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KOMATSU PC128US-2 PC138US-2 PC138USLC-2 SHOP MANUAL SEBM018419 – PDF
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Description
KOMATSU PC128US-2 PC138US-2 PC138USLC-2 SHOP MANUAL SEBM018419 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC128US-2 PC138US-2 PC138USLC-2 SHOP MANUAL SEBM018419 – PDF DOWNLOAD
Language : English
Pages : 1029
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC128US-2 PC138US-2 PC138USLC-2 SHOP MANUAL SEBM018419 – PDF DOWNLOAD
MAIN MENU.............................................................................................................................................................................. 0 COVER.................................................................................................................................................................................. 1 CONTENTS............................................................................................................................................................................... 2 FOREWORD............................................................................................................................................................................... 10 GENERAL............................................................................................................................................................................ 10 HOW TO READ THE SHOP MANUAL........................................................................................................................................................ 11 HOISTING INSTRUCTIONS.............................................................................................................................................................. 12 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER......................................................................................................................... 13 COATING MATERIALS.................................................................................................................................................................. 15 STANDARD TIGHTENING TORQUE......................................................................................................................................................... 17 ELECTRIC WIRE CODE................................................................................................................................................................. 20 CONVERSION TABLE................................................................................................................................................................... 21 UNITS.............................................................................................................................................................................. 27 01 GENERAL............................................................................................................................................................................ 28 GENERAL ASSEMBLY DRAWING........................................................................................................................................................... 29 SPECIFICATIONS..................................................................................................................................................................... 40 WEIGHT TABLE....................................................................................................................................................................... 62 LIST OF LUBRICANTS AND WATER....................................................................................................................................................... 76 10 STRUCTURE AND FUNCTION............................................................................................................................................................. 78 PTO................................................................................................................................................................................ 79 RADIATOR AND OIL COOLER............................................................................................................................................................ 80 POWER TRAIN........................................................................................................................................................................ 84 SWING CIRCLE....................................................................................................................................................................... 85 SWING MACHINERY.................................................................................................................................................................... 86 TRACK FRAME........................................................................................................................................................................ 88 IDLER CUSHION...................................................................................................................................................................... 90 HYDRAULIC COMPONENT LAYOUT......................................................................................................................................................... 91 VALVE CONTROL...................................................................................................................................................................... 93 HYDRAULIC TANK AND FILTER.......................................................................................................................................................... 97 HYDRAULIC PUMP (PISTON PUMP)....................................................................................................................................................... 99 CONTROL VALVE...................................................................................................................................................................... 127 SUCTION SAFETY VALVE............................................................................................................................................................... 149 CLSS............................................................................................................................................................................... 150 SELF PRESSURE REDUCING VALVE....................................................................................................................................................... 187 CENTER SWIVEL JOINT................................................................................................................................................................ 194 TRAVEL MOTOR (FINAL DRIVE)......................................................................................................................................................... 196 SWING MOTOR........................................................................................................................................................................ 205 SOLENOID VALVE..................................................................................................................................................................... 211 PPC ACCUMULATOR.................................................................................................................................................................... 213 ACCUMULATOR FOR BREAKER (OPT)...................................................................................................................................................... 214 PPC VALVE.......................................................................................................................................................................... 215 HYDRAULIC DRIFT PREVENTION VALVE................................................................................................................................................... 228 ARM HYDRAULIC DRIFT PREVENTION VALVE............................................................................................................................................... 233 AIR-CONDITIONER PIPING............................................................................................................................................................. 237 ELECTRIC COMPONENT LAYOUT.......................................................................................................................................................... 240 ENGINE CONTROL..................................................................................................................................................................... 244 ELECTRIC CONTROL SYSTEM............................................................................................................................................................ 265 MONITOR SYSTEM..................................................................................................................................................................... 313 20 TESTING AND ADJUSTING............................................................................................................................................................... 322 STANDARD VALUE TABLE............................................................................................................................................................... 323 STANDARD VALUE TABLE FOR ENGINE................................................................................................................................................ 323 STANDARD VALUE TABLE FOR CHASSIS............................................................................................................................................... 325 STANDARD VALUE TABLE FOR ELECTRICAL PARTS...................................................................................................................................... 346 TESTING AND ADJUSTING.............................................................................................................................................................. 