Pc128us Pc138us 2 Sebm018419 U0412

SEBM018419
MACHINE MODEL SERIAL NUMBER
PC128US-2 5001 and up

PC138US-2 4501 and up
PC138USLC-2 1001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• PC128US-2, PC138US-2, PC138USLC-2 mounts the S4D102E and SAA4D95LE engine.

For details of the engine, see the 102 Series and 95 Series Engine Shop Manual.
© 2004
All Rights Reserved
Printed in Japan 12-04(02) 00-1
(19)
CONTENTS
No. of page
01 GENERAL ................................................................................................................01-1
10 STRUCTURE AND FUNCTION .................................................................10-1
20 TESTING AND ADJUSTING .......................................................................20-1
30 DISASSEMBLY AND ASSEMBLY ..........................................................30-1
40 MAINTENANCE STANDARD .....................................................................40-1
90 OTHERS ....................................................................................................................90-1
00-2 PC128US-2
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The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number number
q 00-1 (19) 01-6 (15) 10-4-1 (15) 10-32 10-61
00-2 (4) 01-7 (11) 10-4-2 (15) 10-33 (18) 10-62
q 00-2-1 (19) 01-8 (11) 10-5 10-34 10-63
q 00-2-2 (19) 01-9 (15) 10-6 10-35 10-64
q 00-2-3 (19) 01-10 (15) 10-7 (15) 10-36 (15) 10-65
q 00-2-4 (19) 01-10-1 (15) 10-7-1 (15) 10-37 (15) 10-66
q 00-2-5 (19) 01-10-2 (15) 10-8 (15) 10-37-1 (15) 10-67
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00-4 01-10-4 (11) 10-9 10-39 10-69
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00-8 01-10-8 (15) 10-13 (4) 10-43 (15) 10-73 (18)
00-9 01-10-9 (15) 10-13-1 (15) 10-44 (15) 10-74
00-10 01-10-10 (15) 10-13-2 (11) 10-45 (15) 10-75
00-11 01-10-11 (15) 10-14 (15) 10-45-1 (10) 10-76 (7)
00-12 01-10-12 (15) 10-14-1 (15) 10-45-2 (5) 10-77 (7)
00-13 01-10-13 (15) 10-15 (10) 10-45-3 (5) 10-78 (7)
00-14 01-10-14 (15) 10-15-1 (15) 10-45-4 (15) 10-79 (7)
00-15 01-10-15 (15) 10-15-2 (15) 10-45-5 (15) 10-80 (7)
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01-14-4 (15) 10-22 (10) 10-47 10-88
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01-2 (10) 01-14-6 (15) 10-23 10-49 10-90
01-3 (10) 01-14-7 (15) 10-24 10-50 10-91 (11)
01-4 (10) 01-14-8 (15) 10-25 (10) 10-51 10-92 (11)
01-4-1 (10) 01-14-9 (15) 10-26 (15) 10-52 10-93 (10)
01-4-2 (10) 01-14-10 (15) 10-27 (10) 10-53 10-94
01-4-3 (15) 01-15 (15) 10-27-1 (15) 10-54 10-95 (18)
01-4-4 (15) 01-16 (11) 10-27-2 (10) 10-55 10-96 (2)
01-4-5 (15) 10-27-3 (18) 10-56 10-97 (2)
01-4-6 (15) 10-1 (15) 10-28 10-57 10-98 (18)
01-4-7 (15) 10-2 10-29 10-58 10-99
01-4-8 (15) 10-3 (15) 10-30 10-59 10-100
01-5 (15) 10-4 10-31 10-60 10-101
PC128US-2 00-2-1
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10-102 10-132-7 (15) 10-147-7 (15) 20-105 (17) 20-209 (17)
10-103 10-133 (15) 10-148 (15) 20-106 (17) 20-210 (1)
10-104 10-133-1 (15) 10-149 (10) 20-107 (17) 20-211 (1)
10-105 10-134 (10) 10-149-1 (15) 20-108 (17) 20-212 (17)
10-106 10-134-1 (15) 10-150 (18) 20-108-1 (17) 20-214 (10)
10-107 10-135 (10) 10-151 (7) 20-108-2 (17) 20-215 (10)
10-108 10-136 (10) 10-151-1 (15) 20-108-3 (17) 20-216 (10)
10-109 10-136-1 (10) 10-151-2 (15) 20-108-4 (17) 20-217 (7)
10-110 10-136-2 (15) 10-151-3 (11) 20-108-5 (17) 20-218 (7)
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10-115 10-138 (7) 20-2 (17) 20-109 (7) 20-218-6 (7)
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10-117 (15) 10-138-2 (18) 20-3 (10) 20-111 (1) 20-218-9 (17)
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10-122-2 (15) 10-142 (18) q 20-8-3 (19) 20-119 (7) 20-223 (17)
10-122-3 (7) 10-142-1 (15) q 20-8-4 (19) 20-120 (7) 20-224 (17)
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10-122-5 (7) 10-143 (10) 20-8-6 (17) 20-122 (1) 20-226 (17)
10-122-6 (15) 10-143-1 (15) 20-8-7 (17) 20-123 (1) 20-227 (17)
10-122-7 (13) 10-143-2 (15) 20-8-8 (17) 20-124 (7) q 20-228 (19)
10-122-8 (18) 10-143-3 (15) q 20-8-9 (19) 20-125 (10) 20-229 (17)
10-122-9 (13) 10-143-4 (15) q 20-8-10 (19) 20-126 (1) 20-230 (17)
10-123 (10) 10-143-5 (15) 20-8-11 (17) 20-127 (1) 20-230-1 (17)
10-123-1 (18) 10-144 (10) 20-8-12 (17) 20-128 (1) 20-230-2 (17)
10-123-2 (18) 10-144-1 (15) 20-9 (7) 20-129 (17) 20-230-3 (17)
10-124 (10) 10-144-2 (15) 20-10 (7) 20-130 (1) 20-230-4 (17)
10-125 (15) 10-144-3 (15) 20-11 (18) 20-131 (1) 20-230-5 (17)
10-126 (10) 10-144-4 (15) 20-12 (10) 20-132 (1) 20-230-6 (17)
10-127 (15) 10-144-5 (15) 20-13 (1) 20-133 (14) 20-230-7 (17)
10-128 (10) 10-144-6 (15) 20-14 (1) 20-134 (14) 20-230-8 (17)
10-128-1 (15) 10-144-7 (18) 20-15 (1) 20-135 (17) 20-230-9 (17)
10-128-2 (15) 10-145 (15) 20-16 (17) 20-136 (17) q 20-230-10 (19)
10-129 (10) 10-146 (18) 20-17 (7) 20-137 (17) q 20-230-11 (19)
10-130 (10) 10-146-1 (11) 20-18 (7) 20-138 (17) q 20-230-12 (19)
10-131 (10) 10-146-2 (15) 20-19 (17) 20-201 (14) Q 20-230-13 (19)
10-132 (10) 10-147 (10) 20-20 (17) 20-202 (1) 20-231 (17)
10-132-1 (15) 10-147-1 (10) 20-21 (17) 20-203 (1) 20-232 (17)
10-132-2 (7) 10-147-2 (10) 20-22 (17) 20-204 (17) 20-233 (17)
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10-132-5 (15) 10-147-5 (15) q 20-103 (19) 20-207 (17) 20-236 (17)
10-132-6 (15) 10-147-6 (15) q 20-104 (19) 20-208 (17) 20-237 (17)
00-2-2 PC128US-2
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20-241 (17) 20-327 (17) 20-515 (1) 20-708 (17) 20-832 (17)
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20-243 (17) 20-329 (17) 20-517 (1) 20-710 (17) 20-834 (17)
20-244 (17) 20-330 (17) 20-551 (17) 20-711 (17) 20-835 (17)
20-245 (17) 20-331 (17) 20-552 (17) 20-712 (17) 20-836 (17)
q 20-246 (19) 20-332 (17) 20-554 (7) 20-713 (17) 20-837 (17)
q 20-246-1 (19) 20-334 (17) 20-555 (7) 20-714 (17) 20-838 (17)
20-246-2 (17) 20-335 (17) 20-556 (17) 20-715 (17) 20-839 (17)
20-246-3 (17) 20-336 (17) 20-557 (7) 20-716 (17) 20-840 (17)
q 20-246-4 (19) 20-338 (17) 20-558 (17) 20-717 (17) 20-841 (17)
q 20-246-5 (19) 20-339 (17) 20-559 (17) 20-718 (17) 20-901 (17)
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20-319 (17) 20-507 (1) 20-603 (17) 20-824 (17) 20-962 (14)
20-320 (17) 20-508 (1) 20-701 (17) 20-825 (17) 20-963 (14)
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20-322 (17) 20-510 (1) 20-703 (7) 20-827 (17) 20-965 (14)
20-323 (17) 20-511 (1) 20-704 (7) 20-828 (17) 20-966 (14)
PC128US-2 00-2-3
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20-967 (14) 30-43 (16) 30-95 (16) q 30-146 (19) 40-26-2 (15)
20-968 (14) 30-44 (16) 30-96 (16) q 30-147 (19) 40-26-3 (15)
20-969 (14) 30-45 (16) 30-97 (16) q 30-148 (19) 40-26-4 (15)
20-970 (14) 30-46 (16) 30-98 (16) q 30-149 (19) 40-26-5 (15)
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20-972 (14) 30-48 (16) 30-100 (16) q 30-151 (19) 40-26-7 (15)
20-973 (14) 30-49 (16) 30-101 (16) q 30-152 (19) 40-26-8 (15)
20-974 (14) 30-50 (16) 30-102 (16) q 30-153 (19) 40-26-9 (15)
30-51 (16) 30-103 (16) q 30-154 (19) 40-26-10 (15)
30-1 (16) 30-52 (16) 30-104 (16) 30-155 (16) 40-27 (15)
30-2 (16) 30-53 (16) 30-105 (16) 30-156 (16) 40-28
30-3 (16) 30-54 (16) 30-106 (16) 30-157 (16) 40-29 (10)
30-4 (16) 30-55 (16) 30-107 (16) 40-30 (15)
30-5 (16) 30-56 (16) 30-108 (16) 40-1 (15) 40-31
30-6 (16) 30-57 (16) 30-109 (16) 40-2 (15) 40-32 (11)
30-7 (16) 30-58 (16) 30-110 (16) 40-3 (14) 40-33 (11)
q 30-8 (19) 30-59 (16) 30-111 (16) 40-3-1 (15) 40-34 (15)
30-9 (16) 30-60 (16) 30-112 (16) 40-3-2 (15) 40-34-1 (15)
30-10 (16) 30-61 (16) 30-113 (16) 40-4 (14) 40-35 (15)
30-11 (16) 30-62 (16) 30-114 (16) 40-5 (15) 40-35-1 (15)
30-12 (16) 30-63 (16) 30-115 (16) 40-5-1 (10) 40-36 (15)
30-13 (16) 30-64 (16) 30-116 (16) 40-6 (10) 40-37 (13)
30-14 (16) 30-65 (16) 30-117 (16) 40-6-1 (11) 40-37-1 (15)
30-15 (16) 30-66 (16) 30-118 (16) 40-6-2 (15) 40-37-2 (15)
30-16 (16) 30-67 (16) 30-119 (16) 40-7 (11) 40-38 (2)
30-17 (16) 30-68 (16) 30-120 (16) 40-8 (15) 40-39 (15)
30-18 (16) 30-69 (16) 30-121 (16) 40-9 (11) 40-40 (15)
30-19 (16) 30-70 (16) 30-122 (16) 40-10 (15) 40-41
30-20 (16) 30-71 (16) 30-123 (16) 40-11 (15) 40-42
q 30-21 (19) 30-72 (16) 30-124 (16) 40-12 (10) 40-43 (11)
30-22 (16) 30-73 (16) 30-125 (16) 40-13 (7) 40-44 (2)
30-23 (16) 30-74 (16) 30-126 (16) 40-14 (15) 40-45 (10)
30-24 (16) 30-75 (16) 30-127 (16) 40-15 (15) 40-45-1 (15)
30-25 (16) 30-76 (16) 30-128 (16) 40-15-1 (15) 40-45-3 (10)
30-26 (16) 30-77 (16) 30-129 (16) 40-15-2 (15) 40-45-4 (10)
30-27 (16) 30-78 (16) 30-130 (16) 40-15-3 (15) 40-45-5 (15)
30-28 (16) 30-79 (16) 30-131 (16) 40-15-4 (15) 40-45-7 (10)
30-29 (16) 30-80 (16) 30-132 (16) 40-16 (15) 40-45-8 (10)
30-30 (16) 30-81 (16) 30-133 (16) 40-17 (15) 40-45-9 (15)
q 30-31 (19) 30-82 (16) 30-134 (16) 40-17-1 (15) 40-46
q 30-32 (19) 30-83 (16) 30-135 (16) 40-17-2 (15) 40-47
30-33 (16) 30-84 (16) q 30-136 (19) 40-18 (15) 40-47-1 (15)
30-34 (16) 30-85 (16) q 30-137 (19) 40-18-1 (15)
30-35 (16) 30-86 (16) q 30-138 (19) 40-19 (15) 90-1 (15)
30-36 (16) 30-87 (16) q 30-139 (19) 40-20 90-2 (15)
30-37 (16) 30-88 (16) q 30-140 (19) 40-21 (15) 90-3
30-38 (16) 30-89 (16) 30-141 (16) 40-22 (15) 90-5
30-39 (16) 30-90 (16) q 30-142 (19) 40-23 (15) 90-5-2 (11)
30-40 (16) 30-91 (16) q 30-143 (19) 40-24 90-7 (10)
30-41 (16) 30-92 (16) q 30-144 (19) 40-25 (15) 90-7-2 (10)
30-42 (16) 30-94 (16) q 30-145 (19) 40-26 (15) 90-9 (10)
00-2-4 PC128US-2
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90-9-2 (15)
90-11 (10)
90-11-2 (15)
90-13 (10)
90-13-2 (15)
90-13-4 (10)
90-13-6 (15)
90-13-8 (10)
90-13-10 (15)
90-15 (10)
90-17 (10)
90-17-2 (10)
90-17-4 (10)
90-17-6 (11)
90-17-8 (11)
90-17-10 (15)
90-17-12 (15)
90-17-14 (15)
90-17-16 (15)
90-17-18 (15)
90-19 (10)
90-21 (10)
90-23 (10)
90-25 (10)
90-27 (15)
90-29 (15)
90-31 (15)
90-33 (15)
90-35 (15)
PC128US-2 00-2-5
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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 danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
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
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 judge-
ments. 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 fur-
ther 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 under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance 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 com-
ponent, 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
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
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 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 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,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth 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.
Type 1
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 hydrau-
lic 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
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
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 Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 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
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
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.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 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.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
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 kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 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.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(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 – –
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
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 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
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue 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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
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
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
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
GENERAL GENERAL ASSEMBLY DRAWING
SPECIFICATION DIMENSIONAL DRAWING

PC128US-2 Serial No.: 7731 and up
PC128US-2
Item Unit
7731 and up
Standard specification 12,950
Machine weight kg
Blade specification 13,450
Bucket capacity m3 0.45
Engine type — Komatsu S4D102E-1 Diesel engine
Engine rated output kW{HP}/rpm 64 {85.8}/2,200
A Standard specification mm 7,220
Overall length
A' Blade specification mm 7,955
B Overall height mm 2,850
C Overall width mm 2,515
D Shoe width mm 500
E Trail swing radius mm 1,480
F Crawler overall length mm 3,480
G Distance between tambler center mm 2,750
H Cab height mm 2,810
Minimum ground clearance mm 390
Traveling speed (Low/High) km/h 3.2/5.1
Continuous swing speed rpm 11.0
PC128US-2 01-4-3
(15)
PC138US-2
Item Unit
4501 and up
Machine weight kg
Engine type — Komatsu SAA4D95LE-3-A Diesel engine
Engine rated output kW{HP}/rpm 66.2 {88.7}/2,200
A Standard specification mm 7,220
Overall length
A' Blade specification mm 7,955
C Overall width mm 2,515
D Shoe width mm 500
01-4-4 PC128US-2
(15)
PC138USLC-2 Serial No.: 1001 – 1500
PC138USLC-2
Item Unit
1001 – 1500
Machine weight kg
Engine type — Komatsu S4D102E-1 Diesel engine
Engine rated output kW{HP}/rpm 64 {85.8}/2,200
A Standard specification 7,395
Overall length mm
A' Blade specification 8,035
C Standard specification 2,590
Overall width mm
C' Blade specification 2,515
Standard specification 600
D Shoe width mm
Blade specification 500
PC128US-2 01-4-5
(15)
PC138USLC-2 Serial No.: 1501 and up
PC138USLC-2
Item Unit
1501 and up
Machine weight kg
Engine type — Komatsu SAA4D95LE-3-E Diesel engine
Engine rated output kW{HP}/rpm 66.2 {88.7}/2,200
A Standard specification 7,390
Overall length mm
A' Blade specification 8,035
C Standard specification 2,590
Overall width mm
C' Blade specification 2,515
Standard specification 600
D Shoe width mm
Blade specification 500
01-4-6 PC128US-2
(15)
WORKING RANGE DRAWING

PC128US-2
Working range (mm)
7731 and up
A Maximum digging radius 8,230
B Maximum digging depth 5,405
C Maximum digging height 9,260
D Maximum vertical wall digging depth 4,860
E Maximum dumping height 6,910
F Minimum swing radius of work equipment 1,980
G Maximum reach at ground level 8,110
H Maximum raising distance of blade 470
I Maximum lowering distance of blade 530
PC128US-2 01-4-7
(15)

PC138US-2 PC138USLC-2
Working range (mm)
4501 and up 1001 and up
A Maximum digging radius 8,300
B Maximum digging depth 5,480
C Maximum digging height 9,340
D Maximum vertical wall digging depth 4,900
E Maximum dumping height 6,840
F Minimum swing radius of work equipment 1,980
G Maximum reach at ground level 8,180
H Maximum raising distance of blade 470
I Maximum lowering distance of blade 525 490
01-4-8 PC128US-2
(15)
GENERAL SPECIFICATIONS
SPECIFICATIONS
FOR STD SPEC.
PC128US-2 Serial No.: 5001 – 7730
PC128US-2
Machine model
Without blade With 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 mm 5,235 5,235
2,440 mm 8' level
Working ranges
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
Performance
Max. blade lifting amount mm — 470 [535]

Max. blade lowering amount mm — 530 [465]
Max. digging force (bucket) KN {kg} 93.2 {9,500} 93.2 {9,500}
Swing speed
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
Ground pressure 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]
Dimension
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
mm 6,725 [6,790] 6,725 [6,790]
min. swing radius
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
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
PC128US-2 01-5
(15)
PC128US-2
Machine model
Serial No. 5001 – 7730
Model S4D102E-1
4-cycle, water-cooled, in-line, vertical,
Type 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}

Performance
Engine
Max. torpue Nm/rpm{kgm/rpm} 329/1,300 {33.5/1,300}
High idling speed rpm 2,400
Low idling speed rpm 950
Min. fuel consumption ratio g/kWh{g/HPh} 224 {165}
Starting motor 24V, 4.5 kw
Alternator 24V, 25A
Battery 12V, 64 Ah x 2
Radiator type CF19-4
Carrier roller 1 on each side

Undercarriage
Track roller 7 on each side
Track shoe (iron shoe) Asembly-type triple grouster, 42 on each side

(road liner) Road liner, 42 on each side
HPV95 (for 105cc/rev.)
Hydraulic pump
Type x no. Variable displacement piston type x 1
Discharge ¬ /min 226 (at 2,200rpm)

2
Set pressure (at operation) MPa {kg/cm } 31.9 {325}
(at traveling) 34.8 {355}

Hydraulic motor control
Type x no. 6-spool type x 1

valve
Hydraulic system
Control method Hydraulic type
GM18VL-J
Travel motor Variable displacement piston type
(with brake valve, holding brake) x 2
KMF40ABE-3
Swing motor 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 (CF40-1)
01-6 PC128US-2
(15)
PC128US-2
Machine model
STD (without blade) OPT (with blade)
Serial No. 5001 – 7730
Type Reciprocating piston tipe Reciprocating piston tipe

Boom cylinder
Cylinder inner diameter 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

Work equipment cylinder
Stroke mm 1,175 1,175

Hydraulic system

Bucket cylinder
Stroke mm 885 885
Type — Reciprocating piston tipe

Blade cylinder
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 01-7
A
FOR NORTH AMERICA SPEC.

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

Max. digging depth of cut for
mm 5,235 5,235
2,440 mm 8' level
Working ranges

Performance


Swing speed
Serial No. 5001 – 6456 rpm 12 12

Overall height (for transport) mm 2,850 [2,890] 2,850 [2,890]
Dimension

min. swing radius mm 6,725 [6,790] 6,725 [6,790]

01-8 PC128US-2
A
PC128US-2
Machine model
Serial No. 5001 – 7730
Model S4D102E-1
Flywheel horsepower kW/rpm{HP/rpm} 64/2,200 {87/2,200}

Performance
Engine
Maximum torpue Nm/rpm{kgm/rpm} 329/1,300 {33.5/1,300}
Alternator 24V, 25A
Battery 12V, 72Ah x 2

Undercarriage

Asembly-type triple grouster, 42 on each side
Track shoe [Road liner, 42 on each side]
Hydraulic pump
Set pressure (at operation) MPa {kg/cm2} 31.9 {325}

control
valve
Hydraulic system

Hydraulic motor
GM18VL-J
(with brake valve, parking brake) x 2
KMF40ABE-3
(with shockless safety valve, parking brake) x 1
Hydraulic oil filter Air cooled (CF40-1)
PC128US-2 01-9
(15)
PC128US-2
Machine model
Serial No. 5001 – 7730

Boom cylinder
Stroke mm 1,055 1,055

Arm cylinder

Stroke mm 1,175 1,175

Hydraulic system

Bucket cylinder
Stroke mm 885 885

Blade cylinder
Stroke mm — 181
01-10 PC128US-2
(15)
FOR KUK SPEC.

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

mm 5,760 5,760
2,440 mm 8' level
Working ranges

Performance


Swing speed
Serial No. 5001 – 6456 rpm 12 12
2
Ground pressure kPa {kg/cm } 42.2 {0.43} 43.1 {0.44}

Overall height (for transport) mm 3,190 [3,230] 3,190 [3,230]
Dimension


fl The above values are for the machines equipped with the long arm and 0.36 m3 bucket.
PC128US-2 01-10-1
(15)
PC128US-2
Machine model
Serial No. 5001 – 7730
Model S4D102E-1
Flywheel horsepower kW/rpm{HP/rpm} 64/2,200 {87/2,200}

Performance
Engine
Maximum torpue Nm/rpm{kgm/rpm} 329/1,300 {33.5/1,300}
Alternator 24V, 35A
Battery 12V, 64Ah x 2

Undercarriage

Asembly-type triple grouster, 42 on each side
Track shoe [Road liner, 42 on each side]
Hydraulic pump

control
valve
Hydraulic system

Hydraulic motor
GM18VL-J
(with brake valve, parking brake) x 2
KMF40ABE-3
(with shockless safety valve, parking brake) x 1
Hydraulic oil filter Air cooled (CF40-1)
01-10-2 PC128US-2
(15)
PC128US-2
Machine model
Serial No. 5001 – 7730

Boom cylinder
Stroke mm 1,055 1,055

Arm cylinder

Stroke mm 1,175 1,175

Hydraulic system

Bucket cylinder
Stroke mm 885 885

Blade cylinder
Stroke mm — 181
PC128US-2 01-10-3
A

PC128US-2
Machine model
Serial No. 7731 and up

mm 5,195 5,195
2,440 mm 8' level
Working ranges

Persormance


Swing speed rpm 11.0 11.0

Dimension


01-10-4 PC128US-2
A
PC128US-2
Machine model
Model S4D102E-1

Performance

Engine

Alternator 24V, 25A
(For KUK spec.) 24V, 35A
(For North America spec.) 12V, 72 Ah x 2
Undercarriage

Hydraulic pump

Control

valve
Hydraulic system
GM18VL-J
Hydraulic motor
Travel motor
Variable displacement piston type
KMF40ABE-3

PC128US-2 01-10-5
(15)
PC128US-2
Machine model

Boom cylinder
Stroke mm 1,055 1,055

Arm cylinder

Stroke mm 1,175 1,175

Hydraulic system

Bucket cylinder
Stroke mm 885 885

Blade cylinder
Stroke mm — 181
01-10-6 PC128US-2
(15)

PC138US-2
Machine model

mm 5,265 5,265
2,440 mm 8' level
Working ranges

Persormance



Dimension


PC128US-2 01-10-7
(15)
PC138US-2
Machine model
Model SAA4D95LE-3-A
Type direct injection, with turbochatger, after cooler
Rated horsepower kW/rpm{HP/rpm} 66.2/2,200 {88.7/2,200}

Performance

Engine
Low idling speed rpm 1,100

Alternator 24V, 25A
(For KUK spec.) 24V, 35A
(For North America spec.) 12V, 72 Ah x 2
Radiator type Corrugated aluminum (4-line)
Undercarriage

Hydraulic pump

Control

valve
Hydraulic system
GM20VL2-P
Hydraulic motor
Travel motor
KMF40ABE-3

Hydraulic cooler Air cooled (CF40)
01-10-8 PC128US-2
(15)
PC138US-2
Machine model

Boom cylinder
Stroke mm 1,055 1,055

Arm cylinder

Stroke mm 1,175 1,175

Hydraulic system

Bucket cylinder
Stroke mm 885 885

Blade cylinder
Stroke mm — 181
PC128US-2 01-10-9
(15)

PC138USLC-2
Machine model
Serial No. 1001 – 1500

mm 5,265 5,265
2,440 mm 8' level
Working ranges

Performance

Max. blade lifting amount mm — 470
Max. blade lowering amount mm — 490

2

Overall height (for transport) mm 2,850 2,850
Overall height to top of cab mm 2,815 2,815
Dimension
Ground clearance of counterweight mm 900 900

Min. ground clearance mm 395 395
Height of work equipment at mm 6,770 6,770
min. swing radius
Overall height of machine cab mm 1,980 1,980
01-10-10 PC128US-2
(15)
PC138USLC-2
Machine model
Serial No. 1001 – 1500
Model S4D102E-1

Performance

Engine

Alternator 24V, 25A
Undercar-

riage

Control Hydraulic pump

Type x no.
Variable displacement piston type x 1
2
valve

Hydraulic system
GM20VL-P
Hydraulic motor
Travel motor
KMF40ABE-3

PC128US-2 01-10-11
(15)
PC138USLC-2
Machine model
Serial No. 1001 – 1500

Boom cylinder
Stroke mm 1,055 1,055

Arm cylinder

Stroke mm 1,175 1,175

Hydraulic system

Bucket cylinder
Stroke mm 885 885

Blade cylinder
Stroke mm — 181
01-10-12 PC128US-2
(15)

PC138USLC-2
Machine model

mm 5,265 5,265
2,440 mm 8' level
Working ranges

Performance

Max. blade lifting amount mm — 470
Max. blade lowering amount mm — 490

2

Overall height (for transport) mm 2,850 2,850
Overall height to top of cab mm 2,815 2,815
Dimension
Ground clearance of counterweight mm 900 900

Min. ground clearance mm 395 395
Height of work equipment at mm 6,770 6,770
min. swing radius
Overall height of machine cab mm 1,980 1,980
PC128US-2 01-10-13
(15)
PC138USLC-2
Machine model
Model SAA4D95LE-3-A
Type direct injection, with turbochatger, after cooler
Rated horsepower kW/rpm{HP/rpm} 66.2/2,200 {88.7/2,200}

Performance

Engine
Low idling speed rpm 1,100

Alternator 24V, 25A
Radiator type Corrugated aluminum (4-line)
Undercar-

riage

Control Hydraulic pump

Type x no.
Variable displacement piston type x 1
2
valve

Hydraulic system
GM20VL2-P
Hydraulic motor
Travel motor
KMF40ABE-3

Hydraulic cooler Air cooled (CF40)
01-10-14 PC128US-2
(15)
PC138USLC-2
Machine model

Boom cylinder
Stroke mm 1,055 1,055

Arm cylinder

Stroke mm 1,175 1,175

Hydraulic system

Bucket cylinder
Stroke mm 885 885

Blade cylinder
Stroke mm — 181
PC128US-2 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
Serial No. 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
Revolving frame 1,500 1,500
Operator’s cab 228 228
Operator’s seat 12.6 12.6
Fuel tank (excl. fuel) 98 98
Hydraulic tank (excl. hydraulic oil) 92 92
Control valve 80 96
Self pressure reducing valve 4.8 4.8
Counterweight 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
• Recoil spring assembly 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
PC128US-2 01-11
(15)
Unit: kg
PC128US-2
Machine model
Serial No. 5001 – 7730
Track shoe assembly
• Triple grouser shoe (500mm) 740 x 2 740 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
Boom cylinder assembly 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
01-12 PC128US-2
(15)
FOR NORTH AMERICA SPEC.

PC128US-2
Machine model
Serial No. 5001 – 7730
• PTO 4.1 4.1


Revolving frame assembly 1,500 1,500
Operator’s seat 12.6 12.6
Control valve 80 96
Swing motor 26 26
Swing circle assembly 155 155
• Idler 81 x 2 81 x 2
• Idler cushion 72.9 x 2 72.9 x 2
• Sprocket 33.7 x 2 33.7 x 2
Track shoe assembly
• Road liner (rubber pad type) (500mm) 765 x 2 765 x 2
PC128US-2 01-13
(15)
Unit: kg
PC128US-2
Machine model
Serial No. 5001 – 7730
Link assembly 85.6 85.6
01-14 PC128US-2
(15)
FOR KUK SPEC.

PC128US-2
Machine model
Serial No. 5001 – 7730
• PTO 4.1 4.1

Operator’s seat 35 35
Control valve 96 106
Boom hydraulic drift prevention valve 5.1 5.1
Swing motor 26 26
• Idler 81 x 2 81 x 2
• Sprocket 33.7 x 2 33.7 x 2
Track shoe assembly
PC128US-2 01-14-1
(15)
Unit: kg
PC128US-2
Machine model
Serial No. 5001 – 7730
Arm assembly (long arm) 480 480

3
Bucket assembly (0.36 m ) 376 376

01-14-2 PC128US-2
(15)
PC128US-2 Serial No.: 7731 and up Unit: kg
PC128US-2
Machine model
• PTO 4.1 4.1
Control valve 80 96
(For KUK spec.) 96 106
Swing motor 26 26
• Idler 81 x 2 81 x 2

• Sprocket 33.7 x 2 33.7 x 2
Track shoe assembly

• Triple grouser shoe (500mm) *1 740 x 2 740 x 2
*2 710 x 2 710 x 2
*2 795 x 2 795 x 2
*1. Serial No.: 7731 – 9000
*2. Serial No.: 9001 and up
PC128US-2 01-14-3
(15)
Unit: kg
PC128US-2
Machine model

01-14-4 PC128US-2
(15)
PC138US-2 Serial No.: 4501 and up Unit: kg
PC138US-2
Machine model
• PTO 4.1 4.1
Control valve 80 96
(For KUK spec.) 96 106
Swing motor 26 26
• Idler 78 x 2 78 x 2
• Idler cushion 69 x 2 69 x 2

• Sprocket 33.7 x 2 33.7 x 2
Track shoe assembly
PC128US-2 01-14-5
(15)
Unit: kg
PC138US-2
Machine model
Arm cylinder assembly 135 135

Bucket cylinder assembly 95 95
01-14-6 PC128US-2
(15)
PC138USLC-2 Serial No.: 1001 – 1500 Unit: kg
PC138USLC-2
Machine model
Serial No. 1001 – 1500

• PTO 4.1 4.1

Control valve 80 96
Swing motor 26 26

• Idler 81 x 2 81 x 2
• Sprocket 33.1 x 2 33.1 x 2
Track shoe assembly

*2 895 x 2 895 x 2
*2 805 x 2 805 x 2

*1. Serial No.: 1001 – 1300
*2. Serial No.: 1301 and up
PC128US-2 01-14-7
(15)
Unit: kg
PC138USLC-2
Machine model
Serial No. 1001 – 1500
01-14-8 PC128US-2
(15)
PC138USLC-2 Serial No.: 1501 and up Unit: kg
PC138USLC-2
Machine model
• PTO 4.1 4.1
Control valve 80 96
Swing motor 26 26

• Idler 78 x 2 78 x 2
• Idler cushion 69 x 2 69 x 2
• Sprocket 33.1 x 2 33.1 x 2
Track shoe assembly

PC128US-2 01-14-9
(15)
Unit: kg
PC138USLC-2
Machine model
Arm cylinder assembly 135 135
Bucket cylinder assembly 95 95
01-14-10 PC128US-2
(15)
GENERAL LIST OF LUBRICANTS AND WATER
LIST OF LUBRICANTS AND WATER

PROPER SELECTION
AMBIENT TEMPERATURE
RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104 122°F
–30 –20 –10 0 10 20 30 40 50°C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Swing machinery case Engine oil

Final drive case SAE 30
PTO gear case
SAE 30
Hydraulic system SAE 10W-30
SAE 15W-40
ASTM D975 No.2

Fuel tank Diesel fuel
*1
Greasing system Grease NLGI No.2
Cooling system Water Add antifreeze
*1: ASTM D975 No.1

Swing Final drive
Engine oil machinery PTO gear Hydraulic Cooling
pan case Fuel tank
case (each) case system system
liter 17.5 2.5 2.5 0.75 120 195 18.2

Specified
capacity US gal 4.62 0.66 0.66 0.20 31.68 51.48 4.80
liter 16 2.5 2.5 0.75 69 — —

Refill
capacity US gal 4.23 0.66 0.66 0.20 18.22 — —

Swing Final drive
Engine oil machinery PTO gear Hydraulic Cooling
pan case Fuel tank
case (each) case system system
liter 11.5 2.5 2.5 0.75 120 195 14.2

Specified
capacity US gal 3.04 0.66 0.66 0.20 31.68 51.48 3.75
liter 11 2.5 2.5 0.75 69 — —

Refill
capacity US gal 2.91 0.66 0.66 0.20 18.22 — —
PC128US-2 01-15
(15)
GENERAL LIST OF LUBRICANTS AND WATER
REMARK
• When fuel sulphur content is less than 0.5%,
change oil in the oil pan according to every
periodic maintenance hours described in this
manual.
Change oil according to the following table if
fuel sulphur content is above 0.5%.
• When starting the engine in an atmospheric

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

API classification CC, reduce the engine oil
change interval to half.
• There is no problem if single grade oil is

mixed with multigrade oil (SAE10W-30, 15W-
40), 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 ap-
proved 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 inspec-
tion and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Change interval of oil in

Fuel sulphur content engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
01-16 PC128US-2
A
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)
STRUCTURE AND FUNCTION PTO
PTO
1. Coupling 5. Hydraulic pump

2. Shaft 6. Oil filler plug
3. Breather 7. Level plug
4. Gauge
10-2 PC128US-2
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
RADIATOR AND OIL COOLER

PC128US-2 10-3
(15)
1. Oil cooler SPECIFICATION

2. Radiator Radiator
3. Shroud Core type : CF19-4
4. Reservoir tank Fin pitch : 3.5/2 mm
5. Oil cooler outlet Total heat dissipation surface : 34.06 m2
6. Oil cooler inlet Pressure valve cracking pressure :
7. Radiator cap 49.0 ± 14.7 kPa {0.5 ± 0.15 kg/cm2}
8. Radiator inlet hose Vacuum valve cracking pressure :
9. Radiator outlet hose -4.9 – 0 kPa {-0.05 – 0 kg/cm2}
10. Drain valve
11. Fan Oil cooler
Core type : CF40-1
Fin pitch : 4.5/2 mm
Total heat dissipation surface : 8.79 m2
10-4 PC128US-2

PC128US-2 10-4-1
(15)
1. Shroud 8. Chage air cooler outlet hose

2. Reservoir tank 9. Oil cooler inlet
3. Oil cooler 10. Oil cooler outlet
4. Charge air cooler 11. Charge air inlet hose
5. Radiator cap 12. Radiator outlet hose
6. Radiator 13. Drain valve
7. Radiator inlet hose
Specification
Radiator Oil cooler Charge air cooler
Core type Aluminum wave CF40

(4-line)
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 49.0 ± 14.7

(kPa {kg/cm2}) {0.5 ± 0.15} — —
Vacuum valve cracking pressure -4.9 – 0 — —

(kPa {kg/cm2}) {-0.05 – 0}
10-4-2 PC128US-2
(15)
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
1. Swing pinion (number of teeth : 11) Specification

2. Case Reduction ratio : (14 + 61)/14 × (17 + 61)/17 = 24.58
3. No. 2 sun gear (number of teeth : 17) Swing reduction ratio : 201.11
4. No. 2 planetary carrier (number of teeth : 17) Swing speed : 12 rpm(PC128US-2 Serial No.:
5. Ring gear (number of teeth : 61) 5001 – 6456)
6. No. 1 planetary carrier (number of teeth : 17) : 11 rpm(PC128US-2 Serial No.:
7. No. 1 sun gear (number of teeth : 14) 6457 and up)
8. Oil filler port : 11 rpm(PC138USLC-2 Serial No.:
9. Swing motor 1001 – 1500)
10. Level gauge Lubricating oil : SAE30CD
11. No. 1 planetary gear (number of teeth : 24) Lubricating oil amount : 2.5 ¬
12. No. 2 planetary gear (number of teeth : 22)
13. Drain plug
14. Swing circle (number of teeth : 90)
PC128US-2 10-7
(15)
STRUCTURE AND FUNCTION SWING MACHINERY

1. Swing pinion (number of teeth : 11) Specification

2. Case Reduction ratio : (14 + 61)/14 × (17 + 61)/17 = 24.58
3. No. 2 sun gear (number of teeth : 17) Swing reduction ratio : 201.11
4. No. 2 planetary carrier (number of teeth : 17) Swing speed : 11 rpm
5. Ring gear (number of teeth : 61) Lubricating oil : SAE30CD
6. No. 1 planetary carrier (number of teeth : 17) Lubricating oil amount : 2.5 ¬
7. No. 1 sun gear (number of teeth : 14)
8. Oil filler port
9. Swing motor
10. Level gauge
13. Drain plug
14. Swing circle (number of teeth : 90)
10-7-1 PC128US-2
(15)
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME
PC128US-2
PC138US-2
1. Idler 5. Sprocket
2. Track frame 6. Track roller
3. Carrier roller 7. Idler cushion
4. Travel motor 8. Track shoe
10-8 PC128US-2
(15)
STRUCTURE AND FUNCTION TRACK FRAME
PC138USLC-2
1. Idler 5. Sprocket
2. Track frame 6. Track roller
3. Carrier roller 7. Idler cushion
4. Travel motor 8. Track shoe
PC128US-2 10-8-1
0
STRUCTURE AND FUNCTION IDLER CUSHION
IDLER CUSHION
1. Idler Specification
2. Support Grease : G2-LI
3. Yoke Amount of filled grease : 140 cc
4. Cylinder
5. Recoil spring
6. U-packing
7. Pilot
8. Nut
9. Valve
10. Grease fitting
PC128US-2 10-9
STRUCTURE AND FUNCTION HYDRAULIC COMPONENT LAYOUT
HYDRAULIC COMPONENT LAYOUT
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Swing motor
6. Hydraulic pump
7. Oil cooler
8. L.H. travel motor
9. L. H. PPC valve
10. Blade PPC valve (Blade specification)
11. R. H. PPC valve
12. Center swivel joint
13. 2-actuator attachment PPC valve
(Option for PC128US-2 KUK only)
(Option for PC138US-2 KUK only)
14. Travel PPC valve
15. 1-actuator attachment PPC valve
(When with attachment)
16. Boom hydraulic anti-burst valve
(For PC128US-2 KUK only)
(For PC138US-2 KUK only)
17. Blade cylinder (Blade specification)
18. Self pressure reducing valve
19. Control valve
20. 4-spool solenoid valve
• PPC lock
• 2-speed travel speed selection
• Swing holding brake
• 2-stage relief
10-10 PC128US-2
(15)
STRUCTURE AND FUNCTION VALVE CONTROL

10-13-1 PC128US-2
(15)
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)
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
15. Attachment PPC valve
(Attachment installable machine)
16. Attachment pedal
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
J Attachment discharge from arm LEFT side
K Attachment pedal LOCK
L Attachment pedal HALF stroke
M Attachment pedal FULL stroke
PC128US-2 10-13-2
A
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER

1. Hydraulic tank Specification

2. Filter element Tank capacity : 99 ¬
3. Bypass valve Hydraulic oil amount in tank : 69 ¬
4. Bypass strainer Pressure valve cracking pressure :
5. Suction strainer 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2}
6. Drain plug Vacuum valve cracking pressure :
7. Sight gauge -0.49 – 0 kPa {-0.005 – 0 kg/cm2}
8. Oil filler cap Bypass valve set pressure :
9. Pressure valve 103 ± 19.6 kPa {1.05 ± 0.2 kg/cm2}
10. Vacuum valve
10-14 PC128US-2
(15)
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER

1. Hydraulic tank Specification

2. Filter element Tank capacity : 99 ¬
3. Bypass valve Hydraulic oil amount in tank : 69 ¬
4. Suction strainer Pressure valve cracking pressure :
5. Drain plug 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2}
6. Sight gauge Vacuum valve cracking pressure :
7. Oil filler cap -0.49 – 0 kPa {-0.005 – 0 kg/cm2}
8. Pressure valve Bypass valve set pressure :
9. Vacuum valve 147 ± 29.4 kPa {1.5 ± 0.3 kg/cm2}
PC128US-2 10-14-1
(15)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP (PISTON PUMP)

MAIN PUMP
Type : HPV95 (for 105cc/rev.)
PC128US-2 Serial No.: 5001 – 7730
1. Main pump IM : PC mode changeover current

2. LS valve PA : Main pump delivery
3. PC valve PB : Main pump pressure input
4. Fixed throttle valve PD : Main pump drain
5. PC-EPC valve (for changing PC mode) PEPC : EPC valve source pressure inlet
PLS : Control valve LS pressure inlet
PS : Main pump absorption
PC128US-2 10-15
0

1. Main pump PLS : Control valve LS pressure inlet

4. Fixed choke valve PO : Main pump drain
5. PC-EPC valve (for PC mode selection) IM : PC mode change current
6. LS-EPC valve (for LS set selection) PEPC : EPC valve basic pressure inlet
PS : Main pump absorption
10-15-1 PC128US-2
(15)

1. Main pump IM : PC mode change current

4. Fixed choke valve PS : Main pump absorption
5. PC-EPC valve (for PC mode selection) PD1 : Case drain
6. LS-EPC valve (for LS set selection) PLS : Control valve LS pressure inlet
PEPC : EPC valve basic pressure inlet
PC128US-2 10-15-2
(15)

1. Shaft 8. Valve plate

2. Cradle 9. End cap
3. Case 10. Spring
4. Rocker cam 11. Servo last chance filter
5. Shoe 12. Servo piston
6. Piston 13. Slider
7. Cylinder block
10-16 PC128US-2
(15)

1. Shaft 8. Valve plate

2. Cradle 9. End cap
3. Case 10. Spring
4. Rocker cam 11. Servo last chance filter
5. Shoe 12. Servo piston
6. Piston 13. Slider
7. Cylinder block
PC128US-2 10-16-1
(15)

2) Operation in direction for maximum

pump delivery
• When the LS differential pressure ∆PLS (12) comes to the drain pressure PT, and
between the pump discharge pressure PP since the pump discharge pressure PP is
and the LS pressure PLS reduces (when applied to port J on the small diameter
the control valve is large and the dis- side, the servo piston (12) is pushed to
charge pressure PP drops, for example), the right side and the swash plate is
the combined force of the LS pressure moved to the delivery increasing direc-
PLS and the spring (4) pushes the spool tion.
(6) to the right side. • When port G is applied with the output
• When the spool (6) moves, port D is pressure of the EPC valve for the LS
connected to port E to bring the PC valve valve, the piston (7) is pushed to the left
in line. At the time, the PC valve is side.
connected to the drain port, and the cir- • This is effective to reduce the spring (4)
cuit D – K is applied with the drain pres- set force, and the differential pressure be-
sure PT. (The operation of the PC valve tween the oil pressure PP when ports D
will be explained later.) and E of the spool (6) are connected and
• Therefore, the pressure on the piston PP changes.
large diameter side of the servo piston
10-26 PC128US-2
(15)
PC128US-2 Serial No.: 5001 – 7730
3) Operation in the direction to reduce pump

delivery
• When the servo piston (12) moves to the • Since the pump discharge pressure PP is
left side (in the direction to reduce the applied to the J port on the piston small
pump delivery), the LS differential pres- diameter side, the servo piston (12) is
sure ∆PLS will increase (for example, the pressed to the left side due to the area
control valve opening area decreases and difference between the large diameter
.
=.
the pump discharge pressure PP inside and the small diameter side of the
creases) and the force of the discharge servo piston (12). So, the swash plate is
pressure PP will push the spool (6) to the moved in the direction where the deliv-
left side. ery is reduced.
• When the spool (6) moves, the pump dis-
charge pressure PP will be forwarded
from the C port to the D port and will come
from the K port to the piston large diam-
eter side.
PC128US-2 10-27
0

3) Operation in direction for minimum

pump delivery
• The following explains move of the servo • Though the pump discharge pressure PP
piston (12) to the left side (in the direc- comes to port J of the piston small diam-
tion for minimum pump delivery). When eter side, the servo piston (12) is pushed
the LS differential pressure ∆PLS in- to the left side due to the area difference
creases (when the control valve opening between the piston large diameter side
area becomes small and the pump dis- and the piston small diameter side of the
charge pressure PP increases, for ex- servo piston (12) and the swash plate is
ample), the force of the discharge pres- moved in the delivery reducing direction.
sure PP pushes the spool (6) to the left • When port G is applied with the LS se-
side. lection pressure, it is effective to reduce
• As the spool (6) moves, the pump dis- the spring (4) set force.
charge pressure PP flows from port C to
port D and comes from port K to the pis-
ton large diameter side.
10-27-1 PC128US-2
(15)
PC128US-2 Serial No.: 5001 – 7730
4) When the servo piston balances

• Suppose that the area receiving pressure • At the time, the relations of the areas re-
on the piston large diameter side is A1, ceiving pressure at the both ends of the
the area on the piston small diameter side servo piston are A0 : A1 = 1 : 1.75. When
is A0 and the pressure applied to the pis- they balance with each other, the pres-
ton large diameter side is PEN. sures applied to the both ends of the pis-
• When the pump discharge pressure PP of ton are related as follows: PP : PEN .=. 1.75
the LS valve balances with the combined : 1.
force of the LS pressure PLS and the • The spring (4) force has been adjusted so
spring (4) force Z and the relations A0 x that the spool (6) balance stop position is
PP = A1 x PEN hold, the servo piston (12) determined at the center of the standard
will stop at the position and the swash when PP – PLS = 2.21 MPa (22.5kg/cm2).
plate angle will be held at the intermedi-
ate 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 10-27-2
0

4) When the servo piston balances

• The area receiving the pressure on the • At the time, the relations of areas receiv-
piston large diameter side is supposed to ing the pressure on the both ends of the
be A1, the one on the small diameter side servo piston (12) are A0 : A1 = 1 : 1.75,
is supposed to be A0 and the pressure and the ones
. of pressures applied on the
flowing to the piston large diameter side piston both. ends at the balancing time are
is supposed to be PEN. PP : PEN = 1.75 : 1 approximately.
• When the pump discharge pressure PP • The spring (4) force has been adjusted so
of the LS valve balances with the com- that the balance stop position of the spool
bined force of the LS pressure PLS and (6) is determined when PP – PLS = 2.21
the spring (4) force Z and the relations of Mpa {22.5 kg/cm2} is satisfied at the stan-
A0 x PP = A1 x PEN are satisfied, the dard center.
servo piston (12) stops at the position and • When port G is applied with PSIG (EPC
the swash plate is held at the intermedi- valve output pressure for LS valve of 0 –
ate position (stops where the opening 2.9 Mpa {10 – 30 kg/cm2}), however, the
from port D to port E of the spool (6) is balance stop position changes proportion-
almost equal to the one from port C to ally to the PSIG pressure in the range of
port D). PP – PLS from 2.1 to 0.6 Mpa {21.5 to 6.5
kg/cm2}.
10-27-3 PC128US-2
(18)
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 (1) sure PP. And the pressure output from
• The pump controller provides a com- the PC valve (the pressure at the C
mand current to the PC-EPC valve so- port) varies with the spool position.
lenoid (1). This command current ac- • The value of the command current X
tuates the PC-EPC valve and outputs is determined depending on type of
a signal pressure. When receiving the work (lever control), selection of work-
signal pressure, the PC valve changes ing mode, set point of engine speed
the force given to the piston (2). and actual speed.
• The spool (3) stops where the force to
the piston (2) balances with the com-
bined force of the spring setting force
of the springs (4) and (6) on the oppo-
site side and the force given to the
spool (3) by the pump discharge pres-
10-28 PC128US-2
3) When the pump controller is out of order than the spring set force. So, the spool
and the PC redundant switch is set to ON (3) balances at a position in the left
a. In case of light load to main pump side.
• When the pump controller is out of • At the time, the C port has the same
order, set the PC redundant switch to pressure as the drain pressure at the
ON to change the circuit to the resis- D port, and the drain pressure PT is
tor side. In this case, since the curled to the large diameter side of the
rent is too large when the power is di- servo piston (9) through the LS valve.
rectly taken from the battery, the re- Then, the servo piston (9) moves in
sistor is connected to control the cur- the direction where the delivery in-
rent to the PC-EPC valve solenoid. creases because the pressure on the
• At the time, the current becomes con- small diameter side of the piston is
stant and the piston (2) pressing force large.
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 10-33
(18)
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 1. Swing bleed valve

(pressure sensor is intalled) 2. Travel junction valve
A1 : To swing motor MB 3. Arm regeneration valve
A2 : To L.H. travel motor A 4. Boom drift prevention valve
A3 : To R.H. travel motor A 5. Cover
A4 : To boom cylinder bottom 6. Service valve
A5 : To arm cylinder head 7. Bucket valve
A6 : To bucket cylinder head 8. Arm valve
A7 : To attachment 1 9. Boom valve
B1 : To swing motor MA 10. R.H. travel valve
B2 : To L.H. travel motor B 11. L.H. travel valve
B3 : To R.H. travel motor B 12. Swing valve
B4 : To boom cylinder head 13. PT port block
B5 : To arm cylinder bottom 14. Safety-suction valve
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 PC128US-2
(15)
7 spool valve
(6 spool valve + service valve)
PC128US-2 10-37
(15)

10-37-1 PC128US-2
(15)
CROSS-SECTIONAL DRAWING
fl Cross-sectional drawing shows 7-spool valve (6-spool + service valve).
(1/8)
1. Safety-suction valve 8 Safety-suction valve mount (service B)

2. Suction valve (L.H. travel A) 9. Suction valve (Bucket bottom)
3. Suction valve (R.H. travel A) 10. Suction valve (Arm bottom)
4. Suction valve (Boom bottom) 11. Suction valve (Boom head)
5. Suction valve (Arm head) 12. Suction valve (R.H. travel B)
6. Suction valve (Bucket head) 13. Suction valve (L.H. travel B)
7. Safety-suction valve mount (service A) 14. Lift check valve
10-38 PC128US-2
(15)
(2/8)
1. Main relief valve

2. Spool (swing)
3. Spool (L.H. travel)
4. Spool (R.H. ravel)
5. Spool (boom)
6. Spool (arm)
7. Spool (bucket)
8. Spool (service)
PC128US-2 10-39
(3/8)
1. Pressure compensation valve F (swing) 9. Pressure compensation valve R (service)

2. Pressure compensation valve F (L.H. travel) 10. Variable pressure compensation valve
3. Pressure compensation valve F (R.H. travel) 11. Pressure compensation valve R (bucket)
4. Pressure compensation valve F (boom) 12. Pressure compensation valve R (arm)
5. Pressure compensation valve F (arm) 13. Pressure compensation valve R (boom)
6. Pressure compensation valve F (bucket) 14. Pressure compensation valve R (R.H. travel)
7. Pressure compensation valve F (service) 15. Pressure compensation valve R (L.H. travel)
8. Unload valve 16. 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 PC128US-2
(15)
(4/8)
1. LS pressure detection plug

2. LS bypass plug
3. Pump pressure detection plug
4. Check valve (bucket head)
5. Check valve (arm head)
6. Check valve (boom bottom)
7. LS selection valve
PC128US-2 10-41
(5/8)
1. Main relief valve 7. Swing bleed valve

2. Cooler bypass valve 8. Pressure compensation valve F
3. Lift check valve
4. LS selection valve F : Flow control valve
5. Spool (swing) R : Pressure reducing valve
6. Pressure compensation valve R
10-42 PC128US-2
(15)
(6/8)
1. Suction valve (A) 8. Suction valve (B)

2. Suction valve (B) 9. Spool (R.H. travel)
3. Spool (L.H. travel) 10. Pressure compensation valve R
4. Pressure compensation valve R 11. Pressure compensation valve F
5. Travel junction valve
6. Pressure compensation valve F F : Flow control valve
7. Suction valve (A) R : Pressure reducing valve
PC128US-2 10-43
(15)
(7/8)
1. Suction valve (A) 9. Spool

2. Boom drift prevention valve 10. Pressure compensation valve R
3. Suction valve (B) 11. Arm regemeration valve
4. Spool 12. Pressure compensation valve F
8. Suction valve (B)
10-44 PC128US-2
(15)
(8/8)
1. Suction valve (A) 9. Variable pressure compensation valve

2. Suction valve (B) 10. Pressure compensation valve R
4. Pressure compensation valve R 12. Pressure relief plug
5. Pressure compensation valve F 13. Unload valve
6. Safty-suction valve mount (A)
7. Safty-suction valve mount (B) F : Flow control valve
8. Spool R : Pressure reducing valve
PC128US-2 10-45
(15)
FOR KUK SPEC.

PC128US-2
OUTLINE
There are the following 2 types of control valve.
• 8-spool valve
(6-spool valve + Full-flow service valve + Half-
flow service valve)
• 9-spool valve
(6-spool valve + Blade valve + Full-flow ser-
vice valve + Half-flow 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.
External appearance and cross section is given
only for the 9 spool valve.
AA : Pressure sensor port PB8 : From service 1 (Full-flow) PPC valve
(pressure sensor is intalled) PB9 : From service 2 (Half-flow) PPC valve
A1 : To swing motor MB P : From main pump
A2 : To L.H. travel motor A PP : To main pump
A3 : To R.H. travel motor A PX : From 2-stage relief solenoid valve
A4 : To boom cylinder bottom SA : From swing stroke control solenoid valve
A5 : To blade cylinder bottom SB : From swing stroke control solenoid valve
A6 : To arm cylinder head TS1 : To tank
A7 : To bucket cylinder head TS2 : To tank
A8 : To attachment 1 TB : To tank
A9 : To attachment 2 TC : To oil cooler
B1 : To swing motor MA TSW : To swing motor
B2 : To L.H. travel motor B 1. Swing bleed valve
B3 : To R.H. travel motor B 2. Travel junction valve
B4 : To boom cylinder head 3. Arm regeneration valve
B5 : To blade cylinder head 4. Boom drift prevention valve
B6 : To arm cylinder bottom 5. Cover
B7 : To bucket cylinder bottom 6. Service valve 2
B8 : To attachment 1 7. Service valve 1
B9 : To attachment 2 8. Bucket valve
BP : From boom RAISE PPC/EPC valve 9. Arm valve
LS : To pump LS valve 10. Blade valve
PA1 : From swing L.H. PPC/EPC valve 11. Boom valve
PA2 : From L.H. travel forward PPC valve 12. R.H. travel valve
PA3 : From R.H. travel reverse PPC valve 13. L.H. travel valve
PA4 : From boom RAISE PPC/EPC valve 14. Swing valve
PA5 : From blade LOWER PPC valve 15. PT port block
PA6 : From arm OUT PPC/EPC valve
PA7 : From bucket DUMP PPC/EPC valve
PA8 : From service 1 (Full-flow) PPC valve
PA9 : From service 2 (Half-flow) 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 blade RAISE PPC valve
PB6 : From arm IN PPC/EPC valve
PB7 : From bucket CURL PPC/EPC valve
10-45-1 PC128US-2
0
(2/9)
1. Main relief valve 6. Spool (Blade)

2. Spool (Swing) 7. Spool (Arm)
3. Spool (L.H. travel) 8. Spool (Bucket)
4. Spool (R.H. travel) 9. Spool (Service 1)
5. Spool (Boom) 10. Spool (Service 2)
PC128US-2 10-45-4
(15)
(3/9)
1. Pressure compensation valve F (Swing) 12. Pressure compensation valve (Service 1)

2. Pressure compensation valve F (L.H. travel) 13. Pressure compensation valve R (Bucket)
3. Pressure compensation valve F (R.H. travel) 14. Pressure compensation valve R (Arm)
4. Pressure compensation valve F (Boom) 15. Pressure compensation valve R (Blade)
5. Pressure compensation valve F (Blade) 16. Pressure compensation valve R (Boom)
6. Pressure compensation valve F (Arm) 17. Pressure compensation valve R (R.H. travel)
7. Pressure compensation valve F (Bucket) 18. Pressure compensation valve R (L.H. travel)
8. Pressure compensation valve F (Service 1) 19. Pressure compensation valve R (Swing)
9. Pressure compensation valve F (Service 2)
10. Unload valve F : Flow control valve
11. Variable pressure compensation valve R : Pressure control valve
(Service 2)
10-45-5 PC128US-2
(15)
(4/9)
1. LS pressure pickup plug

2. LS bypass plug
3. Pump pressure pickup plug
4. Check valve (Bucket head)
5. Check valve (Arm head)
6. Check valve (Boom bottom)
7. LS selector valve
PC128US-2 10-45-6
5
(5/9)
1. Main relief valve F : Flow control valve

2. Cooler bypass valve R : Pressure reducing valve
3. Lift check valve
4. LS selection valve
5. Spool
7. Swing bleed valve
8. Pressure compensation valve F
10-45-7 PC128US-2
(15)
(6/9)
1. Suction valve (A) 8. Suction valve (B)

2. Suction valve (B) 9. Spool (R.H. travel)
3. Spool 10. Pressure compensation valve R
4. Pressure compensation valve R 11. Pressure compensation valve F
5. Travel junction valve
PC128US-2 10-45-8
(15)
(7/9)
1. Suction valve (A) 9. Spool

2. Boom drift prevention valve 10. Pressure compensation valve R
3. Suction valve (B) 11. Arm regemeration valve
8. Suction valve (B)
10-45-9 PC128US-2
(15)
(8/9)
1. Suction valve (A) 9. Pressure compensation valve R

2. Suction valve (B) 10. Pressure compensation valve F
3. Spool 11. Pressure relief plug
4. Pressure compensation valve R 12. Unload valve
6. Safty-suction valve (A) F : Flow control valve
7. Safty-suction valve mount (B) R : Pressure reducing valve
8. Spool
PC128US-2 10-45-10
(15)
(9/9)
1. Safety-suction valve (A)

2. Safety-suction valve (B)
3. Variable pressure compensation valve
4. Spool
F : Flow control valve

R : Pressure reducing valve
10-45-11 PC128US-2
(15)
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 pres-
sure compensation accuracy of the travel cir-
cuit and limits reduction of the travel speed
to small extent.
• The bypass circuit is closed in case of inde-
pendent 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 pres-
sure 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 CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

STD (WITHOUT BLADE)
1. Cover A1 : From control valve (R.H. travel Forward)

2. Body A2 : To R.H. travel motor B
3. Slipper seal B1 : From control valve (L.H. travel Forward)
4. O-ring B2 : To L.H. travel motor A
5. Shaft 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
PC128US-2 10-91
A
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
OPT (WITH BLADE)
1. Cover D2 : To L.H. travel motor B

2. Body E1 : From travel 2nd speed selector solenoid
3. Slipper seal valve
4. Dust seal E2 : To L.H./R.H. travel motor D
5. Shaft F1 : From control valve (Blade “LOWER”)
F2 : To L.H./R.H. blade cylinder bottom
A1 : From control valve (R.H. travel “Forward”) G1 : From control valve (Blade “RAISE”)
A2 : To R.H. travel motor B G2 : To L.H./R.H. blade cylinder head
B1 : From control valve (L.H. travel “Forward”) DR1 : To hydraulic tank
B2 : To L.H. travel motor A DR2 : From L.H. travel motor C1, R.H. travel mo-
C1 : From control valve (R.H. travel “Reverse”) tor C2
C2 : To R.H. travel motor A
D1 : From control valve (L.H. travel “Reverse”)
10-92 PC128US-2
A
STRUCTURE AND FUNCTION TRAVEL MOTOR
Specification
Type GM18VL-J GM20VL-J GM20VL-P GM20VL2-P

PC128US-2 Serial No. 5001 and up 5001 – 6072 6073 and up —
Spec. STD OPT(traction up) —
PC138US-2 Serial No. — — — 4501 and up
Spec. — — — STD
PC138USLC-2 Serial No. — — 1001 – 1500 1501 and up
Spec. — — STD STD
Theoretical delivery Hi 33.2 {33.2} 34.0 {34.0} 31.5 {31.5}
(cm3/rev{cc/rev}) Lo 52.7 {52.7} 55.8 {55.8}
Rated speed Hi 3,267.7 3,191 3,035 3,444
(rpm) Lo 2,147.3 2,028 1,929 2,025
Brake releasing pressure 0.68
(MPa{kg/cm2}) {6.94}
Hi-Lo switching pressure 2.94

(MPa{kg/cm2}) {30}
Final drive reduction ratio 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 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 configura-
tion is as per the right figure.
• Functions and operations of these compo-
nents 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, trav-
eling with reduced engine speed is very dan-
gerous because the motor idles and runs
away.
These valves let the machine travel at a speed
appropriate for the engine speed (pump de-
livery) to prevent this danger.
Operation at oil supply

• When the travel lever is operated, the pres-
surized oil from the control valve will be sup-
plied 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 PC128US-2
(18)
STRUCTURE AND FUNCTION ACCUMULATOR FOR BREAKER (IF EQUIPPED)
ACCUMULATOR FOR BREAKER

(If equipped)
FOR LOW PRESSURE
1. Cap
2. Core
3. Guard rubber
4. Lid
5. Plug
6. Shell
Specification
Type of gas : Nitrogen gas
Gas valume : 0.48 ¬
Sealed gas pressure : 0.1 MPa {1 kg/cm2}(at 80 ºC)
Max. actuating pressure : 6.86 MPa {70 kg/cm2}
FOR HIGH PRESSURE
1. Cap
2. Gas plug
3. Plug
4. Shell
Specification
Type of gas : Nitrogen gas
Gas valume : 0.5 ¬
Sealed gas pressure :
5.88 MPa {60 kg/cm2}(at 80 ºC)
Max. actuating pressure : 20.6 MPa {210 kg/cm2}
PC128US-2 10-111
C
STRUCTURE AND FUNCTION PPC VALVE
FOR TRAVEL
P : From main pump P3 : R.H reverse

T : To tank P4 : R.H forward
P1 : L.H reverse P5 : Travel signal
P2 : L.H forward
10-116 PC128US-2
(15)
PC128US-2 Serial No. 5001 – 6300
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar
PC128US-2 10-117
(15)
PC128US-2 Serial No. 6301 and up

PC138USLC-2 Serial No. 1001 and up
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar 8. Pin
10-117-1 PC128US-2
(15)
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 pres-
surized 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, com-
pressed in proportion to strokes of the opera-
tion lever. Thus, the P1 port pressure, too,
increases in proportion to strokes of the op-
eration 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
3. In the fine control mode (when operation le-

ver 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 con-
nected to the drain room D and relieves pres-
surized 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 con-
trol hole f and the drain room D is shut down.
And, almost at the same time, the hole is con-
nected to the pump pressure room PP and
starts supplying pump the pressure. This sup-
ply continues until the P1 port pressure is re-
covered 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)
FOR BLADE, SERVICE
1. Spool P : From self pressure reducing valve

2. Metering spring T : To tank
3. Centering spring P1 : To blade or service valve
4. Piston P2 : To blade or service valve
5. Lever
6. Plate
7. Retainer
8. Body
9. Filter
10-120 PC128US-2
(15)
STRUCTURE AND FUNCTION BOOM HYDRAULI DRIFT PREVENTION T VALVE
BOOM HYDRAULIC DRIFT PREVENTION VALVE

(FOR KUK SPEC.)
PC128US-2 Serial No.: 5001 – 7730
1. Poppet CY : To boom cylinder bottom

2. Check valve spring PI : From PPC valve (pilot pressure)
3. Pilot spool T : To hydraulic tank
4. Pilot spring V : From control valve
5. Safety-suction valve
PC128US-2 10-122-1
C
STRUCTURE AND FUNCTION BOOM HYDRAULIC DRIFT PREVENTION VALVE

1. Poppet CY : To boom cylinder bottom

2. Check valve spring PI : From PPC valve (pilot pressure)
3. Pilot spool T : To hydraulic tank
4. Pilot spring V : From control valve
5. Safety-suction valve
10-122-2 PC128US-2
(15)
STRUCTURE AND FUNCTION ARM HYDRAULIC DRIFT PREVENTION VALVE
ARM HYDRAULIC DRIFT PREVENTION VALVE

(FOR KUK SPEC.) (If equipped)
1. Pilot spool V : From control valve

2. Spring (1st stage of spool) T : To hydraulic tank
3. Spring (2nd stage of spool) CY : To hydraulic cylinder
4. Safety valve PI : From PPC valve
5. Check valve PCV : From pressure pickup and equalizer circuits
6. Spring
10-122-6 PC128US-2
(15)
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 equip-
ment.
Operation
1. When work equipment is in neutral
[When piping is normal]
• Check valve (5) is closed by the work equip-
ment 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 cyl-
inder, thus the work equipment cylinder is
held.
• If the pressure in the work equipment cylin-
der rises high abnormally, work equipment
cylinder holding pressure operates safety
valve (4).
[When piping bursts]

• Even if piping A between the main valve and
work equipment cylinder bursts, chamber a
is shut off from chamber b as in the case
where the piping is normal. Accordingly, the
work equipment cylinder is held.
PC128US-2 10-122-7
C
2. When oil is sent from main valve to cylinder

• If pressure of the oil sent from the main valve
to chamber a is higher than the total of pres-
sure 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.

