700 controller (input signal system) troubleshooting

H-cc

Hydraulic, mechanical system troubleshooting

M-cc

Machine monitor system troubleshooting

E3-cc system

E1-cc system

2. How to Read Troubleshooting (Method) Every Failure Mode


1) Title column
The title column of troubleshooting describes a troubleshooting code, service code, and
failuremode (nature of trouble).
2) Itemization
Even for the same nature of trouble, if the method of this diagnosis depends on a model, device,
or event, the contents of the nature of trouble is subdivided into a) to ?. ([2] of the example).
(This is called itemization.) Select and execute the corresponding troubleshooting. If no itemization is performed, advance troubleshooting from the beginning of the nature of trouble.
3) How to advance troubleshooting
YES

As a result of testing or measuring YES NO of


, advance to the next step
by
NO
advancing one branch of either YES or NO. (Note: The No. described in the upper right-hand
is a serial number, but not a No. showing a procedure.)
corners of
If the branch of YES or NO as the result of testing or measurement is directly coupled with a
cause, the cause is referred to and the corrective action at the right is executed. ([3] of the
example)
When the testing or measuring method and decision value in the lower column of
matches the decision value and questionnaires in the lower column of
described, NO is
applied if they deviate from the YES decision value and are not matched.
Regarding the preparatory work and decision value necessary for testing or measurement in
the lower column of the nature of trouble, because the preparatory work may be ignored and
the operation or handling method be mistaken or equipment be damaged, read them well
before testing or measurement starts and advance the work.
4) General precautions
To advance the failure mode (nature of trouble), all common precautions ([4] of the example) are
marked with a fl next to the title.Because the precautions marked with a fl are omitted in
,
be sure to execute them at the testing of
.
5) Diagnostic tools
To advance this diagnosis, prepare the necessary diagnostic tools referring to the TESTING OR
ADJUSTING AND TROUBLESHOOTING EQUIPMENT LIST and advance the work.

20-254
(17)

PC128US-2

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

6) Device locations and pin numbers


For the testing or measuring locations of wiring connector CN cc and connector pin numbers
shown in the flow of this diagnosis, advance the work referring to the connector type, mounting
locations, and connector pin No. table.

<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.

Is the voltage between the alternator R and the machine


body normal?

NO

Defective alternator

Replace

Hot short-circuit of harness between


P02 (female) (11) and alternator R

Repair or
replace

Defective monitor panel

Replace

YES

2
Disconnect P02.
Set the starting switch to ON.
1V max.

Is the voltage between P02 (11)


and the machine body normal?

NO

YES

PC128US-2

20-255
(17)

DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT


TROUBLESHOOTING

TROUBLESHOOTING

DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT


TROUBLESHOOTING
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
When an abnormality occurred diagnosis advances in accordance with the decision table CR700 controller (decelerator control system) or CR700 controller (pump control system) that correspond to the contents of a failure. However, refer to this flow for the detailed diagnostic contents or procedure.
Further, for the diagnosis, ask the operator of detailed questions as much as possible and check the
following items previously. [1] connected state of the controller (check using monitoring codes 0200,
1000, 1001, 1002, 1003*, 1004*), [2] fuse blown, [3] power generation (charge input) voltage (monitoring
*: PC138US-2
Serial No.: 4501 and up
code 0043).
PC138USLC-2 Serial No.: 1501 and up
Besides, the confirmation procedures of the testing items No. 3 and 4 in the following flow are described
on the next page and later pages.
YES

E02 (PC-EPC system)


E03 (Swing holding brake system)
E05 (Governor motor system)

To item 2

1
Is service code of
monitor panel
displayed?

YES

E2: Troubleshooting (C mode) of CR700 controller (pump control


system) at the number level of cc
E3: Troubleshooting (E mode) of CR700 controller (decelerator
control system) at the number level of cc

5 YES

Is engine electrical
YES system without
display of failure
4
code normal?

2
Is service code of
monitor panel
NO displayed?

Engine system or
YES hydraulic
(mechanical)
system?

Check service code


by performing
operation

Is input and output


signal of governor
NO pump
controller normal?

Check it by
monitoring

Diagnose in the
corresponding mode
Diagnose engine
main unit (S mode)

Diagnose engine
electrical system (E
mode) (flow without
Flow of part without
NO display)
decision table
abnormality display

Diagnose by hydraulic (mechanical) system


Decide system from
engine speed after NO (H mode)
hydraulic adjustment
Is all working
equipment slow and
does engine speed
decrease at heavy
load?
Diagnose by input signal system (F mode)

NO

fl Decide the details in accordance with the CR700 controller (decelerator control system) (pump
control system) decision table.

20-256
(17)

PC128US-2

DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT


TROUBLESHOOTING

TROUBLESHOOTING

For an output signal of the monitor panel, if there is no abnormality display of a communication system
sent by S-NET, it may be decided that the output signal is sent. When there is no abnormality display,
perform testing directly, such as an incorrect operation, according to the following points.Besides, whenan
abnormality occurred in the S-NET system, note diagnosis because the default mode is automatically
switched as shown below.

Default Mode When Communication Between Monitor Panel and


Governor Pump Controller is Disabled
Setting mode

Pump control side

Governor control side

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

Recognized to be below 30C

Recognized to be below 30C

Travel speed

Lo

Automatic warm-up

ON (Automatic warm-up mode)

1. Confirmation Points of Monitor Panel Output Signal


fl For the monitoring mode operation method, refer to Monitor Panel Display and Special Function
1) Component connected state
(1) Set the monitoring mode and display monitoring code 08.
(2) The state indicates that the connected component comes on in the clock display portion (bit).
fl [1], [2], and [3] come on.
2) Confirmation of working mode signal
(1) Set the monitoring mode and display monitoring code 10.
(2) Switch the working mode as shown in Table 1 and check the change of the engine speed.

Table 1
Working mode
A

Arm crane

PC128US-2

Operation

Engine speed (no load maximum speed) (rpm)

Work equipment

About 2,400

Travel

About 2,400

Work equipment

About 2,200

Travel

About 2,200

Work equipment

About 2,000

Travel

About 2,000

Work equipment

About 1,500

Travel

About 1,500

20-257
(17)

DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT


TROUBLESHOOTING

TROUBLESHOOTING

3) Confirmation of Travel Speed Selector Signal


(1) Set the monitoring mode and display monitoring code 1060.
(2) Check that the travel speed selector switch Hi, engine of 1,500 rpm or more, travel Hi travel
bit [4] comes on (or comes out).
(): The bit is ON (bit (4) comes on) above 27.46 MPa {280 kg/cm2} when the oil pressure rises
and is OFF (bit [4] comes out) below 15.69 MPa {160 kg/cm2} when the oil pressure falls.
2. Confirmation of CR700 Controller Input Signal
fl Check the input signal of each controller according to the following procedure.
Pump control system
1) Confirmation of input signal
(1) Testing of hydraulic switch
i) Set the monitoring mode and display monitoring code 1023.
ii) Operate each work equipment lever and check the lighting state of a bit pattern.
fl For the bit pattern list, refer to the monitor panel display and special functions.
(2) Testing of speed center (test it with an engine speed)
i) Set the monitoring mode and display monitoring code 1010.
ii) Change the speed by the fuel dial and measure the engine speed at that time.
(3) Testing of pump discharge pressure sensor
i) Set the monitoring mode and display monitoring code 1042.
fl When the display is 24.0, it indicates that the pressure is 24 MPa.
ii) Measure the oil pressure of the pump.
(4) Testing of kerosene mode input signal
i) Set the monitoring mode and display monitoring code 1021.
ii) Ground the CR700 controller connector CR2 [6] to the GND and check that the bit [6]
comes on.
2) Confirmation of output signal
(1) Testing of LS-EPC solenoid output current
i) Set the monitoring mode and display monitoring code 1054.
ii) When all levers are neutral and set in the A mode, measure the engine full current value.
fl When all levers are neutral: 900 100 mA Refer to the monitor display example.
At engine full and lever operation (other than travel): 0 A
(2) Confirmation of the ON OFF solenoid state
i) Set the monitoring mode and display monitoring code 1060.
ii) Referring to Table 3, check that the corresponding bit comes on.
Table 3 Solenoid Type and Operating Condition
Solenoid name

Operating condition

Bit that comes ON

Swing holding brake

Either swing or operating equipment


lever operation

Monitor code 1060 [1]

Travel Hi/Lo

Fuel dial above 1,500 rpm and travel


speed switch
Hi and travel switch ON and travel Hi
rotation

Monitor code 1060 [4]

2-stage relief

At travel lever operation

Monitor code 1060 [6]

Note 1: Perform the lever operation slightly in such degree that the machine cannot move.

20-258
(17)

PC128US-2

TROUBLESHOOTING

DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT


TROUBLESHOOTING

Engine throttle Control System


1) Confirmation of Input Signal
(1) Testing of fuel dial input voltage
i) Set the monitoring mode and display monitoring code 1034.
ii) Measure the voltage when the fuel dial is rotated from low idle to high idle.
fl The voltage is 0.3 to 4.3 V.
(2) Testing of decelerator potentiometer voltage
i) Set the monitoring mode and display monitoring code 1035.
ii) Measure the potentiometer voltage when the fuel dial is rotated from low idle to high
idle.
fl The voltage at auto decelerator OFF.
: 2.15 4.55 V
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
: 2.67 4.55 V
PC138US-2
Serial No.: 9501 and up
PC138USLC-2 Serial No.: 1501 and up
2) Confirmation of Output Signal
(1) Confirmation of decelerator motor driving signal
i) Set the monitoring mode and display monitoring code 1024.
ii) Check that bit [3] comes on when the fuel dial is rotated to the directions of the engine
speed Acceleration and Deceleration.

PC128US-2

20-259
(17)

TROUBLESHOOTING OF ELECTRICAL SYSTEM


(E MODE)

PC128US-2
Serial No.: 5001 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM ....... 20-301-1
RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM ......................................... 20-302
E-1 Abnormality in PC-EPC system ...................................................................................................... 20-310
a) Speeds of all work equipment, travel, swing are slow or lack power .................................... 20-311
b) There is excessive drop in engine speed, or engine stalls ...................................................... 20-312
E-2 Abnormality in PPC lock solenoid system ..................................................................................... 20-318
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move .......... 20-318
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move .............. 20-318
E-3 Abnormality in swing lock solenoid system ................................................................................. 20-322
a) Even when swing lock switch is turned OFF, upper structure does not swing ...................... 20-322
b) Even when swing lock switch is turned to LOCK, upper structure swings ............................ 20-323
E-4 Abnormality in travel speed solenoid system ............................................................................... 20-326
a) Even when travel speed selector switch is turned to Hi, travel speed
does not change to high speed .................................................................................................. 20-326
b) Even when travel speed selector switch is turned to Lo, travel speed
does not change to low speed ................................................................................................... 20-326
E-5 Trouble in automatic travel speed control system ........................................................................ 20-329
a) Main pump pressure sensor system ......................................................................................... 20-329
b) Engine speed sensor system ...................................................................................................... 20-329
E-6 Abnormality in engine starting system ......................................................................................... 20-334

PC128US-2

20-301
(17)

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL


SYSTEM
PC-EPC SYSTEM
PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500

PPC LOCK SOLENOID SYSTEM


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

20-302
(17)

PC128US-2

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

SWING LOCK SOLENOID SYSTEM


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

TRAVEL SPEED SOLENOID SYSTEM


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

PC128US-2

20-303
(17)

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

AUTOMATIC TRAVEL SPEED CONTROL SYSTEM


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

20-304
(17)

PC128US-2

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

ENGINE STARTING SYSTEM


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

PC128US-2

20-305
(17)

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

PC-EPC SYSTEM
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up

PPC LOCK SOLENOID SYSTEM


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

20-306
(17)

PC128US-2

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

TRAVEL SPEED SOLENOID SYSTEM


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

SWING LOCK SOLENOID SYSTEM


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

PC128US-2

20-307
(17)

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

RELATED ELECTRICAL CIRCUIT DIAGRAM


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

20-308
(17)

PC128US-2

TROUBLESHOOTING

RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM

ENGINE STARTING SYSTEM


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

PC128US-2

20-309
(17)

TROUBLESHOOTING

E-1

E-1 Abnormality in PC-EPC system


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
Items to check on LED display of pump controller when this failure mode occurs
For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the 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 C01 (13) - PC-EPC solenoid C13 (1) is short
circuited]
Output stops, LED flashes. (See display pattern a).
4) When there is abnormality in machine model selection
LED flashes. (See display pattern c).
Note : When kerosene mode selector switch (terminal) is connected, ignore the flashing and carry
out troubleshooting.
5) When there is disconnection in speed sensor [when there is abnormal voltage at C01 (2), (3)]
. Output is made same as when engine speed is minimum, LED flashes. (See display pattern
d).
Note : When engine speed becomes abnormally low, LED does not flash.
6) When there is disconnection in PC-EPC solenoid output [when there is disconnection between
C01 (13) - PC-EPC solenoid C13 (1)]
LED flashes. (See display pattern b).
2. Display ( : ON, : OFF)
1) Display pattern a (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, then OFF for 2.0 seconds)
2) Display pattern b (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
3) Display pattern c (method of re-enaction: pattern below is repeated when starting switch is ON)

(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5
seconds, then OFF for 2.0 seconds)
4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)

(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5
seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
5) If more than one of the above failures occurs at the same time, the above patterns a to d are
repeated.
Note : indicates ON for 0.1 second, indicates OFF for 0.1 second.

20-310
(17)

PC128US-2

E-1

TROUBLESHOOTING

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Speeds of all work equipment, travel, swing are slow or lack power

Cause

Is resistance
YES between C05
(female) (4) and
3
chassis ground
normal?

Is resistance
between C13
YES (female) (1) - (2),
between (1)(2) chassis ground
normal?

Between C13
2
(female) (1) - (2) :
NO
Is resistance
500 - 1000
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

Short circuit with chassis


ground in wiring harness
NO between C05 (female) (4)
and C03 (female) (2)

Repair or replace

Defective PC-EPC solenoid

Replace

Defective contact,
disconnection, or short
circuit with chassis ground
in wiring harness between
C01 (female) (3) - E07
(female) (1) or C01 (4) - E07
(2)

Repair or replace

Defective engine speed


sensor

Replace

Defective pump controller

Replace

Defective contact,
disconnection, or short
circuit with chassis ground
in wiring harness between
C01 (male) (5) - C09 (male)
(1), C05 (female) (6) - C09
(female) (2) or C01 (female)
(10) - C09 (male) (3)

Repair or replace

Defective machine model


selection connector

Replace

Short circuit with chassis


ground in wiring harness
between C01 (female) (13)
and C05 (female) (2)

Repair or replace

Defective emergency pump


drive switch

Replace

20-311
(17)

TROUBLESHOOTING

E-1

b) There is excessive drop in engine speed, or engine stalls


fl When fuse 2 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit
related to fuse 2.)

Cause

2 YES

Defective pump controller

Is voltage between
YES C01 (1) and chassis
ground normal?

5 YES

Is pump controller
LED off?

Is resistance

(female) (1) and (2)


normal?

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?

YES between C13


Turn starting
switch ON.

Replace

Defective contact or
disconnection in wiring
Repair or replace
harness between fuse 2 and
C01 (female) (1)

NO
20 30 V
Turn starting switch
ON.
1

Remedy

Defective contact,
disconnection, or short circuit
with chassis ground in wiring
harness between C05 (female)
Repair or replace
(3) and C13 (female) (1), or
7 14
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

Defective pump controller

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

E-1 Related electric circuit diagram

PC128US-2

20-313
(17)

TROUBLESHOOTING

E-1

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Items to check on LED display of pump controller when this failure mode occurs
For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the 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

Defective PC-EPC solenoid

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

Defective engine speed


sensor

Replace

Defective pump controller

Replace

Defective machine model


set up or arm crane set up

Reset up

Short circuit with chassis


ground in wiring harness
between CR3 (female) (16)
and C05 (female) (3)

Repair or replace

Defective emergency pump


Replace
drive switch

20-315
(17)

TROUBLESHOOTING

E-1

b) There is excessive drop in engine speed, or engine stalls


fl When fuse 1 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit
related to fuse 2.)

Cause

2 YES

Defective pump controller

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)

YES between C13

Turn starting
switch ON.

(male) (1) and (2)


normal?

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

Defective PC-EPC solenoid

Replace

Defective pump controller

Replace

Defective machine model


set up or arm crane set up

Reset up

NO
6 YES

Start engine.

Turn starting
switch OFF.
Disconnect C06.

Replace

Defective contact or
disconnection in wiring
Repair or replace
harness between fuse 1 and
CR3 (female) (2) (12) (22)

NO
20 30 V
Turn starting switch
ON.

Remedy

Defective contact,
disconnection, or short circuit
with chassis ground in wiring
harness between CR3 (female)
Repair or replace
(16) and C06 (female) (3), or
defective contact or
disconnection in wiring
harness between CR3 (female)
(23) and C06 (female) (6)
Defective emergency pump
Replace
drive switch

PC128US-2

TROUBLESHOOTING

E-1

E-1 Related electric circuit diagram


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

PC128US-2

20-317
(17)

TROUBLESHOOTING

E-2

E-2 Abnormality in PPC lock solenoid system


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move
Cause

Remedy

Defective contact or

4 YES disconnection in wiring

Is resistance
YES between S12 and
S13 (wiring
harness end)
2
normal?
Is resistance

YES between V07 (male)


1
Is voltage between
V07 (female) (1)
and chassis
ground normal?

(1) - (2), between


(1)(2) - chassis
ground normal?

Is resistance
YES between S13
(wiring harness
end) and chassis
3
ground normal?

Defective contact or
disconnection in wiring
NO harness between S13 and
Max. 1
Turn starting switch OFF. chassis ground
Disconnect S13.

Max. 1
Turn starting
NO
switch OFF.
Remove S12 and S13.
Safety lock lever: FREE

Between V07 (male)


(1) - (2) :
500 - 1000 NO
Between V07 (male) (1)(2) chassis ground : Min. 1 M
Turn starting switch OFF.
Disconnect V07.

20 30 V
Turn starting switch
ON.
NO

harness between V07


(female) (2) and S12

Repair or replace

Repair or replace

Defective PPC lock switch

Replace

Defective PPC lock solenoid

Replace

Defective contact or
disconnection in wiring
harness between fuse 3 and
V07 (female) (1)

Repair or replace

b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move

Cause

YES
1
Is voltage between
V07 (1) and (2)
normal?

2 YES

Is resistance
Safety lock lever
between S12 and
[LOCK] (solenoid NO S13 (switch end)
OFF) : Max. 1 V
normal?
Safety lock lever
NO

Min. 1 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

Defective PPC lock solenoid

Replace

Defective contact or
disconnection in wiring
harness between S13 and
chassis ground

Repair or replace

Defective PPC lock switch

Replace

PC128US-2

TROUBLESHOOTING

E-2

E-2 Related electrical circuit diagram

PC128US-2

20-319
(17)

TROUBLESHOOTING

E-2

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move
Cause

4 YES Defective contact or


Is resistance
YES between S10
(female) (1) - fuse
3
(14)normal?
Is resistance
YES between S10
(female) (2) chassis ground
2
normal?
Is resistance

YES between V7 (male)


1

(2) - (1), between


(2)(1) - chassis
ground normal?

Defective contact or
disconnection in wiring
NO harness between S10
Max. 1
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

Defective PPC lock switch

Replace

Defective PPC lock solenoid

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

Defective PPC lock solenoid

Replace

Defective contact in wiring


harness between S10
(female) (2) - V7 (female) (2)

Repair or replace

Defective PPC lock switch

Replace

PC128US-2

TROUBLESHOOTING

E-2

E-2 Related electrical circuit diagram

PC128US-2

20-321
(17)

TROUBLESHOOTING

E-3

E-3 Abnormality in swing lock solenoid system


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when swing lock switch is turned OFF, upper structure does not swing
Cause

4 YES
resistance
YES Is
between S08
3
(female) (2), S30

When C03 (female)


(female) (2) - chassis
is grounded to
ground normal?
chassis, is
Min. 1
YES resistance between
NO
S08 (female) (1),
Turn starting switch
2
S30 (female) (1),
OFF.
S05 (female) (1) Is resistance
Disconnect C03, S08,
chassis ground
between S08
and S30.
normal?
YES (male) (1) - (2), S30
(male) (1) - (2) or
Min. 1
NO
S05 (male) (1) - (2)
1
Turn starting switch OFF.
normal?
Is resistance
Disconnect C03, S08, and
Min. 1
between V04
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

YES between C03


5
Is voltage between
A C03 (female) (1)
and chassis
ground normal?
20 30 V
Turn starting switch
ON.

(female) (2) and


chassis ground
normal?

Min. 1
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

Defective swing holding


brake solenoid valve

Replace

Defective contact or
disconnection in wiring
harness between X05
(female) (3) and chassis
ground

Repair or replace

Defective contact or
disconnection in wiring
harness between V04
(female) (1) and C03
(female) (4)

Repair or replace

Defective contact or
disconnection in wiring
Repair or replace
harness between C03 (female)
(2) and chassis ground
Defective contact or
disconnection in wiring
Repair or replace
harness between fuse 2 and
C03 (female) (1)

10 YES

Is resistance
B between X05
(male) (3) and (4)
normal?

Defective swing or arm IN


pressure switch (S08, S30
or S05)

8 YES Go to B
Is resistance
YES between X05
(female) (3) and
7
chassis ground
When V04 (female)
normal?
is grounded to
Min. 1
YES chassis, is
NO
resistance between
Turn starting switch
C03 (female) (4) and
6
OFF.
chassis ground
Disconnect X05.
normal?

Remedy

Defective swing holding


auto brake controller

Replace

Defective contact or
disconnection in wiring
harness between X05
(female) (4) and C03
(female) (3)

Repair or replace

Defective swing lock switch

Repair or replace

PC128US-2

TROUBLESHOOTING

E-3

b) Even when swing lock switch is turned to LOCK, upper structure swings

Cause

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

Defective swing holding


brake solenoid

Replace

Defective contact or
disconnection in wiring
harness between V04
(female) (2) and X05
(female) (4)

Repair or replace

Defective swing lock switch Replace

E-3 Related electrical circuit diagram

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

YES between CR3


5
Is voltage between
A CR3 (female) (2)
(12) (22) and
chassis ground
normal?
20 30 V
Turn starting switch
ON.

Min. 1
NO
Turn starting switch
OFF.
Disconnect C03 and V4.

(female) (7) - X05


(female) (3)
normal?

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

Defective swing or arm IN


pressure switch (S08, S30
or S05)

Replace

Defective swing holding


brake solenoid valve

Replace

NO

Is resistance
YES between X05
(female) (4) and V4
9
(female) (2)
normal?

NO
Max. 1
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

Defective swing holding


auto brake controller

Replace

Defective contact or
disconnection in wiring
harness between X05
(female) (4) and V4 (female)
(2)

Repair or replace

Defective swing lock switch

Repair or replace

PC128US-2

E-3

TROUBLESHOOTING

b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause

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

Defective swing holding


brake solenoid

Replace

Defective contact or
disconnection in wiring
harness between V4
(female) (2) and X05
(female) (4)

Repair or replace

Defective swing lock switch Replace

E-3 Related electrical circuit diagram

PC128US-2

20-325
(17)

TROUBLESHOOTING

E-4

E-4 Abnormalty travel speed solenoid system


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Even when travel speed selector switch is turned to Hi, travel speed does not change to high speed
fl When fuse 2 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit
related to fuse 2.)
Cause

Remedy

Defective contact or

4 YES disconnection in wiring


Is resistance
M39
YES between
(female) (1) and
chassis ground
3
normal?
Is resistance

YES between M39


2
Is resistance
V05 (male)
YES between
(1) - (2), between

1
Is voltage between
V05 (female) (1)
and chassis
ground normal?

(1)(2) - chassis
ground normal?

