Komatsu PC128US-2, PC138US-2, PC138USLC-2E0 Hydraulic Excavator Shop Manual – SEBM018419

This complete service repair workshop manual PDF download for the Komatsu PC128US-2, PC138US-2 & PC138USLC-2E0 Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

SERIAL NUMBERS :
PC128US-2 – 5001-7730 avance
PC128US-2 – 7731 and up GALEO
PC138US-2 – 4501 and up GALEO
PC138USLC-2E0 – 1001 and up GALEO

TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM018419
Total Pages : 1029

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FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS

01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANTS AND WATER

10 STRUCTURE AND FUNCTION
PTO
RADIATOR AND OIL COOLER
POWER TRAIN
SWING CIRCLE
SWING MACHINERY
TRACK FRAME
IDLER CUSHION
HYDRAULIC COMPONENT LAYOUT
VALVE CONTROL
HYDRAULIC TANK AND FILTER
HYDRAULIC PUMP (PISTON PUMP)
CONTROL VALVE
SUCTION SAFETY VALVE
CLSS
SELF PRESSURE REDUCING VALVE
CENTER SWIVEL JOINT
TRAVEL MOTOR (FINAL DRIVE)
SWING MOTOR
SOLENOID VALVE
PPC ACCUMULATOR
ACCUMULATOR FOR BREAKER (OPT)
PPC VALVE
HYDRAULIC DRIFT PREVENTION VALVE
ARM HYDRAULIC DRIFT PREVENTION VALVE
AIR-CONDITIONER PIPING
ELECTRIC COMPONENT LAYOUT
ENGINE CONTROL
ELECTRIC CONTROL SYSTEM
MONITOR SYSTEM

