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KOMATSU PC128US-8 HYDRAULIC EXCAVATOR SHOP MANUAL WEN00003-00 – PDF DOWNLOAD
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Description
KOMATSU PC128US-8 HYDRAULIC EXCAVATOR SHOP MANUAL WEN00003-00 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC128US-8 HYDRAULIC EXCAVATOR SHOP MANUAL WEN00003-00 – PDF DOWNLOAD
Language : English
Pages : 933
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC128US-8 HYDRAULIC EXCAVATOR SHOP MANUAL WEN00003-00 – PDF DOWNLOAD
00 Index and foreword.................................................................................... 3 Index................................................................................................ 4 Table of contents................................................................................ 4 Foreword and general information..................................................................... 11 Safety notice.................................................................................... 11 How to read the shop manual...................................................................... 16 Explanation of terms for maintenance standard.................................................... 18 Handling of electric equipment and hydraulic component........................................... 20 Handling of connectors newly used for engines.................................................... 29 How to read electric wire code................................................................... 32 Precautions when carrying out operation.......................................................... 35 Method of disassembling and connecting push-pull type coupler.................................... 38 Standard tightening torque table................................................................. 41 Conversion table................................................................................. 45 01 Specification......................................................................................... 51 Specification and technical data..................................................................... 53 Specification dimension drawing.................................................................. 53 Working range diagram............................................................................ 54 Specifications................................................................................... 55 Weight table..................................................................................... 58 Table of fuel, coolant and lubricants............................................................ 60 10 Structure, function and maintenance standard.......................................................... 63 Engine and cooling system............................................................................ 66 Engine mount..................................................................................... 66 PTO.............................................................................................. 67 Cooling system................................................................................... 68 Power train.......................................................................................... 70 Power train...................................................................................... 70 Swing circle..................................................................................... 71 Swing machinery.................................................................................. 72 Undercarriage and frame.............................................................................. 74 Track frame...................................................................................... 74 Idler cushion.................................................................................... 75 Idler............................................................................................ 76 Track roller..................................................................................... 77 Carrier roller................................................................................... 78 Sprocket......................................................................................... 79 Track shoe....................................................................................... 80 Hydraulic system..................................................................................... 86 Hydraulic equipment layout drawing............................................................... 86 Valve control.................................................................................... 88 Hydraulic tank and filter........................................................................ 90 Hydraulic pump................................................................................... 92 Control valve....................................................................................118 CLSS.............................................................................................130 Functions and operation by valve.................................................................134 PPC valve........................................................................................164 Swing motor......................................................................................181 Travel motor.....................................................................................189 Center swivel joint..............................................................................198 Solenoid valve...................................................................................202 PPC accumulator..................................................................................206 Holding valve....................................................................................208 Work equipment.......................................................................................214 Work equipment...................................................................................214 Dimensions of components.........................................................................216 Hydraulic cylinder...............................................................................220 Cab and its attachments..............................................................................222 Air conditioner..................................................................................222 Electrical system....................................................................................234 Electronic control system........................................................................234 Monitor system...................................................................................267 KOMTRAX system...................................................................................281 Sensor...........................................................................................283 20 Standard value table..................................................................................289 Standard service value table.........................................................................291 Standard value table for engine related parts....................................................291 Standard value table for chassis related