357 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING............................................................................................................................... 358 MEASURING ENGINE SPEED......................................................................................................................................................... 359 MEASURING EXHAUST COLOR........................................................................................................................................................ 361 ADJUSTING VALVE CLEARANCE...................................................................................................................................................... 362 MEASURING BLOW-BY PRESSURE..................................................................................................................................................... 364 MEASURING ENGINE OIL PRESSURE.................................................................................................................................................. 365 TESTING AND ADJUSTING FUEL INJECTION TIMING.................................................................................................................................... 366 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.............................................................................................................. 371 TESTING AND ADJUSTING FAN BELT TENSION......................................................................................................................................... 372 ADJUSTING ENGINE SPEED SENSOR.................................................................................................................................................. 373 ADJUSTING FUEL CONTROL CABLE................................................................................................................................................... 374 ADJUSTING ENGINE STOP SOLENOID LINKAGE......................................................................................................................................... 375 TESTING CLEARANCE OF SWING CIRCLE BEARING...................................................................................................................................... 376 CHECKING WEAR OF SPROCKET...................................................................................................................................................... 377 TESTING AND ADJUSTING TRACK SHOE TENSION....................................................................................................................................... 378 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT.............................................................................................. 379 TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)................................................................................................ 382 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE...................................................................... 384 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE............................................................................................................................ 387 MEASURING SOLENOID VALVE OUTPUT PRESSURE....................................................................................................................................... 388 MEASURING PPC VALVE OUTPUT PRESSURE............................................................................................................................................ 389 ADJUSTING PPC VALVE............................................................................................................................................................ 390 TESTING AND ADJUSTING TRAVEL DEVIATION......................................................................................................................................... 391 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................................................................ 392 MEASURING OIL LEAKAGE IN SWING MOTOR........................................................................................................................................... 393 MEASURING OIL LEAKAGE IN TRAVEL MOTOR.......................................................................................................................................... 393 BLEEDING AIR................................................................................................................................................................... 394 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.............................................................................................................................. 396 RELEASING REMAINING PRESSURE IN HYDRAULIC TANK................................................................................................................................ 396 PROCEDURE FOR CHECKING DIODE................................................................................................................................................... 397 PM CLINIC INSPECTION TABLE..................................................................................................................................................... 398 TROUBLESHOOTING.................................................................................................................................................................... 404 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................................................................ 405 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................................................................... 406 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................................................................... 407 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................................. 415 CONNECTOR TYPES AND MOUNTING LOCATIONS......................................................................................................................................... 416 CONNECTOR ARRANGEMENT DIAGRAM.................................................................................................................................................. 418 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................................................................... 431 T-ADAPTER TABLE................................................................................................................................................................ 452 FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM (SERIAL NO.: 7731 AND UP)................................................................................................ 456 MONITOR PANEL DISPLAY SPECIAL FUNCTIONS (SERIAL NO.: 7731 AND UP).............................................................................................................. 458 METHOD OF USING TROUBLESHOOTING CHARTS (SERIAL NO.: 5001 -7730)................................................................................................................ 477 JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM (SERIAL NO.: 5001 -7730)................................................................................ 479 HOW TO READ DECISION LIST (SERIAL NO.: 7731 AND UP)............................................................................................................................ 481 METHOD OF USING TROUBLESHOOTING CHARTS (SERIAL NO.: 7731 AND UP)............................................................................................................... 483 DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT TROUBLESHOOTING (SERIAL NO.:7731 AND UP)....................................................................................... 485 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) (SERIAL NO.: 5001-7730).......................................................................................................... 490 JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM..................................................................................................... 491 RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM.................................................................................................................. 493 E-1 ABNORMALITY IN PC-EPC SYSTEM........................................................................................................................................... 501 A) SPEEDS OF ALL WORK EQUIPMENT , TRAVEL, SWING ARE SLOW OR LACK POWER................................................................................................. 502 B) THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS........................................................................................................... 503 E-2 ABNOMALITY IN PPC LOCK SOLENOID SYSTEM............................................................................................................................... 509 A) EVEN WHEN SAFETY LOCK LEVER IS SET TO FREE, NO WORK EQUIPMENT, TRAVEL, SWING MOVE.................................................................................. 509 B) EVEN WHEN SAFETY LOCK LEVER IS SET TO LOCK, WORK EQUIPMENT, TRAVEL, SWING MOVE...................................................................................... 509 E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM.............................................................................................................................. 513 A) EVEN WHEN SWING LOCK SWITCH IS TURNED OFF, UPPER STRUCTURE DOES NOT SWING........................................................................................... 513 B) EVEN WHEN SWING LOCK SWITCH IS TURNED TO LOCK, UPPER STRUCTURE SWINGS............................................................................................... 514 E-4 ABNOMALITY IN TRAVEL SPEED SOLENOID SYSTEM............................................................................................................................. 517 A) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO HI, TRAVEL SPEED DOES NOT CHANGE TO HIGH SPEED.................................................................. 