10795750-DKP8P8EM-Download Komatsu Pc138us-8 Pc138uslc-8 Excavator Manual

SEN01968-02
HYDRAULIC EXCAVATOR
-8 PC138US PC138USLC -8
SERIAL NUMBERS
PC138US- 20001 PC138USLC- 20001
and up
SEN01977-02
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC138US-8 PC138USLC-8
Machine model
Serial number
20001 and up 20001 and up
00 Index and foreword

Index
Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
PC138US, USLC-8
SEN01977-02
Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows: Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Shop Manual, contents binder, binder label and tabs 00 Index and foreword Index Foreword and general information 01 Specification Specification and technical data 10 Structure, function and maintenance standard Engine and cooling system Power train Undercarriage and frame Hydraulic system, Part 1 Hydraulic system, Part 2 Hydraulic system, Part 3 Work equipment Cab and its attachments Electrical system 20 Standard value table Standard service value table 30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 4 Troubleshooting of electrical system (E-mode) Form Number SEN01968-02 SEN01969-02 SEN01977-02 q SEN01978-01 q SEN01970-01 SEN01979-01 SEN01971-02 SEN02545-01 SEN02546-01 SEN02547-01 SEN02548-01 SEN02549-02 q SEN02550-01 SEN02551-00 SEN02552-01 SEN02553-01 SEN01972-01 SEN02457-01 SEN01973-01 SEN02458-01 SEN02459-00 SEN02460-01 SEN01974-01 SEN02461-01 SEN02462-00 SEN02463-01 SEN02464-01 SEN02465-01 SEN02466-00 SEN02467-00 PC138US, USLC-8
SEN01977-02
Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode) 50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train Undercarriage and frame Hydraulic system Work equipment Body Cab and its attachments Electrical system 90 Diagrams and drawings Hydraulic circuit diagram Electrical diagrams and drawings
SEN02468-01 SEN02469-01 SEN01975-00 SEN02709-00 SEN02710-00 SEN02711-00 SEN02712-00 SEN02713-00 SEN02714-00 SEN02715-00 SEN02716-00 SEN01976-01 SEN01980-00 SEN01981-01
PC138US, USLC-8
SEN01977-02
Table of contents
00 Index and foreword Index SEN01977-02 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN01978-01 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard.......................................................................... 9 Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines.......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN01979-01 Specification dimension drawings ............................................................................................... 2 Working range diagram ............................................................................................................... 3 Specifications .............................................................................................................................. 4 List of weights.............................................................................................................................. 10 Table of fuel, coolant and lubricants ............................................................................................ 14 10 Structure, function and maintenance standard Engine and cooling system SEN02545-01 Engine mount .............................................................................................................................. 2 PTO ............................................................................................................................................. 3 Cooling system............................................................................................................................ 4 Power train SEN02546-01 Power train .................................................................................................................................. 2 Swing circle ................................................................................................................................. 3 Swing machinery ......................................................................................................................... 4 Undercarriage and frame SEN02547-01 Track frame ................................................................................................................................. 2 Idler cushion ................................................................................................................................ 4 Idler ............................................................................................................................................. 6 Track roller................................................................................................................................... 7 Carrier roller ................................................................................................................................ 8 Sprocket ...................................................................................................................................... 9 Track shoe................................................................................................................................... 10 Hydraulic system, Part 1 SEN02548-01 Hydraulic equipment layout drawing ........................................................................................... 2 Valve control................................................................................................................................ 4 Hydraulic tank and filter............................................................................................................... 6 Hydraulic pump ........................................................................................................................... 8 Hydraulic system, Part 2 SEN02549-02 Control valve ............................................................................................................................... 2 CLSS ........................................................................................................................................... 14 Functions and operation by valve................................................................................................ 18 Hydraulic system, Part 3 SEN02550-01 PPC valve.................................................................................................................................... 2
PC138US, USLC-8
SEN01977-02
Swing motor ................................................................................................................................ 19 Travel motor ................................................................................................................................ 27 Center swivel joint ....................................................................................................................... 36 Solenoid valve............................................................................................................................. 40 PPC accumulator ........................................................................................................................ 44 Holding valve............................................................................................................................... 46 Multi-control valve ....................................................................................................................... 51 Work equipment SEN02551-00 Work equipment .......................................................................................................................... 2 Dimensions of components ......................................................................................................... 4 Hydraulic cylinder........................................................................................................................ 8 Cab and its attachments SEN02552-01 Air conditioner ............................................................................................................................. 2 Electrical system SEN02553-01 Electronic control system ............................................................................................................ 2 Monitor system............................................................................................................................ 35 KOMTRAX system ...................................................................................................................... 49 Sensor......................................................................................................................................... 51 20 Standard value table Standard service value table SEN02457-01 Standard value table for engine related parts.............................................................................. 2 Standard value table for chassis related parts ............................................................................ 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN02458-01 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Testing engine speed .................................................................................................................. 6 Testing exhaust temperature....................................................................................................... 7 Checking exhaust gas color ........................................................................................................ 8 Adjusting valve clearance ........................................................................................................... 9 Testing compression pressure .................................................................................................... 11 Testing blow-by pressure ............................................................................................................ 13 Testing engine oil pressure ......................................................................................................... 14 Handling fuel system parts .......................................................................................................... 15 Releasing residual pressure from fuel system ............................................................................ 15 Testing fuel pressure ................................................................................................................... 16 Testing fuel return rate and fuel leakage ..................................................................................... 17 Bleeding air from fuel circuit........................................................................................................ 19 Checking fuel circuit for leakage ................................................................................................. 21 Testing and adjusting alternator belt tension............................................................................... 22 Testing swing circle bearing clearance........................................................................................ 23 Checking and adjusting air conditioner compressor belt tension ................................................ 24 Checking and adjusting track shoe tension................................................................................. 25 Testing and adjusting oil pressure in work equipment, swing, and travel circuits........................ 27 Testing control circuit basic pressure .......................................................................................... 30 Testing and adjusting oil pressure in pump PC control circuit..................................................... 31 Testing and adjusting oil pressure in pump LS control circuit ..................................................... 34 Testing solenoid valve output pressure ....................................................................................... 38 Testing PPC valve output pressure ............................................................................................. 39 Adjusting play of work equipment and swing PPC valves........................................................... 41 Checking parts which cause hydraulic drift of work equipment................................................... 42 Testing and adjusting travel deviation ......................................................................................... 44 Releasing residual pressure from hydraulic circuit...................................................................... 46 Testing oil leakage....................................................................................................................... 47 Bleeding air from each part ......................................................................................................... 50 PC138US, USLC-8
SEN01977-02