(male) (1) and (2)


normal?

Defective contact or
disconnection in wiring
harness between M39
Max. 1 . Turn
NO (female) (1) and chassis
Starting switch OFF.
ground
Disconnect S13.

Turn starting switch


OFF.
Disconnect S12 and NO
S13.
Safety lock lever: FREE

Between V05 (male)


(1) - (2): 20 - 60
Between V06 (male) NO
(1)(2) - chassis ground :
Min. 1 M
Turn starting switch OFF.
Disconnect V05.

20 - 30 V
Turn starting switch
ON.
NO

harness between V05


(female) (2) and M39
(female) (2)

Repair or replace

Repair or replace

Defective travel speed


selector switch

Replace

Defective travel speed


solenoid

Replace

Defective contact or
disconnection in wiring
Repair or replace
harness between fuse 3 and
V05 (female) (1)

b) Even when travel speed selector switch is turned to Lo, travel speed does not change to low speed

Cause

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

Defective travel speed


solenoid

Replace

Short circuit with chassis


ground in wiring harness
between V05 (female) (2)
and M39 (female) (2)

Repair or replace

Defective travel speed


selector switch

Replace

PC128US-2

TROUBLESHOOTING

E-4

E-4 Related electrical circuit diagram

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

Defective travel speed


solenoid

Replace

Defective contact or
disconnection in wiring
harness between fuse 1 and
CR3 (female) (2) (12) (22)

Repair or replace

Is resistance

YES between CR3


(female) (27) and
2
3
(3) normal?

Is resistance
V5 (male)
YES between
(2) - (1), between (2)
- chassis ground
normal?
1
Is voltage between
CR3 (female)
(2),(12),(22) and
chassis ground
normal?

Turn starting switch NO


OFF.
Disconnect CR3.
Safety lock lever: FREE

Between V5 (male)
(2) - (1): 37 - 60
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.

E-4 Related electrical circuit diagram

20-328
(17)

PC128US-2

TROUBLESHOOTING

E-5

E-5 Trouble in automatic travel speed control system


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl If this failure mode is detected, the travel speed does not change automatically.
a) Main pump pressure sensor system
Cause

2 YES
YES Is voltage between
C05 (5) and (10)
normal?

Is voltage between
C05 (2) and (1)
normal?

Defective governor pump


controller

Replace

Disconnection, defective
contact, or short circuit
with power source or chassis ground in wiring harness between C02 (female)
(5) C05 (female) (3)

Repair or
replace

Disconnection, defective
contact, or short circuit
with chassis ground in wiring harness between C02
(female) (10) C05 (female)
(1)

Repair or
replace

Disconnection, defective
contact, or short circuit
with chassis ground in wiring harness between C02
(female) (2) C05 (female)
(2)

Repair or
replace

Run engine at full NO


throttle
Relieve travel system and set
lever in neutral repeatedly

Remedy

Lever Neutral return


0.5 4.5V

Turn starting switch


ON.
18 28V

YES
3

Is voltage between
C05 (2) and chassis
NO ground normal?
Disconnect C05
Turn starting switch NO
ON.
18 28V

b) Engine speed sensor system


Cause

2 YES
Is resistance beYES tween C02 (female) (6) and (11)
normal?
1
Is resistance between E07 (male)
(1) and (2) normal?

Turn starting switch NO


OFF.
Disconnect C02.
500 1,000

Turn starting switch


OFF
Disconnect E07
NO
500 1,000

PC128US-2

Defective automatic Lo/Hi


travel speed controller

Remedy

Replace

Disconnection, defective
contact, or short circuit with
power source or chassis
Repair or
ground in wiring harness
between C02 (female) (6)
replace
E07 (female) (1) or between
C02 (female) (10) E07 (female) (2)
Defective engine speed
sensor (Internal disconnection, defective contact,
short circuit with chassis
ground)

Replace

20-329
(17)

TROUBLESHOOTING

E-5

E-5 Related electrical circuit diagram

20-330
(17)

PC128US-2

E-5

TROUBLESHOOTING

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl If this failure mode is detected, the travel speed does not change automatically.
a) Main pump pressure sensor system
Cause

2 YES
YES Is voltage between
CR1 (13) and (21)
normal?

Is voltage between
C05 (B) and (A)
normal?

Defective governor pump


controller

Replace

Disconnection, defective
contact, or short circuit
with power source or chassis ground in wiring harness between CR1 (female)
(13) C05 (female) (C)

Repair or
replace

Disconnection, defective
contact, or short circuit
with chassis ground in wiring harness between CR1
(female) (21) C05 (female)
(A)

Repair or
replace

Disconnection, defective
contact, or short circuit
with chassis ground in wiring harness between CR1
(female) (22) C05 (female)
(B)

Repair or
replace

Run engine at full NO


throttle
Relieve travel system and set
lever in neutral repeatedly

Remedy

Lever Neutral return


0.5 4.5V

Turn starting switch


ON.
4.5 5.5V

YES
3

Is voltage between
C05 (B) and
NO chassis ground
normal?
Disconnect C05
Turn starting switch NO
ON.
4.5 5.5V

b) Engine speed sensor system


Cause

2 YES
Is resistance beYES tween CR3 (female) (39) and (40)
normal?
1
Is resistance between E07 (male)
(1) and (2) normal?

Turn starting switch NO


OFF.
Disconnect CR3.
500 1,000

Turn starting switch


OFF
Disconnect E07
NO
500 1,000

PC128US-2

Defective automatic Lo/Hi


travel speed controller

Remedy

Replace

Disconnection, defective
contact, or short circuit with
power source or chassis
Repair or
ground in wiring harness
between CR3 (female) (39) replace
E07 (female) (2) or between
CR3 (female) (40) E07 (female) (1)
Defective engine speed
sensor (Internal disconnection, defective contact,
short circuit with chassis
ground)

Replace

20-331
(17)

TROUBLESHOOTING

E-5

E-5 Related electrical circuit diagram

20-332
(17)

PC128US-2

TROUBLESHOOTING

E-6

E-6 Abnormality in engine starting system


PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going
YES
on the next step.
4
fl When fuse 1 is normal. (If fuse 1 is blown,
Is voltage between
check for a short circuit with the ground
YES starting motor
YES
terminal B and
in the circuit related to fuse 1.)
chassis ground
normal?

5
Is voltage between
battery relay
terminal M and
NO chassis ground
normal?

20 30 V
Turn starting
switch ON.

20 30 V
Turn starting
switch ON.

3
Is there sound of
YES starting motor
pinion engaging?

6 YES
Is voltage between
battery relay
terminal B and
NO chassis ground
normal?
NO
20 30 V
Turn starting switch
ON.

YES

Turn starting switch


ON START.

7
Is voltage between
safety relay
terminal C and
NO chassis ground
normal?

YES

9
Is voltage between
YES M02 (1) and
chassis ground
normal?
20 30 V
8
Turn starting switch
ON.
Is voltage between
safety relay
terminal B and
NO
NO chassis ground
normal?

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.

Turn starting switch NO


OFF.

YES
15

Is voltage
between starting
switch terminal BR
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.

YES
16
Is voltage
between starting
switch terminal B
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.

17 YES
Is voltage between
fuse 1 inlet and
NO chassis ground
normal?

NO
20 30 V
Turn starting switch
ON.

20-334
(17)

PC128US-2

E-6

TROUBLESHOOTING

Cause

YES

Remedy

Defective starting motor

Replace

Defective contact or
disconnection in wiring
harness between battery
relay terminal M and
starting motor terminal B

Repair or replace

Defective battery relay

Replace

Defective contact or
disconnection in wiring
harness between battery (+)
terminal and battery relay
terminal B

Repair or replace

Defective contact or
disconnection in wiring
harness between safety
relay terminal C and
starting motor terminal S

Repair or replace

Defective safety relay

Replace

Defective contact,
disconnection, or short
circuit with power source in
wiring harness between
alternator terminal R and
M02 (female) (2)

Repair or replace

10
Is voltage between
M02 (2) and
chassis ground
normal?
Max. 13 V
Turn starting
switch ON.

11 YES

Is voltage between
alternator terminal
NO R and chassis
ground normal?

NO
Max. 13 V
Disconnect terminal R.
Turn starting switch ON.
12 YES

Is voltage between
starting switch
terminal C (T09)
and chassis
ground normal?
20 - 30 V
NO
Turn starting switch
ON.

Defective alternator
Defective contact or
disconnection in wiring
harness between starting
switch terminal C (T9) and
M02 (female) (1)

Repair or replace

Defective starting switch


(circuit C)

Replace

Defective contact or
disconnection in wiring
harness between starting
Repair or replace
motor terminal B and safety
relay terminal B

Defective battery relay

Replace

Defective contact or
disconnection in wiring
harness between battery
relay E and chassis ground

Repair or replace

Defective contact or
disconnection in wiring
harness between starting
switch terminal BR (T7) and
battery relay terminal BR

Repair or replace

Defective starting switch


(circuit BR)

Replace

Defective contact or
disconnection in wiring
harness between fuse 1
outlet and starting switch
terminal B (T6)

Repair or replace

Defective contact or
disconnection in wiring
harness between battery (+)
terminal - M11 (1), (2) - fuse
1 inlet
Lack of battery capacity

PC128US-2

Replace

Repair or replace

Charge or replace

20-335
(17)

TROUBLESHOOTING

E-6

E-6 Related electrical circuit diagram

20-336
(17)

PC128US-2

TROUBLESHOOTING

E-6

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

fl Before carrying out troubleshooting, check that all the


4
related connectors are properly inserted.
Is voltage between
fl Always connect any disconnected
YES starting motor
connectors before going on the
terminal B and
chassis ground
next step.
normal?
fl When fuse 1 is normal. (If fuse 1 is blown,
20 30 V
check for a short circuit with the ground
Turn starting
NO
switch ON.
in the circuit related to fuse 1.)

YES
5
Is voltage between
battery relay
terminal M and
chassis ground
normal?
20 30 V
Turn starting
switch ON.

3
Is there sound of

YES starting motor

pinion engaging?
Turn starting switch
ON START.

6 YES
Is voltage between
battery relay
terminal B and
NO chassis ground
normal?
NO
20 30 V
Turn starting switch
ON.

YES

YES

7
Is voltage between
safety relay
terminal S and
NO chassis ground
normal?
20 30 V
Turn starting
switch ON.

8
Is voltage between
safety relay
terminal C and
NO chassis ground
normal?

20 30 V
Turn starting
switch ON.

YES Is sound heard


from battery relay?

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.

Turn starting switch NO


OFF.

YES
25

Is voltage
between starting
switch terminal BR
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.

26
Is voltage
between starting
switch terminal B
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.

YES

27 YES
Is voltage between
fuse 20 inlet and
NO chassis ground
normal?

NO
20 30 V
Turn starting switch
ON.

20-338
(17)

PC128US-2

E-6

TROUBLESHOOTING
Cause

Remedy

Defective starting motor

Replace

Defective contact or
disconnection in wiring
harness between battery
relay terminal M and
starting motor terminal B

Repair or replace

Defective battery relay

Replace

Defective contact or
disconnection in wiring
harness between battery (+) Repair or replace
terminal and battery relay
terminal B

YES

Defective starting motor

Replace

Defective contact or
disconnection in wiring
harness between safety
relay terminal C and
starting motor terminal S

Repair or replace

Defective safety relay

Replace

11
Is voltage between

YES M02 (2) and

chassis ground
normal?

10
Is voltage between
M02 (1) and
chassis ground
normal?
20 30 V
Turn starting
switch ON.
PPC lock switch:
LOCK

Max. 13 V
Turn starting
switch ON.

12 YES
Is voltage between
alternator terminal
NO R and chassis
ground normal?

NO
Max. 13 V
Disconnect terminal R.
Turn starting switch ON.

Defective contact,
disconnection, or short
circuit with power source in
wiring harness between
alternator terminal R and
M02 (female) (2)
Defective alternator

Replace

Repair or replace

Go to A

NO

Defective contact or
disconnection in wiring
harness between safety
relay terminal B and heater
relay terminal B

Replace

Defective battery relay

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

Defective R06 relay

Defective PPC lock switch

20
Is voltage between
S10 (1) and chassis

Is voltage between
starting switch T12
NO and chassis
ground normal?

Repair or replace

Replace

(female) (1) (including fuse


14)
Defective starting switch

NO (between B - ACC)

Is voltage between
starting switch T9
and chassis
ground normal?
20 30 V
Starting switch:
START
PPC lock switch:
LOCK

Replace

Disconnection or defective

22 YES contact in wiring harness

(17)

Repair or replace

Disconnection or defective
contact in wiring harness

20 30 V
Starting switch:
ON

20-340

Replace

21 YES between T12 - fuse 14 - S10


Repair or replace

NO ground normal?
20 30 V
Starting switch:
ON

Repair or replace

Disconnection or defective
contact in wiring harness
between R06 (female) (2) chassis ground
Disconnection or defective
contact in wiring harness
between S10 (female) (3) R06 (female) (1)

19

20 30 V
Starting switch: ON

Disconnection or defective
contact in wiring harness
between V03 (female) (6) M02 (female) (1)

Is voltage between
R06 (5) and chassis
NO ground normal?

20 30 V
Starting switch:
START
PPC lock switch:
LOCK

18 YES

Remedy

between T9 - R06 (female)


(5)
Defective starting switch

NO (Between B - C)

Repair or replace

Replace

PC128US-2

TROUBLESHOOTING

E-6

E-6 ENGINE STARTING SYSTEM


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

PC128US-2

20-341
(17)

TABLE OF FAILURE MODES AND CAUSES

TROUBLESHOOTING

l. 017tr
\ IVI
-

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

Speeds of all work equipment,

travel, swing are slow or lack power

Check that there is no abnormal noise from the pump before starting troubleshooting.
abnormal noise, carry out troubleshooting
for H-4.)

(If there is any

Cause

4 YES

Remedy

main pump

epair or replace

Defective PC valve or
PC-EPC valve

epair or replace

Defective
valve

main relief

epair or replace

Defective

unload valve

,epair or replace

Defective self pressure


reducing valve

lepair or replace

(Pressure reducing
valve, LS circuit)
Defective operation
main valve

tepair or replace

Defective

YES

3r

pressure) normal?
-See TESTING AND NO
ADJUSTING.

YEIS Is main pump


relief pressure
normal?

GotoA

. See TESTING AND


ADJUSTING.

NO

pressure reducing
. Arm relief

pressure) normal?

* 2.7: i,, MPa


NO
(28 ? i., kglcms)
* Engine at full throttle

* 3.24 f 0.49 MPa


(33 + 5 kg/cm?)
*Engine at full
throttle

6
A

YES

Is LS differential
pressure normal?

Defective
valve

- 2.2 * 0.1 MPa


NO
(22.5 * 1 kg/ems)
- Engine at full throttle
f Operate travel on
one side under no
load.

Note :Check the control circuit equipment.


adjusting control circuit oil pressure.

20-404
0

For details,

see, TESTING

AND

of

pump LS

ADJUSTING,

Ieplace

Testing and

PC1 28US-2

H-3

TROUBLESHOOTING

H-3 No work equipment,

travel, swing move


Cause

3 YES
YE

NO

IO

YES

fiiisz?p
Al

NO

NO

20-406
0

Defective PPC lock solenoid


valve

Replace

Defective chassis wiring


harness

Repair or replace

Go to Troubleshooting of
Electric System E-3b)

Repair or replace

Defective self pressure


reducing valve

Repair or replace

Defective main pump

Repair or replace

Defective PTO

Repair or replace

p5jiiiJHP

- 3.24 f 0.49 MPa


(33 f 5 kg/cm9
- Engine at full
throttle

Remedy

PC1 28US-2

H-4, H-5

TROUBLESHOOTING

H-4 Abnormal

noise generated

(around pump)
Cause

3 YES
YE

Go to Item 4

pi+JHImproper hydraulic oil

NO
YE

Remedy

Are there bubbles


in hydraulic tank?

:hange
lydraulic oil

Suction strainer blocked by


external object (cloth, etc.)

Is suction strainer
blocked by
external object?

n
Is hydraulic tank
oil level normal?

Defect inside main pump

Repair or replace

Operate for a short time


and watch for any change
in symptoms

Check again
[according to
change in
symptoms)

Improper hydraulic oil

Add hydraulic oi
Fine control
ability is poor or
response is poor

% External object:
cloth, etc.

N0

H-5 Fain control ability is poor or response is poor

Cause

YES
1
Is pump servo
orifice clogged?

2 YES
Does condition
_ become normal
NO when LS valve is
replaced?

Remedy

Clogged orifice for servo


pump

Jean

Defective LS valve

Replace

Defective servo piston

Replace

NO

PC1 28US-2

20-407
0

TROUBLESHOOTING

H-6

H-6 Boom is slow or lacks power

5 YES
YES
-

Is leakage from
hydraulic cylinder
normal?

4
YES
-

Is main pump
relief pressure
normal?

3
Does pressure
* 31237: JJ:;;
compensation
MPa 1325 T:z kg/cm?)
valve (pressure
-Engine at full
NO
YES reducing valve
throttle
piston, flow control
valve + pressure
reducing valve)
2
_
move smoothly?
YES Does control valve
P* It is also possible to
- spool move
interchange with
smoothly?
$;w.compensation NO
1
Is PPC valve
output pressure
normal?
* 3.24 * 0.49 MPa
133 t 5 kg/cm4
. Engine at full
throttle
- Operate lever fully.

20-408
0

Note

* 15 cclmin
*Engine at full
throttle

NO

6 YES
Is pressure
reducing valve
piston throttle free
of clogging?
NO

: In this case, always

be sure to
return the valves to their original
positions after checking.

NO

NO

PC128US-2

ELECTRICAL

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM


Monitor

panel

CIRCUIT DIAGRAM

FOR MONITOR

Starting

FOR MONITOR

SYSTEM

SYSTEM

Alarm
buzzer

switch

B BRACC C R, Rz

OFF 0
HEAT 0 0 o--o
ON

000

START 0 0 0 O--o
Q
Fuse

Bat terv
308

308

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

No display appears when starting switch is turned ON

Before carrying out troubleshooting,


check that all the related connectors are properly
Alwavs connect any disconnected connectors before going on the next step.
Check fuse 2 before starting troubleshooting.

YES
, I
Is voltage between
PO1 (female) (1)
and (3) normal?
*20-30V
*Turn starting
switch ON.

YES
Is fuse 2 normal?

NO

M-l

Related electrical

inserted.

Defective monitor panel

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

Before carrying out troubleshooting,


check that all the related connectors are properly
Always connect any disconnected connectors before going on the next step.

Cause

Defective monitor panel

M-3
*
*
a)

Remedy

Replace

Some items do not light up during self check (all lamps light up for 3
seconds) when starting switch is turned ON

Before carrying out troubleshooting,


check that all the related connectors are properly
Always connect any disconnected connectors before going on the next step.
No gauges
Preheating

(fuel level, engine water temperature)


pilot lamp does not light up

Defective monitor panel

Caution

lamps (engine oil pressure, battery

YES
I

Is there
disconnection in

* Check visually for


blown bulb.

20-504
0

1 Remedy

Replace

charge) do not light up

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

check that allthe related connectors


are properly
connectors
before going on the next step.

inserted.

Cause

YES

Defective monitor panel

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

check that all the related connectors


are properly
connectors
before going on the next step.

P=2 YES

(female) (9) and (3)


Is continl
*Turn stalrting switch NO
chassis E
normal?
- Disconnect POl.
-Turn starting switch
OFF.
NO
* Max. 0.5 R
-Disconnect sensor
(+) terminal 617).

M-5 Related electrical

Monitor

inserted.

Remedy

Defective monitor panel

Replace

Defective contact or
disconnection in wiring
harness between PO1
(female) (9) and S17 Wiring
harness end)

Repair or replace
wiring harness

Defective engine oil


pressuresensor

Replace

circuit diagram

Panel
I

PO1 (04016)

w-2
(SWP12)
$iJ

Engine oil
Pressure switch

a
s17

TXP02420

20-506
0

PC128US-2

M-6

TROUBLESHOOTING

M-6
*
*

Preheating
HEAT

pilot lamp does not light up when starting switch is at

Before carrying out troubleshooting,


check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.

Cause

YES

Remedy

Defective monitor panel

Replace

Disconnection in wiring
harness between PO1
(female) (13) and starting
switch Rl, or defective
starting switch

Repair or replace

Is voltage between
PO1 (13) and (3)
normal?

*Turn starting switch NO


to HEAT position.
.20-30V

M-6 Related electrical

Monitor

circuit diagram

Panel

TXP0242

PC1 28US-2

20-507
0

M-7

TROUBLESHOOTING

M-7
*
Ir
*

Engine oil pressure caution lamp lights up when engine is running

Before carrying out troubleshooting,


check that all the related connectors
are properly
Always connect any disconnected connectors before going on the next step.
Wheri engine oil pressure is normal.

Remedy

Cause

Defective engine oil


pressure sensor

YES
1

-Disconnect S13.
* Start engine.

2 YES

Defective monitor panel

Is circuit between
_ PO1 (female) (9)
_
NO and chassis
ground insulated?

Contact of chassis ground


with wiring harness
between PO1 (female) (9)
and P13

NO
- Min. 1 MR
* Disconnect PO1 and P13.
-Turn starting switch OFF.

M-7 Related

Monitor

electrical

Replace

Does engine oil


pressure caution
lamp go out?

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
*
*
*

Charge caution lamp lights up when engine is running

Before carrying out troubleshooting,


check that all the related connectors are properly
Always connect any disconnected connectors before going on the next step.
When charging is being carried out normally.

inserted.

Cause

2 YES
Is continuiW
YES_ between POI
1
(female) (10) and
(3) normal?
Is voltage of
alternator terminal R normal?

ti
NO

* Stan engine.
* 27.5 - 29.5 v

. Start engine.
* Measure voltage
between alternator
No
terminal R and chassis
ground.
-27.5 - 29.5 V

M-8 Related electrical

Monitor

Remedy

Defective monitor panel

Replace

Contact of chassis ground


with wiring harness
between PO1 (female) (10)
and alternator terminal R

Repair or replace

Defective generation of
electricity by alternator

Replace

circuit diagram

Panel
I

Alternator

PO 1 (040 16)

TXP02419

PC1 28US-2

20-509
0

M-9

TROUBLESHOOTING

M-9
*

Abnormality

in engine water temperature

gauge

*
*

Before carrying
out troubl&hooting,
check that all the related connectors
are properly
Always connect any disconnected
connectors
before going on the next step.
When engine water temperature
is normal.

a)

After engine is started,

temperature

remains

at bottom

inserted.

level and does not move

RemedY

YES
1

Does level go up
one at a time and
finally go out?

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

Defective monitor panel

Replace

Note 1) If the condition is normal, the


display goes up one level
approx. every 2 sec.