• If piping A between the main valve and work
equipment cylinder bursts, the oil in cham-
ber 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 PC128US-2
(18)
3. When oil is returned from work equipment

cylinder to main valve
• The work equipment cylinder holding pres-
sure is applied to chamber b and check valve
(5) closes.
• The pilot pressure from the PPC valve is ap-
plied port Pi. If it is higher than the force of
spring (2) (area of ød), spool (1) moves to the
right standby position (1st-stage stroke).
• At this time, chambers a and b are not con-
nected to each other.
• If the pilot pressure rises higher than the force
of spring (3) (area of ød), spool (1) moves fur-
ther 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.

• If piping A between the main valve and work
equipment cylinder bursts, the oil in cham-
ber a flows out through the burst part. Since
the oil supplied from chamber b to chamber
a flows through opening c of spool (1), how-
ever, the cylinder does not fall suddenly.
PC128US-2 10-122-9
C
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING

A : Hot air/cold air spurting with outlet port

B : Internal air circulation port
C : External air inlet
1. Hot water drain piping 5. Receiver tank

2. Air conditioner compressor 6. Condenser
3. Hot water return piping 7. Air conditioner unit
4. Refrigerant piping 8. Duct
10-123-1 PC128US-2
(18)
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING

A: Hot air/cold air spurting with outlet port

B: Internal air circulation port
C: External air inlet
D: Refrigerant checking port
1. Hot water drain piping 5. Receiver tank

2. Air conditioner compressor 6. Condenser
3. Hot water return piping 7. Air conditioner unit
4. Refrigerant piping 8. Duct
PC128US-2 10-123-2
(18)
STRUCTURE AND FUNCTION ELECTRIC COMPONENT LAYOUT
ELECTRIC COMPONENT LAYOUT

PC128US-2 Serial No.: 5001 – 7730
10-124 PC128US-2
0
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

PC138USLC-2 Serial No. : 1001 and up
fl For the layout drawings of electrical equip-
ment 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)
PC128US-2 Serial No.: 5001 – 7730
10-126 PC128US-2
0
39. Temperature control switch

40. Wind volume selection switch
41. Air conditioner switch
42. Horn switch
43. Monitor panel
44. Light switch
45. Car heater switch (Model with heater)
46. One touch deceralation pilot lamp
47. Starting switch
48. Fuse box
49. Throttle control motor
50. Overload alarm buzzer reset switch (Standard
for KUK only)
51. Additional light switch (Standard for North
America)
52. Wiper switch
53. Wiper controller
54. Swing lock switch
55. Travel speed selection switch
56. PPC lock switch
57. One touch deceralation switch
58. Additional light relay
59. Alarm buzzer
60. Room light
61. Antenna (Standard for North America only)
62. Car radio (Standard for North America only)
63. Speaker (Standard for North America only)
64. Waper motor

fl For the layout drawings of electrical equip-
ment 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
ENGINE CONTROL
PC128US-2 Serial No.: 5001 – 7730
1. Fuel adjust motor 7. Deceleration controller

2. One-touch deceleration pilot lamp 8. Battery relay
3. Fuel adjust dial 9. Battery
4. Starter 10. One-touch deceleration switch
5. Starter switch 11. Governor
6. Engine stop solenoid 12. Fuel injection pump
10-128 PC128US-2
0

1. Starting switch 8. Battery

2. Fuel control dial 9. Fuel control motor
3. Safety relay 10. Fuel control motor relay
4. Starting motor 11. Engine stop solenoid relay
5. Engine stop solenoid 12. Governor lever
6. Controller 13. Fuel injection pump
7. Battery relay
PC128US-2 10-128-1
(15)

1. Starting switch 8. Battery

2. Fuel control dial 9. Fuel control motor
3. Safety relay 10. Fuel control motor relay
4. Starting motor 11. Engine stop solenoid relay
5. Engine stop solenoid 12. Governor lever
6. Controller 13. Fuel injection pump
7. Battery relay
10-128-2 PC128US-2
(15)

1. Battery 10. Safety relay

2. Battery relay 11. Fuel control dial
3. Fusible link 12. Fuel control motor
4. Starting switch 13. Fuel control motor relay (for driving)
5. Fuse box 14. Fuel control motor relay (for acceleration)
6. Controller 15. Fuel control motor relay (for deceleration)
7. Safety lock lever 16. Engine stop solenoid
8. PPC lock switch 17. Starting motor
9. Starting motor cut relay
PC128US-2 10-132-1
(15)
START OF ENGINE
• When the starting switch comes to the ON po-
sition, the engine stop solenoid (16) drives the
governor stop lever to the "RUN" side. A fail-
safe 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 re-
lay (9) interrupts the start signal to the start-
ing 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 accel-
eration (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 mo-
tor (12) through the fuel control motor relays
(13), (14) and (15).
• The fuel control motor (12) shortens or ex-
tends 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.
10-132-2 PC128US-2
7

1. Battery 10. Safety relay

2. Battery relay 11. Fuel control dial
3. Fusible link 12. Fuel control motor
4. Starting switch 13. Engine stop solenoid relay
5. Fuse box 14. Fuel control motor relay (for acceleration)
6. Controller 15. Fuel control motor relay (for deceleration)
7. Safety lock lever 16. Engine stop solenoid
8. PPC lock switch 17. Starting motor
PC128US-2 10-132-3
(15)
START OF ENGINE
• When the starting switch comes to the ON po-
sition, the engine stop solenoid (16) drives the
governor stop lever to the "RUN" side. A fail-
safe 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 re-
lay (9) interrupts the start signal to the start-
ing 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 accel-
eration (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 mo-
tor (12) through the fuel control motor relays
(13), (14) and (15).
• The fuel control motor (12) shortens or ex-
tends 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 burn-
ing.
• The time to supply the suction current is lim-
ited to 3 seconds after starting switch (4) is
turned to the ON position by replacing the 2-
wire engine stop solenoid (16) (which uses the
same wire for the suction and holding cur-
rents) with the 3-wire one (which uses inde-
pendent wires for the suction and holding A: Operation of starting switch
currents) and adding a timer function and B: Suction coil current
engine stop solenoid relay (13) to controller C: Holding coil current
(6). t: 3 seconds
10-132-4 PC128US-2
(15)
AUTO-DECELERATOR
1. Battery 14. Travel PPC oil pressure switch

2. Battery relay 15. Work equipment control lever PPC
3. Fusible link oil pressure switch
4. Starting switch 16. Hydraulic pump
5. Fuse box 17. Control valve
6. Controller 17a. Self pressure reducing valve
7. Fuel control dial 17b. Main relief valve
8. Fuel control motor 18. PPC lock solenoid valve
9. Monitor panel 19. L.H. work equipment PPC valve
10. Fuel injection pump 20. R.H. work equipment PPC valve
11. Boom RAISE PPC oil pressure switch 21. Travel PPC valve
12. Arm IN PPC oil pressure switch 22. Blade PPC valve (Blade specification)
13. Swing PPC oil pressure switch
I/O Signals
a. Controller power supply e. PPC oil pressure switch signal
b. Solenoid power supply f. Throttle signal
c. Monitor panel power supply g. Fuel control motor drive signal
d. S-NET signal h. Potentiometer signal
PC128US-2 10-132-5
(15)
FUNCTION
• When the all control levers are set to NEU-
TRAL 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
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 immedi-
ately 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 low-
ers 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 en-
gine speed is kept for the 2nd deceleration
speed, the engine speed rises immediately to
the speed that is set with the fuel dial.
A: All work equipment levers at "NEUTRAL"
B: Work equipment lever at "OPERATION"
C: Speed that is set with fuel control dial
D: 1st deceleration speed
E: 2nd deceleration speed (1,400 rpm)
F : 200 ± 50 rpm
G: 0.2 sec.
H: 4 sec.
J : Max. 2 sec.
K: Max. 1 sec.
10-132-6 PC128US-2
(15)

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 immedi-
ately 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 low-
ers 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 en-
gine speed is kept for the 2nd deceleration
speed, the engine speed rises immediately to
the speed that is set with the fuel dial.
A: All work equipment levers at "NEUTRAL"
B: Work equipment lever at "OPERATION"
C: Speed that is set with fuel control dial
D: 1st deceleration speed
E: 2nd deceleration speed (1,300 rpm)
F : 100 ± 50 rpm
G: 0.2 sec.
H: 4 sec.
J : Max. 2 sec.
K: Max. 1 sec.
PC128US-2 10-132-7
(15)
SYSTEM COMPONENTS
FUEL ADJUST DIAL
PC128US-2 Serial No.: 5001 – 7730
ª1 : PC128US-2 Serial No. 6301 and up
1. One-touch deceleration pilot lamp 5. Shaft

2. Fuel adjust dial 6. Joint
3. Boss 7. Bracket
4. Boss 8. Fuel adjust motor
PC128US-2 10-133
(14)

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. 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 PC128US-2
(15)

1. Cable
2. Connector
3. Potentiometer
4. Pulley
5. Gear unit
6. Motor
Input/Output signal
DEUTSCH-6P [CN-M48]
Pin No. Signal name I/O signal
1 Potentiometer input Input
2 Potentiometer output Output
3 Potentiometer GND —
4 NC —
5 Motor (+) Input
6 Motor (–) Input
PC128US-2 10-134-1
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

10-136-2 PC128US-2
(15)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Resistor (for driving pump in an emergency)
9. Swing holding brake release switch
12. PPC lock witch
14. Safety relay
15. Fuel control motor relay (for driving)
16. Fuel control motor relay (for acceleration)
17. Fuel control motor relay (for deceleration)
18. Fuel control dial
19. Fuel control motor
20. Monitor panel
21. Hydraulic pump pressure sensor
22. Travel/swing alarm (option)
24. Travel speed selector solenoid valve
25. Swing holding brake solenoid valve
27. LS-EPC valve
28. PC-EPC valve
33. Boom RAISE PPC oil pressure switch
34. Travel PPC oil pressure switch
35. Arm IN PPC oil pressure switch
37. Work equipment control lever
PPC oil pressure switch
38. Engine stop solenoid
39. Starting motor
42. Hydraulic pump
42a. Servo piston
42b. LS valve
42c. PC valve
43. Control valve
43a. Self pressure reducing valve
43b. Main relief valve
44. Travel motor
45. Swing motor
PC128US-2 10-136-3
A

10-136-4 PC128US-2
(15)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Resistor (for driving pump in an emergency)
9. Swing holding brake release switch
12. PPC lock witch
14. Safety relay
15. Engine stop solenoid relay
16. Fuel control motor relay (for acceleration)
17. Fuel control motor relay (for deceleration)
18. Fuel control dial
19. Fuel control motor
20. Monitor panel
21. Hydraulic pump pressure sensor
22. Travel/swing alarm (option)
24. Travel speed selector solenoid valve
25. Swing holding brake solenoid valve
27. LS-EPC valve
28. PC-EPC valve
33. Boom RAISE PPC oil pressure switch
34. Travel PPC oil pressure switch
35. Arm IN PPC oil pressure switch
37. Work equipment control lever
PPC oil pressure switch
38. Engine stop solenoid
39. Starting motor
42. Hydraulic pump
42a. Servo piston
42b. LS valve
42c. PC valve
43. Control valve
43a. Self pressure reducing valve
43b. Main relief valve
44. Travel motor
45. Swing motor
46. Heater relay
47. Air heater
PC128US-2 10-136-5
(15)

1. Battery 11. LS-EPC valve

2. Battery relay 12. Engine speed sensor
3. Fusible link 13. Coolant temperature sensor
4. Starting switch 14. Control valve
5. Fuse box 14a. Self pressure reducing valve
6. Controller 14b. Main relief valve
7. Resistor (for driving pump in an emergency) 15. Hydraulic pump
8. Emergency pump drive switch 15a. Servo valve
9. Monitor panel 15b. LS valve
10. PC-EPC valve 15c. PC valve
Input/Output signals
a. Controller power supply e. PC-FPC valve drive signal
b. Solenoid power supply f. LS-FPC valve drive signal
c. Monitor panel power supply g. Coolant temperature signal
d. S-NET signal h. Engine speed signal
PC128US-2 10-138-1
(15)
Function
• This function is for selecting any of the three
working modes "A," "B" and "E" with the work-
ing 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 depend-
ing 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 con-

troller prevents the engine from stopping by
throttling the pump absorption torque.
10-138-2 PC128US-2
(18)
CONTROL METHOD IN EACH MODE
Mode A
• Matching point in Mode A
66.2 kW/2,200 rpm
PC138USLC-2 Serial No.: 1001 – 1500 Mode A
{88.7 HP/2,200 rpm}
• 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 10-138-3
(15)
Mode E and Mode B

PC128US-2
• Matching point in Mode E : Model
PC138USLC-2
85% partial output point in Mode A
• Matching point in Mode B : 54.4 kW/2,000 rpm
E mode
75% partial output point in Mode A {72.9 HP/2,000 rpm}
• At the time, the controller lowers the engine 47.8 kW/1,800 rpm
speed by keeping the pump absorption torque B mode
{64.1 HP/1,800 rpm}
constant along the equal horsepower curve
with the compound control both on the en-
gine side and on the pump side.
Therefore, the engine is used in high fuel effi-
cient ranges.
10-138-4 PC128US-2
(15)

1. Battery 9. Travel PPC valve

2. Battery relay 10. Travel PPC oil pressure switch
3. Fusible link 11. Engine
4. Starting switch 12. Hydraulic pump
5. Fuse box 13. Control valve
6. Controller 13a. Self pressure reducing valve
7. 2-stage relief solenoid 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
Condition Relief pressure
31.9 MPa {325 kg/cm2}, and the relief pressure
rises to 34.8 MPa {355 kg/cm2} when the 2-
31.9 MPa {325 kg/cm2}
stage relief function is operated. Therefore, During travel ↓
the oil pressure will rise more.
34.8 MPa {355 kg/cm2}
10-139-1 PC128US-2
(15)
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 Swing
lock lock Function Operation
switch lamp
• When the swing control lever is returned

Swing to the neutral position, the swing holding
ON Gose out holding brake is actuated after approx. 4 seconds.
• When the swing control lever is operated,
brake
the swing holding brake is released, and
it is possible to operate the swing freely.
• If abnormality occurs in the swing hold-

ing brake system and OFF, the swing hold-
ing brake is canceled and it becomes pos-
OFF Lights up Swing sible to operate the swing.
lock • However, even when the swing control
level is returned to the nertral position, the
swing holding brake is not actuated.
PC128US-2 10-141
(18)
Swing holding brake release

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

breake release (When abnormality) (When controlleris
switch safe)
Swing lock
switch ON OFF ON OFF
Swing
Swing Swing Swing holding
Swing brake lock lock lock
breake
operates released operates
operates
Input/Output Signal time chart
10-142 PC128US-2
(18)

1. Battery 12. Swing motor

2. Battery relay 13. L.H. work equipment PPC valve
3. Fusible link 14. Arm IN PPC oil pressure switch
4. Starting switch 15. Swing PPC oil pressure switch
5. Fuse box 16. Engine
6. Controller 17. Hydraulic pump
7. Swing holding brake release switch 18. Control valve
8. Swing lock switch 18a. Self pressure reducing valve
9. Monitor panel 18b. Main relief valve
10. Swing holding brake solenoid valve 19. Travel/swing alarm (option)
Input/Output Signals
a. Controller power supply e. Solenoid valve drive signal
b. Solenoid power supply f. Swing PPC oil pressure switch signal
c. Monitor panel power supply g. Arm IN PPC oil pressure switch signal
d. S-NET signal h. Alarm operation signal
PC128US-2 10-142-1
(15)

1. Battery 10. R.H. travel motor

2. Battery relay 11. Engine speed sensor
3. Fusible link 12. Pump pressure sensor
4. Starting switch 13. Engine
5. Fuse box 14. Hydraulic pump
6. Controller 15. Control valve
7. Monitor panel 15a. Self pressure reducing valve
8. Travel speed selector solenoid valve 15b. Main relief valve
9. L.H. travel motor 16. Travel/swing alarm (option)
a. Controller power supply e. Solenoid valve drive signal
b. Solenoid power supply f. Engine speed signal
c. Monitor panel power supply g. Pump pressure signal
d. S-NET signal h. Alarm operation signal
10-143-1 PC128US-2
(15)
FUNCTION
Travel Speed Selection
1. Travel Speed "Manual" Change

Standard Specification and Blade Specifica-
tion (option)
Standard Specification
PC128US-2 Serial No.: 5001 – 7730 Travel speed LOW HIGH
• When the travel speed selector switch selector switch (low speed) (high speed)
is set to LOW or HIGH, the motor capac- Motor capacity
ity changes and travel speeds can be se- (cc/rev) 52.7 33.2
lected. Travel speed
(km/h) 3.2 5.1
Travel motor swash plate

angle Maximum Minimum
Blade Specification (Option) Travel speed LOW HIGH

PC128US-2 Serial No. : 5001 – 7730 selector switch (low speed) (high speed)
• When the travel speed selector switch or Motor capacity
the travel accelerator pedal is operated, (cc/rev) 52.7 33.2
Release
Travel accelerator pedal
the motor capacity changes and travel Travel speed

speeds can be selected. (km/h) 3.2 5.1
fl The travel accelerator pedal works when Travel motor swash
the travel speed selector switch is set to plate angle Maximum Minimum
the LOW position. Motor capacity
When the switch is set to the HIGH posi- (cc/rev) 33.2 33.2
Step on
tion, the travel speed does not change Travel speed

even if the pedal is stepped on. (km/h) 5.1 5.1
Travel motor swash Minimum Minimum

plate angle
PC128US-2 10-143-2
(15)
Standard Specification and Blade Specifica- Travel speed LOW HIGH

tion (option) selector switch (low speed) (high speed)
PC138US-2 Serial No.: 4501 and up Motor capacity
PC138USLC-2 Serial No.: 1501 and up (cc/rev) 55.8 31.5
Travel speed
(km/h) 2.9 5.1
Travel motor swash plate

angle Maximum Minimum
10-143-3 PC128US-2
(15)
2. "Automatic"change of travel speed

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 auto-
matically.
• If engine speed becomes 1,700 rpm or
is in HIGH and travel speed is LOW,
travel speed changes to HIGH auto-
matically.
fl If travel speed selector switch is in
LOW, travel speed is not changed au-
tomatically.
2) Automatic selection corresponding to dis-

charge pressure of pump
• If travel pressure of 27.5MPa {280 kg/
cm2} or higher continues for 0.02 sec-
onds or more when travel speed se-
lector switch is in HIGH, travel speed
changes to LOW automatically.
cm2} or lower continues for 0.20 sec-
changes to HIGH automatically.
tomatically.
PC128US-2 10-143-4
(15)
2. "Automatic"change of travel speed

1) Automatic selection corresponding to

engine speed
• If engine speed drops to 1,500 rpm or
is in HIGH and travel speed is HIGH,
travel speed changes to LOW auto-
matically.
• If engine speed becomes 1,700 rpm or
is in HIGH and travel speed is LOW,
travel speed changes to HIGH auto-
matically.
tomatically.
2) Automatic selection corresponding to dis-

charge pressure of pump
cm2} or higher continues for 0.02 sec-
changes to LOW automatically.
cm2} or lower continues for 0.20 sec-
changes to HIGH automatically.
tomatically.
10-143-5 PC128US-2
(15)

1. Battery 10. Left work equipment PPC valve

2. Battery relay 11. Right work equipment PPC valve
3. Fusible link 12. Traveling PPC valve
4. Starting switch 13. Blade PPC valve (Blade specification)
5. Fuse box 14. Engine
7. Safety lock lever 16. Operation valve
8. PPC lock switch 16a. Self pressure reducing valve
9. PPC lock solenoid valve 16b. Man relief valve
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 cur-
rent to PPC lock solenoid valve, making op-
eration lever on the work equipment disabled.
PC128US-2 10-144-1
(15)
OVERLOAD ALARM FUNCTION

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

1. Battery Input/Output signals

2. Battery relay a. Power supply of controller
3. Fusible link b. Power supply of solenoids
4. Starting switch c. Power supply of monitor panel
5. Fuse box d. S-NET signal
6 Controller e. Overload alarm actuation signal
7. Monitor panel f. Overload alarm pressure signal
8. Overload alarm actuation switch
9. Overload alarm pressure switch
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 no-
tify the operator of possibility of tipping over
of the machine by an overload.
10-144-2 PC128US-2
(15)
ENGINE CONTROL FUNCTION

1. Battery 12. Fuel control motor relay (for deceleration)

2. Battery relay 13. PC-EPC valve
3. Fusible link 14. Governor lever
4. Starting switch 15. Coolant temperature sensor
5. Fuse box 16. Hydraulic pump
6. Controller 16a. Servo valve
7. Monitor panel 16b. LS valve
8. Fuel control dial 16c. PC valve
9. Fuel control motor 17. Operation valve
10. Fuel control motor relay (for driving) 17a. Self-pressure reduction valve
11. Fuel control motor relay (for acceleration) 17b. Main relief valve
a. Power supply of controller g. Throttle signal
b. Power supply of solenoids h. Potentiometer signal
c. Power supply of monitor panel i. Fuel control motor driving signal
d. S-NET signal j. Acceleration signal
e. EPC valve driving signal k. Deceleration signal
f. Coolant-temperature signal
PC128US-2 10-144-3
(15)

1. Battery 13. Heater relay

2. Battery relay 14. Air heater
3. Fusible link 15. Governor lever
4. Starting switch 16. Engine speed sensor
5. Fuse box 17. Coolant temperature sensor
7. Monitor panel 18a. Servo valve
8. Fuel control dial 18b. LS valve
9. Fuel control motor 18c. PC valve
10. Fuel control motor relay (for acceleration) 19. Operation valve
11. Fuel control motor relay (for deceleration) 19a. Self-pressure reduction valve
12. PC-EPC valve 19b. Main relief valve
a. Power supply of controller h. Engine speed signal
b. Power supply of solenoids i. Throttle signal
c. Power supply of monitor panel j. Potentiometer signal
d. S-NET signal k. Acceleration signal
e. EPC valve driving signal l. Deceleration signal
f. Heater drive signal m. Starting switch C signal
g. Coolant-temperature signal n. Preheating pilot signal
10-144-4 PC128US-2
(15)
1. Automatic engine warming-up function

• Raises engine speed automatically to
warm up engine if coolant temperature
was low after start-up of engine.
Operational conditions (both required) Operation
Coolant temperature: Less than 30°C ←
Engine speed: 1,200 rpm or less Engine speed: 1,200 rpm or less
Release conditions (either one required) Release

Auto- Coolant temperature: 30°C or higher ←
matic Duration of automatic warming-up: 10 minutes or more Engine speed: Any
Manual Fuel control dial: Holded in 70% or more of full for 3 seconds or more

Operational conditions (both required) Operation
Coolant temperature: Less than 30°C ←
Engine speed: 1,300 rpm or less Engine speed: 1,300 rpm or less
Release conditions (either one required) Release

Auto- Coolant temperature: 30°C or higher ←
matic Duration of automatic warming-up: 10 minutes or more Engine speed: Any
Manual Fuel control dial: Holded in 70% or more of full for 3 seconds or more
2. Overheat prevention function

• Prevents overheat to protect engine by re-
ducing load on pump if coolant tempera-
ture rised too much.
Operational conditions Operation and actions taken Release conditions

Coolant temperature: Less than 105°C
Operational mode: All modes Fuel control dial: To be returned to the
Coolant temperature: ← Engine speed: Low idling ← low idling position
105°C or higher Engine coolant monitor : Turns ON • The original conditions are restored
Alarm buzzer: Sounds if two requirements above were ob-
tained (manual restoration).

Operational mode: A mode, E mode Coolant temperature: Less than 102°C
Coolant temperature: ← Engine speed: To be held as it is ← • The original conditions are restored
102°C or higher Engine coolant monitor: Turns ON if the requirement above was ob-
Delivery of pump: To be reduced tained (automatic restoration).

Operational mode: A mode Coolant temperature: Less than 100°C
Coolant temperature: ← Engine speed: To be held as it is ← • The original conditions are restored
100°C or higher Engine coolant monitor: Turns ON if the requirement above was ob-
Delivery of pump: To be reduced tained (automatic restoration).
PC128US-2 10-144-5
(15)
3. Turbocharger protection function

• When the engine is started at low tem-
perature, 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 Operation
Coolant temperature: Max. 30°C ← Protection of turbocharger

Engine speed: Min. 1,300 rpm (See above figure)
4. Function of preventing production of white

smoke when engine is started at low voltage
high current tester
• When the engine is started at low tem-
perature, the intake air is warmed auto-
matically to improve the combustion effi-
ciency and prevent production of white
smoke caused by incomplete combustion.
Operating condition Operation
Air heater: Preheating time is
Coolant temperature: Max. 30°C ← selectable
Engine speed: Min. 1,000 rpm (Select preheating time in ser-
vice adjustment mode: 0/30/60/
100 sec)
10-144-6 PC128US-2
(15)
SELF DIAGNOSIS FUNCTION

1. Error code display/Alarm functions

• Controller always watches electronic de-
vices which constitutes the system, in-
cluding controller itself, each potentiom-
eter which issues input signals, each so-
lenoid valve which receives output sig-
nals, and EPC valves, to check for they nor-
mal operation.
• If problem occurred in any of these de-
vices, the controller diagnoses it and dis-
play 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" sec-
tion as for the details of display and mea-
sures to be taken.
2. Error code memory function

• Controller takes in memory the error code
diagnosed about problem which occurred
in advanced system.
fl Refer to the "TESTING AND ADJUSTING"
section as for the details of display and
how to reset.
PC128US-2 10-144-7
(18)
SYSTEM COMPONENTS
ENGINE SPEED SENSOR
Function 1. Wire
PC128US-2 Serial No.: 5001 – 7730 2. Magnet
• The engine speed sensor is installed on the 3. Terminal
ring gear of the engine flywheel. It electri- 4. Housing
cally counts number of gear teeth that pass 5. Connector
its front side and sends the counting to the
pump controller.

• The engine speed sensor is installed on the
ring gear of the engine flywheel. It electri-
cally 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 gener-

ates current every time a gear tooth passes
its front side.
PC128US-2 10-145
(15)
PPC HYDRAULIC SWITCH
Specification 1. Plug
Contact structre : Normally opened 2. Switch
Operating (ON) pressure : 3. Connector
490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure :
294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
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 2-
stage relief solenoid valve.

• 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 con-
troller.
10-146 PC128US-2
(18)
OVERLOAD ALARM PRESSURE SWITCH

(For KUK spec.)
PC128US-2 Serial No.: 5001 – 7730
Specifications
Composition of contacts: Normally open contacts
Operating (ON) pressure:
14.7 ± 0.98 MPa {150 ± 10 kg/cm2}
Function
• One pressure switch is installed to the boom
cylinder bottom circuit to sense the hydraulic
pressure on the boom cylinder bottom side.
PC128US-2 10-146-1
A

1. Plug
2. Sensor
3. Connector
Function
• One pressure switch is installed to the boom
cylinder bottom circuit to sense the hydraulic
pressure on the boom cylinder bottom side.
10-146-2 PC128US-2
(15)
CONTROLLER
Model selection table

CN-CR2, 37P CN-CR2, 27P CN-CR2, 7P CN-CR2, 16P
PC128US-2 × c c ×
Attachment selection table
CN-CR1, 17P CN-CR1, 11P CN-CR2, 17P
Standard arm c × ×
Long arm × c ×
Standard arm,
c × c
X-counterweight
long arm,
X-counterweight × c c
Slide arm c c ×
Multi changer arm × × ×
c : GND
× : OPEN
10-147-3 PC128US-2
(15)
DEUTSCH-24P [CN-CR1]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 Fuel control motor feedback potentiometer Input 13 Pump pressure sensor Input
2 Boom cylinder bottom pressure sensor Input 14 Off-set angle Input
3 Boom angle Input 15 NC —
4 GND (signal) — 16 NC —
PPC hydraulic pressure switch for work 17 Attachment 1 Input
5 Input
equipment control lever PPC hydraulic pressure switch for traveling
18 (right/left and front/rear) Input
6 PPC hydraulic pressure switch for Arm IN Input
7 Fuel control dial Input 19 Boom cylinder head pressure sensor Input
8 Slide level Input 20 Arm angle Input
9 NC — 21 GND (analog) —
10 GND (signal) — 22 Power supply for sensor (+5V) Output
11 Attachment 2 Input 23 Swing lock switch Input
12 PPC hydraulic pressure switch for Boom-RAISE Input 24 PPC hydraulic switch for swing (left/right) Input
DEUTSCH-40P (1) [CN-CR2]

1 NC — 21 S-NET Input/Output
2 Set Input 22 CAN0-L Input/Output
3 Mode selection 2 Input 23 CAN1-L Input/Output
4 232C_RxD Input 24 Flash memory write permission signal Input
5 Swing holding brake release switch Input 25 NC —
6 Kerosene mode Input 26 Reset 2 Input
7 UU/US selection signal Input 27 Model selection 2 Input
8 Electric system Output 28 Arm crane equipment signal Input
9 Data Output 29 GND (pulse) —
10 NC — 30 NC —
11 NC — 31 GND (S-NET) —
12 CAN shield — 32 CAN0-H Input/Output
13 Mode selection 1 Input 33 CAN1-H Input/Output
14 232C_TxD Output 34 GND (232C) —
15 Backup light signal Input 35 Arm angle against level ground alarm cancel Input
16 Main monitor selection signal Input 36 Reset 1 Input
17 Model selection 3 Input 37 Model selection 1 Input
18 Strobe Output 38 Clear Input
19 Clock Output 39 GND (pulse) —
20 Slide-arm limit switch Input 40 Engine speed sensor (+) Input

1 Power supply of controller Input 21 GND (controller) —
2 Power supply of solenoids Input 22 Power supply of solenoids Input
3 GND (common to all solenoids) — 23 GND (common to all solenoids) —
4 NC — 24 Key signal Input
5 Arm IN EPC valve Output 25 Fuel control motor relay (for acceleration) Output
6 LS-EPC valve Output 26 Boom-RAISE EPC valve Output
7 Swing holding brake solenoid valve Output 27 Solenoid valve for travel speed selection Output
8 One touch deceleration pilot lamp Output 28 2-stage relief solenoid valve Output
9 One touch deceleration switch Input 29 Deceleration signal Input
10 Input Work equipment emergency operation Input

Air conditioner compressor signal 30
switch
12 Power supply of solenoids Input 32 GND (controller) —
13 GND (common to all solenoids) — 33 GND (controller) —
14 Key signal Input 34 NC —
15 Left off set stop EPC valve Output 35 Fuel control motor relay (for deceleration) Output
16 PC-EPC valve Output 36 NC —
17 Travel/swing alarm Output 37 Arm crane relay Output
18 Fuel control motor relay (for driving) Output 38 PPC lock solenoid valve Output
19 Acceleration signal Input 39 Auto deceleration signal Input
20 Alarm buzzer cancel switch Input 40 NC —
PC128US-2 10-147-4
7

10-147-5 PC128US-2
(15)
DEUTSCH-24P [CN-CR1]
1 Fuel control motor feedback potentiometer Input 14 Off-set angle (For PC128UU) Input
2 Boom cylinder bottom pressure sensor Input 15 NC —
3 Boom angle Input 16 NC —
4 GND (signal) — 17 C-terminal signal Input
5 Air conditioner compressor signal Input PPC hydraulic pressure switch for boom
18 LOWER Input
6 PPC hydraulic pressure switch for Arm IN Input
7 Fuel control dial Input 19 NC —
8 Swing boom angle sensor Input 20 Arm angle (For arm crame) Input
9 NC — 21 GND (analog) —
10 GND (signal) — 22 Power supply for sensor (+5V) Output
11 Preheating signal Input 23 ACC terminal signal Input
12 PPC hydraulic pressure switch for Arm out Input 24 PPC hydraulic switch for boom RAISE Input
13 Pump pressure sensor Input

1 NC — 21 S-NET Input/Output
2 Set Input 22 CAN0-L Input/Output
3 Mode selection 2 Input 23 CAN1-L Input/Output
4 232C_RxD Input 24 Flash memory write permission signal Input
5 NC — 25 Exterior parts interference prevention reset switch Input
6 NC — 26 Reset 2 Input
7 Swing lock switch Input 27 Alarm switch Input
8 Electric system Output 28 NC —
9 Data Output 29 GND (pulse) —
10 NC — 30 NC —
11 NC — 31 GND (S-NET) —
12 CAN shield — 32 CAN0-H Input/Output
13 Mode selection 1 Input 33 CAN1-H Input/Output
14 232C_TxD Output 34 GND (232C) —
15 NC — 35 NC —
16 Working lamp switch Input 36 Reset 1 Input
17 Swing holding brake release switch Input 37 NC —
18 Strobe Output 38 Clear Input
19 Clock Output 39 GND (pulse) —
20 NC — 40 Engine speed sensor (+) Input

1 Power supply of controller Input 22 Power supply of solenoids Input
2 Power supply of solenoids Input 23 GND (common to all solenoids) —
3 GND (common to all solenoids) — 24 Key signal (ACC) Input
4 Engine stop solenoid relay drive signal Output 25 Fuel control motor relay (for acceleration) Output
5 Arm IN EPC valve Output 26 Boom-RAISE EPC valve Output
6 LS-EPC valve Output 27 Solenoid valve for travel speed selection Output
7 Swing holding brake solenoid valve Output 28 2-stage relief solenoid valve Output
8 Swing/Travel alarm buzzer Output 29 Right offset PPC oil pressure switch Input
9 Service PPC oil pressure switch Input 30 Swing PPC oil pressure switch (Right and left) Input
10 Bucket pull-in oil pressure switch Input 31 GND (controller) —
12 Power supply of solenoids Input 33 GND (controller) —
13 GND (common to all solenoids) — 34 NC —
14 Key signal (ACC) Input 35 Fuel control motor relay (for deceleration) Output
15 Left off set stop EPC valve (For PC128UU) Output 36 Boom-LOWER EPC valve Output
16 PC-EPC valve Output 37 Arm crane relay Output
17 Right offset stop solenoid valve Output 38 PPC lock solenoid valve Output
18 Heater relay start signal Output 39 NC —
19 Left offset PPC oil pressure switch Input Travel PPC oil pressure switch
40 Input
20 Bucket push-out oil pressure switch Input (Right, left, front, and rear)
21 GND (controller) —
PC128US-2 10-147-6
(15)
PUMP PRESSURE SENSOR
PC128US-2 Serial No.: 6301 – 7730
1. Sensor
2. Connector
Function
• Mounted on the inlet circuit of control valve,
this sensor changes discharging pressure of
pump into voltage, and send it to automatic
travel speed change controller.

1. Plug
2. Sensor
3. Connector
Function
• Mounted on the inlet circuit of control valve,
this sensor changes discharging pressure of
pump into voltage, and send it to automatic
travel speed change controller.
10-147-7 PC128US-2
(15)
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 “Hydrau-
lic Pump (Piston pump)”.
LS-EPC valve
fl Refer to the section describing the “Hydrau-
lic 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 PC128US-2
(15)
STRUCTURE AND FUNCTION MONITOR SYSTEM
MONITOR SYSTEM
PC128US-2 Serial No.: 5001 – 7730
• This system monitors the machine status us-

ing sensors installed on various parts of the
machine, processes the monitoring data and
displays it on the panel to notifies the current
machine status to the operator.
• The monitor panel mainly consists of the fol-
lowing blocks:
1. Monitor block that generates alarms
should the machine fail.
2. Pilot block that displays status of the ma-
chine during operation.
3. Gauge block that constantly displays sta-
tus of the machine status through in and
out of operation.
• The monitor panel also equips with the 4-sys-
tem indicator and its operation switches.
PC128US-2 10-149
0

1. Monitor panel Description

2. Battery • The monitor system monitors conditions of
3. Controller the machine with sensors mounted on its each
4. Sensors and switches section, processes promptly the information
5. Wiper motor, window washer motor obtained, and displays it on panel to let op-
erator know the conditions of the machine.
a. Power supply
b. Switch signal
c. Caution signal
d. Sensor/switch signal
e. Sensor/switch signal
f. Output for driving
10-149-1 PC128US-2
(15)
MONITOR PANEL
PC128US-2 Serial No.: 5001 – 7730
Outline
• Monitor panel has monitoring function, gauge • It has LCD display in gauge display position.
display function, service meter function and • It has lamps in monitor display position.
switching function.
• CPU (Central Processing Unit) is installed in
it.
Input and output signals

AMP040-16P [CN-P01]
1 Power source (24V) — 9 Engine oil pressure Input
2 Power source (24V) — 10 Battery charging level Input
3 GND — 11 Spare caution —
4 GND — 12 Swing lock Input
5 Starting signal Input 13 Preheating Input
6 Coolant temperature Input 14 — —
7 Fuel level Input 15 Alarm buzzer Output
8 — — 16 Lighting Input
KES-4P(1) [CX-P02] KES-3P [CN-C12]

1 — — 1 — —
2 Work light Output 2 Car heater Hi Output
3 Lighting Output 3 Car heater Lo Output
4 Power source (24V) — 4 Car heater Hi —
10-150 PC128US-2
(18)

Outline
• The monitor panel has the functions to dis- flat type sheet switches. Pressing any of
play a monitor, gauge, service meter and elec- these switches changes the conditions of
tric system. It has also an alarm buzzer built the machine, which are shown by LEDs lo-
in. cated above the switches turned ON.
• A CPU (Central Processing Unit) mounted in- • The monitor does not give correct display if
side processes, displays and outputs infor- any of the monitor panel unit, controller, or
mation. the wiring between monitor-panel and con-
• The monitor's switch section consists of three troller is in abnormal condition.
AMP070-12P [CN-P01] AMP040-20P [CN-P02]
1 Starting switch (battery) Input 1 Engine coolant temperature Input
2 Starting switch (battery) Input 2 Fuel level Input
3 Window washer motor output Output 3 Radiator coolant level Input
4 Starting switch (C-terminal) Input 4 NC Input
5 Wiper W-contact Input 5 Air cleaner clogging Input
6 GND — 6 NC Input
7 GND — 7 Engine oil pressure Input
8 VB + (24V) Input 8 Engine oil level Input
9 Wiper motor (+) Output 9 S-NET signal Input/Output
10 Wiper motor (–) Output 10 S-NET signal Input/Output
11 Alarm buzzer ON signal Input 11 Battery charge level Input
12 Wiper P-contact Input 12 NC —
13 GND (analog signal) —
14 NC —
15 Pull-up window limit switch Input
16 Alarm buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Lamp switch Input
20 GND (S-NET) —
10-151-1 PC128US-2
(15)
METER DISPLAY
Display Display Remarks

No. category Display item Display area Display method
color
Time counting while engine is in operation
1 Service meter 0 – 99999.9 h (alternator is generating) (Always lit even if
starting switch is OFF)
Count time during engine operates.

Blue LCD
[*1]
Display Alphanumerics in Displays 2 digit alphanumerics (user code or
2 2 digits service code) if electric control system is in
abnormal condition.
3a Gauge See picture above All the segments of the corresponding level
and lower are turned ON.
Coolant Specified tempera- (Level 8 (102°C or higher):Monitor lamp
3b Caution temperature ture (102°C) or blinks. Level 9: Monitor lamp blinks and Red LED
higher alarm buzzer sounds.)
4a Gauge See picture above All the segments of the corresponding level Blue LCD
Fuel level Specified level and lower are turned on. (Level 1 (42 ¬ or
4b Caution less): Monitor lamp blinks.) Red LED
(42 ¬) or lower
Turned on for about 30 seconds after start-
ing switch was turned to "HEAT". It blinks
Preheating During preheating (for about 10 seconds) after preheating was
5
over to notify it to operator, and then it is
turned off.
• Turned on when the swing lock function is
Swing lock When swing-lock active.
6 Pilot is in operation • Blinks when swing holding brake release Green
switch was turn on.
• Turned ON when specified oil maintenance
periods (125h, 250, and 500h) elapsed.
Oil When specified (Also, elapsed time and telephone No. of
[*2] oil-maintenance Lamp
7 maintenance your dealer are shown on service meter.)
periods elapsed • Not turned on if no oil maintenance pe-
riod has been specified.
Battery charge Charge in fault

level (charge voltage < Turned ON when starting switch was turned
8 battery voltage) on; turned off after engine started running.
Engine oil Lower than the In normal condition : turned OFF
Caution pressure specified pressure In abnormal condition : turned ON Red
9 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.)
[*3] Overload specified pressure
10 14.7 MPa {150 kg/ cm2}
[*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 SWITCH
No. Name Function Operation
Used to select a travel speed from two of them.

"Lo" is lit : Travel in low speed.
Travel speed selector "Hi" is lit : Travel in high speed. Lo ←→ Hi
1 switch <The speed is locked at Lo when arm crane is
used.>
Activates the function to reduce fuel consump-

tion.
Turned ON : The function is active.
2 Auto-deceleration switch Turned OFF : The function is not active. ON ←→ OFF
<The function is made inactive when arm crane (Lit)
is used.>
Activates wiper of front glass.

"ON" is lit : Wiper works continuously. OFF → INT → ON
3 Wiper switch "INT" is lit: Wiper works intermittently. (Not lit) (Intermittent) (Continuous)
Not lit : Wiper is not working.
[When wiper is not working]

ON : Washer fluid is sprayed
and wiper works continu-
ously.
OFF : Wiper works twice and
stops after the switch was
released.
Sprays washer fluid onto front glass. [When wiper is working inter-
4 Wind washer switch mittently]
ON : Washer fluid is sprayed
and wiper works continu-
ously.
OFF : Wiper works twice and re-
turns to intermittent op-
eration after the switch
was released.
Sets the movement and force of the working
equipment.
* Operation mode selector "A" is lit : A mode (for heavy duty work)
5 switch "E" is lit : E mode (for fuel economical operation) A ←→ E ←→B
"B" is lit : B mode (for breaker work)
<All "A, E, and B" are off when arm crane is used.>
* 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 PC128US-2
A
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Applicable model PC128US-2, 138USLC-2
Engine S4D102E-1
Standard value
Item Measurement conditions Unit for new machine Service limit value
High idling rpm 2,400 ± 60 —

Engine speed Low idling rpm 925 + 050 —
Rated speed rpm 2,200 —
At sudden acceleration Bosch Max. 5.5 7.5

Exhaust gas color index
At high idling Max. 1.0 2.0
Valve clearance Intake valve 0.25 —

(normal temperature) mm
Exhaust valve 0.51 —
(Water temperature:
Blow-by pressure Operating range) Pa
(SAE 30 oil) {mm H2O} Max. 490 {50} 980 {100}
At high idling
(Water temperature:
Operating range)
At high idling 343 – 588 {3.5 – 6.0} 245 {2.5}
Oil pressure KPa
(SAE 30 oil) At low idling (SAE30) {kg/cm2}
Min. 9.8 {1.0} 69 {0.7}
At low idling (SAE10W) Min. 78 {0.8} 69 {0.7}
Whole speed range

Oil temperature (inside oil pan) °C 80 – 110 120
Fuel injection timing Before top dead center deg 14 ± 1 —
Fan belt tension Deflection when pressed

(alternator) with finger force of mm 9.5 – 12.7 —
approx. 58.8 N {6 kg.}
20-2 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

Applicable model PC138US-2, 138USLC-2
Engine SAA4D95LE-3-A
Standard value
Item Measurement conditions Unit for new machine Service limit value
High idling rpm 2,400 ± 60 —

Engine speed Low idling rpm 1,100 ± 50 —
Rated speed rpm 2,200 —
At sudden acceleration Bosch Max. 4.5 5.5

Exhaust gas color index
At high idling Max. 1.0 2.0
Valve clearance Intake valve 0.35 —

(normal temperature) mm
Exhaust valve 0.50 —
(Water temperature:
Blow-by pressure Operating range) Pa
(SAE 30 oil) {mm H2O} Max. 490 {50} 980 {100}
At high idling
(Water temperature:
Operating range)
At high idling 343 – 588 {3.5 – 6.0} 245 {2.5}
Oil pressure KPa
(SAE 30 oil) At low idling (SAE30) {kg/cm2}
Min. 294 {3.0} 196 {2.0}
At low idling (SAE10W) Min. 245 {2.5} 147 {1.5}
Whole speed range

Oil temperature (inside oil pan) °C 80 – 115 120
Fuel injection timing Before top dead center deg 6 ± 0.75 —
Fan belt tension Deflection when pressed

(alternator) with finger force of mm 6 – 10 —
approx. 58.8 N {6 kg.}
PC128US-2 20-2-1
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Applicable model PC128US-2
Cate- Standard value Service limit

gory Item Measurement conditions Unit Serial No. for new value
machine
5001 – 7730 Max.24.5 Max.31.4
• Engine at full throttle {Max.2.5} {Max.3.2}
Blade control lever • Oil temperature: 45 – 55 ºC
25.50 ± 6.86
Operating effort of
7731 and up Max.32.36

• Fit push-pull scale to center of {2.6 ± 0.7} {Max.3.3}
control lever
control lever knob to measure Max.27.5 Max.36.3

• Fit push-pull scale to tip of control 5001 – 7730
N {Max.2.8} {Max.3.7}
Travel control lever pedal to measure {kg}
7731 and up 24.52 ± 5.88 Max.39.23
• Measure max. value to end of {2.5 ± 0.6} {Max.4.0}
travel
5001 – 7730 — —
Travel pedal
7731 and up 74.5 ± 18.6 Max.107.6
{7.6 ± 1.9} {Max.11}
+ 1.96
• Hydraulic oil temperature: 45 – 55 ºC 31.87 ± 0.49 31.87 – 0.98
Boom {325 ± 5} {325 +– 10
20
}
• Engine at full throttle
• Pump discharge pressure + 1.96
• Relieve only circuit to be measured 31.87 ± 0.49 31.87 – 0.98
Arm 5001 and up
{325 ± 5} {325 +– 10
20
}
+ 1.96
31.87 ± 0.49 31.87 – 0.98
Bucket {325 ± 5} {325 +– 10
20
}
+ 1.47
31.38 ± 0.98 31.38 – 2.45
5001 – 7730
{320 ± 10} {320 +– 25
15
}
Swing + 1.47
27.46 ± 0.98 27.46 – 2.45
7731 and up
{280 ± 10} {280 +– 25
15
}
+ 1.96 + 1.96
31.87 0 31.87 – 0.98
Blade RAISE
{325 + 20
0 } {325 +– 10
20
}
32.36 ± 1.47 32.36 ± 2.45

Hydraulic pressure
Blade LOWER
MPa {330 ± 15} {330 ± 25}
{kg/cm}
34.81 ± 0.98 34.81 ± 1.96
Travel
Target {355 ± 10} {355 ± 20}
value
(Range) 3.24 ± 0.20 3.24 ± 0.49
Control
{33 ± 2} {33 ± 5}
• Hydraulic oil Control levers at 3.43 ± 0.98 3.43 ± 0.98

temperature HOLD {35 ± 10} {35 ± 10}
Servo piston : 45 – 55 ºC
7731 and up
input pressure • Engine at full At pump relief
throttle (normal actua- 15.98 ± 1.47 15.98 ± 2.45
tion) {163 ± 15} {163 ± 25}
• Hydraulic oil
temperature All levers at 2.75 ± 0.98 —
: 45 – 55 ºC HOLD {28 ± 10} {—}
• Engine at full
LS differential throttle
pressure flLS differential
pressure = Travel rotating
pump outlet under no load 2.21 ± 0.1 —
port pressure – Travel lever at {22.5 ± 1} {—}
LS pressure half-way position
20-4 PC128US-2
(14)

machine
fl See Fig. A
• Hydraulic oil temperature: 45 – 55°C
• Stop after swinging one turn and
Overrun when measure distance that swing circle Deg. 5001 and up Max. 60 Max. 70
stopping swing moves (mm) (Max. 580) (Max. 676)
• Figure in ( ) shows movement at
outside of swing circle
fl See Fig. A
5001 – 6462 2.8 ± 0.3 Max. 3.5
• Engine at full throttle (3.4 ± 0.3) (Max. 4.0)
• Hydraulic oil temperature
: 45 – 55°C 90°
• Time taken to swing 90° and 3.2 ± 0.3 Max. 4.0
180° from starting position 6463 and up (3.9 ± 0.3) (Max. 4.6)
• Figure in ( ) shows time when
Time taken to start bucket is at rated load
swing Sec.
5001 – 6462 3.3 ± 0.4 Max. 5.2

(4.8 ± 0.5) (Max. 6.3)
180°
3.8 ± 0.4 Max. 5.9
6463 and up (5.5 ± 0.5) (Max. 7.2)
fl See Fig. A
Swing
• Engine at full throttle 5001 – 6462 25 ± 2 25 ± 4

Time taken to swing • Swing one turn, and measure time Sec.
taken to swing next 5 turns
6463 and up 28.6 ± 2 28.6 ± 4
fl See Fig. B
• Engine stopped
• Bucket at rated load (450 kg) or full
of soil.
• Set machine on 15° slope, and set
upper structure at an uphill angle of
Hydraulic drift of 45°. Deg. 0 0
swing • Make match marks on swing circle (mm) 5001 and up (0) (0)
outer race and track frame.
• Measure distance that match marks
move apart after 15 minutes.
• Figure in ( ) shows at rated load.

Leakage from swing • Relieve swing circuit.
motor ¬/min 5001 and up Max. 3 Max. 6
PC128US-2 20-5
(14)

machine
Total work fl See Fig. G
equipment
(hydraulic drift • Place in above posture and measure Max. 500 Max. 700
at tip of bucket extension or retraction of each cyl-
teeth) inder and downward movement at
Hydraulic drift of work equipment
Boom cylinder tip of bucket teeth.

(amount of • Horizontal, flat ground
retraction of • Bucket: Rated load (450 kg) Max. 15 Max. 23
cylinder) • Levers at HOLD
• Engine stopped
Arm cylinder • Hydraulic oil temperature: 45 – 55°C
(amount of • Start measuring immediately after
extension of setting. mm 5001 and up Max. 50 Max. 75
cylinder) • Measure hydraulic drift every 5 min-
utes, and judge from results for 15
Bucket cylinder minutes.
(amount of
retraction of Max. 40 Max. 60
cylinder)
• Engine stopped
Blade • Hydraulic oil temperature: 45 – 55°C
(hydraulic drift • Set blade at maximum lifting height Max. 31 Max. 47
at tip of blade) and measure downward movement
at edge of blade for 15 minutes.
Boom fl See Fig. H

3.8 ± 0.3
RAISE
Bucket teeth in Max. 4.4

• Engine at full throttle (Until touching (Until touching
contact with cushion) cushion)
Work equipment
ground • Hydraulic oil temperature

: 45 – 55°C
LOWER
Cylinder fully 3.1 ± 0.3 Max. 4.2

extended
fl See Fig. I
Arm 3.2 ± 0.3 Max. 4.0
IN
• Engine at full throttle (Until touching (Until touching

Cylinder fully cushion) cushion)
retracted • Hydraulic oil temperature
: 45 – 55°C
Work equipment speed
3.1 ± 0.3 Max. 3.7

OUT
(Until touching (Until touching

Fully extended cushion) cushion)
Sec 5001 and up
fl See Fig. J
CURL
Bucket
Cylinder fully • Engine at full throttle 2.9 ± 0.3 Max. 3.7
retracted • Hydraulic oil temperature
: 45 – 55°C
DUMP
Fully extended 2.3 ± 0.2 Max. 2.9
fl See Fig. K
RAISE
Blade
Blade in contact • Engine at full throttle 1.3 ± 0.3 Max. 2.5
with ground • Hydraulic oil temperature
: 45 – 55°C
LOWER
Blade fully 1.3 ± 0.3 Max. 2.5

raised
PC128US-2 20-7
(18)

Applicable model PC138USLC-2
Cate- Standard value

gory Item Measurement conditions Unit for new machine Service limit value
• Hydraulic oil temperature : 45 – 55 ºC

Engine speed
• Engine oil pressure :

Within operating range
At 1-pump relief • Engine coolant temperature : rpm Min. 2,100 Min. 2,000
• 1 pump relief: Bucket relief
• Center of lever
Boom control lever
knob N → RAISE, LOWER 85 ± 10 Min.75 Max.95
• Tip of pedal
• Read max. value
Arm control lever
to end of travel N → IN, OUT 85 ± 10 Min.75 Max.95
• Engine stopped
Bucket control lever N → CURL, DUMP 85 ± 10 Min.75 Max.95
Travel of control levers
Swing control lever N → LEFT, RIGHT 85 ± 10 Min.75 Max.95

mm
Blade control lever N → RAISE, LOWER 53 ± 6 Min.47 Max.59
N → FORWARD,
Travel control lever REVERSE 115 ± 12 Min.103 Max.127
(LEFT, RIGHT)
Work equipment,
3–5 5–8
swing
Play of control lever
Travel 10 ± 3 10 ± 5
Boom control lever • Engine at full throttle 15.7 ± 3.9 Max.24.5

• Oil temperature: 45 – 55 ºC {1.6 ± 0.4} {Max.2.5}
• Fit push-pull scale to center of
Arm control lever control lever knob to measure 15.7 ± 3.9 Max.24.5
Operating effort of control lever
• Fit push-pull scale to tip of control {1.6 ± 0.4} {Max.2.5}

pedal to measure
Bucket control lever • Measure max. value to end of 12.7 ± 2.9 Max.21.6
travel {1.3 ± 0.3} {Max.2.2}
N 12.7 ± 2.9 Max.21.6

Swing control lever {kg} {1.3 ± 0.3} {Max.2.2}
Blade control lever 25.50 ± 6.86 Max.32.32

{2.6 ± 0.7} {Max.3.3}
Travel control lever 24.52 ± 5.88 Max.39.23

{2.5 ± 0.6} {Max.4.0}
Travel pedal 74.5 ± 18.6 Max.107.6

{7.6 ± 1.9} {Max.11}
PC128US-2 20-8-1
(17)

gory Item Measurement conditions Unit Service limit value
for new machine
+ 1.96
Boom {325 +– 10
20
• Engine at full throttle {325 ± 5} }
• Pump discharge pressure
• Relieve only circuit to be measured + 1.96
31.87 ± 0.49 31.87 – 0.98
Arm {325 +– 10
20
{325 ± 5} }
+ 1.96
31.87 ± 0.49 31.87 – 0.98
Bucket + 20
{325 ± 5} {325 – 10 }
+ 1.47
27.46 ± 0.98 27.46 – 2.45
Swing {280 +– 25
15
{280 ± 10} }
+ 1.96 + 1.96
31.87 0 31.87 – 0.98
Hydraulic pressure
Blade RAISE + 20
{325 +– 10
20
}
{325 0 }
32.36 ± 1.47 32.36 ± 2.45

Blade LOWER MPa {330 ± 25}
{330 ± 15}
{kg/cm2}
Target 34.81 ± 0.98 34.81 ± 1.96

Travel {355 ± 20}
value {355 ± 10}
(Range)
3.24 ± 0.20 3.24 ± 0.49

Control {33 ± 5}
{33 ± 2}

15.98 ± 1.47 15.98 ± 2.45
throttle (normal actua-
{163 ± 15} {163 ± 25}
tion)
• Hydraulic oil
: 45 – 55 ºC HOLD {28 ± 10} {—}
• Engine at full
fl See Fig. A
Swing
Overrun when • Stop after swinging one turn and Deg. Max. 65 Max. 75
stopping swing measure distance that swing circle (mm) (Max. 610) (Max. 720)
moves
20-8-2 PC128US-2
(17)

for new machine
fl See Fig. A
90° 2.9 ± 0.3 Max. 3.6
Time taken to : 45 – 55°C
start swing • Time taken to swing 90° and Sec.
180° from starting position
• Figure in ( ) shows time when 4.0 ± 0.4 Max. 6.0
bucket is at rated load 180° (5.0 ± 0.5) (Max. 6.5)
fl See Fig. A
Time taken to swing • Hydraulic oil temperature: 45 – 55°C Sec. 25 ± 2 25 ± 4
• Swing one turn, and measure time
Swing
fl See Fig. B
• Engine stopped
of soil.
Hydraulic drift of upper structure at an uphill angle of Deg. 0 0
swing 45°. (mm) (0) (0)
• Make match marks on swing circle

motor ¬/min Max. 3 Max. 6
fl See Fig. C
• Engine at full throttle Lo Max. 41.6 50.6
: 45 – 55°C
Travel speed (1) • Raise track on one side at a Sec.
time, rotate one turn, then mea-
sure time taken for next 5 turns
with no load. Hi Max. 26.5 32.6
Travel
fl See Fig. D
• Engine at full throttle Lo Max. 25.3 Max. 30.6
: 45 – 55°C
Travel speed (2) • Run up for at least 10 m, and Sec.
measure time taken to travel
next 20 m on flat ground.
Hi Max. 15.2 Max. 18.3
PC128US-2 20-8-3
(19)

for new machine
fl See Fig. D
fl See Fig. E
Travel deviation • Run up for at least 10 m, and mea- Max. 200 220
sure deviation when traveling next
20 m on flat ground.
fl Use a hard horizontal surface.
mm
fl See Fig. F
Travel
• Engine stopped
Hydraulic drift of • Stop machine on 12° slope with
sprocket facing straight up the 0 0
travel
slope.
• Measure the distance the machine
moves in 5 minutes.

Leakage from travel • Lock shoes and relieve travel circuit. ¬/min
motor Max. 1.1 Max. 1.65

equipment
extension or retraction of each cyl-
at tip of bucket inder and downward movement at
teeth) tip of bucket teeth.
• Horizontal, flat ground
Boom cylinder • Bucket: Rated load (450 kg)
• Levers at HOLD
(amount of • Engine stopped
Max. 15 Max. 23
retraction of • Hydraulic oil temperature: 45 – 55°C
cylinder) • Start measuring immediately after
setting.
• Measure hydraulic drift every 5 min-
Work equipment
Arm cylinder utes, and judge from results for 15

minutes.
(amount of
mm Max. 50 Max. 75
extension of
cylinder)
Bucket cylinder
(amount of
Max. 40 Max. 60
retraction of
cylinder)
• Engine stopped
(hydraulic drift • Set blade at maximum lifting height
and measure downward movement Max. 31 Max. 47
at tip of blade) at edge of blade for 15 minutes.
20-8-4 PC128US-2
(19)

for new machine
fl See Fig. H
Boom 3.8 ± 0.3
RAISE
Max. 4.4
Bucket teeth in • Engine at full throttle (Until touching (Until touching
contact with • Hydraulic oil temperature cushion) cushion)
ground : 45 – 55°C
LOWER
extended
fl See Fig. I
3.2 ± 0.3 Max. 4.0
IN
Arm • Engine at full throttle (Until touching (Until touching
Cylinder fully • Hydraulic oil temperature cushion) cushion)
retracted : 45 – 55°C
3.1 ± 0.3 Max. 3.7

OUT
Fully extended (Until touching (Until touching

cushion) cushion)
Sec.
fl See Fig. J
CURL
Bucket • Engine at full throttle 3.2 ± 0.3 Max. 4.0

Cylinder fully • Hydraulic oil temperature
Work equipment
DUMP
fl See Fig. K
RAISE
Blade • Engine at full throttle 1.3 ± 0.3 Max. 2.5

Blade in contact • Hydraulic oil temperature
with ground : 45 – 55°C
LOWER

raised
fl See Fig. L
• Engine at low idling
: 45 – 55°C
• Fully retract arm and bucket
cylinders, then lower boom from
Time lag
maximum height and measure

Boom time taken from point where Sec. Max. 3 Max. 3
bucket contacts ground to point
where chassis rises from ground
PC128US-2 20-8-5
(18)

for new machine
fl See Fig. M
: 45 – 55°C
• Set top surface of boom horizon-
Arm tal, retract bucket cylinder fully, Max. 2 Max. 2
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.
fl See Fig. N
: 45 – 55°C
Time lag

Bucket tal, retract arm cylinder fully, then Sec Max. 2 Max. 2
extend bucket cylinder and
measure time taken for bucket to
Work equipment

at bottom.
fl See Fig. O
: 45 – 55°C
• Lower blade from maximum Max. 2 Max. 2
Blade height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.