parts...................................................292 30 Testing and adjusting.................................................................................301 Related information on testing and adjusting.........................................................303 Tools for testing, adjusting, and troubleshooting................................................303 Sketches of special tools........................................................................307 Engine and cooling system............................................................................308 Testing engine speed.............................................................................308 Testing exhaust temperature......................................................................309 Checking exhaust gas color.......................................................................310 Adjusting valve clearance........................................................................311 Testing compression pressure.....................................................................313 Testing blow-by pressure.........................................................................315 Testing engine oil pressure......................................................................316 Handling fuel system parts.......................................................................317 Releasing residual pressure from fuel system.....................................................317 Testing fuel pressure............................................................................318 Testing fuel return rate and fuel leakage........................................................319 Bleeding air from fuel circuit...................................................................321 Checking fuel circuit for leakage................................................................323 Testing and adjusting alternator belt tension....................................................324 Checking and adjusting air conditioner compressor belt tension...................................325 Power train..........................................................................................326 Testing swing circle bearing clearance...........................................................326 Undercarriage and frame..............................................................................327 Checking and adjusting track shoe tension........................................................327 Hydraulic system.....................................................................................329 Testing and adjusting oil pressure in work equipment, swing, and travel circuits.................329 Testing control circuit basic pressure...........................................................332 Testing and adjusting oil pressure in pump PC control circuit....................................333 Testing and adjusting oil pressure in pump LS control circuit....................................336 Testing solenoid valve output pressure...........................................................340 Testing PPC valve output pressure................................................................341 Adjusting play of work equipment and swing PPC valves............................................343 Checking parts which cause hydraulic drift of work equipment.....................................344 Testing and adjusting travel deviation...........................................................346 Releasing residual pressure from hydraulic circuit...............................................348 Testing oil leakage..............................................................................349 Bleeding air from each part......................................................................352 Cab and its attachments..............................................................................354 Checking cab tipping stopper.....................................................................354 Adjusting mirrors................................................................................354 Electrical system....................................................................................356 Special functions of machine monitor.............................................................356 Handling voltage circuit of engine controller....................................................408 Preparation work for troubleshooting of electrical system........................................409 Procedure for testing diodes.....................................................................414 Pm-Clinic............................................................................................415 Pm Clinic service................................................................................415 40 Troubleshooting.......................................................................................419 Related information on troubleshooting...............................................................424 Points to remember when performing troubleshooting...............................................424 How to proceed in troubleshooting................................................................426 Checks before troubleshooting....................................................................428 Classification and procedures for troubleshooting................................................429 Information in troubleshooting table.............................................................430 Phenomena looking like troubles and troubleshooting Nos..........................................432 Connection table of connector by No. of pins.....................................................435 T-box and T-adapter list.........................................................................472 Failure code table...............................................................................476 Fuse locations...................................................................................480 Troubleshooting by failure code......................................................................482 Failure code [989L00] Engine controller lock caution 1...........................................482 Failure code [989M00] Engine controller lock caution 2...........................................482 Failure code [989N00] Engine controller lock caution 3...........................................483 Failure code [AB00KE] Charge voltage low.........................................................484 Failure code [B@BAZG] Eng oil press. low.........................................................486 Failure code [B@BAZK] Eng oil level low..........................................................486 Failure code [B@BCNS] Eng coolant overheat.......................................................487 Failure code [B@HANS] Hydr oil overheat..........................................................487 Failure code [CA111] ECM critical internal failure...............................................488 Failure code [CA115] Eng. Ne and Bkup speed sensor error.........................................491 Failure code [CA122] Charge air press sensor high error..........................................492 Failure code [CA123] Charge air press sensor low error...........................................494 Failure code [CA131] Throttle sensor high error..................................................496 Failure code [CA132] Throttle sensor low error...................................................498 Failure code [CA144] Coolant temp. sensor high error.............................................499 Failure code [CA145] Coolant temp. sensor low error..............................................500 Failure code [CA153] Charge air temp. sensor high error..........................................501 Failure code [CA154] Charge air temp. sensor low error...........................................502 Failure code [CA187] Sensor sup. 2 volt. low error...............................................503 Failure code [CA221] Ambient air press. sensor high error........................................504 Failure code [CA222] Ambient air press. sensor low error.........................................506 Failure code [CA227] Sensor sup. 2 volt. high error..............................................508 Failure code [CA234] Eng. overspeed..............................................................509 Failure code [CA238] Ne speed sensor sup. volt. error............................................510 Failure code [CA271] IMV/PCV1 short error........................................................512 Failure code [CA272] IMV/PCV1 open error.........................................................513 Failure code [CA322] Injector #1 (L #1) system open/short error..................................514 Failure code [CA324] Injector #3 (L #3) system open/short error..................................516 Failure code [CA331] Injector #2 (L #2) system open/short error..................................518 Failure code [CA332] Injector #4 (L #4) system open/short error..................................520 Failure code [CA351] Inj. drive circuit error....................................................522 Failure code [CA352] Sensor sup. 1 volt. low error...............................................525 Failure code [CA386] Sensor sup. 1 volt. high error..............................................526 Failure code [CA435] Abnormality in engine oil pressure switch...................................528 Failure code [CA441] Battery voltage low error...................................................529 Failure code [CA442] Battery voltage high error..................................................529 Failure code [CA449] Rail press. very high error.................................................530 Failure code [CA451] Rail press. sensor high error...............................................532 Failure code [CA452] Rail press. sensor low error................................................534 Failure code [CA553] Rail press. high error......................................................534 Failure code [CA559] Rail press. low error.......................................................535 Failure code [CA689] Eng. Ne speed sensor error..................................................538 Failure code [CA731] Eng. Bkup speed sensor phase error..........................................540 Failure code [CA757] All persistent data lost error..............................................540 Failure code [CA778] Eng. Bkup speed sensor error................................................542 Failure code [CA1633] KOMNET datalink timeout error..............................................544 Failure code [CA2185] Throttle sens. sup. volt. high error.......................................546 Failure code [CA2186] Throttle sens. sup. volt. low error........................................548 Failure code [CA2249] Rail press. very low error.................................................548 Failure code [CA2311] Abnormality in IMV solenoid................................................549 Failure code [D110KB] Battery relay drive short..................................................550 Failure code [D19JKZ] Personal code relay abnormality............................................552 Failure code [D862KA] GPS antenna discon.........................................................554 Failure code [DA22KK] Pump solenoid power low error..............................................556 Failure code [DA25KP] 5V sensor 1 power abnormality..............................................558 Failure code [DA26KP] 5V sensor 2 power abnormality..............................................561 Failure code [DA2RMC] CAN discon (Pump controller detected)......................................562 Failure code [DAF8KB] Short circuit in camera power supply.......................................564 Failure code [DAFGMC] GPS module error...........................................................566 Failure code [DAFRMC] CAN discon (Monitor detected)..............................................568 Failure code [DGH2KB] Hydr oil sensor short......................................................570 Failure code [DHPAMA] Pump press sensor abnormality..............................................572 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality...........................574 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality..........................576 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality...........................578 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality..........................580 Failure code [DHSKMA] Blade raise PPC press sensor abnormality...................................582 Failure code [DHSLMA] Blade lower PPC press sensor abnormality...................................584 Failure code [DHX1MA] Overload sensor abnormality (Analog).......................................586 Failure code [DV20KB] Travel alarm S/C...........................................................587 Failure code [DW43KA] Travel speed sol discon....................................................588 Failure code [DW43KB] Travel speed sol short.....................................................589 Failure code [DW45KA] Swing brake sol discon.....................................................590 Failure code [DW45KB] Swing brake sol short......................................................592 Failure code [DW91KA] Travel junction sol discon.................................................594 Failure code [DW91KB] Travel junction sol short..................................................595 Failure code [DWJ0KA] Merge-divider sol discon...................................................596 Failure code [DWJ0KB] Merge-divider sol short....................................................597 Failure code [DXA8KA] PC-EPC sol discon..........................................................598 Failure code [DXA8KB] PC-EPC sol short...........................................................600 Failure code [DXE4KA] Service current EPC discon.................................................602 Failure code [DXE4KB] Service current EPC short..................................................603 Failure code [DY20KA] Wiper working abnormality..................................................604 Failure code [DY20MA] Wiper parking abnormality..................................................606 Failure code [DY2CKA] Washer drive discon........................................................608 Failure code [DY2CKB] Washer drive short.........................................................610 