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Komatsu PC128UU-1 PC128US-1 Service Repair Manual – PDF DOWNLOAD
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Komatsu PC128UU-1 PC128US-1 Service Repair Manual
MACHINE MODEL SERIAL NUMBER
PC128UU-1 2347 and up
PC128US-1 1715 and up
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Description
Komatsu PC128UU-1 PC128US-1 Service Repair Manual
FILE DETAILS:
Komatsu PC128UU-1 PC128US-1 Service Repair Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC128UU-1, PC128US-1
Serial Number: 2347 and up, 1715 and up
Book Code: SEBM009805
Language: English
Pages: 794
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC128UU-1 PC128US-1 Service Repair Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. 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.
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’ to “Causes” are also included In this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC128UU-1 PC128US-1 Service Repair Manual
COVER....................................................................................................................................................... 1 CONTENTS.................................................................................................................................................... 2 01 GENERAL.................................................................................................................................................. 27 GENERAL ASSEMBLY DRAWING................................................................................................................................ 28 SPECIFICATIONS.......................................................................................................................................... 30 WEIGHT TABLE............................................................................................................................................ 34 LIST OF LUBRICANTS AND WATER............................................................................................................................ 36 10 STRUCTURE AND FUNCTION .................................................................................................................................. 38 RADIATOR AND OIL COOLER................................................................................................................................. 39 PTO (COUPLING).......................................................................................................................................... 40 ENGINE CONTROL.......................................................................................................................................... 41 POWER TRAIN SYSTEM...................................................................................................................................... 42 SWING CIRCLE............................................................................................................................................ 43 SWING MACHINERY......................................................................................................................................... 44 TRACK FRAME ............................................................................................................................................ 45 IDLER CUSHION........................................................................................................................................... 46 TRACK SHOE.............................................................................................................................................. 47 HYDRAULIC PIPING DRAWING................................................................................................................................ 50 HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................... 54 HYDRAULIC TANK.......................................................................................................................................... 57 HYDRAULIC PUMP.......................................................................................................................................... 58 CONTROL VALVE........................................................................................................................................... 75 CLSS.................................................................................................................................................... 90 SWING MOTOR.............................................................................................................................................122 TRAVEL MOTOR............................................................................................................................................134 CENTER SWIVEL JOINT.....................................................................................................................................145 VALVE CONTROL...........................................................................................................................................147 PPC VALVE...............................................................................................................................................150 PPC SHUTTLE AND TRAVEL JUNCTION VALVE...................................................................................................................162 EPC SOLENOID VALVE......................................................................................................................................166 BOOM HOLDING VALVE......................................................................................................................................182 WORK EQUIPMENT..........................................................................................................................................185 AIR CONDITIONER ........................................................................................................................................187 ACTUAL ELECTRICAL WIRING DIAGRAM........................................................................................................................188 ELECTRONIC CIRCUIT DIAGRAM..............................................................................................................................195 ELECTRONIC CONTROL SYSTEM...............................................................................................................................199 MACHINE MONITORING SYSTEM...............................................................................................................................246 20 TESTING AND ADJUSTING....................................................................................................................................255 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...........................................................................................................256 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS..........................................................................................................258 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS (EXCEPT AUTOMATIC HORIZONTAL DIGGING MACHINE).........................................................274 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS.......................................................................................................282 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................................................................288 MEASURING ENGINE SPEED..................................................................................................................................289 MEASURING EXHAUST COLOR.................................................................................................................................290 ADJUSTMENT VALVE CLEARANCE..............................................................................................................................291 MEASUREMENT BLOW-BY PRESSURE............................................................................................................................292 MEASUREMENT ENGINE OIL PRESSURE.........................................................................................................................292 TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING.........................................................................................................293 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...........................................................................................294 ADJUSTING ENGINE SPEED SENSOR...........................................................................................................................294 ADJUSTING FUEL CONTROL CABLE............................................................................................................................295 