Internal leakage level
: 45 – 55 ºC
Eachcylinder • Engine full Max. 3.5 Max. 15
• Circuit to be measured is relieved.
cc/
min
Center swivel
joint Max. 10 Max. 50
20-8-6 PC128US-2
(17)


for new machine

Engine speed
• Engine oil pressure :

At 1-pump relief • Engine coolant temperature : rpm Min. 2,100 Min. 2,000
• 1 pump relief: Bucket relief
• Center of lever
Boom control lever
knob N → RAISE, LOWER 100 ± 11 100 ± 21
• Tip of pedal
• Read max. value
Arm control lever
to end of travel N → IN, OUT 100 ± 11 100 ± 21
• Engine stopped
Bucket control lever N → CURL, DUMP 100 ± 11 100 ± 21
Travel of control levers
Swing control lever N → LEFT, RIGHT 100 ± 11 100 ± 21

mm
Blade control lever N → RAISE, LOWER 53 ± 6 Min.47 Max.59
N → FORWARD,
Travel control lever REVERSE 115 ± 12 Min.103 Max.127
(LEFT, RIGHT)
Work equipment,
3–5 5–8
swing
Play of control lever
Travel 10 ± 3 10 ± 5
Boom control lever • Engine at full throttle 16.67 ± 3.92 Max.25.5

• Oil temperature: 45 – 55 ºC {1.7 ± 0.4} {Max.2.6}
• Fit push-pull scale to center of
Arm control lever control lever knob to measure 16.67 ± 3.92 Max.25.5
Operating effort of control lever
• Fit push-pull scale to tip of control {1.7 ± 0.4} {Max.2.6}

pedal to measure
Bucket control lever • Measure max. value to end of 13.73 ± 2.94 Max.22.56
travel {1.4 ± 0.3} {Max.2.3}
N 13.73 ± 2.94 Max.22.56

Swing control lever {kg} {1.4 ± 0.3} {Max.2.3}
Blade control lever 25.51 ± 6.86 Max.32.36

{2.6 ± 0.7} {Max.3.3}
Travel control lever 24.52 ± 5.88 Max.39.23

{2.5 ± 0.6} {Max.4.0}
Travel pedal 74.5 ± 18.6 Max.107.6

{7.6 ± 1.9} {Max.11}
PC128US-2 20-8-7
(17)

for new machine
+ 1.96
Boom {325 +– 10
20
• Engine at full throttle {325 ± 5} }
• Pump discharge pressure
• Relieve only circuit to be measured + 1.96
31.87 ± 0.49 31.87 – 0.98
Arm + 20
{325 ± 5} {325 – 10 }
+ 1.96
31.87 ± 0.49 31.87 – 0.98
Bucket + 20
{325 ± 5} {325 – 10 }
+ 1.47
27.46 ± 0.98 27.46 – 2.45
Swing {280 +– 25
15
{280 ± 10} }
+ 1.96 + 1.96
31.87 0 31.87 – 0.98
Hydraulic pressure
Blade RAISE + 20
{325 +– 10
20
}
{325 0 }
32.36 ± 1.47 32.36 ± 2.45

Blade LOWER MPa {330 ± 25}
{330 ± 15}
{kg/cm}
Target 34.81 ± 0.98 34.81 ± 1.96

Travel {355 ± 20}
value {355 ± 10}
(Range)
3.24 ± 0.20 3.24 ± 0.49

Control {33 ± 5}
{33 ± 2}

15.98 ± 1.47 15.98 ± 2.45
throttle (normal actua-
{163 ± 15} {163 ± 25}
tion)
• Hydraulic oil
: 45 – 55 ºC HOLD {28 ± 10} {—}
• Engine at full
fl See Fig. A
Swing
Overrun when • Stop after swinging one turn and Deg. Max. 65 Max. 75
stopping swing measure distance that swing circle (mm) (Max. 610) (Max. 720)
moves
20-8-8 PC128US-2
(17)

for new machine
fl See Fig. A
90° 3.3 ± 0.3 Max. 4.1
Time taken to : 45 – 55°C
start swing • Time taken to swing 90° and Sec.
180° from starting position
• Figure in ( ) shows time when 4.6 ± 0.5 Max. 6.4
bucket is at rated load 180° (5.8 ± 0.5) (Max. 7.5)
fl See Fig. A
Time taken to swing • Hydraulic oil temperature: 45 – 55°C Sec. 28.6 ± 2 28.6 ± 4
• Swing one turn, and measure time
Swing
fl See Fig. B
• Engine stopped
of soil.
Hydraulic drift of upper structure at an uphill angle of Deg. 0 0
swing 45°. (mm) (0) (0)
• Make match marks on swing circle

motor ¬/min Max. 3 Max. 6
fl See Fig. C
• Engine at full throttle Lo Max. 45 54
: 45 – 55°C
Travel speed (1) • Raise track on one side at a Sec.
time, rotate one turn, then mea-
sure time taken for next 5 turns
with no load. Hi Max. 26.9 32.3
Travel
fl See Fig. D
• Engine at full throttle Lo Max. 26.1 Max. 31.4
: 45 – 55°C
Travel speed (2) • Run up for at least 10 m, and Sec.
measure time taken to travel
next 20 m on flat ground.
Hi Max. 14.9 Max. 18
PC128US-2 20-8-9
(19)

for new machine
fl See Fig. D
fl See Fig. E
Travel deviation • Run up for at least 10 m, and mea- Max. 200 220
sure deviation when traveling next
20 m on flat ground.
fl Use a hard horizontal surface.
mm
fl See Fig. F
Travel
• Engine stopped
Hydraulic drift of • Stop machine on 12° slope with
sprocket facing straight up the 0 0
travel
slope.
• Measure the distance the machine
moves in 5 minutes.

Leakage from travel • Lock shoes and relieve travel circuit. ¬/min
motor Max. 1.1 Max. 1.65

equipment
extension or retraction of each cyl-
at tip of bucket inder and downward movement at
teeth) tip of bucket teeth.
• Horizontal, flat ground
Boom cylinder • Bucket: Rated load (450 kg)
• Levers at HOLD
(amount of • Engine stopped
Max. 15 Max. 23
retraction of • Hydraulic oil temperature: 45 – 55°C
cylinder) • Start measuring immediately after
setting.
• Measure hydraulic drift every 5 min-
Work equipment
Arm cylinder utes, and judge from results for 15

minutes.
(amount of
mm Max. 50 Max. 75
extension of
cylinder)
Bucket cylinder
(amount of
Max. 40 Max. 60
retraction of
cylinder)
• Engine stopped
(hydraulic drift • Set blade at maximum lifting height
and measure downward movement Max. 31 Max. 47
at tip of blade) at edge of blade for 15 minutes.
20-8-10 PC128US-2
(19)

for new machine
fl See Fig. H
Boom 3.8 ± 0.3
RAISE
Max. 4.4
Bucket teeth in • Engine at full throttle (Untill touching (Untill touching
contact with • Hydraulic oil temperature chshion) chshion)
ground : 45 – 55°C
LOWER
extended
fl See Fig. I
3.2 ± 0.3 Max. 4.0
IN
Arm • Engine at full throttle (Untill touching (Untill touching
Cylinder fully • Hydraulic oil temperature chshion) chshion)
3.1 ± 0.3 Max. 3.7

OUT
Fully extended (Untill touching (Untill touching

chshion) chshion)
Sec.
fl See Fig. J
CURL
Bucket • Engine at full throttle 3.2 ± 0.3 Max. 4.0

Cylinder fully • Hydraulic oil temperature
Work equipment
DUMP
fl See Fig. K
RAISE
Blade • Engine at full throttle 1.3 ± 0.3 Max. 2.5

Blade in contact • Hydraulic oil temperature
with ground : 45 – 55°C
LOWER

raised
fl See Fig. L
: 45 – 55°C
• Fully retract arm and bucket
cylinders, then lower boom from
Time lag
maximum height and measure

Boom time taken from point where Sec. Max. 3 Max. 3
bucket contacts ground to point
where chassis rises from ground
PC128US-2 20-8-11
(17)

for new machine
fl See Fig. M
: 45 – 55°C
Arm tal, retract bucket cylinder fully, Max. 2 Max. 2
then extend arm cylinder and
measure time taken for arm to
at bottom.
fl See Fig. N
: 45 – 55°C
Time lag

Bucket tal, retract arm cylinder fully, then Sec Max. 2 Max. 2
extend bucket cylinder and
measure time taken for bucket to
Work equipment

at bottom.
fl See Fig. O
: 45 – 55°C
• Lower blade from maximum Max. 2 Max. 2
Blade height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.

Internal leakage level
: 45 – 55 ºC
Eachcylinder • Engine full Max. 3.5 Max. 15
• Circuit to be measured is relieved.
cc/
min
Center swivel
joint Max. 10 Max. 50
20-8-12 PC128US-2
(17)
Pump performance curve
• TVC current: 0.4 A

• Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)
Test pump Discharge Average Standard value Judgement

Check point discharge pressure of pressure for discharge standard lower
pressure other pump amount limit
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) Q (¬/min) Q (¬/min)
P1 + P2
As desired P1 P2 See graph See graph
2
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 AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspec- Measurement
tem component No. tion Judgment table
method conditions
If the condition is as shown in the table 1) Turn starting
below, it is normal switch OFF.
Measure voltage
Because normal power 2) Insert T-adapter.
supply is used between 3) Turn starting
Power supply voltage CR3 CR3 (1), (21) and chassis, switch ON.
voltage is applied even in 20 – 30 V
starting motor switch
OFF state.
Between CR3 (2), (12),
(22) and chassis

Measure voltage
below, it is normal switch ON.

Diesel fuel mode 0–5V 2) Insert T-adapter.
Engine
PC-EPC solenoid CR3 full Between
Kerosene mode 0–7V
(16) –
Engine chassis Diesel fuel mode 6 – 13 V
slow Kerosene mode
Controller
If the condition is as shown in the table

Measure voltage Measure voltage
1) Turn starting
At standard 2) Insert T-adapter.
Kerosene mode CR2 Between 4–6V
mode
(6) –
At kerosene chassis 0–1V
mode

CR1 CR2 (27) – CR1 (4) Max. 1 V 2) Insert T-adapter.
Model selection 3) Turn starting
CR2
switch ON.

Measure resistance

2) Insert T-adapter.
Attachment STD arm Long arm
CR1 3) Turn starting
Attachment selection CR (17) – CR1 (10) Max. 1 V Min. 7 V
CR2 switch ON.
CR (11) – CR1 (10) Min. 7 V Max. 1 V
CR (17) – CR1 (10) Min. 7 V Min. 7 V

resistance
Measure
PPC hydraulic lock 2) Disconnect

V07 Between (1) – (2) 37 – 60 Ω connector.
solenoid (male)
Chassis control
Between (1), (2) – chassis Min. 1 MΩ

resistance
Measure
Swing holding brake V04 Between (1) – (2) 37 – 60 Ω 2) Disconnect

solenoid (male) connector.
20-16 PC128US-2
(17)

tem component No. tion Judgment table
method conditions
Because normal power 2) Insert T-adapter.
Measure voltage
supply is used between 3) Turn starting
CR3 [1], [21] and chassis, switch ON.
voltage is applied even in 20 – 30 V
Power supply voltage CR3 starting motor switch
OFF state.
Between CR3 [2], [12],
[22] and chassis
* The voltage can be checked in monitor-
ing mode "1036".

Measure voltage
Engine Diesel fuel mode 0 – 5 V 2) Insert T-adapter.

full Between
Kerosene mode 0 – 7 V
PC-EPC solenoid CR3 [16] –
Engine chassis Diesel fuel mode 6 – 13 V
slow Kerosene mode
* The controller output current can be
checked in monitoring mode "1050".

Measure voltage
2) Disconnect
At swing brake
Controller
cancel switch Max. 1 V connector.

Swing holding brake OFF (at release) Between 3) Insert T-adapter.
CR3
release solenoid CR3 [7] –
At swing brake CR3 [3]
cancel switch
ON (at normal 20 – 30 V
time)

below, it is normal. switch ON.
Monitoring mode: "1020", "1021"
Monitoring
Model selec- Model selec- UU/US selec- Tire 2 signal

tion 1 (1020, tion 2 (1020, tion (1020, (1021 bit(5))
Model selection — bit (3)) bit (6)) bit (5))
Bit OFF Bit ON Bit ON Bit ON

Monitoring mode: "1020"
Attachment Attachment Attachment
Monitoring
selection 1 selection 2 selection 3

Attachment selection — (1020, bit (2)) (1020, bit (1)) (1020, bit (4))
Standard
arm Bit ON Bit OFF Bit OFF
Long arm Bit OFF Bit ON Bit OFF
PC128US-2 20-19
(17)
Sys- Name of Connector Inspec-

tion Measurement
tem component No. Judgment table conditions
method
Monitoring mode: "1001"
Monitoring
Model/Attachment code
Model selection Standard arm 020
—
Attachment selection
Long arm 021
* The model and attachment codes do not
make difference in performance.

below, it is normal.
adjustment
switch ON.
Service
Diesel fuel/Kerosene mode "31"

Select in service adjust-
—
ment mode Standard mode 310
Kerosene mode 311
If the condition is as shown in the table 1) Start engine.

Monitoring
below, it is normal. 2) Reset safety

Monitoring mode: "1023", bit (6)
Boom RAISE pressure lock lever.
—
sensor Boom RAISE position Bit ON 3) Operate work
equipment.
Neutral position Bit OFF

Monitoring
2) Reset safety
Controller
lock lever.
Arm IN pressure switch — 3) Operate work
Arm IN position Bit ON
equipment.

Monitoring
2) Reset safety
lock lever.
Swing pressure switch — 3) Operate work
Swing (Right or left) position Bit ON
equipment.

below, it is normal. 2) Reset safety
Monitoring

lock lever.
Travel pressure switch — Travel (Forward, reverse, 3) Operate work
right, or left) position Bit ON
equipment.
If the condition is as shown in the table

Monitoring mode
Monitoring
Other work equipment • Arm OUT "1028" (1)

pressure switches • Blade, attachment "1028" (2)
 Arm OUT, bucket • Bucket CURL "1028" (3)
 —
• Bucket DUMP "1028" (4)
 CURL, bucket DUMP, 
 blade, attachment  Other work equipment operation Bit ON
20-20 PC128US-2
(17)
Sys- Name of Connector Inspec-

tion Measurement
tem component No. Judgment table conditions
method
resistance
Measure
Between (1) – (2) 37 – 60 Ω 2) Disconnect
PPC hydraulic lock
V07 connector.
solenoid Between (1), (2) – chassis Min. 1 MΩ
(male)

resistance
Measure

Swing holding brake V04
connector.
solenoid (male) Between (1), (2) – chassis Min. 1 MΩ
* The controller output can be checked in
monitoring mode "1060", bit (1).

resistance
Measure

Travel acceleration V05
connector.
solenoid (male) Between (1), (2) – chassis Min. 1 MΩ

Chassis control

resistance
Measure
V06 Between (1) – (2) 37 – 60 Ω 2) Disconnect

2-stage relief solenoid connector.
(male) Between (1), (2) – chassis Min. 1 MΩ

resistance
Measure

C13
PC-EPC solenoid connector.
monitoring mode "1050".

resistance
Measure

C14
LS-EPC solenoid connector.

below, it is normal 2) Insert T-adapter.
resistance
Measure
Between (A) – (B) 4.5 – 5.5 V

Pressure sensor C05
Between (e) – (P) 0.5 – 4.5 V
(male)
PC128US-2 20-21
(17)

tem component No. tion Judgment table conditions
method
resistance
Measure
Between (1) – (2) 500 – 1,000 Ω 2) Disconnect
connector.
Measurement in the AC range 1) Start engine.

Chassis control
2) Insert T-adapter.
Measure
Between (1) – (2) 0.5 – 3.0 V
voltage
Engine speed sensor E07

(male) * The controller output can be checked in
1) Thread the speed sensor until it

Adjustment
touches the ring gear and return it by

1 ± 1/6 rotations.
2) Perform normal operation according
to the above adjustment.
20-22 PC128US-2
(17)
TESTING AND ADJUSTING
Tools for testing, adjusting and troubleshooting ................................................................................. 20-102

Measuring engine speed ........................................................................................................................ 20-103
Measuring exhaust color ........................................................................................................................ 20-105
Adjusting valve clearance ....................................................................................................................... 20-106
Measuring blow-by pressure ................................................................................................................. 20-108
Measuring engine oil pressure ........................................................................................................... 20-108-1
Testing and adjusting fuel injection timing ........................................................................................ 20-108-2
Testing and adjusting belt tension for air conditioner compressor ................................................. 20-108-7
Testing and adjusting fan belt tension ............................................................................................... 20-108-8
Adjusting engine speed sensor ........................................................................................................... 20-108-9
Adjusting fuel control cable ................................................................................................................... 20-109
Adjusting engine stop solenoid linkage ................................................................................................ 20-110
Testing clearance of swing circle bearing ............................................................................................. 20-111
Checking wear of sprocket ..................................................................................................................... 20-112
Testing and adjusting track shoe tension .............................................................................................. 20-113
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ......................... 20-114
Testing and adjusting output pressure of PC valve (servo piston input pressure) ............................ 20-117
Testing and adjusting LS valve output pressure
(servo piston input pressure)and LS differential pressure .................................................................. 20-119
Testing and adjusting control circuit oil pressure ................................................................................ 20-122
Measuring solenoid valve output pressure .......................................................................................... 20-123
Measuring PPC valve output pressure .................................................................................................. 20-124
Adjusting PPC valve ................................................................................................................................ 20-125
Testing and adjusting travel deviation .................................................................................................. 20-126
Checking location of cause of hydraulic drift of work equipment ...................................................... 20-127
Measuring oil leakage in swing motor .................................................................................................. 20-128
Measuring oil leakage in travel motor ................................................................................................... 20-128
Bleeding air .............................................................................................................................................. 20-129
Releasing remaining pressure in hydraulic circuit ............................................................................... 20-131
Releasing remaining pressure in hydraulic tank .................................................................................. 20-131
Procedure for checking diode ................................................................................................................ 20-132
Pm clinic inspection table ....................................................................................................................... 20-133
PC128US-2 20-101
(17)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Check or measurement item Symbol Part No. Part Name Remarks
1 799-205-1100 Tachometer kit Digital display :

Engine speed A 2 795-790-2500 Take-off drive 6.0 – 99,999.9rpm
3 6090-02-9190 Gear box

Coolant and oil temperatures B 799-101-1502 Digital temperature gauge - 99.9 – +1,299 ºC
Pressure gauge
1 799-101-5002 Hydraulic tester : 2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
• 799-101-5160 Nipple PT1/8
2 799-101-5220 Nipple 10 x 1.25
07002-11023 O-ring
Oil pressure
C Male, female both 14 x 1.5
• 790-261-1311 (female PT 1/8)
Male, female both 18 x 1.5
• 790-261-1321 (female PT 1/8)
3 Adapter
• 790-261-1331 (female PT 1/8)
• 790-261-1340 (female PT 1/8)
4 799-401-2320 Hydraulic gauge 1.0 MPa{10kg/cm2}
5 799-401-2701 Differential pressure gauge

Adjusting fuel injection timing D 795-799-1131 Gear
1 799-201-1504 Blow-by checker

Blow-by pressure E
2 795-790-1950 Tool
Valve clearance Commercially
F available Feeler gauge
1 790-201-9001 Handy Smoke Checker

Exhaust color G Bosch index: 0 – 9
Commercially
2 available Smoke meter
1 79A-264-0021 0 – 294N{0 – 30kg}

Operating effort H Push-pull scale
2 79A-264-0091 0 – 490N{0 – 50kg}
Stroke, hydraulic drift I Commercially Scale

available
Work equipment speed J Commercially Stop watch
available
Measuring voltage and resis- K Commercially
tance values available
Tester
1 790-601-8000 T-adapter kit
2 799-601-7370 For 6-pin relay
3 799-601-7050 SW-6P
Troubleshooting of wiring 4 799-601-7080 M-1P

L Adapter
harnesses and sensors SW-12P
5 799-601-7310
6 799-601-7320 SW-16P
7 799-601-7340 M-16P
8 799-601-7540 070-18P
Measuring wear of sprocket M 796-127-1140 Wear gauge
20-102 PC128US-2
(19)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

PC128US-2 Serial No.: 5001 – 7730
fl Measure the engine speed under the following
conditions.
• Coolant temperature: Within operating range
1. Remove air conditioner compressor top cover.
2. Remove air conditioner compressor belt.
3. Remove cover (1) at timing gear case end.
4. Install tool A2 to speed pick-up port.
5. Connect bracket of tool A1, probe and tachom-

eter to tool A2.
6. Start the engine, and measure the engine speed

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

Measurement of engine speed
ª The measuring method is identical with the
method described above.
ª The engine speed can be displayed in monitoring
mode "1010".
PC128US-2 20-103
(19)
TESTING AND ADJUSTING MEASURING ENGINE SPEED

fl Measure the engine speed under the follow-
ing condition.
• Coolant temperature: Within operating
range
• Hydraulic oil temperature: 45 – 55 ºC
1. Remove the cover for setting the injection tim-

ing of the injection pump from the timing gear
case and install tool A3.
2. Connect bracket [1], probe [2] and tachometer

to tool A3.
3. Start the engine and measure the following re-

volving speeds.
1) Measure the low idling speed and high
idling speed.
2) Set the fuel control lever to the low idling
and high idling positions and measure the
revolving speeds at the respective posi-
tions.
3) Revolving speed when pump is relieved
Relieve the pump and run engine at full
throttle and measure its revolving speed.
20-104 PC128US-2
(19)
TESTING AND ADJUSTING 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 tem-
perature part.
1. Measuring with handy smoke checker G1

1) Fit filter paper in tool G1.
2) Insert the exhaust gas intake port into the ex-
haust 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 out-
let 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 out-
let.
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 ex-
haust 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

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 com-
pression top dead center.
3. When the No.1 cylinder is at top dead center, ad-

just the valves marked . Next, rotate the crank-
shaft one turn (360º) in the normal direction and
adjust the valve clearance of the remaining valves
marked .
fl Make a counter mark on the crankshakft pul-
ley or damper, then rotate 360º.
4. To adjust the valve clearance, loosen locknut (7),

then insert feeler gauge F between rocker lever
(4) and valve stem (5), and turn adjustment screw
(6) until the clearance is a sliding fit. Then tighten
locknut (7) to hold the adjustment screw in posi-
tion.
9 Locknut : 23.5 Nm {2.4 kgm}
fl After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 180º each time and adjust the valve
clearance of each cylinder according to the
firing order.
• Firing order : 1 – 3 – 4 – 2
fl Note that there is no timing mark on the front
pulley, so set to compression top dead center
as follows.
1) If the firing order is followed, No. 3 cylinder
comes after No. 1 cylinder, so watch the move-
ment of the valves of No. 2 cylinder when ro-
tating.
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 cen-
ter. (When setting No. 2 cylinder, watch No. 3
cylinder.)
20-106 PC128US-2
(17)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
PC138US-2 Serial No.: 4501 and up a Adjust the valve clearance according to the
PC138USLC-2 Serial No.: 1501 and up following procedure. Loosen locknut (8) of
adjustment screw (7). Insert filler gauge of
Method of adjusting valve clearance
the specified thickness between valve stem
(6) and rocker arm (5) and adjust the valve
clearance so that the filler gauge will move
2. Turn the crankshaft forward and bring cylinder
lightly.
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 cyl-
inders) moves (opens) when cylinder No. 1
comes near the compression top dead cen-
ter.
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 crank-
shaft 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 follow-
ing conditions.
• Coolant temperature : Within operating range
• Hydraulic oil temperature: 50 – 80 ºC
1. Install the nozzle of blow-by checker E to the blow-

by 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 PC128US-2
(17)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

fl Measure the engine oil pressure under the fol- PC128US-2 Serial No.: 5001 and up
lowing conditions. PC138USLC-2 Serial No.: 1001 – 1500
• Coolant temperature : Within operating range
1. Remove engine oil pressure switch (1).
2. Fit a nipple C3 and install oil pressure gauge C2

(0.981 MPa {10 kg/cm2}).
3. Start the engine, and measure the engine oil pres-

sure with the engine at low idling and at high
idling.

PC128US-2 20-108-1
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

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 INJEC-
TION PUMP.
20-108-2 PC128US-2
(17)
PC138US-2 Serial No.: 4501 and up 2. Remove front cover (3) of the fuel injection
PC138USLC-2 Serial No.: 1501 and up pump.
3. Install the fuel injection pump holder and drive
Adjustment by use of match marks
gear as one unit to the engine.
a Apply this method usually.
4. Insert the timing check pin 4.0 – 4.5 mm in diam-
(Then installing the fuel injection pump to the
eter and 80 mm in length on hole a of the front
original engine without repairing it, when check-
gear cover and match it to the hole of the drive
ing only the injection timing, etc.)
gear.
a Check that the timing check pin enters
1. Bring cylinder No. 1 to the compression top dead
straight and the hole of the fuel injection
center.
pump holder is aligned with the mounting
1) Turn the crankshaft forward and match
hole of the front gear cover (in which the
1.4Top line (1) on the crank pulley to pointer
mounting bolt will be inserted).
(2).
a If the holes are deviated from each other,
remove the fuel injection pump and check its
engagement with the drive gear.
2) Check that cylinder No. 1 is at the compres-

sion top dead center by the following method.
If the following condition is not obtained, turn
5. Remove the timing check pin and tighten each
the crankshaft one more turn.
bolt.
a If the fuel injection pump is removed:
Check that C is seen at the tooth tip of
the idler gear.
a If the fuel injection pump is installed to
the engine: Remove the head cover and
check that (both air intake valve and
exhaust valve of cylinder No. 1 have the
valve clearance).
PC128US-2 20-108-3
(17)
Adjustment by delivery valve method 4. Using spring pusher O2, compress the valve
(When installing a repaired or replaced fuel injection spring and remove valve cotter (5).
pump, when checking after disassembling or replac- 5. Loosen spring pusher O2 and remove spring
ing the gear train) seat (6) and valve spring (7).

2. Bring cylinder No. 1 to the compression top dead
center.
1) Turn the crankshaft forward and match injec-
tion 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 clear-
ance.
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 fin-
gers 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 PC128US-2
(17)
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 cylin-
der No. 1.
9. Turn the crankshaft forward so that the dial
gauge indicates standard dimension a.
BTDC °(Deg) 6 ± 0.75
a mm 0.42 ± 0.08
12. Set the fuel injection lever to the FULL position.

13. Loosen the nut at the oblong hole of the injection
pump mounting flange, then loosen the injection
pump mounting bolts (14).
10. Disconnect fuel injection pipe (10) of cylinder

No. 1.
11. Remove delivery valve holder (11), and remove
delivery valve (12) and spring (13) from its
inside. Then, install delivery valve holder (11)
again.
14. Turning the injection pump outward and operat-

ing 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 injec-
tion timing is delayed. If the former is slanted
toward the cylinder block, the latter is
advanced.
15. Tighten injection pump mounting bolts (14) alter-
nately.
16. Tighten the nut at the oblong hole of the injection
pump mounting flange.
PC128US-2 20-108-5
(17)
17. Turn the crankshaft forward and check that the

pointer of the dial gauge is in the standard range
shown in the following table when cylinder No. 1
is at the top dead center (when the pointer of the
dial gauge starts moving in reverse). If the
pointer of the dial gauge is out of this range,
repeat the above steps from 7.
Dimension when cylinder is at top
dead center (mm)
0 ± 0.08
18. Remove the delivery valve holder (11) and install

delivery valve (12) and spring (13) to it, then
install delivery valve holder (14) again.
a Replace the o-ring and copper gasket of the
delivery valve.
WARNING! Tighten the delivery valve 3

times to secure it. (If it is not tightened suffi-
ciently, 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 PC128US-2
(17)
TESTING AND ADJUSTING BELT TENSION
TESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR
TESTING AND ADJUSTING BELT

PC128US-2 Serial No.: 5001 – 7730
TENSION FOR AIR CONDITIONER
COMPRESSOR
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 re-
placing 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.

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 fol-
lows:
1. Loosen two mounting bolts (2) and (3) of com-
pressor assembly (1).
2. Loosen nut (4) and thread and adjust adjustment
bolt (5) so that the deflection of the belt can be PC138US-2 Serial No.: 4501 and up
set to 12 to 15 (about 58.8 N {about 6 kgf}). PC138USLC-2 Serial No.: 1501 and up
3. When the position of compressor assembly (1) is
fixed, tighten two mounting bolts (2) and (3) to
secure them in position.
4. After tightening adjustment bolt (5) two or three
rotations, tighten nut (4) and secure adjusting bolt
(5).
5. After adjusting the belt tension, repeat the above
testing procedure to check that the belt tension is
within the standard value.
PC128US-2 20-108-7
(17)
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION

fl When deflection a made by pressing the interme-
diate point of the belt between the alternator pul-
ley and drive pulley is out of the standard range
or when the belt was replaced, adjust the belt ten-
sion according to the following procedure.
1. Open the engine hood and remove the cover be-

tween 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 alter-
nator 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 proce-
dure shown above.
20-108-8 PC128US-2
(17)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

1. Screw in until the tip of sensor (1) contacts gear
(2).
2. When gear (2) contacts sensor (1), turn back 1±1/

6 turn.
3. Tighten locknut (3).

fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
fl Be particularly careful when securing the sen-
sor wiring to ensure that no excessive force
is brought to bear on the wiring. PC128US-2 Serial No.: 5001 and up

PC128US-2 20-108-9
(17)
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING 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 CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl After adjusting, use the measurement pro-
cedure 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 ad-
justed, the low pressure setting will also
change, so adjust the low pressure set-
ting 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.
WISE.
TERCLOCKWISE.
fl After adjusting, use the measurement pro-
cedure 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, ad-
just 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.
WISE
TERCLOCKWISE
fl Amount of adjustment for one turn of ad-
justment screw : 14.0 MPa {143 kg/cm2}
PC128US-2 20-115
(18)
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
2) After adjusting, tighten locknut (7).

9 Locknut
: 53.9 – 73.5 Nm {5.5 – 7.5 kgm}
fl After completion of adjustment, use the
measurement procedure above to check
the oil pressure again.
20-116 PC128US-2
7
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING OUTPUT PRESSURE

OF PC VALVE (SERVO PISTON
INPUT PRESSURE)
Measuring
fl Oil temperature when measuring : 45 – 55 ºC
1. Remove pressure measurement plugs (1) and (2)

(Thread dia.= 10 mm, Pitch=1.25 mm), and install
oil pressure gauge C1 (39.2 MPa {400 kg/cm2}).
2. Turn the swing lock switch ON.
3. Run the engine at full throttle and measure the

oil pressure when the arm IN circuit is relieved.
[Reference]
If there is any abnormality with problem in the
LS valve or servo piston, the servo piston input
pressure becomes a value close to 0 or the same
pressure as the pump discharge pressure.
PC128US-2 20-117
(18)
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
Adjusting
fl 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) Remove nut (3) and disconnect hose.
2) Loosen locknut (4), and if the work equipment
speed is slow, turn screw (5) clockwise; if the
engine speed drops, turn the screw counter-
clockwise.
20-118 PC128US-2
7
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
Air bleeding procedure
Air bleeding item
1 2 3 4 5 6 7
Bleed air Start Bleed air Bleed air Bleed air Pressurize Start
from engine from from from hydraulic operation
pump cylinder swing travel tank
Nature of work motor motor
• Change hydraulic oil
• Clean strainer → → → → → →
(Note) (Note)
• Replace return filter element → →
• Replace, repair pump → → → →
• 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 → → →
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 re-
lieve 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 Pm CLINIC INSPECTION TABLE
Pm CLINIC INSPECTION TABLE PC128US-2 # 5001 and up

Machine Serial No.
HOUR INSPECTION Mounted engine S4D102E-1
Work instruction No. Date of execution Service meter Inspector

Month: Day: Year: hours
INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK

Is there abnormality before starting inspection? What is maximum level of coolant temperature? Outside temperature
(During operation)
....................................................................................................................
Max. ˚C
.................................................................................................................... Min. ˚C
White Green Green Green Green Red Red
.................................................................................................................... 1 2 3 4 5 6 7 Height m
Check of work equipment for damage Good Bad

Boom foot Lower part of boom Arm cylinder bracket Revolving frame Other parts
Check of coolant level, oil level, and monitor
Engine coolant Engine oil Hydraulic oil Monitor ( ) Good Bad
Display of self-diagnosis Monitor panel
Good Bad
fl If machine is cold, warm it up.

Standard Measure-
value for Service limit ment
Item Condition Unit value Good Bad
new machine result
Low idling 925 – 975 —
Engine speed Engine at full throttle rpm 2,340 – 2,460 —
Bucket CURL relief Min. 2,100 Min. 2,000
kPa Max. 0.49 Max. 0.98
Blow-by pressure Arm IN relief
Engine
{mmAq} {Max. 50} {Max. 100}

0.34 – 0.59 Min. 0.25
High idling {3.5 – 6.0} {Min. 2.5}
SAE30
Min. 0.10 Min. 0.07
Low idling {Min. 1.0} {Min. 0.7}
Lubricating oil MPa
pressure {kg/cm2} 0.34 – 0.59 Min. 0.25
High idling {3.5 – 6.0} {Min. 2.5}
SAE10W
Min. 0.08 Min. 0.07
Low idling
{Min. 0.8} {Min. 0.7}
Hydraulic oil
45 – 55 ˚C ˚C — —
temperature
Boom raised No load applied and
(to just before cushion) extended to end 3.5 – 4.1 Max. 4.4
Arm out
2.8 – 3.4 Max. 3.7
(to just before cushion) Boom in horizontal
Engine at full throttle
Arm in position
2.9 – 3.5 Max. 4.0
(to just before cushion)

Bucket curled Boom and arm in 2.6 – 3.2 Max. 3.7
horizontal positions
Blade raised 1.0 – 1.6 Max. 2.5
sec
Left
5-turn swing 25 ± 2 25 ± 4
Right
Engine at full
Left
throttle Max. 26 Max. 32
High speed
Right
5-turn travel
Left
Low speed Max. 39 Max. 48
Right
Hydraulic drift of
Rated load applied and engine stopped mm/15min Max. 500 Max. 700
work equipment
PC128US-2 20-133
(14)
PC128US-2 # 5001 and up

< >: Reference value
pressure
Standard Measure-
Condition Item Unit value Good Bad
Oil
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
Engine at full 3.04 – 3.43 2.75 – 3.73
throttle {31 – 35} {28 – 38}
<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}
Left-swing 30.4 – 32.4 28.9 – 32.9
Main relief valve and safety valve
circuit relieved Serial No. {310 – 330} {295 – 335}

Right-swing 5001 – 7730 30.4 – 32.4 28.9 – 32.9
circuit relieved {310 – 330} {295 – 335}
Right-swing 26.5 – 28.4 25.0 – 28.9
circuit relieved Serial No. Engine at full {270 – 290} {255 – 295}
Main oil pressure
Left-swing 7731 and up throttle 26.5 – 28.4 25.0 – 28.9
MPa
31.9 – 33.8 30.9 – 33.8
Blade-RAISE circuit relieved {kg/cm2}
{325 – 345} {315 – 345}
Blade-LOWER circuit 30.9 – 33.8 29.9 – 34.8
relieved {315 – 345} {305 – 355}
Right-travel-forward circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
Right-travel-reverse circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
Left-travel-forward circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
Left-travel-reverse circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
2.45 – 4.41 2.45 – 4.41
All levers in neutral {25.0 – 45.0} {25.0 – 45.0}
Servo piston input
PC pressure 14.5 – 17.5 13.5 – 18.4
Bucket-CURL circuit relieved {148 – 178} {138 – 188}
Engine at full
1.77 – 3.73
Control lever in neutral throttle —
{18.0 – 38.0}
LS differential
LS 1-side track running idle pressure 2.11 – 2.30
Travel speed: Hi —
{21.5 – 23.5}
Travel lever in half position
20-134 PC128US-2
(14)
Pm CLINIC INSPECTION TABLE PC138USLC-2 # 1001 – 1500

Machine Serial No.
HOUR INSPECTION Mounted engine S4D102E-1


(During operation)
....................................................................................................................
Max. ˚C
.................................................................................................................... Min. ˚C
.................................................................................................................... 1 2 3 4 5 6 7 Height m

Good Bad

Standard Measure-
new machine result
Low idling 925 – 975 —
kPa Max. 0.49 Max. 0.98
Engine
{mmAq} {Max. 50} {Max. 100}

0.34 – 0.59 Min. 0.25
High idling {3.5 – 6.0} {Min. 2.5}
SAE30
Min. 0.10 Min. 0.07
Lubricating oil MPa
High idling {3.5 – 6.0} {Min. 2.5}
SAE10W
Min. 0.08 Min. 0.07
Low idling
{Min. 0.8} {Min. 0.7}
Hydraulic oil
45 – 55 ˚C ˚C — —
temperature
Arm out
2.8 – 3.4 Max. 3.7
Arm in position
2.9 – 3.5 Max. 4.0

sec
Left
5-turn swing 23.0 – 27.0 21.0 – 29.0
Right
Engine at full
Left
throttle Max. 26.5 Max. 32.6
High speed
Right
5-turn travel
Left
Low speed Max. 41.6 Max. 50.6
Right
Hydraulic drift of
Rated load applied and engine stopped mm/15min Max. 500 Max. 700
work equipment
PC128US-2 20-135
(17)
PC138USLC-2 # 1001 – 1500

pressure
Standard Measure-
Oil
new machine result

<2.45 – 3.43> <2.45 – 3.43>
Low idling {<25 – 35>} {<25 – 35>}
Engine at full 3.04 – 3.43 2.75 – 3.73
throttle {31 – 35} {28 – 38}
<2.45 – 3.43> —
{<25 – 35>} —
Boom-RAISE circuit 31.4 – 32.4 30.9 – 33.8
relieved {320 – 330} {315 – 345}
31.4 – 32.4 30.9 – 33.8
Arm-IN circuit relieved {320 – 330} {315 – 345}
Bucket-CURL circuit 31.4 – 32.4 30.9 – 33.8
relieved {320 – 330} {315 – 345}

Right-swing circuit 26.5 – 28.4 25.0 – 28.9
relieved {270 – 290} {255 – 295}
Left-swing circuit 26.5 – 28.4 25.0 – 28.9
relieved Engine at full {270 – 290} {255 – 295}
Main oil pressure
Blade-RAISE circuit throttle 31.9 – 33.8 30.9 – 33.8
relieved {325 – 345} {315 – 345}
Blade-LOWER circuit MPa 30.9 – 33.8 29.9 – 34.8
relieved {kg/cm2} {315 – 345} {305 – 355}
Right-travel-forward 33.8 – 35.8 32.9 – 36.8
Right-travel-reverse 33.8 – 35.8 32.9 – 36.8
Left-travel-forward 33.8 – 35.8 32.9 – 36.8
Left-travel-reverse 33.8 – 35.8 32.9 – 36.8
2.45 – 4.41 2.45 – 4.41
Servo piston input
PC pressure
Bucket-CURL circuit 14.5 – 17.5 13.5 – 18.4
relieved {148 – 178} {138 – 188}
Engine at full 1.77 – 3.73
Control lever in neutral —
throttle {18.0 – 38.0}
LS 1-side track running idle LS differential
Travel speed: Hi pressure 2.11 – 2.30
—
Travel lever in half {21.5 – 23.5}
position
20-136 PC128US-2
(17)
PC138US-2 # 4501 and up

PC138USLC-2 # 1501 and up
Machine Serial No.
HOUR INSPECTION Mounted engine SAA4D95LE-3-A


(During operation)
....................................................................................................................
Max. ˚C
.................................................................................................................... Min. ˚C
.................................................................................................................... 1 2 3 4 5 6 7 Height m

Good Bad

Standard Measure-
new machine result
Low idling 1,050 – 1,150 —
kPa Max. 0.49 Max. 0.98
Engine
{mmAq} {Max. 50} {Max. 100}

0.34 – 0.59 Min. 0.25
High idling {3.5 – 6.0} {Min. 2.5}
SAE30
Min. 0.10 Min. 0.07
Lubricating oil MPa
High idling {3.5 – 6.0} {Min. 2.5}
SAE10W
Min. 0.08 Min. 0.07
Low idling
{Min. 0.8} {Min. 0.7}
Hydraulic oil
45 – 55 ˚C ˚C — —
temperature
Arm out
2.8 – 3.4 Max. 3.7
Arm in position
2.9 – 3.5 Max. 4.0

sec
Left
5-turn swing 23.0 – 27.0 21.0 – 29.0
Right
#1001 – 2599 Left/Right Max. 26 Max. 32

High
#2600 – 4500 Engine at Left/Right Max. 26.9 Max. 32.3
speed
#4501 and up full throttle Left/Right Max. 27 Max. 33
5-turn travel
#1001 – 2599 Left/Right Max. 39 Max. 48
Low
Left/Right
speed #2600 – 4500 Max. 43.5 Max. 52.2
#4501 and up Left/Right Max. 45 Max. 54
Hydraulic drift of Rated load applied and engine stopped mm/15min
work equipment Max. 500 Max. 700
PC128US-2 20-137
(17)
PC138US-2 # 4501 and up

PC138USLC-2 # 1501 and up
pressure
Standard Measure-
Oil
new machine result

<2.45 – 3.43> <2.45 – 3.43>
Low idling {<25 – 35>} {<25 – 35>}
Engine at full 3.04 – 3.43 2.75 – 3.73
throttle {31 – 35} {28 – 38}
<2.45 – 3.43> —
{<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}
Left-swing 26.5 – 28.4 25.0 – 28.9
31.9 – 33.8 30.9 – 33.8
Blade-RAISE circuit relieved Engine at full {325 – 345} {315 – 345}
Main oil pressure
Blade-LOWER circuit throttle 30.9 – 33.8 29.9 – 34.8
MPa {315 – 345} {305 – 355}
relieved
{kg/cm2}
Right-travel-forward circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
Right-travel-reverse circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
Left-travel-forward circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
Left-travel-reverse circuit 33.8 – 35.8 32.9 – 36.8
relieved {345 – 365} {335 – 375}
2.45 – 4.41 2.45 – 4.41
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
Travel speed: Hi LS differential 2.11 – 2.30
—
Travel lever in half position pressure {21.5 – 23.5}
20-138 PC128US-2
(17)
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)
Troubleshooting of controller CR700 [deceleration control system] (E mode)
Troubleshooting of controller CR700 [pump control system] (C mode)
Troubleshooting of controller CR700 [input signal system] (F mode)
Troubleshooting of engine (S mode) ..................................................................................................... 20-951
PC128US-2 20-201
(14)
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 re-
pairs 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, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted 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 fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful 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 connec-

tors
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 plat-
ing at the joint will peel and cause improper
connection or breakage.
20-204 PC128US-2
(17)
(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 solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
(4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, 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 short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity 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 sur-
face 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive 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 clean-
ing with compressed air.
PC128US-2 20-205
(17)
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 connec-
tors 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 con-
nectors 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 im-
proper contact to occur, so always cover
the connector.
20-206 PC128US-2
(17)
‡ Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age 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 connec-
tor, 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, re-
place 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 po-
sition.
fl If the connector cannot be corrected eas-
ily, 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 connec-
tors 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)
‡ 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 wa-
ter 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 com- TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
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 connec-
tor.
TEW00202
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected 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 reas-
semble.
20-208 PC128US-2
(17)
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 con-
trol 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 con-
nected 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 CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
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

Lubricating oil, coolant
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

equipment
Electrical
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
Hydraulic, mechani-
1. Check for abnormal noise, smell — Repair

cal equipment
2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 24 – 30V Replace

Electrics, electrical equipment
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 Disconnect
attention to water leaking on connectors or terminals) — connector and dry
6. Check for blown, corroded fuses — Replace

After running for
7. Check alternator voltage (engine running at 1/2 throttle or several minutes:
above) 27.5 – 29.5 V Replace
20-212 PC128US-2
(17)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

fl The Address column in this table shows the address in the connector pin allocation drawing (3-
dimensional drawing).
Connec- Ad- Connec- Ad-
Connec- tor No. of Connec- tor No. of
tor No. pins Place of use dress tor No. pins Place of use dress
type type
A01 L 2 Intermediate connector A-2 D23 KES 2 PC-EPC valve diode F-5
A02 X 3 Intermediate connector B-2 D24 KES 2 Pumping switch diode F-5
Body ground
A03 SWP 16 Intermediate connector A-2 E11 — — (Ribbon heater relay) R-5
A04 SWP 16 Intermediate connector A-2 E13 — — Starting motor N-3
A05 DT 3 Intermediate connector B-2 E14 — — Ribbon heater relay R-6
A06 DT 8 Intermediate connector A-1 E15 X 3 Intermediate connector N-7
A07 DT 8 Intermediate connector A-2 E16 L 2 Engine air heater relay M-6
A08 SWP 8 Intermediate connector B-2 E17 X 2 Alternator O-3
Intermediate connector
A09 SWP 16 (Arm crane) C-2 E20 SWP 8 Intermediate connector M-5
A10 DT 8 (Arm crane) A-1 E30 — — Safety relay N-3
A20 S 16 Intermediate connector D-9 F01 X 2 Travel/swing alarm (OPT) H-2
A21 S 16 Intermediate connector D-4 F02 M 2 Arm crane revolving light K-8
A22 S 12 Intermediate connector D-4 FB1 — — Fuse box F-6
A23 SWP 12 Intermediate connector H-5 H08 M 6 Intermediate connector F-6
C09 DT 4 Attachment selection connector E-8 H09 S 8 Intermediate connector F-6
C06 SUMITOMO 16 Prolix switch D-8 H16 M 2 Arm crane buzzer A-6
C05 DT 3 Pressure sensor G-6 K19 M 2 Pump prolix resistor F-8
C10 M 2 Arm ground cancel selection F-8 M02 X 2 Safety relay O-3
C13 X 2 EPC valve solenoid for PC I-8 M10 DEUTSCH 2 Intermediate connector G-6
C14 X 2 EPC valve solenoid for LS J-8 M11 L 2 Fusible link L-3
CR1 DT 24 CR700 Controller F-7 M13 DT 2 Boom work equipment lamp G-7
CR2 DT 40 CR700 Controller F-7 M13 M 2 Speaker (Right) K-8
CR3 CT 40 CR700 Controller F-7 M14 L 2 Fusible link L-3
D01 KES 2 Window washer diode F-5 M15 L 2 Fusible link L-3
D05 KES 2 Swing holding brake diode F-5 M16 X 2 Horn I-2
YAZAKI
D06 KES 2 Travel speed diode F-5 M22 090 2 Horn switch B-7
E07 X 2 Engine speed sensor N-6 M26 SWP 12 A/C unit E-9
Swing holding brake cancel
D08 KES 2 switch diode E-5 M28 X 2 Window washer L-5
D14 SWP 2 Battery relay diode L-4 M30 M 2 OPT power supply G-3
D15 — 2 Stop solenoid diode O-7 M31 M 2 OPT power supply D-9
D17 KES 2 Heater relay diode E-4 M34 X 1 Airconditioner compressor Q-7
D20 KES 2 PPC hydraulic lock diode F-5 M36F M 1 Kerosene mode F-8
D22 SWP 2 Battery relay diode L-4 M36M M 1 Kerosene mode F-8
20-218-2 PC128US-2
(17)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM

20-218-4 PC128US-2
(17)

fl The Address column in this table shows the address in the connector pin allocation drawing (3-
dimensional drawing).
type type
A01 L 2 Intermediate connector L-4 HOLD Terminal 1 Engine stop solenoid Q-2
A02 SWP 14 Intermediate connector L-4 H08 M 6 Intermediate connector F-4
A03 SWP 14 Intermediate connector K-4 H09 S 8 Intermediate connector F-4
A06 DT 8 (Arm crane) A-6 H16 M 2 Arm crane buzzer A-4
A20 S 16 Intermediate connector C-7 J1 SUMITOMO 20 Junction connector F-7
A21 S 16 Intermediate connector D-4 J2 SUMITOMO 20 Junction connector F-6
AR DT 3 Alternator M-5 J3 SUMITOMO 20 Junction connector F-6
C05 DT 3 Pressure sensor G-8 K19 M 2 Pump prolix resistance F-7
C06 SUMITOMO 16 Prolix switch C-7 M02 X 2 Safety relay H-1
C13 X 2 EPC valve solenoid (PC) J-9 M10 DT 2 Intermediate connector G-7
C14 X 2 EPC valve solenoid (LS) I-9 M11 L 2 Fusible link L-4
CR1 DT 24 CR 700 controller F-6 M13 M 2 Boom working lamp G-9
CR2 DT 40 CR 700 controller F-6 M13 M 2 Speaker (Right) K-9
CR3 DT 40 CR 700 controller F-6 M14 L 2 Fusible link L-4
Diode  Heater relay
Engine stop solenoid
D01 SWP 8  F-3 M16 SWP 2 Horn A-3
Swing holding brake  M22 090 2 Horn switch B-5

D02 SWP 8 Diode release, Battery relay,  F-3
Window washer  M26 SWP 12 Air conditioner unit E-7
2-stage ralief, PPC  M28 KES 2 Window washer L-6
Diode holding brake, Travel  H-3
safety lock, Swing
D03 SWP 8 
speed selector  M30 M 2 Power source (Opt) F-4
E07 DT 2 Engine speed sensor M-5 M31 M 2 Power source (Opt) D-7
E11 Terminal 1 Electrical intake air heater relay H-1 M34 X 1 Air conditioner compressor Q-8
E12 Terminal 1 Relay ground H-1 M38 M 3 Light switch B-7
E14 Terminal 1 Electrical intake air heater relay G-2 M40 YAZAKI 2 Cigarette lighter A-4
E17 X 2 Alternator N-3 M40 M 2 Cab working lamp (STD) H-9
E30 Terminal 1 Safety relay H-3 M41 SWP 6 Arm crane monitor A-6
E50 Terminal 1 Starting motor Q-4 M41 M 2 Cab working lamp (OPT) J-9
E51 Terminal 1 Electrical intake air heater relay G-2 M47 090 20 Intermediate connector B-6
E52 Terminal 1 Electrical intake air heater relay P-9 M48 DT 6 Auto-decelation motor L-5
EU1 M 2 Overload alarm switch F-5 M49 PA 9 Radio F-5
F01 DT 2 Travel and swing alarm (Opt) H-9 M50 M 6 Wiper motor A-5
F02 M 2 Arm crane beacon lamp K-9 M51 M 3 Fuel dial B-6
FB1 — — Fuse box F-5 M52 DT 2 (Engine stop solenoid relay) I-3
GND Terminal 1 Engine stop solenoid Q-2 M71 M 2 Room lamp L-9
20-218-8 PC128US-2
(17)

type type
M73 M 2 Speaker (Left) L-8 T01 Terminal 1 Battery L-6
M80 — 20 Air conditioner panel F-4 T02 Terminal 1 Revolving ground L-5
M81 — 16 Air conditioner panel F-5 T03 Terminal 1 Revolving ground L-5
M83 SUMITOMO 3 Intake duct (Air conditioner) F-6 T04 M 1 Radio ground F-5
M84 SWP 14 (Air conditioner unit) F-5 T05 Terminal 1 Floor ground C-3
M85 SWP 16 (Air conditioner unit) F-7 T06 Terminal 1 Floor frame ground B-3
M87 S 12 Air conditioner unit D-3 T21 Terminal 1 Engine stop solenoid relay I-1
M88 YAZAKI 10 B-3 T22 Terminal 1 Engine stop solenoid relay I-3
PULL Terminal 1 Engine stop solenoid Q-2 V03 SHINAGAWA 6 Starting motor relay B-6
P01 AMP 12 Monitor panel A-5 V4 DT 2 Swing holding brake solenoid valve G-8
P02 AMP 20 Monitor panel A-5 V5 DT 2 Travel speed selector solenoid valve G-9
P03 M 2 Buzzer cancel switch C-7 V6 DT 2 2-stage relief solenoid valve G-8
P06 X 2 Fuel level gauge I-9 V7 DT 2 PPC hydraulic safety lock solenoid H-9
P07 X 2 Engine coolant temperature sensor P-8 V06 X 1 Intermediate connector E-7
Airconditioner outsideair
P09 SWP 2 temperature sensor E-3 V07 X 1 Intermediate connector E-7
P15 AMP 2 A-5 V08 X 1 Intermediate connector E-7
R06 SHINAGAWA 6 Starting motor cutout relay B-6 V09 X 1 Intermediate connector E-7
R08 SHINAGAWA 6 Deceleration relay J-3 W03 M 2 Rear limit switch K-9
R09 SHINAGAWA 6 Accelerator relay J-3 X05 M 4 Swing lock switch C-7
R10 SHINAGAWA 6 Beacon lamp drive relay B-6
S01 X 2 Drive pressure switch C-3
S05 X 2 Arm IN pressure switch G-6
S08 X 2 Left swing pressure switch G-5
S10 M 3 PPC hydraulic lock switch E-3
S17 Terminal 1 Engine oil pressure switch N-4
S30 X 2 Right swing pressure switch G-5
S31 X 2 Boom RAISE oil pressure switch G-6
S32 X 2 Boom DUMP oil pressure switch G-6
S33 X 2 Boom LOWER oil pressure switch G-6
S34 X 2 Bucket digging pressure switch G-6
S35 X 2 Bucket DUMP oil pressure switch G-7
S36 X 2 Intermediate connector G-7
S37 X 2 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)
CONNECTOR ARRANGEMENT DIAGRAM

20-218-10 PC128US-2
(17)
PC128US-2 20-218-11
(17)
20-218-12 PC128US-2
(17)
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.
Num- X Type Connector

ber of T-adapter Part
Pins Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— • Quantity: 20 pieces • Quantity: 20 pieces —
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red
PC128US-2 20-219
(17)
Num- SWP Type Connector

Pins Male (Female housing) Female (Male housing)
Number
BWP04708
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
20-220 PC128US-2
(17)
Num- SWP Type Connector

Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:
— • Quantity: 20 pieces • Quantity: 20 pieces —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red
PC128US-2 20-221
(17)
Num- M Type Connector

Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
BWP04718
BWP04717
2 799-601-7090
BWP04719 BWP04720
3 799-601-7110
BWP04721 BWP04722
4 799-601-7120
BWP04723 BWP04724
6 799-601-7130
BWP04725 BWP04726
8 799-601-7340
20-222 PC128US-2
(17)
Num- S Type Connector

ber of T-adapter
Part Number
BWP04728
8 BWP04727 799-601-7140
10 BWP04729 BWP04730
799-601-7150
(white)
12 BWP04731 BWP04732
(white) 799-601-7350
16 BWP04733 BWP04734
799-601-7330
(white)
PC128US-2 20-223
(17)
Num- S Type Connector

Number
BWP04736
10 BWP04735
(blue) —
— —
12 BWP04737 BWP04738
799-601-7160
(blue)
16 BWP04739 BWP04740
(blue) 799-601-7170
20-224 PC128US-2
(17)
Num- MIC Type Connector

Number
7 Body part number: 79A-222-2640 Body part number: 79A-222-2630 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
11 Body part number: 79A-222-2680 Body part number: 79A-222-2670 —

BWP04742
BWP04741
5 799-601-2710
Body part number: 79A-222-2620 Body part number: 79A-222-2610

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

PC128US-2 20-225
(17)
Num- MIC Type Connector

Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

— (Quantity: 50 pieces) (Quantity: 50 pieces) —
20-226 PC128US-2
(17)
Num- AMP040 Type Connector

Number
BWP04752
BWP04751
8 799-601-7180
Housing part number: 79A-222-3430

— (Quantity: 5 pieces)
BWP04753 BWP047544
12 799-601-7190

BWP04755 BWP04756
16 799-601-7210

BWP04757 BWP04758
20 799-601-7220
— 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)
Num- AMP070 Type Connector

Number
10 799-601-7510
— Part number: 7821-92-7330
BWP04761 BWP04762
12 799-601-7520
— Part number: 7891-92-7340
BWP04763 BWP04764
14 799-601-7530
— Part number: 7891-92-7350
BWP04765 BWP04766
18 799-601-7540
— Part number: 7891-92-7360
BWP04767 BWP04768
20 799-601-7550
— Part number: 7891-92-7370
20-228 PC128US-2
(19)
Num- L Type Connector

ber of T-adapter
Part Number
BWP04770
2 BWP04769 —
— —
Num- PA Type Connector

ber of T-adapter
Pins Male (Female housing) Female (Male housing) Part Number
BWP04772
9 BWP04771 —
— —
Num- BENDIX (MS) Type Connector

BWP04774
BWP04773
10 799-601-3460
— —
PC128US-2 20-229
(17)
Num- KES1 Automobile Type Connector

ber of T-adapter
Part Number
BWP04776
BWP04775
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
08027-10620 (Black) 08027-10670 (Black)
20-230 PC128US-2
(17)
Num- KES1 Automobile Type Connector

ber of T-adapter
Part Number
BWP04784
BWP04783
8 —
08027-10820 (Black) 08027-10870 (Black)
Num- Connector for relay (Socket)

BWP04786
BWP04785
5 799-601-7360
— —
BWP04788
BWP04787
6 799-601-7370
— —
Type F Type Connector

(shell
size T-adapter
Pin (Male terminal) Body (Female terminal) Part Number
code)
4 —
— —
PC128US-2 20-230-1
(17)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

08191-11205, 08191-11206 08191-14105, 08191-14106
18-8
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-230-2 PC128US-2
(17)

Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
PC128US-2 20-230-3
(17)

Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-230-4 PC128US-2
(17)

Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
PC128US-2 20-230-5
(17)

Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-230-6 PC128US-2
(17)
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC128US-2 20-230-7
(17)
DT Series connector
Number
Number
8GR:
799-601-9060
8B:
799-601-9070
8 8G:
799-601-9080
8BR:
799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR:
799-601-9110
12B:
799-601-9120
12 12G:
799-601-9130
12BR:
799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
20-230-8 PC128US-2
(17)
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
of Pins T-adapter Part
Body (plug) Body (receptacle) Number
1 —
Part number:08192-31200 (Contact size #12) Part number:08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC128US-2 20-230-9
(17)
DRC26 Series connector

No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
20-230-10 PC128US-2
(19)
TESTING AND ADJUSTING T-ADAPTER TABLE
T-ADAPTER TABLE
a The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring har-
ness checker assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
799-601-2600 For measuring box Econo-21P Q Q Q Q Q Q

799-601-3100 For measuring box MS-37P Q
799-601-3200 For measuring box MS-37P Q
799-601-3300 For measuring box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 CASE Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 CASE Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
PC128US-2 20-230-11
(19)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Cace Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Blown Q Q
799-601-9110 DT 12P-Gray Q Q
20-230-12 PC128US-2
(19)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Blown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 2-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 For measuring box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
799-601-9420 For boost pres- 3P Q

sure, fuel
799-601-9430 PVC socket 2P Q
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P Q
for HST controller
AMP 1-963215-1
799-601-9720 AMP 1-963217-1 16P Q
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P Q
for HST controller
PC128US-2 20-230-13
(19)
TROUBLESHOOTING FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM
FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM

MECHANISM
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 (Monitor panel → CR700 controller)
2) Auto-decelerator (ON/OFF) signal (Monitor panel → CR700 controller)
3) Travel Hi/Lo signal (Monitor panel → CR700 controller)
4) Coolant temperature (coolant temperature) information (Monitor panel → CR700 controller)
5) Service code (failure code) information (CR700 controller → Monitor panel)
PC128US-2 20-231
(17)
TROUBLESHOOTING FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM

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 (Monitor panel → CR700 controller)
2) Auto-decelerator (ON/OFF) signal (Monitor panel → CR700 controller)
3) Travel Hi/Lo signal (Monitor panel → CR700 controller)
4) Coolant temperature (water temperature) information (Monitor panel → CR700 controller)
5) Service code (failure code) information (CR700 controller → Monitor panel)
6) Preheating signal (CR700 controller → Monitor panel)
20-232 PC128US-2
(17)
TROUBLESHOOTING MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS

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 per-
formed 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 Abnormal system
E02 PC-EPC system
E03 Swing holding brake system
E05 Decelerator motor system
PC128US-2 20-233
(17)
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 sec-
ond or third digit from the left of ser-
vice meter display portion (2).
iii) Press “Setting switch (5)”. (1) Digital meter display portion
(5) Setting switch
(7) Auto decelerator switch
Example 1) When [01] is displayed on ser-

vice meter display portion (2):
Example 2) When [E213] occurred six hours

before:
fl If it is also occurring cur-
rently, “E” is displayed on
the third digit from the left of
service meter display portion
(2). When it is normal cur-
rently, “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 PC128US-2
(17)
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)” + “Work-
ing mode selector (UP) switch (3)”.
(3) To return the display of a service code,
press “Buzzer cancel switch (8)” + “ Work-
ing mode selector (DOWN) switch (4).
(4) To terminate the display of a service code,
press “Buzzer cancel switch (8)” + “Auto-
decelerator 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 Abnormality system User code
E101 Incorrect description contents —
E108 Detection of engine water temperature exceeding 105˚C —
E112 Wiper motor driven forward rotation system short circuit —
E113 Wiper drive reverse rotation system short circuit —
E114 Window washer drive system short circuit —
E115 Washing is disabled for 10 seconds —
E116 Storage is disabled for 10 seconds —
E203 Swing holding brake solenoid system short circuit E03
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 E03
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
PC128US-2 20-235
(17)
Service code 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) —
Boom angle potentiometer corrected value error

E255 —
(beyond correction value range)
E256 Checksum error —
E306 Feedback potentiometer system error —
E308 Fuel dial input value error E05
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
20-236 PC128US-2
(17)
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

a monitoring code.
switch (8)” + “Auto decelerator switch
(3) (or “Working mode selector
(DOWN) switch (4))” and set them so
iii) Press “Setting switch (5)”. (1) Digital meter display portion
(5) Setting switch
(7) Auto decelerator switch
Example 1) When monitoring code 1010 (en-

gine 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
(17)
(2) To advance the display of a service code,

press “Buzzer cancel switch (8)” + “Work-
ing mode selector (UP) switch (3)”.
(3) To return the display of a service code,
press “Buzzer cancel switch (8)” + “ Work-
ing mode selector (DOWN) switch (4).
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 Description Unit Component name
0008 S-NET connected state (6bit) CR700 controller
0041 Water temperature sensor voltage × 10 mV CR700 controller
0042 Fuel sensor voltage × 10 mV CR700 controller
0043 Charge voltage × 100 mV CR700 controller
0045 Sensor input 1 (6bit) CR700 controller
0046 Sensor input 2 (6bit) CR700 controller
0047 Output state (6bit) CR700 controller
0048 Wiper state (6bit) CR700 controller
0049 Reserved (6bit) CR700 controller
0200 Program version (Monitor) — CR700 controller
1000 Software version No. — CR700 controller
1001 Attachment selection — CR700 controller
1002 Model selection — CR700 controller
1003 Attachment code (*1) — CR700 controller
1004 Option selection state (*1) (6bit) CR700 controller
1016 Second throttle command (*1) rpm CR700 controller
1027 ON/OFF input 5 (*1) (6bit) CR700 controller
1028 ON/OFF input 6 (*1) (6bit) CR700 controller
1036 Power supply voltage (*1) V CR700 controller
1061 ON/OFF output (*1) (6bit) CR700 controller
1010 Engine speed rpm CR700 controller
1020 ON/OFF input 1 (6bit) CR700 controller
1024 ON/OFF input and output (6bit) CR700 controller
1030 Work equipment angle sensor voltage First boom V CR700 controller
1032 Work angle sensor voltage Arm V CR700 controller
1034 Fuel dial voltage V CR700 controller
1035 Feedback potentiometer voltage V CR700 controller
1040 Boom bottom voltage MPa CR700 controller
1042 Pump pressure MPa CR700 controller
1050 EPC output current PC-EPC × 10 mA CR700 controller
1054 EPC output current LS-EPC × 10 mA CR700 controller
1060 ON/OFF output (6bit) CR700 controller
(*1) PC138US-2 Serial No.: 4501 and up
20-238 PC128US-2
(17)
3) Bit pattern list (The bit of the corresponding

