Komatsu PC128US-2 PC138US-2 PC138USLC-2E0 Excavator Shop Manual SEBM018419

Description

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

FILE DETAILS:

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

Language : English
Pages : 1029
Downloadable : Yes
File Type : PDF

DESCRIPTION:

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

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

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

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

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

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

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24