After engine is started, temperature

immediately

goes up (there is no overheating

but gauge enters

red range)
Cause

2 YES
Is resistance
YES between PO7
1
(male) (1) and (2)
normal?
Is voltage between
p
PO1 (3) and chassis - * Start engine
* Min. 4 kQ
ground normal?
* Disconnect P07.
*Start engine.
* Max. 0.1 V

Monitor

Defective monitor panel

NO

NO

M-9 Related electrical

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

Before carrying out troubleshooting,


check that all the related connectors are properly
Always connect any disconnected connectors before going on the next step.
When fuel level is normal.

a) No segments

on fuel gauge light up


Cause

Defective fuel level sensor


(internal disconnection)

YES

Defective contact or
disconnection in wiring
harness between PO1
(female) (7) and PO6
(female) (I), or defective
contact or disconnection in
wiring harness between
fuel level sensor f-end) and
chassis ground

segments light
Does fuel gauge
* Ground PO6 (female) - give full tank
(1) to chassis.
No display?
*Turn startina switch
ON.
* ;;;:3;.ircuit PO1 (7) NO
*Wait for approx. 1
minute.
. Turn starting switch ON.
*Wait for approx. 1 minute.

-1

YES
2
--out?
Is resistance of
. fuel level SenSOr

3 YES

normal?
1

PO1 (3) and chassis

-Start engine.
. Max. 0.1 V

PC128US-2

II

Do all segments
on fuel gauge go
-1

* Disconnect P06.
NO
-Turnstarting switch
ON.
*Wait for approx. 1 minute.

p
. Remove sensor.
* Move float by hand NO
and measure resistance
behveen PO6 (male) (1)
and chassis ground.
* F position: Max. 10 L2
* E position: Min. 85 Q
* Disconnect P4.

seplace

Iepair or replace
viring harness

teplace

at full tank display

Cause

Remedy

Defective monitor panel

b) Fuel level has gone down but fuel gauge remains

YE

inserted.

Remedy

Defective monitor panel

?eplace

Short circuit with chassis


ground in wiring harness
between PO1 (female) (7)
and PO6 (female) (1)

Repair or replace
wiring harness

Defective fuel level sensor

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

YES Is voltage between


1 - PO1 (3) and chassis ground normal?
-

normal?
- Remove sensor.
.zdv;;;;;rV
hand

* start engie.
- Max. 0.1 V

k
NO

NO

Cause

1 Remedy

Defective monitor panel

Replace

Defective contact or
disconnection in wiring
harness between PO1
(female) (3) and chassis
ground

Repair or replace
wiring harness

Defective fuel level sensor

Replace

resistance between PO6 (male)


(1) and chassis ground.
* F position: Max. 10 Q
* Disconnect P06.

M-10 Related

Monitor

electrical

circuit diagram

Panel
I

PO 1 (040 16)

Fuel
level
sensor

TXP02425

20-512
a

PC1 28lJ.S2

M-II

TROUBLESHOOTING

M-l 1 Defective operation


*
Ir
a)

of alarm buzzer

Before carrvino out troubleshooting,


check that all the related connectors are properly
Always connect any disconnected connectors before going on the next step.
Buzzer does not sound

inserted.