No. comes on.)
fl [1] to [6] of digital display portion (1) indi-
cate a bit No.
fl A monitoring code No. (four digits) is dis-
played on the second to fifth digit from
the left of service meter display portion
(2).
Code No. Item Bit Detailed description (state when a bit comes on)
[1] At ID2 connection
0008 S-NET connected state
[1] Starting switch “ON” (ON)
[2] Starting switch “Start” (Start) (ON)
[3] Starting switch “Preheat” (ON)
0045 Sensor input 1
[4] Light switch (ON)
[5]
[6]
[1]
[2]
[3] Engine oil pressure (At OPEN time)
0046 Sensor input 2
[4] Engine oil level (At OPEN time)
[5]
[6] Charge level (At decrease time)
[1] Buzzer output (ON)
[2]
[3]
0047 Output state
[4]
[5]
[6]
[1]
[2] Washer output (ON)
[3] Wiper output 1 (ON)
0048 Wiper state
[1] Swing lock switch (ON)
[2] Buzzer cancel switch (ON)
[3] Widow limit switch (ON)
0049 Standby
[4] W contact (ON)
[5] P contact (ON)
[6]
PC128US-2 20-239
(17)
[1]
[2] Arm crane mounting (*1)
[3]
1004 Option selection
[4] Arm ground angle warning cancel (*1)
[5]
[6]
[1] ATT selection 2 (At GND connection)
[3] Model selection 1 (At GND connection)
1020 ON/OFF input 1
[5] UU/US selection (At GND connection)
[6] Model selection 2 (At GND connection)
[1]
[2]
[3]
1021 ON/OFF input 2
[4] Arm crane mounting (At power supply connection)
[5]
[6] Kerosene mode (At GND connection)
[1] Travel selector switch (Panel)
[2] Working mode selector switch
[3] Back lamp
1022 ON/OFF input 3
[4] SET/CLEAR switch
[5] Mode selector (∆) switch
[6] Mode selector (∇) switch
[1]
[2] Another work equipment mode selector switch (ON)
[3] Travel pressure switch (ON)
1023 ON/OFF input 4
[4] Swing pressure switch (ON)
[5] Arm digging pressure switch (ON)
[6] Boom RAISE pressure switch (ON)
[1]
[2]
ON/OFF input and [3] Motor-driven power supply (*1)
1024
output [4]
[5] Motor relay (–)
[6] Motor relay (+)
[1] Crane mode switch [monitor]
[2] Display selector switch [monitor]
ON/OFF input and [3] Arm ground angle warning cancel switch (At connector connection)
1025
output [4]
[5]
[6] Bucket dump inhibition solenoid + Patlight (At relay output)
[1]
[2] Warning cancel (For EU)
ON/OFF input and [3]
1026
output [4]
[5]
[6]
20-240 PC128US-2
(17)
[1]
[2]
[3] Preheating signal (*1)
1027 ON/OFF input 5
[4]
[5] C-terminal signal (*1)
[6]
[1] Arm OUT pressure switch (*1)
[2] Service pressure switch (*1)
[3] Bucket digging pressure switch (*1)
1028 ON/OFF input 6
[4] Bucket DUMP pressure switch (*1)
[5]
[6]
[1] Swing holding brake (At brake release)
[2]
[3]
1060 ON/OFF output
[4] Travel 2nd speed (At travel 2nd speed)
[5] Travel or swing alarm (At alarm output)
[6] 2-stage relief (At travel pressure switch ON)
[1]
[2] Heater relay (*1)
[3]
1061 ON/OFF output
[4]
[5]
[6]
PC128US-2 20-241
(17)
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 accor-
dance with the choice of the operator.
1) Default setting operation procedures

the default setting mode.
(3) (or Working mode selector
iii) Press “Setting switch (5)”.
fl “d SET” is displayed on service
meter display portion (2) and in-
dicator (10) of the mode set as a (1) Digital meter display portion
default value flashes. (2) Service meter display portion
(2) To change (move) the default setting (4) Working mode selector (DOWN) switch
mode, (5) Setting switch
i) press “Working mode selector (UP) (6) Travel speed switch
switch (3) (or Working mode selector (7) Auto decelerator switch
(DOWN) switch (4))”. (8) Buzzer cancel switch
ii) Press “Setting switch (5)”.
(3) To terminate the default setting mode (de-

fault setting mode completion), continue
the “Buzzer cancel switch (8) + “Auto-de-
celerator 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 con-
tents of the working mode default are
not changed.
20-242 PC128US-2
(17)
(4) Confirmation method after working de-

fault setting
i) Check that the LED is changed to nor-
mal 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

This mode is used to adjust the decelerator mo-
tor and the injection pump linkage.
fl For details, refer to the “TESTING AND AD-
JUSTING DECELERATOR MOTOR LEVER
STROKE” of Testing and Adjustment Volume.
1) Decelerator motor adjustment mode display

method
the Decelerator motor adjustment mode.
(1) Digital meter display portion
(5) Setting switch
(7) Auto-decelerator switch
iii) Press “Setting switch (5)”. ii)
fl “GOV” is displayed on digital dis-
play portion (1) and “GSET” is dis-
played on service meter display
portion (2).

continue pressing “Buzzer cancel switch
(8)” + “Auto-decelerator switch (7) for 2.5
seconds or more”.
PC128US-2 20-243
(17)
7. Governor motor adjustment mode

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 Display
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 decel-
erator) OFF (reset it).
2) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds.
[GOV] is displayed on display portion (1),
3) Set the code in the service meter section to "03".
[GSET] is displayed on service meter portion
(8) + (3): Next code
(2).
(8) + (4): Previous code
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 op-

eration in 1-2), and the monitor panel displays normally.
20-244 PC128US-2
(17)
8. Boom Angle Potentiometer Correction Mode

(Only at Arm Crane)
This mode is used to adjust the boom angle po-
tentiometer.
1) Boom Angle Potentiometer Correction Mode

display method
the boom angle potentiometer correction
mode.
switch (8)” + “Auto decelerator switch
ond or third digit from the left of ser- (1) Digital meter display portion
vice meter display portion (2). (2) Service meter display portion
iii) Press “Setting switch (5)”. (3) Working mode selector (UP) switch
fl Check that “1 SET” is displayed (4) Working mode selector (DOWN) switch
on service meter display portion (5) Setting switch
(1) (the central three segments of (6) Travel speed switch
digital display portion (1) flash). (7) Auto decelerator switch
(2) Use the following procedure to adjust the
boom angle potentiometer correction
mode.
i) After switching to the mode of item
i), start the engine and operate
“Boom” to the RAISE side stroke end.
fl “ --” (correctable range) or “---”
(uncorrectable range)” flashes on
the digital display portion.
fl For the correctable range, because
incorrect mounting of the boom
angle potentiometer is assumed,
check it.
ii) Press setting switch (5) for three sec-
onds or more.
fl The same item as item i) flashes
on digital meter display portion
(1).
PC128US-2 20-245
(17)
iii) When normal adjustment can be

made (when the boom angle belongs
to a theoretical value, “ ” is dis-
played on digital meter display por-
tion (2) for five seconds and process-
ing returns to item i) (boom angle po-
tentiometer correction mode).
fl When correction was disabled,
“---” flashes (buzzer sounds five
times) on digital portion (2) and
processing returns to item i).
fl If correction is impossible, be-
cause incorrect mounting of the
boom angle potentiometer is as-
sumed, check it.
20-246 PC128US-2
(19)
9. Display and Setting of “OIL MAINTENANCE FUNCTION”

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

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

setting of 250 hours and the
elapsed time of 245 hours after oil
is replaced are displayed:
PC128US-2 20-246-1
(19)
2) Setting of interval time and resetting of

elapsed time
(1) Interval time setting
iii) Press “Setting switch (5)” (every time (1) Digital meter display portion
it is pressed, it is switched) to select (2) Service meter display portion
an interval time.Example) When the (3) Working mode selector (UP) switch
interval time of 250h is selected (not (4) Setting switch
displayed on digital meter display (5) Travel speed switch
portion (1)) (6) Auto-decelerator switch
fl Display of an interval time (se-
quentially displayed repetitively)
0 : Default mode (Oil maintenance
function is not set)
125h : Sets an interval time every 125
hours.
hours.
hours.
d : Sets the demonstration mode.
(For details, refer to item iv.)
fl Select an interval time according
to the “INSTRUCTION MANUAL”.
iv) When “Buzzer cancel switch (8)” +
“Auto decelerator switch (7)” con-
tinue being pressed for 2.5 seconds
or more, the setting of an interval time
is terminated.
20-246-2 PC128US-2
(17)
(2) Confirmation of elapsed time

fl If an elapsed time does not reach ten
hours before of a replacement inter-
val, nothing is displayed.
(If the elapsed time must be watched
in this state, turn ON the starting
switch continuing pressing “Setting
switch (5)” and continue pressing set-
ting switch (5).
(3) Elapsed time resetting after oil replace-
ment
While an elapsed time and a telephone
number are displayed on the monitor
panel (within 20 seconds), if setting switch
(5) starts being pressed and is held for
about three seconds as is, the elapsed
time is reset and the elapsed time of 0h is
displayed for one second.
(4) Demonstration mode
If the demonstration mode is used, the
demonstration of the oil maintenance
function can be performed at delivery.
fl The elapsed time is fixed to 240 hours and
the same function as the oil maintenance
function is performed.
fl After the demonstration is set, if the start-
ing switch is set to OFF → ON again, the
demonstration starts.
However, if the starting switch OFF ←→
ON is performed four times or more, the
demonstration mode is reset (demonstra-
tion display is performed up to the third
time) and is automatically switched to the
default mode.
(If demonstration must be continued, the
demonstration mode need be set again.)
PC128US-2 20-246-3
(17)
11. Setting model and attachment

Set the specification of machine model and attachment.
(PC128US with standard arm does not need this setting)
No. Operation Display

1 1) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds. Display section displays "10" and service
meter section displays "19SET".
2) Set the code in the service meter section to "19".
(If 19SET has been set, current set value is
displayed in display section.)
3) Press switch (5). Display
Service
meter
2 1) Set the value in the display section to a desired value. When PC138US long arm is selected
Set value Model ATT Remarks
10 PC128US Standard arm Controller default
Display
11 PC128US Long arm
20 PC138US Standard arm
21 PC138US Long arm After switch (5) is pressed, display section
displays "000", and then "---"
2) Press switch (5).
Display
3 1) To finish selection of model and attachment

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

stalled on the right console.
20-246-4 PC128US-2
(17)
11. Service adjustment

This service adjustment is set for adjustment of dispersion of components and parts and for replay to
requests of each user. Perform this adjustment for the following phenomena and users' requests.
fl Basically, the following items do not need to be adjusted, since they are adjusted when delivered.
fl This service adjustment is not effective when a component or a part is broken.
1) Service adjustment items table
The phenomena of the machine which need service adjustment, procedure for changing the set
values, and precautions are listed.
fl Usually, each adjustment value is set to the initial value.
Service adjust- Adjustment Phenomenon of machine/ Procedure for changing Precautions
ment item code/set value Users' request set value
Adjustment of 204 Engine speed lowers Change set value to Adjust to degree that work
PC-EPC valve largely during work. decrease pump absorp- equipment cycle time is not
current tion torque. lengthened.
Work equipment speed Change set value to Adjust to degree that engine
is low. increase pump absorp- speed is not lowered largely.
tion torque.
Travel/Swing 210 Set for each user who Set to 211. Alarm sounds when machine
alarm output wants to sound alarm travels or swings.
(If travel alarm is during swinging.
installed)
Adjustment of 264 Engine speed lowers Change set value to Adjust to degree that work
LS-EPC valve largely during work. decrease pump absorp- equipment cycle time is not
current tion torque. lengthened.
fl Perform this when adjust-
ment with PC-EPC valve
current is insufficient.
fl Even if LS-EPC valve
current is not increased
even if adjusted toward
positive (+) side.
Type of fuel * 310 • Change fuel. 310: Diesel fuel
• When kerosene is
used, engine speed 311: Kerosene
lower largely.
Adjustment of 324 Low idling speed is Set to (–) side. * Since the low idling speed
low idling speed remarkably high. is set by the governor
* stopper, it does not change
Low idling speed is Set to (+) side. under normal condition.
remarkably low.
Adjustment of 334 Arm crane idling speed Set to (–) side.
arm crane mode is remarkably high.
speed * Arm crane idling speed
is remarkably low. Set to (+) side.
Adjustment of E- 344 E-idling speed is Set to (–) side.

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

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 (E- or 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 PC128US-2
(17)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

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 E3-cc system
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 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 itemiza-
tion 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 NO

, advance to the next step by
advancing one branch of either YES or NO. (Note: The No. described in the upper right-hand
corners of is a serial number, but not a No. showing a procedure.)
• 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 PC128US-2
(17)
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 emer-
gency 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. Is the voltage between the al- NO
• Set the starting switch to ON. ternator R and the machine Defective alternator Replace
• 1V max. body normal?
YES
2
• Disconnect P02. NO
Is the voltage between P02 (11) Hot short-circuit of harness between Repair or
• Set the starting switch to ON.
• 1V max. and the machine body normal? P02 (female) (11) and alternator R replace
YES
Defective monitor panel Replace
PC128US-2 20-255
(17)
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT
TROUBLESHOOTING TROUBLESHOOTING

TROUBLESHOOTING
When an abnormality occurred diagnosis advances in accordance with the decision table CR700 control-
ler (decelerator control system) or CR700 controller (pump control system) that correspond to the con-
tents 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
code 0043). *: PC138US-2 Serial No.: 4501 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.
E02 (PC-EPC system)

YES
E03 (Swing holding brake system) To item 2
E05 (Governor motor system)
1
E2: Troubleshooting (C mode) of CR700 controller (pump control
YES
Is service code of system) at the number level of cc Diagnose in the
monitor panel E3: Troubleshooting (E mode) of CR700 controller (decelerator corresponding mode
displayed? control system) at the number level of cc
5 YES Diagnose engine
main unit (S mode)
Is engine electrical
2 YES system without
Is service code of 4 display of failure Diagnose engine
code normal? electrical system (E
monitor panel Engine system or mode) (flow without
NO displayed? YES hydraulic • Flow of part without
decision table NO display)
(mechanical)
• Check service code system? abnormality display
by performing 3 • Decide system from Diagnose by hydraulic (mechanical) system
operation engine speed after NO (H mode)
Is input and output
signal of governor hydraulic adjustment
• Is all working
NO pump equipment slow and
controller normal?
does engine speed
• Check it by decrease at heavy
monitoring 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 PC128US-2
(17)
For an output signal of the monitor panel, if there is no abnormality display of a communication system
sent by S-NET, it may be decided that the output signal is sent. When there is no abnormality display,
perform testing directly, such as an incorrect operation, according to the following points.Besides, whenan
abnormality occurred in the S-NET system, note diagnosis because the default mode is automatically
switched as shown below.
Default Mode When Communication Between Monitor Panel and

Governor Pump Controller is Disabled
Setting mode Pump control side Governor control side

1 Working mode E mode E mode
2 Throttle signal E mode or equivalent E mode or equivalent
3 Auto decelerator ON (Decelerator mode) ON (Decelerator mode)
4 Immersion signal Recognized to be below 30˚C Recognized to be below 30˚C
5 Travel speed Lo —
6 Automatic warm-up — ON (Automatic warm-up mode)
1. Confirmation Points of Monitor Panel Output Signal

fl For the monitoring mode operation method, refer to “Monitor Panel Display and Special Func-
tion”
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
(2) Switch the working mode as shown in Table 1 and check the change of the engine speed.
Table 1
Working mode Operation Engine speed (no load maximum speed) (rpm)
Work equipment About 2,400
A
Travel About 2,400
E
Travel About 2,200
B
Travel About 2,000
Arm crane
Travel About 1,500
PC128US-2 20-257
(17)
3) Confirmation of Travel Speed Selector Signal

(2) Check that the travel speed selector switch Hi, engine of 1,500 rpm or more, travel Hi travel
bit [4] comes on (or comes out).
(ª): The bit is ON (bit (4) comes on) above 27.46 MPa {280 kg/cm2} when the oil pressure rises
and is OFF (bit [4] comes out) below 15.69 MPa {160 kg/cm2} when the oil pressure falls.
2. Confirmation of CR700 Controller Input Signal

fl Check the input signal of each controller according to the following procedure.
• Pump control system
1) Confirmation of input signal
(1) Testing of hydraulic switch
i) Set the monitoring mode and display monitoring code “1023”.
ii) Operate each work equipment lever and check the lighting state of a bit pattern.
fl For the bit pattern list, refer to the monitor panel display and special functions.
(2) Testing of speed center (test it with an engine speed)
ii) Change the speed by the fuel dial and measure the engine speed at that time.
(3) Testing of pump discharge pressure sensor
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
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
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
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
Either swing or operating equipment

Swing holding brake Monitor code “1060” [1]
lever operation
Fuel dial above 1,500 rpm and travel

speed switch
Travel Hi/Lo Monitor code “1060” [4]
Hi and travel switch ON and travel Hi
rotation
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 PC128US-2
(17)
• Engine throttle Control System

1) Confirmation of Input Signal
(1) Testing of fuel dial input voltage
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
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
: 2.67 – 4.55 V
2) Confirmation of Output Signal

(1) Confirmation of decelerator motor driving signal
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)

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
PPC LOCK SOLENOID SYSTEM

20-302 PC128US-2
(17)
SWING LOCK SOLENOID SYSTEM

TRAVEL SPEED SOLENOID SYSTEM

PC128US-2 20-303
(17)
AUTOMATIC TRAVEL SPEED CONTROL SYSTEM

20-304 PC128US-2
(17)
ENGINE STARTING SYSTEM

PC128US-2 20-305
(17)
PC-EPC SYSTEM
PPC LOCK SOLENOID SYSTEM

20-306 PC128US-2
(17)
TRAVEL SPEED SOLENOID SYSTEM

SWING LOCK SOLENOID SYSTEM

PC128US-2 20-307
(17)
RELATED ELECTRICAL CIRCUIT DIAGRAM

20-308 PC128US-2
(17)
ENGINE STARTING SYSTEM

PC128US-2 20-309
(17)
TROUBLESHOOTING E-1
E-1 Abnormality in PC-EPC system

Items to check on LED display of pump controller when this failure mode occurs
• For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the operator’s compart-
ment, 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)
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 PC128US-2
(17)
TROUBLESHOOTING E-1
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 Remedy
4 YES
To A
Is resistance
YES between C05
3 (female) (4) and
chassis ground Short circuit with chassis
Is resistance normal?
between C13 ground in wiring harness
Repair or replace
YES (female) (1) - (2), NO between C05 (female) (4)
between (1)(2) - and C03 (female) (2)
chassis ground
normal?
2 • Between C13 Defective PC-EPC solenoid Replace
(female) (1) - (2) : NO
Is resistance 500 - 1000 Ω
between C01 • Between C13
YES (female) (3) - (4), (female) (1)(2) - chassis ground :
between (3)(4) - Min. 1 MΩ
chassis ground • Turn starting switch OFF.
normal? Defective contact,
• Disconnect C01.
• Between C01 disconnection, or short
(female) (3) - (4) : 5 YES circuit with chassis ground
Repair or replace
500 - 1000 Ω Is resistance in wiring harness between
• Between C01 between E07 C01 (female) (3) - E07
(female) (3)(4) - (female) (1) - (2), (female) (1) or C01 (4) - E07
chassis ground : NO between (1)(2) - (2)
Min. 1 MΩ chassis ground
1 • Turn starting normal? Defective engine speed
switch OFF. sensor Replace
• Disconnect C01. • Between C01 NO
Does LED of pump (female) (3) - (4) :
500 - 1000 Ω
controller flash? • Between C01 (female)
(3)(4) - chassis ground :
Min. 1 MΩ
• Start engine. • Turn starting switch OFF.
• Disconnect E07.
7 YES
Defective pump controller Replace
Is there continuity
YES between C01 Defective contact,
6 (female) (5) - (10), disconnection, or short
between (6) - (10)? circuit with chassis ground
Does model in wiring harness between Repair or replace
selector connector • Between C01 NO C01 (male) (5) - C09 (male)
(female) (5) - (10) :Continuity (1), C05 (female) (6) - C09
NO match machine • Between C01 (female) (female) (2) or C01 (female)
model? (10) - C09 (male) (3)
(6) - (10) : No continuity
• Turn starting switch OFF.
• Disconnect C01.
Defective machine model Replace
NO selection connector
Short circuit with chassis

8 YES ground in wiring harness
Repair or replace
between C01 (female) (13)
Is resistance
between C05 and C05 (female) (2)
A (male) (2),(4) -
chassis ground
normal? Defective emergency pump
Replace
• Min. 1 MΩ NO drive switch
• Disconnect C05.
PC128US-2 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 Remedy
2 YES
Is voltage between
YES C01 (1) and chassis
ground normal? Defective contact or
disconnection in wiring
Repair or replace
• 20 – 30 V NO harness between fuse 2 and
• Turn starting switch C01 (female) (1)
ON.
5 YES
Go to A
1 Is resistance
YES between C05 Defective contact,
4 disconnection, or short circuit
Is pump controller (female) (3) and (4) with chassis ground in wiring
normal? harness between C05 (female)
LED off? Is resistance Repair or replace
(3) and C13 (female) (1), or
YES between C13 • 7 – 14 Ω NO defective contact or
(female) (1) and (2) • Turn starting switch disconnection in wiring
• Turn starting normal? OFF. harness between C05 (female)
switch ON. (4) and C13 (female) (2)
• Disconnect C05.
• 7 – 14 Ω
• Turn starting Defective PC-EPC solenoid Replace
switch OFF. NO
3
• Disconnect C13.
Does pump
controller LED 7 YES Replace
Defective pump controller
NO flash? Is there continuity
YES between C01
• Start engine. (female) (5) - (10), Defective contact or
between (6) - (10)? disconnection in wiring
6 harness between C01 Repair or replace
• Between C01 NO (female) (5) and C09 (male)
Does model (female) (5) - (10) :
Continuity (1), or between C01 (female)
selection (6) and C09 (male) (2)
• Between C01
NO connector match (female) (6) - (10) :
machine model? No continuity
• Turn starting switch
OFF.
• Disconnect C01. Defective machine model
Replace
selection connector
NO
Defective contact,
disconnection, or short circuit
with chassis ground in wiring
harness between C01
YES (female) (7) and C05 (female) Repair or replace
8
(1), or defective contact or
Is there continuity disconnection in wiring
harness between C01
between C05 (female) (13) and C05
A
(female) (1) - (3) (female) (2)
and (2) - (4)?
Defective emergency pump
• Turn starting Replace
NO drive switch
switch OFF.
• Disconnect C05.
20-312 PC128US-2
(17)
TROUBLESHOOTING E-1
E-1 Related electric circuit diagram
PC128US-2 20-313
(17)
TROUBLESHOOTING E-1

Items to check on LED display of pump controller when this failure mode occurs
• For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the operator’s compart-
ment, 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)
seconds, then OFF for 2.0 seconds)
4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)
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 PC128US-2
(17)
TROUBLESHOOTING E-1
a) Speeds of all work equipment, travel, swing are slow or lack power

PC138USLC-2 Serial No.: 1501 and up Cause Remedy
4 YES
Go to A
YES Is resistance
between C06
3 (female) (2) - (5) Disconnection or
Is resistance normal? Short circuit with chassis
between C13 ground in wiring harness Repair or replace
YES (female) (1) - (2), • Between C06 NO between C06 (female) (2)
between (1)(2) - (female) (2) - (5): 8 - 15 Ω (5) and C03 (female) (1) (2)
chassis ground • Turn starting switch OFF
normal? • Disconnect C06
2 • Between C13 Replace
Defective PC-EPC solenoid
(male) (1) - (2) : NO
Is resistance 8 - 15 Ω
between CR2 • Between C13
YES (female) (39) - (40), (male) (1)(2) - chassis ground :
between (39)(40) - Min. 1 MΩ
chassis ground • Turn starting switch OFF.
normal? Defective contact,
• Disconnect CR3. disconnection, or short
• Between CR2 circuit with chassis ground
(female) (39) - (40) : 5 YES
in wiring harness between Repair or replace
500 - 1000 Ω Is resistance CR2 (female) (39) - E07
• Between CR2 between E07 (female) (2) or CR2 (40) -
(female) (39) - (40) (female) (2) - (1), E07 (2)
1 chassis ground : NO between (2)(1) -
Min. 1 MΩ chassis ground
• Turn starting normal? Defective engine speed
Does LED of pump switch OFF. sensor Replace
• Disconnect CR2. • Between CR2 NO
controller flash? (female) (39) - (40) :
500 - 1000 Ω
• Between CR2 (female)
• Start engine.
(39)(40) - chassis ground : Min. 1 MΩ
• Disconnect E07.
6 YES
Is machine model
and attachment set
NO up or arm crane 6
set up correct?
Defective machine model Reset up
NO set up or arm crane set up
Short circuit with chassis

7 YES ground in wiring harness Repair or replace
Is resistance between CR3 (female) (16)
between C05 and C05 (female) (3)
A (male) (2),(6) -
chassis ground
normal? Defective emergency pump
Replace
• Min. 1 MΩ NO drive switch
• Disconnect C05.
PC128US-2 20-315
(17)
TROUBLESHOOTING E-1
b) There is excessive drop in engine speed, or engine stalls
related to fuse 2.)
Cause Remedy
2 YES
Is voltage between
YES CR3 (2) (12) (22)
and chassis
ground normal? Defective contact or
disconnection in wiring Repair or replace
• 20 – 30 V NO harness between fuse 1 and
• Turn starting switch CR3 (female) (2) (12) (22)
ON.
1 5 YES To A
Is resistance Defective contact,
Is pump controller YES between C06 disconnection, or short circuit
LED off? 4 (female) (2) and (5) with chassis ground in wiring
normal? harness between C06
Is resistance (female) (5) and C13 (female) Repair or replace
• Turn starting YES between C13 • 8 – 15 Ω NO (1), or defective contact or
switch ON. (male) (1) and (2) • Turn starting switch disconnection in wiring
normal? harness between C06
OFF. (female) (23) and C13 (female)
• Disconnect C06. (6)
3 • 8 – 15 Ω
• Turn starting Defective PC-EPC solenoid Replace
Does pump NO
switch OFF.
controller LED
• Disconnect C13.
NO flash?
6 YES
• Start engine. Defective pump controller Replace
Is machine model
and attachment set
NO up or arm crane
set up correct?
Defective machine model Reset up
set up or arm crane set up
NO
Defective contact,
disconnection, or short circuit
with chassis ground in wiring
7 YES harness between CR3 (female)
(16) and C06 (female) (3), or Repair or replace
Is there continuity defective contact or
between C06 disconnection in wiring
A harness between CR3 (female)
(female) (2) - (3) (23) and C06 (female) (6)
and (5) - (6)?
Defective emergency pump
drive switch Replace
• Turn starting NO
switch OFF.
• Disconnect C06.
20-316 PC128US-2
(17)
TROUBLESHOOTING E-1

PC128US-2 20-317
(17)
TROUBLESHOOTING E-2
E-2 Abnormality in PPC lock solenoid system

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
Repair or replace
Is resistance harness between V07
(female) (2) and S12
YES between S13
(wiring harness
3 end) and chassis Defective contact or
ground normal? disconnection in wiring
Is resistance Repair or replace
YES between S12 and • Max. 1 Ω NO harness between S13 and
S13 (wiring • Turn starting switch OFF. chassis ground
harness end) • Disconnect S13.
2 normal?
Is resistance • Max. 1 Ω
YES between V07 (male) • Turn starting Defective PPC lock switch Replace
(1) - (2), between NO
(1)(2) - chassis switch OFF.
ground normal? • Remove S12 and S13.
1 • Safety lock lever: FREE
Is voltage between • Between V07 (male)
V07 (female) (1) (1) - (2) : Defective PPC lock solenoid Replace
and chassis 500 - 1000 Ω NO
ground normal? • Between V07 (male) (1)(2) -
chassis ground : Min. 1 MΩ
• 20 – 30 V • Turn starting switch OFF.
• Turn starting switch • Disconnect V07.
Repair or replace
ON. NO harness between fuse 3 and
V07 (female) (1)
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move
Cause Remedy
YES
Defective PPC lock solenoid Replace
1
Is voltage between
V07 (1) and (2) Defective contact or
normal? Repair or replace
harness between S13 and
Is resistance chassis ground
• Safety lock lever between S12 and
[LOCK] (solenoid NO S13 (switch end)
OFF) : Max. 1 V normal?
• Safety lock lever Defective PPC lock switch Replace
[FREE] (solenoid • Min. 1 MΩ NO
ON) : 20 – 30 V • Turn starting switch OFF.
• Turn starting switch • Disconnect S12 and S13.
ON. • Safety lock lever: [LOCK]
20-318 PC128US-2
(17)
TROUBLESHOOTING E-2
E-2 Related electrical circuit diagram
PC128US-2 20-319
(17)
TROUBLESHOOTING E-2

a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move
Cause Remedy
4 YES Defective contact or

Is resistance harness between V7 (female)
YES between S10 (1) and chassis ground
(female) (1) - fuse
3 (14)normal? Defective contact or
Is resistance disconnection in wiring Repair or replace
YES between S10 • Max. 1 Ω NO harness between S10
(female) (2) - • Turn starting switch OFF. (female) (1) - fuse (14)
chassis ground • Disconnect S13.
2 normal?
Is resistance • 37 - 60 Ω
YES between V7 (male) • Turn starting Defective PPC lock switch Replace
(2) - (1), between NO
(2)(1) - chassis switch OFF.
ground normal? • Remove S10.
• Between V7 (male)
Is voltage between (2) - (1) :37 - 60 Ω
V7 (female) (2) and Defective PPC lock solenoid Replace
• Between V7 NO
chassis ground (male) (2) - chassis ground :
normal? Min. 1 MΩ
• 20 – 30 V • Turn starting switch OFF.
• Disconnect V7. Defective contact or
• Turn starting switch disconnection in wiring Repair or replace
ON. NO harness between fuse V7
(female) (2) S10 (female) (2)
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move
Cause Remedy
YES
Defective PPC lock solenoid Replace
1
Is voltage between
V7 (1) and (2) Defective contact in wiring
2 YES
normal? harness between S10 Repair or replace
Is resistance (female) (2) - V7 (female) (2)
• Safety lock lever between S10
[LOCK] (solenoid NO (male) (1) - (2)
OFF) : Max. 1 V normal?
• Safety lock lever Defective PPC lock switch Replace
• Turn starting switch • Disconnect S10.
ON. • Safety lock lever: [LOCK]
20-320 PC128US-2
(17)
TROUBLESHOOTING E-2
PC128US-2 20-321
(17)
TROUBLESHOOTING E-3
E-3 Abnormality in swing lock solenoid system

a) Even when swing lock switch is turned OFF, upper structure does not swing
Cause Remedy
4 YES
Go to A —
YES Is resistance
between S08
3 (female) (2), S30
When C03 (female) (female) (2) - chassis Defective contact or
is grounded to ground normal? disconnection in wiring
chassis, is harness between S08 Repair or replace
YES resistance between • Min. 1 Ω NO (female) (2), S30 (female)
S08 (female) (1), • Turn starting switch (2) - chassis ground
2 S30 (female) (1), OFF.
Is resistance S05 (female) (1) -
chassis ground • Disconnect C03, S08, Defective contact or
between S08 and S30. disconnection in wiring Repair or replace
YES (male) (1) - (2), S30 normal?
harness between C03
(male) (1) - (2) or • Min. 1 Ω NO (female) (3) - S08 (female)
1 S05 (male) (1) - (2) (1), S30 (female) (1)
normal? • Turn starting switch OFF.
Is resistance • Disconnect C03, S08, and
between V04 • Min. 1 Ω S30.
Defective swing or arm IN
• Disconnect S08, pressure switch (S08, S30 Replace
(male) (1) and (2) NO or S05)
S30, and S05.
normal? • Start engine.
• Operate swing or arm control
• 20 – 60 Ω lever slightly (but do not move
• Turn starting switch work equipment). Defective swing holding Replace
OFF. brake solenoid valve
• Disconnect V04. NO
8 YES Go to B —
Is resistance
YES between X05
7 (female) (3) and
When V04 (female) chassis ground Defective contact or
is grounded to normal? disconnection in wiring
harness between X05 Repair or replace
YES chassis, is • Min. 1 Ω NO (female) (3) and chassis
resistance between • Turn starting switch
C03 (female) (4) and ground
6 OFF.
chassis ground
Is resistance normal? • Disconnect X05. Defective contact or
YES between C03 • Min. 1 Ω harness between V04 Repair or replace
(female) (2) and NO
chassis ground • Turn starting switch (female) (1) and C03
5 normal? OFF. (female) (4)
Is voltage between • Disconnect C03 and V04.
• Min. 1 Ω Defective contact or
A C03 (female) (1) • Turn starting switch disconnection in wiring
and chassis Repair or replace
OFF. NO harness between C03 (female)
ground normal? • Disconnect C03. (2) and chassis ground
• 20 – 30 V Defective contact or
• Turn starting switch disconnection in wiring
ON. Repair or replace
NO harness between fuse 2 and
C03 (female) (1)
10 YES Defective swing holding

Replace
Is resistance auto brake controller
YES between X05
(female) (4) and Defective contact or
9 V04 (female) (2)
normal? disconnection in wiring
Is resistance harness between X05 Repair or replace
B between X05 • Max. 1 Ω NO (female) (4) and C03
(male) (3) and (4) • Turn starting switch OFF. (female) (3)
normal? • Disconnect X05 and V04.
• Min. 1 Ω
Defective swing lock switch Repair or replace
• Turn starting switch NO
OFF.
• Disconnect X05.
20-322 PC128US-2
(17)
TROUBLESHOOTING E-3
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause Remedy
YES Defective swing holding Replace

1 brake solenoid
Is voltage between
V04 (1) and (2) disconnection in wiring
2 YES
normal? harness between V04 Repair or replace
Is resistance
between X05 (male) (female) (2) and X05
• Swing lock switch (3) and (4), between (female) (4)
[LOCK] (solenoid NO (4) and chassis
OFF) : Max. 1 V ground normal?
• Swing lock switch Defective swing lock switch Replace
• Turn starting switch • Disconnect X05.
ON. • Swing lock switch: [LOCK]
PC128US-2 20-323
(17)
TROUBLESHOOTING E-3

a) Even when swing lock switch is turned OFF, upper structure does not swing
Cause Remedy
4 YES
Go to A —
YES Is resistance
between S08
3 (female) (2), S30
When CR 1(female) (female) (2) - chassis Defective contact or
(12) is grounded to ground normal? disconnection in wiring
chassis, is harness between S08 Repair or replace
YES resistance between • Min. 1 Ω NO (female) (2), S30 (female)
S08 (female) (1), • Turn starting switch (2) - chassis ground
2 S30 (female) (1), OFF.
Is resistance CR3 (female) (30) -
chassis ground • Disconnect C03, S08, Defective contact or
between S08 and S30. disconnection in wiring
YES (male) (1) - (2), S30 normal?
harness between CR3 Repair or replace
(male) (1) - (2) or • Min. 1 Ω NO (female) (30) - S08 (female)
1 S05 (male) (1) - (2) (1), S30 (female) (1)
normal? • Turn starting switch OFF.
• Disconnect C03, S08, and
Is resistance • Min. 1 Ω S30.
Defective swing or arm IN
between V4 (male) • Disconnect S08, pressure switch (S08, S30 Replace
(1) and (2) normal? S30, and S05. NO or S05)
• Start engine.
• Operate swing or arm control
• 37 – 60 Ω lever slightly (but do not move
• Turn starting switch work equipment). Defective swing holding Replace
OFF. brake solenoid valve
8 YES Go to B —
Is resistance
YES between X05
7 (female) (2) and
When V4 (female) is chassis ground Defective contact or
grounded to normal? disconnection in wiring
harness between X05 Repair or replace
YES chassis, is • Min. 1 Ω NO (female) (3) and chassis
resistance between • Turn starting switch
CR3 (female) (3) ground
6 OFF.
and chassis ground
Is resistance normal? • Disconnect X05. Defective contact or
YES between CR3 • Min. 1 Ω harness between V4 Repair or replace
(female) (7) - X05 NO
(female) (3) • Turn starting switch (female) (1) and CR3
5 normal? OFF. (female) (3)
Is voltage between • Disconnect C03 and V4.
• Min. 1 Ω Defective contact or
A CR3 (female) (2) • Turn starting switch disconnection in wiring
(12) (22) and Repair or replace
chassis ground OFF. NO harness between CR3 (female)
normal? • Disconnect C03. (7) - X05 (female) (3)
• 20 – 30 V Defective contact or
• Turn starting switch disconnection in wiring
ON. Repair or replace
CR3 (female) (2) (12) (22)
10 YES Defective swing holding

Replace
Is resistance auto brake controller
YES between X05
(female) (4) and V4 Defective contact or
9 (female) (2)
Is resistance harness between X05 Repair or replace
B between X05 • Max. 1 Ω NO (female) (4) and V4 (female)
(male) (3) and (4) • Turn starting switch OFF. (2)
normal? • Disconnect X05 and V4.
• Min. 1 Ω
Defective swing lock switch Repair or replace
OFF.
• Disconnect X05.
20-324 PC128US-2
(17)
TROUBLESHOOTING E-3
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause Remedy
YES Defective swing holding Replace

1 brake solenoid
Is voltage between
V4 (1) and (2) disconnection in wiring
2 YES
normal? harness between V4 Repair or replace
Is resistance
between X05 (male) (female) (2) and X05
• Swing lock switch (4) and (2), between (female) (4)
[LOCK] (solenoid NO (4) and chassis
OFF) : Max. 1 V ground normal?
• Swing lock switch Defective swing lock switch Replace
• Turn starting switch • Disconnect X05.
ON. • Swing lock switch: [LOCK]
PC128US-2 20-325
(17)
TROUBLESHOOTING E-4
E-4 Abnormalty travel speed solenoid system

a) Even when travel speed selector switch is turned to Hi, travel speed does not change to high speed
related to fuse 2.)
Cause Remedy
harness between V05 Repair or replace
Is resistance (female) (2) and M39
YES between M39
(female) (1) and
(female) (2)
3 chassis ground Defective contact or

Is resistance harness between M39 Repair or replace
YES between M39 • Max. 1 Ω . Turn NO (female) (1) and chassis
• Starting switch OFF. ground
(male) (1) and (2)
2 • Disconnect S13.
normal?
Is resistance
YES between V05 (male)
(1) - (2), between OFF. Defective travel speed Replace
(1)(2) - chassis • Disconnect S12 and NO selector switch
ground normal? S13.
Is voltage between • Between V05 (male)
V05 (female) (1) (1) - (2): 20 - 60 Ω Defective travel speed Replace
and chassis • Between V06 (male) NO solenoid
ground normal? (1)(2) - chassis ground :
Min. 1 MΩ
• 20 - 30 V • Turn starting switch OFF.
• Turn starting switch • Disconnect V05.
Repair or replace
ON. NO 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 Remedy
YES Defective travel speed Replace

1 solenoid
Is voltage between
V05 (1) and (2) Short circuit with chassis
2 YES ground in wiring harness
normal? Repair or replace
Is resistance between V05 (female) (2)
between M39 and M39 (female) (2)
• Travel speed (male) (1) - (2),
selector switch NO between (1)(2) -
[Lo] (solenoid OFF) : chassis ground
Max. 1V normal? Defective travel speed
• Travel speed Replace
selector switch [Hi] • Min. 1 MΩ NO selector switch
(solenoid ON) : • Turn starting switch OFF.
20 – 30 V • Disconnect M39.
ON. • Travel speed selector
switch : [Lo]
20-326 PC128US-2
(17)
TROUBLESHOOTING E-4
PC128US-2 20-327
(17)
TROUBLESHOOTING E-4

related to fuse 1.)
fl Befor carrying out troubleshooting check that main pump pressure sensor system is normal.
Cause Remedy
YES
Defective controller Replace
Is resistance
YES between CR3
2 (female) (27) and Defective contact,
(3) normal? 3 disconnect, or short circuit
Is resistance with chassis ground in
Repair or replace
YES between V5 (male)
(2) - (1), between (2)
• Turn starting switch NO wiring harness between
OFF. CR3 (female) (27) (3) - V5
- chassis ground (female) (2) (1)
1 normal? • Disconnect CR3.
• Safety lock lever: FREE
Is voltage between • Between V5 (male) Defective travel speed
CR3 (female) (2) - (1): 37 - 60 Ω Replace
solenoid
(2),(12),(22) and • Between V5 (male) NO
chassis ground
(1)(2) - chassis ground : Min. 1 MΩ
normal?
• Turn starting switch OFF. Defective contact or
• 20 - 30 V • Disconnect V5. disconnection in wiring
• Turn starting switch Repair or replace
ON.
CR3 (female) (2) (12) (22)
20-328 PC128US-2
(17)
TROUBLESHOOTING E-5
E-5 Trouble in automatic travel speed control system

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 Remedy
2 YES Defective governor pump Replace

controller
YES Is voltage between
C05 (5) and (10) Disconnection, defective
normal? contact, or short circuit
with power source or chas- Repair or
• Run engine at full NO sis ground in wiring har- replace
throttle ness between C02 (female)
1 (5) – C05 (female) (3)
• Relieve travel system and set
Is voltage between lever in neutral repeatedly
↔
C05 (2) and (1)

normal? • Lever – Neutral return
• 0.5 – 4.5V Disconnection, defective
• Turn starting switch contact, or short circuit
ON. YES with chassis ground in wir- Repair or
• 18 – 28V 3 ing harness between C02 replace
(female) (10) – C05 (female)
Is voltage between (1)
C05 (2) and chassis
NO ground normal? Disconnection, defective
contact, or short circuit
with chassis ground in wir- Repair or
• Disconnect C05 ing harness between C02 replace
• Turn starting switch NO (female) (2) – C05 (female)
ON. (2)
• 18 – 28V
b) Engine speed sensor system
Cause Remedy
2 YES Defective automatic Lo/Hi Replace

travel speed controller
Is resistance be-
YES tween C02 (fe- Disconnection, defective
male) (6) and (11) contact, or short circuit with
1 normal? power source or chassis
ground in wiring harness Repair or
Is resistance be- • Turn starting switch NO between C02 (female) (6) – replace
tween E07 (male) OFF. E07 (female) (1) or between
C02 (female) (10) – E07 (fe-
(1) and (2) nor- • Disconnect C02. male) (2)
mal? • 500 – 1,000Ω
• Turn starting switch Defective engine speed

sensor (Internal disconnec-
OFF tion, defective contact, Replace
• Disconnect E07 NO short circuit with chassis
• 500 – 1,000Ω ground)
PC128US-2 20-329
(17)
TROUBLESHOOTING E-5
20-330 PC128US-2
(17)
TROUBLESHOOTING E-5

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 Remedy
2 YES Defective governor pump Replace

controller
YES Is voltage between
CR1 (13) and (21) Disconnection, defective
with power source or chas- Repair or
• Run engine at full NO sis ground in wiring har- replace
throttle ness between CR1 (female)
1 (13) – C05 (female) (C)
• Relieve travel system and set
Is voltage between lever in neutral repeatedly
↔
C05 (B) and (A)

normal? • Lever – Neutral return
• 0.5 – 4.5V Disconnection, defective
• Turn starting switch contact, or short circuit
ON. YES with chassis ground in wir- Repair or
• 4.5 – 5.5V 3 ing harness between CR1 replace
(female) (21) – C05 (female)
Is voltage between (A)
C05 (B) and
NO chassis ground Disconnection, defective
with chassis ground in wir- Repair or
• Disconnect C05 ing harness between CR1 replace
• Turn starting switch NO (female) (22) – C05 (female)
ON. (B)
• 4.5 – 5.5V
b) Engine speed sensor system
Cause Remedy
2 YES Defective automatic Lo/Hi Replace

travel speed controller
Is resistance be-
YES tween CR3 (fe- Disconnection, defective
male) (39) and (40) contact, or short circuit with
1 normal? power source or chassis
ground in wiring harness Repair or
Is resistance be- • Turn starting switch NO between CR3 (female) (39) – replace
tween E07 (male) OFF. E07 (female) (2) or between
CR3 (female) (40) – E07 (fe-
(1) and (2) nor- • Disconnect CR3. male) (1)
mal? • 500 – 1,000Ω
• Turn starting switch Defective engine speed

sensor (Internal disconnec-
OFF tion, defective contact, Replace
• Disconnect E07 NO short circuit with chassis
• 500 – 1,000Ω ground)
PC128US-2 20-331
(17)
TROUBLESHOOTING E-5
20-332 PC128US-2
(17)
TROUBLESHOOTING E-6
E-6 Abnormality in engine starting system

fl Always connect any disconnected connectors before going YES
on the next step.
fl When fuse 1 is normal. (If fuse 1 is blown, 4
check for a short circuit with the ground Is voltage between
YES starting motor
in the circuit related to fuse 1.) terminal B and YES
chassis ground 5
normal? Is voltage between
• 20 – 30 V battery relay
• Turn starting terminal M and
NO chassis ground 6 YES
switch ON.
battery relay
• 20 – 30 V terminal B and
• Turn starting NO chassis ground
3 switch ON. normal?
Is there sound of • 20 – 30 V NO
YES starting motor • Turn starting switch
ON.
pinion engaging?
YES
ON ↔ START.
7
YES
Is voltage between
safety relay
terminal C and
NO chassis ground 9
normal?
Is voltage between
• 20 – 30 V YES M02 (1) and
• Turn starting switch chassis ground
2 ON. normal?
• 20 – 30 V
YES Is sound heard 8 • Turn starting switch
from battery relay? Is voltage between ON.
safety relay
• Turn starting terminal B and NO
NO chassis ground
switch ON ↔ OFF. normal?
• 20 – 30 V
ON.
NO
14 YES
Is there continuity
YES between battery
relay terminal E and
chassis ground?
1 13
Is voltage between OFF.
Is specific gravity battery relay
of battery normal? terminal BR and
NO chassis ground YES
normal?
15
• Min. 1.24 • 20 – 30 V
• Turn starting switch Is voltage
between starting
ON. switch terminal BR YES
NO and chassis 16
ground normal? Is voltage
• 20 – 30 V between starting
• Turn starting switch terminal B
NO and chassis 17 YES
switch ON.
ground normal? Is voltage between
• 20 – 30 V fuse 1 inlet and
switch ON. normal?
• 20 – 30 V NO
ON.
20-334 PC128US-2
(17)
TROUBLESHOOTING E-6
Cause Remedy
Defective starting motor Replace
harness between battery Repair or replace
relay terminal M and
starting motor terminal B
Defective battery relay Replace
harness between battery (+) Repair or replace
terminal and battery relay
terminal B
harness between safety Repair or replace
relay terminal C and
starting motor terminal S
YES Defective safety relay Replace

10
Is voltage between Defective contact,
M02 (2) and disconnection, or short
chassis ground
11 YES circuit with power source in
wiring harness between Repair or replace
alternator terminal R and
alternator terminal M02 (female) (2)
• Max. 13 V
• Turn starting NO R and chassis
ground normal? Replace
switch ON. Defective alternator
• Max. 13 V NO
• Disconnect terminal R.
• Turn starting switch ON. Defective contact or
12 YES Repair or replace
harness between starting
Is voltage between
starting switch switch terminal C (T9) and
terminal C (T09) M02 (female) (1)
and chassis
ground normal? Defective starting switch Replace
• 20 - 30 V NO (circuit C)
ON. Defective contact or
harness between starting Repair or replace
motor terminal B and safety
relay terminal B
Repair or replace
harness between battery
relay E and chassis ground
switch terminal BR (T7) and
battery relay terminal BR
Defective starting switch

Replace
(circuit BR)
harness between fuse 1 Repair or replace
outlet and starting switch
terminal B (T6)
harness between battery (+)
terminal - M11 (1), (2) - fuse
1 inlet
Lack of battery capacity Charge or replace
PC128US-2 20-335
(17)
TROUBLESHOOTING E-6
20-336 PC128US-2
(17)
TROUBLESHOOTING E-6

YES
fl Before carrying out troubleshooting, check that all the
related connectors are properly inserted. 4
fl Always connect any disconnected Is voltage between
YES starting motor
connectors before going on the terminal B and YES
chassis ground 5
next step. normal? Is voltage between
fl When fuse 1 is normal. (If fuse 1 is blown, • 20 – 30 V battery relay
check for a short circuit with the ground • Turn starting
NO
terminal M and
6 YES
switch ON. chassis ground
in the circuit related to fuse 1.) normal? Is voltage between
battery relay
3 • 20 – 30 V terminal B and
Is there sound of switch ON. normal?
YES starting motor • 20 – 30 V NO
pinion engaging? • Turn starting switch
ON.
• Turn starting switch YES
ON ↔ START.
7 YES
Is voltage between
safety relay
terminal S and
NO chassis ground
normal?
• 20 – 30 V
• Turn starting
8
switch ON.
Is voltage between
safety relay
terminal C and
NO chassis ground
normal?
2
• 20 – 30 V YES
YES Is sound heard • Turn starting
from battery relay? switch ON.
9
• Turn starting
switch ON ↔ OFF. Is voltage between
safety relay
terminal B and
NO chassis ground
normal?
• 20 – 30 V
• Turn starting
switch ON.
NO
24 YES
Is there continuity
YES between battery
1 relay terminal E and
chassis ground?
Is specific gravity 23
of battery normal? Is voltage between OFF.
battery relay
terminal BR and
• Min. 1.26 NO chassis ground YES
normal?
25
• 20 – 30 V
• Turn starting switch Is voltage
between starting
ON. switch terminal BR YES
NO and chassis 26
ground normal? Is voltage
• 20 – 30 V between starting
• Turn starting switch terminal B
NO and chassis 27 YES
switch ON.
ground normal? Is voltage between
• 20 – 30 V fuse 20 inlet and
switch ON. normal?
• 20 – 30 V NO
ON.
20-338 PC128US-2
(17)
TROUBLESHOOTING E-6
Cause Remedy
harness between battery Repair or replace
relay terminal M and
starting motor terminal B
terminal and battery relay
terminal B
harness between safety Repair or replace
relay terminal C and
starting motor terminal S
YES
Defective safety relay Replace
11
Is voltage between Defective contact,
YES M02 (2) and disconnection, or short
chassis ground
12 YES circuit with power source in Replace
normal? Is voltage between wiring harness between
alternator terminal alternator terminal R and
10 • Max. 13 V M02 (female) (2)
• Turn starting NO R and chassis
Is voltage between ground normal?
M02 (1) and switch ON. Defective alternator Repair or replace
• Max. 13 V NO
chassis ground
• Disconnect terminal R.
normal?
• Turn starting switch ON.
• 20 – 30 V
• Turn starting
switch ON.
• PPC lock switch: Go to A
LOCK NO
harness between safety Replace
relay terminal B and heater
relay terminal B
Repair or replace
harness between battery
relay E and chassis ground
switch terminal BR (T7) and
battery relay terminal BR
Defective starting switch Replace

(circuit BR)
harness between fuse 1 Repair or replace
outlet and starting switch
terminal B (T6)
terminal - M11 (1), (2) - fuse
1 inlet
Lack of battery capacity Charge or replace
PC128US-2 20-339
(17)
TROUBLESHOOTING E-6
Cause Remedy
Disconnection or defective
13 YES contact in wiring harness
Repair or replace
between V03 (female) (6) -
Is voltage between M02 (female) (1)
A V03 (6) and chassis
ground normal? YES Defective V3 relay or Replace relay
malfunction of KOMTRAX
14
• 20 – 30 V
• Starting switch: Is voltage between
START Disconnection or defective
V03 (3) and chassis YES contact in wiring harness
• PPC lock switch: NO ground normal? Repair or replace
LOCK 15 between R06 (female) (3) -
V3 (female) (3)
• 20 – 30 V Is voltage between
• Starting switch: R06 (3) and chassis
START NO ground normal? 16 YES
Go to B
• PPC lock switch:
LOCK Is voltage between
• 20 – 30 V R06 (5) and chassis
• Starting switch: NO ground normal?
START
Go to C
• PPC lock switch: • 20 – 30 V NO
LOCK
• Starting switch:
START
18 YES • PPC lock switch:LOCK
Defective R06 relay Replace
Is resistance
YES between R06
(female) (2) -
chassis ground Disconnection or defective
normal? contact in wiring harness
17 between R06 (female) (2) - Repair or replace
• Max. 1 Ω NO
• Starting switch: OFF chassis ground
Is voltage between
R06 (1) and chassis • Disconnect R06. Disconnection or defective
B
ground normal? YES contact in wiring harness
between S10 (female) (3) - Repair or replace
19 R06 (female) (1)
• 20 – 30 V
• Starting switch: ON Is voltage between
S10 (3) and chassis YES
NO ground normal? 20 Defective PPC lock switch Replace
• 20 – 30 V Is voltage between Disconnection or defective

• Starting switch: S10 (1) and chassis contact in wiring harness
NO ground normal? 21 YES between T12 - fuse 14 - S10
ON Repair or replace
Is voltage between (female) (1) (including fuse
• 20 – 30 V starting switch T12 14)
• Starting switch: NO and chassis
ON ground normal? Defective starting switch
Replace
• 20 – 30 V NO (between B - ACC)
ON Disconnection or defective
22 YES contact in wiring harness
Repair or replace
Is voltage between between T9 - R06 (female)
starting switch T9 (5)
C and chassis
ground normal?
Defective starting switch Replace
• 20 – 30 V NO (Between B - C)
START
• PPC lock switch:
LOCK
20-340 PC128US-2
(17)
TROUBLESHOOTING E-6
E-6 ENGINE STARTING SYSTEM

PC128US-2 20-341
(17)
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)

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 The fuel level gauge indicates FULL all the time ............................................................................ 20-580
M-19 The fuel level gauge indicates nothing............................................................................................ 20-580
M-20 Though the swing lock switch is set to ON (lock), (the swing lock monitor) does not come ON..... 20-582
M-21 While the engine is rotating, the service meter does not advance.................................................. 20-582
M-22 The fuel level sensor system is defective ....................................................................................... 20-583
M-23 The coolant temperature sensor system is defective...................................................................... 20-584
M-24 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
M-25 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 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM

20-556 PC128US-2
(17)

20-558 PC128US-2
(17)
PC128US-2 20-559
(17)
TROUBLESHOOTING M-1
M-1 [E101] (An error history data abnormality) is displayed.

" 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 bat-
tery 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 ar- Is the service code displayed NO
rangement," check the situa- —
again after the "Resetting ar- Normal
tions for a while in the normal
operation. (See Note 1.) rangement" is taken?
YES
2
• Set the starting switch to Disconnection, defective contact or
Is the voltage between P01 (8) NO ground fault of harness among the bat- Repair or
OFF. and the machine body normal?
• 20 – 30V tery, M13 (1), (2) and P01 (female) (8) replace
YES
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 PC128US-2
(17)
TROUBLESHOOTING M-1

" 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 bat-
tery 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 ar- Is the service code displayed NO
rangement," check the situa- —
again after the "Resetting ar- Normal
tions for a while in the normal
operation. (See Note 1.) rangement" is taken?
YES
2
• Set the starting switch to Disconnection, defective contact or
Is the voltage between P01 (8) NO ground fault of harness among the bat- Repair or
OFF. and the machine body normal?
• 20 – 30V tery, M13 (1), (2) and P01 (female) (8) replace
YES
Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)
PC128US-2 20-561
(17)
TROUBLESHOOTING M-2, M-3, M-4, M-5, M-6, M-7
M-2 [E108] (Detection of engine water temperature 105°) is displayed.
Cause Remedy
1
Does the coolant temperature gauge NO
on the monitor indicate a red range
and is the caution lamp flashing?
YES
See M-13-c). —
2
Is "E" shown in front of the serv- NO Failure of engine body system
• Set the starting switch to ON. —
ice code? (See Note 1.)
YES
Note 1 : The monitor panel has returned to normal as far as the display is concerned. Since the coolant tem-
perature sensor detected water temperatures of over 105°C so far, remove the factors in the trouble-
shooting 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 PC128US-2
(17)
TROUBLESHOOTING M-8
M-8 When the starting switch is set to ON, the whole monitor panel does
not come ON for 3 sec.
" 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. Are the voltages among P01 (8) – NO
(6), (7), P02 (1), (2) – (6) and (7)
• 20 – 30V
normal?
YES
Defective monitor panel. Replace
2
Disconnection, defective contact or Repair or
• Set the starting switch to ON. Is the voltage between Fuse 13 NO ground fault of harness between Fuse
• 20 – 30V and the machine body normal? replace
13 and battery relay RM.
YES Disconnection, defective contact or Repair or
ground fault of harness between P01
replace
(female) (1) (2) and Fuse 13
3
• Set the starting switch to ON. Is the voltage between Fuse 18 NO
ground fault of harness between Fuse
18 and Battery B.
YES Disconnection, defective contact or
ground fault of harness between P02 Repair or
(female) (19) and Fuse 6 replace
b) When part of the monitor panel does not come ON
Cause Remedy
PC128US-2 20-563
(17)
TROUBLESHOOTING M-8
M-8 a) Related Electrical Circuit Diagram
20-564 PC128US-2
(17)
TROUBLESHOOTING M-8

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. Are the voltages among P01 (8) – NO
(6), (7), P02 (1), (2) – (6) and (7)
• 20 – 30V
normal?
YES
2
• Set the starting switch to ON. Is the voltage between Fuse 12 NO ground fault of harness between Fuse
12 and battery relay RM.
YES Disconnection, defective contact or Repair or
ground fault of harness between P01
replace
(female) (1) (2) and Fuse 12
3
• Set the starting switch to ON. Is the voltage between Fuse 18 NO
ground fault of harness between Fuse
18 and Battery B.
YES Disconnection, defective contact or
ground fault of harness between P02 Repair or
(female) (19) and Fuse 6 replace
b) When part of the monitor panel does not come ON
Cause Remedy
PC128US-2 20-565
(17)
TROUBLESHOOTING M-8, M-9
M-9 The starting switch is set to ON, and the whole monitor panel
remains lighted.
Cause Remedy
20-566 PC128US-2
(17)
TROUBLESHOOTING M-10
M-10 (The engine pre-heating monitor) comes ON even without

pre-heating arrangement.
Cause Remedy
1
• Disconnect the terminal R1. Is the voltage between the starting NO
• Set the starting switch to ON. switch R1 and the machine body Defective starting switch Replace
• Max. 1V normal?
YES
2
• Set the starting switch to Is the voltage between P02 (18) NO Hot short circuit of harness between Repair or
ON. and the machine body normal? starting switch R1 and P02 (female) replace
• Max. 1V (18)
YES
PC128US-2 20-567
(17)

a Make sure that S-NET is normal
Cause Remedy
1
• Disconnect the terminal R1. Is the voltage between the starting NO
• Set the starting switch to ON. switch R1 and the machine body Defective starting switch Replace
• Max. 1V normal?
YES
2
• Set the starting switch to Is the voltage between CR1 (11) NO Hot short circuit of harness between Repair or
ON. and the machine body normal? starting switch R1 and CR1 (female) replace
• Max. 1V (11)
YES
3
Are the monitoring code [0045] – NO
(3) and [1027] – (3) ON?
YES
4
Is the monitoring code [1061] – NO Replace
Defective controller
(2) ON?
YES
20-568 PC128US-2
(17)
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 Is the voltage between the alter- NO
min. nator R and the machine body Defective alternator Replace
• 20 – 30V normal?
YES
2
• Engine start, Medium speed Is the voltage between P02 (fe- NO Disconnection or defective contact of Repair or
min. male) (11) and the machine body harness between alternator R and P02 replace
• 20 – 30V normal? (female) (11)
YES


PC128US-2 20-569
(17)
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
Does the display disappear when NO
• Engine slow the oil pressure sensor terminal S17
is disconnected at engine slow?
YES
The oil pressure sensor is defective Replace
(at low pressure).
2
• Set the starting switch to OFF. Is there continuity between P02
(female) (7) and the machine
NO
• Disconnect the sensor harness Defective monitor panel Replace
and P02. body?
YES Ground fault of harness between P02 Repair or
(female) (7) and sensor terminal S17 replace
M-11 b) Related Electrical Circuit Diagram


20-570 PC128US-2
(17)
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. Is the voltage between the alter- NO
• Set the starting switch to ON. nator R and the machine body Defective alternator Replace
• Max. 1V normal?
YES
2
• Disconnect P02.
• Set the starting switch to ON. Is the voltage between P02 (11) NO Hot short-circuit of harness between Repair or
and the machine body normal? P02 (female) (11) and alternator R replace
• Max. 1V
YES


PC128US-2 20-571
(17)
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. Is there continuity between the NO
• Disconnect the sensor terminal sensor terminal S17 and the ma- Defective oil pressure sensor Replace
S17. chine body?
YES
2
• Set the starting switch to ON. Is there continuity between P02 NO Disconnection or defective contact of
• Disconnect P02 and sensor (female) (11) and the sensor ter- harness between P02 (female) (7) and Repair or
terminal S17. minal S17? sensor terminal S17 replace
YES
M-12 b) Related Electrical Circuit Diagram


20-572 PC128US-2
(17)
M-13 When the starting switch is set to ON and the engine is started, pre-
cautions 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 Remedy
See M-12-b). —
b) (Battery charge level) flashes.
Cause Remedy
See M-12-a). —
PC128US-2 20-573
(17)
c) (Coolant temperature) flashes.

! Before diagnosis, make sure that the engine oil pressure is normal.
Cause Remedy
1
• Engine start Is the coolant temperature gauge NO
• Medium speed min. in the red range?
YES
2
Is only Level 1 (the lowest level)
• Engine start 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. Is the resistance value between Disconnection or defective contact of Repair or
• Disconnect P02 and P07. P02 (female) (1) and P07 (fe-
NO harness between P02 (female) (1) and
replace
• Max. 1 Ω male) (1) normal? P07 (female) (1)
YES Disconnection or defective contact of Repair or

harness between P02 (female) (1) and
P07 (female) (2) replace
M-13 c) Related Electrical Circuit Diagram


20-574 PC128US-2
(17)
d) (Fuel level) flashes.