517 B) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO LO, TRAVEL SPEED DOES NOT CHANGE TO LOW SPEED................................................................... 517 E-5 TROUBLE IN AUTOMATIC TRAVEL SPEED CONTROL SYSTEM....................................................................................................................... 520 A) MAIN PUMP PRESSURE SENSOR SYSTEM.................................................................................................................................... 520 B) ENGINE SPEED SENSOR SYSTEM.......................................................................................................................................... 520 E-6 ABNORMALITY IN ENGINE STARTING SYSTEM.................................................................................................................................. 525 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEMS (H MODE)...................................................................................................................... 533 TABLE OF FAILURE MODES AND CAUSES.......................................................................................................................................... 534 H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER.................................................................................................... 538 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS............................................................................................................. 539 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE................................................................................................................................. 540 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)................................................................................................................................ 541 H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...................................................................................................................... 541 H-6 BOOM IS SLOW OR LACKS POWER........................................................................................................................................... 542 ARM IS SLOW OR LACKS POWER............................................................................................................................................. 543 BUCKET IS SLOW OR LACKS POWER.......................................................................................................................................... 543 H-7 WORK EQUIOPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE..................................................................................................................... 544 H-8 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)...................................................................................................................... 544 H-9 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)............................................................................................................................. 544 H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)......................................................................................................................... 545 H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)............................................................................................................................. 545 H-12 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDENTLY, OTHER WORK EQUIPMENT MOVES............................................................................................. 546 H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW....................................................................................................... 546 H-14 IN SWING+BOOM RAISE, BOOM IS SLOW..................................................................................................................................... 547 A) DEVIATION IS EXCESSIVE DURING NORMAL TRAVEL......................................................................................................................... 547 B) DEVIATION IS EXCESSIVE WHEN STARTING................................................................................................................................ 547 H-15 TRAVEL SPEED IS SLOW.................................................................................................................................................. 548 H-16 STEERING IS DIFFICULT TO TURN OR LACKS POWER.......................................................................................................................... 549 H-17 TRAVEL SPPED DOES NOT SWITCH.......................................................................................................................................... 551 H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).................................................................................................................................. 551 H-19 UPPER STRUCTURE DOES NOT SWING........................................................................................................................................ 552 A) DOES NOT SWING IN EITHER DIRECTION (LEFT AND RIGHT)................................................................................................................. 552 B) DOES NOT SWING IN ONE DIRECTION ONLY (LEFT AND RIGHT)............................................................................................................... 552 H-20 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).................................................................................................................................. 553 A) ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT)................................................................................................... 553 B) ACCELERATION IS POOR OR SWING SPEED IS SLOW (ONE DIRECTION ONLY).................................................................................................... 553 H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING................................................................................................................................. 554 A) EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT) (WHEN OPERATION OF CONTROL VALVE SPOOL AND PPC CIRCUIT THROTTL.......................................... 554 B) EXCESSIVE OVERRUN WHEN STOPPING SWING (ONE DIRECTION ONLY).......................................................................................................... 554 H-22 EXCESIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)............................................................................................................... 555 H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING................................................................................................................................. 555 H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING.................................................................................................................................... 556 A) WHEN SWING HOLDING BRAKE IS ACTUATED................................................................................................................................ 556 B) WHEN SWING HOLDING BRAKE IS RELEASED................................................................................................................................ 556 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) (SERIAL NO.: 5001-7730)..................................................................................................... 557 ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM.............................................................................................................................. 558 M-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON.................................................................................................................. 559 M-2 DISPLAY DOES NOT GO OUT AFTER COMPLETION OF SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED.............................................. 560 M-3 SOME ITEMS DO NOT LIGHT UP DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED ON...................................................... 560 A) NO GAUGES (FUEL LEVEL, ENGINE WATER TEMPERATURE) LIGHT UP. PREHEATING PILOT LAMP DOES NOT LIGHT UP................................................................. 560 B) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE) DO NOT LIGHT UP................................................................................................. 560 M-4 CHARGE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)...................................................................... 561 M-5 ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)......................................................... 562 M-6 PREHEATING PILOT LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS AT HEAT............................................................................................... 563 M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING..................................................................................................... 564 M-8 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING.................................................................................................................. 565 M-9 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE......................................................................................................................... 566 A) AFTER ENGINE IS STARTED, TEMPERATURE REMAINS AT BOTTOM LEVEL AND DOES NOT MOVE...................................................................................... 566 B) AFTER ENGINE IS STARTED, TEMPERATURE IMMEDIATELY GOES UP (THERE IS NO OVERHEATING BUT GAUGE ENTERS RED RANGE)....................................................... 566 M-10 ABNORMALITY IN FUEL GUAGE............................................................................................................................................. 