Checking cab tipping stopper ...................................................................................................... 52 Adjusting mirrors ......................................................................................................................... 52 Testing and adjusting, Part 2 SEN02459-00 Special functions of machine monitor.......................................................................................... 2 Testing and adjusting, Part 3 SEN02460-01 Handling voltage circuit of engine controller................................................................................ 2 Preparation work for troubleshooting of electrical system........................................................... 3 Procedure for testing diodes ....................................................................................................... 8 Pm Clinic service......................................................................................................................... 9 40 Troubleshooting Failure code table and fuse locations SEN02461-01 Failure code table........................................................................................................................ 2 Fuse locations ............................................................................................................................. 6 General information on troubleshooting SEN02462-00 Points to remember when troubleshooting.................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3 Checks before troubleshooting.................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Information in troubleshooting table ............................................................................................ 6 Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8 Wiring table for connector pin numbers....................................................................................... 11 T-adapter box and T-adapter table .............................................................................................. 44 Troubleshooting by failure code, Part 1 SEN02463-01 Failure code [989L00] Engine controller lock caution 1............................................................... 3 Failure code [989M00] Engine controller lock caution 2.............................................................. 3 Failure code [989N00] Engine controller lock caution 3 .............................................................. 4 Failure code [AB00KE] Charge voltage low ................................................................................ 6 Failure code [B@BAZG] Eng oil press. low................................................................................. 8 Failure code [B@BAZK] Eng oil level low ................................................................................... 8 Failure code [B@BCNS] Eng coolant overheat........................................................................... 9 Failure code [B@HANS] Hydr oil overheat ................................................................................. 9 Failure code [CA111] ECM critical internal failure ....................................................................... 10 Failure code [CA115] Eng. Ne and Bkup speed sensor error ..................................................... 13 Failure code [CA122] Charge air press sensor high error........................................................... 14 Failure code [CA123] Charge air press sensor low error ............................................................ 16 Failure code [CA131] Throttle sensor high error ......................................................................... 18 Failure code [CA132] Throttle sensor low error........................................................................... 20 Failure code [CA144] Coolant temp. sensor high error ............................................................... 21 Failure code [CA145] Coolant temp. sensor low error ................................................................ 22 Failure code [CA153] Charge air temp. sensor high error........................................................... 23 Failure code [CA154] Charge air temp. sensor low error ............................................................ 24 Failure code [CA187] Sensor sup. 2 volt. low error..................................................................... 24 Failure code [CA221] Ambient air press. sensor high error ........................................................ 26 Failure code [CA222] Ambient air press. sensor low error.......................................................... 28 Failure code [CA227] Sensor sup. 2 volt. high error ................................................................... 30 Failure code [CA234] Eng. overspeed ........................................................................................ 32 Failure code [CA238] Ne speed sensor sup. volt. error .............................................................. 34 Failure code [CA271] IMV/PCV1 short error ............................................................................... 36 Failure code [CA272] IMV/PCV1 open error ............................................................................... 37 Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 38 Failure code [CA324] Injector #3 (L/B #3) system open/short error ............................................ 40 Failure code [CA331] Injector #2 (L/B #2) system open/short error ............................................ 42 Failure code [CA332] Injector #4 (L/B #4) system open/short error ............................................ 44 Troubleshooting by failure code, Part 2 SEN02464-01 Failure code [CA351] Inj. drive circuit error ................................................................................. 3
PC138US, USLC-8
SEN01977-02
Failure code [CA352] Sensor sup. 1 volt. low error..................................................................... 6 Failure code [CA386] Sensor sup. 1 volt. high error ................................................................... 8 Failure code [CA435] Abnormality in engine oil pressure switch ................................................ 10 Failure code [CA441] Battery voltage low error .......................................................................... 11 Failure code [CA442] Battery voltage high error ......................................................................... 11 Failure code [CA449] Rail press. very high error ........................................................................ 12 Failure code [CA451] Rail press. sensor high error .................................................................... 14 Failure code [CA452] Rail press. sensor low error...................................................................... 16 Failure code [CA553] Rail press. high error ................................................................................ 16 Failure code [CA559] Rail press. low error ................................................................................. 17 Failure code [CA689] Eng. Ne speed sensor error ..................................................................... 20 Failure code [CA731] Eng. Bkup speed sensor phase error....................................................... 22 Failure code [CA757] All persistent data lost error...................................................................... 22 Failure code [CA778] Eng. Bkup speed sensor error.................................................................. 24 Failure code [CA1633] KOMNET datalink timeout error ............................................................. 26 Failure code [CA2185] Throttle sens. sup. volt. high error.......................................................... 28 Failure code [CA2186] Throttle sens. sup. volt. low error ........................................................... 30 Failure code [CA2249] Rail press. very low error........................................................................ 30 Failure code [CA2311] Abnormality in IMV solenoid ................................................................... 31 Failure code [D110KB] Battery relay drive short ......................................................................... 32 Failure code [D19JKZ] Personal code relay abnormality ............................................................ 34 Failure code [D862KA] GPS antenna discon .............................................................................. 36 Failure code [DA22KK] Pump solenoid power low error ............................................................. 38 Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................. 40 Failure code [DA26KP] 5V sensor 2 power abnormality ............................................................. 43 Troubleshooting by failure code, Part 3 SEN02465-01 Failure code [DA2RMC] CAN discon (Pump controller detected) ............................................... 4 Failure code [DAF8KB] Short circuit in camera power supply .................................................... 6 Failure code [DAFGMC] GPS module error ................................................................................ 8 Failure code [DAFRMC] CAN discon (Monitor detected) ............................................................ 10 Failure code [DGH2KB] Hydr oil sensor short............................................................................. 12 Failure code [DHPAMA] Pump press sensor abnormality........................................................... 14 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality ............................... 16 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality ............................ 18 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality............................... 20 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................. 22 Failure code [DHSKMA] Blade raise PPC press sensor abnormality ......................................... 24 Failure code [DHSLMA] Blade lower PPC press sensor abnormality ......................................... 26 Failure code [DHX1MA] Overload sensor abnormality (Analog) ................................................. 28 Failure code [DV20KB] Travel alarm S/C.................................................................................... 29 Failure code [DW43KA] Travel speed sol discon ........................................................................ 30 Failure code [DW43KB] Travel speed sol short .......................................................................... 31 Failure code [DW45KA] Swing brake sol discon......................................................................... 32 Failure code [DW45KB] Swing brake sol short ........................................................................... 34 Failure code [DW91KA] Travel junction sol discon ..................................................................... 36 Failure code [DW91KB] Travel junction sol short........................................................................ 37 Failure code [DWJ0KA] Merge-divider sol discon....................................................................... 38 Failure code [DWJ0KB] Merge-divider sol short ......................................................................... 39 Troubleshooting by failure code, Part 4 SEN02466-00 Failure code [DXA8KA] PC-EPC sol discon................................................................................ 2 Failure code [DXA8KB] PC-EPC sol short .................................................................................. 4 Failure code [DXE4KA] Service current EPC discon .................................................................. 6 Failure code [DXE4KB] Service current EPC short..................................................................... 7 Failure code [DY20KA] Wiper working abnormality .................................................................... 8 Failure code [DY20MA] Wiper parking abnormality .................................................................... 10 Failure code [DY2CKA] Washer drive discon.............................................................................. 12 Failure code [DY2CKB] Washer drive short ................................................................................ 14
PC138US, USLC-8
SEN01977-02
Failure code [DY2DKB] Wiper drive (for) short ........................................................................... 16 Failure code [DY2EKB] Wiper drive (rev) short........................................................................... 18 Troubleshooting of electrical system (E-mode) SEN02467-00 Before carrying out troubleshooting of electrical system............................................................. 3 Information in troubleshooting table ............................................................................................ 5 E-1 When starting switch turned ON, machine monitor displays nothing.................................... 6 E-2 When starting switch turned ON (before starting engine), basic check item lights up .......... 8 E-3 Engine does not start (Engine does not turn) ....................................................................... 9 E-4 Preheater does not operate .................................................................................................. 12 E-5 Automatic warm-up system does not operate (in cold season) ............................................ 14 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked.......... 16 E-7 Precaution lights up while engine is running......................................................................... 18 E-8 Emergency stop item lights up while engine is running ........................................................ 21 E-9 Engine coolant temperature gauge does not indicate normally............................................ 22 E-10 Hydraulic oil temperature gauge does not indicate normally .............................................. 23 E-11 Fuel level gauge does not indicate normally ....................................................................... 25 E-12 Contents of display by machine monitor are different from applicable machine................. 27 E-13 Machine monitor does not display some items................................................................... 