Remedy

YES

Defective monitor panel

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

~~~

*Turn starting switch


ON.

b)

Buzzer continues

Defective contact or
disconnection in wiring
harness between battery
relay terminal M - Ml4 (1).
(2)-CN-4(l)-fuse2-PO4
(female) (2). or blown fuse !5

NO

Iepair or replace
wiring harness

to sound and does not stop


Remedy

Replace
when PO1 is
disconnected?

Contact of chassis ground


with wiring harness
between PO1 (female) (15)
and PO4 (female) (1)

-Disconnect POl.
NO
-Turn starting switch
ON.

M-l 1 Related

electrical

circuit diagram

1 (KESl

PO4 (M2)

2)
@.

Panel

=
-

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

M-12 Service meter does not advance when engine is running


*
Ir

Before carrying out troubleshooting,


check that all the related connectors are properly
Always connect any disconnected connectors before going on the next step.

a)

When battery

charge caution

inserted.

lamp does not light up


Remedy

YES

1
Is voltage between
PO1 (female) (10)
and (3) normal?

NO

*Start engine.
.20-30V

b)

When battery

charge caution

Jc Carry out Troubleshooting

Defective monitor panel

Replace

Contact of chassis ground


with wiring harness
between PO1 (female) (10)
and CN-2 (female) (5)

Repair or replace
wiring harness

lamp lights up
Remedy

No. M-9.

Defective monitor panel

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

M-12 Related electrical

Monitor

Contact of chassis ground


with wiring harness
between PO1 (female) (10)
and tilternator terminal R

Replace

circuit diagram

Panel
I

PO1 (04016)

CN-2
(SWP12)
@

Alternator

El7 (X2) -o
--OR
0

TXP02419

20-5 14
0

PC1 28US-2

M-13

TROUBLESHOOTING

M-13 Night lighting does not light up


J, -Before carrying out troubleshooting,
check that all the related connectors are properly
-k .Always connect any disconnected connectors before going on the next step.
a)

Gauge lighting

inserted.

does not light up


Remedy

Cause

1
Is voltage between
PO1 (female) (16)
and (3) normal?

Blown lamp (mslde monitor


panel) for night lighting

YES

Defective contact or
disconnection in wiring
harness between PO1
(female) (16) and PO2
(female) (3)

11

* Disconnect POl.
NO
. Turn starting switch
ON.
. Turn light switch ON.
.20-30V

b)

Service mefer

lighting

Remedy

Replace

circuit diagram

Lighting

switch

,...

PC1 28US-2

does not light up

Defective monitor panel

electrical

Repair or replace
wiring harness

Cause

M-13 Related

Rep,ace

Fusible
I ink

Battery
relay

TXP02428

20-515
0

M-14

TROUBLESHOOTING

M-14 Heater does not work


*
*

Before carrying out troubleshooting,


check that all the related connectors are properly
Always connect any disconnected connectors before going on the next step.

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.

* Turn starting switch


OFF.
NO
-Disconnect M06.

b)

inserted.

F
Go to troubleshooting of
heater
Defective contact or
disconnection in wiring
harness between MO6
(female) (4) and chassis
ground

Repair or replace

Defective heater switch

Replace

Only Lo does not work


Cause

2 YES
Is there continuity
YES between Ml 2
(female) (2) and
1
chassis ground?
~
Is there continuity
_ - DisconnectM12.
between MO6
-Turn starting switch
(male) (3) and (4)?
-Turn starting switch

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

Defective heater switch

Replace

*Turn heater switch to


Lo.

c)

Only Hi does not work


Cause

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

Defective heater switch

Ieplace

-Turn heater switch to


Hi.

20-5 16
0

PC1 28US-2

TROU~~LESHOOTING

M-14

M-14 Related electrical circuit diagram

Preheating

switch
~06 (KES~

~12 (KES~

4)

PC1 28US-2

3)

Preheating
switch

,____

TXP0.2429

20-517
0

TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
Actions to be taken on monitor panel and phenomena on machine body
at the time of abnormality occurrence ....................................................................................................... 20-554
Electrical circuit diagram of mode M System .............................................................................................. 20-556
M-1
[E101] (An error history data abnormality) is displayed .................................................................. 20-560
M-2
[E108] (Detection of engine water temperature 105 ) is displayed................................................ 20-562
M-3
[E112] (Short circuit of wiper normal rotation output) is displayed .................................................. 20-562
M-4
[E113] (Short circuit of wiper reverse rotation output) is displayed ................................................. 20-562
M-5
[E114] (Contact of washer output with 24V) is displayed................................................................ 20-562
M-6
[E115] (Impossibility in 10 sec. at the time of wiping away) is displayed ........................................ 20-562
M-7
[E116] (Impossibility in 10 sec. of storage) is displayed.................................................................. 20-562
M-8
When the starting switch is set to ON, the whole monitor panel does not come ON for 3 sec ....... 20-563
a) When the whole monitor panel does not come ON .................................................................... 20-563
b) When part of the monitor panel does not come ON ................................................................... 20-563
M-9
The starting switch is set to ON, and the whole monitor panel remains lighted.............................. 20-566
M-10 (The engine pre-heating monitor) comes ON even without pre-heating arrangement ................... 20-567
M-11 When the starting switch is set to ON, the engine is started, the basic check items flash.............. 20-569
a) Alternator system........................................................................................................................ 20-569
b) Engine oil pressure system ........................................................................................................ 20-570
M-12 When the starting switch is set to ON (the engine stopped), precautions and
emergency stop items flash. (But "Battery" and "Engine oil pressure" do not come ON)............... 20-571
a) Alternator system........................................................................................................................ 20-571
b) Oil pressure sensor system ........................................................................................................ 20-572
M-13 When the starting switch is set to ON and the engine is started, precautions and emergency
stop items flash. (But when inspection items before diagnosis and engine are normal) ................ 20-573
a) (Engine oil pressure) flashes ...................................................................................................... 20-573
b) (Battery charge level) flashes ..................................................................................................... 20-573
c) (Coolant temperature) flashes .................................................................................................... 20-574
d) (Fuel level) flashes ..................................................................................................................... 20-575
M-14 When the starting switch is set to ON (the engine stops), the buzzer does not sound for 1 sec
Though caution items flash, the buzzer does not sound ................................................................ 20-576
M-15 Monitor panel night lighting does not come ON. (The liquid crystal display is normal)................... 20-577
M-16 The coolant temperature gauge does not rise ................................................................................ 20-578
M-17 The coolant temperature gauge does not indicate
(During operation, the gauge does not indicate any stage) ............................................................ 20-578

PC128US-2

20-551
(17)

M-18
M-19
M-20
M-21
M-22
M-23
M-24

M-25

The fuel level gauge indicates FULL all the time ............................................................................ 20-580
The fuel level gauge indicates nothing............................................................................................ 20-580
Though the swing lock switch is set to ON (lock), (the swing lock monitor) does not come ON..... 20-582
While the engine is rotating, the service meter does not advance.................................................. 20-582
The fuel level sensor system is defective ....................................................................................... 20-583
The coolant temperature sensor system is defective...................................................................... 20-584
The windshield wiper does not work, or works though the wiper is not switched ON..................... 20-585
a) The windshield wiper does not work........................................................................................... 20-585
b) The windshield wiper works though it is not switched ON .......................................................... 20-585
The washer motor does not work, or works though the washer is not switched ON ...................... 20-588
a) The washer motor does not work ............................................................................................... 20-588
b) The washer motor works though the washer is not switched ON............................................... 20-588

! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were
inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and
connectors were returned to the original positions, the machine has restored.
! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the
service code "E" is displayed. (When the service code is not displayed, the machine has restored.)
! Before diagnosis, check if related connectors are engaged properly.
! Be sure to return disconnected connectors to the original positions before proceeding to the next step.

20-552
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM


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

20-556
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM

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

20-558
(17)

PC128US-2

TROUBLESHOOTING

PC128US-2

ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM

20-559
(17)

TROUBLESHOOTING

M-1

M-1 [E101] (An error history data abnormality) is displayed.


PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
" This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13
connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the battery terminals are disconnected and connected for troubleshooting. This is not an abnormality.
(When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF)
" When the service code is displayed again after the resetting arrangement is made, follow the procedures
below for diagnosis:

Cause

Remedy

1
After making the "Resetting arrangement," check the situations for a while in the normal
operation. (See Note 1.)

Is the service code displayed NO


again after the "Resetting arrangement" is taken?

Normal

YES

2
Set the starting switch to
OFF.
20 30V

Is the voltage between P01 (8) NO


and the machine body normal?

Disconnection, defective contact or


ground fault of harness among the bat- Repair or
tery, M13 (1), (2) and P01 (female) (8) replace

YES
Defective monitor panel

Replace

Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)

M-1 Related Electrical Circuit Diagram

20-560
(17)

PC128US-2

TROUBLESHOOTING

M-1

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
" This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13
connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the battery terminals are disconnected and connected for troubleshooting. This is not an abnormality.
(When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF)
" When the service code is displayed again after the resetting arrangement is made, follow the procedures
below for diagnosis:

Cause

Remedy

1
After making the "Resetting arrangement," check the situations for a while in the normal
operation. (See Note 1.)

Is the service code displayed NO


again after the "Resetting arrangement" is taken?

Normal

YES

2
Set the starting switch to
OFF.
20 30V

Is the voltage between P01 (8) NO


and the machine body normal?

Disconnection, defective contact or


ground fault of harness among the bat- Repair or
tery, M13 (1), (2) and P01 (female) (8) replace

YES
Defective monitor panel

Replace

Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)

M-1 Related Electrical Circuit Diagram

PC128US-2

20-561
(17)

TROUBLESHOOTING

M-2, M-3, M-4, M-5, M-6, M-7

M-2 [E108] (Detection of engine water temperature 105) is displayed.

Cause

Remedy

1
Does the coolant temperature gauge NO
on the monitor indicate a red range
and is the caution lamp flashing?

YES
See M-13-c).

Failure of engine body system


(See Note 1.)

2
Set the starting switch to ON.

Is "E" shown in front of the serv- NO


ice code?

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.

M-3 [E112] (Short circuit of wiper normal rotation output) is displayed.


" See M-24.

M-4 [E113] (Short circuit of wiper reverse rotation output) is displayed.


" See M-24.

M-5 [E114] (Contact of washer output with 24V) is displayed.


" See M-25.

M-6 [E115] (Impossibility in 10 sec. at the time of wiping away) is


displayed.
" See M-24.

M-7 [E116] (Impossibility in 10 sec. of storage) is displayed.


" See M-24.

20-562
(17)

PC128US-2

TROUBLESHOOTING

M-8

M-8 When the starting switch is set to ON, the whole monitor panel does
not come ON for 3 sec.
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
" Make sure that Fuses 6, 13 and 18 are not blown.
a) When the whole monitor panel does not come ON

Cause

Remedy

1
Set the starting switch to ON.
20 30V

Are the voltages among P01 (8) NO


(6), (7), P02 (1), (2) (6) and (7)
normal?

YES
Defective monitor panel.

Replace

2
Set the starting switch to ON.
20 30V

Is the voltage between Fuse 13 NO


and the machine body normal?

YES

Disconnection, defective contact or Repair or


ground fault of harness between Fuse
replace
13 and battery relay RM.
Disconnection, defective contact or
ground fault of harness between P01
(female) (1) (2) and Fuse 13

Repair or
replace

3
Set the starting switch to ON.
20 30V

Is the voltage between Fuse 18 NO


and the machine body normal?

YES

Disconnection, defective contact or Repair or


ground fault of harness between Fuse
replace
18 and Battery B.
Disconnection, defective contact or
ground fault of harness between P02
(female) (19) and Fuse 6

Repair or
replace

b) When part of the monitor panel does not come ON

Cause

Defective monitor panel

PC128US-2

Remedy

Replace

20-563
(17)

TROUBLESHOOTING

M-8

M-8 a) Related Electrical Circuit Diagram

20-564
(17)

PC128US-2

M-8

TROUBLESHOOTING

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
a Make sure that Fuses 6, 12 and 18 are not blown.
a) When the whole monitor panel does not come ON

Cause

Remedy

1
Set the starting switch to ON.
20 30V

Are the voltages among P01 (8) NO


(6), (7), P02 (1), (2) (6) and (7)
normal?

YES
Defective monitor panel.

Replace

2
Set the starting switch to ON.
20 30V

Is the voltage between Fuse 12 NO


and the machine body normal?

YES

Disconnection, defective contact or Repair or


ground fault of harness between Fuse
replace
12 and battery relay RM.
Disconnection, defective contact or
ground fault of harness between P01
(female) (1) (2) and Fuse 12

Repair or
replace

3
Set the starting switch to ON.
20 30V

Is the voltage between Fuse 18 NO


and the machine body normal?

YES

Disconnection, defective contact or Repair or


ground fault of harness between Fuse
replace
18 and Battery B.
Disconnection, defective contact or
ground fault of harness between P02
(female) (19) and Fuse 6

Repair or
replace

b) When part of the monitor panel does not come ON

Cause

Defective monitor panel

PC128US-2

Remedy

Replace

20-565
(17)

TROUBLESHOOTING

M-8, M-9

M-8 a) Related Electrical Circuit Diagram

M-9 The starting switch is set to ON, and the whole monitor panel
remains lighted.
Cause

Defective monitor panel

20-566
(17)

Remedy

Replace

PC128US-2

TROUBLESHOOTING

M-10

M-10

(The engine pre-heating monitor) comes ON even without


pre-heating arrangement.

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

Remedy

1
Disconnect the terminal R1.
Set the starting switch to ON.
Max. 1V

Is the voltage between the starting NO


switch R1 and the machine body
normal?

Defective starting switch

Replace

YES

2
Set the starting switch to
ON.
Max. 1V

Is the voltage between P02 (18) NO


and the machine body normal?

Hot short circuit of harness between Repair or


starting switch R1 and P02 (female) replace
(18)

YES
Defective monitor panel

Replace

M-10 Related Electrical Circuit Diagram

PC128US-2

20-567
(17)

TROUBLESHOOTING

M-10

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
a Make sure that S-NET is normal
Cause

Remedy

1
Disconnect the terminal R1.
Set the starting switch to ON.
Max. 1V

Is the voltage between the starting NO


switch R1 and the machine body
normal?

Defective starting switch

Replace

YES

2
Set the starting switch to
ON.
Max. 1V

Is the voltage between CR1 (11) NO


and the machine body normal?

Hot short circuit of harness between Repair or


starting switch R1 and CR1 (female) replace
(11)

YES

3
Are the monitoring code [0045] NO
(3) and [1027] (3) ON?

Defective controller

Replace

Defective controller

Replace

Defective monitor panel

Replace

YES

4
Is the monitoring code [1061] NO
(2) ON?

YES

M-10 Related Electrical Circuit Diagram

20-568
(17)

PC128US-2

TROUBLESHOOTING

M-11

M-11 When the starting switch is set to ON, the engine is started, the
basic check items flash.
a Inspect both the alternator system and the engine oil pressure system.
a) Alternator system
a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is
defective.
Cause

Remedy

1
Engine start, Medium speed
min.
20 30V

Is the voltage between the alter- NO


nator R and the machine body
normal?

Defective alternator

Replace

YES

2
Engine start, Medium speed
min.
20 30V

Is the voltage between P02 (fe- NO


male) (11) and the machine body
normal?

Disconnection or defective contact of Repair or


harness between alternator R and P02 replace
(female) (11)

YES
Defective monitor panel.

Replace

M-11 a) Related Electrical Circuit Diagram


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

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

PC128US-2

20-569
(17)

TROUBLESHOOTING

M-11

b) Engine oil pressure system


a When the engine oil pressure is normal
a Check Bit (3) of Monitoring Code [0046] When it is ON, the monitor panel is defective.

Cause

Remedy

1
Engine slow

Does the display disappear when NO


the oil pressure sensor terminal S17
is disconnected at engine slow?

YES

The oil pressure sensor is defective


(at low pressure).

Replace

Defective monitor panel

Replace

2
Set the starting switch to OFF.
Disconnect the sensor harness
and P02.

Is there continuity between P02


NO
(female) (7) and the machine
body?

YES

Ground fault of harness between P02 Repair or


(female) (7) and sensor terminal S17
replace

M-11 b) Related Electrical Circuit Diagram


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

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

20-570
(17)

PC128US-2

TROUBLESHOOTING

M-12

M-12 When the starting switch is set to ON (the engine stopped),


precautions and emergency stop items flash.
(But "Battery" and "Engine oil pressure" do not come ON.)
a

Inspect both the alternator system and the engine hydraulic system.

a) Alternator system
a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is
defective.

Cause

Remedy

1
Disconnect the terminal R.
Set the starting switch to ON.
Max. 1V

Is the voltage between the alter- NO


nator R and the machine body
normal?

Defective alternator

Replace

YES

2
Disconnect P02.
Set the starting switch to ON.
Max. 1V

Is the voltage between P02 (11) NO


and the machine body normal?

Hot short-circuit of harness between Repair or


P02 (female) (11) and alternator R
replace

YES
Defective monitor panel

Replace

M-12 a) Related Electrical Circuit Diagram


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

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

PC128US-2

20-571
(17)

TROUBLESHOOTING

M-12

b) Oil pressure sensor system


a When the engine oil pressure is normal
a Check Bit (3) of Monitoring Code [0046] When it is ON, the monitor panel is defective.

Cause

Remedy

1
Set the starting switch to OFF.
Disconnect the sensor terminal
S17.

Is there continuity between the NO


sensor terminal S17 and the machine body?

Defective oil pressure sensor

Replace

YES

2
Set the starting switch to ON.
Disconnect P02 and sensor
terminal S17.

Is there continuity between P02 NO


(female) (11) and the sensor terminal S17?

Disconnection or defective contact of


harness between P02 (female) (7) and Repair or
replace
sensor terminal S17

YES
Defective monitor panel

Replace

M-12 b) Related Electrical Circuit Diagram


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

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)

(Engine oil pressure) flashes.


! Before diagnosis, make sure that the engine oil pressure is normal.

Cause

See M-12-b).

b)

(Battery charge level) flashes.

Cause

See M-12-a).

PC128US-2

Remedy

Remedy

20-573
(17)

TROUBLESHOOTING

c)

M-13

(Coolant temperature) flashes.


!

Before diagnosis, make sure that the engine oil pressure is normal.

Cause

Remedy

1
Engine start
Medium speed min.

Is the coolant temperature gauge NO


in the red range?

Defective monitor panel

Replace

YES

2
Engine start

Is only Level 1 (the lowest level)


of the gauge displayed after P07 NO
is disconnected?

YES

The coolant temperature sensor


system is defective. (See M-25.)

3
Set the starting switch to OFF.
Disconnect P02 and P07.
Max. 1

Is the resistance value between


NO
P02 (female) (1) and P07 (female) (1) normal?

Disconnection or defective contact of Repair or


harness between P02 (female) (1) and
replace
P07 (female) (1)

YES

Disconnection or defective contact of Repair or


harness between P02 (female) (1) and
replace
P07 (female) (2)

M-13 c) Related Electrical Circuit Diagram


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

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

20-574
(17)

PC128US-2

TROUBLESHOOTING

d)

M-13

(Fuel level) flashes.


! Before diagnosis, make sure that fuel is not empty.

Cause

Remedy

1
Engine start

Is the fuel gauge in the red range?

NO

Defective monitor panel

Replace

The fuel level sensor system is


defective. (See M-22.)

YES
Engine start
Wait for 2 minutes approx.
(The display of fuel level is
arranged to be slightly delayed because the fuel level
fluctuates.)

Connect P06 (female) (1) to


the machine body ground.
Set the starting switch to
ON.
Max. 0.3V

2
Does the gauge indication come
on up to Level 9 (the right end) NO
when P06 (female) (1) is connected to the machine body ground?

YES

3
Is the voltage between P02 (2) NO
and the machine body normal?

YES

Disconnection or defective contact of


harness between P02 (female) (2) and Repair or
replace
P06 (female) (1)
Defective monitor panel

Replace

M-13 d) Related Electrical Circuit Diagram


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

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?

Defective buzzer cancel switch

Replace

YES

2
Disconnect P03.
Set the starting switch to ON.
20 30V

Is the voltage between P02 (16) NO


and the machine body normal?

Ground fault of harness between P02 Repair or


(female) (16) and P03 (female) (2)
replace

YES
Defective monitor panel

Replace

M-14 Related Electrical Circuit Diagram


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

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

20-576
(17)

PC128US-2

TROUBLESHOOTING

M-15

M-15 Monitor panel night lighting does not come ON.


(The liquid crystal display is normal.)
! When the headlamp and the working lamp come ON normally,

Cause

Remedy

1
Set the starting switch to ON.
Set to Monitoring Code
[0045].

NO

Is Bit (4) of Monitoring Code


[0045] OFF?

YES
Defective monitor panel

Replace

2
Set the starting switch to ON.
Set the lighting switch to ON.
20 30V

Is the voltage between P02 (19) NO


and the machine body normal?

Disconnection or defective contact of


Repair or
harness between P02 (female) (19)
replace
and M47 (male) (14)

YES
Defective monitor panel

Replace

M-15 Related Electrical Circuit Diagram

PC128US-2

20-577
(17)

TROUBLESHOOTING

M-16, M-17

M-16 The coolant temperature gauge does not rise.


!

When engine water temperature does not rise practically, flashes the engine system.

Cause

Remedy

1
Disconnect P07.
Set the starting switch to ON.

When a short connector is connected to P07 (female), does the gauge NO


level rise step by step and does the
gauge go out finally?

YES

The coolant temperature sensor


system is defective. (See M-23.)

Disconnection or defective contact of


harness between P02 (female) (1) and
P07 (female) (1)

Repair or
replace

Disconnection or defective contact of


harness between P02 (female) (13)
(20) and machine body P02 (female)
(2) machine body

Repair or
replace

Defective monitor panel

Replace

2
Set the starting switch to OFF.
Disconnect P02 and P07.

Is there continuity between P02 NO


(female) (1) and P07 (female)
(1)?

YES

3
Set the starting switch to OFF.
Disconnect P02 and P07.

Is there continuity between P02


(female) (13) (20) and P07
(female) (2)?

NO

YES

M-17 The coolant temperature gauge does not indicate.


(During operation, the gauge does not indicate any stage.)
! When the starting switch is set to ON, the gauge level will rise step by step and the gauge will go out finally
or during operation the gauge does not indicate any satage.
Cause

Remedy

1
Disconnect P07.
Set the starting switch to ON.

Does the gauge indication appear NO


when P07 is disconnected?

YES

The coolant temperature sensor


system is defective. (See M-23.)

2
Set the starting switch to ON.
Disconnect P02 and P07.

Is there continuity between P02 NO


(female) (1) and the machine
body?

YES

20-578
(17)

Defective monitor panel

Replace

Ground fault of harness between P02


(female) (1) and P07 (female) (1)

Repair or
replace

PC128US-2

TROUBLESHOOTING

M-16, M-17

M-16, M-17 Related Electrical Circuit Diagram


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

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

The fuel level sensor system is


defective. (See M-22.)

Defective monitor panel

Replace

2
Set the starting switch to
OFF.
Disconnect P02 and P06.

Is there continuity between P02 (fe- NO


male) (2) and the machine body?

YES

Ground fault of harness between P02 Repair or


(female) (2) and P06 (female) (1)
replace

M-19 The fuel level gauge indicates nothing.


! Before the diagnosis, make sure that fuel remains in the fuel tank.

Cause

Remedy

1
Disconnect P06.
Set the starting switch to ON.

Does the gauge indicate anything NO


after P06 (female) (1) is connected to the machine body ground?

YES

The fuel level sensor system is


defective. (See M-22.)

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)

Disconnection or defective contact of


harness between P02 (female) (2) and Repair or
replace
P06 (female) (1)
Defective monitor panel

Replace

PC128US-2

TROUBLESHOOTING

M-18, M-19

M-18, M-19 Related Electrical Circuit Diagram


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

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

PC128US-2

20-581
(17)

TROUBLESHOOTING

M-20, M-21

M-20 Though the swing lock switch is set to ON (lock),


(the swing lock monitor) does not come ON.
! Execute this troubleshooting only when the swing lock is in operation practically.
Cause

Remedy

1
Is the voltage between P02 (17) NO
and the machine body as per the
table?

Set the starting switch to ON.

Disconnection or defective contact of


Repair or
harness between P02 (female) (17)
replace
and X05 (male) (1)

YES
Table
Swing lock switch ON
Swing lock switch OFF

Defective monitor panel

Replace

Max. 1V
20 30V

M-20 Related Electrical Circuit Diagram


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

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.

Is the battery charge level caution NO


lamp ON?

Defective monitor panel

Replace

See M-12 a).

YES

20-582
(17)

PC128US-2

TROUBLESHOOTING

M-22

M-22 The fuel level sensor system is defective.


! Before the diagnosis, remove the fuel level sensor.

Cause

Remedy

1
Check by raising and lowering
the float if the resistance valve NO
between the connector (1) and
the flange is as per the table.

YES

2
NO

Defective sensor (See Note 2.)

Replace

Does the float have large crack, NO


chip or flaw?

Defective contact of connector

Clean or
replace the
connector.

Interference of sensor in tank

Replace the
sensor.
(See Note 2.)

Defective sensor

Replace

Does the arm move smoothly?

YES

YES

4
Is it found in visual check that the NO
harness is cut?

Disconnection of harness (See Note 3.)


(Defective clamp)
(Apply of external force)

YES

Table
Upper stopper position
(Full)

About Max. 12

Lower stopper position


(Empty)

About 85 110

Note 1 : Difference between Fuel Level and Gauge Indication