! Before diagnosis, make sure that fuel is not empty.
Cause Remedy
1
NO Replace
• Engine start Is the fuel gauge in the red range? Defective monitor panel
YES
• Engine start 2
• Wait for 2 minutes approx. Does the gauge indication come
(The display of fuel level is on up to Level 9 (the right end) NO
arranged to be slightly de- when P06 (female) (1) is connect-
layed because the fuel level ed to the machine body ground?
fluctuates.) YES
The fuel level sensor system is
—
defective. (See M-22.)
• Connect P06 (female) (1) to 3

the machine body ground. Disconnection or defective contact of
• Set the starting switch to Is the voltage between P02 (2) NO harness between P02 (female) (2) and Repair or
ON. and the machine body normal? P06 (female) (1) replace
• Max. 0.3V
YES
M-13 d) Related Electrical Circuit Diagram


PC128US-2 20-575
(17)
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 Remedy
• Set the starting switch to 1
OFF.
• Disconnect P03. Is the resistance value between NO
• Set the buzzer cancel switch Defective buzzer cancel switch Replace
P03 (female) (1) a d (2) normal?
to ON : Max. 1Ω
• Set the buzzer cancel switch
to OFF : Min. 1 M Ω YES
2
• Disconnect P03. Is the voltage between P02 (16) NO Ground fault of harness between P02 Repair or
• Set the starting switch to ON. and the machine body normal? (female) (16) and P03 (female) (2) replace
• 20 – 30V
YES


20-576 PC128US-2
(17)
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. NO
Is Bit (4) of Monitoring Code
• Set to Monitoring Code
[0045] OFF?
[0045].
YES
2
• Set the starting switch to ON. Disconnection or defective contact of
Is the voltage between P02 (19) NO Repair or
• Set the lighting switch to ON. harness between P02 (female) (19)
and the machine body normal? replace
• 20 – 30V and M47 (male) (14)
YES
PC128US-2 20-577
(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
When a short connector is connect-
• Disconnect P07. ed to P07 (female), does the gauge NO
• Set the starting switch to ON. level rise step by step and does the
gauge go out finally?
YES
2
Is there continuity between P02 NO Disconnection or defective contact of
• Set the starting switch to OFF. Repair or
(female) (1) and P07 (female) harness between P02 (female) (1) and
• Disconnect P02 and P07. (1)? replace
P07 (female) (1)
YES
3
Disconnection or defective contact of
Is there continuity between P02
• Set the starting switch to OFF. NO harness between P02 (female) (13) Repair or
(female) (13) (20) and P07
• Disconnect P02 and P07. (female) (2)? (20) and machine body P02 (female) replace
(2) machine body
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. Does the gauge indication appear NO
• Set the starting switch to ON. when P07 is disconnected?
YES
2
• Set the starting switch to ON. Is there continuity between P02 NO
(female) (1) and the machine Defective monitor panel Replace
• Disconnect P02 and P07.
body?
(female) (1) and P07 (female) (1) replace
20-578 PC128US-2
(17)
M-16, M-17 Related Electrical Circuit Diagram


PC128US-2 20-579
(17)
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 Remedy
• Set the starting switch to ON. 1

• Wait for 2 minutes approx. When P06 is disconnected, does the NO
(The display of fuel level is gauge level fall step by step and does
arranged to be slightly de- the gauge indication go out finally?
layed because the fuel level
fluctuates.) YES
The fuel level sensor system is —
2
• Set the starting switch to
Is there continuity between P02 (fe- NO
OFF. Defective monitor panel Replace
male) (2) and the machine body?
• Disconnect P02 and P06.
(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
Does the gauge indicate anything NO
• Disconnect P06. after P06 (female) (1) is connect-
• Set the starting switch to ON. ed to the machine body ground?
YES
The fuel level sensor system is —
2
Is there continuity between P02 (fe- Disconnection or defective contact of
• Set the starting switch to OFF. male) (2) and the machine body after NO harness between P02 (female) (2) and Repair or
• Disconnect P02 and P06. P06 (female) (1) is connected to the P06 (female) (1) replace
machine body ground?
YES
20-580 PC128US-2
(17)
M-18, M-19 Related Electrical Circuit Diagram


PC128US-2 20-581
(17)
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 Disconnection or defective contact of
Repair or
• Set the starting switch to ON. and the machine body as per the harness between P02 (female) (17)
table? and X05 (male) (1) replace
YES
Table Defective monitor panel Replace
Swing lock switch ON Max. 1V
Swing lock switch OFF 20 – 30V


M-21 While the engine is rotating, the service meter does not advance.
Cause Remedy
1
• Start the engine. Is the battery charge level caution NO
Medium speed min. lamp ON?
YES
See M-12 a). —
20-582 PC128US-2
(17)
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
Does the arm move smoothly? NO Defective sensor (See Note 2.) Replace
YES
3
Does the float have large crack, NO Clean or
chip or flaw? Defective contact of connector replace the
connector.
YES Replace the
Interference of sensor in tank sensor.
(See Note 2.)
4
Is it found in visual check that the NO Defective sensor Replace
harness is cut?
YES Disconnection of harness (See Note 3.)

(Defective clamp)
(Apply of external force)
Table
Upper stopper position About Max. 12Ω
(Full)
Lower stopper position About 85 – 110Ω
(Empty)
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 improp-
erly.
Note 3 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.
PC128US-2 20-583
(17)
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 Clean the
Defective contact of connector connector or
(See Note 1.) replace the
sensor.
2
Is it found in visual check that the NO Defective sensor Replace
harness is cut?
YES Disconnection of harness (See Note 2.)

Replace the
(Defective clamp)
sensor.
(Apply of external force)
Table
Normal temperature (25°C) About 37 – 50k Ω
100°C About 3.5 – 4.0k Ω
Note 1 : In case of recurrence, the machine side connector (female side) is supposed to be defective. So, check
the machine side connector and harness.
Note 2 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.
20-584 PC128US-2
(17)
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 Remedy
1
• Front window : Close position
• Set the starting switch to ON. Does Bit (3) of the monitoring NO
• Set the monitoring code to code [0049] come on?
[0049].
YES
2
• Set the wiper switch to "ON" When the wiper switch is set to
or "INT." "ON" or "INT," do Bits (4) and (5) NO Defective monitor panel Replace
• Set the monitoring code to of the monitoring code [0049] go
[0049]. out?
YES
3
• Set the starting switch to ON. Are the voltages between pins of NO
M50 as per Table 1?
YES
Defective wiper motor Replace
4
Are the resistance values be- Disconnection, defective contact, short- Repair or
• Set the starting switch to OFF. tween pins from P01 (female) and NO circuit of ground fault of harness of im- replace
• Disconnect P02 and M50. M50 (male) as per Table 2? proper resistance value
YES
5 Check the
• Set the starting switch to OFF. front window,
Is the resistance value between NO The rear limit switch is defective, or the or replace the
• Disconnect Terminals (1)
Terminals (1) and (2) of the rear front window is opened.
and (2) of W03. rear limit
limit switch W03 normal? switch.
• Max. 1Ω
YES
6
.• Set the starting switch to OFF. Are the resistance values between
• Disconnect P02 and Termi- the rear limit switch W03 terminal NO Disconnection or defective contact of Repair or
nals (1) and (2) of W03. (1) and P02 (female) (15) and be- harness of improper resistance value replace
• Max. 1Ω tween W03 Terminal (2) and the
machine body normal?
YES
b) The windshield wiper works though it is not switched ON.
Cause Remedy
1
• Front window : Closed position
• Set the starting switch to ON. Does Bit (3) of the monitoring NO
• Set the monitoring code to code [0049] come ON?
[0049]
YES

2
• Set the wiper switch to "ON" When the wiper switch is set to NO
or "INT." "ON" or "INT," do Bits (4) and (5) of Defective monitor panel Replace
• Set the monitoring code to the monitoring code [0049] go out?
[0049]. Hot short circuit of harness between
YES P01 (female) (9) and M50 (female) (3) Repair or
or between P01 (female) (10) and M50 replace
(female) (1)
PC128US-2 20-585
(17)
Table 1
Timing Chart when the windshield wiper is set to ON
Item Symbol Set time

Temporary stop
time to the next Tia 0.13 sec
operation
Safety circuit during
wiper operation Tsa 10 sec
(Safety function 1)
Temporary halt time
at wiper blade stor- Tip 1.5 sec
age
Safety circuit at
wiper storage Tsp 10 sec
(Safety function 2)
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 Tia 4 sec
the next operation
Safety circuit during
wiper operation (Safety Tsa 10 sec
function 1)
Temporary halt time at
wiper blade storage Tip 1.5 sec
Safety circuit at wiper

storage Tsp 10 sec
(Safety function 2)
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) (12) and M50 (male) (4) Max. 1Ω
Between P01 (female) (6), (7) and M50 (male) (5)
Between M50 (female) (1), (3), (4), (5), (6) and GND Min. 1MΩ
20-586 PC128US-2
(17)


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. Is the voltage among P01 (fe- NO Hot short circuit of harness between
• Disconnect P02 and M28. male) (3), M28 (female) (2) and Replace
P01 (female) (3) and M28 (female) (1).
• Max. 1V the machine body normal?
YES
• Defective monitor panel Repair or
• Defective diode replace
a-2) When [E114] is not displayed.
Cause Remedy
1
• Set the starting switch to ON. Is the voltage among Fuse 4, NO Disconnection or defective contact of Repair or
• Disconnect M28. M28 (female) (2) and the ma- harness between Fuse 4 and M28 (fe- replace
• Max. 20 – 30V chine body normal? male) (2).
YES
2
• Set the starting switch to OFF. Is the resistance value between NO Disconnection or defective contact of
• Disconnect P01 and M28. P01 (female) (3), M28 (female) harness between P01 (female) (3) and Repair or
• Max. 1Ω (1) normal? M28 (female) (1). replace
YES
3
• Set the starting switch to ON. Is the voltage between P01 (fe- NO
• Set the washer switch to ON. male) (3) and the machine body Defective washer motor Replace
• Max. 1V normal?
YES
b) The washer motor works though the washer is not switched ON.
Cause Remedy
1
• Set the starting switch to OFF. Is the resistance value between NO Ground fault of harness between P01 Repair or
• Disconnect P02 and M28. M28 (female) (1) and the ma- (female) (3) and M28 (female) (1). replace
• Min. 1M Ω chine body normal?
YES
20-588 PC128US-2
(17)


PC128US-2 20-589
(17)
TROUBLESHOOTING OF COMMUNICATION
SYSTEM (N MODE)

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

1 Cause Remedy
Are [128] and "US" intermittently NO
displayed in the monitoring code
1002?
YES
The machine has restored. —
2
• 7.5V min. Is the voltage between CR2 (21) NO
• Disconnect CR2 and measure and the machine body normal?
the voltage on the harness
side. YES
Defective controller CR700 Replace
3
Is the resistance value among NO Disconnection of harness among P02
P02 (9), (10) and CR2 (21) (9), (10) and CR2 (21) Replace
normal?
YES
• 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 PC128US-2
(17)
TROUBLESHOOTING N-1

1 Cause Remedy
Are model code and attachment NO
code displayed according to
setting in monitoring code 1001?
YES
The machine has restored. —
2
• 7.5V min. Is the voltage between CR2 (21) NO
• Disconnect CR2 and measure and the machine body normal?
the voltage on the harness
side. YES
3
Is the resistance value among NO Disconnection of harness among P02
P02 (9), (10) and CR2 (21) (9), (10) and CR2 (21) Replace
normal?
YES
N-1 Related Electrical Circuit Diagram
PC128US-2 20-603
(17)
TROUBLESHOOTING OF CONTROLLER CR700
[DECELERATION CONTROL SYSTEM]
(E MODE)

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 T-
adapter, 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
TROUBLESHOOTING [DECELERATION CONTROL SYSTEM]
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 turbo-
charger because of cold engine coolant (lower than 30°C).
Any rpm
Engine is forced to be fixed at the rpm for (Follows the throttle
Deceleration-motor warming-up. (Any throttle direction is ignored.) direction.)
potentiometer
(Controls the process.)
2 seconds
Starting switch Starting switch

turned "ON" turned to "START"
A: Turbocharger protection time B: Modulation time

C: Modulation range 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-tempera-
ture 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-adjust-
ment 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 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

(1/2)
20-708 PC128US-2
(17)
(2/2)
PC128US-2 20-709
(17)

(1/2)
20-710 PC128US-2
(17)
(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 Is voltage normal between CR3 NO
• 20 – 30V (1),(11) – (21), (31), (32), (33)?
YES
2
• Starting switch ON Is voltage between fuse 18 and NO Disconnection or defective contact of Repair or
• 20 – 30V body normal? harness between fuse 18 and battery. replace
YES Disconnection or defective contact of

harnesses between fuse 18 and CR3 Repair or
(female) (1),(11). replace

20-712 PC128US-2
(17)
TROUBLESHOOTING E-1

PC128US-2 20-713
(17)
TROUBLESHOOTING E-2
E-2 [E321] [E322] "Short circuit/Disconnection in motor drive relay

system" is displayed
Cause Remedy
1
• Turn starting switch ON;
operate fuel dial. Is current value normal between NO
• 1.2A or less CR3 (female) (18) and (23)?
• Temperature of engine
coolant: 30°C or higher YES
2
• Detach R07 and CR3. Is resistance value normal between NO Defective harness; defective connector Repair or
• Min. 1 MΩ CR3 (female) (18) and body? CN-A09 replace
YES
Defective relay Replace
20-714 PC128US-2
(17)
TROUBLESHOOTING E-3
E-3 [E323] [E324] "Short circuit/Disconnection in accelerator relay sys-

tem" is displayed
Cause Remedy
1
operate dial (up). Is current value normal between NO
• 1.2A or less CR3 (female) (25) and (23)?
YES
2
• Detach R09 and CR3. Is resistance value normal between NO Defective harness; defective connector Repair or
• Min. 1 MΩ CR3 (female) (25) and body? CN-A09 replace
YES

PC128US-2 20-715
(17)
TROUBLESHOOTING E-3

20-716 PC128US-2
(17)
TROUBLESHOOTING E-4
E-4 [E325] [E326] "Short circuit/Disconnection in decelerator relay sys-

tem" is displayed
Cause Remedy
1
operate dial (down). Is current value normal between NO
• 1.2A or less. CR3 (female) (35) and (23)?
YES
2
• Detach R08 and CR3. Is resistance value normal between NO Repair or
• Min. 1 MΩ CR3 (female) (35) and body? Defective harness
replace
YES

PC128US-2 20-717
(17)
TROUBLESHOOTING E-4

20-718 PC128US-2
(17)
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.

Cause Remedy
• Turn starting switch ON. 1
• 4A or less if normal
When dialed up: Is current value normal between NO
(+) on (5) side, (–) on (6) side M48 (female) (5) (motor (+)) and
When dialed down: (6)(motor (–))?
(–) on (5) side, (+) on (6) side YES
Defective motor (drive system) Replace
motor
• Resistance value between
(1) and (2) of eachrelay:
290 Ω ± 10%
• Operation of each relay
(when starting switch is ON) 2
When neutral: Do relays of R07, R08 and R09 NO
(3) and (6) continue. operate normally? Defective relay Replace
When dialed up:
R07, and R09 (3) and (5)
YES
continue. Repair or
When dialed down: Defective harness; fuse (9) blown
replace
R07, and R08 (3) and (5)
continue.
PC128US-2 20-719
(17)
TROUBLESHOOTING E-5

20-720 PC128US-2
(17)
TROUBLESHOOTING E-6
E-6 [E308] "Abnormality in fuel dial input value" is displayed

! Check that the input value is normal in the monitoring mode.
Cause Remedy
1
• Fuel control dial voltage:
Fuel control dial FULL: 0.7 V Is fuel control dial voltage of NO
monitoring 1034 normal?
–
Fuel control dial SLOW: 4.3 V

YES
• Disconnect M51.
• M51 (male)
Between (1) – (2): 2
0.25 – 5 kΩ
Between (2) – (3): Is resistance between M51 (male) NO
Defective fuel control dial Replace
0.25 – 5 kΩ (1), (2), and (3) normal?
Between (1) – (3): 4 – 6 kΩ
• Between M51 (male) (1), (2), YES
(3) – chassis ground: Defective wiring harness Repair or
Min. 1 MΩ replace
PC128US-2 20-721
(17)
TROUBLESHOOTING E-7
E-7 [E227] "Abnormality in engine speed sensor system" Is displayed
Cause Remedy
• Turn starting switch OFF: 0 1

• Engine slow:
93 +50 (930 rpm) (*1) Is engine speed (monitoring code NO
110 ± 5 (1,100 rpm) (*2) 1010) normal?
• Engine full:
240 ± 5 (2,400 rpm) YES
2
• Detach E07 Is resistance value normal bet- NO Replace
Defective engine speed sensor
• 500 – 1,000 Ω ween E07 (male) (1) and (2)?
YES
3
• Detach CR2 Is resistance value normal bet- NO Replace
• 500 – 1,000 Ω ween CR2 (female) (39) and Defective harness motor
(40)?
YES Faulty installation of engine-speed Testing and
sensor adjusting



20-722 PC128US-2
(17)
TROUBLESHOOTING E-8
E-8 [E306] "Abnormality in motor feedback potentiometer input value" is

displayed
! Check that the input value is normal in the monitoring mode.
Cause Remedy
• Reset auto-decelerator.
• Feedback potentiometer 1
voltage:
Fuel control dial FULL: Is feedback potentiometer voltage NO
4.2 V (*1) of monitoring 1035 normal?
4.6 V (*2)
Fuel control dial SLOW: YES
2.1 V (*1)
2.7 V (*2)
• Disconnect M48.
• M48 (male)
Between (1) – (2): 2
0.36 – 3.9 kΩ
Between (2) – (3): Is resistance between M48 (male) NO
Defective decelerator motor Replace
1.4 – 5.5 kΩ (1), (2), and (3) normal?
Between (1) – (3): 5 ± 1 kΩ
• Between M48 (male) (1), (2), YES
(3) – chassis ground: Defective wiring harness Repair or
Min. 1 MΩ replace


PC128US-2 20-723
(17)
TROUBLESHOOTING E-8

20-724 PC128US-2
(17)
TROUBLESHOOTING E-9
E-9 [E258] "Short circuit in potentiometer power supply" is displayed
1 Cause Remedy
• Disconnect CR1.
• Resistance between CR1 Is resistance between CR1 (female) NO
(female) (22) – chassis (22) and chassis ground normal?
ground: Min. 1 MΩ
YES
2
• Disconnect M48.
ground: Min. 1 MΩ
YES
Defective deceleration motor Replace
3
• Disconnect M51.
• Resistance between CR1 Is resistance between CR1 (female) NO Defective wiring harness Repair or
(female) (22) – chassis (22) and chassis ground normal? (Short circuit in 5-V line) replace
ground: Min. 1 MΩ
YES
Defective fuel control dial Replace

PC128US-2 20-725
(17)
TROUBLESHOOTING E-9

20-726 PC128US-2
(17)
TROUBLESHOOTING E-10
E-10 [E304] [E314] "Short circuit/Disconnection in engine stop solenoid

relay system" is displayed
Cause Remedy
1
• Disconnect CR3.
ground: 68 Ω ± 10%
YES
• Disconnect M52. 2
• Resistance between M52 Are resistance between stop solenoid
(male) (1) – (2): 68 Ω ± 10% relay M52 (male) (1) and (2) and NO
resistance between each pin and Defective stop solenoid relay Replace
• Resistance between M52
(male) (1), (2) – chassis chassis ground normal?
ground: Min. 1 MΩ YES
• Disconnect D32 3
(with M52 disconnected). NO
Is resistance between CR3 (female) Defective wiring harness Repair or
• Resistance between CR3
(4) and chassis ground normal? (Grounding fault) replace
(female) (4) – chassis
ground: Min. 1 MΩ
YES
Defective diode (D03) Replace
PC128US-2 20-727
(17)
TROUBLESHOOTING E-11
E-11 Auto-decelerator does not operate

! Check the auto-decelerator reset input signal and each pressure switch input signal in the monitoring mode.
Cause Remedy
1
When auto-decelerator reset
switch is pressed; Is auto-decelerator reset switch NO
Defective monitor panel or controller Replace
• Bit (2): ON (Auto-decelerator of monitoring 1022 normal?
reset)
YES
Monitoring code [1023]
• Bit (1): OFF (Boom LOWER 2
pressure switch)
• Bit (3): OFF (Travel pressure Is each pressure switch signal of
switch) monitoring 1023 and 1028 nor- NO
• Bit (4): OFF (Swing pressure mal?
switch) YES
• Bit (5): OFF (Arm IN Defective controller Replace
pressure switch)
• Bit (6): OFF (Boom RAISE
pressure switch) 3
Monitoring code [1028] When pressure switch connector of
• Bit (1): OFF (Arm OUT abnormal part is disconnected,
NO Defective pressure switch
(Internal seizure) Replace
pressure switch) does bit keep lighting?
• Bit (2): OFF (Att, blade
RAISE/LOWER pressure YES Repair or
Defective wiring harness
switch) (Grounding fault in signal line) replace
• Bit (3): OFF (Bucket CURL
pressure switch)
• Bit (4): OFF (Bucket DUMP
pressure switch)
! The pressure switches for the blade and attachments are not shown in this figure.
20-728 PC128US-2
(17)
[PUMP CONTROL SYSTEM]
(C MODE)

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 T-
adapter, 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
TROUBLESHOOTING CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED
TABLE FOR DETERMINING CONTROLLER CR700 (PUMP CONTROL

SYSTEM) OR OIL PRESSURE IN RELATED
Controller CR700 (E2: XX type)
Results of self-diagnosis displayed
Abnormality in power supply of
Disconnection in travel speed

Short circuit in swing holding
Disconnection in swing hold-
Short circuit in 2-Stage relief

Short circuit in travel speed
ing brake solenoid system
selection solenoid system

Disconnection in PC-EPC
Disconnection in LS-EPC
Disconnection in 2-Stage
Short circuit in PC-EPC
Short circuit in LS-EPC

brake solenoid system
relief solenoid system

solenoid system
solenoid system
solenoid system
solenoid system
solenoid system
controller
User codes LED E02 E03 —
Failure mode Service codes off 232 233 203 213 206 216 205 215 222 223
Slower speed or reduced power of entire work equipment, traveling,
ment, traveling, and
Entire work-equip-
and swinging
Substantial drop of engine speed, or engine stop
swinging
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
Work-equipment
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
Compound
the time of operation.

operation
Boom moves slower in the case of the swing + boom (RAISE) oper-
ation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Traveling system
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)
Both R.H. and L.H.
Does not swing.
One side only
Worsened acceleration Both R.H. and L.H.
Swinging system
performance or speed
of swinging One side only
Both R.H. and L.H.
Greater drift when
swinging is stopped
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 C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
Diagnosis codes when abnormality was found by checking monitoring
— — — — — — — — — — —
codes
Items checked only by monitoring
20-808 PC128US-2
(17)
! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.

Controller CR700 Items to be checked in the monitoring mode
(E2: XX type)
Diagnosis codes when no service code is

Results of self diagno- Oil-pressure switch Status of solenoid in
sis displayed operation
Pump discharge pressure input

Abnormality in engine speed
Service pressure switch (2)

pressure sensor system
Swing holding brake (1)
PPC initial pressure (2)
PC-EPC current output
LS-EPC current output

Abnormality in pump
Engine speed input

Kerosene mode (6)
Boom LOWER (2)
Bucket DUMP (2)

Bucket CURL (2)
Boom RAISE (6)
2-stage relief (6)

sensor system
Arm OUT (2)

Traveling (3)
Swinging (4)
Model code
Arm IN (5)
Traveling
displayed
— Bit patterns Monitoring codes
224 227 1023 1021 1060 1002 1010 1042 1050 1054
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 F-6 F-7 F-8 F-9 F-10 — — — — — — — — —
PC128US-2 20-809
(17)

Controller CR700 (E2: XX type)
Results of self-diagnosis displayed
Abnormality in power supply of
Disconnection in travel speed

Disconnection in swing hold-
Short circuit in swing holding
Short circuit in 2-Stage relief

Short circuit in travel speed
ing brake solenoid system
Disconnection in PC-EPC
Disconnection in LS-EPC
Disconnection in 2-Stage
Short circuit in PC-EPC
Short circuit in LS-EPC

brake solenoid system
relief solenoid system

solenoid system
solenoid system
solenoid system
solenoid system
solenoid system
controller
User codes LED E02 E03 —
Failure mode Service codes off 232 233 203 213 206 216 205 215 222 223
Slower speed or reduced power of entire work equipment, traveling,
ment, traveling, and
Entire work-equip-
and swinging
Substantial drop of engine speed, or engine stop
swinging
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
Work-equipment
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
Compound
the time of operation.

operation
Boom moves slower in the case of the swing + boom (RAISE) oper-
ation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Traveling system
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)
Both R.H. and L.H.
Does not swing.
One side only
Worsened acceleration Both R.H. and L.H.
Swinging system
performance or speed
of swinging One side only
Both R.H. and L.H.
Greater drift when
swinging is stopped
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 C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
Diagnosis codes when abnormality was found by checking monitoring
— — — — — — — — — — —
codes
Items checked only by monitoring
20-810 PC128US-2
(17)
! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.

Controller CR700 Items to be checked in the monitoring mode
(E2: XX type)
Diagnosis codes when no service code is

Results of self diagno- Oil-pressure switch Status of solenoid in
sis displayed operation
Pump discharge pressure input

Abnormality in engine speed
Service pressure switch (2)

pressure sensor system
Swing holding brake (1)
PPC initial pressure (2)
PC-EPC current output
LS-EPC current output

Abnormality in pump
Engine speed input

Kerosene mode (6)
Boom LOWER (1)
Bucket DUMP (4)

Bucket CURL (3)
Boom RAISE (6)
2-stage relief (6)

sensor system
Arm OUT (1)

Traveling (3)
Swinging (4)
Model code
Arm IN (5)
Traveling
displayed
— Bit patterns Monitoring codes
224 227 1023 1028 1021 1060 1002 1010 1042 1050 1054
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 F-6 F-7 F-8 F-9 F-10 — — — — — — — — —
PC128US-2 20-811
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM

(1/2)
20-812 PC128US-2
(17)
(2/2)
PC128US-2 20-813
(17)

(1/2)
20-814 PC128US-2
(17)
(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 Remedy
2 YES
Is voltage normal
YES between CR3 (14),
1 (24) – (21), (31),
Is voltage normal (32), (33)? Disconnection or defective con- Repair or
between CR3 (1), tact of harnesses between CR3 replace
• Turn starting switch NO (14), (24) and CNM47 (3)
(11) and each (21),
(31), (32) and ON
(33)? • 20 – 30 V Disconnection or defective
contact between fuse (18) and
• Attach T-adapter CR3 (1),(11); Disconnection or Replace
• Turn starting switch NO defectivecontact between CR3 motor
OFF: 20 – 30 V (21),(31),(32),(33) and CN-A04
(12),(14)
C-1 Related electric circuit diagram

20-816 PC128US-2
(17)
TROUBLESHOOTING C-1

PC128US-2 20-817
(17)
TROUBLESHOOTING C-2
C-2 [E232] "Short circuit in PC-EPC solenoid system" is displayed

! Be sure to turn emergency pump drive switch to DOWN (normal).
Cause Remedy
YES
Ground fault or hot-short-circuit

2 of harness between CR3 (fe- Repair or
Do resistance values 4 YES male)(16) and C06 (female)(3);
between CR3 (fe- Do resistance val- or hot short circuit of harness replace
YES male)(16) and (23), ues between C06 between CR3 (female)(23) and
and between (16) (male) (2) and (3), C06 (female)(6).
and body match with YES between (5) and (6),
Table 1? and between C06
• Turn starting switch 3 (male) (2), (3), (5),
(6) and body match
1 OFF. Do resistance val- withTable 2? Defective emergency pump-
• Disconnect CR3. ues between C06 drive switch (inner ground Replace
Do resistance values • Attach directcoupled (female) (2) and (5), • Turn starting NO fault or hot short circuit)
between C13 (male) connector to NO and between (2) and switch OFF.
(1) and (2), and be- CN-D23 and D24. body match with Ta- • Disconnect C06.
tween (1) and body ble 1? • Turn emergency Ground fault or hot-short-cir-
match with Table 1? • Turn starting switch pump drive switch to cuit of harness between C06
OFF. DOWN (normal). (female)(2) and C13 (female); Repair or
• Turn starting switch or hot short circuit of harness
• Disconnect C06.
OFF. NO between C06 (female)(5) and replace
• Disconnect C13. C13 (female)(2).
• Defective PC-EPC solenoid
(internal short-circuit or Replace
NO ground fault)
• Defective diode
Table 1
Diagnosis No.2 Diagnosis No.3 Diagnosis No.4 Resistance
C13 (male) (1) – (2) CR3 (female) (16) – (23) C06 (female) (2) – (5) 8 – 15 Ω
C13 (male) (1) – body CR3 (female) (16) – body C06 (female) (2) – 2body Min. 1 M Ω
Table 2
Diagnosis No.5 Resistance
C06 (male) (2) – (3), (5) – (6) Max. 1 Ω
C06 (female) (2), (3), (5), (6) – body Min. 1 M Ω
20-818 PC128US-2
(17)
TROUBLESHOOTING C-2


PC128US-2 20-819
(17)
TROUBLESHOOTING C-3
C-3 [E233] "Disconnection in PC-EPC solenoid system" Is displayed

! If a solenoid or its harness was disconnected, current does not flow through the solenoid. If ground fault
occurs on the 2-pin side of the solenoid, current (about 1 A) remains to flow.
! Be sure to turn emergency-pump drive switch to DOWN (normal).
Cause Remedy
YES
Disconnection or defective con-

2 tact of harness between CR3
4 YES (female)(16) and C06 (fe- Repair or
Do resistance values male)(3); or disconnection, de-
between CR3 (fe- Do resistance val- fective contact or ground fault of replace
YES male) (16) and (23), ues between C06 harness between CR3 (fe-
and between (23) (male) (2) and (3), male)(23) and C06 (female)(6).
and body match with YES between (5) and (6)
Table 1? and between C06
• Turn starting switch 3 (male) (2), (3), (5),
(6) and body match Defective emergency pump-
1 OFF. Do resistance val- with Table 2?
ues between C06 drive switch (inner disconnec- Replace
• Disconnect CR3.
Do resistance values • Attach directcoupled (female) (2) and (5), • Turn starting NO tion, defective contact or
ground fault).
between C13 (male) connector to NO and between (2) and switch OFF.
(1) and (2), and be- CN-D23 and D24. body match with Ta- • Disconnect C06.
tween (2) and body ble 1? • Turn emergency Disconnection of defective con-
match with Table 1? pump drive switch to tact of harness between C06 (fe-
• Turn starting switch male)(2) and C13 (female); or
OFF. DOWN (normal). disconnection, defective contact Repair or
• Disconnect C06. or ground fault of harness be- replace
OFF. NO tween C06 (female)(5) and C06
• Disconnect C13. (female)(2).
• Defective PC-EPC solenoid
(internal short circuit or Replace
NO ground fault)
• Defective diode
Table 1
Diagnosis No.2 Diagnosis No.3 Diagnosis No.4 Resistance
C13 (male) (1) –(2) CR3 (female) (16) – (23) C06 (female) (2) – (5) 8 – 15 Ω
C13 (male) (1) – body CR3 (female) (16) – body C06 (female) (2) – 2body Min. 1 M Ω
Table 2
Diagnosis No.5 Resistance
C06 (male) (2) – (3), (5) – (6) Max.1 Ω
C06 (female) (2), (3), (5), (6) – body Min. 1 M Ω
20-820 PC128US-2
(17)
TROUBLESHOOTING C-3


PC128US-2 20-821
(17)
TROUBLESHOOTING C-4
C-4 [E203] "Short circuit in swing holding brake solenoid system" is dis-
played
! 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 Remedy
3 YES Defective controller CR700 Replace

Is resistance nor-
YES mal between CR3
(female)(7) and
2 body?
to A
Do resistance values • Turn starting switch NO
YES between V04 (male) OFF.
(1) and (2), and be- • Disconnect CR3.
1 tween (2) and body • Turn swing lock switch OFF.
Is [E203] displayed match with Table 1? • Attach a direct coupled con-
after replacing the • Turn starting nector to CN-D08.
solenoid and con- switch OFF. • 37 – 60 Ω
nector with other • Disconnect V04.
ones? NO
Defective swing-holding-brake
• Turn starting solenoid (inner short-circuit or Replace
switch OFF. NO ground fault)
• Replace V04 with
another one.
• Start engine. Ground fault of either harness
• Operate swing-lev- 5 YES connecting CR3 (female) (7) – Repair or
er or a lever of D08 (2), (1) to M47 (19), or (1) replace
work-equipment YES Is resistance normal to X05 (male)(3).
between X05 (male)
(for just a moment). 4 (4) and body? Ground fault of harness con-
Is resistance nor- necting X05 (male)(4) – M47 Repair or
mal between X05 • Turn starting switch NO (3) and then to V04 (female) replace
A (female) (3), (4) OFF. (2).
and body? • Disconnect X05.
• 37 – 60 Ω
• Turn starting switch Defective swing-lock switch
OFF. (inner short circuit) Replace
NO
• Disconnect X05.
• Turn swing lock switch OFF.
• Min. 1 M Ω
Table 1
V04 (male)(1) – (2) 37 – 60 Ω
V04 (male)(2) – body Min. 1 M Ω
20-822 PC128US-2
(17)
TROUBLESHOOTING C-4
PC128US-2 20-823
(17)
TROUBLESHOOTING C-4

! 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.)
check.
Cause Remedy

Is resistance nor-
YES mal between CR3
(female)(7) and
2 body?
to A
Do resistance values • Turn starting switch NO
YES between V4 (male) OFF.
(1) and (2), and be- • Disconnect CR3.
1 tween (2) and body • Turn swing lock switch OFF.
Is [E203] displayed match with Table 1? • Attach a direct coupled be-
after replacing the • Turn starting tween D02 (4) – (8).
solenoid and con- switch OFF. • 37 – 60 Ω
ones? NO
Defective swing-holding-brake
• Turn starting solenoid (inner short-circuit or Replace
switch OFF. NO ground fault)
• Replace V4 with
another one.
• Start engine. Ground fault of either harness
• Operate swing-lev- 5 YES connecting CR3 (female) (7) – Repair or
er or a lever of D02 (8), (4) to M47 (19) to replace
work-equipment YES Is resistance normal X05 (male)(3).
between X05 (male)
(for just a moment). 4 (4) and body? Ground fault of harness con-
Is resistance nor- necting X05 (male)(4) – M47 Repair or
mal between X05 • Turn starting switch NO (3) and then to V4 (female) replace
A (female) (3), (4) OFF. (2).
and body? • Disconnect X05.
• 37 – 60 Ω
• Turn starting switch Defective swing-lock switch
OFF. (inner short circuit) Replace
NO
• Disconnect X05.
• Turn swing lock switch OFF.
• Min. 1 M Ω
Table 1
V4 (male)(1) – (2) 37 – 60 Ω
20-824 PC128US-2
(17)
TROUBLESHOOTING C-4
PC128US-2 20-825
(17)
TROUBLESHOOTING C-5
C-5 [E213] "Disconnection in swing holding brake solenoid system" is

displayed
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 Remedy

Does resistance
YES between CR3 (fe-
2 male) (7) and body
match with Table 1?
YES Is resistance nor- • Turn starting switch NO
to A
mal between V04
ON.
1 (male)(1) and (2)? • Disconnect D08.
Is [E213] displayed
after replacing the • Turn starting
solenoid and con- switch OFF.
• Disconnect V04.
NO
nector with other
ones? • 37 – 60 Ω
• Turn starting switch Defective swing holding brake
OFF. solenoid (inner disconnection Replace
• Replace V04 with NO or hot short circuit)
another one.
• Turn starting switch ON. Disconnection or defective con-
6 YES tact of either harness connect- Repair or
ing D08 (female)(1) – M47 (19) replace
Is resistance nor-
or (1) – X05 (male)(3).
YES mal between CR3
5 (female) (7) and
D08 (female) (2)? Disconnection or defective
Is resistance nor- contact of harness between Repair or
YES mal between X05 • Turn starting NO CR3 (female)(7) and D08 (fe- replace
(male) (4) and switch OFF. male)(2).
4 body? • Disconnect D08, CR3.
Disconnection, defective con-
• Max. 1 Ω
Is resistance nor- tact or hot short circuit of ei- Repair or
mal between X05 • Turn starting ther harness connecting X05
A switch OFF. NO (male)(4) – M47 (20) or M47 replace
(female) (3) and
(4)? • Disconnect X05. (20) – V04 (female)(2).
• 37 – 60 ohm
• Turn starting Defective swing lock switch
switch OFF. (inner disconnection or hot Replace
• Disconnect X05. NO short circuit)
• Max.1 Ω
Table 1
Diagnosis No. 3 Voltage Measuring conditions
0 – 10 V 4 – 5 seconds after putting all levers to Neutral.
D08(1) – body
20 – 30 V When swing-lever or a lever of work equipment is operated (just for a moment)
20-826 PC128US-2
(17)
TROUBLESHOOTING C-5
PC128US-2 20-827
(17)
TROUBLESHOOTING C-5

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 Remedy

Does resistance
YES between CR3 (fe-
2 male) (7) and body
match with Table 1?
YES Is resistance nor- • Turn starting switch NO
to A
mal between V4
ON.
1 (male)(1) and (2)? • Disconnect D02.
Is [E213] displayed
• Disconnect V4.
NO
nector with other
ones? • 37 – 60 Ω
• Turn starting switch Defective swing holding brake
OFF. solenoid (inner disconnection Replace
• Replace V4 with NO or hot short circuit)
another one.
• Turn starting switch ON. Disconnection or defective con-
6 YES tact of either harness connect- Repair or
ing D02 (female)(8) – M47 (19) replace
Is resistance nor-
– X05 (male)(3).
YES mal between CR3
5 (female) (7) and
D02 (female) (8)? Disconnection or defective
Is resistance nor- contact of harness between Repair or
YES mal between X05 • Turn starting NO CR3 (female)(7) and D02 (fe- replace
(male) (4) and switch OFF. male)(8).
4 body? • Disconnect D02, CR3.
• Max. 1 Ω
Is resistance nor- tact or hot short circuit of ei- Repair or
mal between X05 • Turn starting ther harness connecting X05
A switch OFF. NO (male)(4) – M47 (20) or M47 replace
(female) (3) and
(4)? • Disconnect X05. (20) – V4 (female)(2).
• 37 – 60 ohm
• Turn starting Defective swing lock switch
switch OFF. (inner disconnection or hot Replace
• Disconnect X05. NO short circuit)
• Max.1 Ω
Table 1
Diagnosis No. 3 Voltage Measuring conditions
0 – 10 V 4 – 5 seconds after putting all levers to Neutral.
D02(8) – body
20 – 30 V When swing-lever or a lever of work equipment is operated (just for a moment)
20-828 PC128US-2
(17)
TROUBLESHOOTING C-5
PC128US-2 20-829
(17)
TROUBLESHOOTING C-6
C-6 [E206] "Short circuit in travel Hi/Lo selection solenoid system" is

displayed
Cause Remedy
3 YES Defective engine throttle and

Replace
pump controller
YES Is resistance nor-
2 mal between CR3
Ground fault of harness con-
Do resistance val- (female)(27) and
body? necting CR3 (female)(27) – Repair or
ues between V05 A08 (1) and then to V05 (fe-
YES (male)(1) and (2), replace
• Turn starting NO male)(2); or continuing diode
and between (2) switch OFF.
1 and body, match • Disconnect CR3.
D07.
Is [E206] displayed with Table 1? • 37 – 60 Ω
solenoid and con- switch OFF. NO
ones?
• Turn starting switch Defective travel-Hi/Lo selec-
OFF. tion solenoid (inner short cir- Replace
• Replace V05 with NO cuit or ground fault)
another one.
• Start engine.
• Turn travel-speed
switch to "Mi" or
"Hi".
• Operate travel lever
just for a moment.
Table 1
V05 (male)(1) – (2) 37 – 60 Ω
20-830 PC128US-2
(17)
TROUBLESHOOTING C-6

Cause Remedy

Replace
pump controller
YES Is resistance nor-
2 mal between CR3
Do resistance val- (female)(27) and Ground fault of harness con-
ues between V5 body? necting CR3 (female)(27) – V5 Repair or
YES (male)(1) and (2), (female)(2); or continuing di- replace
• Turn starting NO
and between (2) switch OFF. ode D01(1) – (5).
1 and body, match • Disconnect CR3.
Is [E206] displayed with Table 1? • 37 – 60 Ω
solenoid and con- switch OFF. NO
ones?
• Turn starting switch Defective travel-Hi/Lo selec-
OFF. tion solenoid (inner short cir- Replace
• Replace V5 with NO cuit or ground fault)
another one.
• Start engine.
• Turn travel-speed
switch to "Mi" or
"Hi".
• Operate travel lever
just for a moment.
Table 1
V5 (male)(1) – (2) 37 – 60 Ω
PC128US-2 20-831
(17)
TROUBLESHOOTING C-7
C-7 [E216] "Disconnection in travel Hi/Lo selection solenoid system" is

displayed
Cause Remedy

Replace
Is resistance nor- pump-controller
YES mal between CR3
2 (female) (27) and Disconnection or defective
body? contact of harness connecting Repair or
YES Is resistance be- CR3 (female) (27) – A08 (1)
tween V05 (male) • Turn starting NO and then – V05 (female) (2), replace
switch OFF.
1 (1) and (2) normal?
• Disconnect CR3.
or V05 (female) (1) to body.
Is [E216] displayed
• Turn starting • 37 – 60 Ω
after replacing the
nector with other
ones? • 37 – 60 Ω
• Turn starting switch Defective travel-speed sole-
OFF. noid (inner disconnection or Replace
• Replace V03 with NO hot short circuit)
another one.
ON.
20-832 PC128US-2
(17)
TROUBLESHOOTING C-7

Cause Remedy

Replace
Is resistance nor- pump-controller
YES mal between CR3
2 (female) (27) and Disconnection or defective
body? contact of harness connecting Repair or
YES Is resistance be- CR3 (female) (27) – A08 (1)
tween V5 (male) • Turn starting NO and then – V5 (female) (2), or replace
switch OFF.
1 (1) and (2) normal? • Disconnect CR3.
V5 (female) (1) to body.
Is [E216] displayed
• Turn starting • 37 – 60 Ω
after replacing the
nector with other
ones? • 37 – 60 Ω
• Turn starting switch Defective travel-speed sole-
another one.
ON.
PC128US-2 20-833
(17)
TROUBLESHOOTING C-8
C-8 [E205] "Short circuit in 2-stage relief solenoid system" is displayed

Cause Remedy
3 YES
Is resistance nor-
YES mal between CR3
2 (female) (28) and
Do resistance values body? Ground fault of harness be-
YES between V06 (male) tween CR3 (female) (28) and Repair or
(1) and (2) and be- • Turn starting NO V06 (female) (2) replace
switch OFF.
1 tween (2) and body • Disconnect CR3.
match with Table 1?
Is [E205] displayed • Turn starting switch • 37 – 60 Ω
after replacing the
solenoid and con- OFF.
nector with other
ones?
• Turn starting switch Defective 2-stage relief sole-
OFF. noid (inner short-circuit or Replace
• Replace V06 with NO ground fault)
another one.
• Start engine.
• Turn on swing lock
switch.
Table 1
V06 (male)(1) – (2) 37 – 60 Ω
20-834 PC128US-2
(17)
TROUBLESHOOTING C-8

Cause Remedy
3 YES
Is resistance nor-
YES mal between CR3
2 (female) (28) and
Do resistance values body? Ground fault of harness be-
YES between V6 (male) tween CR3 (female) (28) and Repair or
(1) and (2) and be- • Turn starting NO V6 (female) (2) replace
switch OFF.
1 tween (2) and body
• Disconnect CR3.
match with Table 1?
Is [E205] displayed • Turn starting switch • 37 – 60 Ω
after replacing the
nector with other
ones?
OFF. noid (inner short-circuit or Replace
• Replace V6 with NO ground fault)
another one.
• Start engine.
• Turn on swing lock
switch.
Table 1
V6 (male)(1) – (2) 37 – 60 Ω
PC128US-2 20-835
(17)
TROUBLESHOOTING C-9
C-9 [E215] "Disconnection in 2-stage relief solenoid system" is

displayed
Cause Remedy
3 YES
Is resistance nor-
YES mal between CR3
2 (female) (28) and
tact or hot short circuit of har-
body? ness between CR3 (female) Repair or
YES Is resistance bet- • Turn starting switch NO
(28) and V06 (female) (2), or replace
ween V06 (male) (1) between V06 (female) (1) and
1 and (2) normal? OFF. body.
• Disconnect CR3.
Is [E215] displayed
• Turn starting switch • 37 – 60 Ω
after replacing the
nector with other
ones? • 37 – 60 Ω
another one.
ON.
20-836 PC128US-2
(17)
TROUBLESHOOTING C-9

Cause Remedy
3 YES
Is resistance nor-
YES mal between CR3
2 (female) (28) and Disconnection, defective con-
body? tact or hot short circuit of har-
YES Is resistance bet- ness between CR3 (female) Repair or
ween V6 (male) (1) • Turn starting switch NO (28) and V6 (female) (2), or be- replace
OFF. tween V6 (female) (1) and body.
1 and (2) normal?
• Disconnect CR3.
Is [E215] displayed
• Turn starting switch • 37 – 60 Ω
after replacing the
nector with other
ones? • 37 – 60 Ω
another one.
ON.
PC128US-2 20-837
(17)
TROUBLESHOOTING C-10
C-10 [E222] "Short circuit in LS-EPC solenoid system" is displayed
Cause Remedy
2 YES
Do resistance val-
ues between CR3
YES (female) (6) and (13)
and between (6) and Ground fault or hot short cir-
1 body match with Ta- cuit of harnessbetween CR3
Do resistance values ble 1? (female) (6) and C14 (female) Repair or
between C14 (male) (1), or hot short circuit of har- replace
• Turn starting switch NO ness between CR3 (female)
(1) and (2) and be- OFF.
tween (1) and body (13) and C14 (female)(2).
• Disconnect CR3.
match with Table 1?
• Turn starting switch Defective LS-EPC solenoid
OFF. (inner ground fault or hot short Replace
• Disconnect C14. NO circuit)
Table 1
Diagnosis No.1 Diagnosis No.2 Resistance
C14 (male) (1) – (2) CR3 (female) (6) – (13) 8 – 15 Ω
C14 (male) (1) – body CR3 (female) (6) – body Min. 1 M Ω


20-838 PC128US-2
(17)
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 Remedy
2 YES
Do resistance val-
ues between CR3
YES (female) (6) and (13)
Disconnection or defective con-
1 and between (13)
tact of harness between CR3
and body match with
Do resistance val- Table 1? (female)(6) and C14 (female) Repair or
ues between C14 (1); or disconnection, defective replace
(male) (1) and (2) • Turn starting switch NO contact, or ground fault of har-
and between (2) and OFF. ness between CR3 (female)
body match with Ta- • Disconnect CR3. (13) and C14 (female) (2).
ble 1?
• Turn starting switch Defective LS-EPC solenoid
OFF. (inner ground fault or hot short Replace
NO circuit)
• Disconnect C14.
Table 1
Diagnosis No.1 Diagnosis No.2 Resistance
C14 (male) (1) – (2) CR3 (female) (6) – (13) 8 – 15 Ω
C14 (male) (1) – body CR3 (female) (13) – body Min. 1 M Ω


PC128US-2 20-839
(17)
C-12 [E224] "Abnormality in pump pressure sensor system" is displayed
Cause Remedy

YES CR1
(13) – (21)
Disconnection, ground fault or
Repair or
2 • Turn starting switch NO
hot short circuit between C05
replace
(C) and CR1 (13).
OFF.
YES C05 • Attach T-adapter.
(C) – (A) • Run engine at full speed.
• Repeat operations:
1 arm excavation relief
• Run engine at full
T-adapter (B) – (C) speed. Neutral lever.
to C05 of pump • Repeat operations: • 0.5 – 4.5 V Defective pump pressure sen-
Replace
pressure sensor? arm-excavation relief NO sor)
• Turn starting switch Neutral lever. • Defective controller CR700

• 0.5 – 4.5 V • Disconnection, ground fault or
OFF. hot short circuit between CR3 Repair or
• Attach T-adapter. CR3 (22) and C05 (B)
• Run engine at full NO replace
• Disconnection between CR3
speed. (21) and C05 (C)
•5V


20-840 PC128US-2
(17)
C-13 [E227] "Abnormality in engine speed sensor system" Is displayed
Cause Remedy
2 YES
Is resistance be-
YES tween CR2 (female) Disconnection, defective con-
1 (40) and (39) nor- tact or ground fault of harness
mal? between CR2(female)(40) and Repair or
Is resistance be- E07 (female) (1), or between replace
tween E07 (male) • Turn starting switch NO
CR2 (female)(39) and E07 (fe-
(1) and (2) normal? OFF. male)(2).
• Disconnect CR2.
• 500 – 1000 Ω Defective engine speed sensor
• Turn starting switch (inner disconnection, defective Replace
OFF. NO contact or ground fault).
• Disconnect E07.
• 500 – 1000 Ω


PC128US-2 20-841
(17)
[INPUT SIGNAL SYSTEM]
(F MODE)

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

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

20-902 PC128US-2
(17)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM

PC128US-2 20-903
(17)
TROUBLESHOOTING F-1
F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON

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 Remedy
• Detach S08.
• Start engine. 1
• Put swing lever in Neutral: Is resistance between S08 (male)
(1) and (2) normal? NO
Min. 1 M Ω Defective L.H. swing pressure switch Replace
• Operate swing lever for L.H. Is the connection insulated from
swinging: Max. 1 Ω body?
• Refer to Note. YES
• Detach S30. 2
• Start engine.
Min. 1 M Ω Defective R.H. swing pressure switch Replace
Is the connection insulated from
• Operate swing lever for body?
R.H. swinging: Max.1 Ω
3
• Turn starting switch OFF. Are resistance values between Disconnection, defective contact or
• Detach S08 and S30 from CR1 (female) (24) and each of NO ground fault of harness between CR1 Repair or
CR1. S08 and S30 (female) (2) normal?
(female)(24) and S08 (female)(2) or replace
• CR1 – S08/S30: Max.1 Ω Are the connections insulated
S30 (female)(2).
• Harness – body: Min. 1 M Ω from body?
YES
4
• Start engine.
• Put swing-lever in Neutral: Is voltage between CR1(24) and NO Defective controller CR700 Replace
20 – 30 V body normal?
• Operate swing lever:
Max. 1 V YES
5
• Start engine. Is voltage between CR1(24) and NO Disconnection or defective contact of
• Operate swing lever: body normal? harness between S08 (female)(1) or Repair or
S30 (female)(1) and body GND. replace
Max.1 V
YES
[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 PC128US-2
(17)
TROUBLESHOOTING F-1
F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON

Turn on swing-lock switch before operating swing lever (even if just for a moment).
Cause Remedy
• Detach S08.
• Start engine. 1
Min. 1 M Ω Defective L.H. swing pressure switch Replace
• Operate swing lever for L.H. Is the connection insulated from
swinging: Max. 1 Ω body?
• Detach S30. 2
• Start engine.
Min. 1 M Ω Defective R.H. swing pressure switch Replace
• Operate swing lever for body?
R.H. swinging: Max.1 Ω
3
• Turn starting switch OFF. Are resistance values between Disconnection, defective contact or
• Detach S08 and S30 from CR3 (female) (30) and each of NO ground fault of harness between CR3 Repair or
CR3. S08 and S30 (female) (2) normal?
(female)(30) and S08 (female)(2) or replace
• CR3 – S08/S30: Max.1 Ω Are the connections insulated
S30 (female)(2).
• Harness – body: Min. 1 M Ω from body?
YES
4
• Start engine.
• Put swing-lever in Neutral: Is voltage between CR3(30) and NO Defective controller CR700 Replace
20 – 30 V body normal?
• Operate swing lever:
Max. 1 V YES
5
• Start engine. Is voltage between CR3(24) and NO Disconnection or defective contact of
• Operate swing lever: body normal? harness between S08 (female)(1) or Repair or
S30 (female)(1) and body GND. replace
Max.1 V
YES
PC128US-2 20-905
(17)
TROUBLESHOOTING F-2
F-2 Bit-pattern 1023-(3) Travel pressure switch is not turned ON

Look around to be sure of safety before operating travel lever (even if just for a moment).
Cause Remedy
• Detach S01. 1
• Start engine.
• Put travel lever in Neutral: Is resistance between S01 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective travel pressure switch Replace
• Operate travel lever: nection insulated from body?
Max. 1 Ω
• Refer to Note.
YES
2
• Detach S01 from CR1. Is resistance between CR1 (fe-
male)(18) and S01 (female)(2) NO Disconnection, defective contact or
• Between CR1 and S01: ground fault of harness between CR1 Repair or
Max. 1 Ω normal? Is the connection insulat- replace
ed from body? (female) (18) and S01 (female) (2)
• Between harness and body:
Min. 1 M Ω YES
3
• Start engine. Is voltage between CR1(18) and NO
• Put swing lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
4
• Start engine. Disconnection or defective contact of
• Operate travel lever: Is voltage between CR1(18) and NO harness between S01 (female) (1) and Repair or
body normal? body GND. replace
Max. 1 V
YES
20-906 PC128US-2
(17)
TROUBLESHOOTING F-2
F-2 Bit-pattern 1023-(3) Travel pressure switch is not turned ON

Look around to be sure of safety before operating travel lever (even if just for a moment).
Cause Remedy
• Detach S01. 1
• Start engine.
• Put travel lever in Neutral: Is resistance between S01 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective travel pressure switch Replace
• Operate travel lever: nection insulated from body?
Max. 1 Ω
• Refer to Note.
YES
2
• Detach S01 from CR3. Is resistance between CR3 (fe-
male)(40) and S01 (female)(2) NO Disconnection, defective contact or
• Between CR3 and S01: ground fault of harness between CR3 Repair or
Max. 1 Ω normal? Is the connection insulat- replace
ed from body? (female) (40) and S01 (female) (2)
• Between harness and body:
Min. 1 M Ω YES
3
• Start engine. Is voltage between CR3(40) and NO
• Put swing lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
4
• Start engine. Disconnection or defective contact of
• Operate travel lever: Is voltage between CR3(40) and NO harness between S01 (female) (1) and Repair or
body normal? body GND. replace
Max. 1 V
YES
PC128US-2 20-907
(17)
TROUBLESHOOTING F-3
F-3 Bit-pattern 1023-(2) Boom LOWER pressure switch is not turned ON

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.
Is resistance between CR1 (5) NO
• Put boom lever in Neutral: Defective controller CR700 Replace
and body normal?
20 – 30 V
YES
2
• Start engine.
• Put boom lever in LOWER: Is resistance between CR1 (5) NO
Max. 1 V and body normal?
YES
• Disconnect S33. 3
• Start engine.
• Put boom lever in Neutral: Is resistance between S33 (male) NO
Defective boom LOWER pressure
Min. 1 M Ω (1) and (2) normal? Is the con-
switch
Replace
• Put boom lever in LOWER: nection insulated from body?
Max. 1 Ω YES
• Refer to Note.
• Turn starting switch OFF. 4

• Disconnect S33 from CR1. Is resistance between CR1 (fe-
• Between CR1 and S33: male) (5) and S33 (female) (2) NO Disconnection, defective contact or
Max. 1 Ω normal? Is the connection insu- ground fault of harness between CR1 Repair or
(female)(5) and S33 (female)(2). replace
• Between harness and body: lated from body?
Min. 1 M Ω YES Disconnection or defective contact of
Repair or
harness between S33 (female)(1) and
replace
body GND.
• if it is Max. 1 V, go to NO.
20-908 PC128US-2
(17)
TROUBLESHOOTING F-3
F-3 Bit-pattern 1023-(1) Boom LOWER pressure switch is not turned ON

Cause Remedy
1
• Start engine.
• Put boom lever in Neutral: Defective controller CR700 Replace
and body normal?
20 – 30 V
YES
2
• Start engine.
• Put boom lever in LOWER: Is resistance between CR1 (18) NO
YES
• Start engine.
Defective boom LOWER pressure
Min. 1 M Ω (18) and (2) normal? Is the con-
switch
Replace
• Put boom lever in LOWER: nection insulated from body?
Max. 1 Ω YES
• Refer to Note.

(female)(18 ) and S33 (female)(2). replace
Repair or
replace
body GND.
PC128US-2 20-909
(17)
TROUBLESHOOTING F-4
F-4 Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON

Cause Remedy
1
• Start engine.
• Put boom lever in Neutral: Is resistance between CR1 (12) NO Defective controller CR700 Replace
20 – 30 V and body normal?
YES
2
• Start engine.
• Put boom lever in RAISE:
and body normal?
Max. 1 V
YES
• Start engine.
Min. 1 M Ω Defective boom RAISE pressure
(1) and (2) normal? Is the connec- Replace
• Put boom lever in RAISE: switch
tion insulated from body?
Max. 1 Ω
YES
• Refer to Note.

4
• Between CR1 and S31: Disconnection, defective contact or
male) (12) and S31 (female) (2) NO
Max. 1 Ω ground fault of harness between CR1 Repair or
normal? Is the connection insulat- replace
• Between harness and body: (female)(12) and S31 (female)(2).
ed from body?
Min. 1 M Ω
harness between S31 (female)(1) and replace
body GND.
• if it is Max.1 V, go to NO.
20-910 PC128US-2
(17)
TROUBLESHOOTING F-4
F-4 Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON

Cause Remedy
1
• Start engine.
• Put boom lever in Neutral: Is resistance between CR1 (24) NO Defective controller CR700 Replace
YES
2
• Start engine.
• Put boom lever in RAISE:
and body normal?
Max. 1 V
YES
• Start engine.
Min. 1 M Ω Defective boom RAISE pressure
(1) and (2) normal? Is the connec- Replace
• Put boom lever in RAISE: switch
tion insulated from body?
Max. 1 Ω
YES
• Refer to Note.