27 E-14 Function switch does not work............................................................................................ 27 E-15 Auto-decelerator does not operate normally....................................................................... 28 E-16 Working mode does not change ......................................................................................... 29 E-17 Travel speed does not change............................................................................................ 30 E-18 Alarm buzzer cannot be stopped ........................................................................................ 31 E-19 Windshield wiper and window washer do not operate........................................................ 32 E-20 Swing holding brake does not operate normally................................................................. 36 E-21 Travel alarm does not sound or does not stop sounding .................................................... 38 E-22 Air conditioner does not operate normally (including air conditioner abnormality record) .. 39 E-23 While starting switch is in OFF position, service meter is not displayed............................. 51 E-24 Machine monitor cannot be set in service mode ................................................................ 51 E-25 Monitoring function does not display lever control signal normally..................................... 52 E-26 KOMTRAX system does not operate normally ................................................................... 68 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02468-01 Information contained in troubleshooting table............................................................................ 3 System chart for hydraulic and mechanical systems .................................................................. 4 H-1 Speed or power of all work equipment, swing, and travel are low........................................ 6 H-2 Engine speed sharply drops or engine stalls ........................................................................ 7 H-3 No work equipment, travel and swing move......................................................................... 8 H-4 Abnormal noise is heard from around hydraulic pump ......................................................... 8 H-5 Fine control mode does not function .................................................................................... 9 H-6 Speed or power of boom is low ............................................................................................ 10 H-7 Speed or power of arm is low ............................................................................................... 11 H-8 Speed or power of bucket is low........................................................................................... 12 H-9 Work equipment does not move in its single operation ........................................................ 13 H-10 Hydraulic drift of work equipment is large........................................................................... 14 H-11 Time lag of work equipment is large ................................................................................... 15 H-12 Work equipment loaded more is slower during compound operation................................. 15 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE ..................... 15 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel .. 16 H-15 Machine deviates during travel........................................................................................... 17 H-16 Travel speed is low ............................................................................................................. 18 H-17 Machine cannot be steered easily or steering power is low ............................................... 19 H-18 Travel speed does not change or it is kept low or high....................................................... 20 H-19 Track does not move (Only either side).............................................................................. 20 H-20 Machine does not swing ..................................................................................................... 21 H-21 Swing acceleration or swing speed is low .......................................................................... 22 H-22 Excessive overrun when stopping swing............................................................................ 23 H-23 When upper structure stops swinging, it makes large shock.............................................. 24
PC138US, USLC-8
SEN01977-02
H-24 When upper structure stops swinging, it makes large sound ............................................. 24 H-25 Hydraulic drift of swing is large........................................................................................... 25 H-26 Flow rate in attachment circuit cannot be adjusted ............................................................ 26 Troubleshooting of engine (S-mode) SEN02469-01 Method of using troubleshooting chart ........................................................................................ 4 S-1 Starting performance is poor ................................................................................................ 8 S-2 Engine does not start............................................................................................................ 9 S-3 Engine does not pick up smoothly........................................................................................ 12 S-4 Engine stops during operations ............................................................................................ 13 S-5 Engine does not rotate smoothly .......................................................................................... 14 S-6 Engine lacks output (or lacks power).................................................................................... 15 S-7 Exhaust smoke is black (incomplete combustion)................................................................ 16 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 17 S-9 Oil becomes contaminated quickly ....................................................................................... 18 S-10 Fuel consumption is excessive........................................................................................... 19 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20 S-12 Oil pressure drops .............................................................................................................. 21 S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 22 S-14 Coolant temperature becomes too high (overheating) ....................................................... 23 S-15 Abnormal noise is made ..................................................................................................... 24 S-16 Vibration is excessive ......................................................................................................... 25 50 Disassembly and assembly General information on disassembly and assembly SEN02709-00 How to read this manual ............................................................................................................. 2 List of adhesives ......................................................................................................................... 4 Special tool list ............................................................................................................................ 7 Sketche of special tool ................................................................................................................ 11 Engine and cooling system SEN02710-00 Removal and installation of fuel supply pump assembly............................................................. 2 Removal and installation of fuel injector assembly ..................................................................... 4 Removal and installation of front oil seal..................................................................................... 7 Removal and installation of rear oil seal ..................................................................................... 9 Removal and installation of cylinder head assembly .................................................................. 12 Removal and installation of radiator assembly............................................................................ 19 Removal and installation of aftercooler assembly ....................................................................... 21 Removal and installation of work equipment oil cooler assembly ............................................... 23 Removal and installation of engine and work equipment pump assembly.................................. 26 Removal and installation of fuel tank assembly .......................................................................... 31 Power train SEN02711-00 Removal and installation of travel motor and final drive assembly ............................................. 2 Removal and installation of swing motor and swing machinery assembly.................................. 4 Disassembly and assembly of swing machinery assembly......................................................... 6 Removal and installation of swing circle assembly ..................................................................... 12 Undercarriage and frame SEN02712-00 Disassembly and assembly of track roller................................................................................... 2 Disassembly and assembly of idler assembly............................................................................. 5 Disassembly and assembly of recoil spring ................................................................................ 8 Removal and installation of of track shoe assembly ................................................................... 11 Removal and installation of sprocket .......................................................................................... 13 Removal and installation of revolving frame assembly ............................................................... 14 Removal and installation of counterweight assembly (Machine without add-on weight)............. 16 Removal and installation of counterweight assembly (Machine with add-on weight).................. 18 Hydraulic system SEN02713-00 Removal and installation of center swivel joint assembly ........................................................... 2 Disassembly and assembly of center swivel joint assembly ....................................................... 4 PC138US, USLC-8
SEN01977-02
Removal and installation of hydraulic tank assembly .................................................................. 5 Removal and installation of hydraulic pump assembly................................................................ 8 Removal and installation of control valve assembly.................................................................... 12 Disassembly and assembly of control valve assembly ............................................................... 17 Disassembly and assembly of work equipment PPC valve assembly ........................................ 27 Disassembly and assembly of travel PPC valve assembly ......................................................... 30 Disassembly and assembly of hydraulic cylinder assembly........................................................ 32 Work equipment Body SEN02714-00 Removal and installation of work equipment assembly............................................................... 2 Cab and its attachments SEN02715-00 Removal and installation of operator cab assembly.................................................................... 2 Removal and installation of operator's cab glass (stuck glass) ................................................... 4 Removal and installation of front window assembly.................................................................... 13 Removal and installation of floor frame assembly....................................................................... 14 Electrical system SEN02716-00 Removal and installation of air compressor assembly ................................................................ 2 Removal and installation of air conditioner condenser................................................................ 3 Removal and installation of air compressor unit assembly ......................................................... 4 Removal and installation of machine monitor assembly ............................................................. 7 Removal and installation of pump controller assembly ............................................................... 8 Removal and installation of engine controller assembly ............................................................. 9 Removal and installation of KOMTRAX communications module............................................... 10 90 Diagrams and drawings Hydraulic circuit diagram SEN01980-00 Hydraulic circuit diagram ............................................................................................................. 3 Electrical diagrams and drawings SEN01981-01 Electrical circuit diagram ............................................................................................................. 3 Connectors table and arrangement drawing ............................................................................... 5
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PC138US, USLC-8
SEN01977-02
PC138US, USLC-8
11
SEN01977-02
PC138US, USLC-8 Hydraulic excavator Form No. SEN01977-02
2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (02)
12
PC138US, USLC-8
SEN01978-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number