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
TESTING AND ADJUSTING FAN BELT TENSION
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING FUEL CONTROL CABLE
ADJUSTING ENGINE STOP SOLENOID LINKAGE
TESTING CLEARANCE OF SWING CIRCLE BEARING
CHECKING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING PPC VALVE
TESTING AND ADJUSTING TRAVEL DEVIATION
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING OIL LEAKAGE IN SWING MOTOR
MEASURING OIL LEAKAGE IN TRAVEL MOTOR
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE IN HYDRAULIC TANK
PROCEDURE FOR CHECKING DIODE
PM CLINIC INSPECTION TABLE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM (SERIAL NO.: 7731 AND UP)
MONITOR PANEL DISPLAY SPECIAL FUNCTIONS (SERIAL NO.: 7731 AND UP)
METHOD OF USING TROUBLESHOOTING CHARTS (SERIAL NO.: 5001 -7730)
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM (SERIAL NO.: 5001 -7730)
HOW TO READ DECISION LIST (SERIAL NO.: 7731 AND UP)
METHOD OF USING TROUBLESHOOTING CHARTS (SERIAL NO.: 7731 AND UP)
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT TROUBLESHOOTING (SERIAL NO.:7731 AND UP)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) (SERIAL NO.: 5001-7730)
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM
RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
E-1 ABNORMALITY IN PC-EPC SYSTEM
A) SPEEDS OF ALL WORK EQUIPMENT , TRAVEL, SWING ARE SLOW OR LACK POWER
B) THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
E-2 ABNOMALITY IN PPC LOCK SOLENOID SYSTEM
A) EVEN WHEN SAFETY LOCK LEVER IS SET TO FREE, NO WORK EQUIPMENT, TRAVEL, SWING MOVE
B) EVEN WHEN SAFETY LOCK LEVER IS SET TO LOCK, WORK EQUIPMENT, TRAVEL, SWING MOVE
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM
A) EVEN WHEN SWING LOCK SWITCH IS TURNED OFF, UPPER STRUCTURE DOES NOT SWING
B) EVEN WHEN SWING LOCK SWITCH IS TURNED TO LOCK, UPPER STRUCTURE SWINGS
E-4 ABNOMALITY IN TRAVEL SPEED SOLENOID SYSTEM
A) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO HI, TRAVEL SPEED DOES NOT CHANGE TO HIGH SPEED
B) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO LO, TRAVEL SPEED DOES NOT CHANGE TO LOW SPEED
E-5 TROUBLE IN AUTOMATIC TRAVEL SPEED CONTROL SYSTEM
A) MAIN PUMP PRESSURE SENSOR SYSTEM
B) ENGINE SPEED SENSOR SYSTEM
E-6 ABNORMALITY IN ENGINE STARTING SYSTEM
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEMS (H MODE)
TABLE OF FAILURE MODES AND CAUSES
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR
H-6 BOOM IS SLOW OR LACKS POWER
ARM IS SLOW OR LACKS POWER
BUCKET IS SLOW OR LACKS POWER
H-7 WORK EQUIOPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE
H-8 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)
H-9 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)
H-12 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDENTLY, OTHER WORK EQUIPMENT MOVES
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW
H-14 IN SWING+BOOM RAISE, BOOM IS SLOW
A) DEVIATION IS EXCESSIVE DURING NORMAL TRAVEL
B) DEVIATION IS EXCESSIVE WHEN STARTING
H-15 TRAVEL SPEED IS SLOW
H-16 STEERING IS DIFFICULT TO TURN OR LACKS POWER
H-17 TRAVEL SPPED DOES NOT SWITCH
H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)
H-19 UPPER STRUCTURE DOES NOT SWING
A) DOES NOT SWING IN EITHER DIRECTION (LEFT AND RIGHT)
B) DOES NOT SWING IN ONE DIRECTION ONLY (LEFT AND RIGHT)
H-20 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)
A) ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT)
B) ACCELERATION IS POOR OR SWING SPEED IS SLOW (ONE DIRECTION ONLY)
H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING
A) EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT) (WHEN OPERATION OF CONTROL VALVE SPOOL AND PPC CIRCUIT THROTTL
B) EXCESSIVE OVERRUN WHEN STOPPING SWING (ONE DIRECTION ONLY)
H-22 EXCESIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING
A) WHEN SWING HOLDING BRAKE IS ACTUATED
B) WHEN SWING HOLDING BRAKE IS RELEASED
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) (SERIAL NO.: 5001-7730)
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM
M-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON
M-2 DISPLAY DOES NOT GO OUT AFTER COMPLETION OF SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED
M-3 SOME ITEMS DO NOT LIGHT UP DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED ON
A) NO GAUGES (FUEL LEVEL, ENGINE WATER TEMPERATURE) LIGHT UP. PREHEATING PILOT LAMP DOES NOT LIGHT UP
B) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE) DO NOT LIGHT UP
M-4 CHARGE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)
M-5 ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)
M-6 PREHEATING PILOT LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS AT HEAT