When the gauge indication is FULL, the fuel level is indicated as 78~100%, and when the indication is
at the lowest position, the fuel level is indicated as 14.5% max. When the machine body is inclined, the
actual indication is different from them. Check the gauge 2 or more minutes later than parking the
machine body on a level ground. (The gauge is arranged to indicate fuel level slowly because the fuel
level fluctuates.)
Note 2 : Install the sensor carefully so that it does not interfere inside the tank or that it may be installed improperly.
Note 3 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.

PC128US-2

20-583
(17)

TROUBLESHOOTING

M-23

M-23 The coolant temperature sensor system is defective.


Cause

Remedy

1
Is the resistance value between the NO
temperature sensor connectors
(male) (1) and (2) as per the table?

YES

Defective contact of connector


(See Note 1.)

Clean the
connector or
replace the
sensor.

Defective sensor

Replace

2
Is it found in visual check that the NO
harness is cut?

YES

Disconnection of harness (See Note 2.)


Replace the
(Defective clamp)
sensor.
(Apply of external force)

Table
Normal temperature (25C)

About 37 50k

100C

About 3.5 4.0k

Note 1 : In case of recurrence, the machine side connector (female side) is supposed to be defective. So, check
the machine side connector and harness.
Note 2 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.

20-584
(17)

PC128US-2

TROUBLESHOOTING

M-24

M-24 The windshield wiper does not work, or works though the wiper is
not switched ON.
a) The windshield wiper does not work.
! Make sure that the fuse 18 is normal.
! Execute this diagnosis when the service code [E112] [E113], [E115] or [E116] is displayed.
Cause
Front window : Close position
Set the starting switch to ON.
Set the monitoring code to
[0049].

Remedy

1
NO

Does Bit (3) of the monitoring


code [0049] come on?

YES
Set the starting switch to ON.
Set the wiper switch to "ON"
or "INT."
Set the monitoring code to
[0049].

2
When the wiper switch is set to
"ON" or "INT," do Bits (4) and (5) NO
of the monitoring code [0049] go
out?

Defective monitor panel

Replace

Defective wiper motor

Replace

YES

3
Set the starting switch to ON.

NO

Are the voltages between pins of


M50 as per Table 1?

YES

4
Set the starting switch to OFF.
Disconnect P02 and M50.

Are the resistance values between pins from P01 (female) and NO
M50 (male) as per Table 2?

YES

Set the starting switch to OFF.


Disconnect Terminals (1)
and (2) of W03.
Max. 1

Disconnection, defective contact, short- Repair or


circuit of ground fault of harness of im- replace
proper resistance value
Defective monitor panel

5
Is the resistance value between NO
Terminals (1) and (2) of the rear
limit switch W03 normal?

Replace

Check the
front window,
The rear limit switch is defective, or the or replace the
front window is opened.
rear limit
switch.

YES

6
. Set the starting switch to OFF.
Disconnect P02 and Terminals (1) and (2) of W03.
Max. 1

Are the resistance values between


the rear limit switch W03 terminal NO
(1) and P02 (female) (15) and between W03 Terminal (2) and the
machine body normal?

Disconnection or defective contact of Repair or


harness of improper resistance value
replace

YES
Defective monitor panel

Replace

b) The windshield wiper works though it is not switched ON.


Cause

Remedy

1
Front window : Closed position
Set the starting switch to ON.
Set the monitoring code to
[0049]

NO

Does Bit (3) of the monitoring


code [0049] come ON?

Defective monitor panel

Replace

Defective monitor panel

Replace

YES
Set the starting switch to ON.
Set the wiper switch to "ON"
or "INT."
Set the monitoring code to
[0049].

PC128US-2

2
When the wiper switch is set to NO
"ON" or "INT," do Bits (4) and (5) of
the monitoring code [0049] go out?

YES

Hot short circuit of harness between


P01 (female) (9) and M50 (female) (3) Repair or
or between P01 (female) (10) and M50 replace
(female) (1)

20-585
(17)

TROUBLESHOOTING

M-24

Table 1
Timing Chart when the windshield wiper is set to ON
Symbol

Set time

Temporary stop
time to the next
operation

Item

Tia

0.13 sec

Safety circuit during


wiper operation
(Safety function 1)

Tsa

10 sec

Temporary halt time


at wiper blade storage

Tip

1.5 sec

Safety circuit at
wiper storage
(Safety function 2)

Tsp

10 sec

When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in the range
of 20 30V.

Timing Chart when the windshield wiper is set to INT.


Item

Symbol Set time

Temporary stop time to


the next operation

Tia

4 sec

Safety circuit during


wiper operation (Safety
function 1)

Tsa

10 sec

Temporary halt time at


wiper blade storage

Tip

1.5 sec

Safety circuit at wiper


storage
(Safety function 2)

Tsp

10 sec

When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in
the range from 20 30V.
Table 2
Diagnosis 1

Resistance value

Between P01 (female) (10) and M50 (male) (1)


Between P01 (female) (9) and M50 (male) (3)
Between P01 (female) (12) and M50 (male) (4)

Max. 1

Between P01 (female) (6), (7) and M50 (male) (5)


Between P01 (female) (5) and M50 (male) (6)
Between M50 (female) (1), (3), (4), (5), (6) and GND

20-586
(17)

Min. 1M

PC128US-2

TROUBLESHOOTING

M-24

M-24 Related Electrical Circuit Diagram


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

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

PC128US-2

20-587
(17)

TROUBLESHOOTING

M25

M-25 The washer motor does not work, or works though the washer is not
switched ON.
a) The washer motor does not work.
! Make sure that Fuse 4 is normal.
a-1) When [E114] is displayed.

Cause

Remedy

1
Set the starting switch to ON.
Disconnect P02 and M28.
Max. 1V

Is the voltage among P01 (fe- NO


male) (3), M28 (female) (2) and
the machine body normal?

YES

Hot short circuit of harness between


Replace
P01 (female) (3) and M28 (female) (1).
Defective monitor panel
Defective diode

Repair or
replace

a-2) When [E114] is not displayed.

Cause

Remedy

1
Set the starting switch to ON.
Disconnect M28.
Max. 20 30V

Is the voltage among Fuse 4, NO


M28 (female) (2) and the machine body normal?

Disconnection or defective contact of Repair or


harness between Fuse 4 and M28 (fe- replace
male) (2).

YES

2
Set the starting switch to OFF.
Disconnect P01 and M28.
Max. 1

Is the resistance value between NO


P01 (female) (3), M28 (female)
(1) normal?

Disconnection or defective contact of


harness between P01 (female) (3) and
M28 (female) (1).

Repair or
replace

Defective washer motor

Replace

Defective monitor panel

Replace

YES

3
Set the starting switch to ON.
Set the washer switch to ON.
Max. 1V

Is the voltage between P01 (fe- NO


male) (3) and the machine body
normal?

YES

b) The washer motor works though the washer is not switched ON.

Cause

Remedy

1
Set the starting switch to OFF.
Disconnect P02 and M28.
Min. 1M

Is the resistance value between NO


M28 (female) (1) and the machine body normal?

Ground fault of harness between P01 Repair or


(female) (3) and M28 (female) (1).
replace

YES
Defective monitor panel

20-588
(17)

Replace

PC128US-2

TROUBLESHOOTING

M-25

M-25 Related Electrical Circuit Diagram


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

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

PC128US-2

20-589
(17)

TROUBLESHOOTING OF COMMUNICATION
SYSTEM (N MODE)

PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
N-1 [E218] Communication abnormality ................................................................................................... 20-602

! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were
inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and
connectors were returned to the original positions, the machine has restored.
! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the
service code "E" is displayed. (When the service code is not displayed, the machine has restored.)
! Before diagnosis, check if related connectors are engaged properly.
! Be sure to return disconnected connectors to the original positions before proceeding to the next step.
PC128US-2

20-601
(17)

TROUBLESHOOTING

N-1

N-1

[E218] Communication abnormality

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
1

Cause

Remedy

Are [128] and "US" intermittently NO


displayed in the monitoring code
1002?

YES

Set the starting switch to ON.


7.5V min.
Disconnect CR2 and measure
the voltage on the harness
side.

The machine has restored.

Defective controller CR700

Replace

2
Is the voltage between CR2 (21) NO
and the machine body normal?

YES

3
Is the resistance value among NO
P02 (9), (10) and CR2 (21)
normal?

YES

Disconnection of harness among P02


Replace
(9), (10) and CR2 (21)
Defective monitor panel

Replace

When each controller is not connected to the network, "---" is displayed. When a correct alphanumeric
character is not displayed (when another model is displayed), the model of each controller has not been
selected properly.

N-1 Related Electrical Circuit Diagram

20-602
(17)

PC128US-2

TROUBLESHOOTING

N-1

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
1

Cause

Remedy

Are model code and attachment NO


code displayed according to
setting in monitoring code 1001?

YES

Set the starting switch to ON.


7.5V min.
Disconnect CR2 and measure
the voltage on the harness
side.

The machine has restored.

Defective controller CR700

Replace

2
Is the voltage between CR2 (21) NO
and the machine body normal?

YES

3
Is the resistance value among NO
P02 (9), (10) and CR2 (21)
normal?

YES

Disconnection of harness among P02


Replace
(9), (10) and CR2 (21)
Defective monitor panel

Replace

N-1 Related Electrical Circuit Diagram

PC128US-2

20-603
(17)

TROUBLESHOOTING OF CONTROLLER CR700


[DECELERATION CONTROL SYSTEM]
(E MODE)
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
Cautions when troubleshooting controller CR700 [Deceleration control system] ....................................... 20-702
Response of controller and phenomena on machine body when abnormality has occurred...................... 20-704
Table for determining controller (Engine throttle control system) or engine related .................................... 20-706
Electric circuit diagram of E mode system ................................................................................................. 20-708
E-1
Abnormality in power supply of controller CR700 (LED on controller is OFF) ................................ 20-712
E-2
[E321] [E322] "Short circuit/disconnection in motor drive relay system" is displayed .................... 20-714
E-3
[E323] [E324] "Short circuit/disconnection in accelerator relay system" is displayed ..................... 20-715
E-4
[E325] [E326] "Short circuit/disconnection in decelerator relay system" is displayed..................... 20-717
E-5
[E328] "Abnormality in motor stall system" is displayed ................................................................. 20-719
E-6
[E308] "Abnormality in fuel dial input value" is displayed ............................................................... 20-721
E-7
[E227] "Abnormality in engine speed sensor system" is displayed ................................................ 20-722
E-8
[E306] "Abnormality in motor feedback potentiometer input value" is displayed ............................ 20-723
E-9
[E258] "Short circuit in potentiometer power supply" is displayed .................................................. 20-725
E-10 [E304] [E314] "Short circuit/disconnection in engine stop solenoid relay system" is displayed...... 20-727
E-11 Auto-decelerator does not operate ................................................................................................. 20-728

! During troubleshooting after an abnormality occurred, if service code "E" is not displayed when you inserted
a T-adapter after detaching a connector, or when you connected the connector after detaching the Tadapter, the normal condition has been restored already.
! If you have turned off starting-switch after an abnormality occurred, turn it on and check to see if service
code "E" is displayed. (If it is not displayed, the normal condition has been restored).
! Before starting troubleshooting, check for any faulty engagement of related connectors.
! Before going to next step in the troubleshooting procedure, be sure to connect any connector you have
detached.

PC128US-2

20-701
(17)

CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700


[DECELERATION CONTROL SYSTEM]

TROUBLESHOOTING

CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700


[DECELERATION CONTROL SYSTEM]
1. The machine has the control function as shown below for starting cold engine to prevent seizure of turbocharger because of cold engine coolant (lower than 30C).

Deceleration-motor
potentiometer
(Controls the process.)

Engine is forced to be fixed at the rpm for


warming-up. (Any throttle direction is ignored.)

Any rpm
(Follows the throttle
direction.)

2 seconds
Starting switch
turned "ON"

A: Turbocharger protection time


C: Modulation range

Starting switch
turned to "START"

B: Modulation time
D: When engine speed does not reach 1,200 rpm

The machine does not allow engine to start when coolant is cold (lower than 30 C) when the deceleration
motor was found normal by the check of whether or not the deceleration motor linkage worked.
! To release this control of cold engine start, connect a short-circuit connector to engine-coolant-temperature sensor (CN-P07) connected to CN-P02 ((1)) on monitor panel and cause short circuit between it
and GND {or between CN-P07 (female) (1) and GND}, or check operation in the deceleration-adjustment mode.
2. Cautions when an abnormality occurred with no user code displayed
The engine is under the control of controller CR700.
Problems which may occur in this system include:
1) Higher (lower) idling speed
2) Lower rpm in high idle
3) Higher (lower) rpm in auto-deceleration
4) Higher (lower) engine speed during auto-matic warming-up
5) Hunting
6) Engine does not stop.
If an abnormality occurred, and it was alarmed in the clock-display section on monitor panel, look up to the
corresponding diagnosis flow of E1 through E10 according to the quick-reference table for troubleshooting.
If no abnormality was alarmed on the display though it existed in the machine body, you have to determine
whether it occurred in "mechanical system or electric system". The problems listed in 1) - 6) above may
also occur due to faulty adjustment of the linkage between deceleration motor and injection pump. If any of
1) - 6) above occurred without no alarm on the display, diagnose it according to the following procedure:

20-702
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM


PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
(1/2)

20-708
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

(2/2)

PC128US-2

20-709
(17)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
(1/2)

20-710
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

(2/2)

PC128US-2

20-711
(17)

TROUBLESHOOTING

E-1

E-1

Abnormality in power supply of controller CR700


(LED on controller is OFF)

! Check that fuse 11 is not blown.


! If starting motor runs normally, follow the procedure below. (Otherwise, refer to E-8.)

Cause

Remedy

1
Turn starting switch ON
20 30V

Is voltage normal between CR3 NO


(1),(11) (21), (31), (32), (33)?

YES
Defective controller CR700

Replace

2
Starting switch ON
20 30V

Is voltage between fuse 18 and NO


body normal?

YES

Disconnection or defective contact of Repair or


harness between fuse 18 and battery.
replace
Disconnection or defective contact of
harnesses between fuse 18 and CR3 Repair or
replace
(female) (1),(11).

E-1 Related electric circuit diagram


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

20-712
(17)

PC128US-2

TROUBLESHOOTING

E-1

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

PC128US-2

20-713
(17)

TROUBLESHOOTING

E-2

E-2

[E321] [E322] "Short circuit/Disconnection in motor drive relay


system" is displayed
Cause

Turn starting switch ON;


operate fuel dial.
1.2A or less
Temperature of engine
coolant: 30C or higher

Remedy

1
Is current value normal between NO
CR3 (female) (18) and (23)?

YES
Defective controller

Replace

2
Detach R07 and CR3.
Min. 1 M

Is resistance value normal between NO


CR3 (female) (18) and body?

Defective harness; defective connector Repair or


CN-A09
replace

YES
Defective relay

Replace

E-2 Related electric circuit diagram

20-714
(17)

PC128US-2

TROUBLESHOOTING

E-3

E-3

[E323] [E324] "Short circuit/Disconnection in accelerator relay system" is displayed

Cause

Remedy

1
Turn starting switch ON;
operate dial (up).
1.2A or less

Is current value normal between NO


CR3 (female) (25) and (23)?

YES
Defective controller

Replace

2
Detach R09 and CR3.
Min. 1 M

Is resistance value normal between NO


CR3 (female) (25) and body?

Defective harness; defective connector Repair or


CN-A09
replace

YES
Defective relay

Replace

E-3 Related electric circuit diagram


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

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

[E325] [E326] "Short circuit/Disconnection in decelerator relay system" is displayed


Cause

Remedy

1
Turn starting switch ON;
operate dial (down).
1.2A or less.

Is current value normal between NO


CR3 (female) (35) and (23)?

YES
Defective controller

Replace

Defective harness

Repair or
replace

Defective relay

Replace

2
Detach R08 and CR3.
Min. 1 M

Is resistance value normal between NO


CR3 (female) (35) and body?

YES

E-4 Related electric circuit diagram


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

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

[E328] "Abnormality in motor stall system" is displayed

! Abnormality in motor stall is alarmed if motor did not follow the operation of dial for 10 seconds after the
operation. Check by monitoring whether input signal and relay output are normal while the alarm issued
remains on the display.
PC128US-2
Serial No.: 5001 and up
PC138USLC-2 Serial No.: 1001 1500
Cause
Turn starting switch ON.
4A or less if normal
When dialed up:
(+) on (5) side, () on (6) side
When dialed down:
() on (5) side, (+) on (6) side

Resistance value between


(1) and (2) of eachrelay:
290 10%
Operation of each relay
(when starting switch is ON)
When neutral:
(3) and (6) continue.
When dialed up:
R07, and R09 (3) and (5)
continue.
When dialed down:
R07, and R08 (3) and (5)
continue.

Remedy

1
Is current value normal between NO
M48 (female) (5) (motor (+)) and
(6)(motor ())?

YES
Defective motor (drive system)

Replace
motor

Defective relay

Replace

Defective harness; fuse (9) blown

Repair or
replace

2
Do relays of R07, R08 and R09 NO
operate normally?

YES

E-5 Related electric circuit diagram

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

[E308] "Abnormality in fuel dial input value" is displayed

! Check that the input value is normal in the monitoring mode.


Cause

Remedy

Fuel control dial voltage:


Fuel control dial FULL: 0.7 V

Is fuel control dial voltage of NO


monitoring 1034 normal?

Fuel control dial SLOW: 4.3 V


Disconnect M51.
M51 (male)
Between (1) (2):
0.25 5 k
Between (2) (3):
0.25 5 k
Between (1) (3): 4 6 k
Between M51 (male) (1), (2),
(3) chassis ground:
Min. 1 M

YES
Defective controller

Replace

Defective fuel control dial

Replace

Defective wiring harness

Repair or
replace

2
Is resistance between M51 (male) NO
(1), (2), and (3) normal?

YES

E-6 Related electric circuit diagram

PC128US-2

20-721
(17)

TROUBLESHOOTING

E-7

E-7

[E227] "Abnormality in engine speed sensor system" Is displayed


Cause

Turn starting switch OFF: 0


Engine slow:
93 +50 (930 rpm) (*1)
110 5 (1,100 rpm) (*2)
Engine full:
240 5 (2,400 rpm)

Remedy

1
NO

Is engine speed (monitoring code


1010) normal?

YES
Defective controller

Replace

Defective engine speed sensor

Replace

Defective harness

Replace
motor

Faulty installation of engine-speed


sensor

Testing and
adjusting

2
Detach E07
500 1,000

Is resistance value normal between E07 (male) (1) and (2)?

NO

YES
3
Detach CR2
500 1,000

Is resistance value normal between CR2 (female) (39) and


(40)?

YES

(*1) PC128US-2
PC138USLC-2
(*2) PC138US-2
PC138USLC-2

NO

Serial No.: 7731 and up


Serial No.: 1001 1500
Serial No.: 4501 and up
Serial No.: 1501 and up

E-7 Related electric circuit diagram


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

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

20-722
(17)

PC128US-2

E-8

TROUBLESHOOTING

E-8

[E306] "Abnormality in motor feedback potentiometer input value" is


displayed

! Check that the input value is normal in the monitoring mode.

Cause
Reset auto-decelerator.
Feedback potentiometer
voltage:
Fuel control dial FULL:
4.2 V (*1)
4.6 V (*2)
Fuel control dial SLOW:
2.1 V (*1)
2.7 V (*2)
Disconnect M48.
M48 (male)
Between (1) (2):
0.36 3.9 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

Defective decelerator motor

Replace

Defective wiring harness

Repair or
replace

2
Is resistance between M48 (male) NO
(1), (2), and (3) normal?

YES

Serial No.: 7731 and up


Serial No.: 1001 1500
Serial No.: 4501 and up
Serial No.: 1501 and up

E-8 Related electric circuit diagram


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

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

[E258] "Short circuit in potentiometer power supply" is displayed

Disconnect CR1.
Resistance between CR1
(female) (22) chassis
ground: Min. 1 M

Cause

Remedy

Is resistance between CR1 (female) NO


(22) and chassis ground normal?

YES

Disconnect M48.
Resistance between CR1
(female) (22) chassis
ground: Min. 1 M

Defective controller

Replace

Defective deceleration motor

Replace

Defective wiring harness


(Short circuit in 5-V line)

Repair or
replace

Defective fuel control dial

Replace

2
Is resistance between CR1 (female) NO
(22) and chassis ground normal?

YES

Disconnect M51.
Resistance between CR1
(female) (22) chassis
ground: Min. 1 M

3
Is resistance between CR1 (female) NO
(22) and chassis ground normal?

YES

E-9 Related electric circuit diagram


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

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

E-10 [E304] [E314] "Short circuit/Disconnection in engine stop solenoid


relay system" is displayed
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Cause
Disconnect CR3.
Resistance between CR3
(female) (4) chassis
ground: 68 10%

Remedy

1
Is resistance between CR3 (female)
(4) and chassis ground normal?

NO

YES
Defective controller

Replace

Defective stop solenoid relay

Replace

Defective wiring harness


(Grounding fault)

Repair or
replace

Defective diode (D03)

Replace

Disconnect M52.
Resistance between M52
(male) (1) (2): 68 10%
Resistance between M52
(male) (1), (2) chassis
ground: Min. 1 M

Are resistance between stop solenoid


relay M52 (male) (1) and (2) and
resistance between each pin and
chassis ground normal?

Disconnect D32
(with M52 disconnected).
Resistance between CR3
(female) (4) chassis
ground: Min. 1 M

Is resistance between CR3 (female)


(4) and chassis ground normal?

NO

YES
3
NO

YES

E-10 Related electric circuit diagram

PC128US-2

20-727
(17)

TROUBLESHOOTING

E-11

E-11 Auto-decelerator does not operate


PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
! Check the auto-decelerator reset input signal and each pressure switch input signal in the monitoring mode.

Cause
When auto-decelerator reset
switch is pressed;
Bit (2): ON (Auto-decelerator
reset)

Remedy

1
Is auto-decelerator reset switch NO
of monitoring 1022 normal?

Defective monitor panel or controller

Replace

Defective controller

Replace

Defective pressure switch


(Internal seizure)

Replace

Defective wiring harness


(Grounding fault in signal line)

Repair or
replace

YES
Monitoring code [1023]
Bit (1): OFF (Boom LOWER
pressure switch)
Bit (3): OFF (Travel pressure
switch)
Bit (4): OFF (Swing pressure
switch)
Bit (5): OFF (Arm IN
pressure switch)
Bit (6): OFF (Boom RAISE
pressure switch)
Monitoring code [1028]
Bit (1): OFF (Arm OUT
pressure switch)
Bit (2): OFF (Att, blade
RAISE/LOWER pressure
switch)
Bit (3): OFF (Bucket CURL
pressure switch)
Bit (4): OFF (Bucket DUMP
pressure switch)

2
Is each pressure switch signal of
monitoring 1023 and 1028 nor- NO
mal?

YES

3
When pressure switch connector of
NO
abnormal part is disconnected,
does bit keep lighting?

YES

E-11 Related electric circuit diagram

! The pressure switches for the blade and attachments are not shown in this figure.

20-728
(17)

PC128US-2

TROUBLESHOOTING OF CONTROLLER CR700


[PUMP CONTROL SYSTEM]
(C MODE)
PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
Cautions when troubleshooting controller CR700 [Pump control system] .................................................. 20-802
Response of controller and phenomena on machine body when abnormality has occurred...................... 20-804
Table for determining controller CR700 [Pump control system] or oil pressure in ralated .......................... 20-808
Electric circuit diagram of C mode system ................................................................................................. 20-812
Troubleshooting flow chart for each failure mode
C-1
Abnormality in power supply of controller (LED on controller is OFF) ............................................ 20-816
C-2
[E232] "Short circuit in PC-EPC solenoid system" is displayed ...................................................... 20-818
C-3
[E233] "Disconnection in PC-EPC solenoid system" is displayed .................................................. 20-820
C-4
[E203] "Short circuit in swing holding brake solenoid system" is displayed.................................... 20-822
C-5
[E213] "Disconnection in swing holding brake solenoid system" is displayed ................................ 20-826
C-6
[E206] "Short circuit in travel Hi/Lo selection solenoid system" is displayed .................................. 20-830
C-7
[E216] "Disconnection in travel Hi/Lo selection solenoid system" is displayed............................... 20-832
C-8
[E205] "Short circuit in 2-stage relief solenoid system" is displayed............................................... 20-834
C-9
[E215] "Disconnection in 2-stage relief solenoid system" is displayed ........................................... 20-836
C-10 [E222] "Short circuit in LS-EPC solenoid system" is displayed ...................................................... 20-838
C-11 [E223] "Disconnection in LS-EPC solenoid system" is displayed ................................................... 20-839
C-12 [E224] "Abnormality in pump pressure sensor system" is displayed .............................................. 20-840
C-13 [E227] "Abnormality in engine speed sensor system" is displayed ................................................ 20-841

! During troubleshooting after an abnormality occurred, if no service code "E" is displayed when you inserted
a T-adapter after detaching a connector, or when you connected the connector after detaching the Tadapter, the normal condition has been restored already.
! Before starting troubleshooting, check for any faulty engagement of related connectors.
! Before going to next step in the troubleshooting procedure, be sure to connect the connector you have
detached.

PC128US-2

20-801
(17)

TABLE FOR DETERMINING CONTROLLER


CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED

TROUBLESHOOTING

TABLE FOR DETERMINING CONTROLLER CR700 (PUMP CONTROL


SYSTEM) OR OIL PRESSURE IN RELATED
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Controller CR700 (E2: XX type)
Abnormality in power supply of
controller
Short circuit in PC-EPC
solenoid system
Disconnection in PC-EPC
solenoid system
Short circuit in swing holding
brake solenoid system
Disconnection in swing holding brake solenoid system
Short circuit in travel speed
selection solenoid system
Disconnection in travel speed
selection solenoid system
Short circuit in 2-Stage relief
solenoid system
Disconnection in 2-Stage
relief solenoid system
Short circuit in LS-EPC
solenoid system
Disconnection in LS-EPC
solenoid system

Results of self-diagnosis displayed

User codes

Traveling system

Compound
operation

Work-equipment

Entire work-equipment, traveling, and


swinging

Failure mode

Service codes
Slower speed or reduced power of entire work equipment, traveling,
and swinging
Substantial drop of engine speed, or engine stop
Entire work equipment, traveling, and swinging are inoperable.
Abnormal noise (from around pump)
Auto-deceleration inoperable
Poor fine control performance, or poor response
Slower or less powerful movement of boom
Slower or less powerful movement of arm
Slower or less powerful movement of bucket
Boom inoperable
Arm inoperable
Bucket inoperable
Greater hydraulic drift
Greater time lag (engine slow)
Independent relief causes other work equipment's movement.
Full power cannot be attained when pressure is increased.
Worsened or weaker stroke-end cushion of boom RAISE
In the case of compound operation, the greater the load, the longer
the time of operation.
Boom moves slower in the case of the swing + boom (RAISE) operation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Travel deviation
Deviation is great at the start of traveling
Slower traveling speed
Steering is hard or not powerful.
Traveling speed is unchangeable, or faster than the set speed.
Inoperable (only on one side)
Does not swing.

Swinging system

E02
E03

LED
off 232 233 203 213 206 216 205 215 222 223

Worsened acceleration
performance or speed
of swinging