Foreword and general information
Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
PC138US, USLC-8
SEN01978-01
Safety notice
(Rev. 2007/03)
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.
8)
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Precautions against work which you are not used to or you are used to too much
6 Safety check before starting work 7 8
9 Good physical condition and preparation 10
2.
Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
PC138US, USLC-8
SEN01978-01
3) 4)
When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
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9) 10)
3.
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.
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13) 14) 15)
16)
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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4.
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
q
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
5.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
6.
Wire ropes (Standard Z twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.
Example of O-ring (Fitted to every joint of hoses and tubes)
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
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How to read the shop manual

q q q
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
1.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
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3.
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table.
q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 ) Revisions Revised brochures are shown in the shop manual composition table.
4.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol k a 4 3 2 5 6 Item Safety Caution Weight Tightening torque Coat Oil, coolant Drain Remarks Special safety precautions are necessary when performing work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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Explanation of terms for maintenance standard
The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the standard size and the range of difference from the standard size is called the tolerance. q The tolerance with the symbols of + or is indicated on the right side of the standard size.
q
Example: Standard size 120 a
Tolerance 0.022 0.126
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (0.022/0.126) Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
Example: Standard size 60 Tolerance Shaft Hole 0.030 +0.046 0.076 +0
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2.
Standard clearance and standard value The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the standard value, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
q
5.
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the clearance limit. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
q
6.
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the interference. q The range (A B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the standard interference. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the repair limit. q If a part is worn to the repair limit must be replaced or repaired. q The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the allowable value. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
q
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
q
4.
10
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Handling of electric equipment and hydraulic component
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
5)
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3.
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2]
q
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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2)
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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3)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
Disconnection
Connection (Example of incomplete setting of (a))
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4)
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
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4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1. Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
2.
3.
4.
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5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
6.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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Handling of connectors newly used for engines

a Mainly, following engines are object for following connectors. q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines) Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you. 2.
q
1.
Pull lock type (PACKARD-2) 107 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
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3.
Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow.
q
114 engine
107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04) While pressing lock (D), pull out connector (4) in the direction of the arrow.
3)
107 engine
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
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4)
125 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
1)
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it clicks.
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
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How to read electric wire code

a
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV Conductor Insulator Conductor Insulator Conductor Insulator Material Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Using temperature range (C) Example of use General wiring (Nominal No. 5 and above) 30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely 50 to +110 cold district, wiring at high-temperature place
AVS
Heat-resistant low-voltAEX age wire for automobile
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2.
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 CovAV Standard 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8 50/0.45 7.95 3.7 5.5 5.3
15 84/0.45 13.36 4.8 7.0 7.0
20 41/0.80 20.61 6.0 8.2 8.2
30 70/0.80 35.19 8.0 10.8 10.8
40 85/0.80 42.73 8.6 11.4 11.4
50
60
85
100
108/0.80 127/0.80 169/0.80 217/0.80 54.29 9.8 13.0 13.0 63.84 10.4 13.6 13.6 84.96 12.0 16.0 16.0 109.1 13.6 17.6 17.6
f of nominal No. denotes flexible.
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3.
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: GW means that the background is Green and marking is White. 4. Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch WG

AEX R B R D Y G L

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

YW GL

Gr Br

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Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1.
q q q q q q q q q q
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2) Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234 Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3)
If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
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2.
q q q q q q q q q q q q q
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, Bleeding air. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see Disassembly and assembly. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
a 3.
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4)
5)
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly and assembly.
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Method of disassembling and connecting push-pull type coupler

k k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
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Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
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Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
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Standard tightening torque table

1.
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a The following table corresponds to the bolts in Fig. A. Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Nm kgm 11.8 14.7 1.2 1.5 27 34 2.8 3.5 59 74 6.0 7.5 98 123 10.0 12.5 153 190 15.5 19.5 235 285 23.5 29.5 320 400 33.0 41.0 455 565 46.5 58.0 610 765 62.5 78.0 785 980 80.0 100.0 1,150 1,440 118 147 1,520 1,910 155 195 1,960 2,450 200 250 2,450 3,040 250 310 2,890 3,630 295 370
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
The following table corresponds to the bolts in Fig. B. Width across flats mm 10 13 14 27 Tightening torque Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2
a Fig. B
Thread diameter of bolt mm 6 8 10 12