M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING
M-8 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING
M-9 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
A) AFTER ENGINE IS STARTED, TEMPERATURE REMAINS AT BOTTOM LEVEL AND DOES NOT MOVE
B) AFTER ENGINE IS STARTED, TEMPERATURE IMMEDIATELY GOES UP (THERE IS NO OVERHEATING BUT GAUGE ENTERS RED RANGE)
M-10 ABNORMALITY IN FUEL GUAGE
A) NO SEGMENTS ON FUEL GAUGE LIGHT UP
B) FUEL LEVEL HAS GONE DOWN BUT FUEL GAUGE REMAINS AT FULL TANK DISPLAY
C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT GIVE FULL TANK DISPLAY
M-11 DEFECTIVE OPERATION OF ALARM BUZZER
A) BUZZER DOES NOT SOUND
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP
M-12 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING
A) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP
B) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP
M-13 NIGHT LIGHTING DOES NOT LIGHT UP
A) GAUGE LIGHTING DOES NOT LIGHT UP
B) SERVICE METER LIGHTING DOES NOT LIGHT UP
M-14 HEATER DOES NOT WORK
A) NEITHER HI NOR LO WORK
B) ONLY LO DOES NOT WORK
C) ONLY HI DOES NOT WORK
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) (SERIAL NO.: PC128US-2; 7731 & UP AND PC138USLC-2; 1001 & UP)
ACTIONS TO BE TAKEN ON MONITOR AND PHENOMENA ON MACHINE BODY AT THE TIME OF ABNORMALITY OCCURRENCE
ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM
M-1 [E101] (AN ERROR HISTORY DATA ABNORMALITY) IS DISPLAYED
M-2 [E108] (DETECTION OF ENGINE WATER TEMPERATURE 105°) IS DISPLAYED
M-3 [E112] (SHORT CIRCUITOF WIPER NORMAL ROTATION OUTPUT) IS DISPLAYED)
M-4 [E113] (SHORT CIRCUIT OF WIPER REVERSE ROTATION OUTPUT) IS DISPLAYED
M-5 [E114] (CONTACT OF WASHER OUTPUT WITH 24V) IS DISPLAYED
M-6 [E115] (IMPOSSIBILITY IN 10 SEC. AT THE TIME OF WIPING AWAY) IS DISPLAYED
M-7 [E116] (IMPOSSIBILITY IN 10 SEC. OF STORAGE) IS DISPLAYED
M-8 WHEN THE STARTING SWITCH IS SET TO ON, THE WHOLE MONITOR PANEL DOES NOT COME ON FOR 3 SEC
A) WHEN THE WHOLE MONITOR PANEL DOES NOT COME ON
B) WHEN PART OF THE MONITOR PANEL DOES NOT COME ON
M-9 THE STARTING SWITCH IS SET TO ON, AND THE WHOLE MONITOR PANEL REMAINS LIGHTED
M-10 (THE ENGINE PRE-HEATING MONITOR) COMES ON EVEN WITHOUT PREHEATING ARRANGEMENT
M-11 WHEN THE STARTING SWITCH IS SET TO ON, THE ENGINE IS STARTED, THE BASIC CHECK ITEMS FLASH
A) ALTERNATOR SYSTEM
B) ENGINE OIL PRESSURE SYSTEM
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) ALTERNATOR SYSTEM
B) OIL PRESSURE SENSOR SYSTEM
M-13 WHEN THE STARTING SWITCH IS SET TO ON (THE ENGINE STOPPED), PRECAUTIONS AND EMERGENCY STOP ITEMS FLASH. (BUT WHEN INSPEC
A) (ENGINE OIL PRESSURE) FLASHES
B) (BATTERY CHARGE LEVEL) FLASHES
C) (COOLANT TEMPERATURE) FLASHES
D) (FUEL LEVEL) FLASHES
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
M-15 MONITOR PANEL NIGHT LIGHTING DOES NOT COME ON. (THE LIQUID CRYSTAL DISPLAY IS NORMAL)
M-16 THE COOLANT TEMPERATURE GAUGE DOES NOT RISE
M-17 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE (DURING OPERATION, THE GAUGE DOES NOT INDICATE ANY STAGE)
M-18 THE FUEL LEVEL GAUGE INDICATES FULL ALL THE TIME
M-19 THE FUEL LEVEL GAUGE INDICATES NOTHING
M-20 THOUGH THE SWING LOCK SWITCH IS SET TO ON (LOCK), (THE SWING LOCK MONITOR) DOES NOT COME ON
M-21 WHILE THE ENGINE IS ROTATING, THE SERVICE METER DOES NOT ADVANCE
M-22 THE FUEL LEVEL SENSOR SYSTEM IS DEFECTIVE
M-23 THE COOLANT TEMPERATURE SENSOR SYSTEM IS DEFECTIVE
M-24 THE WINDSHEILD WIPER DOES NOT WORK, OR WORKS THOUGH THE WIPER IS NOT SWITCHED ON
A) THE WINDSHEILD WIPER DOES NOT WORK
B) THE WINDSHEILD WIPER WORKS THOUGH IT IS NOT SWITCHED ON
M-25 THE WASHER MOTOR DOES NOT WORK, OR WORKS THOUGH THE WASHER IS NOT SWITCHED ON
A) THE WASHER MOTOR DOES NOT WORK
B) THE WASHER MOTOR WORKS THOUGH THE WASHER IS NOT SWITCHED ON
TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE) SERIAL NO.: 7731 AND UP
N-1 [E218] COMMUNICATION ABNORMALITY
TROUBLESHOOTING OF CONTROLLER CR700 [DELEERATION CONTROL SYSTEM] (E MODE) SERIAL.: 7731 AND UP
CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [DELERATION CONTROL SYSTEM]
RESPONSE OF CONTROLLER AND PHENOMENA ON MACHINE BODY WHEN ABNORMALITY HAS OCCURRED
TABLE FOR DETERMINING CONTROLLER (ENGINE THROTTLE CONTROL SYSTEM) OR ENGINE RELATED
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
E-1 ABNORMALITY IN POWER SUPPLY OF CONTROLLER CR700 (LED ON CONTROLLER IS OFF)
E-2 [E321] [E322] “SHORT CIRCUIT/DISCONNECTION IN MOTOR DRIVE RELAY SYSTEM” IS DISPLAYED
E-3 [E323] [E324] “SHORT CIRCUIT/DISCONNECTION IN ACCELERATOR RELAY SYSTEM” IS DISPLAYED
E-4 [E325] [E326] “SHORT CIRCUIT/DISCONNECTION IN DECELERATOR RELAY SYSTEM” IS DISPLAYED