Both R.H. and L.H.


One side only
Both R.H. and L.H.
One side only

Both R.H. and L.H.


One side only
Greater shock when swinging is stopped (only on one side)
Greater abnormal noise when swinging is stopped
Greater hydraulic drift When swing holding brake is released
during swinging
When swing holding brake is operating
Diagnosis codes when service codes are displayed
Diagnosis codes when abnormality was found by checking monitoring
codes
Greater drift when
swinging is stopped

C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11

Items checked only by monitoring

20-808
(17)

PC128US-2

TABLE FOR DETERMINING CONTROLLER


CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED

TROUBLESHOOTING

! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.

LS-EPC current output

PC-EPC current output

Monitoring codes

1023

1021

1060

1002 1010 1042 1050 1054

Diagnosis codes when no service code is


displayed

Bit patterns
227

Engine speed input

Model code

Traveling

2-stage relief (6)

PPC initial pressure (2)

Swing holding brake (1)

Kerosene mode (6)

Service pressure switch (2)

Bucket DUMP (2)

Bucket CURL (2)

Arm OUT (2)

Arm IN (5)

Boom RAISE (6)

Boom LOWER (2)

Traveling (3)

224

Status of solenoid in
operation

Oil-pressure switch

Pump discharge pressure input

Items to be checked in the monitoring mode

Swinging (4)

Abnormality in pump
pressure sensor system

Abnormality in engine speed


sensor system

Controller CR700
(E2: XX type)
Results of self diagnosis displayed

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

H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
C-12

C-13

F-1

F-2

F-3

F-4

F-5

PC128US-2

F-6

F-7

F-8

F-9 F-10

20-809
(17)

TABLE FOR DETERMINING CONTROLLER


CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED

TROUBLESHOOTING

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Controller CR700 (E2: XX type)
Abnormality in power supply of
controller
Short circuit in PC-EPC
solenoid system
Disconnection in PC-EPC
solenoid system
Short circuit in swing holding
brake solenoid system
Disconnection in swing holding brake solenoid system
Short circuit in travel speed
selection solenoid system
Disconnection in travel speed
selection solenoid system
Short circuit in 2-Stage relief
solenoid system
Disconnection in 2-Stage
relief solenoid system
Short circuit in LS-EPC
solenoid system
Disconnection in LS-EPC
solenoid system

Results of self-diagnosis displayed

User codes

Traveling system

Compound
operation

Work-equipment

Entire work-equipment, traveling, and


swinging

Failure mode

Service codes
Slower speed or reduced power of entire work equipment, traveling,
and swinging
Substantial drop of engine speed, or engine stop
Entire work equipment, traveling, and swinging are inoperable.
Abnormal noise (from around pump)
Auto-deceleration inoperable
Poor fine control performance, or poor response
Slower or less powerful movement of boom
Slower or less powerful movement of arm
Slower or less powerful movement of bucket
Boom inoperable
Arm inoperable
Bucket inoperable
Greater hydraulic drift
Greater time lag (engine slow)
Independent relief causes other work equipment's movement.
Full power cannot be attained when pressure is increased.
Worsened or weaker stroke-end cushion of boom RAISE
In the case of compound operation, the greater the load, the longer
the time of operation.
Boom moves slower in the case of the swing + boom (RAISE) operation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Travel deviation
Deviation is great at the start of traveling
Slower traveling speed
Steering is hard or not powerful.
Traveling speed is unchangeable, or faster than the set speed.
Inoperable (only on one side)
Does not swing.

Swinging system

E02
E03

LED
off 232 233 203 213 206 216 205 215 222 223

Worsened acceleration
performance or speed
of swinging

Both R.H. and L.H.


One side only
Both R.H. and L.H.
One side only

Both R.H. and L.H.


One side only
Greater shock when swinging is stopped (only on one side)
Greater abnormal noise when swinging is stopped
Greater hydraulic drift When swing holding brake is released
during swinging
When swing holding brake is operating
Diagnosis codes when service codes are displayed
Diagnosis codes when abnormality was found by checking monitoring
codes
Greater drift when
swinging is stopped

C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11

Items checked only by monitoring

20-810
(17)

PC128US-2

TABLE FOR DETERMINING CONTROLLER


CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED

TROUBLESHOOTING

! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.

1023

LS-EPC current output

PC-EPC current output

Monitoring codes
1028

1021

1060

1002 1010 1042 1050 1054

Diagnosis codes when no service code is


displayed

Bit patterns
227

Engine speed input

Model code

Traveling

2-stage relief (6)

PPC initial pressure (2)

Swing holding brake (1)

Kerosene mode (6)

Service pressure switch (2)

Bucket DUMP (4)

Bucket CURL (3)

Arm OUT (1)

Arm IN (5)

Boom RAISE (6)

Boom LOWER (1)

Traveling (3)

224

Status of solenoid in
operation

Oil-pressure switch

Pump discharge pressure input

Items to be checked in the monitoring mode

Swinging (4)

Abnormality in pump
pressure sensor system

Abnormality in engine speed


sensor system

Controller CR700
(E2: XX type)
Results of self diagnosis displayed

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

H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
C-12

C-13

F-1

F-2

F-3

F-4

F-5

PC128US-2

F-6

F-7

F-8

F-9 F-10

20-811
(17)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM


PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
(1/2)

20-812
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM

(2/2)

PC128US-2

20-813
(17)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
(1/2)

20-814
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM

(2/2)

PC128US-2

20-815
(17)

TROUBLESHOOTING

C-1

C-1

Abnormality in power supply of controller (LED on controller is OFF)

! Check that fuses (1) and (18) are not blown.

Cause
2 YES

Defective controller

Remedy
Replace

Is voltage normal

YES between CR3 (14),


(24) (21), (31),
1

(32), (33)?
Is voltage normal
between CR3 (1),
Turn starting switch NO
(11) and each (21),
ON
(31), (32) and
20 30 V
(33)?
Attach T-adapter
Turn starting switch NO
OFF: 20 30 V

Disconnection or defective con- Repair or


tact of harnesses between CR3 replace
(14), (24) and CNM47 (3)
Disconnection or defective
contact between fuse (18) and
CR3 (1),(11); Disconnection or Replace
defectivecontact between CR3 motor
(21),(31),(32),(33) and CN-A04
(12),(14)

C-1 Related electric circuit diagram


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

20-816
(17)

PC128US-2

TROUBLESHOOTING

C-1

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

PC128US-2

20-817
(17)

TROUBLESHOOTING

C-2
!

C-2

[E232] "Short circuit in PC-EPC solenoid system" is displayed

Be sure to turn emergency pump drive switch to DOWN (normal).

Cause
YES

Defective controller CR700

4 YES
Do resistance values
Do resistance valbetween CR3 (feYES male)(16) and (23),
ues between C06
(male) (2) and (3),
and between (16)
YES
between (5) and (6),
and body match with
and between C06
Table 1?
(male) (2), (3), (5),
3
Turn starting switch
(6) and body match
Do
resistance
valOFF.
with Table 2?
1
ues between C06
Disconnect CR3.
Do resistance values
(female) (2) and (5),
NO
Turn starting
Attach directcoupled
switch OFF.
between C13 (male)
connector to
NO and between (2) and
body match with Ta Disconnect C06.
(1) and (2), and beCN-D23 and D24.
ble 1?
Turn emergency
tween (1) and body
pump drive switch to
match with Table 1?
Turn starting switch
DOWN (normal).
OFF.
Turn starting switch
Disconnect C06.
OFF.
NO
Disconnect C13.

Replace

Ground fault or hot-short-circuit


of harness between CR3 (fe- Repair or
male)(16) and C06 (female)(3);
or hot short circuit of harness replace
between CR3 (female)(23) and
C06 (female)(6).

Defective emergency pumpdrive switch (inner ground Replace


fault or hot short circuit)
Ground fault or hot-short-circuit of harness between C06
(female)(2) and C13 (female); Repair or
or hot short circuit of harness
between C06 (female)(5) and replace
C13 (female)(2).
Defective PC-EPC solenoid
(internal short-circuit or
ground fault)
Defective diode

NO

Remedy

Replace

Table 1
Diagnosis No.2

Diagnosis No.3

Diagnosis No.4

C13 (male) (1) (2)

CR3 (female) (16) (23)

C06 (female) (2) (5)

C13 (male) (1) body

CR3 (female) (16) body

C06 (female) (2) 2body

Resistance
8 15
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

C-2 Related electric circuit diagram


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

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

PC128US-2

20-819
(17)

TROUBLESHOOTING

C-3

C-3

[E233] "Disconnection in PC-EPC solenoid system" Is displayed

! If a solenoid or its harness was disconnected, current does not flow through the solenoid. If ground fault
occurs on the 2-pin side of the solenoid, current (about 1 A) remains to flow.
! Be sure to turn emergency-pump drive switch to DOWN (normal).

Cause
YES

Defective controller CR700

Disconnection or defective contact of harness between CR3


(female)(16) and C06 (fe4
YES
Do resistance values
male)(3); or disconnection, deDo resistance valbetween CR3 (fefective contact or ground fault of
YES male) (16) and (23),
ues between C06
harness between CR3 (fe(male) (2) and (3),
male)(23) and C06 (female)(6).
and between (23)
YES
between (5) and (6)
and body match with
and between C06
Table 1?
3 (male) (2), (3), (5),
Turn starting switch
(6) and body match
Defective emergency pumpDo resistance valOFF.
with Table 2?
1
drive switch (inner disconnecues between C06
Disconnect CR3.
Do resistance values
(female) (2) and (5),
NO tion, defective contact or
Turn starting
Attach directcoupled
ground fault).
switch OFF.
between C13 (male)
connector to
NO and between (2) and
body
match
with
Ta
Disconnect
C06.
(1) and (2), and beCN-D23 and D24.
Disconnection of defective conble 1?
Turn emergency
tween (2) and body
tact of harness between C06 (fepump drive switch to
match with Table 1?
Turn starting switch
male)(2) and C13 (female); or
DOWN (normal).
OFF.
disconnection, defective contact
Turn starting switch
Disconnect C06.
or ground fault of harness beOFF.
NO
tween C06 (female)(5) and C06
Disconnect C13.
(female)(2).

Defective PC-EPC solenoid


(internal short circuit or
ground fault)
Defective diode

NO

Remedy
Replace

Repair or
replace

Replace

Repair or
replace

Replace

Table 1
Diagnosis No.2

Diagnosis No.3

Diagnosis No.4

C13 (male) (1) (2)

CR3 (female) (16) (23)

C06 (female) (2) (5)

C13 (male) (1) body

CR3 (female) (16) body

C06 (female) (2) 2body

Resistance
8 15
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

C-3 Related electric circuit diagram


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

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

PC128US-2

20-821
(17)

TROUBLESHOOTING

C-4

C-4

[E203] "Short circuit in swing holding brake solenoid system" is displayed

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that
service code "E" is displayed. (If it is not displayed, the normal condition has been restored.)
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
Cause
3 YES
Is resistance norYES mal between CR3
(female)(7) and
body?
2
Do resistance values

YES between V04 (male)

(1) and (2), and between (2) and body


match with Table 1?
Turn starting
switch OFF.
Disconnect V04.

Is [E203] displayed
after replacing the
solenoid and connector with other
ones?
Turn starting
switch OFF.
NO
Replace V04 with
another one.
Start engine.
Operate swing-lever or a lever of
work-equipment
(for just a moment).

Turn starting switch NO


OFF.
Disconnect CR3.
Turn swing lock switch OFF.
Attach a direct coupled connector to CN-D08.
37 60

NO

YES Is resistance normal

Is resistance normal between X05


(female) (3), (4)
and body?

between X05 (male)


(4) and body?

Turn starting switch NO


OFF.
Disconnect X05.
37 60

Turn starting switch


OFF.
NO
Disconnect X05.
Turn swing lock switch OFF.
Min. 1 M

Replace

to A

Defective swing-holding-brake
solenoid (inner short-circuit or Replace
ground fault)

5 YES
4

Defective controller CR700

Remedy

Ground fault of either harness


connecting CR3 (female) (7) Repair or
D08 (2), (1) to M47 (19), or (1) replace
to X05 (male)(3).
Ground fault of harness connecting X05 (male)(4) M47 Repair or
(3) and then to V04 (female) replace
(2).
Defective swing-lock switch
Replace
(inner short circuit)

Table 1
V04 (male)(1) (2)

37 60

V04 (male)(2) body

Min. 1 M

20-822
(17)

PC128US-2

TROUBLESHOOTING

C-4

C-4 Related electric circuit diagram

PC128US-2

20-823
(17)

TROUBLESHOOTING

C-4

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that
service code "E" is displayed. (If it is not displayed, the normal condition has been restored.)
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
Cause
3 YES
Is resistance norYES mal between CR3
(female)(7) and
body?
2
Do resistance values

YES between V4 (male)

(1) and (2), and between (2) and body


match with Table 1?
Turn starting
switch OFF.
Disconnect V4.

Is [E203] displayed
after replacing the
solenoid and connector with other
ones?
Turn starting
switch OFF.
NO
Replace V4 with
another one.
Start engine.
Operate swing-lever or a lever of
work-equipment
(for just a moment).

Turn starting switch NO


OFF.
Disconnect CR3.
Turn swing lock switch OFF.
Attach a direct coupled between D02 (4) (8).
37 60

NO

YES Is resistance normal

Is resistance normal between X05


(female) (3), (4)
and body?

between X05 (male)


(4) and body?

Turn starting switch NO


OFF.
Disconnect X05.
37 60

Turn starting switch


OFF.
NO
Disconnect X05.
Turn swing lock switch OFF.
Min. 1 M

Replace

to A

Defective swing-holding-brake
solenoid (inner short-circuit or Replace
ground fault)

5 YES
4

Defective controller CR700

Remedy

Ground fault of either harness


connecting CR3 (female) (7) Repair or
D02 (8), (4) to M47 (19) to replace
X05 (male)(3).
Ground fault of harness connecting X05 (male)(4) M47 Repair or
(3) and then to V4 (female) replace
(2).
Defective swing-lock switch
Replace
(inner short circuit)

Table 1
V4 (male)(1) (2)

37 60

V4 (male)(2) body

Min. 1 M

20-824
(17)

PC128US-2

TROUBLESHOOTING

C-4

C-4 Related electric circuit diagram

PC128US-2

20-825
(17)

TROUBLESHOOTING

C-5

C-5

[E213] "Disconnection in swing holding brake solenoid system" is


displayed

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
NOTE: [Note] An error [E213] is detected if swing holding brake release switch was turned OFF (swinging
enabled); this is not a failure.
NOTE: [Note] If an error [E213] was detected when swing lock switch was turned ON (swinging locked), do
troubleshooting (F-9) of the swing lock signal input system.

Cause
3 YES
Does resistance
YES between CR3 (fe2
male) (7) and body
match with Table 1?
YES Is resistance nor
Turn starting switch NO
mal between V04
ON.
1 (male)(1) and (2)?
Disconnect D08.
Is [E213] displayed

Turn
starting
after replacing the
switch OFF.
solenoid and conNO
Disconnect V04.
nector with other

37

60

ones?
Turn starting switch
OFF.
Replace V04 with NO
another one.
Turn starting switch ON.

Defective controller CR700

Remedy

Replace

to A

Defective swing holding brake


solenoid (inner disconnection Replace
or hot short circuit)
Disconnection or defective con-

6 YES tact of either harness connect- Repair or


Is resistance nor-

YES mal between CR3

Is resistance norYES mal between X05


(male) (4) and
4
body?
Is resistance nor Turn starting
mal between X05
switch OFF.
(female) (3) and
Disconnect X05.
(4)?
37 60 ohm
Turn starting
switch OFF.
Disconnect X05. NO
Max.1

ing D08 (female)(1) M47 (19) replace


or (1) X05 (male)(3).

(female) (7) and


D08 (female) (2)?

Disconnection or defective
contact of harness between Repair or
Turn starting
NO CR3 (female)(7) and D08 (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

4 5 seconds after putting all levers to Neutral.

20 30 V

When swing-lever or a lever of work equipment is operated (just for a moment)

PC128US-2

TROUBLESHOOTING

C-5

C-5 Related electric circuit diagram

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.

Defective controller CR700

Remedy

Replace

to A

Defective swing holding brake


solenoid (inner disconnection Replace
or hot short circuit)
Disconnection or defective con-

6 YES tact of either harness connect- Repair or


Is resistance nor-

YES mal between CR3

Is resistance norYES mal between X05


(male) (4) and
4
body?
Is resistance nor Turn starting
mal between X05
switch OFF.
(female) (3) and
Disconnect X05.
(4)?
37 60 ohm
Turn starting
switch OFF.
Disconnect X05. NO
Max.1

ing D02 (female)(8) M47 (19) replace


X05 (male)(3).

(female) (7) and


D02 (female) (8)?

Disconnection or defective
contact of harness between Repair or
Turn starting
NO CR3 (female)(7) and D02 (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

4 5 seconds after putting all levers to Neutral.

20 30 V

When swing-lever or a lever of work equipment is operated (just for a moment)

PC128US-2

TROUBLESHOOTING

C-5

C-5 Related electric circuit diagram

PC128US-2

20-829
(17)

TROUBLESHOOTING

C-6

C-6

[E206] "Short circuit in travel Hi/Lo selection solenoid system" is


displayed

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Cause
3 YES
YES Is resistance normal between CR3
2
(female)(27) and
Do resistance valbody?
ues between V05
YES (male)(1) and (2),
Turn starting
and between (2)
switch OFF.
1
and body, match
Disconnect CR3.
with Table 1?
Is [E206] displayed
37 60
Turn starting
after replacing the
switch OFF.
solenoid and conNO
nector with other
Disconnect V05.
ones?
Turn starting switch
OFF.
Replace V05 with NO
another one.
Start engine.
Turn travel-speed
switch to "Mi" or
"Hi".
Operate travel lever
just for a moment.

NO

Remedy

Defective engine throttle and


Replace
pump controller
Ground fault of harness connecting CR3 (female)(27) Repair or
A08 (1) and then to V05 (fereplace
male)(2); or continuing diode
D07.

Defective travel-Hi/Lo selection solenoid (inner short cir- Replace


cuit or ground fault)

Table 1
V05 (male)(1) (2)

37 60

V05 (male)(2) body

Min. 1 M

C-6 Related electric circuit diagram

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

Defective engine throttle and


Replace
pump controller
Ground fault of harness connecting CR3 (female)(27) V5 Repair or
(female)(2); or continuing di- replace
ode D01(1) (5).

Defective travel-Hi/Lo selection solenoid (inner short cir- Replace


cuit or ground fault)

Table 1
V5 (male)(1) (2)

37 60

V5 (male)(2) body

Min. 1 M

C-6 Related electric circuit diagram

PC128US-2

20-831
(17)

TROUBLESHOOTING

C-7

C-7

[E216] "Disconnection in travel Hi/Lo selection solenoid system" is


displayed

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Cause
3 YES
Is resistance norYES mal between CR3
2
(female) (27) and
body?
YES Is resistance be
Turn starting
tween V05 (male)
switch OFF.
(1)
and
(2)
normal?
1
Disconnect CR3.
Is [E216] displayed
37 60

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

Defective engine throttle and


Replace
pump-controller
Disconnection or defective
contact of harness connecting Repair or
CR3 (female) (27) A08 (1)
and then V05 (female) (2), replace
or V05 (female) (1) to body.

Defective travel-speed solenoid (inner disconnection or Replace


hot short circuit)

C-7 Related electric circuit diagram

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

Defective engine throttle and


Replace
pump-controller
Disconnection or defective
contact of harness connecting Repair or
CR3 (female) (27) A08 (1)
and then V5 (female) (2), or replace
V5 (female) (1) to body.

Defective travel-speed solenoid (inner disconnection or Replace


hot short circuit)

C-7 Related electric circuit diagram

PC128US-2

20-833
(17)

TROUBLESHOOTING

C-8

C-8

[E205] "Short circuit in 2-stage relief solenoid system" is displayed

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Cause
3 YES

Defective controller CR700

Remedy

Replace

Is resistance nor-

YES mal between CR3

2
(female) (28) and
Do resistance values
body?
between
V06
(male)
YES
Turn starting
(1) and (2) and beswitch OFF.
1 tween (2) and body Disconnect CR3.
match with Table 1?
Is [E205] displayed
Turn starting switch 37 60
after replacing the
OFF.
solenoid and conNO
Disconnect V06.
nector with other
ones?
Turn starting switch
OFF.
Replace V06 with NO
another one.
Start engine.
Turn on swing lock
switch.

NO

Ground fault of harness between CR3 (female) (28) and Repair or


replace
V06 (female) (2)

Defective 2-stage relief solenoid (inner short-circuit or Replace


ground fault)

Table 1
V06 (male)(1) (2)

37 60

V06 (male)(2) body

Min. 1 M

C-8 Related electric circuit diagram

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

Defective controller CR700

Remedy

Replace

Ground fault of harness between CR3 (female) (28) and Repair or


replace
V6 (female) (2)

Defective 2-stage relief solenoid (inner short-circuit or Replace


ground fault)

Table 1
V6 (male)(1) (2)

37 60

V6 (male)(2) body

Min. 1 M

C-8 Related electric circuit diagram

PC128US-2

20-835
(17)

TROUBLESHOOTING

C-9

C-9

[E215] "Disconnection in 2-stage relief solenoid system" is


displayed

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Cause
3 YES
Is resistance norYES mal between CR3
2
(female) (28) and
body?
YES Is resistance bet Turn starting switch NO
ween V06 (male) (1)
OFF.
and (2) normal?
1
Disconnect CR3.
Is [E215] displayed
37 60
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.

Defective controller CR700

Remedy

Replace

Disconnection, defective contact or hot short circuit of harness between CR3 (female) Repair or
(28) and V06 (female) (2), or replace
between V06 (female) (1) and
body.

Defective 2-stage relief solenoid (inner disconnection or Replace


hot short circuit)

C-9 Related electric circuit diagram

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.

Defective controller CR700

Remedy

Replace

Disconnection, defective contact or hot short circuit of harness between CR3 (female) Repair or
(28) and V6 (female) (2), or be- replace
tween V6 (female) (1) and body.

Defective 2-stage relief solenoid (inner disconnection or Replace


hot short circuit)

C-9 Related electric circuit diagram

PC128US-2

20-837
(17)

TROUBLESHOOTING

C-10

C-10 [E222] "Short circuit in LS-EPC solenoid system" is displayed

Cause
2 YES

Defective controller CR700

Do resistance values between CR3


YES (female) (6) and (13)
and between (6) and
1
body match with Table 1?
Do resistance values
between C14 (male)
Turn starting switch NO
(1) and (2) and beOFF.
tween (1) and body
Disconnect CR3.
match with Table 1?

Remedy
Replace

Ground fault or hot short circuit of harnessbetween CR3


(female) (6) and C14 (female) Repair or
(1), or hot short circuit of har- replace
ness between CR3 (female)
(13) and C14 (female)(2).
Defective LS-EPC solenoid
(inner ground fault or hot short
circuit)

Turn starting switch


OFF.
NO
Disconnect C14.

Replace

Table 1
Diagnosis No.1

Diagnosis No.2

Resistance

C14 (male) (1) (2)

CR3 (female) (6) (13)

8 15

C14 (male) (1) body

CR3 (female) (6) body

Min. 1 M

C-10 Related electric circuit diagram


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

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

20-838
(17)

PC128US-2

TROUBLESHOOTING

C-11

C-11 [E223] "Disconnection in LS-EPC solenoid system" is displayed


! If a solenoid or its harness was disconnected, current does not flow through the solenoid.
If ground fault occurs on the 2-pin side of the solenoid, current (about 1A) remains to flow.
! Be sure to turn emergency-pump drive switch to DOWN (normal).

Cause
2 YES

Defective controller CR700

Do resistance values between CR3


YES (female) (6) and (13)
and between (13)
1
and body match with
Do resistance valTable 1?
ues between C14
Turn starting switch NO
(male) (1) and (2)
OFF.
and between (2) and
body match with Ta Disconnect CR3.
ble 1?
Turn starting switch
OFF.
NO
Disconnect C14.

Remedy
Replace

Disconnection or defective contact of harness between CR3


(female)(6) and C14 (female) Repair or
(1); or disconnection, defective replace
contact, or ground fault of harness between CR3 (female)
(13) and C14 (female) (2).
Defective LS-EPC solenoid
(inner ground fault or hot short
circuit)

Replace

Table 1
Diagnosis No.1

Diagnosis No.2

C14 (male) (1) (2)

CR3 (female) (6) (13)

C14 (male) (1) body

CR3 (female) (13) body

Resistance
8 15
Min. 1 M

C-11 Related electric circuit diagram


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

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

PC128US-2

20-839
(17)

TROUBLESHOOTING

C-12

C-12 [E224] "Abnormality in pump pressure sensor system" is displayed


Cause
3 YES
YES

2
YES

1
T-adapter (B) (C)
to C05 of pump
pressure sensor?

C05
(C) (A)

Defective controller CR700

Remedy

Replace

CR1
(13) (21)
Turn starting switch NO
OFF.
Attach T-adapter.
Run engine at full speed.
Repeat operations:
arm excavation relief

Run engine at full


Neutral lever.
speed.
0.5 4.5 V
Repeat operations:
arm-excavation relief NO

Neutral lever.
Turn starting switch
0.5 4.5 V
OFF.
Attach T-adapter.
NO
Run engine at full
speed.
5V

Disconnection, ground fault or


Repair or
hot short circuit between C05
replace
(C) and CR1 (13).

Defective pump pressure senReplace


sor)
Defective controller CR700
Disconnection, ground fault or
hot short circuit between CR3 Repair or
CR3 (22) and C05 (B)
replace
Disconnection between CR3
(21) and C05 (C)

C-12 Related electric circuit diagram


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

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

20-840
(17)

PC128US-2

TROUBLESHOOTING

C-13

C-13 [E227] "Abnormality in engine speed sensor system" Is displayed


Cause
2 YES
Is resistance beYES tween CR2 (female)
(40) and (39) nor1
mal?
Is resistance be
Turn starting switch NO
tween E07 (male)
OFF.
(1) and (2) normal?
Disconnect CR2.
500 1000
Turn starting switch
OFF.
NO
Disconnect E07.
500 1000

Defective controller CR700

Remedy
Replace

Disconnection, defective contact or ground fault of harness


between CR2(female)(40) and Repair or
E07 (female) (1), or between replace
CR2 (female)(39) and E07 (female)(2).
Defective engine speed sensor
(inner disconnection, defective Replace
contact or ground fault).

C-13 Related electric circuit diagram


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

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

PC128US-2

20-841
(17)

TROUBLESHOOTING OF CONTROLLER CR700


[INPUT SIGNAL SYSTEM]
(F MODE)
PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Electric circuit diagram for f mode............................................................................................................... 20-902
F-1
Bit-pattern 1023-(4) Swing pressure switch is not turned ON........................................................ 20-904
F-2
Bit-pattern 1023-(3) Travel pressure switch is not turned ON........................................................ 20-906
F-3
Bit-pattern 1023-(2) Boom LOWER pressure switch is not turned ON .......................................... 20-908
F-4
Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON ............................................ 20-910
F-5
Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON ...................................................... 20-912
F-6
Bit-pattern 1023-(2) Arm OUT pressure switch is not turned ON .................................................. 20-914
F-7
Bit-pattern 1023-(2) Bucket CURL pressure switch is not turned ON............................................ 20-916
F-8
Bit-pattern 1023-(2) Bucket DUMP pressure switch is not turned ON ........................................... 20-918
F-9
Bit-pattern 1023-(2) Service pressure switch is not turned ON...................................................... 20-920
F-10 Bit-pattern 1021-(6) Kerosene mode connection is not turned ON................................................ 20-922

PC128US-2
Serial No.: 7731 and up
PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Electric circuit diagram for f mode............................................................................................................... 20-903
F-1
Bit-pattern 1023-(4) Swing pressure switch is not turned ON........................................................ 20-905
F-2
Bit-pattern 1023-(3) Travel pressure switch is not turned ON........................................................ 20-907
F-3
Bit-pattern 1023-(1) Boom LOWER pressure switch is not turned ON .......................................... 20-909
F-4
Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON .............................................20-911
F-5
Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON ...................................................... 20-913
F-6
Bit-pattern 1028-(1) Arm OUT pressure switch is not turned ON .................................................. 20-915
F-7
Bit-pattern 1028-(3) Bucket CURL pressure switch is not turned ON............................................ 20-917
F-8
Bit-pattern 1028-(4) Bucket DUMP pressure switch is not turned ON ........................................... 20-919
F-9
Bit-pattern 1028-(2) Service pressure switch is not turned ON...................................................... 20-921

In troubleshooting after an abnormality occurred, if the display in the Monitoring mode is normal after you