a Fig. A
kgm 0.6 1.0 1.4 2.4 3.5 4.7 7.6 9.2
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2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Width across flats mm 14 17 22 Tightening torque Nm kgm 59 74 6.0 7.5 98 123 10.0 12.5 235 285 23.5 29.5
Thread diameter of bolt mm 10 12 16
3.
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42 Tightening torque Nm {kgm} Range Target 35 63 { 3.5 6.5} 44 { 4.5} 84 132 { 8.5 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 186 {13.0 19.0} tor. 363 480 {37.0 49.0} 422 {43.0} 746 1,010 {76.0 103} 883 {90.0} Width across flats mm
Nominal No. 02 03,04 05,06 10,12 14
4.
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52 Width across flats mm 14 17 19 22 24 27 30 32 32 36 Tightening torque Nm {kgm} Range Target 5.88 8.82 {0.6 0.9} 7.35 {0.75} 9.81 12.74 {1.0 1.3} 11.27 {1.15} 14.7 19.6 {1.5 2.0} 17.64 {1.8} 19.6 24.5 {2.0 2.5} 22.54 {2.3} 24.5 34.3 {2.5 3.5} 29.4 {3.0} 34.3 44.1 {3.5 4.5} 39.2 {4.0} 44.1 53.9 {4.5 5.5} 49.0 {5.0} 58.8 78.4 {6.0 8.0} 68.6 {7.0} 93.1 122.5 { 9.5 12.5} 107.8 {11.0} 107.8 147.0 {11.0 15.0} 127.4 {13.0} 127.4 176.4 {13.0 18.0} 151.9 {15.5} 181.3 240.1 {18.5 24.5} 210.7 {21.5} 274.4 367.5 {28.0 37.5} 323.4 {33.0}
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5.
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Thread size (mm) 14 18 22 24 30 33 36 42 Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2
Nominal No. of hose 02 03 04 05 06 (10) (12) (14)
Width across flats 19 22 24 27 32 36 41 46 55
Range 34 54 { 3.5 5.5} 34 63 { 3.5 6.5} 54 93 { 5.5 9.5} 59 98 { 6.0 10.0} 84 132 { 8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
6.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14 Nm 10 2 24 4 43 6 77 12 Tightening torque Bolts and nuts kgm 1.02 0.20 2.45 0.41 4.38 0.61 7.85 1.22
7.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14 Tightening torque Nm 82 10 2 12 2 24 4 36 5 kgm 0.81 0.20 1.02 0.20 1.22 0.20 2.45 0.41 3.67 0.51
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8.
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1 Tightening torque Nm 31 82 12 2 15 2 24 4 36 5 60 9 kgm 0.31 0.10 0.81 0.20 1.22 0.20 1.53 0.20 2.45 0.41 3.67 0.51 6.12 0.92
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Conversion table
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
2.
Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
(B) 5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 (A) 50 60 70 80 90
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Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929 2.244 2.638 3.032 3.425 3.819 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 50 60 70 80 90
Kilogram to pound 0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42 1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62 2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83 3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03 4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24 5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44 1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03 123.46 145.51 167.55 189.60 211.64 125.66 147.71 169.76 191.80 213.85 127.87 149.91 171.96 194.01 216.05 130.07 152.12 174.17 196.21 218.26
0 10 20 30 40 50 60 70 80 90
Liters to U.S. Gallons 0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095 13.209 15.850 18.492 21.134 23.775 13.473 16.115 18.756 21.398 24.040 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944 14.529 17.171 19.813 22.455 25.096 14.795 17.435 20.077 22.719 25.361 15.058 17.700 20.341 22.983 25.625 15.322 17.964 20.605 23.247 25.889 15.586 18.228 20.870 23.511 26.153
0 10 20 30 40 50 60 70 80 90
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Liters to U.K. Gallons 0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117 12.528 14.738 16.938 19.137 21.337 12.758 14.958 17.158 19.357 21.557 12.978 15.178 17.378 19.577 21.777
0 10 20 30 40 50 60 70 80 90
kgm to ft.lb 0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4 412.3 484.6 556.9 629.3 701.6 419.5 491.8 564.2 636.5 708.8 426.8 499.1 571.4 643.7 716.1
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7 1084.9 1157.3 1129.6 1301.9 1374.3 1092.2 1164.5 1236.8 1309.2 1381.5 1099.4 1171.7 1244.1 1316.4 1388.7 1106.6 1179.0 1251.3 1323.6 1396.0 1113.9 1186.2 1258.5 1330.9 1403.2 1121.1 1193.4 1265.8 1338.1 1410.4 1128.3 1200.7 1273.0 1345.3 1417.7 1135.6 1207.9 1280.1 1352.6 1424.9 1142.8 1215.1 1287.5 1359.8 1432.1 1150.0 1222.4 1294.7 1367.0 1439.4
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PC138US, USLC-8
SEN01978-01
kg/cm2 to lb/in2 0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414 1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428 2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442 3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456 4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470 5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485 6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499 1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 953.0 1,095 1,237 1,380 1,522 1,664 1,806 1,949 2,091 2,233 2,375 2,518 2,660 2,802 2,944 3,086 3,229 3,371 3,513 825.0 967.2 1,109 1,252 1,394 1,536 1,678 1,821 1,963 2,105 2,247 2,389 2,532 2,674 2,816 2,958 3,101 3,243 3,385 3,527 839.2 981.4 1,124 1,266 1,408 1,550 1,693 1,835 1,977 2,119 2,262 2,404 2,546 2,688 2,830 2,973 3,115 3,257 3,399 3,542
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
PC138US, USLC-8
39
SEN01978-01
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1C = 33.8F F 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10
F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4
40
PC138US, USLC-8
SEN01978-01
PC138US, USLC-8
41
SEN01978-01
42
SEN01979-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
01 Specification
Specification and technical data
Specification dimension drawings ................................................................................................................... 2 Working range diagram................................................................................................................................... 3 Specifications .................................................................................................................................................. 4 List of weights ............................................................................................................................................... 10 Table of fuel, coolant and lubricants.............................................................................................................. 14
PC138US, USLC-8
SEN01979-01
01 Specification
Specification dimension drawings
Item Standard specification Machine weight Bucket capacity Engine type Engine rated output Net [ISO 9249/SAE J1349] Gross [SAE J1955] A A' B Overall length Overall height Standard specification Reinforced blade specification Reinforced blade specification
Unit kg m3 kW{HP}/rpm mm mm mm mm mm mm mm mm mm mm km/h rpm
PC138US-8 13,400 14,050 0.50
PC138USLC-8 14,500 15,150
Komatsu SAA4D95LE-5 Diesel engine 68.4{91.7}/2,200 72.1{96.6}/2,200 7,260 7,970 2,850 2,490 500 1,480 3,610 2,880 2,815 395 2.9/5.1 11.0 2,590 600 1,545 3,870 3,140 7,390 8,040
C Overall width D Shoe width E F Tail swing radius Crawler overall length
G Distance between tambler center H Cab height Ground clearance Traveling speed (Low/High) Continuous swing speed
There are net value and gross value for displaying engine rate output. Gross value is measurement of engine alone, and net value is measurement with close to on-board conditions.
PC138US, USLC-8
01 Specification
SEN01979-01
Working range diagram
Working range (mm) A B C D E F G H I Maximum digging reach Maximum digging depth Maximum digging height Maximum vertical wall digging depth Maximum dumping height Minimum swing radius of work equipment Maximum reach at ground level Maximum raising distance of blade Maximum lowering distance of blade
PC138US-8 8,300 5,480 9,340 4,900 6,840 1,980 8,180 470 525
PC138USLC-8 8,300 5,480 9,340 4,900 6,840 1,980 8,180 470 490
PC138US, USLC-8
SEN01979-01
01 Specification
Specifications
Machine model Serial No. Bucket capacity Operating weight Max. digging depth Max. vertical wall depth Working ranges Max. digging reach Max. reach at ground level Max. digging height Max. dumping height Max. blade lifting amount Max. blade lowering amount Maximum digging force (bucket) Swing speed Swing max. slope angle Travel speed (Low/High) Gradeability Ground pressure Overall length (for transport) Overall width Overall height (for transport) Overall height (for work) Ground clearance of counterweight Min. ground clearance Dimension Tail swing radius Min. swing radius of work equipment Height of work equipment at min. swing radius Crawler overall width Crawler overall length Length of track on ground Track gauge Overall height of machine cab Blade width x height m3 kg mm mm mm mm mm mm mm mm kN{kg} rpm Degree km/h deg. kPa{kg/cm }
2
1
PC138US-8 Standard specification 0.50 13,400 5,480 4,900 8,300 8,180 9,340 6,840 93.2{9,500} 11.0 19.0 2.9/5.1 35 42.2{0.43} 7,260 2,490 2,850 2,830 900 395 1,480 1,980 6,770 2,490 3,610 2,880 1,990 2,090 Reinforced blade specification 0.50 14,050 5,480 4,900 8,300 8,180 9,340 6,840 470 525 93.2{9,500} 11.0 19.0 2.9/5.1 35 44.1{0.45} 7,970 2,490 2,850 2,830 900 395 1,480 1,980 6,770 2,490 3,610 2,880 1,990 2,090 2,490 x 590 20001 and up
Performance
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
The values are based on the machine with the triple grouser shoe.
PC138US, USLC-8
01 Specification
SEN01979-01
1
PC138USLC-8 Standard specification 0.50 14,500 5,480 4,900 8,300 8,180 9,340 6,840 93.2{9,500} 11.0 19.0 2.9/5.1 35 35.3{0.36} 7,390 2,590 2,850 2,830 900 395 1,545 1,980 6,770 2,590 3,870 3,140 1,990 2,145 Reinforced blade specification 0.50 15,150 5,480 4,900 8,300 8,180 9,340 6,840 470 490 93.2{9,500} 11.0 19.0 2.9/5.1 35 37.3{0.38} 8,040 2,590 2,850 2,830 900 395 1,545 1,980 6,770 2,590 3,870 3,140 1,990 2,145 2,590 x 590 20001 and up
PC138US, USLC-8
SEN01979-01
01 Specification
Machine model Serial No. Model Type No. of cylinders-bore x stroke Piston displacement Rated horsepower Net [ISO 9249/SAE J1349] Gross [SAE J1995] Max. torque High idling speed Low idling speed Min. fuel consumption ratio Starting motor Alternator Battery (*1) Radiator core type Aftercooler core type Undercarriage Carrier roller Track roller Track shoe (iron shoe) (road liner) Hydraulic motor Control valve Hydraulic pump Type x no. Discharge Set pressure Type x no. Control method Travel motor Swing motor l/min MPa{kg/cm2} mm l{cc} kW{HP}/rpm Nm{kgm}/rpm rpm rpm g/kWh {g/HPh}
PC138US-8 Standard specification Reinforced blade specification 20001 and up SAA4D95LE-5 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and air cooled aftercooler 95 x 115 3.260{3,260} 68.4{91.7}/2,200 72.1{96.6}/2,200 350{35.7}/1,500 2,300 1,100 224{167} 24 V, 4.5 kW 24 V, 35 A 12 V, 64 Ah x 2 4-array aluminum mesh core Aluminum mesh core 1 on each side 7 on each side Assembly-type triple grouser shoe, 43 on each side Assembly-type road liner, 43 on each side Variable displacement piston type x 1 121+121 (at 2,200 rpm) 34.8{355} 6-spool type x 1 Hydraulic type Variable displacement piston type (with brake valve and parking brake) x 2 Fixed displacement piston type (with safety valve and holding brake) x 1 Box-shaped, open Tank return side Air cooled (CF40)
Hydraulic system
Hydraulic tank Hydraulic oil filter Hydraulic cooler
*1. Battery capacity (Ah) is based on 5-hour rate. a There are net value and gross value for displaying engine rate horsepower. Gross value is measurement of engine alone, and net value is measurement with close to on-board conditions.
Performance
Engine
PC138US, USLC-8
01 Specification
SEN01979-01
PC138USLC-8 Standard specification Reinforced blade specification 20001 and up SAA4D95LE-5 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and air cooled aftercooler 95 x 115 3.260{3,260} 68.4{91.7}/2,200 72.1{96.6}/2,200 350{35.7}/1,500 2,300 1,100 224{167} 24 V, 4.5 kW 24 V, 35 A 12 V, 64 Ah x 2 4-array aluminum mesh core Aluminum mesh core 2 on each side 8 on each side Assembly-type triple grouser shoe, 46 on each side Assembly-type road liner, 46 on each side Variable displacement piston type x 1 121+121 (at 2,200 rpm) 34.8{355} 6-spool type x 1 Hydraulic type Variable displacement piston type (with brake valve and parking brake) x 2 Fixed displacement piston type (with safety valve and holding brake) x 1 Box-shaped, open Tank return side Air cooled (CF40)
PC138US, USLC-8
SEN01979-01
01 Specification
Machine model Serial No. Type Boom cylinder Cylinder inner diameter Piston rod diameter Stroke Max. length between pins Min. length between pins Type Arm cylinder Cylinder inner diameter Piston rod diameter Stroke Max. length between pins Min. length between pins Type Bucket cylinder Cylinder inner diameter Piston rod diameter Stroke Max. length between pins Min. length between pins Type Blade cylinder Cylinder inner diameter Piston rod diameter Stroke Max. length between pins Min. length between pins mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
PC138US-8 Standard specification Reciprocating piston type 105 70 1,055 2,555 1,500 Reciprocating piston type 110 75 1,175 2,798 1,623 Reciprocating piston type 95 65 885 2,263 1,378 Reinforced blade specification Reciprocating piston type 105 70 1,055 2,555 1,500 Reciprocating piston type 110 75 1,175 2,798 1,623 Reciprocating piston type 95 65 885 2,263 1,378 Reciprocating piston type 110 75 181 870 689 20001 and up
Work equipment cylinder
Hydraulic system
PC138US, USLC-8
01 Specification
SEN01979-01
PC138USLC-8 Standard specification Reciprocating piston type 105 70 1,055 2,555 1,500 Reciprocating piston type 110 75 1,175 2,798 1,623 Reciprocating piston type 95 65 885 2,263 1,378 Reinforced blade specification Reciprocating piston type 105 70 1,055 2,555 1,500 Reciprocating piston type 110 75 1,175 2,798 1,623 Reciprocating piston type 95 65 885 2,263 1,378 Reciprocating piston type 110 75 181 870 689 20001 and up
PC138US, USLC-8
SEN01979-01
01 Specification
List of weights
k
1
Unit: kg
This weight table is prepared for your reference when handling or transporting the components.
PC138US-8 Standard specification 458 332 18.1 5.5 102 (6 x 2) 82.2 7.9 10.2 8.1 0.7 1,400 375 38 90.6 79.5 95 3,240 500 20 152.6 71.6 28.6 2,300 1,305 79 x 2 69 x 2 16.5 x 2 22 x 14 145 x 2 33.1 x 2 755 x 2 840 x 2 930 x 2 975 x 2 860 x 2 750 x 2 810 x 2 Blade specification 458 332 18.1 5.5 102 (6 x 2) 82.2 7.9 10.2 8.1 0.7 1,400 375 38 90.6 79.5 99 2,855 500 20 152.6 71.6 43.6 2,410 1,415 79 x 2 69 x 2 16.5 x 2 22 x 14 145 x 2 33.1 x 2 755 x 2 840 x 2 930 x 2 975 x 2 860 x 2 750 x 2 810 x 2 20001 and up
Machine model Serial No. Engine assembly (excl. coolant and oil) Engine (excl. coolant and oil) Engine mount PTO Hydraulic pump Filter (for KA specification) Cooling assembly (excl. coolant and oil) Radiator (excl. coolant) Oil cooler (excl. oil) Aftercooler Fuel cooler (excl. fuel) Revolving frame Operator cab Operator seat Fuel cooler (excl. fuel) Hydraulic tank (excl. hydraulic oil) Control valve Counterweight Added counterweight Swing motor (incl. brake valve) Swing circle Swing machinery Center swivel joint Track frame assembly (excl. track shoe) Track frame Idler assembly Recoil spring assembly Carrier roller Track roller Travel motor (with final drive) Sprocket Track shoe assembly Triple grouser shoe (500 mm) Triple grouser shoe (600 mm) Triple grouser shoe (700 mm) Triple grouser shoe (750 mm) Single grouser shoe (510 mm) City pad shoe (500 mm) City pad shoe (600 mm) Road liner (500 mm)
10
PC138US, USLC-8
01 Specification
SEN01979-01
1
Unit: kg PC138USLC-8 Standard specification 458 332 18.1 5.5 102 (6 x 2) 82.2 7.9 10.2 8.1 0.7 1,400 375 39 90.6 79.5 95 3,240 500 20 152.6 71.6 28.6 2,540 1,460 79 x 2 71 x 2 16.5 x 4 22 x 16 145 x 2 33.1 x 2 805 x 2 895 x 2 995 x 2 800 x 2 895 x 2 870 x 2 Blade specification 458 332 18.1 5.5 102 (6 x 2) 82.2 7.9 10.2 8.1 0.7 1,400 375 39 90.6 79.5 99 2,855 500 20 152.6 71.6 43.6 2,680 1,600 79 x 2 71 x 2 16.5 x 4 22 x 16 145 x 2 33.1 x 2 805 x 2 895 x 2 995 x 2 800 x 2 895 x 2 870 x 2 20001 and up
PC138US, USLC-8
11
SEN01979-01
01 Specification
Unit: kg Machine model Serial No. Boom assembly Arm assembly Bucket link assembly Bucket assembly 955 mm width (incl. side cutter) 980 mm width (incl. side cutter) Blade assembly Reinforced blade (BOC type, incl. BOC) Blade (edge-welding type) Reinforced wide blade (BOC type, incl. BOC) Wide blade (edge-welding type) Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Blade cylinder assembly 101.3 x 2 125.3 77.8 688 668 702 682 101.3 x 2 125.3 77.8 59.5 x 2 399 399 820 356 85.6 PC138US-8 Standard specification Blade specification 820 356 85.6 20001 and up
BOC: Bolt-On Cutting edge
12
PC138US, USLC-8
01 Specification
SEN01979-01
Unit: kg PC138USLC-8 Standard specification 820 356 85.6 399 Blade specification 820 356 85.6 399 20001 and up
101.3 x 2 125.3 77.8
688 668 702 682 101.3 x 2 125.3 77.8 59.5 x 2
PC138US, USLC-8
13
SEN01979-01
01 Specification
Table of fuel, coolant and lubricants

a
For details of the notes (Note. 1, Note. 2 ) in the table, see the Operation and Maintenance Manual.
14
PC138US, USLC-8
01 Specification
SEN01979-01
Unit: l Reservoir Engine oil pan Swing machinery case Final drive case (each side) PTO case Hydraulic system Fuel tank Cooling system Specified capacity 11.5 2.5 2.1 0.75 120 195 12.4 Refill capacity 11.0 2.5 2.1 0.75 69
PC138US, USLC-8
15
SEN01979-01
01 Specification
16
PC138US, USLC-8
SEN02545-01
HYDRAULIC EXCAVATOR PC138US-8 PC138USLC-8
Machine model
Serial number
10 Structure, function and maintenance standard

Engine and cooling system
Engine mount.................................................................................................................................................. 2 PTO................................................................................................................................................................. 3 Cooling system ............................................................................................................................................... 4
PC138US, USLC-8
SEN02545-01
Engine mount
PC138US, USLC-8
SEN02545-01
PTO
a
PTO: Abbreviation for Power Take Off
1. 2. 3. 4. 5. 6.
Flywheel Coupling Hydraulic pump shaft Drain plug Oil filler plug Oil level plug
PC138US, USLC-8
SEN02545-01
Cooling system
PC138US, USLC-8
SEN02545-01
1. 2. 3. 4. 5. 6. 7. 8. 9.
Radiator cap Shroud Reservoir tank Oil cooler inlet Oil cooler Aftercooler Radiator Fuel cooler Fuel cooler outlet
10. 11. 12. 13. 14. 15. 16. 17.
Fuel cooler inlet Radiator outlet hose Radiator inlet hose Aftercooler outlet hose Fan guard Oil cooler outlet Aftercooler inlet hose Drain plug
Specifications
Radiator Core type Fine pitch (mm) Total heat dissipation surface (m) Pressure valve cracking pressure (kPa{kg/cm}) Vacuum valve cracking pressure (kPa{kg/cm}) 4-array aluminum mesh core 3.5/2 22.03 49.0 14.7 {0.5 0.15} -4.9 0 {-0.05 0} Oil cooler CF40 3.0/2 12.78 Aftercooler Aluminum mesh core 4.0/2 6.68 Fuel cooler Drawn cup 4.0/2 0.59
PC138US, USLC-8
SEN02545-01
PC138US, USLC-8
SEN02546-01
Machine model
Serial number

Power train
Power train...................................................................................................................................................... 2 Swing circle..................................................................................................................................................... 3 Swing machinery............................................................................................................................................. 4
PC138US, USLC-8
SEN02546-01
Power train
1. 2.
3. 4. 5. 6.
Idler Control valve 2a. Self pressure reducing valve 2b. Pump merge-divider valve 2c. Travel junction valve PPC lock solenoid valve 2nd travel speed select solenoid valve Swing holding brake solenoid valve Pump merge-divider solenoid valve
7. 8. 9. 10. 11. 12. 13. 14.
Travel junction solenoid valve Travel motor Hydraulic pump Engine Swing motor Center swivel joint Swing machinery Swing circle
PC138US, USLC-8
SEN02546-01
Swing circle
Unit: mm No. 1 Item Bearing clearance Basic clearance 0.5 1.6 Criteria Clearance limit 2.6 Remedy Replace
2. 3. 4. 5. 6. 7.
Swing circle bearing lubrication Swing circle pinion lubrication Outer race Ball Seal Inner race (Number of teeth: 90)
a. b.
Inner race soft zone position Outer race soft zone position
Specifications
Reduction ratio Grease Grease quantity (l) 90/11=8.182 G2-LI 9.1
PC138US, USLC-8
SEN02546-01
Swing machinery
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Level gauge Oil feed pipe Oil filler cap Swing pinion (Number of teeth: 11) Swing machinery case No. 2 planetary carrier No. 2 sun gear (Number of teeth: 17) Ring gear (Number of teeth: 61) No. 1 planetary carrier No. 1 sun gear (Number of teeth: 14) Swing motor No. 1 planetary gear (Number of teeth: 24) No. 2 planetary gear (Number of teeth: 22) Drain plug
Specifications
Reduction ratio Swing reduction ratio Swing speed (rpm) (14+61) / 14 (17+61) / 17 = 24.58 24.58 8.182 = 201.11 11.0
PC138US, USLC-8
SEN02546-01
Unit: mm No. 1 2 3 4 5 6 7 8 Item Backlash between swing motor shaft and No. 1 sun gear Backlash between No. 1 sun gear and No. 1 planetary gear Backlash between No. 1 planetary gear and ring gear Backlash between No. 1 planetary carrier and No. 2 sun gear Backlash between No. 2 sun gear and No. 2 planetary gear Backlash between No. 2 planetary gear and ring gear Backlash between No. 2 planetary carrier and swing pinion Back lash between swing pinion and swing circle Outside diameter of oil seal contacting surface on swing pinion collar 0.07 0.18 0.13 0.31 0.15 0.34 0.14 0.34 0.13 0.31 0.15 0.34 0.08 0.19 0.13 1.16 Standard size 145 Tolerance 0 -0.100 Criteria Standard clearance Clearance limit 0.4 0.6 0.7 0.7 Replace 0.6 0.7 0.4 2.3 Repair limit 144.8 Repair by hard chrome-plating or replace Remedy
PC138US, USLC-8
SEN02546-01
PC138US, USLC-8
SEN02547-01
Machine model
Serial number