4
• Between CR1 and S31: Disconnection, defective contact or
male) (24) and S31 (female) (2) NO
Max. 1 Ω ground fault of harness between CR1 Repair or
normal? Is the connection insulat- replace
• Between harness and body: (female)(24) and S31 (female)(2).
ed from body?
Min. 1 M Ω
harness between S31 (female)(1) and replace
body GND.
• if it is Max.1 V, go to NO.
PC128US-2 20-911
(17)
TROUBLESHOOTING F-5
F-5 Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON

Cause Remedy
1
• Start engine.
• Put arm lever in Neutral: Is resistance between CR1 (6) NO
YES
2
• Start engine.
• Put arm lever in IN: Is resistance between CR1 (6) NO
YES
• Disconnect S05.
• Start engine.
3
• Put arm lever in Neutral: Is resistance between S05 (male) NO
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm IN pressure switch Replace
• Put arm lever in IN: nection insulated from body?
Max. 1 Ω

(female) (6) and S05 (female) (2). replace
Min. 1 M Ω Disconnection or defective contact of
YES
harness between S05 (female)(1) and Repair or
body GND. replace
20-912 PC128US-2
(17)
TROUBLESHOOTING F-5
F-5 Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON

Cause Remedy
1
• Start engine.
• Put arm lever in Neutral: Is resistance between CR1 (12) NO
YES
2
• Start engine.
• Put arm lever in IN: Is resistance between CR1 (12) NO
YES
• Disconnect S05.
• Start engine.
3
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm IN pressure switch Replace
• Put arm lever in IN: nection insulated from body?
Max. 1 Ω

(female) (12) and S05 (female) (2). replace
Min. 1 M Ω Disconnection or defective contact of
YES
body GND. replace
PC128US-2 20-913
(17)
TROUBLESHOOTING F-6
F-6 Bit-pattern 1023-(2) Arm OUT pressure switch is not turned ON

Cause Remedy
1
• Start engine. Is resistance between CR1 (5) NO
• Put arm-lever in Neutral: and body normal? Defective controller CR700 Replace
20 – 30 V
YES
2
• Start engine.
• Put arm lever in OUT: Is resistance between CR1 (5) NO
YES
• Disconnect S32.
• Start engine.
3
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm OUT pressure switch Replace
• Put arm lever in OUT: nection insulated from body?
Max. 1 Ω

• DisconnectS32 from CR1. Is resistance between CR1 (fe-
male) (5) and S32 (female) (2) NO Disconnection, defective contact or Repair or
• Between CR1 and S32: ground fault of harness between CR1 replace
Max. 1 Ω normal? Is the connection insulat-
(female)(5) and S32 (female)(2).
• Between harness and body: ed from body?
Repair or
replace
body GND.
20-914 PC128US-2
(17)
TROUBLESHOOTING F-6
F-6 Bit-pattern 1028-(1) Arm OUT pressure switch is not turned ON

Cause Remedy
1
• Start engine. Is resistance between CR1 (6) NO
• Put arm-lever in Neutral: and body normal? Defective controller CR700 Replace
20 – 30 V
YES
2
• Start engine.
• Put arm lever in OUT: Is resistance between CR1 (6) NO
YES
• Disconnect S32.
• Start engine.
3
Min. 1 M Ω (1) and (2) normal? Is the con- Defective arm OUT pressure switch Replace
• Put arm lever in OUT: nection insulated from body?
Max. 1 Ω

• DisconnectS32 from CR1. Is resistance between CR1 (fe-
male) (6) and S32 (female) (2) NO Disconnection, defective contact or Repair or
• Between CR1 and S32: ground fault of harness between CR1 replace
Max. 1 Ω normal? Is the connection insulat-
(female)(6) and S32 (female)(2).
• Between harness and body: ed from body?
Repair or
replace
body GND.
PC128US-2 20-915
(17)
TROUBLESHOOTING F-7
F-7 Bit-pattern 1023-(2) Bucket CURL pressure switch is not turned ON

Cause Remedy
1
• Start engine. Is voltage between CR1 (5) and NO
• Put bucket lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in CURL: Is voltage between CR1 (5) and NO
Max. 1 V body normal?
YES
• Start engine. Is resistance between S34 (male)
• Put bucket lever in Neutral: (1) and (2) normal? NO
Min.1 Mz Defective bucket CURL pressure
Is the connection insulated from Replace
• Put bucket lever in CURL: switch
body?
Max. 1 z
4
• Turn starting switch OFF. Is resistance between CR1 (fe-
• Disconnect S34 from CR1. male) (5) and S34 (female) (2) NO Disconnection, defective contact or Repair or
• Between CR1 and S34: normal? ground fault of harness between CR1 replace
Max. 1 z Is the connection insulated from (female) (5) and S34 (female) (2).
• Between harness and body: body?
Min. 1 Mz
body GND. replace
20-916 PC128US-2
(17)
TROUBLESHOOTING F-7
F-7 Bit-pattern 1028-(3) Bucket CURL pressure switch is not turned ON

Cause Remedy
1
• Start engine. Is voltage between CR3 (10) and NO
• Put bucket lever in Neutral: Defective controller CR700 Replace
body normal?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in CURL: Is voltage between CR3 (10) and NO
YES
Min.1 Mz Defective bucket CURL pressure
Is the connection insulated from Replace
• Put bucket lever in CURL: switch
body?
Max. 1 z
4
• Disconnect S34 from CR3. male) (10) and S34 (female) (2) NO Disconnection, defective contact or Repair or
• Between CR3 and S34: normal? ground fault of harness between CR3 replace
Max. 1 z Is the connection insulated from (female) (10) and S34 (female) (2).
Min. 1 Mz
body GND. replace
PC128US-2 20-917
(17)
TROUBLESHOOTING F-8
F-8 Bit-pattern 1023-(2) Bucket DUMP pressure switch is not turned ON

Cause Remedy
1
• Start engine.
Is voltage between CR1 (5) and NO Defective controller CR700
• Put bucket lever in Neutral: Replace
body?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in Dump: Is voltage between CR1 (5) and NO
YES
Min.1 Mz Defective bucket Dump pressure Replace
Is the connection insulated from switch
• Put bucket lever in Dump: body?
Max. 1 z
4
• Disconnect S35 from CR1. male) (5) and S35 (female) (2) NO Disconnection, defective contact or
• Between CR1 and S35: normal? ground fault of harness between CR1 Replace
Max. 1 z Is the connection insulated from (female) (5) and S35 (female) (2). motor
Min. 1 Mz
harness between S35 (female) (2) and Repair or
body GND. replace
20-918 PC128US-2
(17)
TROUBLESHOOTING F-8
F-8 Bit-pattern 1028-(4) Bucket DUMP pressure switch is not turned ON

Cause Remedy
1
• Start engine.
Is voltage between CR3 (20) and NO Defective controller CR700 Replace
• Put bucket lever in Neutral:
body?
20 – 30 V
YES
2
• Start engine.
• Put bucket lever in Dump: Is voltage between CR3 (20) and NO
YES
Min.1 Mz Defective bucket Dump pressure Replace
Is the connection insulated from switch
• Put bucket lever in Dump: body?
Max. 1 z
4
• Disconnect S35 from CR3. male) (20) and S35 (female) (2) NO Disconnection, defective contact or
• Between CR3 and S35: normal? ground fault of harness between CR3 Replace
Max. 1 z Is the connection insulated from (female) (20) and S35 (female) (2). motor
Min. 1 Mz
harness between S35 (female) (2) and Repair or
body GND. replace
PC128US-2 20-919
(17)
TROUBLESHOOTING F-9
F-9 Bit-pattern 1023-(2) Service pressure switch is not turned ON

ATT is caused.
Cause Remedy
1
• Start engine.
• Put swing lever in Neutral: Is voltage between CR1 (5) and NO
20 – 30 V body?
• Operate swing lever: Max. 1 V
YES
• Start engine.
• Put ATT-pedal in Neutral: Is resistance between S40 (male)
Min.1 MΩ (1) and (2) normal? NO
Is the connection insulated from Defective service (front) pressure switch Replace
• Operate ATT pedal service
(front) pressure switch: body?
Max. 1 Ω YES
• Refer to Note.
• Start engine.
Is resistance between S41 (male)
• Put ATT-pedal in Neutral:
Max.1 MΩ Defective service (rear) pressure switch Replace
• Operate ATT pedal service
body?
(front) pressure switch:
Max. 1 Ω YES
• Refer to Note.
4
• Turn starting switch OFF. Are resistance values between CR1 Disconnection, defective contact or Replace
• Disconnect S40 and S41 (female) (5) and each of S40 and NO ground fault of harness between CR1 motor
from CR1. S41 (female) (2) normal? (female) (5) and S40(female)(2) or S41
• Between CR1 and S40, S41: Are the connections insulated from (female)(2).
Max. 1 Ω body?
• Harness body: Min. 1 MΩ
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,
• f it is Max. 1 V, go to NO.
20-920 PC128US-2
(17)
TROUBLESHOOTING F-9
F-9 Bit-pattern 1028-(2) Service pressure switch is not turned ON

blade is caused.
Cause Remedy
1
• Start engine.
• Put swing lever in Neutral: Is voltage between CR3 (9) and NO
20 – 30 V body?
• Operate swing lever: Max. 1 V
YES
• Start engine.
• Put blade lever in Neutral: Is resistance between S38 (male)
Min.1 MΩ (1) and (2) normal? NO
Is the connection insulated from Defective blade LOWER pressure switch Replace
• Operate blade LOWER
pressure switch: body?
Max. 1 Ω YES
• Refer to Note.
• Start engine.
Is resistance between S41 (male)
• Put blade lever in Neutral:
Max.1 MΩ Defective blade RAISE pressure switch Replace
• Operate blade RAISE (front)
body?
pressure switch:
Max. 1 Ω YES
• Refer to Note.
4
• Turn starting switch OFF. Are resistance values between CR3 Disconnection, defective contact or Replace
• Disconnect S38 and S39 (female) (9) and each of S38 and NO ground fault of harness between CR3 motor
from CR3. S39 (female) (2) normal? (female) (9) and S38(female)(2) or S39
• Between CR3 and S40, S41: Are the connections insulated from (female)(2).
Max. 1 Ω body?
• Harness body: Min. 1 MΩ
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,
• f it is Max. 1 V, go to NO.
PC128US-2 20-921
(17)
TROUBLESHOOTING F-10
F-10 Bit-pattern 1021-(6) Kerosene mode connection is not turned ON

★ Shown below is the case where a harness for Kerosene mode is connected (M36M(1) and M36F(1) are
connected).
Cause Remedy
1
• Turn starting switch ON. Disconnection or defective contact of
• S Harness for Kerosene mode:
IIs voltage between CR2 (6) and NO harness between CR2 (female) (6) and Repair or
Connected: 20 – 30 V
Open: Max. 1 V
body normal? (Max. 1V ) fuse (1) in the harness for kerosene replace
mode.
• Max. 1
YES (20 – 30 V)
20-922 PC128US-2
(17)
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)
METHOD OF USING TROUBLE-

SHOOTING CHARTS
This troubleshooting chart is divided into three sec-
tions: 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 us-
ing 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 corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from Causes
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 (b) (2) (3)
[Check items].
(a) w
Questions
A (b) w
(c) w
(d) c
(e) c
Check items
B
C
i b
shooting
Trouble-
ii b
iii b
20-952 PC128US-2
(14)
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 prob-
ability are marked with T.
Check each of the [Questions] and [Check items] in
turn, and marked the ! or T in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
ª1. For [Confirm recent repair history] in the Causes
[Questions] Section, ask the user, and mark
the Cause column with # to use as reference
n)
for locating the cause of the failure. How-
ctio
ever, do not use this when making calcula-
inje
tions to narrow down the causes.
sive
e
ª2. Use the # in the Cause column as reference
renc
xces
zzle
for [Degree of use (Operated for long pe-
n no
erfe
p (e
e
ing
inde
lem
riod)] in the [Questions] section as reference.
, int
ctio
pum
n tim
er e
As a rule, do not use it when calculating the
, cyl
rger
inje
ion
lean
points for locating the cause, but it can be
ctio
ring
cha
zed
ject
e
included if necessary to determine the order
air c
urbo
, sei
ston
r inj
e in
for troubleshooting.
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
ª1 Confirm recent repair history
ª2 Degree of use Operatred for long period
PC128US-2 20-953
(14)
• 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 Causes
• Insufficient intake of air
• Improper condition of fuel injection
d)
ead
n)
eize
• Excessive injection of fuel
ctio
nd h
er s
inje
er a
lung
at
sive
e se
harg
ck, p
elem rence
xces
n tim nozzle
valv
boc
p (ra
ent
terfe
p (e
r
lve,
r
n tu
ing
fler
ce
nde
tion
pum
pum
r, in
aran
f va
muf
e
, cyli
e
rope ized inje
etw
n pis cleaner
arge
ion
ct o
le
rope jection
d
ctio
ring
c
e
ject
air b
a
lve
logg
Clog urboch
t
inje
con
Legend
e in
ton
r va
, se
in
air
e of
: Possible causes (judging from Questions and check items)
d, c
r
e
e
ectiv
ged
ged
ctiv
ctiv
ed t
: Most probable causes (judging from Questions and Check items)
she
kag
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Wor
Seiz
Deff
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
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
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating
Troubleshooting
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
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-954 PC128US-2
(14)
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
Causes
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of -10ºC or below,
ASTM D975 No. 2 diesel fuel is used)
t
elem alve sea
fl Battery charging rate
lter
Ambient Charging rate
100 % 90 % 80 % 75 % 70 %
ve, v
ze fi
ent
temperature
r
r
r
e
inde
eate
20°C 1.28 1.26 1.24 1.23 1.22
rain
gau
f val
0°C 1.29 1.27 1.25 1.24 1.23
, cyl
air h
r, st
ump
–10°C 1.30 1.28 1.26 1.25 1.24
ner
act o
filte
ring
clea
ake
• The specific gravity should exceed the value for the
p
cont
feed
fuel
l int
ston
charging rate of 70% in the above table.
a i r
ctive
trica
ged
ged
ged
• In cold areas the specific gravity must exceed the
n pi
Defe
Clog
value for the charging rate of 75% in the above table.
Clog
Clog
Elec
Wor
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

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
Engine does not pick up smoothly, and combustion is irregular
Check items
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 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
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

Heater mount does not become warm
Is voltage 26–30V between alternator terminal B and terminal E Yes
with engine at low idling? 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)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
ª Use a test stand

20-956 PC128US-2
(14)
Replace Defe
ctive
Replace Defe regu
lato
ctive r
Replace Defe a ltern
ctive ator
Replace
PC128US-2
Defe or d
ctive eter
iora
ªAdjust Defe injec ted
tion batt
tive nozz ery
Replace Defe
injec
tion le
tive timi
Correct Leak injec ng
tion
age, p ump
Clean
TROUBLESHOOTING
Clog clog (rac

ged ging k, pl
a , air
Replace Defe i r brea i n fuel
ung
er st
ctive ther pipi uck)
Replace f e ed p h o l e in
ng
Defe
Causes
ctive ump fuel

boo tank
st co
mpe
nsat
or c
ance
l
(14)
S-1
20-957
TROUBLESHOOTING S-2
S-2 Engine does not start

(1) Engine does not turn
Causes
General causes why engine does not turn
• Internal parts of engine seized
n
witc
ctio
fl If internal parts of the engine are seized, carry
it
nne
ery
ircu
ty s
out troubleshooting for "Engine stops during
batt
al co
safe
ng c
operations".
id
ated
itch
leno
tarti
rmin
or
y or
lay
ot
g sw
• Defective electrical system
rior
of s
t so
rela
gm
e
e
t
r
• Failure in power train
ttery
dete
ttery
el cu
ar
artin
iring
artin
fety
g ge
e ba
e ba
e sa
e or
e fu
e st
e st
ew
r in
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ken
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Bro
Questions

Condition of horn when Horn sounds
starting switch is turned
ON Horn volume is low
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
Check items
move out
When starting switch is turned to ON, there is no clicking

sound
Battery terminal is loose
Troubleshooting of defective wiring in starting circuit
When starting switch is turned ON, linkage is not actuated

When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

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
Troubleshooting
2) When terminal B and terminal C of starting motor are

3) When terminal B and terminal C of safety relay are
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
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy —
20-958 PC128US-2
(14)
TROUBLESHOOTING S-2
(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
Causes
• Supply of fuel impossible
d)
• Supply of fuel is extremely small
eize
• Improper selection of fuel (particularly in winter)
er s
key
lung
nk
el ta
aft,
★ Standards for use of fuel
ck, p
on
e sh
in fu
pist
AMBIENT TEMPRATURE
p (ra
ng
iner
driv
noid
KIND
ump
hole
pipi
-4 14 32 50 68ºF
rain
stra
OF FLUID
pum
nk
mp
-20 -10 0 10 20ºC
sole
p
fuel
r, st
her
in ta
mp
eed
n pu
ed
ion
cut
reat
filte
king
l us
u
en f
fuel
ject
p
ctio
ASTM D975 No.2
fuel
air b
feed
r fue
fuel
, lea
brok
Diesel fuel
e in
inje
ent
e
ged
rope
ged
ged
ASTM D975 No.1
ged
ctiv
ctiv
ffici
ed,
ken
Clog
Defe
Clog
Defe
Clog
Clog
Insu
Seiz
Imp
Bro
Questions

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
When starting switch is turned ON, linkage is not actuated
Check items
When fuel filter is drained, fuel does not come out

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
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
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
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
PC128US-2 20-959
(14)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but

Causes
engine does not start (Fuel is
being injected)
.)
r, etc
k)
stuc
leve
ap
General causes why exhaust smoke comes out but
y
spra
r
cker
nk c
e
engine not start
lung
em
ater
e, ro
el ta
e
syst
ctiv
ck, p
ttery
r he
(valv
ner
in fu
• Lack of rotating force due to defective electri-
defe
fuel
p (ra
t
iner
a
i
i
men
ke a
l
tem
b
cal system
iner
r
ole
inde
ated
,
ir in
zzle
stra
pum
e sys
inta
r ele
a
er h
r
, cyl
n no
g, a
rior
er, s
mp
valv
ed
ical
eath
ane
ion
dete
n
ring
l us
d pu
ctio
• Improper selection of fuel and oil
i
ectr
ject
l
ken
ogg
e
i
r br
f
l
air c
r fue
fuel
inje
ston
e or
e
, bro
e in
e el
e, cl
e
a i
f
rope
ged
ged
ged
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items
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
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 fuel filter, strainer are inspected directly, they are
Troubleshooting
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
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-960 PC128US-2
(14)
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

ap
y
seat
spra
nk c
lve
el ta
ive
• Improper condition of fuel injction
nce
d va
fect
er
• Improper fuel used
er
in fu
fere
r lin
ung
e an
ent
ng
, de
er
er
nter
rain
pipi
e
hole
e
lem
p pl
rain
valv
zzle
ranc
d
cylin
er, i
p st
er e
fuel
pum
r, st
n no
her
clea
t of
pum
harg
lean
reat
filte
king
ring
ntac
ctio
tion
lve
c
air b
feed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
f
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
Troubleshooting
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
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
PC128US-2 20-961
(14)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
• Seized parts inside engine
• Insufficient supply of fuel Causes
• Overheating
c.)
r, et
fl If there is overheating and the engine stops,
k)
leve
stuc
carry out troubleshooting for overheating.
c k er
ger
• Failure in power train
ro d
nk
e, ro
plun
el ta
ent
key
ring
ting
ston
fl If the engine stops because of a failure in
valv
,
ipm
in fu
k
aft,
a
nec
c
the power train, carry out troubleshooting
p pi
ft be
m (
p (r a
ng
er
equ
er
e sh
rain
co n
hole
pipi
for the chassis.
ys te
pum
rain
in
ksha
pum
nk
r tra
ary
driv
p st
in
on,
lve s
fuel
r, st
ther
in ta
r tra
eed
i
cran
l
gea
ion
pist
pum
i
p
x
c va
filte
king
pum
a
p au
ed f
owe
e
fuel
ject
zed
zed
r
zed
air b
feed
ynam
fuel
, lea
pum
e in
in p
fuel
, sei
ent
, sei
, sei
, sei
ged
ged
ged
ged
ctiv
en d
ffici
ken
ure
ken
ken
ken
ken
ken
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro

Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
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
Fuel level lamp lights up
Engine rotates, but stops when power train is operated
Check items
Does not turn at all

When it is attempted to Turns in opposite direction
turn by hand using
barring tool Moves amount of backlash
Shaft does not turn
Troubleshooting of chassis
Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
Troubleshooting
When gear train is inspected, it does not turn

Rotates when pump auxiliary equipment is removed
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy —
Add
20-962 PC128US-2
(14)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly
Causes
• Air in fuel system
p
zzle
pum
• Defective governor mechanism
d no
• Defective electric governor mechanism
feed
p an
(engine with electric governor)
and
pum
nk
tank
el ta
fl If hunting stops when electric governor rod is
k
r
l rac
erno
feed
rn o r
fuel
disconnected, carry out troubleshooting for the
in fu
o
er
gov
een
ontr
ove
een
chassis.
in ta low
iner
rain
hole
w
betw
of g
t of
of c
t
o
stra
nk
it be
p st
is to
her
men
ion
ion
rcuit
pum
circu
ilter
reat
eed
erat
erat
just
fuel
c i
f
air in
air b
feed
g sp
air in
fuel
e ad
e op
e op
ent
idlin
ged
ged
ged
ged,
ctiv
ged,
ctiv
ctiv
ffici
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Questions
Occurs at low idling

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
to Operation Manual
Rust, water are found when fuel tank is drained
Check items
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
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
PC128US-2 20-963
(14)
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output
Causes
ent
stm
m
ray
seat
• Improper fuel used
hrag
e sp
adju
nk
(if non-specified fuel is used, output drops)
lve
el ta
diap or diap
ctiv
e
d va
tive
• Lack of output due to overtaking
renc
m
in fu
r
defe
nge
efec
e an
hrag
ng
ent
iner
erfe
t
ump iner
nsa
u
r
hole
pipi
e
fl If there is overheating and lack of output,
inde
zle,
d
lem
p pl
valv
ranc
stra
, int
mpe
ge,
a
noz
carry out troubleshooting for overheating.
fuel
er e
pum
, cyl
ther
rger
nka
clea
t of
ate
t co
r ,
tion
lean
filte
ing
ring
brea
ntac
er li
estg
cha
tion
lve
ed p
o s
c
k
air c
inje
l lev
fuel
urbo
, lea
e bo
r va
e co
ston
njec
ew
i r
e
a
f
t fue
rope
ged
ged
ged
ctiv
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
Defe
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp
Suddenly
Power was lost
Gradually
Questions

to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idling speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-964 PC128US-2
(14)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
d)
d
n)
hea
eize
ctio
and
er s
at
pray
inje
e se
lung
rger
ve s
sive
valv
e
ck, p
cha
renc
n tim defecti
xces
and
urbo
p (ra
ent
erfe
( e
r
alve
ing
fler
e
nde
p
lem
zle,
en t
ranc
, int
pum
f
u
of v
noz
u
i
er e
, cyl
twe
on p
ed m
rger
clea
ion
lean
tion
tact
o
e
ring
i
cha
air b
ecti
ject
ject
e
logg
v
con
njec
air c
l
urbo
r inj
a
ston
e in
e in
v
e of
d, c
e
i
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
PC128US-2 20-965
(14)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
fl Do not run the engine at idling for more than 20 Causes
minutes continuously. (Both low and high idling)
r
arge
e)
General causes why oil consumption is excessive
och
ngin
Turb
ss e
al
d
• Abnormal combustion of oil
hea
n se
ace
m
ose
oler
er le
• External leakage of oil
surf
yste
der
oke
h
i l co
r (lin
• Wear of lubrication system
cylin
her
), br
ke s
seal
plug
o
reat
inde
d
nd
uide
r
inta
n or
ter o
ping
eal,
n
ain
e
er e
or b
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
il fil
ing
low
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
mo
on r
at b
brea
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
al
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Bro
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
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

When breather element is inspected, it is found to be
Troubleshooting
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
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-966 PC128US-2
(14)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper fuel
end
• Improper oil used
• Operation under excessive load
ine
be
turb
n tu
se
er
r ho
r
drai
e
r lin
harg
athe
r oil
inde
ide
boc
lack
, bre
arge
e gu
, cyl
t tur
is b
r
ther
oole
och
ring
valv
er
al a
oke
l filt
brea
turb
oil c
ston
e se
lve,
t sm
oi
ged
n va
ged
ged
ged
ctiv
n pi
aus
Clog
Defe
Clog
Clog
Clog
Wor
Wor
Exh
Questions

Non-specified oil is being used
Black
Excessive
Amount of blow-by gas Carry out troubleshooting for “Exhaust smoke is black”.
Check items
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
Troubleshooting
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
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
PC128US-2 20-967
(14)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Causes
• Leakage of fuel
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
er
ger
cess
l con
pipin
d pu
o v
n
ng
y
c
p plu
p (ex
spra
f fue
ead
timi
e fee
fuel
pum
h
pum
lder
nt o
tion
insid
from
side
le ho
stme
injec
tion
ction
el in
l
age
e a
injec
nozz
adju
oil s
fuel
e
of fu
leak
i n j
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
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
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 feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-968 PC128US-2
(14)
S-11 Oil is in cooling water, or water

spurts back, or water level goes
Causes
down
General causes why oil is in cooling water
• Internal leakage in lubrication system

• Internal leakage in cooling system
et
gask
k
bloc
ing
ler
d
l coo
, O-r
der
e
ad, h
g
cylin
ittin
cor e
in oi
e
by p
er h
r tra
oler
s in
ylind
rack
used
owe
il co
nal c
en o
en p
en c
s ca
Brok
Brok
Hole
Brok
Inter
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
shooting
Trouble-

Pressure-tightness test of cylinder head shows there is leakage
Replace
Replace
Replace
Replace
Replace
Remedy
PC128US-2 20-969
(14)
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
Selection of SAE No. according to Causes

Type of oil ambient temperature
–30 –20 –10 0 10 20 30 40°C
SAE30CD
g
SAE10WCD
ipin
Engine oil
n
pan
l pa
sor
lic p
ing
SAE10W-30CD
n
e oi
sor
alve
drau
o
braz
e se
side
l
l sen
d
urna
e
tor v
ssur
insi
d hy
an
pipe
SAE15W-40CD
valv
mp
e in
oil p
leve
g, jo
il
ilter
iner
l pre
gula
she
l pu
in o
l pip
lief
ion
l in
oil f
stra
l
arin
, cru
e re
e re
e oi
e oi
e oi
suct
uel
o i
i
of o
n be
ctiv
ctiv
ged
ged
ctiv
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro

Questions

Operation Manual
Caution lamp lights up
Lights up at low idling
Condition when oil Lights up at low, high idling
pressure lamp lights up
Lights up on slopes
Sometimes lights up
Check items
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 stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Carry out troubleshooting
When oil filter is inspected, it is found to be clogged

Troubleshooting
for “Oil level rises”.

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
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy —
Add
20-970 PC128US-2
(14)
S-13 Oil level rises (Water, fuel in oil)

fl If there is oil in the cooling water, carry out trouble-
shooting for “Oil is in cooling water”. Causes
General causes why oil level rises
ver
d co
seal
• Water in oil (milky white)
hea
ent
ump
• Fuel in oil (diluted, and smells of diesel fuel)
ket
side
ipm
ace
• Entry of oil from other component
on p
gas
e
g in
surf
-ring
equ
leev
k
ead
ecti
bloc
n
seal
pipi
iary
er s
re, O
d, h
n j
g
i
der
hold
l
from
ittin
t
rear
e
osta
aux
hea
r co
cylin
s i
by p
rt in
zzle
oole
ged
erm
mp
der
fuel
side
e no
e pu
cylin
e pa
ama
ade
oil c
e th
e of
ks in
sm
ctiv
ctiv
ctiv
ctiv
n, d
kag
ken
ken
Defe
Hole
Defe
Defe
Defe
Crac
Wor
Lea
Bro
Bro
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
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,
Check items
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 cylinder head shows there is leakage
Troubleshooting

Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC128US-2 20-971
(14)
S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes too Causes
high
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
re
ratu
en)
• Defective cooling circulation system
sket
mpe
t op
aug
lley
• Rise in oil temperature in power train
d ga
g
ns
s no
n pu
il te
ture
or fi
hea
er o
doe
oole
fl Carry out troubleshooting for chassis.
rn fa
lve
pera
diat
tat (
vert
g
,
core
e va
r
ead
oil c
, wo
ittin
e
d ra
ump
tem
a t
mos
con
h
w
r
ator
by p
essu
ping
ken
she
der
ater
er p
rque
ther
, bro
radi
, cru
ooli
cylin
p
e pr
ade
ew
wat
s li
in to
e
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge 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
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
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
Power train oil temperature enters red range faster than
engine water temperature
Temperature difference between top and bottom radiator tanks

Carry out troubleshooting for chassis.
is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
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
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
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
20-972 PC128US-2
(14)
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an external
noise. Causes
ead
etc.)
gine
General causes why abnormal noise is made
)
ition
d)
d er h
ion)
ss en
ver,
eize
f pos
ject
cylin
er le
er s
er le
• Abnormality due to defective parts
ce
n
out o
rock
aran
lung
• Abnormal combustion
i
r (lin
r an d
ive
nce
• Air sucked in from intake system
o ard
e cl e
cess
linde
alve
ck, p
enc
arg e
pum ozzle
fere
m (v
ing b
ash
x
rfer
g, cy
valv
p (ra
b o ch
r
p (e
e
on n
ackl
e
yste
lt in
divid
n rin
t
g
t of
pum
n tu r
n
n
i
er, i
ject
b
lve s
i
n be
ush
men
pisto
fler (
train
wee
ion
ion
harg
ic va
ed b
n, fa
i
just
muf
r bet
ized
r of
ject
ject
a r
c
ynam
z
wea
urbo
r ge
d fa
e ad
e in
of ai
side
, sei
e in
, s e
rme
rope
ssive
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
age
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Leak
Seiz
Imp
Exce
Mis
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
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
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC128US-2 20-973
(14)
S-16 Vibration is excessive

fl If there is abnormal noise together with the vi- Causes
bration, carry out troubleshooting also for “Ab-
)
n)
stuck
ctio
normal noise is made”.
ion
, etc.
ned
inje
ush
lever
General causes why vibration is excessive
alig
per)
fuel
en c
mis
cker
(dam
sive
ring
brok
• Defective parts (abnormal wear, breakage)
e, ro
n
xces
bea
i
r tra
t
• Improper alignment
(valv
lts,
a
ash
h
ain
p (e
s
owe
g bo
• Abnormal combustion
ystem
t
ackl
utpu
d, m
pum
nd p
ntin
b
lve s
de o
g ro
train
hing
mou
ion
a
ic va
gine
ctin
insi
ject
bus
a r
nam
e
r ge
nne
ngin
f en
e in
part
m
d y
n co
rope
ter o
n ca
ctiv
se e
ctive
ken
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-974 PC128US-2
(14)
30 DISASSEMBLY AND ASSEMBLY
Method of using manual.................................. 30- 2 MAIN PUMP

Precautions when carrying out operation........ 30- 3 Removal and Installation..........................30- 73
Special tool list ................................................ 30- 5 CONTROL VALVE
Sketche of special tool .................................... 30- 9 Removal and Installation..........................30- 76
CYLINDER HEAD ASSEMBLY Disassembly and Assembly .....................30- 78
Removal and Installation ........................... 30-11 LS SELECTION VALVE
INJECTION PUMP ASSEMBLY Disassembly and Assembly .....................30- 92
Removal and Installation ........................... 30-16 PRESSURE COMPENSATION VALVE
ENGINE AND MAIN PUMP ASSEMBLY Disassembly and Assembly .....................30- 94
Removal and Installation ........................... 30-19 MAIN RELIEF VALVE
RADIATOR, HYDRAULIC OIL COOLER Disassembly and Assembly .....................30- 98
Removal and Installation ........................... 30-31 WORK EQUIPMENT PPC VALVE
RADIATOR ASSEMBLY (FOR BOOM, BUCKET, ARM, SWING CONTROL)
Removal and Installation ........................... 30-33 Disassembly and Assembly .................... 30-100
HYDRAULI OIL COOLER ASSEMBLY TRAVEL PPC VALVE
AFTER COOLER ASSEMBLY HYDRAULIC CYLINDER
FUEL TANK WORK EQUIPMENT
Removal and Installation ........................... 30-38 Removal and Installation..........................30-114
CENTER SWIVEL JOINT OPERATOR'S CAB
Removal and Installation ........................... 30-39 Removal and Installation..........................30-116
Disassembly and Assembly ...................... 30-40 OPERATOR'S CAB GLASS (STUCK GLASS)
SWING MOTOR, SWING MACHINERY Removal and Installation......................... 30-123
Removal and Installation ........................... 30-41 FRONT WINDOW ASSEMBLY
SWING MACHINERY Removal and Installation......................... 30-135
Disassembly and Assembly ...................... 30-42 FLOOR FRAME
REVOLVING FRAME Removal and Installation......................... 30-136
Removal and Installation ........................... 30-55 AIRCONDITIONER COMPRESSOR
SWING CIRCLE Removal and Installation......................... 30-143
Removal and Installation ........................... 30-57 AIRCONDITIONER Condenser
TRAVEL MOTOR AND FINAL DRIVE Removal and Installation......................... 30-145
Removal and Installation ........................... 30-58 AIRCONDITIONER UNIT
RECOIL SPRING Removal and Installation......................... 30-147
Disassembly and Assembly ...................... 30-59 COUNTERWEIGHT
IDLER Removal and Installation......................... 30-155
Disassembly and Assembly ...................... 30-63 MONITOR PANEL ASSEMBLY
TRACK ROLLER Removal and Installation......................... 30-156
Disassembly and Assembly ...................... 30-67 CONTROLLER ASSEMBLY
TRACK SHOE Removal and Installation......................... 30-157
Removal and Installation ........................... 30-70
HYDRAULIC TANK
Removal and Installation ........................... 30-71
PC128US-2 30-1
(16)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
[1] When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
[2] Any special techniques applying only to the installation procedure are marked [*1], and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation proce-
dure it applies to.
(Example)
REMOVAL OF QQQQ ASSEMBLY ........... Title of operation

k ................................................................ Precautions related to safety when carrying out the operation
1. (1) ............................................ Step in operation
a ............................................................ Technique or important point to remember when removing
(1).
2. EEEE (2)............................................ [*1] ..........Indicates that a technique is listed for use
during installation
3. T T T T assembly (3)
6............................................................. See Lubricant and Coolant Table
INSTALLATION OF QQQQ ASSEMBLY ... Title of operation
• Carry out installation in the reverse order to removal.
[*1] ................................................................ Technique used during installation
a ............................................................ Technique or important point to remember when installing
EEEE (2).
• Adding water, oil ..................................... Step in operation
a ............................................................ Point to remember when adding water or oil
5 ......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

[1] For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
30-2 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Nominal
Plug Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210(Nut), 07222-00210(Plug)
03 07376-50315 07221-20315(Nut), 07222-00312(Plug)
04 07376-50422 07221-20422(Nut), 07222-00414(Plug)
05 07376-50522 07221-20522(Nut), 07222-00515(Plug)
06 07376-50628 07221-20628(Nut), 07222-00616(Plug)
10 07376-51034 07221-21034(Nut), 07222-01018(Plug)
12 07376-51234 07221-21234(Nut), 07222-01219(Plug)
1) Hoses and tubes using sleeve nuts

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
2) Split flange type hoses and tubes

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PC128US-2 30-3
(16)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-4 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t : Cannot be substituted, should always be prepared (used)
q : Extremely useful if available, can be substituted with commercially available part
a New/remodel:N .......... Tools with new part numbers, newly developed for this model
R .......... Tools with upgraded part numbers, remodeled from items already available for other
models
Blank ... Tools already available for other models, used without any modification
a Tools marked Q in the Sketch column are tools introduced in special sketches.
remodel
Neces-
Sketch
New/
Q’ty
sity
Component Symbol Part No. Part Name Nature of work, remarks
Disassembl, assembly of Tightening of cylinder head

cylinder head A 1 790-331-1110 Wrench t 1
790-101-2501 Push puller KIT q 1
• 790-101-2510 • Block 1
• 790-101-2550 • Leg 1
• 790-101-2560 • Nut 2
1 Removal of bearing
• 790-101-2570 • Plate 4
790-101-3101 Bearing puller q 1
790-101-4200 Puller q 1
(294 kN {30 ton})
790-101-1102 Hydraulic oil pump q 1
1 796T-426-1140 Push tool t 1 Q

2 Press fit of oil seal
2 790-201-2680 Plate q 1
1 790-201-2850 Spacer t 1
3 Press fit of bearing inner
race
2 790-201-2750 Spacer t 1
790-101-5401 Push tool KIT (C) q 1 Press fit of bearing outer

race
• 790-101-5461 • Plate 1 For main bearing
Disassembly, assembly of F
swing machinery For sub-bearing
4 • 790-101-5441 • Plate 1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
5 790-201-2750 Spacer t 1 Removal separate caler
6 796T-226-1210 Wrench assembly t 1 Q Removal, installation of nut
790-101-5401 Push tool kit (C) q 1
• 790-101-5461 • Plate 1
Press fitting of main bearing
7 outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) q 1
• 790-101-5471 • Plate 1
Press fitting of sub bearing
8 outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
Press fitting of main bearing
9 790-201-2850 Push tool t 1
inner race
PC128US-2 30-5
(16)
remodel
Neces-
Sketch
New/
Q’ty
sity
Component Symbol Part No. Part Name Nature of work, remarks
10 797T-423-1360 Push tool t 1 Q Press fitting of sub bearing

Disassembly, assembly of inner race
F
swing machinery Measurement of running
11 795-630-1803 Torque wrench t 1 torque of shaft
1 791-675-1510 Installer t 1 Application of floating seal
791-600-2001 Compressor (A) 1

or t
791-685-8006 Compressor (B) 1
791-635-3160 Extension t 1
2 Compression of spring
• 790-201-2770 • Spacer t 1
Cylinder
790-101-1600 (686 kN {70 ton}) t 1
Disassembly, assembly of L
idler recoil spring
790-101-1102 Pump t 1
790-201-1500 Push tool KIT q 1
• 790-201-1590 • Plate (Periphery 74) 1
3 • 790-201-1610 • Plate (Periphery 79) 1 Press fit of piston dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
Application of floating seal
1 790-434-1650 Installer t 1 88
Disassembly, assembly of M
track roller Sealing of oil and checking of
2 791-601-1000 Oil pump q 1 air leak
791-616-1040 Remover & installer t 1
Removal,
790-105-1100 Cylinder t 1 PC128US-2 pressfit of
(297 kN {30 ton}) master pin
791-101-1102 Pump t 1
791-616-1110 Frame t 1
791-616-1121 Plate t 1
791-616-1131 Plate t 1
791-616-1150 Guide t 1
791-616-1160 Adapter t 1
791T-616-1280 Adapter t 1 N Q
Expansion, installation of
R
track shoe
791-620-3530 Push t 1
Removal,
PC138USLC- pressfit of
791-620-3260 Push t 1
2 master pin
791-620-3270 Guide t 1
01011-62260 Bolt t 2
01643-62260 Washer t 2
01011-61455 Bolt t 3
01643-31445 Washer t 3
Cylinder
790-105-1100 (297 kN {30 ton}) t 1
790-101-1102 Pump t 1
790-101-2501 Push puller q 1

Disassembly of center Disconnection of rotor from
T
swivel joint shaft
• 790-101-2510 • Block 1
30-6 PC128US-2
(16)
remodel
Neces-
Sketch
New/
Q’ty
sity
Nature of work Symbol Part No. Part Name Nature of work, remarks
• 790-101-2520 • Screw 1
• 790-101-2540 • Washer 1
• 791-112-1180 • Nut 1
Disassembly of center Disconnection of rotor from
T • 790-101-2630 • Leg 2
swivel joint shaft
• 790-101-2570 • Washer 4
• 790-101-2560 • Nut 2
• 791-112-2650 • Adapter 2
790-502-1003 Repair stand t 1

1 Disassembly, assembly of
cylinder
790-101-1102 Pump t 1
790-102-4300 Wrench ass’y t 1

Removal, installation of
2
piston
790-201-4310 Pin t 1
790-201-1702 Push tool KIT t 1
• 790-201-1791 • Push tool 1 Press fit of bucket cylinder

roll bushings
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1811 • Push tool 1

3 Press fit of boom cylinder roll
bushings
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1821 • Push tool 1

Press fit of arm and blade
Disassembly, assembly of cylinder roll bushings
hydraulic cylinder U • 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1610 • Push tool 1 Press fit of bucket cylinder

dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1620 • Push tool 1

Application of boom cylinder
4
dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1630 • Push tool 1

Application of arm and blade
cylinder dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
5 790-720-1000 Expander t 1 Extension of piston ring
PC128US-2 30-7
(16)
remodel
Neces-
Sketch
New/
Q’ty
sity
Nature of work Symbol Part No. Part Name Nature of work, remarks
796-720-1650 Ring t 1 Removal,

Bucket installation
cylinder of piston
07281-01029 Clamp t 1 (PC128UU-2) ring
Disassembly, assembly of U 6
hydraulic cylinder Bucket cylinder Removal,
796-720-1660 Ring t 1 (PC138US-2) installation
(PC138USLC-2) of piston
07281-01159 Clamp t 1 Arm, boom, blade
ring
cylinder
792-785-1100 Remover t 1
• 796-270-1110 • Adapter t 1
Removal, installation, of V 1 Removal of boom foot pin
work equipment and boom Puller
790-101-4000 t 1
(490 kN {50 ton})
790-101-1102 Pump t 1
1 793-498-1210 Lifter (Suction cup) t 2

Operator’s cab glass Removal and installation opera-
(stuck glass) tiors cab glass (stuck glass)
2 20Y-54-13180 Adapter t 2
799-703-1200 Service tool KIT t 1

Floor frame assembly
airconditioner compressor X 799-703-1100 Vacuum pump(100V) t 1 For Japan
assembly Charging of
airconditioner condenser 3 799-703-1110 Vacuum pump(220V) t 1 For overseas air-condi-
assembly tioning gas
airconditioner unit 790-703-1120 Vacuum pump(240V) t 1 For overseas
assembly
799-703-1401 Gas leak detector t 1
30-8 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY SKETCHE OF SPECIAL TOOL
SKETCHE OF SPECIAL TOOL

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
F2-1 Push tool
a Unless otherwise specified, there shall be on burrs or flushes at the corner.
F6 Wrench
PC128US-2 30-9
(16)
DISASSEMBLY AND ASSEMBLY SKETCHE OF SPECIAL TOOL
F-10 Push tool
R Adapter
30-10 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD ASSEMBLY

REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove the counter weight. For details, See

REMOVAL OF COUNTERWEIGHT.
2. Drain the coolant.

6 Coolant: 13.2 l
3. Remove frame (1) and (2).
4. Remove cover (3)
5. Remove connector (M34) (4) and cover (5).
6. Loosen air conditioner compressor (6) mounting

bolt (7) and adjustment bolt and remove air con-
ditioner compressor belt (8).
7. Remove air conditioner compressor (6).

a Put the air conditioner compressor in front of
the turbocharger.
8. Disconnect heater hoses (9).
9. Disconnect air hose (10) and remove aftercooler

hose (11). [*1]
10. Disconnect radiator hose (12). [*2]
11. Remove cover (13).
12. Remove muffler drain tube (14).
13. Remove clamp (15). [*3]
14. Remove mufler (16) and bracket (17) together.
15. Disconnect water temperature sensor connector

(P07) (18).
PC128US-2 30-11
(16)
16. Disconnect spill tube (19).
17. Remove the bracket mounting bolts of fuel filter

(20).
18. Disconnect clip (21) and boost compensator

hose (22).
19. Remove the 4 fuel injection tube (23). [*4]
20. Remove air conditioner compressor bracket (24).
21. Disconnect blow-by hose (25).
22. Remove nut (26) and bracket (27) and discon-

nect engine stop solenoid (28).
23. Disconnect heater terminal E52 (29) and clip

(30).
24. Disconnect air tube (32) from turbocharger (31).
25. Disconnect turbocharger lubrication tubes (33)

and (34) on the engine side.
26. Disconnect clip (35).

a There are 2 spacers.
27. Lift off turbocharger, exhaust manifold, and lubri-

cation tube assembly (36). [*5]
28. Loosen mounting bolts (38) and (39) of alternator

(37) and adjustment bolt (40) and remove alter-
nator belt (41).
30-12 PC128US-2
(16)
29. Remove clamp (42).
30. Disconnect heater hoses (43) and radiator hose

(44). [*2]
31. Remove fan guard (45).
32. Remove the 6 mounting bolts (46) of, fan (47),

and pully (48).
33. Remove water pump assembly (49).
34. Remove cylinder head cover (50). [*6]
35. Loosen locknut (51), and then loosen adjustment

screw (52) by 2 – 3 turns.
a Perform this work for all of the 8 places. [*7]
36. Remove 5 mounting bolts (53), 3 mounting nuts

(54), and rocker arm and shaft assembly (55).
[*8]
37. Remove the 8 push rods (56).
38. Remove the 17 mounting bolts and lift off

exhaust manifold assembly (57). [*9]
4 Clinder head, intake manifold Assembly:
40 kg
PC128US-2 30-13
(16)
INSTALLATION
• Carry out installation in the reverse order to [*4]
3 Fuel injection pipe sleeve nut:
removal.
19.6 – 24.5 Nm {2 – 2.5 kgm}
[*1]
3 Air hose clamp [*5]
3 Mounting bolt of exhaust manihold and
After cooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
turbocharger:
34.3 – 53.9 Nm {3.5 – 5.5 kgm}
[*2]
2 Apply gasket sealant (ThreeBond [*6]
TB1208E) to the range of 30 mm from a Insert the cylinder head cover O-ring in the
each end of radiator hose adapters (of O-ring groove, taking care not to expand or
the radiator and water pump) and con- contact it, and fit it to the cylinder head.
3 Radiator hose clamp: 3 Head cover mounting bolt:

nect the radiator hose. Apply adhesive, if necessary.
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 7.84 – 9.8 Nm {0.8 – 1.0 kgm}
[*3] [*7]
3 Mounting bolt of clamp between turbo- 3 Rock nut: 39.2 – 49 Nm {4 – 5 kgm}
charger and muffler:
1st time: 39.2 – 49 Nm {4 – 5 kgm} [*8]
3 Rocker arm shaft mounting bolt and nut:
2nd time:
68.6 – 122.5 Nm {7 – 12.5 kgm}
19.6 – 29.4 Nm {2 – 3 kgm}
[*9]
1. Tighten the cylinder head mounting bolts in the
following order.
1) Apply molybdenum disulphide LM-P all over
the threads and seating face of each bolt and
the seats of the cylinder head holes.
2) Turn the bolts with the fingers until they are
screwed in the threaded holes of the cylinder
head by 2 – 3 threads in the order of [1] –
[17] shown in the figure.
3) Tighten the bolts to 68.6 ± 9.8 Nm {7 ± 1
kgm} in the order of [1] – [17] shown in the
figure.
4) Tighten the bolts to 107.8 ± 4.9 Nm {11 ± 0.5
kgm} in the order of [1] – [17] shown in the
figure.
a (1): Exhaust side, (2): Air intake side, (3):
Front, (4): Rear
30-14 PC128US-2
(16)
5) Use the tool A1 or make marks f with paint

on the Y bolt heads and their seats on the
cylinder head, and then tighten the bolts in
the order of [1] – [17] so that the mark of
each bolt will be at 90º +30º
0
from the mark of
the cylinder head.
a After tightening the bolts, make 1 punch
mark (g) on each bolt head.
a If there are 5 or more punch marks on a
bolt head, do not use that bolt again but
replace it.
Reference
3 U-clamp nut:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Mounting bolt of nozzle holder:

39.2 – 49 Nm {4 – 5 kgm}
3 Turbocharger unit mounting bolt:

27 – 34 Nm {2.8 – 3.5 kgm}
a If the exhaust manifold is removed, apply

gasket sealant LG-7 in the form of a string 1
mm in diameter as shown below.
• Supplying coolant
Supply coolant from the cooloant filter port to the
specified level, start the engine to circulate cool-
ant and recheck the level.
5 Coolant: 13.2 l
• Bleeding air
Bleed air from the fuel system. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC128US-2 30-15
(16)
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
INJECTION PUMP ASSEMBLY

REMOVAL
k Disconnect the wiring harness from the nega-
tive terminal of the battery.
1. Remove the counterweight. (See REMOVAL OF

COUNTERWEIGHT.)
2. Remove frame (1).
3. Remove oil gauge guide (2).
4. Remove nut (3), and then remove engine stop

solenoid (4) and bracket together.
5. Remove cover (6), loosen the mounting bolts

and adjustment bolt of air conditioner compres-
sor (5), and then remove air conditioner com-
pressor belt (7).
6. Remove blow-by tube (8).
7. Disconnect clamp (9).
8. Remove nut (10) and disconnect fuel control

cable (12) and bracket (11) together.
9. Disconnect spill hose (13) and fuel feed hoses

(14) and (15).
10. Remove fuel filter (16).
11. Disconnect fuel feed hose (17) and fuel return

hose (18).
12. Remove 4 fuel injection tubes (19). [*1]
13. Remove lubrication tube (20).
14. Disconnect boost compensator hose (21).
15. Remove clamp (22) and separate wiring harness

(23) from fuel injection pump (24).
16. Remove bracket (25).
30-16 PC128US-2
(16)
17. Remove cover (26) and set the No. 1 cylinder to

the compression top dead center.
1) Rotate bolt B forward to match the stamped
line of 1.4TOP to pointer C under pulley A.
a If there is not valve clearance in the No. 1
cylinder, the No. 4 is at the compression
top dead center. In this case, rotate bolt
B forward further to match the stamped
line of 1.4TOP to pointer C again.
2) Check that bolt hole D on this side is

matched to the hole of the pump gear (that
the No. 1 cylinder is at the compression top
dead center) by inserting a pin about 8 cm
long (a round rod) [2].
18. Remove 6 mounting bolts (27) on the pulley side,

mounting bolts (28) and (29) on the pump side,
and fuel injection pump (24).
a Do not remove the bolt at part E, since it is
used as a plug. (Remove it to fix the pump
gear when installing.)
a Fuel injection pump (24) is disconnected
from F.
PC128US-2 30-17
(16)
INSTALLATION
1. Before installing fuel injection pump (24), remove
the bolt from part E and secure the gear with M6
bolt [3] 35 mm or longer.
• Carry out installation in the reverse order to

removal.
[*1]
3 Fuel injection pipe sleeve nut:
19.6 – 24.5 Nm {2 – 3.5 kgm}
• Bleed air from the fuel system. For details, see

each part.
30-18 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
ENGINE AND MAIN PUMP

ASSEMBLY
PC128US-2 Serial No. : 5001 – 8100
PC138US-2 Serial No. : 1001 – 3200
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
k Completely ground the work equipment.
k Disconnect the negative (-) terminal of the bat-
tery.
1. Remove the radiator, hydraulic oil cooler assem-

bly by referring to "REMOVAL OF RADIATOR,
HYDRAULIC OIL COOLER ASSEMBLY".
2. Disconnect hose (1) between the radiator upper
tanks.
3. Remove bracket (2) from the fuel tank together
with the reserve tank.
4. Disconnect bracket (3) from the main pump.
a The EPC valve connector is attached to it.
5. Disconnect PPC main pressure hose (4).
6. Disconnect earth cable (5).
7. Disconnect LS pressure input hose (6).
8. Disconnect EPC valve connector (7) (C13).
9. Disconnect suction tube (8) from the main pump.
10. Disconnect main pump output hose (9).
11. Disconnect main pump pressure input hose (10).
12. Disconnect case drain hose (11).
13. Disconnect engine oil filter (12) from the hydrau-
lic oil tank and put it near the main pump.
14. Remove stays (13), (14) and (15).
15. Remove adiabatic cover (16).
17. Remove muffler (18).
a Loosen the turbo charger clamp beforehand.
18. Disconnect heater outlet hose (19).
19. Disconnect airconditioner hose (20).
a Fit blind plugs into the hoses to prevent the
entry of moisture, dust or dirt.
20. Disconnect accelerator cable (21). [*1]

21. Disconnect fuel inlet hose (22) and return hose
(23).
22. Disconnect airconditioner hose clamp (24) at two
positions.
23. Disconnect engine connectors (25) (E15), (26)
(E20), (27) (E16) and (28) (E07) to remove
clamp (29).
24. Disconnect fuel spill hose (30).
a Apply the blind plug to the hose.
PC128US-2 30-19
(16)
25. Disconnect clamp (31) to remove hose (32).
26. Remove engine side cover (33).
27. Disconnect engine connectors (34) (M02) and

(35) (E17).
28. Disconnect starter wire (36) (E13) and safety

relay wire (37) (E30).
29. Disconnect heater return hose (38).
30. Remove three of four engine mounts (39).
31. Temporarily lift engine main pump assembly

(40), remove the remaining mounting bolt and
carefully lift the assembly to remove it. [*2]
4 Engine main pump assembly : 270 kg
INSTALLATION
• Installation is performed in the opposite way to
removal.
[*1]
a Adjust the cable length by referring to
"ADJUSTMENT OF FUEL CONTROL
CABLE".
[*2]
a Install the engine main pump assembly by
placing the engine mounting rubber as
shown in the figure below.
3 Engine mounting tightening bolt :
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
a Supply coolant from the water filler port to
the specified level, start the engine to circu-
late coolant and recheck the level.
• Supplying oil (hydraulic oil tank)

a Supply oil from the oil filler port to the speci-
fied level, start the engine to circulate oil in
the piping and recheck the oil level.
• Bleeding air
a Bleed air from the main pump. For details, see
each part.
30-20 PC128US-2
(16)

ASSEMBLY
PC138US-2 Serial No. : 3201 – 4500
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
tery.
1. Remove the counterweight (See REMOVAL OF

COUNTERWEIGHT).
2. Drain hydraulic oil and coolant.

6 Hydraulic oil: 69 l
(Oil level in hydraulic tank)
6 Coolant: 17.2 l
3. Collect air conditioner gas from air conditioner

circuit.
4. Remove battery (1).
5. Disconnect air hose (2), aftercooler inlet hose

(3), and radiator inlet hose (4). [*1]
6. Disconnect aftercooler outlet hose (5) and radia-

tor outlet hose (6). [*2]
7. Disconnect reservoir tank hose (7) and remove

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

dow washer hose (10) and remove washer tank
(11).
9. Remove bracket (12) from the main pump.
10. Disconnect wiring connectors (13) (C13) and

(14) (C14).
11. Disconnect suction tube (15)
PC128US-2 30-21
(19)
13. Disconnect main pump output hose (17).
14. Disconnect main pump pressure input hose (18).
16. Remove engine oil filter (20) from the hydraulic

tank and move it toward the main pump.
17. Disconnect engine wiring connectors (21) (E15),

(22) (E20), (23) (E16), and (24) (E07) and
remove clamp (25).
18. Remove stays (26), (27), and (28).
19. Remove heat insulation cover (29).
21. Remove muffler (31).

a Loosen the turbocharger clamp.
22. Disconnect heater hose (32).
23. Disconnect 2 air conditioner hoses (33).

a Take measures to prevent dirt, water, etc.
from entering the piping.
30-22 PC128US-2
(16)
24. Disconnect fuel control cable (34). [*3]

a Before disconnecting the fuel control cable,
measure its installed length.
25. Disconnect fuel inlet hose (35) and outlet hose

(36).
a Plug the hoses to stop the fuel.
26. Disconnect fuel spill hose (37).

a Plug the hose to stop the fuel.
27. Disconnect 2 air conditioner hose clamps (38).
28. Disconnect clamp (39) and hose (40).
29. Remove engine side cover (41).
30. Disconnect alternator wiring connector (42)

(M02).
31. Disconnect starting motor wire (43) (E13), and

safety relay wires (44) (E30) and (45) (E17).
33. Remove 4 mounting bolts (47) of the radiator,

aftercooler, and hydraulic oil cooler assembly.
34. Move radiator, aftercooler, and hydraulic oil

cooler assembly (48) toward the battery about 50
mm.
35. Sling engine and main pump assembly (49) tem-

porarily, remove 4 engine mounting bolts (50),
and lift off the engine and main pump assembly.
[*4]
a Check that all the wires and pipes are dis-
connected.
a Take care particularly not to damage the
radiator, aftercooler, and hydraulic oil cooler
assembly.
PC128US-2 30-23
(16)
INSTALLATION
removal.
[*1] [*2]
2 Apply gasket sealant (ThreeBond
TB1208E) to the range of 30 mm from
each end of radiator hose adapters (of
the radiator and water pump) and con-
nect the radiator hose.
3 Air hose clamp:
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
3 Radiator hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Aftercooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*3]
Adjust the cable length. For details, see TEST-
ING AND ADJUSTING, Adjustment of fuel con-
trol cable.
[*4]
a Install the engine main pump assembly by
placing the engine mounting rubber as
shown in the figure below.
3 Engine mounting tightening bolt:
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}

Supply oil from the oil filler port to the specified
level, start the engine to circulate oil in the piping
and recheck the oil level.
5 Hydraulic tank: 69 l
Supply coolant from the coolant filler port to the
5 Coolant: 17.2 l
• Bleeding air
Bleed air from the pump. For details, see TEST-
ING AND ADJUSTING, Bleeding air from each
part.
• Charging air conditioner with refrigerant gas

Using tool X3, charge the air conditioner circuit
with refrigerant gas (R134a).
30-24 PC128US-2
(16)

ASSEMBLY
REMOVAL

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

1. Remove the counterweight.

(See REMOVAL OF COUNTERWEIGHT).
2. Drain the hydraulic oil and the coolant.

6 Coolant: 13.2 l
3. Remove frames (1) and (2).
5. Disconnect connector (M34) (4) and remove

cover (5).
6. Loosen mounting bolts (7) and the adjustment

bolt of air conditioner compressor (6), and then
remove air conditioner compressor belt (8).
7. Remove airconditioner compressor (6).

a Put the air conditioner compressor in front of
the turbocharger.
9. Disconnect air hose (10) and remove after cooler

hose (11). [*1]
10. Disconnect radiator hose (12). [*2]
11. Disconnect coolant temperature sensor connec-

tor (P07) (13).
12. Disconnect heater terminal (E52) (14).
PC128US-2 30-25
(16)
13. Disconnect PULL, GND, and HOLD from the top

of engine stop solenoid terminals (15).
a If the terminal cover falls from the wiring har-
ness, the signal label of the wiring harness
falls, too. Accordingly, take a measure to
hold the terminal cover.
a Terminal name seal is stuck to the engine
stop solenoid.
14. Disconnect clip (16) and (17).
15. Remove nut (19), loosen locknut (20), and dis-

connect fuel control cable (18). [*3]
16. Disconnect fuel hoses (61) and (62).
17. Disconnect starting motor terminals E13 (21) and

E54 (22). [*4]
18. Disconnect clip (23) and separate wiring har-

nesses (24) and (25) from the engine.
19. Disconnect ground terminal (26).
20. Remove clamp (27).
21. Disconnect heater hose (28) and radiator hose

(29). [*2]
22. Remove fan guard (30).
23. Remove the 6 mounting bolts (31) and fan (32).
24. Disconnect air tube (34) from turbocharger (33).
30-26 PC128US-2
(16)
25. Disconnect terminal S17 (35) and connectors

E17 (36) and E07 (37) from the bottom of the tur-
bocharger.
26. Remove clip (38).
27. Remove cap (40), and then remove reservoir

tank (42) and bracket (41) together.
28. Disconnect connectors C14 (43), C13 (44), and

clip (45).
29. Disconnect drain hose (46) and pump pressure

input hose (47).
30. Disconnect pump spout tube (48) and suction

tube (49).
31. Disconnect LS pressure input hose (50) from A.
32. Remove corrosion resistor (51), oil filter (52), and

their brackets together.
33. Remove frame (53).
34. Remove the mounting bolt (54). [*5]
PC128US-2 30-27
(16)
35. Lift off engine assembly (55).

a Use bolt hole B of the exhaust manifold to
sling the engine by 3 points stably.
4 Engine ass’y : 480 kg
30-28 PC128US-2
(16)
INSTALLATION
removal.
[*1]
3 Air hose clamp and aftercooler hose
clamp: 10.8 ± 0.5 Nm {1.1 ± 0.5 kgm}
[*2]
2 Apply gasket sealant (ThreeBond
TB1208E) to the range of 30 mm from
each end of radiator hose adapters (of
the radiator and water pump) and con-
nect the radiator hose.
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
Adjustment to fuel control cable. For details, see
TESTING AND ADJUSTING, testing and adjust-
ing of an accelerator pedal.
[*4]
3 Starting motor terminal E13 (21) (M10):
15.7 – 19.6 Nm {1.6 – 2 kgm}
3 Starting motor terminal E54 (22) (M5):
2.5 – 3 Nm {0.25 – 0.31 kgm}
[*5]
Note that washer B on the inside of the chassis
(INSIDE) and that on the outside of the chassis
(OUTSIDE) to support bottom rubber A of the
engine mount on the chassis are different from
each other.
3 Engine mount mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
PC128US-2 30-29
(16)

5 Hydraulic tank: 69 l (Oil level)
100 l (Capacity)
• Supply coolant
Supply coolant from the coolant filler port to the
5 Coolant: 13.2 l
• Bleeding air
Bleed air from the pump and fuel system. For
details, see TESTING AND ADJUSTING, Bleed-
ing air from each part.
30-30 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC OIL COOLER
RADIATOR, HYDRAULIC OIL

COOLER
PC128US-2 Serial No. : 5001 – 8100
PC138US-2 Serial No. : 1001 – 3200
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
kGradually loosen the hydraulic oil tank cap to
bleed the internal air after completely grounding
the work equipment and stopping the engine.
1. Remove the counterweight assembly by refer-

ring to "REMOVAL OF COUNTERWEIGHT
ASSEMBLY".
2. Drain hydraulic oil and coolant.
6 Hydraulic oil : 69 l
6 Cooling : 18.2 l
circuit.
4. Remove stay (1).
5. Remove stay (2).
a Disconnect the accelerator cable clamped to
stay (2).
6. Remove bracket (3) together with the washer
tank.
a Disconnect the washer motor connector
(M28) from the hose.
7. Remove two batteries (4).
8. Remove battery relay (5).
9. Remove silencer (6) and tube (7) to remove air
cleaner assembly (8).
11. Disconnect airconditioner capacitor pipings (10)
and (11). [*1]
a Make sure to double-engage the wrench
before disconnection.
12. Remove the mounting bolt to remove air condi-
tioner capacitor assembly (12).
13. Remove clamp (13) to remove bracket (14).
14. Disconnect oil cooler outlet hose (15) and inlet
hose (16).
15. Disconnect radiator outlet hose (17) and inlet
hose (18) as well as reserve tank hose (19).
PC128US-2 30-31
(19)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC OIL COOLER
16. Temporarily lift radiator, hydraulic oil cooler

assembly (20) to remove the four mounting bolts
on the bottom.
a Carefully lift and remove the assembly after
slightly lifting it and pulling it to the opposite
side from the engine to make sure that it
does not come in contact with the fan.
4 Radiator/hydraulic oil cooler assembly :
55 kg
INSTALLATION
removal.
[*1]
a Check that the O-ring is not damaged or
deteriorated, then connect the hoses.
• Using tool X3, charge air conditioner gas

(R134a) to air conditioner circuit.
• Refilling with coolant

Add coolant through the coolant filler to the spec-
ified level. Run the engine to circulate the water
through the system. Then check the coolant
level again.
• Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
5 Coolant: 18.2 l
30-32 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR ASSEMBLY
REMOVAL
1. Drain cooling water.
6 Coolant : 17.2 l [*3]
2. Remove the aftercoolar assembly by referring to

"REMOVAL OF AFTER COOLER ASSEMBLY".
3. Remove engine hood stay (1) from radiator

assembly.
4. Disconnect radiator inlet hose (2). [*1]
5. Disconnect radiator outlet hose (3). [*2]
6. Removethe 2 mounting bolts (4) of radiator.
7. Pull up radiator assembly (5) to remove it.

a Raise radiator assembly (5) a little, and then
slide it toward the oil cooler.
a Take care not to damage the radiator core.
INSTALLATION
removal.
[*1] [*2]
8.8 ± 0.5 Nm {0.9 – 0.05 kgm}
• Refilling with coolant

ified level. Run the engine to circulate the cool-
ant through the system. Then check the coolant
level again.
5 Coolant: 17.2 l [*3]
[*3]
Coolant : 13.2 l
PC128US-2 30-33
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULI OIL COOLER
HYDRAULI OIL COOLER

ASSEMBLY
REMOVAL
k Gradually loosen the hydraulic oil tank cap to
1. Drain hydraulic oil

6 Hydraulic oil :
69 l (Oil level in hydraulic tank)
100 l (Capacity)
2. Remove the after cooler assembly by referring to

"REMOVAL OF AFTER COOLER ASSEMBLY".
3. Remove the engine hood cover assembly (1).
4. Disconnect clamp (2), and then disconnect air

intake hose (3) from the air cleaner.
a Move the air intake hose toward the engine.
5. Remove the oil cooler undercover and discon-

nect oil cooler outlet tube (4).
a Prepare an oil receiving can to receive the
leaking hydraulic oil before disconnecting the
tube.
6. Remove 2 mounting bolts of oil cooler inlet tube

(5).
7. Loosen U-clamp (6) and disconnect oil cooler

inlet tube (5) from the hydraulic oil cooler.
a Loosen the U-clamp but do not remove it.
8. Remove 2 oil cooler mounting bolts (7).
30-34 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULI OIL COOLER
9. Raise oil cooler assembly (8) a little, and then

slide it toward the radiator.
11. Pull up oil cooler assembly (8) to remove it.

a Take care not to damage the oil cooler core.
INSTALLATION
removal.

5 Hydraulic oil :
69 l (Oil level in hydraulic tank)
100 l (Capacity)
PC128US-2 30-35
(16)
DISASSEMBLY AND ASSEMBLY AFTER COOLER
AFTER COOLER ASSEMBLY

PC138US-2 Serial No. : 3201 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
k Completely grounding the work equipment.
1. Open 2 engine hoods (1) and remove cover (2).
2. Remove reservoir tank hose (3).
3. Remove aftercooler inlet hose (4). [*1]
4. Disconnect aftercooler outlet hose (5). [*2]
5. Remove 2 aftercooler assembly mounting bolts

(6).
6. Pull up aftercooler assembly (7) to remove it.

a Take care not to damage the aftercooler
core.
INSTALLATION
removal.
[*1] [*2]
3 After cooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
30-36 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY AFTER COOLER
AFTER COOLER ASSEMBLY

REMOVAL
1. Remove mirror (1).
2. Open engine hood (2) and remove cover (3).
3. Remove the undercover and disconnect after-

cooler lower hose (4). [*1]
a "A" is the radiator hose.
5. Disconnect reservoir tank hose (6).
6. Disconnect aftercooler upper hose (7). [*1]
8. Remove mounting bolt (9) and aftercooler (10).
INSTALLATION
removal.
[*1]
3 After cooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
PC128US-2 30-37
(16)
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
REMOVAL

tery.
1. Drain the fuel.
6 Fuel tank : 195 l
2. Remove two hand rails (1) to remove side covers

(2) and (3), and upper covers (4), (5), (6) and (7).
3. Disconnect hose (8) from the radiator, the

mounting bolt and bracket (9) together with the
reserve tank.
4. Disconnect engine fuel return hoses (10) and

(11).
5. Disconnect fuel sensor connector (12) (P06) to

remove clamp (13).
6. Remove brackets (14) and (15) on the left side of

the fuel tank.
7. Disconnect mounting bolt (16) on the right side.
8. Disconnect hoses (17) (to the fuel pump) and

(18) (for draining) from the bottom of the fuel
tank.
a Lift the fuel tank before disconnection.
9. Temporarily lift fuel tank (19), remove the mount-

ing bolt and then carefully lift the tank to remove
it. [*1]
4 Fuel tank assembly : 100 kg
INSTALLATION
removal.
[*1]
2 Fuel tank mounting bolt screw :
Liquefied adhesive (LT-2)
3 Fuel tank mounting bolt :

277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
• Supplying oil (fuel tank)

Supply fuel.
30-38 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

REMOVAL

tery.
1. Remove cover at rear of boom. For details, see

"REMOVAL OF SWING MOTOR AND SWING
MACHINERY ASSEMBLY".
2. Disconnect hoses (1) – (6) between travel motor
and swivel joint.
3. Remove elbow (7).
4. Disconnect drain hose (8).
5. Disconnect hoses (9) – (12) between control
valve and swivel joint.
6. Disconnect hose (13) from solenoid valve.
7. Remove plate (14).
8. Disconnect hoses (for changing the speed) (15)
and (16) between both travel motors and swivel
joint.
9. Remove mounting bolts and lift off center swivel
joint assembly (17). [*1]
a Sling the joint assembly temporarily, then
remove the bolts.
4 Center swivel joint assembly
: 30 kg (Standard specification)
: 45 kg (Blade specification)
INSTALLATION
removal.
[*1]
2 Mounting bolt screw :
3 Mounting bolt :
98.1 – 123.0 Nm {10.0 – 12.5 kgm}
• Bleeding air
Bleed air from the swing motor. For details, see
each part.
PC128US-2 30-39
(16)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

DISASSEMBLY
2. Remove snap ring (2).
3. Using tool T, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
4. Remove O-rings (6) and slipper seals (7) from

swivel shaft (5).
ASSEMBLY
1. Fit slipper seals (7) and O-rings (6) to swivel
rotor.
2. Set swivel shaft (5) to block, then fit it by using

push tool and hitting swivel rotor (4) lightly with
plastic hammer.
2 Contact surfaces of rotor and shaft
: Grease (G2-LI)
a When installing the rotor, take care not to

damage the slipper seals and O-rings.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).