567 A) NO SEGMENTS ON FUEL GAUGE LIGHT UP.................................................................................................................................. 567 B) FUEL LEVEL HAS GONE DOWN BUT FUEL GAUGE REMAINS AT FULL TANK DISPLAY................................................................................................ 567 C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT GIVE FULL TANK DISPLAY................................................................................................ 568 M-11 DEFECTIVE OPERATION OF ALARM BUZZER................................................................................................................................... 569 A) BUZZER DOES NOT SOUND............................................................................................................................................... 569 B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP......................................................................................................................... 569 M-12 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING................................................................................................................. 570 A) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP.................................................................................................................. 570 B) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP.......................................................................................................................... 570 M-13 NIGHT LIGHTING DOES NOT LIGHT UP...................................................................................................................................... 571 A) GAUGE LIGHTING DOES NOT LIGHT UP.................................................................................................................................... 571 B) SERVICE METER LIGHTING DOES NOT LIGHT UP............................................................................................................................ 571 M-14 HEATER DOES NOT WORK.................................................................................................................................................. 572 A) NEITHER HI NOR LO WORK.............................................................................................................................................. 572 B) ONLY LO DOES NOT WORK............................................................................................................................................... 572 C) ONLY HI DOES NOT WORK............................................................................................................................................... 572 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) (SERIAL NO.: PC128US-2; 7731 & UP AND PC138USLC-2; 1001 & UP)............................................................... 574 ACTIONS TO BE TAKEN ON MONITOR AND PHENOMENA ON MACHINE BODY AT THE TIME OF ABNORMALITY OCCURRENCE......................................................................... 577 ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM................................................................................................................................ 579 M-1 [E101] (AN ERROR HISTORY DATA ABNORMALITY) IS DISPLAYED................................................................................................................ 583 M-2 [E108] (DETECTION OF ENGINE WATER TEMPERATURE 105°) IS DISPLAYED....................................................................................................... 585 M-3 [E112] (SHORT CIRCUITOF WIPER NORMAL ROTATION OUTPUT) IS DISPLAYED).................................................................................................... 585 M-4 [E113] (SHORT CIRCUIT OF WIPER REVERSE ROTATION OUTPUT) IS DISPLAYED................................................................................................... 585 M-5 [E114] (CONTACT OF WASHER OUTPUT WITH 24V) IS DISPLAYED................................................................................................................ 585 M-6 [E115] (IMPOSSIBILITY IN 10 SEC. AT THE TIME OF WIPING AWAY) IS DISPLAYED.............................................................................................. 585 M-7 [E116] (IMPOSSIBILITY IN 10 SEC. OF STORAGE) IS DISPLAYED.............................................................................................................. 585 M-8 WHEN THE STARTING SWITCH IS SET TO ON, THE WHOLE MONITOR PANEL DOES NOT COME ON FOR 3 SEC.............................................................................. 586 A) WHEN THE WHOLE MONITOR PANEL DOES NOT COME ON....................................................................................................................... 586 B) WHEN PART OF THE MONITOR PANEL DOES NOT COME ON..................................................................................................................... 586 M-9 THE STARTING SWITCH IS SET TO ON, AND THE WHOLE MONITOR PANEL REMAINS LIGHTED.......................................................................................... 589 M-10 (THE ENGINE PRE-HEATING MONITOR) COMES ON EVEN WITHOUT PREHEATING ARRANGEMENT......................................................................................... 590 M-11 WHEN THE STARTING SWITCH IS SET TO ON, THE ENGINE IS STARTED, THE BASIC CHECK ITEMS FLASH ............................................................................ 592 A) ALTERNATOR SYSTEM................................................................................................................................................... 592 B) ENGINE OIL PRESSURE SYSTEM.......................................................................................................................................... 593 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.)..... 594 A) ALTERNATOR SYSTEM................................................................................................................................................... 594 B) OIL PRESSURE SENSOR SYSTEM.......................................................................................................................................... 595 M-13 WHEN THE STARTING SWITCH IS SET TO ON (THE ENGINE STOPPED), PRECAUTIONS AND EMERGENCY STOP ITEMS FLASH. (BUT WHEN INSPEC.............................................. 596 A) (ENGINE OIL PRESSURE) FLASHES....................................................................................................................................... 596 B) (BATTERY CHARGE LEVEL) FLASHES...................................................................................................................................... 596 C) (COOLANT TEMPERATURE) FLASHES....................................................................................................................................... 597 D) (FUEL LEVEL) FLASHES................................................................................................................................................ 598 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.............................................. 599 M-15 MONITOR PANEL NIGHT LIGHTING DOES NOT COME ON. (THE LIQUID CRYSTAL DISPLAY IS NORMAL)................................................................................. 600 M-16 THE COOLANT TEMPERATURE GAUGE DOES NOT RISE........................................................................................................................... 601 M-17 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE (DURING OPERATION, THE GAUGE DOES NOT INDICATE ANY STAGE)............................................................. 601 M-18 THE FUEL LEVEL GAUGE INDICATES FULL ALL THE TIME...................................................................................................................... 603 M-19 THE FUEL LEVEL GAUGE INDICATES NOTHING................................................................................................................................ 603 M-20 THOUGH THE SWING LOCK SWITCH IS SET TO ON (LOCK), (THE SWING LOCK MONITOR) DOES NOT COME ON.......................................................................... 605 M-21 WHILE THE ENGINE IS ROTATING, THE SERVICE METER DOES NOT ADVANCE...................................................................................................... 605 M-22 THE FUEL LEVEL SENSOR SYSTEM IS DEFECTIVE............................................................................................................................. 606 M-23 THE COOLANT TEMPERATURE SENSOR SYSTEM IS DEFECTIVE.................................................................................................................... 607 M-24 THE WINDSHEILD WIPER DOES NOT WORK, OR WORKS THOUGH THE WIPER IS NOT SWITCHED ON..................................................................................... 608 A) THE WINDSHEILD WIPER DOES NOT WORK.................................................................................................................................. 608 B) THE WINDSHEILD WIPER WORKS THOUGH IT IS NOT SWITCHED ON............................................................................................................. 608 M-25 THE WASHER MOTOR DOES NOT WORK, OR WORKS THOUGH THE WASHER IS NOT SWITCHED ON ........................................................................................ 611 A) THE WASHER MOTOR DOES NOT WORK...................................................................................................................................... 611 B) THE WASHER MOTOR WORKS THOUGH THE WASHER IS NOT SWITCHED ON........................................................................................................ 611 TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE) SERIAL NO.: 7731 AND UP....................................................................................................... 614 N-1 [E218] COMMUNICATION ABNORMALITY....................................................................................................................................... 615 TROUBLESHOOTING OF CONTROLLER CR700 [DELEERATION CONTROL SYSTEM] (E MODE) SERIAL.: 7731 AND UP................................................................................. 617 CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [DELERATION CONTROL SYSTEM]................................................................................................. 