Failure code [DY2DKB] Wiper drive (for) short....................................................612 Failure code [DY2EKB] Wiper drive (rev) short....................................................614 Troubleshooting of electrical system (E-mode)........................................................616 Before carrying out troubleshooting of electrical system.........................................616 Information in troubleshooting table.............................................................618 E-1 When starting switch turned ON, machine monitor displays nothing.............................620 E-2 When starting switch turned ON (before starting engine), basic check item lights up..........622 E-3 Engine does not start (Engine does not turn).................................................623 E-4 Preheater does not operate...................................................................626 E-5 Automatic warm-up system does not operate (in cold season)...................................628 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked..............630 E-7 Precaution lights up while engine is running.................................................632 E-8 Emergency stop item lights up while engine is running........................................635 E-9 Engine coolant temperature gauge does not indicate normally..................................636 E-10 Hydraulic oil temperature gauge does not indicate normally..................................637 E-11 Fuel level gauge does not indicate normally.................................................639 E-12 Contents of display by machine monitor are different from applicable machine................641 E-13 Machine monitor does not display some items.................................................641 E-14 Function switch does not work...............................................................641 E-15 Auto-decelerator does not operate normally..................................................642 E-16 Working mode does not change................................................................643 E-17 Travel speed does not change................................................................644 E-18 Alarm buzzer cannot be stopped..............................................................645 E-19 Windshield wiper and window washer do not operate...........................................646 E-20 Swing holding brake does not operate normally...............................................650 E-21 Travel alarm does not sound or does not stop sounding.......................................652 E-22 Air conditioner does not operate normally (including air conditioner abnormality record)....653 E-23 While starting switch is in OFF position, service meter is not displayed....................665 E-24 Machine monitor cannot be set in service mode...............................................665 E-25 Monitoring function does not display lever control signal normally..........................666 E-26 KOMTRAX system does not operate normally....................................................682 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................683 Information contained in troubleshooting table...................................................683 System chart for hydraulic and mechanical systems................................................684 H-1 Speed or power of all work equipment, swing, and travel are low..............................686 H-2 Engine speed sharply drops or engine stalls..................................................687 H-3 No work equipment, travel and swing move.....................................................688 H-4 Abnormal noise is heard from around hydraulic pump...........................................688 H-5 Fine control mode does not function..........................................................689 H-6 Speed or power of boom is low................................................................690 H-7 Speed or power of arm is low.................................................................691 H-8 Speed or power of bucket is low..............................................................692 H-9 Work equipment does not move in its single operation.........................................693 H-10 Hydraulic drift of work equipment is large..................................................694 H-11 Time lag of work equipment is large.........................................................695 H-12 Work equipment loaded more is slower during compound operation..............................695 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE.........................695 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel......696 H-15 Machine deviates during travel..............................................................697 H-16 Travel speed is low.........................................................................698 H-17 Machine cannot be steered easily or steering power is low...................................699 H-18 Travel speed does not change or it is kept low or high......................................700 H-19 Track does not move (Only either side)......................................................700 H-20 Machine does not swing......................................................................701 H-21 Swing acceleration or swing speed is low....................................................702 H-22 Excessive overrun when stopping swing.......................................................703 H-23 When upper structure stops swinging, it makes large shock...................................704 H-24 When upper structure stops swinging, it makes large sound...................................704 H-25 Hydraulic drift of swing is large...........................................................705 H-26 Flow rate in attachment circuit cannot be adjusted..........................................706 Troubleshooting of engine (S-mode)...................................................................708 Method of using troubleshooting chart............................................................708 S-1 Starting performance is poor.................................................................712 S-2 Engine does not start........................................................................713 S-3 Engine does not pick up smoothly.............................................................716 S-4 Engine stops during operations...............................................................717 S-5 Engine does not rotate smoothly..............................................................718 S-6 Engine lacks output (or lacks power).........................................................719 S-7 Exhaust smoke is black (incomplete combustion)...............................................720 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................721 S-9 Oil becomes contaminated quickly.............................................................722 S-10 Fuel consumption is excessive...............................................................723 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).......................724 S-12 Oil pressure drops..........................................................................725 S-13 Oil level rises (Entry of coolant or fuel)..................................................726 