ADJUSTING FUEL CONTROL CABLE............................................................................................................................296 ADJUSTING ENGINE STOP SOLENOID LINKAGE..................................................................................................................297 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT.......................................................................298 TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE).........................................................................300 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE...............................................302 TESTING AND ADJUSTING CONTROL PUNP CIRCUIT OIL PRESSURE.................................................................................................305 TESTING SOLENOID VALVE OUTPUT PRESSURE..................................................................................................................307 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE.......................................................................................309 ADJUSTING WORK EQUIPMENT, SEING PPC VALVE...............................................................................................................311 TESTING AND ADJUSTING TRAVEL DEVIATION .................................................................................................................312 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT.........................................................................................313 MEASUREMENT OIL LEAKAGE OF SWING, TRAVEL MOTOR..........................................................................................................315 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.......................................................................................................315 TESTING CLEARANCE OF SWING CIRCLE BEARING...............................................................................................................316 TESTING AND ADJUSTING TRACK SHOE TENSION................................................................................................................317 BLEEDING AIR............................................................................................................................................318 PROCEDURE FOR RESETTING ELECTRICAL SYSTEM AND CHECKING OPERATION........................................................................................320 PROCEDURE FOR REPLACING POTENTIOMETER...................................................................................................................332 PREOCEDURE FOR CHECKING DIODE...........................................................................................................................333 TROUBLESHOOTING.........................................................................................................................................334 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................335 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................................................................................................336 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....................................................................................................337 CHECKS BEFORE TROUBLESHOOTING.......................................................................................................................345 CONNECTOR TYPES AND MOUNTING LOCATIONS..............................................................................................................346 CONNECTOR ARRANGEMENT DIAGRAM.......................................................................................................................348 CONNECTOR TYPES AND MOUNTING LOCATIONS..............................................................................................................350 CONNECTOR ARRANGEMENT DIAGRAM.......................................................................................................................352 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................................................355 EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM..............................................................................................365 DISPLAY METHOD FOR MOMITOR PANEL, CONTROLLER........................................................................................................370 METHOD OF USING JUDGEMENT TABLE.....................................................................................................................376 METHOD OF USING TROUBLESHOOTING CHARTS..............................................................................................................377 TROUBLESHOOTING OF CONTROLLER ELECTRICAL SYSTEM (E MODE)............................................................................................379 ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE................................................................................381 JUDGEMENT TABLE FOR 4 SYSTEM....................................................................................................................385 JUDGEMENT TABLE FOR CHASSIS RELATED PARTS.......................................................................................................387 ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM................................................................................................389 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM.......................................................................393 PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS..............................................396 E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) IS DISPLAYED.......................................397 a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM............................................................................................397 b) ABNORMALITY IN COMMUNICATIONS SYSTEM.....................................................................................................398 E-2 ERROR CODE [31](ABNORMALITY IN BOOM POTENTIOMETER SYSTEM) IS DISPLAYED......................................................................399 E-3 ERROR CODE [32](ABNORMALITY IN ARM POTENTIOMETER SYSTEM) IS DISPLAYED.......................................................................400 E-4 ERROR CODE [34](ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM) IS DISPLAYED....................................................................401 E-5 ERROR CODE [41](ABNORMALITY IN ROTATION SENSOR SYSTEM)IS DISPLAYED..........................................................................402 E-6 ERROR CODE [51](ABNORMALITY IN PPC HYDRAULIC LOCK SOLENOID SYSTEM) IS DISPLAYED.............................................................403 E-7 ERROR CODE [52](ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED...............................................................404 E-8 ERROR CODE [54](ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED............................................................405 E-9 ERROR CODE [61](ABNORMALITY IN LS-EPC SOLENOID SYSTEM) IS DISPLAYED.........................................................................406 E-10 ERROR CODE [62](ABNORMALITY IN LS BYPASS SOLENOID SYSTEM) IS DISPLAYED.....................................................................408 E-11 ERROR CODE [71](ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM) IS DISPLAYED...............................................................409 E-12 ERROR CODE [72](ABNORMALITY IN BOOM LOWER STOP SOLENOID SYSTEM) IS DISPLAYED...............................................................410 E-13 ERROR CODE [74](ABNORMALITY IN PC-EPC SOLENOID SYSTEM) IS DISPLAYED........................................................................411 E-14 ERROR CODE [78](ABNORMALITY IN SWING RIGHT BRAKE SOLENOID SYSTEM) IS DISPLAYED.............................................................412 E-15 ERROR CDOE [81](ABNORMALITY IN ARM IN STOP EPC SOLENOID SYSTEM) IS DISPLAYED...............................................................413 E-16 ERROR CODE [C1](BOOM LOWER, BOOM RAISE PRESSURE SWITCHES INPUT AT SAME TIME FOR MORE THAN 3 SECONDS) IS DISPLAYED..........................413 E-17 ABNORMALITY IN PC-EPC SOLENOID SYSTEM (POWER MODE DOES NOT SWITCH).........................................................................414 a) DOES NOT SWITCH TO POWER MODE............................................................................................................414 b) DOES NOT SWITCH TO ECONOMY MODE (STALLS IN LOW SPEED RANGE)..............................................................................415 E-18 ABNORMALITY IN TRAVEL SPEED BOOST SOLENOID SYSTEM (SPEED DOES NOT INCRESE OR DOES NOT DECREASE.............................................416 a)SPEED DOES NOT INCREASE (STAYS AT LOW SPEED)..............................................................................................416 b)SPEED DOES NOT DECREASE (STAYS AT HIGH SPEED).............................................................................................417 E-19 WORK EQUIPMENT DOES NOT WORK EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELESSED...............................................................418 E-20 WORK EQUIPMENT LOCK LEVER IS AT LOCK POSITION BUT WORK EQUIPMENT MOVES.....................................................................419 E-21 DEPTH MODE, HEIGHT MODE, OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE RESCHING SET POSITION)....420 E-22 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE, DEPTH MODE,HEIGHT MODE, OFFSET MODE.................................................421 E-23 CANCEL SWITCH IS NOT TURNED ON, BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRICAL SYSTEM CAUTION LAMP FLASHES...........................422 E-24 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE, ARM IN, LEFT OFFSET (WHEN ERROR CODE [91] IS NOT DISPLAYED)..............................423 E-25 SWING DOES NOT WORK (WHEN NO ERROR DISPLAY IS GIVEN).......................................................................................424 E-26 EXCESSIVE HYDRAULIC DRIFT OF SWING.........................................................................................................425 E-27 OFFSET DOES NOT WORK (PARTICULARLY LEFT OFFSET)............................................................................................426 E-28 ENGINE DOES NOT START......................................................................................................................427 a) STARTING MOTOR DOES NOT TURN.............................................................................................................427 b) ENGINE STOP SOLENOID DOES NOT WORK.......................................................................................................429 E-29 ENGINE DOES NOT STOP ......................................................................................................................430 E-30 WIPER DOES NOT WORK........................................................................................................................431 E-31 ERROR CODE [64](ABNORMALITY IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED................................................................432 E-32 ERROR CODE [68](SHORT CIRCUIT WITH GROUND IN SWIFT SLOW-DOWN CONTROL SIGNAL SYSTEM) IS DISPLAYED...........................................433 E-33 AUTO-DECELERATION DOES NOT WORK WHEN AUTO-DECELERATION IS SWITCHED ON (AUTO-DECELERATION CANCEL SWITCH OFF)................................434 E-34 ENGINE SPEED DOES NOT RISE WHEN AUTO-DECELERATION CANCEL SWITCH IS OFF (AUTO-DECELERATION REMAINS IN EFFECT)...............................435 E-35 AUTO-DECELERATION IS ACTUATED WHEN AUTO-DECELERATION CANCEL SWITCH IS OFF..................................................................435 E-36 DEFECTIVE ENGINE CONTROL...................................................................................................................436 a) DOES NOT WORK, OR WORKS FOR A MOMENT AND THEN STOPS WORKING..............................................................................436 b) SWIFT SLOW-DOWN DOES NOT WORK............................................................................................................439 c) WORKS AT NESR IDLING SPEED, BUT DOES NOT WORK UP TO FULL THROTTLE (LOAD BECOMES HIGH)....................................................440 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...........................................................................................................441 METHOD OF USING TROUBLESHOOTING CHARTS..........................................................................................................442 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...................................................................................446 S-2 ENGINE DOES NOT START.......................................................................................................................448 (1) ENGINE DOES NOT TURN....................................................................................................................448 (2) ENGINE TURNS BUT NO EXHAUST SMOKES COMES OUT (FUEL IS NOT BEING INJECTED)...............................................................449 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..............................................................450 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).........................................................................................451 S-4 ENGINE STOPS DURING OPERATIONS..............................................................................................................452 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)....................................................................................................453 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)........................................................................................................454 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...............................................................................................455 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).....................................................................................456 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................457 S-10 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................................458 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN....................................................................459 S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)......................................................................................460 S-13 OIL LEVEL RISES(WATER, FUEL IN OIL)........................................................................................................461 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...........................................................................................462 S-15 ABNORMAL NOISE IS MADE.....................................................................................................................463 S-16 VIBRATION IS EXCESSIVE.....................................................................................................................464 TROUBLESHOOTING OF CONTROLLER INPUT SIGNAL SYSTEM (F MODE)..........................................................................................465 F-1 MONITOR DISPLAY DOES NOT SHOW [P1](BOOM RAISE PRESSURE SWITCH)..............................................................................466 F-2 MONITOR DISPLAY DOES NOT SHOW [P2](BOOM LOWER PRESSURE SWITCH)..............................................................................467 F-3 MONITOR DISPLAY DOES NOT SHOW [P3](SWING PRESSURE SWITCH)...................................................................................468 F-4 MONITOR DISPLAY DOES NOT SHOW [P4](SWING PRESSURE SWITCH)...................................................................................469 F-5 MONITOR DISPLAY DOES NOT SHOW [P5](ARM IN PRESSURE SWITCH)..................................................................................470 F-6 MONITOR DISPLAY DOES NOT SHOW [P7](TRAVEL PRESSURE SWITCH)..................................................................................471 F-7 MONITOR DISPLAY DOES NOT SHOW [P8](BRAKE PRESSURE SWITCH)...................................................................................472 F-8 MONITOR DISPLAY DOES NOT SHOW [P9] (BUCKET, OFFSET PRESSURE SWITCH).........................................................................473 F-9 CONTROLLER DISPLAY DOES NOT SHOW [UP](KNOB SWITCH)..........................................................................................474 F-10 CONTROLLER DISPLAY DOES NOT SHOW [HI](TRAVEL SPEED BOOST SWITCH)...........................................................................475 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE).............................................................................................476 TABLE OF FAILURE MODES AND CAUSES...............................................................................................................478 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWIJNG, TRAVEL ARE SLOW OR LACK POWER.........................................................................481 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE ATALLS...................................................................................483 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE.......................................................................................................484 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)......................................................................................................484 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR............................................................................................485 H-7 BOOM IS SLOW OR LACKS POWER.................................................................................................................486 H-8 ARM IS SLOW OR LACKS POWER..................................................................................................................488 H-9 BUCKET IS SLOW OR LOCKS POWER...............................................................................................................490 H-10 OFFSET IS SLOW OR LACKS POWER..............................................................................................................491 H-11 WORK EQUIPMENT (BOOM, ARM, BUCKET, OFFSET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).................................................492 H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)...........................................................................................492 H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)..................................................................................................493 H-14 LACK OF POWER WHEN PRESSURE RISES (EXCEPT AUTOMATIC HORIZONTAL DIGGING MACHINE)............................................................493 H-15 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW............................................................................494 H-16 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW..................................................................................................495 H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCEESSIVELY.........................................................................................495 H-18 IN WORK EQUIPMENT (BOOM RAISE) +TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY.....................................................................495 H-19 TRAVEL DEVIATION ..........................................................................................................................496 a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL.................................................................................................496 b) EXCESSIVE TRAVEL DEVIATION WHEN STARTING.................................................................................................496 H-20 TRAVEL SPEED IS SLOW.......................................................................................................................497 H-21 STEERING DOES NOT TURN EASILY OR LACKS POWER...............................................................................................499 H-22 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED.............................................................................501 H-23 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).......................................................................................................501 H-24 DOES NOT SWING.............................................................................................................................502 a) DOES NOT SWING TO EITHER LEFT OR RIGHT...................................................................................................502 b) DOES NOT SWING IN ONE DIRECTION..........................................................................................................502 H-25 SWING ACCELERATION IS POOR LOR SWING SPEED IS SLOW.........................................................................................503 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING......................................................................................................505 a) ONE DIRECTION ONLY.......................................................................................................................505 b) BOTH DIRECTIONS..........................................................................................................................505 H-27 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...................................................................................506 H-28 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...............................................................................................507 H-29 EXCESSIVE HYDRAULIC DRIFT OF SWING.........................................................................................................508 a) WHEN SWING HOLDING BRAKE IS RELESASED....................................................................................................508 b) WHEN SWING HOLDING BRAKE IS APPLIED......................................................................................................508 H-30 BLADE IS SLOW OR LACKS POWER...............................................................................................................509 H-31 EXCESSIVE HYDRAULIC DRIFT OF BLADE.........................................................................................................509 H-32 ERROR CODE [91] IS DISPLAYED ON MONITOR PANEL,ANG BOOM RAISE,BOOM LOWER,AND LEFT OFFSET ALL STOP JUST BEFORE THERE IS INTERFERENCE.........510 H-33 AUTOMATIC STOP IS NOT CARRIED OUT,AND THERE IS INTERFERENCE OF BOOM RAISE,ARM IN,AND LEFT OFFSET...........................................510 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)...................................................................................................511 CHASSIS MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM...............................................................................................512 M-1 WHEN STARTING SWITCH IS TURNED ON, NOTHING IS DISPLAYED (NOTHING LIGHTS UP FOR 3 SEC.)......................................................513 M-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS LIGHT UP,BUT THEY DO NOT GO OUT AFTER 3 SEC.....................................................513 M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SEC.....................................................................514 a) NO GAUGES LIGHT UP.......................................................................................................................514 b) ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP...........................................................................................514 c) CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP..............................................................................................514 d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP.......................................................................................514 M-4 WHEN STRATING SWITCH IS AT ON (ENGINE STOPPED),CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP..................................................515 M-5 WHEN STARTING SWITCH IS AT ON (ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP ..........................................515 M-6 PREHESTING PILOT LAMP DOES NOT LIGHT UP DURING PREHEATING...................................................................................516 M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...........................................516 M-8 CHARGE LEVEL CAUTION LIGHTS UP WHEN ENGINE IS RUNNING.......................................................................................517 M-9 ABNORMALITY IN COOLANT TEMPERATURE SYSTEM IS DISPLAYED......................................................................................517 a) AFTER ENGINE ATARTS, LEVEL STAYS AT BOTTOM AND DOES NOT GO UP............................................................................517 b) AFTER ENGINE ATARTS, LEVEL GOES UP IMMEDIATELY(ENTERS RED RANGE EVEN THOUGH THERE IS NO OVERHEATING).....................................518 M-10 ABNORMAL DISPLAY IS GIVEN FOR FUEL GAUGE SYSTEM............................................................................................518 a) ALL FUEL LEVEL GAUGE SEGMENTS GO OUT.....................................................................................................518 b) FUEL HAS GONE DOWN, BUT FUEL GAUGE CONTINUES TO DISPALY FULL.............................................................................519 c) EVEN WHEN FUEL TANK IS FILLED,FUEL LEVEL GAUGE DOES NOT SHOW FULL........................................................................519 M-11 DEFECTIVE OPERATION OF ALARM BUZZER........................................................................................................520 a) BUZZER DOES NOT SOUND....................................................................................................................520 b) BUZZER DOES NOT STOP SOUNDING............................................................................................................520 M-12 SERVICE MEMTER DOES NOT MOVE WHEN ENGINE IS RUNNING........................................................................................521 a) WHEN CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP.........................................................................................521 b) WHEN CHARGE LEVEL CAUTION LAMP LIGHTS UO.................................................................................................521 M-13 NIGHT LIGHTING DOES NOT LIGHT UP...........................................................................................................522 a) COOLANT TEMPERATURE GAUGE,FULE GAUGE,DEPTH DISPLAY DO NOT LIGHT UP.......................................................................522 b) SERVICE METER DOES NOT LIGHT UP..........................................................................................................522 M-14 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP (THERE IS NO ABNORMALITY DISPLAY ON CONTROLLER,OPERATION IS NORMAL)..........................523 a) STD MACHINE..............................................................................................................................523 b) MACHINE EQUIPPED WITH AUTIMATIC HORIZONTAL DIGGING SYSTEM................................................................................523 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................524 METHOD OF USING MANUAL..................................................................................................................................526 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................527 SPECIAL TOOL LIST.......................................................................................................................................529 SKECHES OF SPECIAL TOOLS................................................................................................................................533 STARTING MOTOR..........................................................................................................................................537 REMOVEL AND INSTALLATION............................................................................................................................537 ALTERNATOR..............................................................................................................................................538 REMOVAL AND INSTALLATION............................................................................................................................538 ENGINE OIL COOLER.......................................................................................................................................539 REMOVEL AND INSTALLATION............................................................................................................................539 FUEL INJECTION PUMP.....................................................................................................................................540 REMOVAL.............................................................................................................................................540 INSTALLATION........................................................................................................................................544 WATER PUMP..............................................................................................................................................547 REMOVAL AND INSTALLATION............................................................................................................................547 NOZZLE HOLDER...........................................................................................................................................548 REMOVAL AND INATALLATION............................................................................................................................548 TURBOCHARGER............................................................................................................................................549 REMOVAL.............................................................................................................................................549 INSTALLATION........................................................................................................................................550 THERMOSTAT..............................................................................................................................................551 REMOVAL AND INSTALLATION............................................................................................................................551 CYLINDER HEAD...........................................................................................................................................552 REMOVAL.............................................................................................................................................552 INSTALLATION........................................................................................................................................558 ENGINE, MAIN PUMP.......................................................................................................................................561 REMOVAL.............................................................................................................................................561 INTALLATION.........................................................................................................................................567 RADIATOR, HYDRAULIC COOLER..............................................................................................................................568 REMOVAL ............................................................................................................................................568 INSTALLATION........................................................................................................................................571 FUEL TANK...............................................................................................................................................572 REMOVAL ............................................................................................................................................572 INSTALLATION........................................................................................................................................573 CENTER SWIVEL JOINT.....................................................................................................................................574 REMOVAL AND INATALLATION............................................................................................................................574 DISASSEMBLY AND ASSEMBLY............................................................................................................................575 SPROCKET ...............................................................................................................................................576 REMOVAL AND INSTALLATION............................................................................................................................576 TRAVEL MOTOR............................................................................................................................................577 REMOVAL AND INSTALLATION............................................................................................................................577 SWING MOTOR, SWINMG MACHINERY...........................................................................................................................578 REMOVAL ............................................................................................................................................578 INSTALLATION........................................................................................................................................579 SWING MACHINERY.........................................................................................................................................580 DISASSEMBLY.........................................................................................................................................580 ASSEMBLY............................................................................................................................................583 SWING MOROR ............................................................................................................................................587 REMOVAL AND INSTALLATION............................................................................................................................587 DISASSEMBLY.........................................................................................................................................588 ASSEMBLY............................................................................................................................................591 REVOLVING FRAME.........................................................................................................................................598 REMOVAL.............................................................................................................................................598 INSTALLATION........................................................................................................................................599 SWING CIRCLE............................................................................................................................................600 REMOVAL AND INSTALLATION............................................................................................................................600 IDLER, RECOIL SPRING....................................................................................................................................601 REMOVAL AND INSTALLATION............................................................................................................................601 RECOIL SPRING...........................................................................................................................................602 DISASSEMBLY.........................................................................................................................................602 ASSEMBLY............................................................................................................................................603 IDLER ..................................................................................................................................................604 DISASSEMBLY.........................................................................................................................................604 ASSEMBLY............................................................................................................................................605 TRACK ROLLER............................................................................................................................................607 REMOVAL AND INSTALLATION............................................................................................................................607 DISASEMBLY..........................................................................................................................................608 ASSEMBLY............................................................................................................................................610 CARRIER ROLLER..........................................................................................................................................612 REMOVAL AND INSTALLATION............................................................................................................................612 SEEEL SHOE RUBBER PAD SHOE, LOAD LINER..................................................................................................................613 REMOVAL AND INSTALLATION............................................................................................................................613 INTEGRATED RUBBER SHOE..................................................................................................................................614 REMOVAL AND INSTALLATION............................................................................................................................614 HYDRAULIC TANK .........................................................................................................................................615 REMOVAL ............................................................................................................................................615 INSTALLATION........................................................................................................................................616 MAIN PUMP...............................................................................................................................................617 REMOVAL.............................................................................................................................................617 INSTALLATION........................................................................................................................................619 DISASSEMBLY.........................................................................................................................................620 ASSEMBLY............................................................................................................................................630 CONTROL PUMP............................................................................................................................................642 REMOVAL AND INSTALLATION............................................................................................................................642 PC-EPC, LS-EPC VALVE....................................................................................................................................643 REMOVAL AND INSTALLATION............................................................................................................................643 PC VALVE................................................................................................................................................644 REMOVAL AND INSTALLATION............................................................................................................................644 LS VALVE................................................................................................................................................645 REMOVAL AND INSTALLATION ...........................................................................................................................645 CONTROL VALVE...........................................................................................................................................646 REMOVAL ............................................................................................................................................646 INSTALLATION........................................................................................................................................648 DISASSEMBLY.........................................................................................................................................649 ASSEMBLY............................................................................................................................................651 LS SELSECT VALVE........................................................................................................................................654 DISASSEMBLY AND ASSEMBLY............................................................................................................................654 LS SHUTTLE VALVE........................................................................................................................................655 DISASSEMBLY AND ASSEMBLY............................................................................................................................655 PRESSURE COMPENSATION VALVE.............................................................................................................................656 DISASSEMBLY AND ASSEMBLY............................................................................................................................656 MAIN RELIEF VALVE.......................................................................................................................................658 REMOVAL AND INSTALLATION............................................................................................................................658 DISASSEMBLY AND ASSEMBLY............................................................................................................................659 SOLENOID VALVE..........................................................................................................................................661 (LS BYPASS, SWING HOLDING BRAKE, TRAVEL SPEED BOOST)................................................................................................661 REMOVAL AND INSTALLATION........................................................................................................................661 (EPC, LEFT OFFSET)..................................................................................................................................662 REMOVAL AND INSTALLATION........................................................................................................................662 WORK EQUIPMENT LH.PPC VALVE (ARM, SWING)................................................................................................................663 REMOVAL AND INSTALLATION............................................................................................................................663 WORK EAUIPMENT R.H. PPC VALVE (BOOM, BUCKET)............................................................................................................664 REMOVAL AND INSTALLATION............................................................................................................................664 WORK EQUIPMENT PPC VALVE (BOOM, BUCKET, ARM, SWING).....................................................................................................665 DISASSEMBLY.........................................................................................................................................665 ASSEMBLY............................................................................................................................................666 TRAVEL PPC VALVE........................................................................................................................................667 REMOVAL AND INSTALLATION............................................................................................................................667 DISASSEMBLY AND ASSEMBLY............................................................................................................................668 PPC VALVE FPR OFFSET CONTROL............................................................................................................................669 REMOVAL AND INSTALLATION............................................................................................................................669 BLADE PPC VALVE.........................................................................................................................................670 REMOVAL AND INSTALLATION............................................................................................................................670 BOOM LOCK VALVE.........................................................................................................................................671 REMOVAL AND INSTALLATION............................................................................................................................671 BOOM CYLINDER...........................................................................................................................................672 REMOVAL ............................................................................................................................................672 INSTALLATION .......................................................................................................................................673 ARM CYLINDER............................................................................................................................................674 REMOVAL ............................................................................................................................................674 INSTALLATION........................................................................................................................................675 BUCKET CYLINDER.........................................................................................................................................676 REMOVAL ............................................................................................................................................676 INSATLLATION........................................................................................................................................677 OFFSET CYLINDER.........................................................................................................................................678 REMOVAL ............................................................................................................................................678 INSTALLATION........................................................................................................................................679 BLADE CYLINDER..........................................................................................................................................680 REMOVAL ............................................................................................................................................680 INSTALLATION........................................................................................................................................681 HYDRAULIC CYLINDER......................................................................................................................................682 DISASSEMBLY.........................................................................................................................................682 ASSEMBLY............................................................................................................................................685 WORK EQUIPMENT..........................................................................................................................................688 REMOVAL ............................................................................................................................................688 INSTALLATION........................................................................................................................................690 BUCKET..................................................................................................................................................691 REMOVAL ............................................................................................................................................691 INSTALLATION........................................................................................................................................692 ARM.....................................................................................................................................................693 REMOVAL ............................................................................................................................................693 INSTALLATION........................................................................................................................................694 BUCKET, ARM.............................................................................................................................................695 REMOVAL ............................................................................................................................................695 INSTALLATION........................................................................................................................................696 SECOND BOOM.............................................................................................................................................697 REMOVAL ............................................................................................................................................697 INSTALLATION .......................................................................................................................................700 1ST BOOM................................................................................................................................................702 REMOVAL ............................................................................................................................................702 INSTALLATION........................................................................................................................................704 BLADE...................................................................................................................................................705 REMOVAL AND INSTALLATION............................................................................................................................705 OPERATOR'S CAB..........................................................................................................................................706 REMOVAL ............................................................................................................................................706 INSTALLATION........................................................................................................................................707 FLOOR FRAME.............................................................................................................................................708 REMOVAL.............................................................................................................................................708 INSTALLATION........................................................................................................................................709 AIR CONDITIONER COMPRESSOR..............................................................................................................................710 REMOVAL ............................................................................................................................................710 INSTALLATION........................................................................................................................................711 AIR CONDENSER...........................................................................................................................................712 REMOVAL ............................................................................................................................................712 INSTALLATION........................................................................................................................................713 COUNTERWEIGHT...........................................................................................................................................714 REMOVAL AND INSTALLATION............................................................................................................................714 CONTROLLER..............................................................................................................................................715 REMOVAL AND INSTALLATION............................................................................................................................715 MONITOR.................................................................................................................................................716 REMOVAL AND INSTALLATION............................................................................................................................716 CAR COOLER UNIT.........................................................................................................................................717 REMOVAL AND INSTALLATION............................................................................................................................717 40 MAINTENANCE STANDARD.....................................................................................................................................718 SWING MACHINERY.........................................................................................................................................719 SWING CIRCLE ...........................................................................................................................................721 TRACK FRAME.............................................................................................................................................722 IDLER...................................................................................................................................................723 CARRIER ROLLER..........................................................................................................................................724 TRACK ROLLER............................................................................................................................................725 SPROCKET................................................................................................................................................726 TRACK SHOE..............................................................................................................................................727 HYDRAULIC PUMP..........................................................................................................................................734 CONTROL VALVE...........................................................................................................................................736 SWING MOTOR.............................................................................................................................................746 TRAVEL MOTOR............................................................................................................................................748 CENTER SWIVEL JOINT.....................................................................................................................................749 PPC VALVE...............................................................................................................................................751 PPC SHUTTLE・TRAVEL JUNCTION VALVE.......................................................................................................................755 EPC SOLENOID VALVE......................................................................................................................................756 BOOM HOLDING VALVE......................................................................................................................................761 HYDRAULIC CYLINDER......................................................................................................................................762 WORK EQUIPMENT..........................................................................................................................................766 DIMENSION OF WORK EQUIPMENT.............................................................................................................................770 90 OTHERS...................................................................................................................................................776 HYDRAULIC PIPING DRAWING................................................................................................................................777 MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (PC128UU-1)..............................................................................778 HYDRAUIC CIRCUIT DIAGRAM (PC128UU-1)....................................................................................................................779 MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (PC128UU-1)..............................................................................780 CLSS....................................................................................................................................................781 OPERATION OF CLSS SYSTEM AS A WHOLE.................................................................................................................781 1) WHEN ALL CONTROL VALVES ARE AT NEUTRAL...........................................................................................................781 2) WHEN BOOM RAISE IS OPERATED INDEPENDENTLY........................................................................................................782 3) WHEN SWING IS OPERATED INDEPENDENTLY.............................................................................................................783 4) WHEN BOOM AND ARM ARE OPERATED SIMULTANEOUSLY....................................................................................................784 ACTUAL ELECTRICAL WIRING DIAGRAM (PC128UU-1)............................................................................................................785 MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (PC128UU-1)..........................................................................786 ELECTRICAL CIRCUIT DIAGRAM (PC128UU-1)..................................................................................................................787 MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (1/2) (PC128UU-1)....................................................................788 MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (2/2) (PC128UU-1)....................................................................789 ELECTRONIC CONTRAL SYSTEM...............................................................................................................................790 OVERALL SYSTEM DRAWING..............................................................................................................................790 MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL .....................................................................................791 HYDRAUIC CIRCUIT DIAGRAM (PC128US-1)....................................................................................................................792 ELECTRICAL CIRCUIT DIAGRAM (PC128US-1)..................................................................................................................793 CONNECTOR ARRANGEMENT DIAGRAM...........................................................................................................................794
KOMATSU PC128UU-1 PC128US-1 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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