618 RESPONSE OF CONTROLLER AND PHENOMENA ON MACHINE BODY WHEN ABNORMALITY HAS OCCURRED......................................................................................... 620 TABLE FOR DETERMINING CONTROLLER (ENGINE THROTTLE CONTROL SYSTEM) OR ENGINE RELATED........................................................................................ 622 ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM................................................................................................................................ 624 E-1 ABNORMALITY IN POWER SUPPLY OF CONTROLLER CR700 (LED ON CONTROLLER IS OFF)............................................................................................. 628 E-2 [E321] [E322] "SHORT CIRCUIT/DISCONNECTION IN MOTOR DRIVE RELAY SYSTEM" IS DISPLAYED................................................................................... 630 E-3 [E323] [E324] "SHORT CIRCUIT/DISCONNECTION IN ACCELERATOR RELAY SYSTEM" IS DISPLAYED................................................................................... 631 E-4 [E325] [E326] "SHORT CIRCUIT/DISCONNECTION IN DECELERATOR RELAY SYSTEM" IS DISPLAYED................................................................................... 633 E-5 [E328] "ABNORMALITY IN MOTOR STALL SYSTEM" IS DISPLAYED................................................................................................................ 635 E-6 [E308] "ABNORMALITY IN FUEL DIAL INPUT VALUE" IS DISPLAYED............................................................................................................. 637 E-7 [E227] "ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED........................................................................................................ 638 E-8 [E306] "ABNORMALITY IN MOTOR FEEDBACK POTENTIOMETER INPUT VALUE" IS DISPLAYED.......................................................................................... 639 E-9 [E258] "SHORT CIRCUIT IN POTENTIOMETER POWER SUPPLY" IS DISPLAYED...................................................................................................... 641 E-10 [E304] [E314] "SHORT CIRCUIT/DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM" IS DISPLAYED......................................................................... 643 E-11 AUTO-DECELERATOR DOES NOT OPERATE..................................................................................................................................... 644 TROUBLESHOOTING OF CONTROLLER CR700 [PUMP CONTROL SYSTEM] (C MODE) SERIAL.: 7731 AND UP........................................................................................ 646 CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [PUMP CONTROL SYSTEM........................................................................................................ 647 RESPONSE OF CONTROLLER AND PHENOMENA ON MACHINE BODY WHEN ABNORMALITY HAS OCCURED.......................................................................................... 649 TABLE FOR DETERMINING CONTROLLER CR700 [PUMP CONTROL SYSTEM] OR OIL PRESSURE IN RELATED.................................................................................... 653 ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM................................................................................................................................ 657 TROUBLESHOOTING FLOW CHART FOR EACH FAILURE MODE........................................................................................................................... 661 C-1 ABNORMALITY IN POWER SUPPLY OF CONTROLLER (LED ON CONTROLLER IS OFF)............................................................................................... 661 C-2 [E232] "SHORT CIRCUIT IN PC-EPC SOLENOID SYSTEM" IS DISPLAYED...................................................................................................... 663 C-3 [E233] "DISCONNECTION IN PC-EPC SOLENOID SYSTEM" IS DISPLAYED...................................................................................................... 665 C-4 [E203] "SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM" IS DISPLAYED......................................................................................... 667 C-5 [E213] "DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM" IS DISPLAYED......................................................................................... 671 C-6 [E206] "SHORT CIRCUIT IN TRAVEL HI/LO SELECTION SOLENOID SYSTEM" IS DISPLAYED...................................................................................... 675 C-7 [E216] "DISCONNECTION IN TRAVEL HI/LO SELECTION SOLENOID SYSTEM" IS DISPLAYED...................................................................................... 677 C-8 [E205] "SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM" IS DISPLAYED.............................................................................................. 679 C-9 [E215] "DISCONNECTION IN 2-STAGE RELIEIF SOLENOID SYSTEM" IS DISPLAYED............................................................................................. 681 C-10 [E222] "SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM" IS DISPLAYED..................................................................................................... 683 C-11 [E223] "DISCONNECTION IN LS-EPC SOLENOID SYSTEM" IS DISPLAYED..................................................................................................... 684 C-12 [E224] "ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM" IS DISPLAYED.................................................................................................. 685 C-13 [E227] "ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED................................................................................................... 686 TROUBLESHOOTING OF CONTROLLER CR700 [INPUT SIGNAL SYSTEM] (F MODE) SERIAL.: 7731 AND UP........................................................................................ 687 ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500.......................................................... 688 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 689 F-1 BIT-PATTERN 1023-(4) SWING PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500...................................... 690 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 691 F-2 BIT-PATTERN 1023-(3) TRAVEL PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500..................................... 692 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 693 F-3 BIT-PATTERN 1023-(2) BOOM LOWER PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500................................. 694 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 695 F-4 BIT-PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500................................. 696 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 697 F-5 BIT-PATTERN 1023-(5) ARM IN PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500..................................... 698 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 699 F-6 BIT-PATTERN 1023-(2) ARM OUT PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500.................................... 700 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 701 F-7 BIT-PATTERN 1023-(2) BUCKET CURL PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500................................ 702 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 703 F-8 BIT-PATTERN 1023-(2) BUCKET DUMP PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500................................ 704 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 705 F-9 BIT-PATTERN 1023-(2) SERVICE PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500.................................... 706 PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up.................................................................................................. 707 F-10 BIT-PATTERN 1021-(6) KEROSENE IS NOT TURNED ON........................................................................................................................ 708 TROUBLESHOOTING OF ENGINE (S MODE)............................................................................................................................................. 709 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................................................... 710 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).............................................................................................................. 714 S-2 ENGINE DOES NOT START.................................................................................................................................................. 716 1) ENGINE DOES NOT TURN................................................................................................................................................ 716 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)............................................................................................ 717 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).......................................................................................... 718 S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW UP IS POOR)................................................................................................................... 719 S-4 ENGINE STOPS DURING OPERATIONS......................................................................................................................................... 720 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).............................................................................................................................. 721 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................................................................................... 722 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................................................................................... 723 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................................................................................................................ 724 S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................................................................................... 