attached a T-adapter instead of a connector detached, or after you connected the connector instead of the
T-adapter detached, the normal condition has been restored.
Before starting troubleshooting, check for any faulty engagement in related connectors.
Before going to next step in troubleshooting process, be sure to connect the connector you have detached.

PC128US-2

20-901
(17)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM

ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM


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

20-902
(17)

PC128US-2

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM

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

PC128US-2

20-903
(17)

TROUBLESHOOTING

F-1

F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON


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

Turn on swing-lock switch before operating swing lever (even if just for a moment).
If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause
Detach S08.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for L.H.
swinging: Max. 1
Refer to Note.

Is resistance between S08 (male)


NO
(1) and (2) normal?
Is the connection insulated from
body?

Detach S30.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for
R.H. swinging: Max.1
Refer to Note.

Is resistance between S30 (male)


NO
(1) and (2) normal?
Is the connection insulated from
body?

Turn starting switch OFF.


Detach S08 and S30 from
CR1.
CR1 S08/S30: Max.1
Harness body: Min. 1 M

Are resistance values between


CR1 (female) (24) and each of NO
S08 and S30 (female) (2) normal?
Are the connections insulated
from body?

Remedy

1
Defective L.H. swing pressure switch

Replace

Defective R.H. swing pressure switch

Replace

YES

YES

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
(female)(24) and S08 (female)(2) or replace
S30 (female)(2).

YES
Start engine.
Put swing-lever in Neutral:
20 30 V
Operate swing lever:
Max. 1 V

4
Is voltage between CR1(24) and NO
body normal?

Defective controller CR700

Replace

YES

5
Start engine.
Operate swing lever:
Max.1 V

Is voltage between CR1(24) and NO


body normal?

Disconnection or defective contact of


harness between S08 (female)(1) or Repair or
replace
S30 (female)(1) and body GND.

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.

F-1 Related electric circuit diagram

20-904
(17)

PC128US-2

TROUBLESHOOTING

F-1

F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON


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

Turn on swing-lock switch before operating swing lever (even if just for a moment).
If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause
Detach S08.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for L.H.
swinging: Max. 1
Refer to Note.

Is resistance between S08 (male)


NO
(1) and (2) normal?
Is the connection insulated from
body?

Detach S30.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for
R.H. swinging: Max.1
Refer to Note.

Is resistance between S30 (male)


NO
(1) and (2) normal?
Is the connection insulated from
body?

Turn starting switch OFF.


Detach S08 and S30 from
CR3.
CR3 S08/S30: Max.1
Harness body: Min. 1 M

Are resistance values between


CR3 (female) (30) and each of NO
S08 and S30 (female) (2) normal?
Are the connections insulated
from body?

Remedy

1
Defective L.H. swing pressure switch

Replace

Defective R.H. swing pressure switch

Replace

YES

YES

Disconnection, defective contact or


ground fault of harness between CR3 Repair or
(female)(30) and S08 (female)(2) or replace
S30 (female)(2).

YES
Start engine.
Put swing-lever in Neutral:
20 30 V
Operate swing lever:
Max. 1 V

4
Is voltage between CR3(30) and NO
body normal?

Defective controller CR700

Replace

YES

5
Start engine.
Operate swing lever:
Max.1 V

Is voltage between CR3(24) and NO


body normal?

Disconnection or defective contact of


harness between S08 (female)(1) or Repair or
replace
S30 (female)(1) and body GND.

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.

F-1 Related electric circuit diagram

PC128US-2

20-905
(17)

TROUBLESHOOTING

F-2

F-2

Bit-pattern 1023-(3) Travel pressure switch is not turned ON

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
Look around to be sure of safety before operating travel lever (even if just for a moment).
If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause
Detach S01.
Start engine.
Put travel lever in Neutral:
Min. 1 M
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?

Defective travel pressure switch

Replace

YES

2
Turn starting switch OFF.
Detach S01 from CR1.
Between CR1 and S01:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR1 (female)(18) and S01 (female)(2) NO


normal? Is the connection insulated from body?

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
replace
(female) (18) and S01 (female) (2)

YES

3
Start engine.
Put swing lever in Neutral:
20 30 V

Is voltage between CR1(18) and NO


body normal?

Defective controller CR700

Replace

YES

4
Start engine.
Operate travel lever:
Max. 1 V

Is voltage between CR1(18) and NO


body normal?

Disconnection or defective contact of


harness between S01 (female) (1) and Repair or
replace
body GND.

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.

F-2 Related electric circuit diagram

20-906
(17)

PC128US-2

TROUBLESHOOTING

F-2

F-2

Bit-pattern 1023-(3) Travel pressure switch is not turned ON

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
Look around to be sure of safety before operating travel lever (even if just for a moment).
If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.

Cause
Detach S01.
Start engine.
Put travel lever in Neutral:
Min. 1 M
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?

Defective travel pressure switch

Replace

YES

2
Turn starting switch OFF.
Detach S01 from CR3.
Between CR3 and S01:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR3 (female)(40) and S01 (female)(2) NO


normal? Is the connection insulated from body?

Disconnection, defective contact or


ground fault of harness between CR3 Repair or
replace
(female) (40) and S01 (female) (2)

YES

3
Start engine.
Put swing lever in Neutral:
20 30 V

Is voltage between CR3(40) and NO


body normal?

Defective controller CR700

Replace

YES

4
Start engine.
Operate travel lever:
Max. 1 V

Is voltage between CR3(40) and NO


body normal?

Disconnection or defective contact of


harness between S01 (female) (1) and Repair or
replace
body GND.

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.

F-2 Related electric circuit diagram

PC128US-2

20-907
(17)

TROUBLESHOOTING

F-3

F-3

Bit-pattern 1023-(2) Boom LOWER pressure switch is not turned ON

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put boom lever in Neutral:
20 30 V

Is resistance between CR1 (5) NO


and body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

YES

2
Start engine.
Put boom lever in LOWER:
Max. 1 V

Is resistance between CR1 (5) NO


and body normal?

YES

Disconnect S33.
Start engine.
Put boom lever in Neutral:
Min. 1 M
Put boom lever in LOWER:
Max. 1
Refer to Note.

Is resistance between S33 (male) NO


(1) and (2) normal? Is the connection insulated from body?

Turn starting switch OFF.


Disconnect S33 from CR1.
Between CR1 and S33:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR1 (female) (5) and S33 (female) (2) NO


normal? Is the connection insulated from body?

Defective boom LOWER pressure


Replace
switch

YES

YES

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
replace
(female)(5) and S33 (female)(2).
Disconnection or defective contact of
Repair or
harness between S33 (female)(1) and
replace
body GND.

[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(5) and body is 20 30 V, go to YES;
if it is Max. 1 V, go to NO.

F-3 Related electric circuit diagram

20-908
(17)

PC128US-2

F-3

TROUBLESHOOTING

F-3

Bit-pattern 1023-(1) Boom LOWER pressure switch is not turned ON

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put boom lever in Neutral:
20 30 V

Is resistance between CR1 (18) NO


and body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

YES

2
Start engine.
Put boom lever in LOWER:
Max. 1 V

Is resistance between CR1 (18) NO


and body normal?

YES

Disconnect S33.
Start engine.
Put boom lever in Neutral:
Min. 1 M
Put boom lever in LOWER:
Max. 1
Refer to Note.

Is resistance between S33 (male) NO


(18) and (2) normal? Is the connection insulated from body?

Turn starting switch OFF.


Disconnect S33 from CR1.
Between CR1 and S33:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR1 (female) (18) and S33 (female) (2) NO


normal? Is the connection insulated from body?

Defective boom LOWER pressure


Replace
switch

YES

YES

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
replace
(female)(18 ) and S33 (female)(2).
Disconnection or defective contact of
Repair or
harness between S33 (female)(1) and
replace
body GND.

[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.

F-3 Related electric circuit diagram

PC128US-2

20-909
(17)

TROUBLESHOOTING

F-4

F-4

Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put boom lever in Neutral:
20 30 V

Is resistance between CR1 (12) NO


and body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective boom RAISE pressure


switch

Replace

YES

2
Start engine.
Put boom lever in RAISE:
Max. 1 V

Is resistance between CR1 (12) NO


and body normal?

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

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
replace
(female)(12) and S31 (female)(2).
Disconnection or defective contact of Repair or
harness between S31 (female)(1) and
replace
body GND.

[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(12) and body is 20 30 V, go to YES;
if it is Max.1 V, go to NO.

F-4 Related electric circuit diagram

20-910
(17)

PC128US-2

TROUBLESHOOTING

F-4

F-4

Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put boom lever in Neutral:
20 30 V

Is resistance between CR1 (24) NO


and body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective boom RAISE pressure


switch

Replace

YES

2
Start engine.
Put boom lever in RAISE:
Max. 1 V

Is resistance between CR1 (24) NO


and body normal?

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

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
replace
(female)(24) and S31 (female)(2).
Disconnection or defective contact of Repair or
harness between S31 (female)(1) and
replace
body GND.

[Note] You may diagnose with a short-circuit connector attached.In step 3 of diagnosis,
if the voltage between CR1(24) and body is 20 30 V, go to YES;
if it is Max.1 V, go to NO.

F-4 Related electric circuit diagram

PC128US-2

20-911
(17)

TROUBLESHOOTING

F-5

F-5

Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put arm lever in Neutral:
20 30 V

Is resistance between CR1 (6) NO


and body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective arm IN pressure switch

Replace

YES

2
Start engine.
Put arm lever in IN:
Max. 1 V

Is resistance between CR1 (6) NO


and body normal?

YES
Disconnect S05.
Start engine.
Put arm lever in Neutral:
Min. 1 M
Put arm lever in IN:
Max. 1
Refer to Note.

Is resistance between S05 (male) NO


(1) and (2) normal? Is the connection insulated from body?

Turn starting switch OFF.


Disconnect S05 from CR1.
Between CR1 and S05:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR1 (female) (6) and S05 (female) (2) NO


normal? Is the connection insulated from body?

YES

YES

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
replace
(female) (6) and S05 (female) (2).
Disconnection or defective contact of
harness between S05 (female)(1) and Repair or
replace
body GND.

[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.

F-5 Related electric circuit diagram

20-912
(17)

PC128US-2

TROUBLESHOOTING

F-5

F-5

Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put arm lever in Neutral:
20 30 V

Is resistance between CR1 (12) NO


and body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective arm IN pressure switch

Replace

YES

2
Start engine.
Put arm lever in IN:
Max. 1 V

Is resistance between CR1 (12) NO


and body normal?

YES
Disconnect S05.
Start engine.
Put arm lever in Neutral:
Min. 1 M
Put arm lever in IN:
Max. 1
Refer to Note.

Is resistance between S05 (male) NO


(1) and (2) normal? Is the connection insulated from body?

Turn starting switch OFF.


Disconnect S05 from CR1.
Between CR1 and S05:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR1 (female) (12) and S05 (female) (2) NO


normal? Is the connection insulated from body?

YES

YES

Disconnection, defective contact or


ground fault of harness between CR1 Repair or
replace
(female) (12) and S05 (female) (2).
Disconnection or defective contact of
harness between S05 (female)(1) and Repair or
replace
body GND.

[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.

F-5 Related electric circuit diagram

PC128US-2

20-913
(17)

F-6

TROUBLESHOOTING

F-6 Bit-pattern 1023-(2) Arm OUT pressure switch is not turned ON


PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put arm-lever in Neutral:
20 30 V

Is resistance between CR1 (5)


and body normal?

NO

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective arm OUT pressure switch

Replace

YES

2
Start engine.
Put arm lever in OUT:
Max. 1 V

Is resistance between CR1 (5) NO


and body normal?

YES
Disconnect S32.
Start engine.
Put arm lever in Neutral:
Min. 1 M
Put arm lever in OUT:
Max. 1
Refer to Note.

Is resistance between S32 (male) NO


(1) and (2) normal? Is the connection insulated from body?

Turn starting switch OFF.


DisconnectS32 from CR1.
Between CR1 and S32:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR1 (female) (5) and S32 (female) (2) NO


normal? Is the connection insulated from body?

YES

YES

Disconnection, defective contact or Repair or


ground fault of harness between CR1 replace
(female)(5) and S32 (female)(2).
Disconnection or defective contact of
Repair or
harness between S32 (female)(1) and
replace
body GND.

[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.

F-6 Related electric circuit diagram

20-914
(17)

PC128US-2

F-6

TROUBLESHOOTING

F-6 Bit-pattern 1028-(1) Arm OUT pressure switch is not turned ON


PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put arm-lever in Neutral:
20 30 V

Is resistance between CR1 (6)


and body normal?

NO

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective arm OUT pressure switch

Replace

YES

2
Start engine.
Put arm lever in OUT:
Max. 1 V

Is resistance between CR1 (6) NO


and body normal?

YES
Disconnect S32.
Start engine.
Put arm lever in Neutral:
Min. 1 M
Put arm lever in OUT:
Max. 1
Refer to Note.

Is resistance between S32 (male) NO


(1) and (2) normal? Is the connection insulated from body?

Turn starting switch OFF.


DisconnectS32 from CR1.
Between CR1 and S32:
Max. 1
Between harness and body:
Min. 1 M

Is resistance between CR1 (female) (6) and S32 (female) (2) NO


normal? Is the connection insulated from body?

YES

YES

Disconnection, defective contact or Repair or


ground fault of harness between CR1 replace
(female)(6) and S32 (female)(2).
Disconnection or defective contact of
Repair or
harness between S32 (female)(1) and
replace
body GND.

[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.

F-6 Related electric circuit diagram

PC128US-2

20-915
(17)

TROUBLESHOOTING

F-7

F-7

Bit-pattern 1023-(2) Bucket CURL pressure switch is not turned ON

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put bucket lever in Neutral:
20 30 V

Is voltage between CR1 (5) and NO


body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

YES

2
Start engine.
Put bucket lever in CURL:
Max. 1 V

Is voltage between CR1 (5) and NO


body normal?

YES

Disconnect S34.
Start engine.
Put bucket lever in Neutral:
Min.1 Mz
Put bucket lever in CURL:
Max. 1 z
Refer to Note.

Is resistance between S34 (male)


(1) and (2) normal?
NO
Is the connection insulated from
body?

Turn starting switch OFF.


Disconnect S34 from CR1.
Between CR1 and S34:
Max. 1 z
Between harness and body:
Min. 1 Mz

Is resistance between CR1 (female) (5) and S34 (female) (2) NO


normal?
Is the connection insulated from
body?

Defective
switch

bucket

CURL

pressure

Replace

YES

YES

Disconnection, defective contact or Repair or


ground fault of harness between CR1 replace
(female) (5) and S34 (female) (2).
Disconnection or defective contact of
harness between S34 (female)(1) and Repair or
replace
body GND.

[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.

F-7 Related electric circuit diagram

20-916
(17)

PC128US-2

F-7

TROUBLESHOOTING

F-7

Bit-pattern 1028-(3) Bucket CURL pressure switch is not turned ON

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put bucket lever in Neutral:
20 30 V

Is voltage between CR3 (10) and NO


body normal?

Defective controller CR700

Replace

Defective controller CR700

Replace

YES

2
Start engine.
Put bucket lever in CURL:
Max. 1 V

Is voltage between CR3 (10) and NO


body normal?

YES

Disconnect S34.
Start engine.
Put bucket lever in Neutral:
Min.1 Mz
Put bucket lever in CURL:
Max. 1 z
Refer to Note.

Is resistance between S34 (male)


(1) and (2) normal?
NO
Is the connection insulated from
body?

Turn starting switch OFF.


Disconnect S34 from CR3.
Between CR3 and S34:
Max. 1 z
Between harness and body:
Min. 1 Mz

Is resistance between CR3 (female) (10) and S34 (female) (2) NO


normal?
Is the connection insulated from
body?

Defective
switch

bucket

CURL

pressure

Replace

YES

YES

Disconnection, defective contact or Repair or


ground fault of harness between CR3 replace
(female) (10) and S34 (female) (2).
Disconnection or defective contact of
harness between S34 (female)(1) and Repair or
replace
body GND.

[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.

F-7 Related electric circuit diagram

PC128US-2

20-917
(17)

TROUBLESHOOTING

F-8

F-8

Bit-pattern 1023-(2) Bucket DUMP pressure switch is not turned ON

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put bucket lever in Neutral:
20 30 V

Is voltage between CR1 (5) and NO


body?

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective bucket Dump pressure


switch

Replace

YES

2
Start engine.
Put bucket lever in Dump:
Max. 1 V

Is voltage between CR1 (5) and NO


body normal?

YES

Disconnect S35.
Start engine.
Put bucket lever in Neutral:
Min.1 Mz
Put bucket lever in Dump:
Max. 1 z
Refer to Note.

Is resistance between S35 (male)


(1) and (2) normal?
NO
Is the connection insulated from
body?

Turn starting switch OFF.


Disconnect S35 from CR1.
Between CR1 and S35:
Max. 1 z
Between harness and body:
Min. 1 Mz

Is resistance between CR1 (female) (5) and S35 (female) (2) NO


normal?
Is the connection insulated from
body?

YES

YES

Disconnection, defective contact or


ground fault of harness between CR1 Replace
motor
(female) (5) and S35 (female) (2).
Disconnection or defective contact of
harness between S35 (female) (2) and Repair or
replace
body GND.

[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.

F-8 Related electric circuit diagram

20-918
(17)

PC128US-2

F-8

TROUBLESHOOTING

F-8

Bit-pattern 1028-(4) Bucket DUMP pressure switch is not turned ON

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put bucket lever in Neutral:
20 30 V

Is voltage between CR3 (20) and NO


body?

Defective controller CR700

Replace

Defective controller CR700

Replace

Defective bucket Dump pressure


switch

Replace

YES

2
Start engine.
Put bucket lever in Dump:
Max. 1 V

Is voltage between CR3 (20) and NO


body normal?

YES

Disconnect S35.
Start engine.
Put bucket lever in Neutral:
Min.1 Mz
Put bucket lever in Dump:
Max. 1 z
Refer to Note.

Is resistance between S35 (male)


(1) and (2) normal?
NO
Is the connection insulated from
body?

Turn starting switch OFF.


Disconnect S35 from CR3.
Between CR3 and S35:
Max. 1 z
Between harness and body:
Min. 1 Mz

Is resistance between CR3 (female) (20) and S35 (female) (2) NO


normal?
Is the connection insulated from
body?

YES

YES

Disconnection, defective contact or


ground fault of harness between CR3 Replace
motor
(female) (20) and S35 (female) (2).
Disconnection or defective contact of
harness between S35 (female) (2) and Repair or
replace
body GND.

[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.

F-8 Related electric circuit diagram

PC128US-2

20-919
(17)

TROUBLESHOOTING

F-9

F-9

Bit-pattern 1023-(2) Service pressure switch is not turned ON

PC128US-2
Serial No.: 7731 and up
PC138USLC-2 Serial No.: 1001 1500
If you take some measurement with engine started, operate a lever to such an extent that no movement of
ATT is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put swing lever in Neutral:
20 30 V
Operate swing lever: Max. 1 V

Disconnect S40.
Start engine.
Put ATT-pedal in Neutral:
Min.1 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.

Turn starting switch OFF.


Disconnect S40 and S41
from CR1.
Between CR1 and S40, S41:
Max. 1
Harness body: Min. 1 M

Is voltage between CR1 (5) and NO


body?

YES
Defective controller CR700

Replace

Defective service (front) pressure switch

Replace

Defective service (rear) pressure switch

Replace

2
Is resistance between S40 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?

YES

3
Is resistance between S41 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?

YES

Are resistance values between CR1


(female) (5) and each of S40 and NO
S41 (female) (2) normal?
Are the connections insulated from
body?

YES

Disconnection, defective contact or Replace


ground fault of harness between CR1 motor
(female) (5) and S40(female)(2) or S41
(female)(2).
Disconnection or defective contact of
Repair or
harness between S40 (female) (1) or
replace
S41 (female) (1) and body GND.

[Note] You may diagnose with a short-circuit connector attached.In this case,
if the voltage between CR1(5) and body is 20 30 V, go to YES;
f it is Max. 1 V, go to NO.

F-9 Related electric circuit diagram

20-920
(17)

PC128US-2

F-9

TROUBLESHOOTING

F-9

Bit-pattern 1028-(2) Service pressure switch is not turned ON

PC138US-2
Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1501 and up
If you take some measurement with engine started, operate a lever to such an extent that no movement of
blade is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)

Cause

Remedy

1
Start engine.
Put swing lever in Neutral:
20 30 V
Operate swing lever: Max. 1 V

Is voltage between CR3 (9) and NO


body?

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.

Turn starting switch OFF.


Disconnect S38 and S39
from CR3.
Between CR3 and S40, S41:
Max. 1
Harness body: Min. 1 M

Replace

2
Is resistance between S38 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?

Defective blade LOWER pressure switch Replace

YES

3
Is resistance between S41 (male)
(1) and (2) normal?
NO
Is the connection insulated from
body?

Defective blade RAISE pressure switch

Replace

YES

Are resistance values between CR3


(female) (9) and each of S38 and NO
S39 (female) (2) normal?
Are the connections insulated from
body?

YES

Disconnection, defective contact or Replace


ground fault of harness between CR3 motor
(female) (9) and S38(female)(2) or S39
(female)(2).
Disconnection or defective contact of
Repair or
harness between S38 (female) (1) or
replace
S39 (female) (1) and body GND.

[Note] You may diagnose with a short-circuit connector attached.In this case,
if the voltage between CR3(9) and body is 20 30 V, go to YES;
f it is Max. 1 V, go to NO.

F-9 Related electric circuit diagram

PC128US-2

20-921
(17)

TROUBLESHOOTING

F-10

F-10 Bit-pattern 1021-(6) Kerosene mode connection is not turned ON


Shown below is the case where a harness for Kerosene mode is connected (M36M(1) and M36F(1) are
connected).

Cause
Turn starting switch ON.
S Harness for Kerosene mode:
Connected: 20 30 V
Open: Max. 1 V
Max. 1

Remedy

Disconnection or defective contact of


harness between CR2 (female) (6) and Repair or
IIs voltage between CR2 (6) and NO
body normal?
(Max. 1V ) fuse (1) in the harness for kerosene replace
mode.
YES (20 30 V)
Replace
Defective controller CR700

F-10 Related electric circuit diagram

20-922
(17)

PC128US-2

TROUBLESHOOTING OF ENGINE
(S MODE)

Method of using troubleshooting charts ............................................................................................. 20-952


S- 1 Starting performance is poor (Starting always takes time) ...................................................... 20-956
S- 2 Engine does not start ................................................................................................................... 20-958
(1) Engine does not turn ............................................................................................................. 20-958
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .................... 20-959
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ................. 20-960
S- 3 Engine does not pick-up smoothly (Follow-up is poor) ............................................................ 20-961
S- 4 Engine stops during operations .................................................................................................. 20-962
S- 5 Engine does not rotate smoothly (Hunting) ............................................................................... 20-963
S- 6 Engine lacks output (or lacks power) .......................................................................................... 20-964
S- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-965
S- 8 Oil consumption is excessive (or exhaust gas is blue).............................................................. 20-966
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-967
S-10 Fuel consumption is excessive .................................................................................................... 20-968
S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-969
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ....................................................... 20-970
S-13 Oil level rises (Water, fuel in oil) ................................................................................................. 20-971
S-14 Water temperature becomes too high (Overheating) ............................................................... 20-972
S-15 Abnormal noise is made .............................................................................................................. 20-973
S-16 Vibration is excessive ................................................................................................................... 20-974

PC128US-2

20-951
(14)

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS


This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items
that can be obtained from the user, depending
on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].

Causes

Questions

(b) (2) (3)

(a)

w
w

(b)
w

(c)
(d)

c
c

Troubleshooting

Check items

(e)

20-952
(14)

i
ii
iii

b
b
b

PC128US-2

METHOD OF USING TROUBLESHOOTING CHARTS

inje
ctio
n)

Causes

Seiz

The basic method of using the troubleshooting chart


is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with !, and of these, causes that have a high probability are marked with T.
Check each of the [Questions] and [Check items] in
turn, and marked the ! or T in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with # to use as reference
for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes.
2. Use the # in the Cause column as reference
for [Degree of use (Operated for long period)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.

ed t
urbo
cha
Clog
rger
ged
, int
air c
erfe
lean
Wor
renc
er e
n pi
e
lem
ston
e
n
ring
Clog
t
, cyl
ged
inde
, sei
r
zed
Imp
inje
rope
ctio
r inj
n no
e
ctio
Defe
zzle
n tim
ctiv
e in
ing
ject
ion
pum
p (e
xces
sive

TROUBLESHOOTING

Confirm recent repair history

Degree of use

Operatred for long period

PC128US-2

20-953
(14)

TROUBLESHOOTING

Example of troubleshooting when exhaust gas is black


Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.

S-7 Exhaust gas is black (incomplete combustion)


General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel

Causes

Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.

Seiz
ed t
Clog urboch
arge
ged
r, in
air
Wor
terfe
n pis cleaner
elem rence
ton
Clog
ring
ent
ged
, cyli
, se
nde
Imp
r
rope ized inje
r
c
tion
inje
Defe
ctio
ctiv
n tim nozzle
e
in
ing
Imp
rope jection
pum
r va
Cru
lve
p (e
she
c
xces
le
d, c
aran
sive
logg
Lea
ce
inje
kag
e
d
ctio
muf
e of
n)
fler
Defe
air b
ctiv
etw
e
e
e
con
n tu
Deff
t
a
r
ectiv
boc
ct o
harg
f va
e in
lve,
er a
ject
valv
ion
nd h
e se
pum
ead
at
p (ra
ck, p
lung
er s
eize
d

METHOD OF USING TROUBLESHOOTING CHARTS

Confirm recent repair history


Degree of use

Operated for long period

Questions

Suddenly became black


Color of exhaust gas

Gradually became black


Blue under light load

Engine oil must be added more frequently


Power was lost

Suddenly
Gradually

Non-specified fuel has been used


Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular


When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged

Troubleshooting

When compression pressure is measured, it is found to be low


Speed of some cylinders does not change when operating
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal

20-954
(14)

Replace

Repair

Replace

Adjust

Replace

Adjust

Adjust

Replace

Replace

Clean

Remedy

Replace

When control rack is pushed, it is found to be heavy or does


not return

PC128US-2

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.