3 Swivel joint mounting bolt :
31.3 ± 2.9 Nm {3.2 ± 0.3 kgm}
30-40 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY
SWING MOTOR,
SWING MACHINERY
REMOVAL

tery.
1. Remove boom rear covers (1) and (2).
2. Disconnect MB and MA port hoses (3) and (4), S

port hose (5), and B and T port hoses (6) and
(7).
3. Remove the mounting bolt and tighten forcing

screw [1] to disconnect swing motor, swing
machinery (8) from the revolving frame. [*1]
a Temporarily lift the swing motor/swing
machinery assembly and gradually lift it
upward according to the amount discon-
nected by the forcing screw.
4. Lift and remove swing motor/swing machinery

assembly (8).
4 Swing motor, swing machinery assembly
: 100 kg
INSTALLATION
removal.
[*1]
2 Swing machinery fitting surface :
Gasket sealant (LG-4 or LG-6)
3 Mounting bolt :
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}
• Bleeding air
Bleed air from the swing motor. For details , see
each part.
PC128US-2 30-41
(16)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
SWING MACHINERY
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
DISASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery.
6 Swing machinery case : Approx. 2.5 l
2. Swing motor
Remove swing motor assembly (1).
4 Swing motor assembly : 30 kg
3. No. 1 carrier, No. 2 sun gear assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 1 carrier and No. 2 sun gear
assembly (3).
3) Disassemble No. 1 carrier and No. 2 sun

gear assembly (3) as follows.
i) Remove snap ring (4), then remove
thrust washer (5), gear (6), bearing (7),
and thrust washer (8).
ii) Knock in pin (9) and knock out shaft (10).

a After removing the shaft, remove pin
(9).
iii) Remove snap ring (11), then remove No.
2 sun gear (12) from carrier (13).
30-42 PC128US-2
(16)
4. Ring gear
Remove ring gear (14).
5. No. 2 carrier assembly

1) Remove spacer (15).
2) Remove No. 2 carrier assembly (16).
3) Disassemble No. 2 carrier assembly as fol-

lows.
i) Push in pin (17), and knock out shaft (18)
from carrier (19).
a After removing the shaft, remove pin
(17).
ii) Remove thrust washer (20), gear (21),
bearing (22), and thrust washer (23).
6. Retainer, collar
1) Remove retainer (24).
2) Set shaft and case assembly to press, push
split collar (25) with push tool F5, and press
fit bearing (26).
a Operate the press gradually and press fit
the bearing to a point where the split col-
lar can be removed.
3) Remove split collar (25).
7. Shaft assembly
1) Set shaft and case assembly (27) to block
[2], then using push tool [3], remove shaft
assembly (28) with press.
2) Remove bearing (26).
PC128US-2 30-43
(16)
3) Using push tool F1, remove bearing (29) and

collar (30) from shaft (31).
8. Oil seal, bearing outer race

1) Remove oil seal (32) from case (33).
2) Using puller [5], remove bearing outer races

(34) and (35) from case (33).
30-44 PC128US-2
(16)
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing outer races

Using push tool F4, press fit outer races (34) and
(35) to case (33).
2. Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
shaft (31).
2) Using push tool F3-1, press fit bearing (29)

with press.
3) Set case assembly (36) to shaft assembly

(28).
4) Using push tool F3-2, press fit bearing (26)

with a press to a point where split collar (25)
enters.
a Press-fitting force : 11.760 N {1,200 kg}
a Press fit the bearing slowly while rotating
the case.
5) Install split collars (25).
6) Screw bolt (12mm, P=1.75mm) into case,

then using push- pull scale [8], measure tan-
gential force in direction of rotation.
a Tangential force : Max. 176.4 N {18 kg}
a The tangential force is the maximum
force at the start of rotation.
PC128US-2 30-45
(16)
3. Oil seal
Using push tool F2, press fit oil seal (32).
2 Periphery of oil seal: LG-6

a Replace the oil seal with a new part.
2 Lip of oil seal : Grease (G2-LI)

a Do not stick LG-6 to the lip and shaft.
4. Retainer
Install retainer (24).

1) Assemble No. 2 carrier assembly as follows.
i) Assemble bearing (22) to gear (21).
ii) Fit top and bottom thrust washers (20)
and (23), then set gear assembly to car-
rier (19).
iii) Align position of pin holes of shaft and

carrier, then tap with plastic hammer and
install shaft (18).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washers.
iv) Insert pin (17).
a After inserting the pin, caulk the car-
rier pin portion.
30-46 PC128US-2
(16)
2) Install No. 2 carrier assembly (16) to shaft

and case assembly.
3) Install spacer (15).
6. Ring gear
Assemble O-ring (37) to shaft and case assem-
bly, and install ring gear (14).
7. No. 1 carrier, No. 2 sun gear assembly

1) Assemble No. 1 carrier and No. 2 sun gear
assembly as follows.
i) Assemble No. 1 carrier (13) to No. 2 sun
gear (12), and install snap ring (11).
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer to
install shaft (10).
iii) Insert pin (9).
a After inserting the pin, caulk the car-
rier pin portion.
a Check that the stepped difference a
between the shaft and carrier is less
than 0.2 mm.
iv) Assemble thrust washer (8), bearing (7),
gear (6), and thrust washer (5), then
install snap ring (4).
PC128US-2 30-47
(16)
2) Install No. 1 carrier and No. 2 sun gear

assembly (3).
3) Install No. 1 sun gear (2).
8. Swing motor assembly

Install swing motor assembly (1).
3 Mounting bolt :
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
9. Refilling with oil (swing machinery case)

Tighten the drain plug and add engine oil EO30-
CD through the oil filler.
5 Swing machinery case : Approx. 2.5 l
30-48 PC128US-2
(16)
SWING MACHINERY
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
6 Swing machinery case: 2.5 l

Lift off the swing motor assembly (1).
4 Swing motor assembly: 30 kg
3. No. 1 sun gear and No. 1 carrier assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 1 carrier assembly (3).
4) Disassemble No. 1 carrier assembly (3)

according to the following procedure.
i) Remove snap ring (5), thrust washer (6),
gear (7), bearing (8), spacer (11) and
thrust washer (9).
ii) Remove snap ring (4).
iii) Remove No. 2 sun gear (13).
4. Ring gear
Remove ring gear (14).
PC128US-2 30-49
(16)

1) Disassemble No. 2 carrier assembly accord-
ing to the following procedure.
i) Remove snap ring (16), thrust washer
(17), gear (18), bearing (19), spacer (23)
and thrust washer (20).
ii) Using tool F6, remove nut (21).
iii) Set shaft and case assembly (27) to
block [2]. Using push tool [3] and the
press, remove shaft assembly (28) and
carrier (22).
a Set a wood board, etc. under the
press so that the shaft assembly will
not be damaged when it comes out
and falls.
iv) Remove sub bearing (25) from carrier
(22).
6. Shaft assembly
Using push tool F1, remove bearing (29) and col-
lar (30) from shaft (31).
7. Oil seal, bearing outer race

1) Remove oil seal (32) from case (33).
30-50 PC128US-2
(16)
2) Using puller [4], remove bearing outer races

(34) and (35) from case (33).
PC128US-2 30-51
(16)
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing outer races

Using push tool F7 and F8, press fit outer races
(34) and (35) to case (33).
2. Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
shaft (31).
2) Using push tool F9, press fit bearing (29)

with press.
a Press-fitting force:
11.8 – 31.4 kN {1.2 – 3.2 ton}
3) Using tool F10 [5], press fit sub bearing (25)

to the No. 2 carrier (22).
4) Using tool [5] and the press, press fit No. 2

carrier (22) to the shaft spline.
2 Splined : Grease (G2-LI)
a Press-fitting force:
7.25 – 31.8 kN {0.74 – 3.24 ton}
a Turning the case, press fit the bearing
slowly.
5) Using tool F6 and install nut (21).

Tighten nut (21) to the specified torque and
give the bearing 3 turns clockwise and coun-
terclockwise respectively, and then tighten
the nut to the specified torque again.
2 Nut (21) : Thread tightener (LT-2)
(Min. 0.5 cc, 10 drops)
3 Nut (21) :
784 – 833 Nm {80 – 85 kgm)
6) Using tool F6 and F11, measure the running

torque of the shaft.
a Running torque: Max. 19.6 Nm {Max. 2.0
kgm}
30-52 PC128US-2
(16)
3. Oil seal
Using push tool F2, press fit oil seal (32).
2 Periphery of oil seal: LG-6

a Replace the oil seal with a new part.
2 Lip of oil seal : Grease (G2-LI)

a Do not stick LG-6 to the lip and shaft.

1) Assemble No. 2 carrier assembly according
to the following procedure.
• Install thrust washer (20), spacer (23),
bearing (19), gear (18), thrust washer
(17), and snap ring (16) to carrier (22).
5. Ring gear
Install ring gear (14).
6. No. 1 carrier ass’y

1) Install No. 2 sun gear (13) to carrier (10), and
then install snap ring (4).
2) Install thrust washer (9), bearing (8), gear
(7), thrust washer (6), and snap ring (5).
PC128US-2 30-53
(16)
3) Install No. 1 carrier assembly (3).

4) Install No. 1 sun gear (2).
3 Mounting bolt:
Install swing motor assembly (1).
98 – 122.5 Nm {10 – 12.5 kgm}
• Supplying oil and grease

Tighten the drain plug and supply engine oil
EO30-CD through the oil filler.
5 Swing machinery case: Approx. 2.5 l
a Apply LG-5 to the fitting part of the drain

tube.
3 Drain plug:
44.1 – 93.1 Nm {4.5 – 9.5 kgm}
a When mounting the assembly on the

machine, apply gasket sealant LG-6 to the
fitting face of the revolving frame.
30-54 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REVOLVING FRAME
REMOVAL
tery.
1. Remove the work equipment assembly by refer-

ring to "REMOVAL OF WORK EQUIPMENT
ASSEMBLY".
2. Disconnect boom cylinder hoses (1) (right) and

(2) (left).
a Be sure to apply the blind plug to the discon-
nected hose.
3. Remove covers (3) and (4).
4. Temporarily lift the boom cylinder to remove pins

(5) on the bottom.
a Check the number and position of the shims
mounted. [*1]
5. Lift boom cylinder assembly (6) to remove it.

4 Boom cylinder assembly : 120 kg
6. Remove operator cab assembly (7) by referring

to "REMOVAL OF OPERATOR CAB ASSEM-
BLY".
7. Disconnect drain hose (8) and hoses (9) and

(10) between control valve and left travel motor
from center swivel joint.
8. Disconnect hoses (11) and (12) between control

valve and right travel motor.
9. Disconnect hoses (13) between solenoid valve

(Boost) and both travel motors.
10. Disconnect plate (14) from revolving frame.
11. Remove mounting bolts (15), leaving one each at

front and rear. [*2]
PC128US-2 30-55
(16)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
12. Lift revolving frame assembly (16) to loosen

remaining bolts (15).
a Carefully remove the remaining bolts by bal-
ancing them using the crane.
a Carefully lift and remove them to prevent
them from coming in contact with the center
swivel joint or other parts.
4 Revolving frame assembly : 6,100 kg
INSTALLATION
removal.
[*1]
2 Surface inside bushing during pin
assembly : Hyper white grease (G2-T)
2 Greasing after pin assembly :
Hyper white grease (G2-T)
kNever put your finger in the pin hole when

adjusting the position.
a Adjust the clearance between the mount on
the boom cylinder bottom and the frame
using the shims so that it becomes 1mm or
less.
[*2]
2 Swing circle contacting face :
Liquefied gasket (LG-1)
2 Revolving frame mounting bolt screw :
3 Revolving frame mounting bolt :
277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}

• Bleeding air
Bleed the air. For details , see TESTING AND
ADJUSTING, Bleeding air from each part.
30-56 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
SWING CIRCLE
REMOVAL
bleed the air from the tank after grounding the
work equipment and stopping the engine and
lock the safety lock lever.
1. Remove the revolving frame assembly by refer-

ring to "REMOVAL OF REVOLVING FRAME
ASSEMBLY".
2. Temporarily lift swing circle assembly (1) to

remove the 38 mounting bolts. [*1]
3. Remove swing circle assembly (1). [*2]

4 Swing circle assembly : 155 kg
INSTALLATION
removal.
[*1]
2 Swing circle mounting bolt :
3 Swing circle mounting bolt :
245 – 308.9 Nm {25 – 31.5 kgm}
[*2]
a Lift swing circle assembly (1) and install it on
the track frame with the inner wheel soft
zone S symbol of the inner race facing the
right side of the body as shown in the figure.
2 Amount of circle grease sealed :
9.1 l (G2-LI grease)
PC128US-2 30-57
(16)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE
TRAVEL MOTOR AND FINAL

DRIVE ASSEMBLY
REMOVAL
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
k Lower the work equipment completely to the
ground and stop the engine. Then loosen the
oil filler cap slowly to release the pressure
inside the hydraulic tank.
2. Swing work equipment 90°, then push up chasis

with work equipment and set block [1] between
track frame and track shoe.
3. Lift off sprocket (1). [*1]

4 Sprocket : 40 kg
4. Remove travel motor cover.
5. Disconnect 4 travel motor hoses (2).
6. Lift off travel motor and final drive assembly. [*2]

a Be extremely careful not to damage the nip-
ple tool surface of the hose mount.
4 Travel motor and final drive assembly:
150 kg
INSTALLATION
removal.
[*1]
2 Thread of travel motor mounting bolt :
Thread tightener (LT-2)
3 Sprocket mounting bolt :
323.6 – 362.8 Nm {33 – 37 kgm}
[*2]
2 Thread of travel motor and final drive
assembly mounting bolt :
3 Travel motor and final drive assembly
mounting bolt :
235 – 285 Nm {23.5 – 29.5 kgm}
a Bleed the air from the travel motor.
Bleeding air from travel motor.

a Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
30-58 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
RECOIL SPRING
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001– 1500
DISASSEMBLY
1. Remove lock plate (1), then remove seat (2) and

valve (3).
2. Remove yoke piston assembly (5) from recoil

spring assembly (4).
3. Disassembly of recoil spring assembly (4)

1) Set recoil spring assembly (4) to tool L2.
kThe recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
a Installed load of spring
: 78,500 N {8,000 kg} (PC128US-2)
: 93,200 N {9,500 kg} (PC138USLC-2)
2) Apply hydraulic pressure slowly to compress
spring, then remove nut (6).
a Compress the spring to a point where the
nut becomes loose.
a Release the hydraulic pressure slowly to
remove the spring tension.
3) Remove pilot (8), spring (7), cylinder (9), and
dust seal (10).
4. Disassembly of yoke piston assembly (5)

1) Remove snap ring (12), then remove U-
packing (13).
2) Remove wear ring (14) from yoke piston (11).
PC128US-2 30-59
(16)
ASSEMBLY
1. Assembly of yoke piston assembly
1) Assemble wear ring (14) to yoke piston (11).
2) Assemble U-packing (13) and secure with
snap ring (14).
2. Assembly of recoil spring assembly

1) Using tool L3, press fit dust seal (10) to cylin-
der (9).
2) Assemble cylinder (9) and pilot (8) to spring
(7), and set to tool L2.
spring, and tighten nut (6) so that installed
length of spring is dimension "a".
a Installed length "a" of spring : 390 mm
4) Remove recoil spring assembly (4) from tool
L2.
3. Assemble yoke piston assembly (5) to recoil

2 Yoke piston sliding portion wear ring :
Grease (G2-LI)
4. Fit valve (3) and seat (2), and secure with lock
plate (1).
a Install the valve so that the direction of the fit-
ting (15) is to the outside.
5. Fill inside of cylinder with a minimum of 120 cc of

grease.
2 Inside cylinder : Grease (G2-LI)
30-60 PC128US-2
(16)
RECOIL SPRING
DISASSEMBLY
1. Remove lock plate (1), then remove seat (2) and

valve (3).
2. Remove yoke piston assembly (5) from recoil

3. Disassembly of recoil spring assembly (4)

1) Set recoil spring assembly (4) to tool L2.
kThe recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
a Installed load of spring :
84,300 N {8,600 kg}
spring, then remove nut (6).
a Compress the spring to a point where the
nut becomes loose.
a Release the hydraulic pressure slowly to
remove the spring tension.
3) Remove pilot (8), and spring (7).
4) Remove snap ring (10), dust seal (11) and
bush (12) from cylinder (9).
4. Disassembly of yoke piston (5) assembly

1) Remove snap ring (14), then remove U-
packing (15).
2) Remove wear ring (16) from yoke piston
(13).
PC128US-2 30-61
(16)
ASSEMBLY
1. Assembly of yoke piston assembly
1) Assemble wear ring (16) to yoke piston (13).
2) Assemble U-packing (15) and secure with
snap ring (14).
2. Assembly of recoil spring assembly

1) Using tool [1], press fit bush (12) to cylinder
(9).
2) Using tool L3, press fit dust seal (11) to cylin-
der (9).
3) Assemble cylinder (9) and pilot (8) to spring
(7), and set to tool L2.
spring, and tighten nut (6) so that installed
length of spring is dimension "a".
a Installed length "a" of spring : 390 mm
5) Remove recoil spring assembly (4) from tool
L2.
3. Assemble yoke piston assembly (5) to recoil

2 Yoke piston sliding portion wear ring :
Grease (G2-LI)
4. Fit valve (3) and seat (2), and secure with lock
plate (1).
a Install the valve so that the direction of the fit-
ting (17) is to the outside.
5. Fill inside of cylinder with a approximately 120 cc

of grease.
2 Inside cylinder : Grease (G2-LI)
30-62 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY IDLER
IDLER
DISASSEMBLY
1. Remove dowel pin (1), then remove support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
3. Pull out idler (4) from shaft (5) and support

assembly (7).
a It is filled with approx. 90 cc. of oil, so drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
4. Remove floating seal (6) (on opposite side) from

idler (4) and shaft (5) and support assembly (7).
5. Remove dowel pin (8), then remove support (7)

from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
PC128US-2 30-63
(16)
ASSEMBLY
1. Press fit bushings (9) and (10) to idler (4).
2. Fit O-ring and install support (7) to shaft (5) with

dowel pin (8).
3. Using tool L1, install floating seal (6) to idler (4)

and shaft (5) and support assembly (7).
a Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it.
a Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
4. Assemble shaft (5) and support assembly (7) to

idler (4).
30-64 PC128US-2
(16)
5. Add oil between shaft (5) and idler (4).

5 Oil : 90 – 105 cc (EO30-CD)
6. Using tool L1, install floating seal (3) to idler (4)

and support (2).
a Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it.
a Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
PC128US-2 30-65
(16)
7. Install O-ring, then install support (2) with dowel

pin (1).
30-66 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
TRACK ROLLER
DISASSEMBLY
1. Remove pin (1), then remove collar (2).
8 5
6
10
4
9
3
2
11
CLP00790
2. Remove floating seal (3) from collar (2) and roller

(4).
3. Pull out roller (4) from shaft (5).

a It is filled with 75 – 85 cc. of oil, so drain the
oil at this point or lay a cloth to prevent the
area from becoming dirty.
4. Remove floating seal (6) (on opposite side) from

roller (4) and shaft (5).
PC128US-2 30-67
(16)
5. Remove collar (8) from shaft (5).
6. Remove bushings (9) and (10) from roller (4).
CLP00791
ASSEMBLY
1. Using push tool [1], press fit bushings (9) and
(10) to roller (4).
2. Assemble collar (8) to shaft (5).
3. Using tool M1, install floating seal (6) to shaft (5).

a When assembling the floating seal, clean the
contact surface of O-ring (6c) and floating
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to the
contact surface of the floating seal.
4. Using tool M1, install floating seals (6) and (3)

to roller (4).
a For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and
5
(3d), see the precautions marked a for Step
3.
5. Assemble shaft (5) to roller (4).

4
CLP00793
6. Turn over roller (4) and shaft (5) assembly.
7. Using tool M1, install floating seal (3) to collar

(2).
4
a For details of the precautions when installing
floating seals (3a) and (3c), see the precau-
tions marked a for Step 3.
5
CLP00866
30-68 PC128US-2
(16)
8. Assemble collar (2) to shaft (5), and install pin

(1). 1
2
CLP00867
9. Using tool M2, apply standard pressure to roller

oil filler port and check air leakage.
a Standard pressure : 0.1 MPa {1 kg/cm²}
a Method of checking :
The standard pressure shall be maintained
for 10 seconds and the indicator of the gauge
shall not go down.
10. Using tool M2, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil : 75 – 85 cc (EO30-CD)
PC128US-2 30-69
(16)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
TRACK SHOE
REMOVAL
1. Lower work equipment to ground, then loosen
lubricator (1), and relieve track tension. [*1]
kThe adjustment cylinder is under extremely
high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards and
forwards.
2. Move machine forward so that position of master

pin is at front of idler, and set block [1] in position.
3. Using tool R, pull out master pin. [*2]
4. Remove tool R, pull out temporary pin, and

remove dust seal, then drive machine in reverse
to lay out track (2). [*3]
INSTALLATION
[*1]
a Adjust the track tension.
Testing and adjusting track tension.
[*2]
a Use tool R and press fit the master pin so
that the protrusion of the master pin is
dimension "a".
Protrusion "a" of master pin : 5.5 ± 2 mm
[*3]
a When assembling the dust seal, coat the
bushing contact surface with grease (G2-LI).
a If the rubber of the road liner (rubber pad type)

becomes worn or broken and the head of the
mounting bolt becomes damaged, replace the
shoe with a new part immediately. If the head of
the mounting bolt becomes fla ttened, it will be
impossible to remove it.
30-70 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL
k Gradually loosen the hydraulic tank cap to

tery.
1. Drain the hydraulic oil.

6 Hydraulic oil : 100 l (Capacity)
69 l (Oil level)
2. Remove the fuel tank assembly by referring to

"REMOVAL OF FUEL TANK ASSEMBLY".
3. Disconnect the clamp from the swing machinery
oil level gauge pipe.
4. Disconnect inter-oil cooler hose (2) and inter-
control valve hose (3) to disconnect hose clamp
(4).
5. Disconnect main pump suction hose (5).

6. Disconnect PPC valve drain hose (6).
7. Disconnect harness clamp (7).
8. Disconnect engine oil filter bracket (8).
a Move the filter assembly close to the engine.
a Put the reserve tank on the main pump.
9. Disconnect self pressure reducing valve drain

hose (9), swing motor drain hose (10), boom lock
valve drain hose (11), solenoid valve drain hose
(12), main pump drain hose (13) and travel
motor drain hose (14).
10. Temporarily lift hydraulic tank (15) and remove

the mounting bolt to slowly lift and remove it. [*1]
4 Hydraulic tank assembly : 95 kg
PC128US-2 30-71
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION
removal.
[*1]
2 Thread of hydraulic tank mounting bolt :
3 Hydraulic tank mounting bolt :
277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}

5 Hydraulic tank : 100 l (Capacity)
69 l (Oil level)
• Bleeding air
Bleed the air.
Bleeding air from each part.
30-72 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY MAIN PUMP
MAIN PUMP
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL

tery.

69 l (Oil level)

ASSEMBLY".
3. Disconnect hose (1) from the radiator upper tank
to remove bracket (2) from the fuel tank together
with the reserve tank.
a An EPC valve connector is mounted to it.
5. Disconnect PPC main pressure hose (4).
6. Disconnect earth cable (5) from the pump side.
8. Disconnect EPC valve connector (7) (C13).
9. Disconnect suction tube (8) from the pump.
10. Disconnect pump output hose (9).
11. Disconnect pump pressure input hose (10).
13. Disconnect muffler drain tube (12).
14. Remove adiabatic cover (13).
15. Disconnect joint (14) between the turbo charger
and the muffler and remove muffler assembly
(15) by removing the mounting bolt.
16. Drain the oil from the flywheel case.
6 Flywheel case : 0.75 l
17. Temporarily lift the pump to remove the mounting

bolt and lift main pump assembly (16) to remove
it. [*1]
a Carefully remove it to prevent it from coming
in contact with the engine oil filter.
a It can be removed easier by lifting it at two
points to make it parallel using a lever block.
4 Main pump assembly : 95 kg
PC128US-2 30-73
(16)
MAIN PUMP
REMOVAL
tery.

ASSEMBLY".

69 l (Oil level)
3. Remove cap (40), and then remove reservoir

tank (42) and bracket (41) together.
4. Disconnect connectors C14 (43), C13 (44), and

clip (45).
5. Disconnect drain hose (46) and pump pressure

input hose (47).
6. Disconnect pump spout tube (48) and suction

tube (49).
7. Disconnect LS pressure input hose (50) from A.
8. Remove the mounting bolts and lift off the main

pump (51). [*1]
4 Main pump assembly : 90 kg
30-74 PC128US-2
(16)

INSTALLATION
removal.
[*1]
2 Mating surface of pump case :
Gasket sealant (LG-6)
• Refilling with oil (PTO gear case)

a Add engine oil E010-CD through the oil filler
to the specified level.

a Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
5 Hydraulic tank : 100 l (Capacity)
69 l (Oil level)
• Bleeding air
a Bleed the air from main pump.
PC128US-2 30-75
(16)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
REMOVAL
stop the engine. Turn on the main switch and
operate the work equipment control levers on
both sides freely to release the PPC pressure,
then turn off the main switch.

1. Drain hydraulic oil.

2. Remove handrail (1), then remove covers (2),

(3), and (4).
3. Disconnect solenoid valve outlet hoses (5) (PPC

main pressure), (6) (2nd travel speed), (7)
(Swing holding brake), and (8) (2nd relief).
4. Disconnect hoses (9) connected to bucket cylin-

der.
5. Disconnect hoses (10) connected to arm cylin-

der.
6. Disconnect hoses (11) and (12) connected to

boom cylinder.
7. Disconnect boom lock valve drain hose (13).
8. Disconnect hoses (14) connected to right travel

motor and hoses (15) connected to left travel
motor.
9. Disconnect 2 hoses (16) connected to both

swing motors.
30-76 PC128US-2
(16)
10. Disconnect hose (17) connected to main pump.
11. Disconnect hose (18) connected to PC-EPC

valve.
12. Disconnect drain hoses (19) and (20).
13. Disconnect hose (21) between main relief valve

and solenoid valve (A2).
14. Disconnect hoses (22) and (23) connected to

main pump (LS valve).
15. Disconnect right PPC hoses (24) (Bucket), (25)

(Arm), (26) (Boom), (27) and (28) (Right and left
travel), and (29) (Swing).
16. Disconnect left PPC hoses (30) (Bucket), (31)

(Arm), (32) (Boom), (33) (Right and left travel),
and (35) (Swing).
17. Disconnect drain hose (36).
18. Sling control valve assembly (38) temporarily

and remove mounting bolts (37).
19. Lift off control valve assembly (38).

4 Control valve assembly
: 85 kg (Standard specification)
:100 kg (Blade specification)
INSTALLATION
removal.

• Bleeding air.
Bleed the air from the circuit between the valve
and the hydraulic cylinder.
PC128US-2 30-77
(16)
CONTROL VALVE
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
DISASSEMBLY
30-78 PC128US-2
(16)
PC128US-2 30-79
(16)
30-80 PC128US-2
(16)
a Pressure is still applied to the safety-suction 7. Boom control valve

valve circuit for a while after the machine is 1) Remove 2 cases (35), then remove 2 springs
stopped. Accordingly, loosen pressure releasing (36) and 2 retainers (37).
plug (1) gradually to release the internal pres- 2) Remove spool assembly (38).
sure. a Do not disassemble the spool assembly.
a Do not disassemble the safety-suction valve,
since its pressure cannot be set while it is 8. Boom hydraulic drift prevention valve
installed to the machine. a When disassembling the boom hydraulic drift
a The spools and pressure compensation valves prevention valve after removing it from the
(flow control valve, pressure reducing valve, and valve unit, remove 4 bolts (39) and 2 bolts
piston) of the valves are not interchangeable with (40).
each other and they must be assembled in their Bolt (41) is used to install plate (42).
own directions. Accordingly, be sure to mark a When disassembling the boom hydraulic drift
them before removing them. prevention valve without removing it from the
valve unit, remove 4 bolts (39) and 1 bolt
1. Valve assembly (41).
1) Remove main relief valve assembly (2). 1) Remove plate (42), then remove spring (43),
2) Remove safety-suction valve assembly (3). piston (44), spring (45), and valve (46).
3) Remove LS select valve assembly (4). 2) Remove spring (47), then piston (48).
4) Remove 10 suction valve assemblies (5). 3) Remove plug (49), then remove sleeve (50).
5) Remove unload valve assembly (6).
9. Arm control valve
2. Lift check valve and cooler bypass valve 1) Remove 2 cases (51), then remove 2 springs
1) Remove case (7), then remove spring (8), (52) and 2 retainers (53).
piston (9), and sleeve (10). 2) Remove spool assembly (54).
2) Remove case (11), then remove spring (12), a Do not disassemble the spool assembly.
piston (13), and sleeve (14).
10. Arm regeneration valve
3. Swing control valve Remove plug (55), then remove spring (56) and
1) Remove 2 cases (15), then remove 2 springs valve (57).
(16) and 2 retainers (17).
11. Bucket control valve
2) Remove spool assembly (18). 1) Remove 2 cases (58), then remove 2 springs
a Do not disassemble the spool assembly. (59) and 2 retainers (60).
2) Remove spool assembly (61).
4. Swing bleed valve a Do not disassemble the spool assembly.
1) Remove flange (19).
2) Remove plug (20), then remove spring (21) 12. Service control valve
and spool (22). 1) Remove 2 cases (62), then remove 2 springs
(63) and 2 retainers (64).
3) Remove plug (23), then remove ball (24). 2) Remove spool assembly (65).
a Do not disassemble the spool assembly.
5. Left travel control valve and right travel con-
trol valve 13. Swing pressure compensation valve
1) Remove 2 cases (25), then remove 2 springs 1) Remove plug (66), then remove valve (67)
(26) and 2 retainers (27). and spring (68).
2) Remove spool assembly (28). 2) Remove plug (69), then remove spring (70),
piston (71), and valve (72).
6. Travel interconnection valve
1) Remove 2 plugs (29), then remove 2 springs
(30), 2 retainers (31), and 2 spools (32).
2) Remove 2 plugs (33), then remove 2 balls
(34).
PC128US-2 30-81
(16)
14. Left travel pressure compensation valve and

right travel pressure compensation valve
1) Loosen plug (73) and remove it together with
valve (74).
2) Loosen plug (75), then remove spring (76)
and valve (77).
15. Boom pressure compensation valve

1) Remove plug (78), then remove valve (79)
and spring (80).
2) Remove plug (81), then spring (82), piston
(83), and valve (84).
16. Arm pressure compensation valve

and spring (87).
(90), and valve (91).
17. Bucket pressure compensation valve

and spring (94).
(97), and valve (98).
18. Service pressure compensation valve

and spring (101).
2) Remove valve (102), then spring (103), and
valve (104).
19. Studs for combination (Addition of service

valve)
a When adding a service valve, disassemble
1) Remove 4 nuts (105), then remove 4 studs.
a Remove the studs with a flat-head
screwdriver.
2) Remove cover (106).
30-82 PC128US-2
(16)
ASSEMBLY
PC128US-2 30-83
(16)
30-84 PC128US-2
(16)
PC128US-2 30-85
(16)
a Before assembling the parts, apply engine oil to 2) Install spring (87) and valve (86), then install
their sliding surfaces. plug (85).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
1. Studs for combination (Addition of service
valve)
5. Boom pressure compensation valve
a When adding a service valve, assemble
1) Install valve (84), piston (83), and spring
(82), then install plug (81).
3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}
1) Tighten 4 studs temporarily.
2) Install service valve assembly.
3) Install cover (106).
2) Install spring (80) and valve (79), then install
4) Install 4 washers and tighten nuts (105).
plug (78).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
a Tighten the nuts in the diagonal order
3 Nut :
6. Right travel pressure compensation valve
1st time : 64 ± 4.9 Nm
and left travel pressure compensation valve
{6.5 ± 0.5 kgm}
1) Install valve (77) and spring (76), then install
At this time, check that the
plug (75).
3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}
height of the stud top is
0.5 – 3 mm above the nut
top. If it is out of this
2) Install valve (74) and plug (73) as one unit.
3 Plug : 107.8 ± 9.8 Nm {11 ± 1 kgm}
range, loosen the nut and
adjust the height of the
stud with a flat-head
screwdriver. 7. Swing pressure compensation valve
2nd time : 83.36 ± 4.9 Nm 1) Install valve (72), piston (71), and spring
{8.5 ± 0.5 kgm} (70), then install plug (69).
3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}
3rd time : 105.42 ± 7.4 Nm
{10.75 ± 0.75 kgm}
Check again that the 2) Install spring (68) and valve (67), then install
height of the stud top is plug (66).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
0.5 – 3 mm above the nut
top.
8. Service control valve
2. Service pressure compensation valve
1) Install spool assembly (65).
1) Install valve (104) and spring (103), then
2) Install 2 retainers (64) and 2 springs (63),
install valve (102).
3 Valve : 215.6 ± 19.6 Nm {22 ± 2 kgm}
then install 2 cases (62).
3 Mounting bolt :
2) Install spring (101) and valve (100), then 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
install plug (99).
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
9. Bucket control valve
1) Install spool assembly (61).
2) Install 2 retainers (60) and 2 springs (59),
3. Bucket pressure compensation valve
3 Mounting bolt :
3 Plug : 166.6 ± 19.6Nm {17 ± 2 kgm}
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
2) Install spring (94) and valve (93), then install 10. Arm regeneration valve
plug (92). Install valve (57) and spring (56), then install plug
3 Plug : 215.6 ± 19.6 Nm {22 ± 2 kgm}
(55).
4. Arm pressure compensation valve

3 Plug : 166.6 ± 19.6 Nm {17 ± 2 kgm}
30-86 PC128US-2
(16)
11. Arm control valve 17. Swing control valve

1) Install spool assembly (54). 1) Install spool assembly (18).
2) Install 2 retainers (53) and 2 springs (52), 2) Install 2 retainers (17) and 2 springs (16),
then install 2 cases (51). then install 2 cases (15).
3 Mounting bolt : 3 Mounting bolt :
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm} 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
12. Boom hydraulic drift prevention valve 18. Cooler bypass valve and lift check valve
1) Install sleeve (50), then install plug (49). 1) Install sleeve (14), piston (13), and spring
2) Install piston (48), then install spring (47). (12), then install case (11).
3 Mounting bolt :
3) Install valve (46), spring (45), piston (44),
and spring (43), then install plate (42).
3 Mounting bolts (39), (40) :
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
2) Install sleeve (10), piston (9), and spring (8),
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
then install case (7).
3 Mounting bolt :
Mounting bolt (41) :
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
13. Boom control valve
1) Install spool assembly (38). 19. Valve assembly
2) Install 2 retainers (37) and 2 springs (36), 1) Install unload valve assembly (6).
3 Unload valve assembly :
3 Mounting bolt : 166.6 ± 19.6 Nm {17 ± 2 kgm}
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
2) Install 10 suction valve assemblies (5).
14. Travel interconnection valve 3 Suction valve assembly :
1) Install 2 balls (34), then install 2 plugs (33). 147 ± 9.8 Nm {15 ± 1 kgm}
3 Plug : 7.4 ± 1.5 Nm {0.75 ± 0.15 kgm} 3) Install LS select valve assembly (4).
2) Install 2 spools (32), 2 retainers (31), and 2 3 LS select valve assembly:
springs (30), then install 2 plugs (29). 127.4 ± 19.6 Nm {13 ± 2 kgm}
3 Plug : 55.9 ± 6.9 Nm {5.7 ± 0.7 kgm} 4) Install safety-suction valve assembly (3).
3 Safety-suction valve assembly :
15. Right travel control valve and left travel con-
186.2 ± 9.8 Nm {19 ± 1 kgm}
trol valve
1) Install spool (28). 5) Install main relief valve assembly (2).
3 Main relief valve assembly :
2) Install 2 retainers (27), 2 springs (26), then
install 2 cases (25).
3 Mounting bolt :
98 ± 9.8 Nm {10 ± 1 kgm}
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
16. Swing bleed valve

1) Install ball (24), then install plug (23).
3 Plug :
7.35 ± 1.5 Nm {0.75 ± 0.15 kgm}
2) Install spool (22) and spring (21), then install
plug (20).
3 Plug : 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
3) Install flange (19).
3 Mounting bolt :
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
PC128US-2 30-87
(16)
CONTROL VALVE
ASSEMBLY
30-88 PC128US-2
(16)
a In this section, only the precautions for assem- a When loosening and tightening plug T1-5L, be
bling the control valve assembly are described. sure to keep the spool in the valve chamber.
3 T1-5L:14.7 – 19.6 Nm {1.5 – 2 kgm}
• Before assembling the parts, apply engine oil to
See LOCTITE shown below.
3 T1-2L: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
their sliding surfaces.
2 Mating face:
See LOCTITE shown below.
2 T1-2L, T1-5L:
Liquid sealant (Sealend 242 or equivalent)
a The tightening torque of the parts and the pre- Apply 1 drop (about 0.02 g) of
cautions are shown below (in random order). LOCTITE No. 638 to each of the
points shown below.
• T (Install cover (1)):
Tighten the nuts in the diagonal order according a Degrease and dry up the threads of the plugs
to the following procedure. and female screws in advance. Do not apply
pressure for 2 hours after tightening them.
3 58.8 – 68.6 Nm {6 – 7 kgm}

1st time :
3 78.5 – 88.3 Nm {8 – 9 kgm}

2nd time :
3 98.1 – 113 Nm {10 – 11.5 kgm}

3rd time :
a The height of the stud top above the nut top:

0.5 – 3 mm
3 T1-2 : 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 T2-8 : 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
3 T2 : 19.6 – 27.5 Nm {2 – 2.8 kgm}
3 T3-5 : 34 – 44 Nm {3.5 – 4.5 kgm}
3 T5 : 49 – 63.7 Nm {5 – 6.5 kgm}
3 T6 : 59 – 78 Nm {6 – 8 kgm}
3 T9 : 88.3 – 107.9 Nm {9 – 11 kgm}
3 T10 : 98.1 – 123 Nm {10 – 12.5 kgm}
3 T11 : 108 – 147 Nm {11 – 15 kgm}
3 T14 : 137 – 157 Nm {14 – 16 kgm}
3 T15 : 147 – 186 Nm {15 – 19 kgm}
3 T18 : 176.6 – 196.2 Nm {18 – 20 kgm}
3 T20 : 196 – 240 Nm {20 – 24.5 kgm}
PC128US-2 30-89
(16)
30-90 PC128US-2
(16)
PC128US-2 30-91
(16)
DISASSEMBLY AND ASSEMBLY LS SELECTION VALVE
LS SELECTION VALVE
DISASSEMBLY
1. Remove valve (2) from sleeve (1).
2. Remove O-rings (4) and (5), and seal (6) from

sleeve (1).
3. Remove plug (7), then remove pistons (8) and

(9), and spring (10).
4. Remove O-ring (11) from plug (7), then remove

seal (12) and O-ring (13) from piston (9).
a After disassembling, if there is any abnormal-
ity in any part except O-rings (4), (5), (11), or
seal (6), replace the whole LS select valve
assembly.
ASSEMBLY
a Before assembling coat the sliding surface with
engine oil.
1. Install O-ring (13) and seal (12) to piston (9),

then assemble piston (8) and spring (10), and
install in sleeve (1).
2. Assemble O-ring (11) to plug (7) and install to

sleeve (1).
3 Plug : 68.6 ± 9.8 Nm {7 ± 1 kgm}
3. Install valve (2) to sleeve (1).
4. Install O-rings (4) and (5), and seal (6) to sleeve

(1).
30-92 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
PRESSURE COMPENSATION VALVE

DISASSEMBLY
Pressure compensation valve A : Bucket (Dump, Curl)

B : Arm (Out, In)
C : Boom (Raise, Lower)
D : Travel (Forward, Reverse)
E : Swing (Left, Right)
30-94 PC128US-2
(16)
Disassembly of pressure compensation valves

A, B, C, D, and E
• Some parts of different part Nos. may have

shapes similar to each other. Take care when
assembling them.
1. A (Bucket)
1) Remove plug (1), then remove spring (2),
2) Remove plug (5), then pull out valve (6) and
remove spring (7) from it.
2. B (Arm)
2) Remove plug (12), then pull out valve (13)
and remove spring (14) from it.
3. C (Boom)
4. D (Travel)
1) Remove plug (22), then remove spring (23)
and valve (24).
2) Remove plug (25), then remove bolt (26) and
washer together.
3) Remove sleeve (27), then remove spring
(28) and valve (29).
5. E (Swing)
(32), and valve (33).
PC128US-2 30-95
(16)
ASSEMBLY
Pressure compensation valve A : Bucket (Dump, Curl)

B : Arm (Out, In)
C : Boom (Raise, Lower)
D : Travel (Forward, Reverse)
E : Swing (Left, Right)
30-96 PC128US-2
(16)
Assembly of pressure compensation valves A, B, 5. E (Swing)

C, D, and E 1) Fit spring (36) to valve (35) and insert them
in valve body, then install O-ring and plug
a Before assembling the parts, apply engine oil to (34).
their sliding surfaces. 2) Install piston (32) and spring (31) to valve (33)
a Tightening torque of plug, bolt, and sleeve and insert them in valve body, then install O-
3 Plugs 1, 8, 12, 15, 22, 30 :
ring and plug (30).
147.0 – 186.0 Nm {15.0 – 19.0 kgm}
3 Plug 25 :
98.1 – 123.0 Nm {10.0 – 12.5 kgm}
3 Plugs 5, 19, 34 :
196.0 – 240.0 Nm {20.0 – 24.5 kgm}
3 Bolt 26 :
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Sleeve 27 :
147.0 – 186.0 Nm {15.0 – 19.0 kgm}
1. A (Bucket)
1) Fit spring (7) to valve (6) and insert them in
valve body, then install O-ring and plug (5).
2) Install piston (3) and spring (2) to valve (4)
and insert them in valve body, then install O-
ring and plug (1).
2. B (Arm)
1) Fit spring (14) to valve (13) and insert them
(12).
2) Install piston (10) and spring (9) to valve (11)
and insert them in valve body, then install O-
ring and plug (8).
3. C (Boom)
(19).
2) Install piston (17) and spring (16) to valve
(18) and insert them in valve body, then
install O-ring and plug (15).
4. D (Travel)
1) Install spring (28) and valve (29) to sleeve
(27) and insert them in valve body and fix
them with washer and bolt (26), then install
O-ring and plug (25) to sleeve (27).
(22).
PC128US-2 30-97
(16)
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
MAIN RELIEF VALVE

DISASSEMBLY
1. Remove ring (1) to remove valve (2) and spring

(3).
2. Loosen nut (4) to remove plug (5) and remove O-

ring (6) from plug (5).
3. Loosen nut (7) to remove holder (8) and remove

retainer (9), O-ring (10) and nut (7) from holder
(8).
4. Remove spring (12) and puppet (13) from sleeve

(11) and remove seat (14).
5. Remove ring (15) and O-ring (16) from seat (14).
6. Remove O-ring (17), seal (18), and O-ring (19)

from sleeve (11).
a If any abnormality is detected on valve (2),
holder (8), retainer (9), seat (14), ring (15),
O-ring (16) or sleeve (11), replace the entire
main relief valve assembly.
30-98 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
ASSEMBLY
a Before assembling the parts, apply engine oil to
their sliding surfaces.
1. Fit O-ring (16) and ring (15) to seat (14), then

install sleeve (11).
2. Install nut (7) and O-ring (10) to holder (8), then

assemble and install retainer (9), puppet (13),
and spring (12) to sleeves (1) and (2).
a Set contact surfaces of seat (14) and puppet
(13) securely.
3. Fit O-ring (6) to plug (5), then install them to

holder (8).
4. Install spring (3) and valve (2) to sleeve (11),

then fit ring (1).
5. Fit O-rings (19) and (17) and seal (18) to sleeve

(11).
6. Tighten nut (7) to specified torque.

3 Nut : 58.8 ± 4.9 Nm {6 ± 0.5 kgm}
7. Tighten nut (4) to specified torque.

3 Nut : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
a After install the main relief valve assembly to the

control valve assembly, adjust the pressure. For
details, see TESTING AND ADJUSTING, Testing
and adjusting hydraulic pressure in work equip-
ment, swing, and travel circuits.
PC128US-2 30-99
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT PPC

VALVE
(FOR BOOM, BUCKET, ARM,
SWING CONTROL)
PC138US-2 Serial No. : 1001 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
DISASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(4).
2. Remove bolts, then remove plate (5).

a Do not remove joint (3) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),

springs (10) and (11), and shim (12).
a Spring (10), (11) consists of each one of two
types of springs with different installed loads
in four places, so check the mounting posi-
tion (oil pressure port) and mark with tags to
prevent mistakes when installing.
5. Pull out valve (13) from body (14).
30-100 PC128US-2
(16)
ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
a When assembling spring (11), set the end
with the small coil diameter (inside diameter)
at shim (12) end.
3. Assemble spring (10), retainer (9), and piston

(8).
a The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Position of port Free length of spring
P1, P2 44.4mm
P3, P4 42.4mm
a The position of each port is marked on the

bottom of the valve body.
2 Piston : Grease (G2-LI)
a When assembling the piston, coat the out-
side of the piston and the inside of the hole in
the body with grease.
4. Fit O-ring to collar (7) and assemble in body (14),

then install seal (6).
5. Install plate (5).

3 Mounting bolt :
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
6. Install joint (3).

2 Sliding portion of joint : Grease (G2-LI)
2 Female thread of body :
a Coat two places on the female thread (A)

with one drop each of Loctite as shown in the
diagram below.
3 Joint : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
a Keep strictly to the tightening torque.
7. Assemble boot (4) and disc (2), and tighten with

nut (1).
3 Nut : 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
a After assembling the disc, adjust the height of
the disc.
Adjusting PPC valve.
PC128US-2 30-101
(16)
WORK EQUIPMENT PPC

VALVE
(FOR BOOM, BUCKET, ARM,
SWING CONTROL)
ASSEMBLY
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
etc. will not cause a trouble.
1. When installing plug (2) to body (1), take care

that its tip will not enter the hole of the body 20
mm in diameter.
3 Plug (2) : 4 – 9 Nm {0.4 ± 0.9 kgm}
2. The head of plug (3) must not be projected from

the body surface.
3 Plug (3) : 6 – 11 Nm {0.6 ± 1.1 kgm}
3. When installing piston (8), apply grease (G2-LI)

to its outside and the inside of the body hole.
4. Install spring (5) with its small diameter side on

the shim (4) side.
• Diameter of spring (Inside diameter)
Small diameter side: 4.9, Large diameter
side: 5.4
5. When installing springs (6) and (7), note that

they are different and they must be installed to
different hydraulic ports.
• Installed height: 34 mm (Common to both
springs)
• Installed load:
Spring (6) (P1, P2): 29 N {3 kg}
Spring (7) (P3, P4): 17.7 N {1.8 kg}
3 Bolt (9): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
30-102 PC128US-2
(16)
6. When installing joint (10) to body (1), apply LOC-

TITE as shown below.
1) When installing the joint, apply 1 drop
(approx. 0.02 g) of LOCTITE (No. 262) each
to 2 places of the female screw (A) of the
body. Before installing the joint, thoroughly
degrease and dry its male screw and the
female screw of the body with DRYSOL.
2) Drop LOCTITE to the following positions.
2 Female screw (A) of body:
LOCTITE No. 262
3 Joint (10) : 39 – 49 Nm {4 – 5 kgm}
7. Install nut (11).

2 Apply 1 drop (about 0.02 g) of LOCTITE
No. 641 to each of the points shown
below.
8. Apply grease (G2-LI) to the rocking part of joint

(10) and the contact surfaces of disc (12) and
piston (8).
2 Quantity of grease (G2-LI)
1) Rocking part of joint: 2 – 4 cc/periphery
2) Contact surfaces of disc and piston: 0.3 – 0.8
cc/place
9. Installation of disc (12)

1) Install disc (12) so that each bolt (9) will be
the center of each side of disc (12) and they
will not interfere with each other during com-
pound operation. (Error: ± 3 degrees)
2) When installing disc (12), adjust it so that the
play of the lever end will be 0.5 – 3 mm (at
200 mm from the center of rotation of the
lever).
3) Fixing disc (12) with [1], tighten nut (13).
a At this time, give play to body (1) or plate
(14) and lock with [2].
3 Nut (13) :
93.1 – 112.7 Nm {9.5 – 11.5 kgm}
PC128US-2 30-103
(16)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
TRAVEL PPC VALVE

1
PC138US-2 Serial No. : 1001 – 4500 2
3
PC138USLC-2 Serial No. : 1001 – 1500
DISASSEMBLY
4
1. Remove screw (1) to remove lever (2).
2
2. Remove mounting bolt (3) to remove case shaft
assembly (4).
5
3. Remove mounting bolt (5) to remove plate (6)
together with damper assembly (7). 18
a Check the thickness and the mounting posi-
tion of washer (18). 1
6
4. Remove mounting bolt (8) to remove damper
assembly (7) from plate (6). 9
5. Remove seal (9) and collar (10). 10
6. Remove piston (11) to remove retainer (12),

springs (13) and (14) and shim (15). 11
a Store shim (15) after checking the thickness 7
and the number of shims at each mounting 12
position. 8
13
7. Remove valve (16) from body (17).
14
15
16
17
CEP00533
• Details of body (17)
30-104 PC128US-2
(16)
ASSEMBLY
1
1. Engage valve (16) with body (17). 2
3
2. Engage shim (15) and spring (14) with valve
(16).
a Mount shim (15) on the position which has 4
been checked at the time of disassembly
with the proper thickness and number. 2
Standard shim thickness : 0.3mm
a Since spring (14) is not symmetric vertically ,
engage it with the smaller diameter side fac- 5
ing the shim.
18
3. Mount spring (13), retainer (12) and piston (11).
2 Piston outside perimeter and body hole :
1
6
Grease (G2-LI)
9
4. Place the O-ring on collar (10) to engage them
with body (17) and mount seal (9) on them.
10
5. Mount damper assembly (7) on plate (6) and
tighten mounting bolt (8). 11
2 Mounting bolt : Adhesive (LT-2) 7
3 Mounting bolt :
12
8
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm} 13
6. Plate (6) together with damper assembly (7) and

14
tighten mounting bolt (5).
a Engage washer (18) with a standard washer 15
(1.6 mm) beforehand.
After completing assembly, measure the dif- 16
ference in the angles when the left and right
levers are at full strokes. If it is larger than
0.7°, change the thickness of the washer
(18) to make it 0.7° or less. 17
• Washer thickness : 1.0, 1.3 or 1.6 mm
a Reducing the washer thickness by 0.3
mm increases the full stroke angle by CEP00533
0.39°.
3 Mounting bolt :
31.0 ± 3.4 Nm {3.15 ± 0.35 kgm}
7. Mount case shaft assembly (4) and tighten

mounting bolt (3).
2 Shaft swaying part, and lever and piston
3 Mounting bolt :
contacting part : Grease (G2-LI)
28.0 ± 3.4 Nm {2.85 ± 0.35 kgm}
8. Mount lever (2) and tighten screw (1).

2 Lever pin and plate swaying part :
3 Screw : 8.8 ± 1.0 Nm {0.9 ± 0.1 kgm}

Grease (G2-LI)
PC128US-2 30-105
(16)
TRAVEL PPC VALVE

ASSEMBLY
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
etc. will not cause a trouble.
1. When installing piston (1), apply grease (G2-LI)

to its outside and the inside of the body hole.
2. Install spring (2) with its small diameter side on

the shim (3) side.
• Diameter of spring (Inside diameter)
Small diameter side: 4.9, Large diameter
side: 5.55
3. Use the insertion jig to insert bushing (4). (Do

not drive in the bushing with impact loads of a
hammer, etc.)
4. Use the insertion jig to insert pin (5). (Do not drive
in the pin with impact loads of a hammer, etc.)
5. Apply grease (G2-LI) to the rocking part of shaft

(6) and the contact surfaces of lever (7) and pis-
ton (1) and the contact surfaces of plate (8) and
pin of lever (9).
2 Quantity of grease (G2-LI)
Rocking part of shaft:4 – 8 cc/periphery
Contact surfaces of lever and piston:
0.3 – 0.8 cc/place
Contact surfaces of plate and pin:
0.3 – 0.8 cc/place
6. Install plate (8) with the cut part on the outside of

the PPC assembly.
7. Install washer (10) 1.6 mm thick first. If the dif-

ference between both sides at the stroke end of
the lever exceeds 0.7°, change the washer thick-
ness to reduce the difference to below 0.7°. (If
the washer thickness is reduced by 0.3 mm, the
stroke end angle is increased by 0.39°.)
• Thickness of washer t: 1.0, 1.3, 1.6
8. Tighten each part to the following torque.

• Plug (11): 6 – 11 Nm {0.6 – 1.1 kgm}
• Bolt (12): 3.9 – 4.9 Nm {0.4 – 0.5 kgm}
(Apply LOCTITE #262.)
• Screw (13): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
• Plug (14): 4 – 9 Nm {0.4 – 0.9 kgm}
• Bolt (15): 25 – 30 Nm {2.5 – 3.2 kgm}
• Bolt (16): 27 – 34 Nm {2.8 – 3.5 kgm}
30-106 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
DISASSEMBLY
a This section explains how to disassemble and
assemble the boom, arm, bucket and blade cyl-
inders. For how to disassemble and assemble
the offset cylinder, refer to "DISASSEMBLY AND
ASSEMBLY OF OFFSET CYLINDER ASSEM-
BLY".
1. Piston rod assembly

1) Remove the piping from the cylinder assem-
bly.
2) Remove the mounting bolt to disconnect
head assembly (1).
3) Remove piston rode assembly (2).
a Place an oil pan or the like under the cyl-
inder to receive oil.
4) Disassemble the piston rod assembly with
the following procedure.
i) Set piston rod assembly (2) on tool U1.
ii) Remove piston assembly lock screw (3).

Screw size
M12 x 1.75 pitch : Boom, arm and blade
M10 x 1.5 pitch : Bucket
a If screw (3) is caulked too tightly to be

removed, force the screw in once and
then tap it to remove it.
PC128US-2 30-107
(16)
iii) Use tool U2 to remove piston assembly

(4).
• If tool U2 is not used, use the four
drill holes (diameter = 10) to loosen
the piston assembly.
iv) Remove plunger (5).
• Arm cylinder and boom cylinder.
v) Remove collar (6).
vi) Remove the head assembly (7).
vii) Remove cap (8) to remove eleven balls

(9) and cushion plunger (10).
• For the arm cylinder only.
a Since cap (8) is made of nylon,
tighten a screw into it and pull it out
with pliers.
2. Sub-disassembly of piston assembly

1) Remove ring (11).
2) Remove wear ring (12).
3) Remove piston ring (13).
4) Remove the O-ring and backup ring (14).
30-108 PC128US-2
(16)
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
PC128US-2 30-109
(16)
ASSEMBLY
a Be careful not to damage the packing, the dust
seal, the O-ring or the like
a Do not forcibly insert the backup ring but make it
warm with hot water (50 to 60°C) before inser-
tion.
1. Sub-assembly of cylinder head assembly

1) Press fit bushing (20) using tool U3.
2) Engage buffer ring (19).
3) Engage rod packing (18).
4) Mount dust seal (17) using tool U4 and fix it
with snap ring (16).
5) Mount the backup ring and O-ring (15).
2. Sub-assembly of piston assembly

1) Expand piston ring (13) using tool U5.
a Set the piston ring on tool U5 and
expand it by rotating the handle eight to
ten times.
2) Reduce piston ring (13) using tool U6.
3) Mount the backup ring and O-ring (14).

4) Engage wear ring (12).
5) Engage ring (11).
a Be careful not to expand the ring abut-
ment joint too much.
2 Ring groove : Grease (G2-LI)
30-110 PC128US-2
(16)
3. Piston rod assembly

1) Set piston rod assembly (2) on tool U1.
2) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (6), and
assemble.
4) Assemble plunger (5).
a Check that there is a small amount of
play at the tip of the plunger.
5) Set cushion plunger (10) on the piston rod

and engage 11 balls (9) and fix them using
cap (8).
6) Assemble piston assembly (4) in the follow-
ing procedure.
• When the rod and piston assembly (2)
are reused
a Completely wash them and clear
them of cut powder or dust.
i) Screw piston assembly (4) and
tighten it using tool U2 until the screw
hole position completely fits.
a Eliminate screw burrs using a file
or the like.
ii) Tighten screw (3).
2 Screw (3) : LOCTITE No. 262
3 Screw (3) :
Boom, arm and blade :
66.2 ± 7.35 Nm
{6.75 ± 0.75 kgm}
Bucket : 30.9 ± 3.4 Nm
{3.15 ± 0.35 kgm}
PC128US-2 30-111
(16)
iii) Caulk the screw at two points through

punching.
• When new rod or/and piston assembly (2) is/

are used
a For the bottom cushion-equipped rod,
mark the cap hole (8) on the rod end sur-
face.
i) Screw piston assembly (4) until it comes

in contact with rod (2) end surface a.
3 Piston assembly (4) :
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, make sure

that there is some play with plunger.
• For the boom and arm cylinders only.
ii) Drill a hole for mounting screw (3).

a Engage the drill with the screw V-
shaped grooves of piston (4) and rod
(2) for horizontal processing.
a Process the bottom cushion-
equipped cylinder (arm cylinder) on
other part than the cap hole (8).
• Screw processing dimensions (mm)
Tap drill Tap drill Tap

Cylinder Tap used
diameter depth depth
Boom, arm
10.3 27 12×1.75 20
and blade
Bucket 8.5 27 10×1.5 20
iii) Clear it of cut powder and dust and com-

pletely wash it after processing.
iv) Tighten screw (3).
2 Screw thread :
3 Screw (3) :
LOCTITE No. 262
Boom, arm and blade :

66.2 ± 7.35 Nm
{6.75 ± 0.75 kgm}
Bucket : 30.9 ± 3.4 Nm
{3.15 ± 0.35 kgm}
v) Caulk the screw at four points through

punching.
30-112 PC128US-2
(16)
7) Engage piston rod assembly (2)

2 Seal : Grease (G2-LI)
a Set the ring abutment joint horizontally

and align the axes of the piston rod
assembly and the cylinder tube to insert
them.
a After insertion, make sure that the ring is
not damaged or dropped and completely
push the piston rod.
8) Mount head assembly (1) and tighten it with

the mounting bolt.
3 Mounting bolt :
Cylinder Tightening torque

Bucket 172±25 Nm {17.5±2.5 kgm}
Arm 270±39 Nm {27.5±4.0 kgm}
Boom 172±25 Nm {17.5±2.5 kgm}
Blade 270±39 Nm {27.5±4.0 kgm}
9) Mount the piping.
PC128US-2 30-113
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL
k Fully extend the work equipment and set a
block at the arm end and lower the bucket tip to

the ground.
1. Remove handrail (1), then remove covers (2),

(3), and (4).
2. Remove undercovers (5) and (6) from boom

mounting section.
3. Disconnect working lamp wiring connector (7)

(M10).
4. Remove guard (8).
5. Disconnect hoses (9) (Arm cylinder bottom), (10)

(Bucket cylinder bottom), (11) (Arm cylinder
head), and (12) (Bucket cylinder head).
a Since the engine will be started, be sure to
plug the disconnected hoses.
6. Disconnect grease tube (13).
7. Remove lock bolt (14). [*1]
8. Remove plate and push out pin (15) to the oppo-

site side until it is removed from cylinder head.
[*2]
a Check the number and location of the shims.
9. Lower boom cylinder (16) onto block [1].

a Connect the cable of the negative (-) terminal
of the battery and start the engine and retract
the boom cylinder.
a Disconnect the cable from the negative (-)
terminal of the battery again.
10. Remove plug (17) from boom foot pin (19).
11. Remove mounting bolts to remove lock plate

(18).
12. Set tool V to boom foot pin (19).
30-114 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
13. Sling work equipment assembly(20) slightly,then

remove pin(19) by using tool V. [*3]
a Lift off work equipment assembly from
revolving frame by using crane.
4 Work equipment assembly : 1,860 kg
INSTALLATION
removal.
[*1]
a When tightening the locknut, tighten so that
the clearance a between the plate and nut is
0.5 – 1.5 mm.
[*2]
2 Inside surface of bushing when assem-
bling pin :
Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :
Grease (LM-G)
kWhen aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust the shim thickness so that clearance
b between cylinder rod (21) and plate (22) is
less than 1 mm.
a Standard shim thickness : 1.0 mm
[*3]
2 Inside surface of bushing when assem-
bling pin :
Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :
Grease (LM-G)
kWhen aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust the shim thickness so that clearance c
between boom (23) and bracket (24) is less
than 0.5 mm.
a Standard shim thickness : 0.5, 1.0, 2.0 mm
• Bleeding air
Bleed the air.
Bleeding air from hydraulic cylinder.

system. Then add oil to the specified level.
PC128US-2 30-115
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
OPERATOR’S CAB
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599
PC138USLC-2 Serial No. :
REMOVAL
tery.
1. Remove louver (1).
2. Remove four screws to remove airconditioner

switch panel (2).
3. Remove screw (3) to slide duct (4) forward.
4. Disconnect airconditioner connectors (M12 and

M31) (5) and (6) to remove duct (4).
5. Disconnect wiper motor connector (CN-75) (7).
6. Disconnect window washer hose (8).

a Bend it to prevent detergent liquid from flow-
ing out of the washer tank.
7. Disconnect radio connector (9)(B3).
8. Remove controller housing panel cover (10).
9. Remove 3 mounting bolts (11) and remove panel

assembly (12) from operatorís cab, then shift it to
rear of operatorís cab.
30-116 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
10. Remove the mounting bolt and lift operator cab

assembly (13) to remove it.
4 Operator cab assembly : 240 kg
INSTALLATION
removal.
PC128US-2 30-117
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
OPERATOR’S CAB
PC138US-2 Serial No. : 2601 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
k When removing the floor frame together, swing
to the left by 135 degrees. (See REMOVAL OF
k Remove the negative (-) terminal from the bat-

FLOOR FRAME ASSEMBLY.).
tery before setting to work.
1. Remove covers (1) – (4) on the monitor panel.

a Be sure to remove in the order of (1), (2), (3),
(4). Otherwise, the covers may not be
removed.
a When removing cover (2), disconnect ciga-
rette lighter connector (CN-M40).
2. Remove cover (5) at the lower front of the opera-

tor seat and remove ducts (6), (7), (8).
3. Remove covers (9), (10), (11) and (12) at the

rear in the operator cab.
4. Loosen four mounting bolts on the bracket

mounting CR700 controller (13) and move the
controller forward (toward the operator).
30-118 PC128US-2
(16)
5. Remove cover (14) and disconnect connectors

(CN-A20)(15), (CN-A21)(16), (CN-A22)(17), and
(CN-M87)(18) at the rear in the operator cab.
6. Remove ducts (19), (20), (21).
7. Disconnect connectors (CN-H08)(22) and (CN-

H09)(23) at the rear left in the operator cab.
8. Disconnect intake duct switching connector (CN-

M83)(25) and remove duct (26).
a Lift the duct (25) to remove.
PC128US-2 30-119
(16)
9. Remove six mounting bolts (8) (marked with )

and four nuts (7)(marked with #). [*1]
a Tighten the nuts (7) together with the floor
frame.
10. Lift and remove the operator cab assembly (29).

4 Operator cab assembly: 280 kg
INSTALLATION
• Carry out installation in reverse oder to removal.
30-120 PC128US-2
(16)
OPERATOR’S CAB
REMOVAL
a When removing the floor frame together, swing
to the left by 135 degrees. (See REMOVAL OF
FLOOR FRAME ASSEMBLY.)
1. Remove the floor mat.
3. Loosen right console (2) and move it inward.

a There is the cigarette lighter, M40.
5. Lower duct joint A, remove connector M88 (4),

and then remove duct (5).
6. Remove covers (6), (7), (8), (9), and (10).
7. Remove ducts (11) and (12).
9. Disconnect connectors A20 (14), A21 (15), and

M87 (16).
10. Remove duct (17).
12. Remove the mounting bolts of controller (19) and

place controller (19) on the floor.
PC128US-2 30-121
(16)
13. Disconnect connector (20).
14. Remove the 2 mounting bolts and duct (21).
15. Disconnect connector R19 (22).
16. Disconnect connector H09 (23), H08 (24), and

V02 (25).
17. Disconnect antenna connector (26).
18. Remove duct hose (27).
19. Disconnect connectors V06 (28) and V09 (29)

from the clip.
20. Disconnect connector V01 (30) (secured with a

screw), (31) (press the hook to disconnect), and
(32) (turn it to disconnect) from KOMTRAX (33).
21. Disconnect wiring harness (34) from the opera-

tor's cab.
22. Take out grommet (35) from the right front of the
cab and disconnect windshield washer hose
from (36).
23. Remove 4 mounting bolts (37) and 6 mounting

bolts (38).
24. Lift off operator's cab assembly (39).