725 S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................................................................................... 726 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN............................................................................................... 727 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................................................................ 728 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).................................................................................................................................. 729 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................................................................... 730 S-15 ABNORMAL NOISE IS MADE................................................................................................................................................ 731 S-16 VIBRATION IS EXCESSIVE................................................................................................................................................ 732 30 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 733 METHOD OF USING MANUAL............................................................................................................................................................. 734 PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................................................................ 735 SPECIAL TOOL LIST.................................................................................................................................................................. 737 SKETCH OF SPECIAL TOOL............................................................................................................................................................. 741 CYLINDER HEAD ASSEMBLY............................................................................................................................................................. 743 REMOVAL........................................................................................................................................................................ 743 INSTALLATION................................................................................................................................................................... 746 INJECTION PUMP ASSEMBLY............................................................................................................................................................ 748 REMOVAL........................................................................................................................................................................ 748 INSTALLATION................................................................................................................................................................... 750 ENGINE AND MAIN PUMP ASSEMBLY...................................................................................................................................................... 751 REMOVAL ....................................................................................................................................................................... 751 INSTALLATION................................................................................................................................................................... 752 RADIATOR, HYDRAULIC OIL COOLER..................................................................................................................................................... 763 REMOVAL........................................................................................................................................................................ 763 INSTALLATION................................................................................................................................................................... 764 RADIATOR ASSEMBLY.................................................................................................................................................................. 765 REMOVAL AND INSTALLATION....................................................................................................................................................... 765 HYDRAULIC OIL COOLER ASSEMBLY...................................................................................................................................................... 766 REMOVAL........................................................................................................................................................................ 766 INSTALLATION................................................................................................................................................................... 767 AFTER COOLER ASSEMBLY.............................................................................................................................................................. 768 REMOVAL AND INSTALLATION....................................................................................................................................................... 768 FUEL TANK.......................................................................................................................................................................... 770 REMOVAL AND INSTALLATION....................................................................................................................................................... 770 CENTER SWIVEL JOINT................................................................................................................................................................ 771 REMOVAL AND INSTALLATION....................................................................................................................................................... 771 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................... 772 SWING MOTOR, SWING MACHINERY....................................................................................................................................................... 773 REMOVAL AND INSTALLATION....................................................................................................................................................... 773 SWING MACHINERY.................................................................................................................................................................... 774 DISASSEMBLY.................................................................................................................................................................... 774 ASSEMBLY....................................................................................................................................................................... 777 REVOLVING FRAME.................................................................................................................................................................... 787 REMOVAL........................................................................................................................................................................ 787 INSTALLATION................................................................................................................................................................... 788 SWING CIRCLE....................................................................................................................................................................... 789 REMOVAL AND INSTALLATION....................................................................................................................................................... 789 TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.............................................................................................................................................. 790 REMOVAL AND INSTALLATION....................................................................................................................................................... 790 RECOIL SPRING...................................................................................................................................................................... 791 DISASSEMBLY.................................................................................................................................................................... 791 ASSEMBLY....................................................................................................................................................................... 792 IDLER ............................................................................................................................................................................. 795 DISASSEMBLY.................................................................................................................................................................... 795 ASSEMBLY....................................................................................................................................................................... 796 TRACK ROLLER....................................................................................................................................................................... 799 DISASSEMBLY.................................................................................................................................................................... 799 ASSEMBLY....................................................................................................................................................................... 800 TRACK SHOE......................................................................................................................................................................... 802 REMOVAL AND INSTALLATION....................................................................................................................................................... 