Three symptoms

Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.

PC128US-2

20-955
(14)

TROUBLESHOOTING

S-1

S-1 Starting performance is poor


(Starting always takes time)
General causes why exhaust smoke comes out but
engine takes time to start
Defective electrical system
Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
(At ambient temperature of -10C or below,
ASTM D975 No. 2 diesel fuel is used)

Causes

n pi
ston
Defe
ring
, cyl
ctive
inde
cont
Clog
r
act o
ged
f val
a
i
r
ve, v
clea
Clog
ner
ged
elem alve sea
fuel
t
Clog
ent
filte
ged
r, st
rain
feed
e
Elec
r
p
ump
trica
gau
l int
ze fi
ake
lter
air h
eate
r

fl Battery charging rate


Ambient
temperature

Charging rate

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

The specific gravity should exceed the value for the


charging rate of 70% in the above table.
In cold areas the specific gravity must exceed the
value for the charging rate of 75% in the above table.

Wor

100 %

Questions

Confirm recent repair history


Degree of use of machine

Operated for long period

Ease of starting

Gradually became worse


Starts when warm

Indicator lamp does not light up


Engine oil must be added more frequently
Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low

Check items

Engine does not pick up smoothly, and combustion is irregular


Blow-by gas is excessive
Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When compression pressure is measured, it is found to be low
When air cleaner element is inspected directly, it is found to be clogged

Troubleshooting

When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Heater mount does not become warm
Is voltage 2630V between alternator terminal B and terminal E
with engine at low idling?

Yes
No

Either specific gravity of electrolyte or voltage of battery is low


Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)

20-956
(14)

Replace

Clean

Clean

Clean

Correct

Remedy

Replace

When fuel tank cap is inspected directly, it is found to be clogged

Use a test stand

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

S-2 Engine does not start


(1) Engine does not turn
Causes

General causes why engine does not turn

fl If internal parts of the engine are seized, carry


out troubleshooting for "Engine stops during
operations".
Defective electrical system
Failure in power train

Confirm recent repair history


Degree of use of machine Operated for long period
Condition of horn when
Horn sounds
starting switch is turned
Horn volume is low
ON
Speed of rotation is low
When starting switch is
Makes grating noise
turned to START, pinion
Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
move out
When starting switch is turned to ON, there is no clicking
sound

20-958
(14)

Replace

Replace

Remedy

Replace

For the following conditions 1) - 5), turn the starting switch


OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are
connected, engine starts
3) When terminal B and terminal C of safety relay are
connected, engine starts
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and
terminal E
When ring gear is inspected directly, tooth surface is found to
be chipped
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected

Replace

Troubleshooting

Specific gravity of electrolyte, voltage of battery is low

Replace

When battery is checked, battery electrolyte is found to be low

Replace

When starting switch is turned ON, linkage is not actuated

Replace

Battery terminal is loose

Replace

Check items

Questions

Defe
ctiv
ew
iring
Defe
ctiv
of s
e or
tarti
Defe
dete
ng c
ctiv
rior
ircu
e st
ated
it
artin
Bro
batt
ken
gm
ery
r
o
i
n
t
or
g ge
Defe
ar
ctiv
e sa
fety
Defe
rela
ctiv
y or
e ba
Defe
ttery
safe
ctiv
ty s
r
e
lay
e ba
witc
Defe
ttery
h
ctiv
t
e
rmin
e fu
el cu
al co
Defe
t so
nne
ctiv
leno
e st
ctio
artin
n
id
g sw
itch

Internal parts of engine seized

Troubleshooting of defective wiring in starting circuit

PC128US-2

S-2

TROUBLESHOOTING

(2) Engine turns but no exhaust smoke comes out


(Fuel is not being injected)
General causes why engine turns but no exhaust smoke
comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)

Standards for use of fuel


AMBIENT TEMPRATURE

KIND
OF FLUID

-4
-20

14
-10

32
0

50
10

68F
20C

ASTM D975 No.2

Diesel fuel

Bro

ASTM D975 No.1

ken
inje
ctio
Defe
n pu
ctiv
mp
e in
driv
ject
Seiz
ion
e sh
ed,
pum
aft,
brok
key
p (ra
en f
Clog
ck, p
eed
ged
p
lung
fuel
ump
Clog
er s
filte
pist
ged
eize
r, st
on
d)
feed
rain
Insu
e
p
r
u
ffici
mp
ent
stra
fuel
Clog
iner
in ta
ged
, lea
nk
Clog
king
ged
fuel
air b
pipi
Defe
reat
ng
ctiv
her
e
hole
fuel
Imp
in fu
cut
rope
sole
el ta
r fue
noid
nk
l us
ed

Causes

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Mud is stuck to fuel tank cap
Check items

When starting switch is turned ON, linkage is not actuated


When fuel filter is drained, fuel does not come out
When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained

Troubleshooting

Inspect injection pump directly


When control rack is pushed, it is found to be heavy, or does
not return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged

PC128US-2

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Remedy

Replace

Cannot be moved by hand even when linkage of fuel cut


solenoid is disconnected

20-959
(14)

TROUBLESHOOTING

S-2

General causes why exhaust smoke comes out but


engine not start

Lack of rotating force due to defective electrical system


Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel and oil

Defe

Causes
ctive
, bro
Defe
ke n
v a lv
ctiv
e sy s
e in
ject
tem
Wor
ion
(valv
n pi
pum
e , ro
ston
p (ra
cke r
Clog
ring
le v e
ck, p
ged
, cyl
r, etc
lung
inde
fuel
Clog
.)
e
r
f
r
i
l
l
stuc
i
t
ner
ged
er, s
k)
f
t
e
r
a
e
iner
d pu
Clog
mp
ged
stra
air c
Defe
iner
l
e
ane
ctiv
r ele
e el
men
ectr
Defe
ical
t
ctiv
inta
e or
ke a
Lea
dete
i
kag
r he
rior
e, cl
ater
ated
ogg
Clog
b
a
i
n
ttery
ged
g, a
ir in
inje
Clog
ctio
fuel
n no
ged
syst
zzle
a
em
i
r br
Imp
,
defe
eat h
rope
ctiv
er h
r fue
e
ole
spra
l us
in fu
y
ed
el t a
nk c
ap

(3) Exhaust smoke comes out but


engine does not start (Fuel is
being injected)

Confirm recent repair history


Degree of use of machine Operated for long period
Questions

Suddenly failed to start


When engine is cranked, abnormal noise is heard from
around cylinder head
Engine oil must be added more frequently
Non-specified fuel is being used
Replacement of filters has not been carried out according to
Operation Manual
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Indicator lamp does not light up
Starting motor cranks engine slowly
Mud is stuck to fuel tank cap
When fuel lever is placed at FULL position, it does not contact stopper

Check items

When engine is cranked with starting motor,


1) Little fuel comes out even when injection pump piping
sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
There is leakage from fuel piping

Troubleshooting

When exhaust manifold is touched immediately after starting


engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly
When control rack is pushed, it is found to be heavy, or
does not return
When compression pressure is measured, it is found to be low
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped

20-960
(14)

Clean

Clean

Correct

Replace

Correct

Clean

Clean

Clean

Replace

Replace

Remedy

Replace

When fuel tank cap is inspected directly, it is found to be clogged

PC128US-2

TROUBLESHOOTING

S-3

S-3 Engine does not pick-up smoothly


(Follow-up is poor)

Causes

General causes why engine does not pick up smoothly


Insufficient intake of air
Insufficient supply of fuel
Improper condition of fuel injction
Improper fuel used

Clog
ged
air c
Clog
lean
ged
er e
lem
f
uel
Clog
ent
filte
ged
r, st
feed
rain
Clog
er
pum
ged
p st
inje
rain
Seiz
ctio
er
ed i
n no
njec
zzle
tion
, de
Wor
fect
pum
n pi
ive
p pl
ston
spra
Seiz
ung
ring
y
er
ed t
,
cylin
urbo
d
Imp
e
c
harg
r lin
rope
er
er, i
r va
nter
Clog
lve
fere
clea
ged
nce
ranc
air b
e
Clog
reat
her
ged
hole
, lea
Defe
king
in fu
ctiv
fuel
el t a
e co
nk c
pipi
ntac
ng
ap
t of
valv
e an
d va
lve
seat

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Engine pick-up suddenly became poor
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Noise of interference is heard from around turbocharger
Color of exhaust gas

Blue under light load


Black

Check items

Clanging sound is heard from around cylinder head


Mud is stuck to fuel tank cap
There is leakage from fuel piping
High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low

Troubleshooting

Blow-by gas is excessive


When air cleaner element is inspected directly, it is found to
be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged

PC128US-2

Replace

Correct

Clean

Adjust

Replace

Replace

Replace

Correct

Clean

Clean

Remedy

Clean

When feed pump is operated, operation is too light or too heavy

20-961
(14)

S-4

TROUBLESHOOTING

S-4 Engine stops during operations


General causes why engine stops during operations
Seized parts inside engine
Insufficient supply of fuel
Overheating

Causes
ken
, sei
zed
Bro
pist
ken
on,
, sei
co n
zed
Brok
nec
cran
en d
ting
ksha
ynam
ro d
ft be
Bro
i
c va
ken
a
ring
lve s
, sei
yste
Bro
zed
m (
ken
gea
valv
pum
r tra
e, ro
in
p au
Bro
cker
ken
x
leve
i
l
i
ary
fuel
r, et
equ
Insu
pum
c.)
ipm
ffici
p
driv
ent
ent
e sh
fuel
Clog
aft,
in ta
ged
key
nk
fuel
Clog
filte
ged
r, st
rain
feed
Bro
er
pum
ken
p st
, sei
rain
z
Clog
ed f
er
eed
ged
, lea
pum
king
Clog
p pi
ston
fuel
ged
pipi
air b
Defe
ng
r
e
a
ther
ctiv
e in
hole
ject
Fail
in fu
ion
ure
el ta
pum
in p
nk
owe
p (r a
r tra
c
k
,
in
plun
ger
stuc
k)

fl If there is overheating and the engine stops,


carry out troubleshooting for overheating.

Failure in power train

Bro

fl If the engine stops because of a failure in


the power train, carry out troubleshooting
for the chassis.

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Engine stopped slowly
There was hunting and engine stopped
Replacement of filters has not been carried out according
to Operation Manual
Non-specified fuel is being used
Fuel level lamp lights up
Fuel tank is found to be empty
When feed pump is operated, operation is too light or too heavy

Check items

Mud is stuck to fuel tank cap


Engine rotates, but stops when power train is operated
Does not turn at all
When it is attempted to
turn by hand using
barring tool

Turns in opposite direction


Moves amount of backlash
Shaft does not turn
Troubleshooting of chassis

Rust and water are found when fuel tank is drained


Metal particles are found when oil is drained
Remove oil pan and inspect directly
Troubleshooting

Remove head cover and inspect directly


When gear train is inspected, it does not turn
Rotates when pump auxiliary equipment is removed
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly

20-962
(14)

Replace

Clean

Correct

Replace

Replace

Clean

Clean

Add

Replace

Replace

Replace

Replace

Remedy

Replace

When control rack is pushed, it is found to be heavy, or


does not return

PC128US-2

S-5

TROUBLESHOOTING

S-5 Engine does not rotate smoothly


(Hunting)
General causes why engine does not rotate smoothly
Air in fuel system
Defective governor mechanism
Defective electric governor mechanism
(engine with electric governor)

Causes

Defe
ctiv
e op
Defe
erat
ctiv
ion
e ad
of g
Defe
ove
just
rn o r
men
ctiv
e op
t of
gov
Low
erat
erno
ion
idlin
of c
r
g sp
Insu
ontr
eed
ffici
o
l rac
is to
ent
k
o
fuel
Clog
in ta low
ged
nk
feed
Clog
pum
ged
p st
fuel
rain
Clog
f
ilter
er
ged,
,
stra
air in
iner
Clog
c
i
rcuit
ged,
betw
air in
een
Clog
circu
fuel
ged
it be
tank
air b
t
w
and
een
reat
feed
feed
her
pum
pum
hole
p
p an
in fu
d no
el t a
zzle
nk

fl If hunting stops when electric governor rod is


disconnected, carry out troubleshooting for the
chassis.

Confirm recent repair history

Questions

Degree of use of machine Operated for long period


Occurs at a certain speed range
Condition of hunting

Occurs at low idling


Occurs even when speed is raised
Occurs on slopes

Replacement of filters has not been carried out according


to Operation Manual
Fuel tank is found to be empty
Rust, water are found when fuel tank is drained

Check items

Leakage from fuel piping


When feed pump is operated,
1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off

Troubleshooting

When governor lever is moved it is found to be stiff


When injection pump is tested, governor is found to be
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged

PC128US-2

Clean

Correct

Correct

Clean

Clean

Add

Adjust

Adjust

Adjust

Remedy

Adjust

When fuel filter, strainer are inspected directly, they are


found to be clogged

20-963
(14)

TROUBLESHOOTING

S-6

S-6 Engine lacks output


(or lacks power)
General causes why engine lacks output

Clog

fl If there is overheating and lack of output,


carry out troubleshooting for overheating.

Seiz

Insufficient intake of air


Insufficient supply of fuel
Improper condition of fuel injection
Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overtaking

ged
air c
lean
ed t
er e
urbo
lem
Wor
cha
ent
rger
n pi
, int
ston
erfe
Clog
ring
renc
ged
, cyl
e
inde
fuel
Clog
r
filte
ged
r
,
s
f
t
e
r
a
ed p
Clog
ump iner
ged
stra
inje
Seiz
iner
c
tion
ed i
noz
njec
zle,
Imp
tion
defe
rope
pum
ctiv
r va
p pl
e sp
Defe
lve
u
ray
nge
clea
ctiv
r
ranc
e co
e
ntac
Ben
t fue
t of
valv
l lev
Clog
e an
er li
ged
nka
d va
ge,
, lea
lve
d
k
seat
Clog
efec
ing
fuel
tive
ged
adju
pipi
a
i
r
brea
Defe
ng
stm
ther
ent
ctiv
e bo
hole
Defe
o
s
in fu
t co
ctiv
el ta
mpe
ew
estg
nk
nsa
t
ate
diap or diap
hrag
hrag
m
m

Causes

Confirm recent repair history


Degree of use of machine Operated for long period

Questions

Power was lost

Suddenly
Gradually

Engine oil must be added more frequently


Replacement of filters has not been carried out according
to Operation Manual
Non-specified fuel is being used
Dust indicator lamp is red
Color of exhaust gas

Black
Blue under light load

Noise of interference is heard from around turbocharger


Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular


High idling speed under no load is normal, but speed
suddenly drops when load is applied
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
There is hunting from engine (rotation is irregular)
Clanging sound is heard from around cylinder head
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be
clogged
When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low


When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or
does not return
When valve clearance is checked directly, it is found to be
outside standard value
When lever is placed at FULL position, it does not contact stopper
When feed pump is operated, operation is too light or too heavy

20-964
(14)

Replace

Replace

Clean

Correct

Adjust

Replace

Adjust

Replace

Correct

Clean

Clean

Replace

Replace

Remedy

Clean

When fuel tank cap is inspected directly, it is found to be clogged

PC128US-2

S-7

TROUBLESHOOTING

S-7 Exhaust smoke is black


(Incomplete combustion)
General causes why exhaust smoke is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel

Causes
Seiz
ed t
urbo
Clog
cha
rger
ged
, int
air c
Wor
erfe
lean
renc
n pi
er e
ston
e
lem
Clog
ent
ring
ged
, cyl
i
i
nde
njec
Imp
r
tion
rope
noz
r inj
zle,
Defe
ecti
o
ctiv
n tim defecti
e in
ve s
ing
Imp
ject
pray
i
rope
on p
r
u
v
m
a
Cru
p
l
v
(
e
e
she
xces
clea
d, c
ranc
sive
logg
Lea
e
inje
ed m
kag
ctio
e of
u
n)
f
fler
air b
Defe
e
ctiv
t we
e
en t
con
Defe
urbo
tact
ctiv
cha
of v
e in
rger
alve
ject
and
and
ion
hea
pum
valv
d
e se
p (ra
at
ck, p
lung
er s
eize
d)

Confirm recent repair history


Degree of use of machine Operated for long period

Questions

Suddenly became black


Color of exhaust gas

Gradually became black


Blue under light load

Engine oil must be added more frequently


Power was lost

Suddenly
Gradually

Non-specified fuel is being used


Noise of interference is heard from around turbocharger
Dust indicator lamp is red
Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular


When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Timing lock on fuel injection pump does not match
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

When compression pressure is measured, it is found to be low


Speed does not change when operation of certain cylinders
is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal

PC128US-2

Replace

Replace

Correct

Replace

Adjust

Adjust

Adjust

Replace

Replace

Clean

Remedy

Replace

When control rack is pushed, it is found to be heavy, or


does not return

20-965
(14)

TROUBLESHOOTING

S-8

S-8 Oil consumption is excessive


(or exhaust smoke is blue)

General causes why oil consumption is excessive


Abnormal combustion of oil
External leakage of oil
Wear of lubrication system

Bro

Causes

ken
pist
on r
Wor
ing
n pi
ston
Clog
ring
ged
, cyl
inde
brea
Lea
r (lin
ther
kag
er le
or b
e fro
ss e
reat
Lea
mo
ngin
her
kag
il fil
h
e)
e fro
ose
ter o
mo
Lea
r
o
il co
il pi
kag
ping
e fro
oler
mo
Lea
kag
il dr
e fro
ain
plug
mo
Bro
ken
il pa
oil c
n or
oole
Wor
cylin
r
n se
der
al a
hea
t tur
Wor
d
bine
n se
a
e
l
n
at b
d
Wor
low
n, b
er e
roke
nd
n re
Dus
Turb
ar s
t su
eal,
cked
och
seal
arge
Wor
in fr
surf
r
n va
om
ace
inta
lve
(ste
ke s
m, g
yste
uide
m
), br
oke
n se
al

fl Do not run the engine at idling for more than 20


minutes continuously. (Both low and high idling)

Confirm recent repair history


Degree of use of machine Operated for long period

Questions

Oil consumption suddenly increased


Engine oil must be added more frequently
Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Amount of blow-by gas

Excessive
None

Area around engine is dirty with oil


Check items

There is oil in engine cooling water


When exhaust pipe is removed, inside is found to be dirty with oil
When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose

Troubleshooting

When compression pressure is measured, it is found to be low


When breather element is inspected, it is found to be
clogged with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside

20-966
(14)

Correct

Correct

Correct

Replace

Replace

Replace

Correct

Correct

Correct

Correct

Clean

Replace

Remedy

Replace

When intake manifold is removed, inside is found to be


dirty with oil

PC128US-2

S-9

TROUBLESHOOTING

S-9 Oil becomes contaminated quickly


General causes why oil becomes contaminated quickly
Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
Improper oil used
Operation under excessive load

Causes

Wor
n pi
ston
Clog
ring
, cyl
ged
inde
brea
Clog
r lin
ther
ged
er
, b re
o
athe
i
l filt
Wor
r ho
er
n va
se
lve,
Clog
valv
ged
e gu
oil c
ide
Clog
oole
ged
r
turb
Defe
och
ctiv
arge
e se
r oil
Exh
al a
drai
aus
t tur
n tu
t sm
boc
be
harg
oke
is b
e
r
turb
lack
ine
end

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
Engine oil must be added more frequently
Non-specified oil is being used
Color of exhaust gas

Blue under light load


Black
Carry out troubleshooting for Exhaust smoke is black.

Check items

Excessive
Amount of blow-by gas

None

When oil filter is inspected, metal particles are found


When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly

When breather element is inspected directly, hose is


broken or is found to be clogged with dirty oil
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger oil drain tube is clogged

PC128US-2

Replace

Clean

Clean

Replace

Replace

Remedy

Clean

Excessive play of turbocharger shaft


When safety valve is directly inspected, spring is found to
be catching or broken
Replace

Troubleshooting

When compression pressure is measured, it is found to be low

20-967
(14)

S-10

TROUBLESHOOTING

S-10 Fuel consumption is excessive


General causes why fuel consumption is excessive
Leakage of fuel
Improper condition of fuel injection
Excessive injection of fuel

Defe
ctive
injec
tion
Defe
pum
ctive
p (ex
nozz
Defe
cess
le ho
ive i
ctive
lder
njec
spra
i
n
j
e
tion
Defe
ction
y
)
ctive
pum
fuel
p plu
Exte
injec
n
ger
rnal
tion
leak
timi
age
ng
Leak
from
age
fuel
of fu
pipin
el in
Defe
side
g, fu
ctive
el fil
h
oil s
ead
ter
Defe
e
c
a
o
l
v
insid
ctive
er
e fee
adju
d pu
stme
mp
nt o
(pist
f fue
on)
l con
trol
linka
ge

Causes

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
Condition of fuel
consumption

More than for other machines of same


model
Gradually increased
Suddenly increased
Black

Exhaust smoke color

White

Seal on injection pump has come off

Check items

There is irregular combustion


When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Troubleshooting

Speed does not change when operation of certain cylinders is stopped


When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found
to be incorrect
Remove head cover and inspect directly
Remove feed pump and inspect directly

20-968
(14)

Adjust

Correct

Correct

Correct

Adjust

Replace

Replace

Remedy

Adjust

When engine speed is measured, low idling and high idling speeds
are found to be high

PC128US-2

S-11

TROUBLESHOOTING

S-11 Oil is in cooling water, or water


spurts back, or water level goes
down

Causes

General causes why oil is in cooling water


Internal leakage in lubrication system
Internal leakage in cooling system
Brok
en o
il co
oler
Brok
core
en c
, O-r
ylind
ing
er h
Brok
e
en p
ad, h
owe
e
a
d
r tra
Hole
gask
in oi
s ca
et
l coo
used
ler
by p
Inter
ittin
nal c
g
rack
s in
cylin
der
bloc
k

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
Oil level

Suddenly increased
Gradually increased

Hard water is being used as cooling water

Excessive air bubbles inside radiator, spurts back


Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
Pressure-tightness test of oil cooler shows there is leakage
Pressure-tightness test of cylinder head shows there is leakage

PC128US-2

Replace

Replace

Replace

Remedy

Replace

Remove oil pan and inspect directly

Replace

Troubleshooting

Check items

Engine oil level has risen, oil is cloudy white

20-969
(14)

TROUBLESHOOTING

S-12

S-12 Oil pressure caution lamp lights


up (Drop in oil pressure)
General causes why oil pressure lamp lights up

Leakage, clogging, wear of lubricating system


Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating

fl Standards for engine oil selection

Type of oil

Selection of SAE No. according to


ambient temperature
30 20

10

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

Confirm recent repair history


Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Operation Manual
Non-specified oil is being used
Caution lamp lights up
Lights up at low idling
Condition when oil
pressure lamp lights up

Lights up at low, high idling


Lights up on slopes

Check items

Sometimes lights up
There is crushing, leakage from hydraulic piping (external)
Oil level sensor lamp lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are found when oil is drained
Metal particles are stuck to oil filter element

Carry out troubleshooting


for Oil level rises.

Oil is cloudy white or smells of diesel oil

Remove oil pan and inspect directly


Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out

20-970
(14)

Replace

Replace

Correct

Adjust

Adjust

Add

Replace

Correct

Clean

Clean

Remedy

Clean

When oil pressure is measured, it is found to be within


standard value
Clean

Troubleshooting

When oil filter is inspected, it is found to be clogged

PC128US-2

S-13

TROUBLESHOOTING

S-13 Oil level rises (Water, fuel in oil)


fl If there is oil in the cooling water, carry out troubleshooting for Oil is in cooling water.

Water in oil (milky white)


Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component

Bro

ken
oil c
oole
Defe
r co
ctiv
re, O
e no
Bro
-ring
zzle
ken
hold
cylin
er s
Wor
der
leev
n, d
hea
e
ama
d, h
ead
Defe
ged
gas
rear
ctiv
ket
e pu
seal
Lea
mp
surf
kag
aux
ace
e of
i
l
iary
fuel
Defe
equ
from
ctiv
ipm
e pa
pipi
ent
Defe
rt in
n
seal
g in
ctiv
s
i
d
side
e
e th
i
n
hea
j
erm
ecti
Hole
d co
on p
osta
sm
ver
ump
t
ade
Crac
by p
ks in
ittin
g
side
cylin
der
bloc
k

General causes why oil level rises

Causes

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
There is oil in radiator cooling water
Fuel must be added more frequently

Check items

Exhaust smoke is white


When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Oil level goes down in clutch, TORQFLOW transmission,
or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low
Pressure-tightness test of oil cooler shows there is leakage
Troubleshooting

Pressure-tightness test of cylinder head shows there is leakage


When compression pressure is measured, it is found to be low
Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove head cover and inspect directly
Remove injection pump and inspect directly
Defective contact with thermostat seal valve

PC128US-2

Replace

Replace

Correct

Replace

Correct

Replace

Correct

Replace

Replace

Remedy

Replace

Remove oil pan and check directly

20-971
(14)

TROUBLESHOOTING

S-14

S-14 Water temperature becomes too


high (Overheating)
General causes why water temperature becomes too
high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature in power train
fl Carry out troubleshooting for chassis.

Bro
ken
wat
er p
Clog
ump
ged
, cru
Clog
she
d ra
ged
diat
radi
or fi
Defe
ator
ns
ctiv
core
e
ther
Defe
mos
ctiv
tat (
ew
doe
ater
Lack
s no
tem
of c
t op
pera
ooli
en)
Fan
ture
n
g
w
belt
g
a
aug
t
e
s
r
l
e
i
p
Clog
ping
ged
, wo
, bro
rn fa
Defe
ken
n pu
ctiv
oil c
lley
e pr
oole
essu
Bro
r
ken
r
e va
cylin
lve
Hole
der
sm
h
ead
ade
,
hea
Rise
by p
d ga
ittin
in to
sket
g
rque
con
vert
er o
il te
mpe
ratu
re

Causes

Confirm recent repair history


Questions

Degree of use of machine Operated for long period


Condition of overheating

Suddenly overheated
Always tends to overheat

Water temperature
gauge

Rises quickly
Does not go down from red range

Radiator water level sensor lights up


Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose

Check items

Excessive air bubbles inside radiator, water spurts back


Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose

Temperature difference between top and bottom radiator tanks


is excessive
Temperature difference between top and bottom radiator tanks
is slight
When water filler port is inspected, core is found to be clogged
When function test is carried out on thermostat, it does not
open even at cracking temperature

Carry out troubleshooting for chassis.

Troubleshooting

Power train oil temperature enters red range faster than


engine water temperature

When water temperature is measured, it is found to be normal


When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
When compression pressure is measured, it is found to be low

20-972
(14)

Replace

Replace

Replace

Replace

Correct

Add

Replace

Replace

Correct

Correct

Remedy

Replace

Remove oil pan and inspect directly

PC128US-2

S-15

TROUBLESHOOTING

S-15 Abnormal noise is made


fl Judge if the noise is an internal noise or an external
noise.

Abnormality due to defective parts


Abnormal combustion
Air sucked in from intake system

Exce
ssive
wea
Seiz
r of
ed t
pisto
urbo
n rin
Mis
c
g, cy
harg
sing
linde
er, i
, sei
r (lin
n
t
e
z
Clog
rfer
ed b
er le
enc
ged
ss en
ush
e
,
i
n
gine
s
g
e
Defe
ized
)
ctiv
i
n
ject
e in
i
on n
ject
Defe
ion
ctiv
pum ozzle
e in
p (ra
Defo
ject
ion
ck, p
rme
pum
d fa
lung
Defe
p (e
n, fa
er s
x
ctiv
n be
cess
eize
e ad
d)
lt in
ive
Brok
just
i
t
n
e
ject
r
fere
men
en d
ion)
nce
ynam
t of
valv
Imp
ic va
rope
e cle
lve s
r ge
aran
yste
Leak
a
m (v
ce
r
train
age
alve
of ai
b
,
ackl
rock
r bet
Defe
er le
ash
wee
ct in
ver,
n tu r
side
etc.)
b o ch
muf
arg e
fler (
r an d
divid
ing b
cylin
oard
d er h
out o
ead
f pos
ition
)

General causes why abnormal noise is made

Causes

Questions

Confirm recent repair history


Degree of use of machine Operated for long period
Condition of abnormal
noise

Gradually occurred
Suddenly occurred

Non-specified fuel is being used


Engine oil must be added more frequently
Color of exhaust gas

Blue under light load


Black

Metal particles are found in oil filter


Blow-by gas is excessive

Check items

Noise of interference is heard from around turbocharger


Engine pickup is poor and combustion is abnormal
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Seal on injection pump has come off
Abnormal noise is loud when accelerating engine
Clanging sound is heard from around cylinder head
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
Troubleshooting

Remove gear cover and inspect directly


Speed does not change when operation of certain cylinders is
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly

PC128US-2

Replace

Replace

Replace

Correct

Replace

Correct

Replace

Correct

Replace

Replace

Replace

Remedy

Replace

When muffler is removed, abnormal noise disappears

20-973
(14)

S-16

TROUBLESHOOTING

S-16 Vibration is excessive

General causes why vibration is excessive

Defective parts (abnormal wear, breakage)


Improper alignment
Abnormal combustion

Causes
Wor
n co
nne
ctin
Wor
g ro
n ca
d, m
m
bus
Loo
ain
hing
bea
se e
ring
ngin
Bro
e
mou
ken
ntin
part
g bo
Cen
insi
lts,
de o
ter o
brok
utpu
f en
en c
Imp
gine
t
s
h
ush
rope
a
a
f
t
nd p
ion
(dam
r ge
owe
Defe
a
per)
r
train
r tra
ctive
i
n
d
b
y
ackl
mis
nam
Defe
alig
ic va
ash
ctiv
ned
lve s
e in
ystem
ject
(valv
ion
e, ro
pum
cker
p (e
lever
xces
, etc.
sive
stuck
fuel
)
inje
ctio
n)

fl If there is abnormal noise together with the vibration, carry out troubleshooting also for Abnormal noise is made.

Questions

Confirm recent repair history