E-5 [E328] “ABNORMALITY IN MOTOR STALL SYSTEM” IS DISPLAYED
E-6 [E308] “ABNORMALITY IN FUEL DIAL INPUT VALUE” IS DISPLAYED
E-7 [E227] “ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM” IS DISPLAYED
E-8 [E306] “ABNORMALITY IN MOTOR FEEDBACK POTENTIOMETER INPUT VALUE” IS DISPLAYED
E-9 [E258] “SHORT CIRCUIT IN POTENTIOMETER POWER SUPPLY” IS DISPLAYED
E-10 [E304] [E314] “SHORT CIRCUIT/DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM” IS DISPLAYED
E-11 AUTO-DECELERATOR DOES NOT OPERATE
TROUBLESHOOTING OF CONTROLLER CR700 [PUMP CONTROL SYSTEM] (C MODE) SERIAL.: 7731 AND UP
CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [PUMP CONTROL SYSTEM
RESPONSE OF CONTROLLER AND PHENOMENA ON MACHINE BODY WHEN ABNORMALITY HAS OCCURED
TABLE FOR DETERMINING CONTROLLER CR700 [PUMP CONTROL SYSTEM] OR OIL PRESSURE IN RELATED
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
TROUBLESHOOTING FLOW CHART FOR EACH FAILURE MODE
C-1 ABNORMALITY IN POWER SUPPLY OF CONTROLLER (LED ON CONTROLLER IS OFF)
C-2 [E232] “SHORT CIRCUIT IN PC-EPC SOLENOID SYSTEM” IS DISPLAYED
C-3 [E233] “DISCONNECTION IN PC-EPC SOLENOID SYSTEM” IS DISPLAYED
C-4 [E203] “SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM” IS DISPLAYED
C-5 [E213] “DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM” IS DISPLAYED
C-6 [E206] “SHORT CIRCUIT IN TRAVEL HI/LO SELECTION SOLENOID SYSTEM” IS DISPLAYED
C-7 [E216] “DISCONNECTION IN TRAVEL HI/LO SELECTION SOLENOID SYSTEM” IS DISPLAYED
C-8 [E205] “SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM” IS DISPLAYED
C-9 [E215] “DISCONNECTION IN 2-STAGE RELIEIF SOLENOID SYSTEM” IS DISPLAYED
C-10 [E222] “SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM” IS DISPLAYED
C-11 [E223] “DISCONNECTION IN LS-EPC SOLENOID SYSTEM” IS DISPLAYED
C-12 [E224] “ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM” IS DISPLAYED
C-13 [E227] “ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM” IS DISPLAYED
TROUBLESHOOTING OF CONTROLLER CR700 [INPUT SIGNAL SYSTEM] (F MODE) SERIAL.: 7731 AND UP
ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
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
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up
F-10 BIT-PATTERN 1021-(6) KEROSENE IS NOT TURNED ON
TROUBLESHOOTING OF ENGINE (S MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
1) ENGINE DOES NOT TURN
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCH OF SPECIAL TOOL
CYLINDER HEAD ASSEMBLY
REMOVAL
INSTALLATION
INJECTION PUMP ASSEMBLY
REMOVAL
INSTALLATION
ENGINE AND MAIN PUMP ASSEMBLY
REMOVAL
INSTALLATION
RADIATOR, HYDRAULIC OIL COOLER
REMOVAL
INSTALLATION
RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION
HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL
INSTALLATION
AFTER COOLER ASSEMBLY
REMOVAL AND INSTALLATION
FUEL TANK
REMOVAL AND INSTALLATION
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY
REMOVAL AND INSTALLATION
SWING MACHINERY
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL
INSTALLATION
SWING CIRCLE
REMOVAL AND INSTALLATION
TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
REMOVAL AND INSTALLATION
RECOIL SPRING
DISASSEMBLY
ASSEMBLY
IDLER
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
DISASSEMBLY
ASSEMBLY
TRACK SHOE
REMOVAL AND INSTALLATION
HYDRAULIC TANK
REMOVAL
INSTALLATION
MAIN PUMP
REMOVAL
INSTALLATION
CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
LS SELECTION VALVE
DISASSEMBLY AND ASSEMBLY
PRESSURE COMPENSATION VALVE
DISASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT PPC VALVE (FOR BOOM, BUCKET, ARM, SWING CONTROL)
DISASSEMBLY
ASSEMBLY
TRAVEL PPC VALVE
DISASSEMBLY
ASSEMBLY
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
OPERATOR’S CAB
REMOVAL
INSTALLATION
OPERATOR’S CAB GLASS (STUCK GLASS)
REMOVAL
INSTALLATION
FRONT WINDOW ASSEMBLY
REMOVAL AND INSTALLATION
FLOOR FRAME
REMOVAL
INSTALLATION
AIR CONDITIONER COMPRESSOR
REMOVAL AND INSTALLATION
AIR CONDITIONER CONDENSOR
REMOVAL AND INSTALLATION
AIR CONDITIONER UNIT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
MONITOR PANEL ASSEMBLY
REMOVAL AND INSTALLATION
CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
SWING MACHINERY
SWING CIRCLE
TRACK FRAME, IDLER CUSHION
IDLER
CARRIER ROLLER
TRACK ROLLER
SPROCKET
TRACK SHOE
HYDRAULIC PUMP (PISTON PUMP)
CONTROL VALVE
SUCTION SAFETY VALVE
SELF PRESSURE REDUCTION VALVE
TRAVEL MOTOR
SWING MOTOR
SOLENOID VALVE
CENTER SWIVEL JOINT
PPC VALVE
BOOM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC)
ARM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC) (IF EQUIPPED)
HYDRAULIC CYLINDER
WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT

90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)(BREAKER: 1 SERVICE VALVE: 50: AMOUNT)
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)(CRASHER: 1 SERVICE VALVE: 100% AMOUNT)
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT) (CRASHER: 2 SERVICE VALVE: 100% AMOUNT)
ELECTRIC CIRCUIT DIAGRAM (AIR CONDITIONER) PC128US-2 (SERIAL NO.: 5001-7730)
ELECTRIC CIRCUIT DIAGRAM (AIR CONDITIONER) PC128US-2 (SERIAL NO.: 7731 AND UP) AND PC138USLC-2 (SERIAL NO.: 1001 AND UP)
HYDRAULIC CIRCUIT DIAGRAM PC128US-2 (SERIAL NO.: 5001-7730)
HYDRAULIC CIRCUIT DIAGRAM PC128US-2 (SERIAL NO.: 7731 AND UP) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1001 AND UP)
HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACUTUATOR ATTACHEMENT PC128US-2 (SERIAL NO.: 5001-7730)
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)
HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT) PC128US-2 (SERIAL NO.: 5001-7730)
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)
HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 5001-7730)
HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 7731 AND UP) & PC138US-2 (SERIAL NO.: 4501 AND UP)
HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 5001-7730)
HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.) PC128US-2 (SERIALNO.: 7731 AND UP) & PC138US-2 (SERIAL NO.: 4501 AND UP)
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 5001-6300)
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 5001-6300)
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 5001-6300)
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 SERIAL NO.: 6301-7730)
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 SERIAL NO.: 6301-7730)
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 7731-7874)
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 7731-7874)
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 7875 AND UP) & PC138USLC-2 (SERIAL NO.: 1001-1500)
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 7875 AND UP) PC138USLC-2 (SERIAL NO.: 1001-1500)
ELECTRIC CIRCUIT DIAGRAM (1/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP)
ELECTRIC CIRCUIT DIAGRAM (2/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP)
ELECTRIC CIRCUIT DIAGRAM (3/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2) PC128US-2 (SERIAL NO.: 5001-6300)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 5001-6300)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2) PC128US-2 (SERIAL NO.: 6301-7730)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 6301-7730)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.)(1/2) PC128US-2 (SERIAL NO.: 7731 AND UP)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 7731 AND UP)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/3) PC138US-2 (SERIAL NO.: 4501 AND UP)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/3) PC138US-2 (SERIAL NO.: 4501 AND UP)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (3/3) PC138US-2 (SERIAL NO.: 4501 AND UP)

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