802 HYDRAULIC TANK..................................................................................................................................................................... 803 REMOVAL........................................................................................................................................................................ 803 INSTALLATION................................................................................................................................................................... 804 MAIN PUMP.......................................................................................................................................................................... 805 REMOVAL........................................................................................................................................................................ 805 INSTALLATION................................................................................................................................................................... 807 CONTROL VALVE...................................................................................................................................................................... 808 REMOVAL ..................................................................................................................................................................... 808 INSTALLATION................................................................................................................................................................... 809 DISASSEMBLY.................................................................................................................................................................... 810 ASSEMBLY....................................................................................................................................................................... 815 LS SELECTION VALVE................................................................................................................................................................. 824 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................... 824 PRESSURE COMPENSATION VALVE........................................................................................................................................................ 825 DISASSEMBLY.................................................................................................................................................................... 825 ASSEMBLY....................................................................................................................................................................... 827 MAIN RELIEF VALVE.................................................................................................................................................................. 829 DISASSEMBLY.................................................................................................................................................................... 829 ASSEMBLY....................................................................................................................................................................... 830 WORK EQUIPMENT PPC VALVE (FOR BOOM, BUCKET, ARM, SWING CONTROL).................................................................................................................... 831 DISASSEMBLY.................................................................................................................................................................... 831 ASSEMBLY....................................................................................................................................................................... 832 TRAVEL PPC VALVE................................................................................................................................................................... 835 DISASSEMBLY.................................................................................................................................................................... 835 ASSEMBLY....................................................................................................................................................................... 836 HYDRAULIC CYLINDER................................................................................................................................................................. 838 DISASSEMBLY.................................................................................................................................................................... 838 ASSEMBLY....................................................................................................................................................................... 841 WORK EQUIPMENT..................................................................................................................................................................... 845 REMOVAL ....................................................................................................................................................................... 845 INSTALLATION................................................................................................................................................................... 846 OPERATOR'S CAB..................................................................................................................................................................... 847 REMOVAL........................................................................................................................................................................ 847 INSTALLATION................................................................................................................................................................... 848 OPERATOR’S CAB GLASS (STUCK GLASS)................................................................................................................................................. 854 REMOVAL........................................................................................................................................................................ 855 INSTALLATION................................................................................................................................................................... 856 FRONT WINDOW ASSEMBLY.............................................................................................................................................................. 866 REMOVAL AND INSTALLATION....................................................................................................................................................... 866 FLOOR FRAME........................................................................................................................................................................ 867 REMOVAL........................................................................................................................................................................ 867 INSTALLATION................................................................................................................................................................... 868 AIR CONDITIONER COMPRESSOR......................................................................................................................................................... 874 REMOVAL AND INSTALLATION....................................................................................................................................................... 874 AIR CONDITIONER CONDENSOR.......................................................................................................................................................... 876 REMOVAL AND INSTALLATION....................................................................................................................................................... 876 AIR CONDITIONER UNIT............................................................................................................................................................... 878 REMOVAL........................................................................................................................................................................ 878 INSTALLATION................................................................................................................................................................... 879 COUNTERWEIGHT...................................................................................................................................................................... 886 REMOVAL AND INSTALLATION....................................................................................................................................................... 886 MONITOR PANEL ASSEMBLY............................................................................................................................................................. 887 REMOVAL AND INSTALLATION....................................................................................................................................................... 887 CONTROLLER ASSEMBLY................................................................................................................................................................ 888 REMOVAL AND INSTALLATION....................................................................................................................................................... 888 40 MAINTENANCE STANDARD............................................................................................................................................................... 889 SWING MACHINERY.................................................................................................................................................................... 890 SWING CIRCLE....................................................................................................................................................................... 894 TRACK FRAME, IDLER CUSHION......................................................................................................................................................... 895 IDLER.............................................................................................................................................................................. 897 CARRIER ROLLER..................................................................................................................................................................... 901 TRACK ROLLER....................................................................................................................................................................... 902 SPROCKET........................................................................................................................................................................... 905 TRACK SHOE......................................................................................................................................................................... 906 HYDRAULIC PUMP (PISTON PUMP)....................................................................................................................................................... 914 CONTROL VALVE...................................................................................................................................................................... 917 SUCTION SAFETY VALVE............................................................................................................................................................... 937 SELF PRESSURE REDUCTION VALVE...................................................................................................................................................... 938 TRAVEL MOTOR....................................................................................................................................................................... 939 SWING MOTOR........................................................................................................................................................................ 940 SOLENOID VALVE..................................................................................................................................................................... 941 CENTER SWIVEL JOINT................................................................................................................................................................ 942 PPC VALVE.......................................................................................................................................................................... 944 BOOM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC)............................................................................................................................... 949 ARM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC) (IF EQUIPPED).................................................................................................................. 951 HYDRAULIC CYLINDER................................................................................................................................................................. 952 WORK EQUIPMENT..................................................................................................................................................................... 955 DIMENSION OF WORK EQUIPMENT........................................................................................................................................................ 958 90 OTHERS............................................................................................................................................................................. 972 HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)(BREAKER: 1 SERVICE VALVE: 50: AMOUNT)....................................................................................................... 974 HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)(CRASHER: 1 SERVICE VALVE: 100% AMOUNT)..................................................................................................... 975 HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT) (CRASHER: 2 SERVICE VALVE: 100% AMOUNT)..................................................................................................... 976 ELECTRIC CIRCUIT DIAGRAM (AIR CONDITIONER) PC128US-2 (SERIAL NO.: 5001-7730)....................................................................................................... 977 ELECTRIC CIRCUIT DIAGRAM (AIR CONDITIONER) PC128US-2 (SERIAL NO.: 7731 AND UP) AND PC138USLC-2 (SERIAL NO.: 1001 AND UP)........................................................... 978 HYDRAULIC CIRCUIT DIAGRAM PC128US-2 (SERIAL NO.: 5001-7730)........................................................................................................................ 979 HYDRAULIC CIRCUIT DIAGRAM PC128US-2 (SERIAL NO.: 7731 AND UP) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1001 AND UP).......................................... 981 HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACUTUATOR ATTACHEMENT PC128US-2 (SERIAL NO.: 5001-7730).......................................................................................... 983 HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACTUATOR ATTACHMENT) PC128US-2 (SERIAL NO.: 7731 AND UP), PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1001 AND UP)............ 985 HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT) PC128US-2 (SERIAL NO.: 5001-7730)................................................................................... 987 HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT) PC128US-2 (SERIAL NO.: 7731 AND UP), PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1001 AND UP).... 989 HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 5001-7730)........................................................................................................ 991 HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 7731 AND UP) & PC138US-2 (SERIAL NO.: 4501 AND UP)................................................................ 993 HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 5001-7730)........................................................................... 995 HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.) PC128US-2 (SERIALNO.: 7731 AND UP) & PC138US-2 (SERIAL NO.: 4501 AND UP).................................... 997 ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 5001-6300)................................................................................................................... 999 ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 5001-6300)................................................................................................................... 999 ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 5001-6300)...................................................................................................................1001 ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 SERIAL NO.: 6301-7730)....................................................................................................................1003 ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 SERIAL NO.: 6301-7730)....................................................................................................................1005 ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 7731-7874)...................................................................................................................1007 ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 7731-7874)...................................................................................................................1009 ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 7875 AND UP) & PC138USLC-2 (SERIAL NO.: 1001-1500)...........................................................................1010 ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 7875 AND UP) PC138USLC-2 (SERIAL NO.: 1001-1500).............................................................................1011 ELECTRIC CIRCUIT DIAGRAM (1/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP).........................................................................1012 ELECTRIC CIRCUIT DIAGRAM (2/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP).........................................................................1013 ELECTRIC CIRCUIT DIAGRAM (3/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP).........................................................................1014 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2) PC128US-2 (SERIAL NO.: 5001-6300)...................................................................................................1016 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 5001-6300)...................................................................................................1018 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2) PC128US-2 (SERIAL NO.: 6301-7730)...................................................................................................1020 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 6301-7730)...................................................................................................1022 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.)(1/2) PC128US-2 (SERIAL NO.: 7731 AND UP)..................................................................................................1024 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 7731 AND UP).................................................................................................1025 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/3) PC138US-2 (SERIAL NO.: 4501 AND UP).................................................................................................1026 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/3) PC138US-2 (SERIAL NO.: 4501 AND UP).................................................................................................1027 ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (3/3) PC138US-2 (SERIAL NO.: 4501 AND UP).................................................................................................1028
DESCRIPTION:
KOMATSU PC128US-2 PC138US-2 PC138USLC-2 SHOP MANUAL SEBM018419 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
S.S 29/12/24