4 Operator's cab assembly: 280 kg
INSTALLATION
• Carry out installation in reverse order to
removed.
30-122 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
OPERATOR’S CAB GLASS (STUCK GLASS)
Amoung the panes of window glass on the 4 (1): Right side window glass
sides of the operator’s cab, 5 panes (1) – (5) are (2): Left side rear window glass
stuck. (3): Door upper window glass
In this section, the procedure for replacing the (4): Door lower window glass
stuck glass is explained. (5): Front window glass
When replacing front window glass (5), remove (6): Front window assembly
front window assembly (6). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the ( 7 ) : Both-sided adhesive tape
front window assembly is installed to the opera- (16) : Center trim seal
tor’s cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
PC128US-2 30-123
(16)
SPECIAL TOOLS
New/Removal
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
REMOVAL
a Remove the window glass to be replaced accor-
ing to the following procedure.
1. Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator’s cab
(metal sheet) (8).
a If a seal cutter is not available, make holes on

the adhesive and both-sided adhesive tape with
a drill and pass a fine wire (piano wire, etc.) [2]
through the holes. Grip the both ends of the wire
with priors [3], etc. (or hold them by winding them
onto something) and move the wire to the right
and left to cut the adhesive and both-sided adhe-
sive tape.
Since the wire may be broken by the frictional
heat, apply lubricant to it.
(The figure shows the operator’s cab of a wheel

loader.)
a If the window glass is broken finaly, it may be

removed with knife [4] and a screwdriver.
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape with
knife [4].

loader.)
2. Remove the window glass.
30-124 PC128US-2
(16)
INSTALLATION
1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking sur-
faces) of the operator’s cab.
a Remove the adhesive and both-sided adhe-
sive tape to a degree that they will not affect
adhesion of the new adhesive. Take care not
to scratch the painted surfaces. (If the
painted surfaces are scratched, adhesion will
be lowered.)
loader.)
2. Remove oil, dust, dirt, etc. from the sticking sur-

faces of cab (8) and window glass (9) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all back part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
PC128US-2 30-125
(16)
3. Apply primer (10).

a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after unpack-
ing it.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a refrig-
erator, leave it at the room temperature
for at least half a dry before stirring it. (If
the primer is unpacked just after taken
out of the refrigertor, water will be con-
densed. Accordingly, leave the primer at
the room temperature for a sufficient
time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.
3) Evenly apply paint primer to the surfaces to
stick both-sided adhesive tapes and the sur-
faces out of those surfaces on operator’s cab
(8) which will be coated with the adhesive.
2 Paint primer:
SUNSTAR PAINT PRIMER
580 SUPER or equivalant
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply the

primer all over dimension (a).
• Dimension to apply primer (a): 25 mm
30-126 PC128US-2
(16)
a As for right side window glass (1), apply

the primer to only the periphery of the
glass to stick the both-sided adhesive
tapes and the areas out of it to apply the
adhesive.
• Part (b)
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wring primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
4) Evenly apply glass primer to the sticking sur-

faces of window glass (9).
2 Glass primer:
SUNSTAR GLASS PRIMER
580 SUPER or equivalant
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply the

primer to the sticking surfaces of window
glass (9) and all over dimension (d)
which will be on both-sided adhesive
tape (7) and operator’s cab (8).
a Do not apply the primer to the boarder
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutues (within 8 hours) to dry.
a Never apply wring the primer. If the
glass primer is applied by mistake, wipe
it off with white gasoline.
PC128US-2 30-127
(16)
4. Stick both-sided adhesive tape (7) along the

inside edge of the glass sticking section.
a Do not remove the release tape of the both-
sided adhesive tape on the glass sticking
side before stiking the glass.
a When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
a When sticking both-sided adhesive tape (7)

around a frame, do not lap its finishing end
over the starting end but make clearance e of
about 5 mm between them.
1) Stick both-sided adhesive tape (7) for right
side window glass (1) as shown in the figure.
a Stick both-sided adhesive tape (7a) addition-

ally for right side window glass (1).
• Positions to stick additional both-sided adhe-
sive tape for right side window glass.
(f) : 140 mm
(g) : 500 mm
2) Stick both-sided adhesive tape (7) for left

side rear window glass (2) as shown in the
figure.
30-128 PC128US-2
(16)
3) Stick both-sided adhesive tape (7) for door

upper window glass (3) and lower window
glass (4) as shown in the figure.
(The figure shows the door upper window
glass.)
(The figure shows the door lower window

glass.)
4) Stick both-sided adhesive tape (7) for front

window glass (5) as shown i the figure.
a Both-sided adhesive tape: 1,004 mm × 2
pieces
• Details of the sticking positions are as

follows.
(h) :Stick to inside end of right and left
front frames (17).
(j) : Retract by "3.0 mm" from the end of
front frame (17).
PC128US-2 30-129
(16)
5. Possition the new window glass.

1) Check the clearance between the window
glass and the operator’s cab on the right, left,
upper, and lower sides, and then adjust it
evenly.
2) Stick tapes [6] between window glass (9) and
operator’s cab (8) and draw positioning line
n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator’s cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the win-
dow glass and operator’s cab before
installing the window glass.
a When positioning front window glass (5),

set its horizontal and vertical positions as
shown below.
Part (m) (Right side):Project by "3.8 mm"
from the frame end.
Part (o) (Upper side):Retract by "3.0
mm" from the frame
end.
6. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
2 Adhesive (Winter):
SEAL 580 SUPER "S"
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where the
temperaure is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
30-130 PC128US-2
(16)
1) Break aluminum seal (13) of the outlet of

adhesive cartridge (12) and install the noz-
zle.
2) Cut the tip of the adhesive nozzle (14) so

that dimension q and r will be as follows.
• Dimension (q) : 10 mm
• Dimension (r) : 15 mm
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
4) Remove the release tape of the both-sided

adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-
sided adhesive tape (7) of the operator’s
cab.
PC128US-2 30-131
(16)
a Apply adhesive (15) to dimensions s and

t of both-sided adhesive tape (7) of oper-
ator’s cab (8).
• Dimension (s) : 10 mm
• Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (7).
a Apply the adhesive evenly.
a As for the right side window glass, apply

the adhesive to the outside of the both-
sided adhesive tape on the periphery of
the glass.
7. Install the window glass.

1) Install window glass (9), matching it to the
lines of the positioning tapes drawn in step 5.
a Sine the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by
pulling window glass (9) from inside of
the operator’s cab with suction cup X1.
(The figure shows the operator's cab of
PC200-7.)
30-132 PC128US-2
(16)
a After installing front window glass (5),

install the center trim seal to its bottom.
Then, apply caulking material all around
the glass to fill part U between the glass
and center trim seal.
a When caulking, neatly arrange the form
of the adhesive at the right and left ends
with a rubber spatula.
2 Adhesive:
Sikaflex 256HV manufactured
by Sika Japan
8. Fix the window glass.

1) After installing right window glass (1) to the
operator’s cab, insert stopper rubbers X2 to
2 places (v) at the bottom of the glass to fix
the glass.
(The figure shows the operator's cab of PC200-
7.)

7.)
PC128US-2 30-133
(16)
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape of fit them completely.
7.)
9. After installing the window glass, remove the

primer and adhesive from the operator’s cab and
window glass.
a Using white gasoline, wipe off the adhesive
before it is dried up.
a When cleaning the glass, do not give an
impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene form
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
30-134 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
FRONT WINDOW ASSEMBLY

stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor’s cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.
REMOVAL
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides). [*1]
2. Remove left lower block (1) and right lower block

(2). [*2]
3. Reset the lock at the rear of the cab.
4. Lower front window assembly (3) carefully a lit-

tle. Put out rollers (4) and (5) under the right and
left sides of the front window through the portion
from which the right and left lower blocks were
removed in step 2 (the bottom of the rails).
5. Twist front window assembly (3) to the right and

left to remove right and left upper rollers (6) and
(7) from the rails, and then remove front window
assembly (3).
a For (6) and (7), see the figure above.
INSTALLATION
removal.
PC128US-2 30-135
(16)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
FLOOR FRAME
PC128US-2 Serial No. : 5001 – 7300
PC138US-2 Serial No. : 1001 – 2600
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL

1. Remove operator’s cab.

(See REMOVAL OF OPERATOR’S CAB)
2. Remove left side cover (1).
3. Disconnect wiring connectors (2) (CN1), (3)

(CN2), (4) (CN4), and (5) (CN3).
4. Disconnect ground cable (6).
5. Remove handrail (7).
7. Disconnect PPC hoses (10) (Bucket dump, arm

out, boom raise, bucket tilt from above).
8. Disconnect PPC hoses (11) (Arm tilt, boom

lower, right swing, and left swing from above).
a If the color tapes are broken and cannot be
judged correctly, put tags, etc. for correct
judgment.
9. Disconnect PPC hoses (12) and (13) for travel

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

(Left).
30-136 PC128US-2
(19)
11. Disconnect PPC main pressure hose (16) (A1).
12. Disconnect PPC drain hose (17).

a Drain hydraulic oil
13. Lift off floor frame assembly (18).

a Take care not to damage the PPC hoses.
4 Floor frame assembly : 65 kg
INSTALLATION
removal.
• Refilling with oil

Run the engine, then check the oil level again.
PC128US-2 30-137
(19)
FLOOR FRAME
PC138US-2 Serial No. : 2601 – 4500
a Swing the upper structure to the left by 135

degrees. (For step 7)
REMOVAL
1. Drain coolant
6 Coolant: 17.2 l
2. Collect air conditioner gas (R134a) from air con-

ditioner circuit.
3. Remove the operator cab assembly by referring

to the "OPERATOR’S CAB ASSEMBLY
[REMOVAL]" section.
4. Remove the side cover (1).
5. Disconnect connectors (1)A01, (2)A03, (3)A04,

(4)A07, (5)A02, (6)A05, (7)A08 , (8)A010 ,and
earth wire(9) and remove tool tray (10).
6. Remove heater hose (11).
7. Remove undercover and disconnect PPC hoses

(12) (P port) and (13) (T port), and four travel
PPC valve hoses (14).
a Four travelling PPC valve hoses may be
removed on the control valve side.
30-138 PC128US-2
(19)
8. Remove upper cover (15) which covers the con-

trol valves.
9. Separate eight work equipment and swing PPC

valve hoses (16).
a The PPC hoses are identified by the follow-
ing markings in the order from the top:
• For bucket CURL: Red
• For boom LOWER: Black
• For left swing: White
• For arm IN: Green
• For bucket DUMP: Red
• For boom RAISE: Yellow
• For right swing: Brown
• For arm OUT: Orange
10. Remove the clamp (17) at the right front of the

revolving frame.
11. Remove the cover from under the seat and dis-
connect air conditioner tubes (18) and (19) from
the air conditioner unit. [*1]
12. Lift and remove floor frame assembly (20).

4 Floor frame assembly: 270 kg
INSTALLATION
[*1]
3 Air conditioner tube nut:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
Filling air conditioning gas

Hydraulic oil
• Start the engine, fill the pipings with hydraulic oil,
and refill to the specified level.
Coolant supply
• Feed coolant from the filling port to the specified
level. Recheck the level after starting the engine
and circulating coolant.
PC128US-2 30-139
(19)
FLOOR FRAME
a Swing the upper structure to the left by 135

degrees. (For step 9)
REMOVAL
1. Drain coolant
6 Coolant: 13.2 l
2. Collect air conditioner gas (134a) from air condi-

tioner circuit.
3. Remove the operator cab assembly by referring

to the "OPERATOR’S CAB ASSEMBLY
[REMOVAL]" section.
4. Remove the side cover (1) and front cover (2).
5. Disconnect connectors (3)A01, (4)A02, (5)A03

and remove from a clip.
6. Disconnect hone connector (6) M18 and earth

wire (7)
7. Remove tool tray.
30-140 PC128US-2
(19)
8. Disconnect 2 heater hoses (11), upper and lower

ones, from under the rear part of the seat.
9. Remove undercover and disconnect PPC hoses

(12) (P port: Blue and White) and (13)(T port:
Red and Green), and four travel PPC valve
hoses (14).
(From the top: Yellow and Black, Yellow and
Green, Yellow and Orange, Yellow and Brown)
a Four travelling PPC valve hoses may be
removed on the control valve side.
10. Remove upper cover (15) which covers the con-

trol valves.
11. Separate eight work equipment and swing PPC

valve hoses (16).
a The PPC hoses are identified by the follow-
ing markings in the order from the top:
• For bucket CURL: Red
• For boom LOWER: Black
• For left swing: White
• For arm IN: Green
• For bucket DUMP: Red
• For boom RAISE: Yellow
• For right swing: Brown
• For arm OUT: Orange
12. Remove the clamp (17) at the right front of the

revolving frame.
PC128US-2 30-141
(16)
13. Remove the cover from under the seat and dis-
connect air conditioner tubes (18) and (19) from
the air conditioner unit. [*1]
14. Lift and remove floor frame assembly (20).

4 Floor frame assembly: 270 kg
INSTALLATION
[*1]
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
Filling air conditioning gas

Hydraulic oil
• Start the engine, fill the pipings with hydraulic oil,
and refill to the specified level.
Coolant supply
• Feed coolant from the filling port to the specified
level. Recheck the level after starting the engine
and circulating coolant.
30-142 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER COMPRESSOR
AIRCONDITIONER
COMPRESSOR
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599
REMOVAL

tery.

ditioner circuit.
2. Open cover (1).
4. Disconnect hoses (3) and (4).

a Plug the hoses and compressor to prevent
dust, water, etc. from entering them.
5. Disconnect wiring connector (5) (M34).
6. Loosen belt tension adjustment bolt (6) and

mounting bolt (7) to remove drive belt (8).
7. Remove bolts (6) and (7) to remove air condi-

tioner compressor assembly (9).
INSTALLATION
removal.
• Filling air-conditioning gas

Using tool X3, charge air conditioner gas
PC128US-2 30-143
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER COMPRESSOR
AIRCONDITIONER
COMPRESSOR
REMOVAL
k Lower the work equipment to the ground com-
pletely.

tery.

ditioner circuit.
2. Open the cover (1).
3. Remove bolt (2) and Loosen bolt (4) and remove

cover (3).
4. Separate hoses (5) and (7) by loosening bolt (6).

a Put blind caps to prevent the entry of dirt or
water into hoses and compressor.
5. Disconnect wire and connector (8)(M34).
6. Loosen mounting bolt (9), lock nut (11), and bolt

(12) to remove air compressor belt . a PC128US-2 Serial No. 9501 and up
7. Remove the bolts (4) and (9) and reomve the air PC138USLC-2 Serial No. 1501 and up
compressor assembly (13).
INSTALLATION
• Carry out installation in reverse oder to reomval.
• Filling new chlorofluorocarbon

30-144 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER CONDENSER
AIRCONDITIONER
CONDENSER
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599
REMOVAL

tery.
1. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

ditioner circuit.
4. Remove air cleaner assembly (3).
5. Disconnect battery relay (4) from bracket.

a Shift the disconnected battery relay forward.
6. Disconnect hose (5) connected to air conditioner

compressor and hose (6) connected to receiver
tank.
a When disconnecting these hoses, be sure to
use two spanners.
7. Remove mounting bolts to remove air conditioner

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

PC128US-2 30-145
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER CONDENSER
AIRCONDITIONER
CONDENSER
REMOVAL
k Lower the work equipment to the ground com-
pletely.

tery.

ditioner circuit.
2. Loosen bolts (1) and remove cover (2).
3. Remove air cleaner cover (3) and remove the

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

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

assembly.
(The wire related to the battery relay must not be
removed.)
6. Loosen bolt (6) and remove the battery relay

mounting plate.
7. Remove battery cover fixing screws (7).
8. Remove hose mounting bolts (8) and (9) and dis-

connect the hose.
a Put blind caps to prevent the entry of dirt or
water into hoses and compressor.
9. Remove bolts (10) and remove condenser [11].
INSTALLATION
• Carry out installation in reverse oder to remaval.

30-146 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY AIRCONDITIONER UNIT
AIRCONDITIONER UNIT
PC128US-2 Serial No. : 5001 – 7299
PC138US-2 Serial No. : 1001 – 2599
REMOVAL

tery.

ditioner circuit.
2. Remove floor mat (1).
4. Remove louver (4) and the four screws to

remove switch panel (5).
5. Remove screw (6) to slide duct (7) forward.
6. Disconnect airconditioner switch connectors (8)

and (9) to remove duct (7).
7. Remove grommet (10).
8. Remove the mounting bolt to disconnect duct
(11) from the airconditioner unit.
9. Disconnect airconditioner unit connector (12)
(M26).
a It is located on the bottom of the centralized
harness.
10. Disconnect heater hoses (13) and (14) at the
rear of the airconditioner unit.
a Since coolant flows out, bend and disconnect
the hose and apply the blind plug to it.
11. Disconnect airconditioner hoses (15) and (16).

a Make sure to double-engage the wrench
before disconnection.
12. Disconnect two relay connectors (17).
PC128US-2 30-147
(19)
13. Remove the mounting bolt to remove aircondi-

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

30-148 PC128US-2
(19)
AIRCONDITIONER UNIT
PC138US-2 Serial No. : 2601 – 4500
PC138USLC-2 Serial No. : 1001 – 1500
REMOVAL
1. Drain coolant.
6 Coolant: 17.2 l

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

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

remove ducts (6), (7), (8).
5. Remove covers (9), (10), (11), (12) at the rear of

the operator cab.
PC128US-2 30-149
(19)
6. Remove the cover (13) and separate the con-

nector (14)(CN-M87). (At the rear right in the
operator cab)
7. Remove ducts (15), (16), (17).
8. Disconnect connectors (CN-M26)(18), (CN-

M85)(19), and (CN-M84)(20) (at the rear of the
operator seat).
9. Disconnect the CR700 controller connector (CN-

021 – 023)(at three positions) and remove the
CR700 controller (21).
30-150 PC128US-2
(16)
10. Remove the heater hose (11).
11. Remove five seat stand mounting bolts and lift

the seat stand by screwing bolts [1] (M12, L =
100mm) into seat stand lifting nuts (left: 2, right:
1).
12. Disconnect two air conditioning hoses, remove

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

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

PC128US-2 30-151
(19)
AIRCONDITIONER UNIT
ASSEMBLY
REMOVAL
k Disconnect negative (-) terminal of the battery.

circuit.
2. Drain engine coolant.
6 Drain 13.2 l of the cooling water.
3. Remove floor mat.
5. Loosen right console (2) and move it inward.

a There is the cigarette lighter, M40.
8. Lower duct joint A, remove connector M88 (6),

and then remove duct (7).
9. Remove duct (8).
10. Disconnect 2 air conditioner tubes (9). [*1]
11. Remove covers (10), (11), (12), and (13).
12. Remove ducts (14) and (15).
30-152 PC128US-2
(19)
13. Remove duct (16).
14. Disconnect connector (17).
15. Remove the 2 mounting bolts and duct (18).
17. Disconnect clip (20).
18. Disconnect connectors M26 (21), M85 (22), and

M84 (23) and remove them from the connector
clips.
19. Disconnect 2 heater hoses (24), upper one and

lower one.
a Do not wet controller B.
20. Remove five seat stand mounting bolts and lift

the seat stand by screwing bolts [1] (M12, L =
100mm) into seat stand lifting nuts (left: 2, right:
1).
21. Remove six air conditioning unit mounting bolts

and remove air conditioning unit assembly (25)
by pulling it out from the downside of the opera-
tor seat.
PC128US-2 30-153
(19)
IINSTALLATION
• Carry out installation in reverse order to removal.
a When installing the hoses of the air conditioning

circuit, care should be taken to prevent the entry
of dirt, dust, water, etc. into hose.
a Check that the pipe couplers of the air condition-
ing hoses have O-rings in them before installa-
tion.
a Check the O-rings for flaw, deterioration, etc.
[*1]
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

ified level. Run the engine to circulate the cool-
ant through the system. Then, check the coolant
level again.
5 Coolant: 13.2 l
30-154 PC128US-2
(19)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL

tery.
1. Remove engine upper cover (1).
2. Disconnect flywheel case oil filler hose (2).
3. Remove fuel gauge connector (3) from the

clamp.
a This is intended to prevent it from coming in
contact with the frame when the counter-
weight is lifted.
4. Sling counterweight assembly temporarily and

remove 3 mounting bolts (4). [*1]
• Width across flats of mounting bolt: 65 mm
5. Lift off counterweight assembly (5) carefully.

4 Counterweight assembly (PC128US-2)
: 3,050 kg (Standard specification)
4 Counterweight assembly (PC138US,

: 2,500 kg (Blade specification)
PC138USLC-2)
: 3,450 kg (Standard specification)
: 3,050 kg (Blade specification)
INSTALLATION
removal.
[*1]
3 Mounting bolt :
3,850 – 4,710 Nm (393 – 480 kgm)
PC128US-2 30-155
(16)
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
MONITOR PANEL ASSEMBLY

REMOVAL
1. Pull cover (2) of monitor panel (1) and remove
the claw stopper.
2. Remove side cover (3).
3. Remove the stopper of cover (4).
4. Remove the 3 mounting bolts of monitor panel

(1) and connectors (5) and (6) on the back side,
then remove monitor panel assembly (1).
INSTALLATION
removal.
30-156 PC128US-2
(16)
DISASSEMBLY AND ASSEMBLY CONTROLLER
CONTROLLER ASSEMBLY
REMOVAL
1. Remove cover (1) from under the rear part of the

seat.
2. Disconnect controller wiring connectors CR1 (2),

CR2 (3) and CR3 (4).
3. Remove the 4 mounting bolts and controller

assembly (5).
INSTALLATION
removal.
PC128US-2 30-157
(16)
40 MAINTENANCE STANDARD
Swing machinery ......................................... 40- 2

Swing circle .................................................. 40- 4
Track frame, idler cushion ........................... 40- 5
Idler ................................................................ 40- 6
Carrier roller .................................................. 40- 8
Track roller .................................................... 40- 9
Sprocket ........................................................ 40-12
Track shoe ..................................................... 40-13
Hydraulic pump (piston pump) ................... 40-17
Control valve ................................................. 40-18
Suction safety valve ..................................... 40-27
Self pressure reduction valve ...................... 40-28
Travel motor .................................................. 40-29
Swing motor ................................................. 40-30
Solenoid valve .............................................. 40-31
Center swivel joint ........................................ 40-32
PPC valve ...................................................... 40-34
Boom hydraulic drift prevention valve
(FOR KUK SPEC.) .......................................... 40-37
Arm hydraulic drift prevention valve
(FOR KUK SPEC.) (If equipped) ................ 40-37-2
Hydraulic cylinder ........................................ 40-38
Work equipment ........................................... 40-41
Dimension of work equipment .................... 40-44
PC128US-2 40-1
(15)
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
40-2 PC128US-2
(15)
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

1 Backlash of swing motor
shaft and No. 1 sun gear 0.07 – 0.18 0.4
Backlash between No. 1

2 sun gear and No. 1 plan- 0.13 – 0.31 0.6
etary gear
3 planetary gear and ring 0.15 – 0.34 0.7
gear
Backlash between No. 1 Replace
4 planetary carrier and No. 2 0.14 – 0.34 0.7
sun gear
gear
etary gear
7 planetary carrier and swing 0.08 – 0.19 0.4
pinion
8 Backlash between swing

pinion and swing circle 0.13 – 1.16 2.3
Standard size Tolerance Repair limit Apply

Wear on swing pinion hardchrome
9 collar’s contact surface 0 plating recondi-
against oil seal 145 – 0.100 144.8
tion, or replace
PC128US-2 40-3
(14)

40-3-1 PC128US-2
(15)
Unit: mm

1 Backlash of swing motor
shaft and No. 1 sun gear 0.07 – 0.18 0.4

etary gear
gear
Backlash between No. 1 Replace
4 planetary carrier and No. 2 0.14 – 0.34 0.7
sun gear
gear
etary gear
7 planetary carrier and swing 0.009 – 0.117 0.2
pinion
8 Backlash between swing

pinion and swing circle 0.13 – 1.16 2.3
Standard size Tolerance Repair limit Apply

Wear on swing pinion hardchrome
9 collar’s contact surface 0 plating recondi-
against oil seal 145 – 0.100 144.8
tion, or replace
PC128US-2 40-3-2
(15)
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
Standard size Clearance limit

1 Clearance between bearing Replace
and circle 0.5 – 1.6 2.6
40-4 PC128US-2
(14)
MAINTENANCE STANDARD TRACK FRAME, IDLER CUSHION
TRACK FRAME, IDLER CUSHION

PC128US-2
PC138US-2
Unit: mm
Standard size Clearance limit
Track Rebuild
Idler guide top frame 84 89
1
and bottom width
Idler Rebuild or
support 82 77 replace
Track Rebuild
frame 185 193
2 Idler guide left
and right width Idler Rebuild or
support 183 175 replace
Standard size Repair limit
Free length Installed Installed Free length Installed

length load load
3 Recoil spring 78.5 kN 69.8 kN Replace

ª1 507 390 {8,000 kg} 494 {7,120 kg}
84.3 kN 75.0 kN
ª2 502 390 {8,600 kg} 490 {7,650 kg}
ª 1. For PC128US-2 Serial No.: 5001 – 5362

ª 2. For PC128US-2 Serial No.: 5363 and up, PC138US-2 Serial No.: 4501 and up
PC128US-2 40-5
(15)
MAINTENANCE STANDARD IDLER
Unit: mm

1 Outer diameter of
protruding portion 527 —
2 Outer diameter of tread 489 477
Depth of protruding Rebuild or

3 portion 19 25
replace
Width of protruding
4 portion 52 42
5 Total width 115 107
6 Width of tread 31.5 36.5
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
7
idler shaft and bushing – 0.250 +0.074
54 – 0.280 0 0.250 – 0.354 1.5
Standard Tolerance Standard in- Interference

Interference between idler size Shaft Hole terference limit Replace
8 and bushing
+0.117 +0.030
61 +0.087 0.057 – 0.117 —
0
9 Side clearance of idler
(on one side) 0.18 – 0.38 1.5
10 Tread wall thickness Rebuild or
(at center of tread) replace
15 9
— Oil amount 90 cc (Engine oil: SAE30CD – Red) —
PC128US-2 40-6-1
A

40-6-2 PC128US-2
(15)
Unit: mm

1 Outer diameter of
protruding portion 527 —
Depth of protruding Rebuild or

3 portion 19 25
replace
4 Width of protruding 52 42
portion
5 Total width 115 107
6 Width of tread 31.5 36.5

Clearance between size Shaft Hole clearance limit
7 idler shaft and bushing – 0.250 +0.074
54 – 0.280 0 0.250 – 0.354 1.5

Interference between idler size Shaft Hole terference limit Replace
8 and bushing +0.117 +0.030
61 +0.087 0.057 – 0.117 —
0
Side clearance of idler
9 (on one side) 0.200 – 0.405 1.5
Tread wall thickness Rebuild or
10 (at center of tread)
16.5 10.5 replace
— Oil amount 90 – 105 cc (Engine oil: SAE30CD) —
PC128US-2 40-7
A
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

Outer diameter of tread Rebuild or
1 replace
116 106
2 Width of tread 123 — —

size Shaft Hole clearance limit
3 Clearance between shaft
and bushing – 0.145 –
40 +0.055 +0.261 —
– 0.035 +0.200 0.226
Replace
size Shaft Hole terference limit
4 Interference between collar
and bushing +0.025
47 +0.061 0.011 – —
+0.036 0 0.061
5 Play on carrier roller in
axial direction 0.363 – 0.537 1.5
Tread wall thickness

6 (at 10 mm away from end Rebuild or
17.7 12.7 replace
face roller)
ª1 72 cc (Engine oil: SAE30CD – Red)

— Oil amount —
ª2 68 – 76 cc (Engine oil: SAE30CD – Red)
ª 1. For PC128US-2 Serial No.: 5001 – 7138

ª 2. For PC128US-2 Serial No.: 7139 and up
For PC138US-2 Serial No.: 4501 and up
40-8 For PC138USLC-2 Serial No.: 1001 and up PC128US-2
(15)
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
PC128US-2 Serial No.: 5001 – 5362
Unit: mm

Diameter of flange
1 (outside) 158 —
Rebuild or
replace
3 Flange width 26.5 —
4 Total width 176 — —
Rebuild or
5 Width of tread 35 — replace

and bushing +0.187
– 0.250
50 – 0.270 – 0.025 0.225 – 0.457 1.5

size Shaft Hole terference limit Replace
7 Interference between roller
and bushing +0.190 +0.090
57 +0.110 0.020 – 0.130 —
+0.060

Track roller side clearance
8 (on one side) 0.155 – 0.345 1.5

(at center of width) 36.5 31.5 replace
PC128US-2 40-9
A
ONE SIDE PIN TYPE

Unit: mm

Diameter of flange
1 (outside) 158 —
Rebuild or
replace
Rebuild or

and bushing +0.186
– 0.250
48 – 0.350 – 0.025 0.225 – 0.536 1.5

55 +0.110 0.017 – 0.127 —
+0.063

8 (on one side) 0.160 – 0.345 1.5

40-10 PC128US-2
(15)
BOTH SIDE PIN TYPE

Unit: mm

Diameter of flange
1 (outside) 158 —
Rebuild or
replace
Rebuild or

and bushing +0.186
– 0.250
48 – 0.350 – 0.025 0.225 – 0.536 1.5

55 +0.110 0.017 – 0.127 —
+0.063

8 (on one side) 0.165 – 0.440 1.5

PC128US-2 40-11
(15)
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Standard size Tolerance Repair limit

Wear on +1.0
1 tooth bottom PC128US-2 547.4 535
– 2.0
diameter
PC138USLC-2 542.8 +1.0 530
– 2.0
Wear on ad- PC128US-2 607 — 595

2 dendum
diameter
PC138USLC-2 607.5 — 595 Rebuild or
replace
3 Wear on addendum width 27 — 22
4 Wear on tooth bottom width 42 ± 1.5 39
+0.465
Tooth bottom PC128US-2 111.7
– 1.160
105.5
5 wall thick-
ness +0.465
PC138USLC-2 109.4 103
– 1.160
40-12 PC128US-2
0
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
TRIPLE SHOE, ROAD LINER, CITY PAD SHOE
ª1. Triple shoe , city pad shoe

ª2. Road liner
fl P portion shows the link of bushing press fitting end.
PC128US-2 40-13
7
PC128US-2
(1/2) Unit: mm

1 Link pitch
175.25 178.25
Reverse or
When turned replace
Standard size
Normal load Impact load
2 Bushing outer diameter
46.3 — 42.3

Reverse or
3 Link height replace
86 81
Link wall thickness

4 (at the section where 24 19
bushing is to be press fit)
5 102.4
Replace
6 Shoe bolt pitch 86.4
7 57
8 Inner width 52.4
9 Link Total width 35 Reverse or

replace
10 Width of tread 30.1
11 Pin protrusion volume 5.5
12 Regular brush protrusion 3.75

volume
13 Total pin length 173

Adjust or
replace
14 Total bushing length 86.7
(master bushing)
15 Bushing wall thickness
7.8 3.8
16 Spacer thickness —
17 Bushing 39.2 – 137.3 kN {4 – 14 ton}
Press fitting —
18 force Regular pin 78.5 – 186.3 kN {8 – 19 ton}
ª
19 Master pin 39.2 – 98.1 kN {4 – 10 ton}
Items with ª marking are applicable to the dry type shoe.
40-14 PC128US-2
(15)
PC128US-2
(2/2) Unit: mm
Tightening torque (Nm {kgm}) Additional tightening angle (deg)
• Triple 196 ± 20 90 ± 10
a. Regular link • City pad {20 ± 2}
• Road liner 147 ± 10 50 ± 5

Shoe bolt {15 ± 1} Retighten
20 Tightening torque Additional tighten- Lower limit torque
(Nm {kgm}) ing angle (deg) (Nm {kgm})
b. Master link
— — —
Number of shoes ª2 42
—
(on one side) ª3 43
Tolerance Standard
Standard size interference
Interference between Shaft Hole
21
bushing and link
+0.387 +0.062
46 0.285 –0.387
+0.347 0
Interference between +0.150 –0.198

22 30 0.198 – 0.400
regular pin and link 0 –0.250
Tolerance Standard
Standard size clearance
Clearance between regular Shaft Hole
23 pin and bushing
+0.150 +0.830
30 0.180 – 0.830 Adjust or
0 +0.330 replace
Tolerance Standard
ª 1 Interference between Shaft Hole
24 master pin and link
+0.020 –0.198
30 –0.250 0.178 – 0.270
–0.020
Tolerance Standard
ª 1 Clearance between master Shaft Hole
25 pin and bushing
–0.200 +0.630
30 0.430 – 0.930
–0.300 +0.230
26 Grouser
height Replace
a. Road liner 58 21
Items with ª 1. marking are applicable to the dry type shoe.

ª 2. Serial No.: 7731 – 9000
ª 3. Serial No.: 9001 and up
PC128US-2 40-15
(15)
PC138US-2
(1/2) Unit: mm

1 Link pitch
175.25 178.25
Reverse or
When turned replace
Standard size
50.6 — 46.6

Reverse or
90 85
Link wall thickness

5 102.4
Replace
7 57
8 Inner width 52.4

replace
12 Regular bushing 3.75

protrusion volume
Adjust or
14 Total bushing length 86.7 replace
(master bushing)

9.0 5
17 Bushing 58.8 – 176.5 kN {6 – 18 ton}
Press fitting
18 force Regular pin 98.1 – 235.4 kN {10 – 24 ton} —
ª
19 Master pin 98.1 – 235.4 kN {10 – 24 ton}
40-15-1 PC128US-2
(15)
PC138US-2
(2/2) Unit: mm

a. Regular link
• Triple 196 ± 20 90 ± 10
{20 ± 2} Retighten
Shoe bolt
Tightening torque Additional tighten- Lower limit torque
20 (Nm {kgm}) ing angle (deg) (Nm {kgm})
b. Master link
— — —
Number of shoes 43 —
(on one side)
Tolerance Standard
21
bushing and link
+0.387 +0.074
50.2 0.273 –0.387
+0.347 0

22 regular pin and link 32 0.238 – 0.400
+0.050 –0.250
Tolerance Standard
23 pin and bushing
+0.150 +0.830
32 0.180 – 0.780 Adjust or
+0.050 +0.330 replace
Tolerance Standard
ª Interference between Shaft Hole
+0.060 –0.188
32 –0.250 0.208 – 0.310
+0.020
Tolerance Standard
ª Clearance between master Shaft Hole
25 pin and bushing
–0.200 +0.830
32 0.530 – 1.130
–0.300 +0.330
26 Grouser height Replace
— —
PC128US-2 40-15-2
(15)
MAINTENANCE STANDARD
PC138USLC-2
(1/2) Unit: mm

1 Link pitch
175.25 178.25
Reverse or
When turned replace
Standard size
50.6 — 46.6

Reverse or
90 85
Link wall thickness

5 102.4
Replace
7 57
8 Inner width 52.4

replace
12 Regular bushing 3.75

protrusion volume
Adjust or
14 Total bushing length 86.7 replace
(master bushing)

9.0 5
17 Bushing 58.8 – 176.5 kN {6 – 18 ton}
Press fitting
18 force Regular pin 98.1 – 235.4 kN {10 – 24 ton} —
ª
19 Master pin 98.1 – 235.4 kN {10 – 24 ton}
40-15-3 PC128US-2
(15)
PC138USLC-2
(2/2) Unit: mm

a. Regular link
• Triple 196 ± 20 90 ± 10
{20 ± 2} Retighten
Shoe bolt
Tightening torque Additional tighten- Lower limit torque
20 (Nm {kgm}) ing angle (deg) (Nm {kgm})
b. Master link
— — —
Number of shoes 46 —
(on one side)
Tolerance Standard
21
bushing and link
+0.387 +0.074
50.2 0.273 –0.387
+0.347 0

22 regular pin and link 32 0.238 – 0.400
+0.050 –0.250
Tolerance Standard
23 pin and bushing
+0.150 +0.830
32 0.180 – 0.780 Adjust or
+0.050 +0.330 replace
Tolerance Standard
ª Interference between Shaft Hole
+0.060 –0.188
32 –0.250 0.208 – 0.310
+0.020
Tolerance Standard
ª Clearance between master Shaft Hole
25 pin and bushing
–0.200 +0.830
32 0.530 – 1.130
–0.300 +0.330
26 Grouser height Replace
— —
PC128US-2 40-15-4
(15)
Triple shoe and city pat shoe
Unit: mm

1 Grouser height ª1 25 15
ª2 20 10
ª1 33 23
2 Shoe height
ª2 29.5 19.5
ª1 8
3 Plate thickness Rebuild or
ª2 9.5
replace
ª1 18
4
ª2 14
ª1 11
5 Grouser edge length
ª2 13
ª1 18
6
ª2 15
ª 1.: PC128US-2 (Serial No.: 5001 – 9000), PC138USLC-2 (Serial No.: 1001 – 1300)
ª 2.: PC128US-2 (Serial No.: 9001 and up), PC138US-2 (Serial No.: 4501 and up),
PC138USLC-2 (Serial No.: 1301 and up)
40-16 PC128US-2
(15)
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP (PISTON PUMP)

TYPE : HPV95 (for 105 cc/rev.)
PC128US-2 Serial No.: 5001 – 7730
PC128US-2 40-17
(15)

40-17-1 PC128US-2
(15)

PC128US-2 40-17-2
(15)
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
7 SPOOL (6 SPOOL + SERVICE VALVE)
(1/9)
40-18 PC128US-2
(15)

(1/9)
PC128US-2 40-18-1
(15)
(2/9)
Unit: mm

1 Suction valve spring × O.D. length load load
5.50±0.40N 4.40 N Replace
46.8 × 7.50 40.6 {0.56±0.04kg} — {0.45 kg} spring if any
damages or
deformations
5.70 N 4.50 N
2 Suction valve spring 16.0 × 16.0 12.0 {0.58 kg} — {0.46 kg}
are found
1.20 N 0.98 N
3 Piston spring 20.0 × 7.0 14.0 {0.12 kg} — {0.10 kg}
PC128US-2 40-19
(15)
(3/9)
Unit: mm

1 Spool return spring × O.D. length load load
230±14.7N 184 N Replace
damages or
deformations
222±13.7N 178 N
2 Spool return spring 45.7 × 28.0 43.0 {22.6±1.40kg} — {18.1 kg}
are found
222±13.7N 178 N
40-20 PC128US-2
(4/9)
Unit: mm

× O.D. length load load
1 Flow control valve spring
9.81±0.98N 7.85 N
36.2 × 5.30 32.0 {1.0±0.10kg} — {0.80 kg}
Pressure reduction valve 17.7±0.98N 13.7 N

2 spring 27.5 × 14.2 18.0 {1.80±0.10kg} — {1.40 kg} Replace
spring if any
Pressure reduction valve 29.4±2.94N 23.5 N damages or
3 spring 28.2 × 14.5 26.0 {3.0±0.30kg} — {2.40 kg} deformations
are found
4 spring 24.1 × 15.0 14.5 {1.0±0.10kg} — {0.80 kg}
74.5 N 59.8 N
5 Relief valve spring 17.1 × 9.0 15.5 {7.60 kg} — {6.10 kg}
Pressure reduction valve 17.6 N 14.1 N

6 spring 32.5 × 14.2 23 {1.8 kg} — {1.44 kg}
PC128US-2 40-21
(15)
(5/9)
Unit: mm

1 Check valve spring × O.D. length load load Replace
spring if any
5.88 N 4.71 N damages or
41.5 × 8.50 31.5 {0.60 kg} — {0.48 kg} deformations
are found
3.14 N 2.25 N
2 Check valve spring 20.3 × 13.7 15.6 {0.32 kg} — {0.26 kg}
40-22 PC128US-2
(15)
(6/9)
Unit: mm

1
Lift check valve spring × O.D. length load load Replace
Cooler bypass valve spring spring if any
135±4.90N 113 N damages or
72.7 × 20.6 42.5 {13.8±0.50kg} — {11.5 kg} deformations
are found
3.92±0.98N 2.94 N
2 Bleed spool return spring 23.3 × 12.5 23.0 {0.40±0.10kg} — {0.30 kg}
PC128US-2 40-23
(15)
(7/9)
Unit: mm

Replace
Free length Installed Installed Installed spring if any
× O.D. length Free length load
1 Travel junction spool load damages or
return spring deformations
13.7±0.10N 10.1 N
17.7 × 8.20 13.0 {1.40±0.10kg} — {1.10 kg} are found
40-24 PC128US-2
(8/9)
Unit: mm

1 Lift check valve spring × O.D. length load load
26.5±1.57N 21.2 N Replace
damages or
deformations
1.94 N 2.35 N
2 Piston return spring 23.7 × 7.70 12.0 {0.30 kg} — {0.24 kg}
are found
5.88 N 4.71 N
PC128US-2 40-25
(15)
(9/9)
40-26 PC128US-2
(15)
FOR KUK SPEC.

PC128US-2
9 spool valve
(6-spool valve + Blade valve + Full-flow service valve + Half-flow service valve)
40-26-2 PC128US-2
(15)
(1/8)
Unit: mm

1 Suction valve spring × O.D. length load load
5.50±0.40N 4.40 N Replace
damages or
deformations
5.70 N 4.50 N
2 Suction valve spring 16.0 × 16.0 12.0 {0.58 kg} — {0.46 kg}
are found
2N 1.6 N
PC128US-2 40-26-3
(15)
(2/8)
Unit: mm

1 Spool return spring × O.D. length load load
230±14.7N 184 N Replace
damages or
deformations
222±13.7N 178 N
are found
222±13.7N 178 N
40-26-4 PC128US-2
(15)
(3/8)
Unit: mm

Free length Installed Installed Installed
Flow control valve spring load
1
9.81±0.98N 7.85 N
36.2 × 5.30 32.0 — {0.80 kg}
{1.0±0.10kg}
Pressure reduction valve 17.7±0.98N 13.7 N Replace
2 spring 27.5 × 14.2 18.0 {1.80±0.10kg} — {1.40 kg} spring if any
Pressure reduction valve 29.4±2.94N 23.5 N damages or
3 spring 28.2 × 14.5 26.0 {3.0±0.30kg} — {2.40 kg} deformations
are found
4 spring 24.1 × 15.0 14.5 {1.0±0.10kg} — {0.80 kg}
74.5 N 59.8 N
5 Relief valve spring 17.1 × 9.0 15.5 {7.60 kg} — {6.10 kg}
Pressure reduction valve 33.3±2N 26.6 N
6 spring 32.5 × 14.2 23.0 {3.4±0.2kg} — {2.7 kg}
PC128US-2 40-26-5
(15)
(4/8)
Unit: mm

spring if any
are found
3.14 N 2.25 N
40-26-6 PC128US-2
(15)
(5/8)
Unit: mm

1
Lift check valve spring × O.D. length load load Replace
Cooler bypass valve spring spring if any
135±4.90N 113 N damages or
72.7 × 20.6 42.5 {13.8±0.50kg} — {11.5 kg} deformations
are found
3.92±0.98N 2.94 N
2 Bleed spool return spring 23.3 × 12.5 23.0 {0.40±0.10kg} — {0.30 kg}
PC128US-2 40-26-7
(15)
(6/8)
Unit: mm

Replace
Free length Installed Installed Installed spring if any
1 Travel junction spool load damages or
return spring deformations
13.7±0.10N 10.1 N
17.7 × 8.20 13.0 {1.40±0.10kg} — {1.10 kg} are found
40-26-8 PC128US-2
(15)
(7/8)
Unit: mm

1 Lift check valve spring × O.D. length load load
26.5±1.57N 21.2 N Replace
damages or
deformations
1.94 N 2.35 N
2 Piston return spring 23.7 × 7.70 12.0 {0.30 kg} — {0.24 kg}
are found
5.88 N 4.71 N
PC128US-2 40-26-9
(15)
(8/8)
40-26-10 PC128US-2
(15)
MAINTENANCE STANDARD SUCTION SAFETY VALVE
SUCTION SAFETY VALVE

FOR SERVICE VALVE
Unit: mm

1 Suction valve spring × O.D. length load load Replace
spring if any
are found
2.06 N 1.57 N
PC128US-2 40-27
(15)
MAINTENANCE STANDARD SELF PRESSURE REDUCTION VALVE
SELF PRESSURE REDUCTION VALVE
Unit: mm

1
Spring × O.D. length load load
(pressure reduction main)
19.6 N 17.7 N
19.2 × 7.20 16.1 {2.0 kg} — {1.80 kg} Replace
spring if any
Spring (pressure reduction 20.6 N 18.6 N damages or
2
valve pilot) 16.5 × 7.20 12.7 {2.10 kg} — {1.90 kg} deformations
are found
200 N 186 N
3 Spring 71.0 × 18.0 59.0 {20.4 kg} — {19.0 kg}
61.7 N 58.8 N
4 Spring (safety valve) 16.1 × 7.80 13.4 {6.30 kg} — {6.0 kg}
40-28 PC128US-2
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
GM18VL-J : PC128US-2 STD (Serial No. 5001 and up)
GM20VL-J : PC128US-2 OPT (Traction up) (Serial No. 5001 – 6072)
GM20VL-P : PC128US-2 OPT (Traction up) (Serial No. 6073 and up)
PC138USLC-2 STD (Serial No. 1001 – 1500)
GM20VL2-P : PC138US-2 STD (Serial No. 4501 and up)
PC138USLC-2 STD (Serial No. 1501 and up)
PC128US-2 40-29
(15)
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF40ABE-3
Unit: mm

0.98 N spring if any
1.28 N
33.0 × 13.8 23.0 {0.13 kg} — {0.10 kg} damages or
deformations
are found
13.7 N 10.8 N
2 Shuttle valve spring 16.4 × 8.90 11.5 {1.40 kg} — {1.10 kg}
40-30 PC128US-2
2
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

STD (WITHOUT BLADE)
Unit: mm
Standard size Standard clearance clearance limit

Clearance between rotor
1 and shaft Replace
80 0.056 – 0.105 0.111
40-32 PC128US-2
A
MAINTENANCE STANDARD CENTER SWIVEL JOINT
OPT (WITH BLADE)
Unit: mm
Standard size Standard clearance clearance limit

Clearance between rotor
1 and shaft Replace
80 0.056 – 0.105 0.111
PC128US-2 40-33
A
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
FOR SWING, WORK EQUIPMENT
PC128US-2 Serial No.: 5001 – 7730 Unit: mm

1 Centering spring load
(for P3 and P4 ports)
29.42 N 23.5 N Replace
44.45 × 15.5 34.0 {3.0 kg} — {2.4 kg} spring if any
damages or
Centering spring deformations
39.22 N 31.4 N
2 (for P1 and P2 ports) 47.93 × 15.5 34.0 {4.0 kg} — {3.2 kg}
are found
17.0 N 13.3 N
3 Metering spring 26.53 × 8.15 24.9 {1.70 kg} — {1.36 kg}
40-34 PC128US-2
(15)

PC128US-2 Serial No.: 5001 and up (For KUK spec.)
PC138USLC-2 Serial No.: 1001 and up Unit: mm

(for P3 and P4 ports)
damages or
Centering spring deformations
39.22 N 31.4 N
2 (for P1 and P2 ports) 47.93 × 15.5 34.0 {4.0 kg} — {3.2 kg}
are found
17.0 N 13.3 N
PC128US-2 40-34-1
(15)
FOR TRAVEL
PC128US-2 Serial No.: 5001 – 6300
Unit: mm

1 Metering spring × O.D. length load load Replace
spring if any
16.7 N 13.7 N
26.5 × 8.15 24.9 {1.70 kg} — {1.40 kg}
damages or
deformations
are found
108 N 86.3 N
2 Centering spring 48.6 × 15.5 32.5 {11.0 kg} — {8.80 kg}
PC128US-2 40-35
(15)

Unit: mm

1 Metering spring × O.D. length load load Replace
spring if any
16.7 N 13.7 N
26.5 × 8.15 24.9 {1.70 kg} — {1.40 kg}
damages or
deformations
are found
108 N 86.3 N
2 Centering spring 48.1 × 15.5 32.5 {11.0 kg} — {8.80 kg}
40-35-1 PC128US-2
(15)
FOR BLADE, FOR SERVICE
For blade Unit: mm

Replace
124.5 N 100 N spring if any
33.9 × 15.3 28.4 {12.7 kg} — {10.2 kg} damages or
deformations
are found
16.7 N 13.3 N
For service Unit: mm

1 Centering spring × O.D. length load load
Replace
207.8 N 167 N spring if any
42.4 × 15.5 28.4 {21.2 kg} — {17.0 kg} damages or
deformations
are found
16.7 N 13.3 N
40-36 PC128US-2
(15)
MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION VALVE
BOOM HYDRAULIC DRIFT PREVENTION VALVE

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

1 Pilot spool spring load
damages or
deformations
4.9 N 3.9 N are found
69.6 N 55.9 N
3 Spool return spring 30.9 × 20.6 29.0 {7.1 kg} — {5.7 kg}
PC128US-2 40-37
C
MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION VALVE

Unit: mm

1 Pilot spool spring × O.D. length load load
damages or
deformations
4.9 N 3.9 N are found
69.6 N 55.9 N
3 Spool return spring 30.9 × 20.6 29.0 {7.1 kg} — {5.7 kg}
40-37-1 PC128US-2
(15)
MAINTENANCE STANDARD ARM HYDRAULIC DRIFT PREVENTION VALVE
ARM HYDRAULIC DRIFT PREVENTION VALVE

(FOR KUK SPEC.) (If equipped)
Unit: mm

1 Check valve spring load
4.9 N 3.9 N
25.4 × 11.6 18 {0.5 kg} — {0.4 kg}
If damaged or
deformed,
replace spring
29.4 N 23.5 N
2 Spool return spring 31.8 × 8.5 25 {3.0 kg} — {2.4 kg}
69.6 N 55.7 N
3 Spool return spring 30.9 × 20.6 29 {7.1 kg} — {5.7 kg}
PC128US-2 40-37-2
(15)
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
BLADE CYLINDER
40-38 PC128US-2
2

PC138USLC-2 Serial No.: 1001 – 1500 Unit: mm

Cylinder
Boom ø 70 – 0.030 +0.259 0.093 – 0.435

– 0.076 +0.063 0.335
Clearance be-
1 tween piston rod Arm ø 75 – 0.030 +0.279 0.095 – 0.455
and bushing – 0.076 +0.065 0.355
Bucket ø 65 – 0.030 +0.250 0.085 – 0.426
– 0.076 +0.055 0.326
Blade ø 75 – 0.030 +0.279 0.095 – 0.455
– 0.076 +0.065 0.355
Boom ø 70 – 0.030 +0.198 0.154 – 1.0
– 0.100 +0.124 0.298
– 0.030 +0.198 0.154 – Replace
Clearance be- Arm ø 70 1.0 bushing
tween piston rod – 0.100 +0.124 0.298
2 support shaft and
Bucket ø 65 – 0.030 +0.174 0.130 – 1.0
bushing – 0.080 +0.100 0.254
Blade ø 70 – 0.030 +0.198 0.154 – 1.0
– 0.100 +0.124 0.298
Boom ø 70 – 0.030 +0.198 0.154 – 1.0
– 0.100 +0.124 0.298
Clearance be- Arm ø 70 – 0.030 +0.198 0.154 – 1.0
tween cylinder – 0.100 +0.124 0.298
3 bottom support – 0.030 +0.174 0.130 –
shaft and bushing Bucket ø 65
– 0.080 +0.100 0.254
1.0
Blade ø 70 – 0.030 +0.198 0.154 – 1.0

– 0.100 +0.124 0.298
Boom 171.6 ± 24.5 Nm {17.5 ± 2.5 kgm}
Arm 269.7 ± 39.2 Nm {27.5 ± 4.0 kgm}

Cylinder head
4 tightening torque
Bucket 171.6 ± 24.5 Nm {17.5 ± 2.5 kgm}
Blade 269.7 ± 39.2 Nm {27.5 ± 4.0 kgm}
Boom 294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}
Arm 294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}

Cylinder piston Re-tighten-
5 tightening torque ing
Bucket 294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}
Blade 294.2 ± 29.4 Nm {30.0 ± 3.0 kgm}
Boom 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
Cylinder piston Arm 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

6 lock screw tight-
ening torque Bucket 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
Blade 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
PC128US-2 40-39
(15)

PC138USLC-2 Serial No.: 1501 and up Unit: mm

Cylinder
Boom ø 70 – 0.030 +0.259 0.093 – 0.435

– 0.076 +0.063 0.335
Clearance be-
1 tween piston rod Arm ø 75 – 0.030 +0.279 0.095 – 0.455
and bushing – 0.076 +0.065 0.355
Bucket ø 65 – 0.030 +0.250 0.085 – 0.426
– 0.076 +0.055 0.326
Blade ø 75 – 0.030 +0.279 0.095 – 0.455
– 0.076 +0.065 0.355
Boom ø 70 – 0.030 +0.190 0.100 – 1.0
– 0.100 +0.070 0.290
– 0.030 +0.190 0.100 – Replace
Clearance be- Arm ø 70 1.0 bushing
tween piston rod – 0.100 +0.070 0.290
2 support shaft and
Bucket ø 65 – 0.030 +0.170 0.100 – 1.0
bushing – 0.080 +0.070 0.250
Blade ø 70 – 0.030 +0.170 0.100 – 1.0
– 0.100 +0.070 0.270
Boom ø 70 – 0.030 +0.190 0.100 – 1.0
– 0.100 +0.070 0.290
Clearance be- Arm ø 70 – 0.030 +0.190 0.100 – 1.0
tween cylinder – 0.100 +0.070 0.290
3 bottom support – 0.030 +0.170 0.100 –
shaft and bushing Bucket ø 65
– 0.080 +0.070 0.250
1.0
Blade ø 70 – 0.030 +0.170 0.100 – 1.0

– 0.100 +0.070 0.270
Boom 172 ± 24.5 Nm {17.5 ± 2.5 kgm}
Arm 270 ± 39 Nm {27.5 ± 4.0 kgm}

Cylinder head
4 tightening torque
Bucket 172 ± 24.5 Nm {17.5 ± 2.5 kgm}
Blade 270 ± 39 Nm {27.5 ± 4.0 kgm}
Boom 294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Arm 294 ± 29.4 Nm {30.0 ± 3.0 kgm}

Cylinder piston Re-tighten-
5 tightening torque ing
Bucket 294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Blade 294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Boom 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
Cylinder piston Arm 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

6 lock screw tight-
ening torque Bucket 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
Blade 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
40-40 PC128US-2
(15)
MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm

Clearance between con- size Shaft Hole clearance limit
1 necting pin and bushing of
revolving frame and boom. – 0.030 +0.130 0.095 –
70 0.8
– 0.100 +0.065 0.230
Clearance between con-
2 necting pin and bushing of 70 – 0.030 +0.141 0.104 – 0.8
boom and arm. – 0.100 +0.074 0.241
arm and link. – 0.080 +0.074 0.209
Replace
arm and bucket. – 0.080 +0.074 0.215
Clearance between con- 0.104 –
5 necting pin and bushing of 65 – 0.030 +0.133 0.8
– 0.080 +0.074 0.213
link and bucket.
Clearance between con- 0.104 –
6 necting pin and bushing of 60 – 0.030 +0.130 0.8
– 0.080 +0.074 0.210
link and link.
Clearance between the 0.154 –
7 blade and track frame 70 – 0.030 +0.198 1.5
– 0.100 +0.124 0.298
mounting pin and bushing
PC128US-2 40-43
A
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit: mm
PC138US-2
PC138USLC-2
No.
Tolerance
Measuring position Standard size
Shaft Hole
1 — ø 70 – 0.030 +0.100
– 0.100 0
Arm side 81.5 +1.0

0
2
Cylinder head side 80 ± 1.2
Boom side 226 +0.5

0
3
Arm side 226 – 0.2
– 0.7
4 — ø 70 – 0.030 +0.100
– 0.100 0
5 — 264 ± 2.0
6 — 213.5 ± 1.0
7 — 640.6 ± 0.5
8 — 2,491 —
9 — 2,101.9 ± 1.5
10 — 290.4 ± 0.5
11 — 487 ± 0.2
12 — 415 ± 0.5
13 — 374.9 —
14 — 1,246.2 —
15 — ø 60 – 0.030 +0.200
– 0.080 0
Link side 259 0

– 0.1
16
Bucket side 261 ± 1.0
17 — ø 60 – 0.030 +0.200
– 0.080 0
Arm side 226 0

– 0.5
18
Bucket side 274 +2.0
0
Min. 1,378 —
19
Max. 2,263 —
40-45-1 PC128US-2
(15)
Unit: mm
PC138US-2
PC138USLC-2
No.
Tolerance
Shaft Hole
1 — ø 70 – 0.030 +0.100
– 0.100 0
Arm side 81.5 +1.0

0
2
Boom side 226 +0.5

0
3
Arm side 226 – 0.2
– 0.7
4 — ø 70 – 0.030 +0.100
– 0.100 0
5 — 284.3 ± 2.0
6 — 230.3 ± 1.0
7 — 635.8 ± 1.0
8 — 2,991.1 —
9 — 2,098.9 ± 1.5
10 — 289.8 ± 0.5
11 — 487 ± 0.2
12 — 415 ± 0.5
13 — 374.9 —
14 — 1,246.2 —
15 — ø 60 – 0.030 +0.200
– 0.080 0
Link side 259 0

– 1.0
16
17 — ø 60 – 0.030 +0.200
– 0.080 0
Arm side 226 0

– 0.5
18
0
Min. 1,378 —
19
Max. 2,263 —
40-45-5 PC128US-2
(15)
Unit: mm
PC138US-2
PC138USLC-2
No.
Tolerance
Shaft Hole
1 — ø 70 – 0.030 +0.100
– 0.100 0
Arm side 81.5 +1.0

0
2
Boom side 226 +0.5

0
3
Arm side 226 – 0.2
– 0.7
4 — ø 70 – 0.030 +0.100
– 0.100 0
5 — 280.5 ± 2.0
6 — 213.0 ± 1.0
7 — 640.7 ± 1.0
8 — 2,088.5 —
9 — 2,101.7 ± 1.5
10 — 290.0 ± 0.5
11 — 487 ± 0.2
12 — 415 ± 0.5
13 — 374.9 —
14 — 1,246.2 —
15 — ø 60 – 0.030 +0.200
– 0.080 0
Link side 259 0

– 1.0
16
17 — ø 60 – 0.030 +0.200
– 0.080 0
Arm side 226 0

– 0.5
18
0
Min. 1,378 —
19
Max. 2,263 —
40-45-9 PC128US-2
(15)
Unit: mm
PC138US-2
No. PC138USLC-2
Measuring position Standard size Tolerance
1 — 371.3 ± 0.5
2 — 51.6 ± 0.5
3 — 97.9˚ —
4 — 374.9 —
5 — 1,231.6 —
6 — 190.2 —
7 — 5˚ —
8 — 0˚ —
9 — ø 60 +0.2
0
10 — ø 64 —
11 — ø 80 +0.25
0
12 — 261 ± 1.0
13 — 50 —
14 — 85 —
15 — 380 +1.0
0
16 — ø 18 —
17 — ø 110 —
18 — ø 130 —
19 — ø 132 —
20 — ø 108 —
21 — 274 —
22 — 51 —
23 — 34 —
24 — 104.2 —
25 — 119.6 —
26 — 74 —
27 — 65 —
40-47-1 PC128US-2
(15)
90 OTHERS
Hydraulic circuit diagram (Attachment)
(Breaker : 1 service valve : 50% amount) ..................................................... 90- 3
(Crasher : 1 service valve : 100% amount) ................................................... 90- 5
(Crasher : 2 service valve : 100% amount) .................................................. 90-5-2
Electric circuit diagram (Air conditioner)
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 7
Electric circuit diagram (Air conditioner)
PC128US-2 (Serial No.: 7731 and up)
PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-7-2
Hydraulic circuit diagram
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 9
PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-9-2
(With 1 actuator attachment)
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 11
PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-11-2
(With blade + 1 actuator attachment)
PC128US-2 (Serial No.: 5001 – 7730) ....................................................... 90- 13
(With blade + 1 actuator attachment)
PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-13-2
Hydraulic circuit diagram (For KUK spec.)
PC128US-2 (Serial No.: 5001 – 7730) ..................................................... 90-13-4
Hydraulic circuit diagram (For KUK spec.)
PC138US-2 (Serial No.: 4501 and up) .................................................... 90-13-6
(With 2 actuator attachment) (For KUK spec.)
PC128US-2 (Serial No.: 5001 – 7730) ..................................................... 90-13-8
(With 2 actuator attachment) (For KUK spec.)
PC138US-2 (Serial No.: 4501 and up) .................................................. 90-13-10
Electric circuit diagram (1/2)
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-15
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-17
PC128US-2 90-1
(15)
PC128US-2 (Serial No.: 6301 – 7730) ..................................................... 90-17-2
PC128US-2 (Serial No.: 6301 – 7730) ..................................................... 90-17-4
PC128US-2 (Serial No.: 7731 – 7874) ..................................................... 90-17-6
PC128US-2 (Serial No.: 7731 – 7874) ..................................................... 90-17-8
PC138USLC-2 (Serial No.: 1001 – 1500) ................................................... 90-17-10
PC138USLC-2 (Serial No.: 1001 – 1500) ................................................... 90-17-12
PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-14
Electric circuit diagram (For KUK spec.) (1/2)
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-19
PC128US-2 (Serial No.: 5001 – 6300) ........................................................ 90-21
PC128US-2 (Serial No.: 6301 – 7730) ........................................................ 90-23
PC128US-2 (Serial No.: 6301 – 7730) ........................................................ 90-25
PC128US-2 (Serial No.: 7731 and up) ....................................................... 90-27
90-2 PC128US-2
(15)
OTHERS HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)

(CRASHER : 2 SERVICE VALVE : 100% AMOUNT)
PC128US-2 90-5-2
A
HYDRAULIC CIRCUIT DIAGRAM
*1. PC128US-2 Serial No.: 7731 and up *2. PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 – 1500 PC138USLC-2 Serial No.: 1501 and up
PC128US-2 90-9-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACTUATOR ATTACHMENT)
PC128US-2 90-11-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT)
PC128US-2 90-13-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.)
PC128US-2 90-13-6
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.)
PC128US-2 90-13-10
(15)
9JB00694
ELECTRIC CIRCUIT DIAGRAM (1/2)
PC128US-2 Serial No.: 7731 – 7874
PC128US-2 90-17-6
A
ELECTRIC CIRCUIT DIAGRAM (2/2) 9JB00695
PC128US-2 Serial No.: 7731 – 7874
PC128US-2 90-17-8
A
PC128US-2 90-17-10
(15)
PC128US-2 90-17-12
(15)
PC128US-2 90-17-14
(15)
PC128US-2 90-17-16
(15)
PC128US-2 90-17-18
(15)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2)
PC128US-2 90-27
(15)
PC128US-2 90-29
(15)
PC128US-2 90-31
(15)
PC128US-2 90-33
(15)
PC128US-2 90-35
(15)

Pc128us Pc138us 2 Sebm018419 U0412

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Pc128us Pc138us 2 Sebm018419 U0412

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SEBM018419

MACHINE MODEL SERIAL NUMBER

PC128US-2 5001 and up

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

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

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

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

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

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE