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KOMATSU PC128UU-2 SHOP MANUAL SEBM018506 – PDF DOWNLOAD
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Description
KOMATSU PC128UU-2 SHOP MANUAL SEBM018506 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC128UU-2 SHOP MANUAL SEBM018506 – PDF DOWNLOAD
Language : English
Pages : 623
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC128UU-2 SHOP MANUAL SEBM018506 – PDF DOWNLOAD
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 26 GENERAL ASSEMBLY DRAWING................................................................................................................. 27 SPECIFICATIONS........................................................................................................................... 29 WEIGHT TABLE............................................................................................................................. 32 LIST OF LUBRICANTS AND COOLANT........................................................................................................... 34 10 STRUCTURE AND FUNCTION.................................................................................................................... 36 PTO...................................................................................................................................... 37 RADIATOR AND OIL COOLER.................................................................................................................. 38 POWER TRAIN.............................................................................................................................. 40 SWING CIRCLE............................................................................................................................. 41 SWING MACHINERY.......................................................................................................................... 42 TRACK FRAME.............................................................................................................................. 43 IDLER CUSHION............................................................................................................................ 44 HYDRAULIC EQUIPMENT LAYOUT DRAWING....................................................................................................... 45 VALVE CONTROL............................................................................................................................ 47 HYDRAULIC TANK AND FILTER................................................................................................................ 48 HYDRAULIC PUMP (PISTON PUMP)............................................................................................................. 49 CONTROL VALVE............................................................................................................................ 70 SUCTION SAFETY VALVE..................................................................................................................... 81 CLSS..................................................................................................................................... 82 SELF PRESSURE REDUCING VALVE.............................................................................................................119 CENTER SWIVEL JOINT......................................................................................................................125 TRAVEL MOTOR ............................................................................................................................126 SWING MOTOR..............................................................................................................................135 SOLENOID VALVE...........................................................................................................................143 EPC SOLENOID VALVE.......................................................................................................................145 PPC ACCUMULATOR..........................................................................................................................150 PPC VALVE................................................................................................................................151 AIR CONDITIONER PIPING...................................................................................................................162 ELECTRIC EQUIPMENT LAYOUT DRAWING........................................................................................................163 ENGINE CONTROL...........................................................................................................................167 ELECTRIC CONTROL SYSTEM..................................................................................................................175 4-SYSTEM.................................................................................................................................186 MONITOR SYSTEM...........................................................................................................................209 20 TESTING AND ADJUSTING.....................................................................................................................215 STANDARD VALUE TABLE FOR ENGINE..........................................................................................................216 STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................217 STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................227 TESTING AND ADJUSTING....................................................................................................................235 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....................................................................................236 MEASURING ENGINE SPEED...............................................................................................................237 MEASURING EXHAUST COLOR..............................................................................................................238 ADJUSTING VALVE CLEARANCE............................................................................................................239 MEASURING BLOW-BY PRESSURE...........................................................................................................240 MEASURING ENGINE OIL PRESSURE........................................................................................................240 TESTING AND ADJUSTING FUEL INJECTION TIMING..........................................................................................241 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION........................................................................242 ADJUSTING ENGINE SPEED SENSOR........................................................................................................242 ADJUSTING FUEL CONTROL CABLE.........................................................................................................243 ADJUSTING ENGINE STOP SOLENOID LINKAGE...............................................................................................244 TESTING CLEARANCE OF SWING CIRCLE BEARING............................................................................................245 MEASURING WEAR OF SPROCKET...........................................................................................................246 TESTING AND ADJUSTING TRACK SHOE.....................................................................................................247 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....................................................248 TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE).........................................................251 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE............................253 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE...................................................................................256 TESTING SOLENOID VALVE OUTPUT PRESSURE...............................................................................................257 MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................................260 ADJUSTING PPC VALVE..................................................................................................................261 TESTING AND ADJUSTING TRAVEL DEVIATION...............................................................................................262 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT..........................................................................263 MEASURING OIL LEAKAGE FROM SWING MOTOR...............................................................................................264 MEASURING OIL LEAKAGE FROM TRAVEL MOTOR..............................................................................................264 BLEEDING FROM EACH PART..............................................................................................................265 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...................................................................................267 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK......................................................................................267 PROCEDURE OF TESTING DIODE...........................................................................................................268 RESETTING PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION....................................................................269 REPLACEMENT PROCEDURE OF POTENTIOMETERS..............................................................................................283 PM CLINIC INSPECTION TABLE...........................................................................................................284 TROUBLESHOOTING..........................................................................................................................286 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................287 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................288 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................................................................289 CHECK BEFORE TROUBLESHOOTING.........................................................................................................297 TYPES AND LOCATIONS OF CONNECTORS....................................................................................................298 CONNECTOR ARRANGEMENT DIAGRAM........................................................................................................301 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................305 EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM...............................................................................317 DISPLAY METHOD FOR MONITOR PANEL, CONTROLLER.........................................................................................323 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................329 TROUBLESHOOTING OF CONTROLLER, ELECTRICAL SYSTEM (E MODE)............................................................................331 ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE.................................................................333 JUDGEMENT TABLE FOR 4 SYSTEM.....................................................................................................337 JUDGEMENT TABLE FOR CHASSIS RELATED PARTS........................................................................................339 ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM.................................................................................341 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM........................................................343 PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS...............................346 E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) IS DISPLAYED........................347 A) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM.............................................................................347 B) ABNORMALITY IN COMMUNICATIONS SYSTEMS.....................................................................................348 E-2 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTIOMETER SYSTEM) IS DISPLAYED......................................................349 E-3 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM) IS DISPLAYED.......................................................350 E-4 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM) IS DISPLAYED....................................................351 E-5 ERROR CODE [41](ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED......................................................352 E-6 ERROR CODE [51] (ABNORMALITY IN PPC HYDRAULIC LOCK SOLENOID SYSTEM) IS DISPLAYED.............................................353 E-7 ERROR CODE [52] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED...............................................354 E-8 ERROR CODE [54] (ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED............................................355 E-9 ERROR CODE [62] (ABNORMALITY IN OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED....................................................356 E-10 ERROR CODE [64] (ABNORMALITY IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED................................................357 E-11 ERROR CODE [71] (ABNORMALITY IN BOOM RAISE STOP EPC SOLENOID SYSTEM) IS DISPLAYED...........................................358 E-12 ERROR CODE [72] (ABNORMALITY IN BOOM LOWER STOP EPC SOLENOID SYSTEM) IS DISPLAYED...........................................359 E-13 ERROR CODE [74] (ABNORMALITY IN PC-EPC SOLENOID SYSTEM) IS DISPLAYED........................................................360 E-14 ERROR CODE [81] (ABNORMALITY IN ARM IN STOP SOLENOID SYSTEM) IS DISPLAYED...................................................361 E-15 ERROR CODE [C1] (3 SECONDS PASSED AFTER BOOM LOWER AND RAISE PRESSURE SWITCHES WERE INPUT SIMULTANEOUSLY) IS DISPLAYED......361 E-16 ABNORMALITY IN TRAVEL SPEED SELECTION SOLENOID SYSTEM (TRAVEL SPEED DOES NOT RISE OR DOES NOT DECREASE).....................362 A) TRAVEL SPEED DOES NOT RISE (BUT KEEPS LOW)................................................................................362 B) TRAVEL SPEED DOES NOT LOWER (BUT KEEPS HIGH)..............................................................................363 E-17 WORK EQUIPMENT DOES NOT MOVE AFTER WORK EQUIPMENT LOCK LEVER IS RELEASED....................................................364 E-18 WORK EQUIPMENT MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET IN LOCK POSITION...............................................365 E-19 DEPTH MODE, HEIGHT MODE, OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHIN....366 E-20 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE, DEPTH MODE, HEIGHT MODE, OFFSET MODE.................................367 E-21 CANCEL SWITCH IS NOT TURNED ON, BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRICAL SYSTEM CAUTION LAMP FLASHES............368 E-22 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE, LOWER, ARM IN, LEFT OFFSET, RIGHT OFFSET (WHEN ERROR CODE [91] IS NOT ....369 A) ALL OPERATIONS STOP IMMEDIATELY BEFORE INTERFERENCE.......................................................................369 B) THERE IS INTERFERENCE.....................................................................................................369 E-23 SWING DOES NOT WORK (WHEN NO ERROR DISPLAY IS GIVEN)........................................................................370 E-24 EXCESSIVE HYDRAULIC DRIFT OF SWING..........................................................................................371 E-25 OFFSET DOES NOT WORK (PARTICULARLY LEFT OFFSET).............................................................................372 E-26 OFFSET DOES NOT WORK (PARTICULARLY RIGHT OFFSET)............................................................................373 E-27 ENGINE DOES NOT START.......................................................................................................374 A) WHEN STARTING MOTOR DOES NOT ROTATE.......................................................................................374 B) ENGINE STOP SOLENOID DOES NOT WORK........................................................................................378 E-28 ENGINE DOES NOT STOP........................................................................................................379 E-29 WIPER DOES NOT OPERATE......................................................................................................380 E-30 ENGINE CONTROL IS ABNORMAL..................................................................................................381 A) WHEN ENGINE DOES NOT START OR IT STARTS BUT STOPS SOON....................................................................381 B) SWIFT SLOW-DOWN DOES NOT WORK.............................................................................................383 C) WORKS AT NEAR IDLING SPEED, BUT DOES NOT WORK UP TO FULL THROTTLE (LOAD BECOMES HIGH).....................................383 TROUBLESHOOTING OF CONTROLLER INPUT SIGNAL SYSTEM (F MODE)...........................................................................385 F-1 MONITOR DOES NOT DISPLAY [P1] (BOOM RAISE PRESSURE SWITCH)...................................................................386 F-2 MONITOR DOES NOT DISPLAY [P2] (BOOM LOWER PRESSURE SWITCH)...................................................................387 F-3 MONITOR DOES NOT DISPLAY [P3] (SWING PRESSURE SWITCH)........................................................................388 F-4 MONITOR DOES NOT DISPLAY [P5] (ARM IN PRESSURE SWITCH).......................................................................389 F-5 MONITOR DOES NOT DISPLAY [P7] (TRAVEL PRESSURE SWITCH).......................................................................390 F-6 MONITOR DOES NOT DISPLAY [HI] (TRAVEL SPEED SELECTOR SWITCH).................................................................391 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).............................................................................392 TABLE OF FAILURE MODES AND CAUSES................................................................................................393 H-1 ALL WORK EQUIPMENT, TRAVEL, AND SWING SPEED OR POWER IS LOW..................................................................395 H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS..............................................................................396 H-3 WORK EQUIPMENT DOES NOT MOVE AT ALL AND MACHINE DOES NOT TRAVEL OR SWING.....................................................397 H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP)..................................................................................398 H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW......................................................................................398 H-6 BOOM SPEED OR POWER IS LOW...................................................................................................399 H-7 ARM SPEED OR POWER IS LOW....................................................................................................400 H-8 BUCKET SPEED OR POWER IS LOW.................................................................................................400 H-9 BLADE SPEED OR POWER IS LOW..................................................................................................400 H-10 OFFSET SPEED OR POWER IS LOW................................................................................................401 H-11 WORK EQUIPMENT (BOOM, ARM, BUCKET, OFFSET MECHANISM, OR BLADE) DOES NOT MOVE................................................402 H-12 HYDRAULIC DRIFT (BOOM, ARM, BUCKET, OR BLADE) IS LARGE.....................................................................402 H-13 TIME LAG IS LONG (ENGINE SPEED IS LOW)......................................................................................403 H-14 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDANTLY, OTHER WORK EQUIPMENT MOVE....................................................403 H-15 SPEED IS HEAVIER OPERATION IS SLOWER DURING COMPOUND OPERATION..............................................................403 H-16 BOOM RAISE SPEED IS LOW DURING COMPOUND OPERATION OF BOOM SWING AND RAISE OPERATIONS........................................404 H-17 TRAVEL SPEED LOWERS DURING COMPOUND OPERATION OF WORK EQUIPMENT OR SWINGING AND TRAVEL......................................404 H-18 MACHINE DEVIATES............................................................................................................405 H-19 TRAVEL SPEED IS LOW.........................................................................................................406 H-20 STEERING CONDITION IS BAD OR STEERING FORCE IS LOW..........................................................................407 H-21 TRAVEL SPEED DOES NOT CHANGE................................................................................................409 H-22 MACHINE DOES NOT TRAVEL (ONLY ONE SIDE).....................................................................................409 H-23 MACHINE DOES NOT SWING......................................................................................................410 A) WHEN MACHINE DOES NOT SWING IN EITHER DIRECTION...........................................................................410 B) WHEN MACHINE DOES NOT SWING IN ONLY ONE DIRECTION.........................................................................410 H-24 SWING ACCELERATION OR SWING SPEED IS LOW....................................................................................411 A) WHEN SWING ACCELERATION OR SWING SPEED IS LOW IN EITHER DIRECTION.........................................................411 B) WHEN SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION.......................................................411 H-25 WORK EQUIPMENT OVERRUNS.....................................................................................................412 A) WHEN WORK EQUIPMENT OVERRUNS IN EITHER DIRECTION..........................................................................412 B) WHEN WORK EQUIPMENT OVERRUNS IN ONLY ONE DIRECTION........................................................................412 H-26 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING (IN ONLY ONE DIRECTION).....................................................413 H-27 LARGE NOISE IS MADE WHEN MACHINE STOPS SWINGING.............................................................................413 H-28 HYDRAULIC DRIFT OF SWING IS LARGE...........................................................................................414 A) WHEN SWING HOLDING BRAKE IS APPLIED.......................................................................................414 B) WHEN SWING HOLDING BRAKE IS RELEASED......................................................................................414 H-29 ERROR CODE[91] IS DISPLAYED ON MONITOR PANEL AND ALL OF BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS STOP JUST BEFORE....415 H-30 BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS DO NOT STOP AUTOMATICALLY AND MACHINE INTERFERES.............................415 TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)...........................................................................................416 ELECTRIC CIRCUIT DIAGRAM OF MONITOR SYSTEM.......................................................................................417 M-1 AFTER STARTING SWITCH IS TURNED TO ON POSITION, NOTHING IS DISPLAYED.........................................................418 M-2 AFTER STARTING SWITCH IS TURNED TO ON POSITION, SELF-CHECK ITEMS (WHICH SHOULD LIGHT UP FOR 3 SECS) ARE TURNED ON BUT NOT....418 M-3 AFTER STARTING SWITCH IS TURNED TO ON POSITION, SOME OF SELF-CHECK ITEMS (WHICH SHOULD LIGHT UP FOR 3 SEC) ARE NOT TURNED....419 A) NO GAUGES (FUEL, ENGINE COOLANT TEMPERATURE) ARE TURNED ON PRE-HEATING PILOT LAMP DOES NOT LIGHT UP.......................419 B) CAUTION LAMPS (ENGINE OIL PRESSURE, CHARGE) DO NO LIGHT UP................................................................419 C) ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP............................................................................419 M-4 AFTER STARTING SWITCH IS TURNED TO ON POSITION (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP.............420 M-5 AFTER STARTING SWITCH IS TURNED TO ON POSTION (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT....421 M-6 AFTER STARTING SWITCH IS TURNED TO HEAT POSITION, PRE-HEATING PILOT LAMP DOES NOT LIGHT UP...................................422 M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING...........................................................423 M-8 CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING........................................................................424 M-9 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE..............................................................................425 A) EVEN IF ENGINE IS OPERATED FOR LONG TIME, COOLANT TEMPERATURE LEVEL DOES NOT RISE AT ALL..................................425 B) LEVEL RISES SOON AFTER ENGINE IS STARTED (TO RED RANGE WHILE ENGINE IS NOT OVERHEATED)....................................425 C) RELATED ELECTRIC CIRCUIT DIAGRAM..........................................................................................425 M-10 ABNORMALITY IN FUEL GAUGE...................................................................................................426 A) ALL SEGMENTS OF FUEL GAUGE GO OFF.........................................................................................426 B) FUEL GAUGE INDICATES FULL WHILE FUEL LEVEL IS LOWERED.....................................................................426 C) FUEL GAUGE DOES NOT INDICATE FULL EVEN IF FUEL TANK IS FULL...............................................................427 M-11 MALFUNCTION OF ALARM BUZZER.................................................................................................428 A) BUZZER DOES NOT SOUND.....................................................................................................428 B) BUZZER DOES NOT STOP SOUNDING.............................................................................................428 M-12 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING......................................................................429 A) WHEN CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP..........................................................................429 B) WHEN CHARGE LEVEL CAUTION LAMP LIGHTS UP..................................................................................429 M-13 LAMPS DO NOT LIGHT UP AT NIGHT..............................................................................................430 A) LAMP FOR GAUGES DOES NOT LIGHT UP.........................................................................................430 B) LAMP FOR SERVICE METER DOES NOT LIGHT UP..................................................................................430 M-14 ELECTRICAL SYSTEM CAUTION LAMPS KEEPS LIGHTING UP...........................................................................431 M-15 HEATER DOES NOT WORK........................................................................................................432 TROUBLESHOOTING OF ENGINE (S MODE)...................................................................................................434 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................435 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................439 S-2 ENGINE DOES NOT START........................................................................................................441 1) ENGINE DOES NOT TURN......................................................................................................441 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)..................................................442 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................................................443 S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW UP IS POOR).........................................................................444 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................445 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................446 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).........................................................................................447 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...............................................................................448 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)......................................................................449 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................450 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................451 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.....................................................452 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................453 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................454 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................455 S-15 ABNORMAL NOISE IS MADE......................................................................................................456 S-16 VIBRATION IS EXCESSIVE......................................................................................................457 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................458 METHOD OF USING MANUAL...................................................................................................................460 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................461 SPECIAL TOOL LIST........................................................................................................................463 SKETCHES OF SPECIAL TOOLS................................................................................................................467 ENGINE, MAIN PUMP........................................................................................................................470 REMOVAL..............................................................................................................................470 INSTALLATION.........................................................................................................................471 RADIATOR, HYDRAULIC OIL COOLER...........................................................................................................472 REMOVAL..............................................................................................................................472 INSTALLATION.........................................................................................................................473 FUEL TANK................................................................................................................................474 REMOVAL AND INSTALLATION.............................................................................................................474 CENTER SWIVEL JOINT......................................................................................................................475 REMOVAL AND INSTALLATION.............................................................................................................475 DISASSEMBLY AND ASSEMBLY.............................................................................................................476 SWING MOTOR, SWING MACHINERY.............................................................................................................477 REMOVAL AND INSTALLATION.............................................................................................................477 SWING MACHINERY..........................................................................................................................478 DISASSEMBLY..........................................................................................................................478 ASSEMBLY.............................................................................................................................481 REVOLVING FRAME..........................................................................................................................485 REMOVAL..............................................................................................................................485 INSTALLATION.........................................................................................................................486 SWING CIRCLE.............................................................................................................................487 REMOVAL AND INSTALLATION.............................................................................................................487 RECOIL SPRING............................................................................................................................488 DISASSEMBLY..........................................................................................................................488 ASSEMBLY.............................................................................................................................489 IDLER....................................................................................................................................490 DISASSEMBLY..........................................................................................................................490 ASSEMBLY.............................................................................................................................491 TRACK ROLLER.............................................................................................................................493 DISASSEMBLY..........................................................................................................................493 ASSEMBLY.............................................................................................................................495 TRACK SHOE...............................................................................................................................497 REMOVAL AND INSTALLATION.............................................................................................................497 HYDRAULIC TANK...........................................................................................................................498 REMOVAL..............................................................................................................................498 INSTALLATION.........................................................................................................................499 MAIN PUMP................................................................................................................................500 REMOVAL..............................................................................................................................500 INSTALLATION.........................................................................................................................501 MAIN CONTROL VALVE.......................................................................................................................502 REMOVAL AND INSTALLATION.............................................................................................................502 CONTROL VALVE............................................................................................................................503 DISASSEMBLY..........................................................................................................................503 ASSEMBLY.............................................................................................................................508 LS SELECT VALVE..........................................................................................................................514 DISASSEMBLY AND ASSEMBLY.............................................................................................................514 MAIN RELIEF VALVE........................................................................................................................515 DISASSEMBLY..........................................................................................................................515 ASSEMBLY.............................................................................................................................516 WORK EQUIPMENT PPC VALVE (BOOM, BUCKET, ARM, SWING)......................................................................................517 DISASSEMBLY..........................................................................................................................517 ASSEMBLY.............................................................................................................................518 TRAVEL PPC...............................................................................................................................519 DISASSEMBLY..........................................................................................................................519 ASSEMBLY.............................................................................................................................520 ARM CYLINDER.............................................................................................................................521 REMOVAL..............................................................................................................................521 INSTALLATION.........................................................................................................................522 OFFSET CYLINDER..........................................................................................................................523 REMOVAL..............................................................................................................................523 INSTALLATION.........................................................................................................................524 HYDRAULIC CYLINDER.......................................................................................................................525 DISASSEMBLY..........................................................................................................................525 ASSEMBLY.............................................................................................................................528 OFFSET CYLINDER..........................................................................................................................532 DISASSEMBLY..........................................................................................................................532 ASSEMBLY.............................................................................................................................534 WORK EQUIPMENT...........................................................................................................................536 REMOVAL..............................................................................................................................536 INSTALLATION.........................................................................................................................538 ARM......................................................................................................................................539 REMOVAL..............................................................................................................................539 INSTALLATION.........................................................................................................................542 SECOND BOOM..............................................................................................................................543 REMOVAL..............................................................................................................................543 INSTALLATION.........................................................................................................................546 OPERATOR CAB.............................................................................................................................548 REMOVAL..............................................................................................................................548 INSTALLATION.........................................................................................................................549 FLOOR FRAME..............................................................................................................................550 REMOVAL..............................................................................................................................550 INSTALLATION.........................................................................................................................552 AIR CONDITIONER COMPRESSOR...............................................................................................................553 REMOVAL AND INSTALLATION.............................................................................................................553 AIR CONDITIONER CAPACITOR................................................................................................................554 REMOVAL AND INSTALLATION.............................................................................................................554 AIR CONDITIONER UNIT.....................................................................................................................555 REMOVAL .............................................................................................................................555 INSTALLATION.........................................................................................................................556 COUNTERWEIGHT............................................................................................................................557 REMOVAL AND INSTALLATION.............................................................................................................557 40 MAINTENANCE STANDARD......................................................................................................................558 SWING MACHINERY..........................................................................................................................559 SWING CIRCLE.............................................................................................................................561 TRACK FRAME, IDLER CUSHION...............................................................................................................562 IDLER....................................................................................................................................563 CARRIER ROLLER...........................................................................................................................565 TRACK ROLLER.............................................................................................................................567 SPROCKET.................................................................................................................................569 TRACK SHOE...............................................................................................................................570 HYDRAULIC PUMP...........................................................................................................................575 CONTROL VALVE............................................................................................................................576 SUCTION SAFETY VALVE.....................................................................................................................586 SELF PRESSURE REDUCTION VALVE............................................................................................................587 TRAVEL MOTOR.............................................................................................................................588 SWING MOTOR..............................................................................................................................589 SOLENOID VALVE...........................................................................................................................590 EPC SOLENOID VALVE.......................................................................................................................591 CENTER SWIVEL JOINT......................................................................................................................592 PPC VALVE................................................................................................................................593 HYDRAULIC CYLINDER.......................................................................................................................596 WORK EQUIPMENT...........................................................................................................................599 DIMENSION OF WORK EQUIPMENT..............................................................................................................602 90 OTHERS....................................................................................................................................606 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................607 ELECTRONIC CIRCUIT DIAGRAM (1/2).........................................................................................................612 ELECTRONIC CIRCUIT DIAGRAM (2/2).........................................................................................................617 AIR CONDITIONER CIRCUIT DIAGRAM..........................................................................................................622
DESCRIPTION:
KOMATSU PC128UU-2 SHOP MANUAL SEBM018506 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 26/12/24