S-14 Coolant temperature becomes too high (overheating)..........................................727 S-15 Abnormal noise is made......................................................................728 S-16 Vibration is excessive......................................................................729 50 Disassembly and assembly..............................................................................731 General information on disassembly and assembly......................................................734 How to read this manual..........................................................................734 Coating materials list...........................................................................736 Special tool list................................................................................739 Sketch of special tool...........................................................................743 Engine and cooling system............................................................................745 Removal and installation of fuel supply pump assembly............................................745 Removal and installation of fuel injector assembly...............................................747 Removal and installation of front oil seal.......................................................750 Removal and installation of rear oil seal........................................................752 Removal and installation of cylinder head assembly...............................................755 Removal and installation of radiator assembly....................................................762 Removal and installation of aftercooler assembly.................................................764 Removal and installation of work equipment oil cooler assembly...................................766 Removal and installation of engine and work equipment pump assembly..............................769 Removal and installation of fuel tank assembly...................................................774 Power train..........................................................................................776 Removal and installation of travel motor and final drive assembly................................776 Disassembly and assembly of travel motor and final drive assembly................................778 Removal and installation of swing motor and swing machinery assembly.............................814 Disassembly and assembly of swing motor and swing machinery assembly.............................816 Removal and installation of swing circle assembly................................................822 Undercarriage and frame..............................................................................823 Disassembly and assembly of track roller.........................................................823 Disassembly and assembly of idler assembly.......................................................826 Disassembly and assembly of recoil spring........................................................829 Spreading and installation of track shoe assembly................................................832 Removal and installation of sprocket.............................................................834 Removal and installation of revolving frame assembly.............................................835 Removal and installation of counterweight assembly (Machine without add-on weight)...............837 Removal and installation of counterweight assembly (Machine with add-on weight)..................839 Hydraulic system.....................................................................................841 Removal and installation of center swivel joint assembly.........................................841 Disassembly and assembly of center swivel joint assembly.........................................843 Removal and installation of hydraulic tank assembly..............................................844 Removal and installation of hydraulic pump assembly..............................................847 Removal and installation of control valve assembly...............................................851 Disassembly and assembly of control valve assembly...............................................856 Disassembly and assembly of work equipment PPC valve assembly....................................866 Disassembly and assembly of travel PPC valve assembly............................................869 Disassembly and assembly of hydraulic cylinder assembly..........................................871 Work equipment.......................................................................................877 Removal and installation of work equipment assembly..............................................877 Cab and its attachments..............................................................................880 Removal and installation of operator cab assembly................................................880 Removal and Installation of operator's cab door..................................................882 Removal and installation of operator's cab glass (stuck glass)...................................885 Removal and installation of front window assembly................................................894 Removal and installation of floor frame assembly.................................................895 Electrical system....................................................................................902 Removal and installation of air compressor assembly..............................................902 Removal and installation of air conditioner condenser............................................903 Removal and installation of air conditioner unit assembly........................................904 Removal and installation of machine monitor assembly.............................................907 Removal and installation of pump controller assembly.............................................908 Removal and installation of engine controller assembly...........................................909 Removal and installation of KOMTRAX communications module........................................910 90 Diagrams and drawings.................................................................................911 Hydraulic diagrams and drawings......................................................................913 Symbols used in hydraulic circuit diagrams.......................................................913 Hydraulic circuit diagram........................................................................915 Electrical diagrams and drawings.....................................................................917 Symbols used in electric circuit diagrams........................................................917 Electrical circuit diagram.......................................................................921 Connectors table and arrangement drawing.........................................................927 Index....................................................................................................928
DESCRIPTION:
KOMATSU PC128US-8 HYDRAULIC EXCAVATOR SHOP MANUAL WEN00003-00 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A Always wear safety glasses when hitting parts with a hammer.
B Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 27/12/24