Undercarriage and frame
Track frame ..................................................................................................................................................... 2 Idler cushion.................................................................................................................................................... 4 Idler ................................................................................................................................................................. 6 Track roller ...................................................................................................................................................... 7 Carrier roller .................................................................................................................................................... 8 Sprocket .......................................................................................................................................................... 9 Track shoe .................................................................................................................................................... 10
PC138US, USLC-8
SEN02547-01
Track frame
PC138US-8
Unit: mm No. Item Standard size 1 Length at idler guide Track frame Idler support Track frame Idler support 84 82 185 183 Criteria Repair limit 89 77 193 175 Rebuilding Rebuilding or replace Rebuilding Rebuilding or replace Remedy
Width at idler guide
3. 4. 5. 6.
Idler Track frame Carrier roller Travel motor
7. 8. 9. 10.
Sprocket Track roller Idler cushion Track shoe
PC138US, USLC-8
SEN02547-01
PC138USLC-8
Unit: mm No. Item Standard size 1 Length at idler guide Track frame Idler support Track frame Idler support 84 82 185 183 Criteria Repair limit 89 77 193 175 Rebuilding Rebuilding or replace Rebuilding Rebuilding or replace Remedy
Width at idler guide
3. 4. 5. 6. 7. 8. 9. 10.
Idler Track frame Carrier roller Travel motor Sprocket Track roller Idler cushion Track shoe
PC138US, USLC-8
SEN02547-01
Idler cushion
PC138US-8
Unit: mm No. Item Standard size 1 Recoil spring Free length 501.4 Installed length 390 Installed load 84.3 kN {8,600 kg} Criteria Repair limit Free length 489 Installed load 75.0 kN {7,650 kg} Replace Remedy
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Idler Support Rod Recoil spring Cylinder U-packing Pilot Nut Valve Grease fitting
Specifications
Grease Grease quantity (cc) G2-LI 118
PC138US, USLC-8
SEN02547-01
PC138USLC-8
Unit: mm No. Item Standard size 1 Recoil spring Free length 513.3 Installed length 390 Installed load 93.2 kN {9,500 kg} Criteria Repair limit Free length 500 Installed load 83.0 kN {8,460 kg} Replace Remedy
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Idler Support Rod Recoil spring Cylinder U-packing Pilot Nut Valve Grease fitting
Specifications
Grease Grease quantity (cc) G2-LI 135
PC138US, USLC-8
SEN02547-01
Idler
Unit: mm No. 1 2 3 4 5 6 Item Outside diameter of projection Outside diameter of tread Tread depth Width of projection Overall width Tread width Standard size 54 Standard size 61 9 10 Side clearance of idler (each side) Tread thickness (at tread center) Standard size 527 489 19 52 115 31.5 Tolerance Shaft -0.250 -0.280 Hole +0.074 0 Criteria Repair limit 477 25 42 107 36.5 Standard clearance 0.250 0.354 Standard interference 0.057 0.117 1.5 Repair limit 9 Rebuilding or replace Clearance limit 1.5 InterferReplace ence limit Rebuilding or replace Rebuilding or replace Remedy
Clearance between idler shaft and bushing
Tolerance Shaft +0.117 +0.087 0.18 0.38 Basic dimension 15 Hole +0.030 0
Interference between bushing and idler
Standard clearance
Clearance limit
Oil capacity
90 cc (engine oil: SAE30CD)
PC138US, USLC-8
SEN02547-01
Track roller
Unit: mm No. 1 2 3 4 5 Item Outside diameter of projection Outside diameter of tread Flange width Overall width Tread width Standard size 50 Standard size 54 8 9 Side clearance of track roller (each side) Tread thickness (at tread center) Standard size 158 130 26.5 176 35 Tolerance Shaft -0.220 -0.240 Hole +0.190 +0.030 Standard clearance 0.250 0.430 Standard interference 0.110 0.220 1.5 Repair limit 33 Rebuilding or replace Criteria Repair limit 120 Clearance limit 1.5 InterferReplace ence limit Rebuilding or replace Rebuilding or replace Remedy
Clearance between Shaft and bushing
Tolerance Shaft +0.190 +0.140 0.41 0.90 Standard size 38 Hole 0.030
Interference between roller and bushing
Standard clearance
Clearance limit
Oil capacity
145 155 cc (engine oil: SAE30CD)
PC138US, USLC-8
SEN02547-01
Carrier roller
Unit: mm No. 1 2 Item Outside diameter of tread Tread width Clearance between shaft and bushing Standard size 40 Standard size 47 5 Side clearance of carrier roller (each side) Tread thickness (at 10 mm from roller outer edge) Standard size 116 123 Tolerance Shaft +0.055 +0.035 Hole +0.261 +0.200 Standard clearance 0.145 0.226 Standard interference 0.011 0.061 1.5 Repair limit 12.7 Rebuilding or replace Criteria Repair limit 106 Clearance limit InterferReplace ence limit Remedy Rebuilding or replace
Tolerance Shaft +0.061 +0.036 0.363 0.537 Standard size 17.7 Hole +0.025 0
Interference between collar and bushing
Standard clearance
Clearance limit
Oil capacity
68 76 cc (engine oil: SAE30CD)
PC138US, USLC-8
SEN02547-01
Sprocket
Unit: mm No. 1 2 3 4 5 Item Standard size Wear on tooth bottom diameter Wear on tooth tip diameter Wear on tooth tip width Wear on tooth bottom width Thickness at tooth bottom 542.8 607.5 27 42 109.4 Criteria Tolerance +1.0 -2.0 1.5 +0.465 -1.160 Repair limit 530 595 22 39 103 Rebuilding or replace Remedy
PC138US, USLC-8
SEN02547-01
Track shoe
Triple grouser shoe, road liner, city pad shoe
*1. Triple grouser shoe, city pad shoe *2. Road liner
a
P portion shows the link of bushing press fitting end.
10
PC138US, USLC-8
SEN02547-01
Unit: mm No. 1 2 3 4 5 6 7 8 9 10 Link 11 12 Pin projection 13 Regular bushing projection 14 Pin overall length 15 Bushing overall length (master bushing) Bushing Press-fit force Regular pin Master pin Internal width Overall width Tread width Shoe bolt pitch Link pitch Bushing external diameter Bushing thickness Link height Link thickness (bushing press fit part) Item Standard size 175.3 Standard size 50.6 9 Standard size 90 23.9 102.4 86.4 57 52.4 35 30.1 3 3.75 168 86.7 58.8 176.5 kN {6 18 ton} 98.1 235.4 kN {10 24 ton} 98.1 235.4 kN {10 24 ton} Adjust or replace Repair or replace Criteria Repair limit 178.3 Reverse 46.6 5 Repair limit 85 18.9 Replace Repair or replace Reverse or replace Remedy
16 Spacer thickness 17 18 19 (*)
*: In case of dry type track.
PC138US, USLC-8
11
SEN02547-01
Unit: mm No. Item Triple grouser shoe a. Regu- City pad shoe lar link Single grouser shoe Road liner b. Master link Tightening torque (Nm {kgm}) Standard size 50.2 32 Standard size 32 Standard size 32 Standard size 32 58 Shaft +0.387 +0.347 +0.150 +0.050 Shaft +0.150 +0.050 Shaft +0.060 +0.020 Shaft -0.200 -0.300 Criteria Tightening torque (Nm {kgm}) Retightening angle (degree) Remedy
196 20 {20 2}
90 10 Retighten
20 Shoe bolt
176 20 {18 2} Retightening angle (degree) Tolerance Hole +0.074 +0.074 -0.188 -0.250 Hole +0.830 +0.330 Hole +0.188 -0.250 Hole +0.830 +0.330
60 5 Torque lower limit (Nm {kgm}) Standard interference 0.273 0.387 0.238 0.400 Standard clearance 0.180 0.780 Standard interference 0.208 0.310 Standard clearance 0.530 1.130 21 Replace Adjust or replace
Interference between bushing 21 and link Interference between regular pin and link Clearance between regular pin and bushing
22
Tolerance
23
Tolerance
24 Interference between master (*) pin and link
Tolerance
25 Clearance between master pin (*) and bushing 26 Grouser height (road liner)
*: In case of dry type track.
12
PC138US, USLC-8
SEN02547-01
Triple grouser shoe
Unit: mm No. 1 2 3 4 5 6 7 8 Grouser tip length Item Grouser overall height Shoe overall height Plate thickness Grouser bottom length Standard size 20 29.5 9.5 20 20 14 13 15 Criteria Repair limit 10 19.5 Rebuilding or replace Remedy
PC138US, USLC-8
13
SEN02547-01
Single shoe
Unit: mm No. 1 2 3 4 5 Item Grouser overall height Shoe overall height Plate thickness Grouser bottom length Grouser tip length Standard size 50 62 12 25 14 Criteria Repair limit 20.5 32.5 Rebuilding or replace Remedy
14
PC138US, USLC-8
SEN02547-01
PC138US, USLC-8
15
SEN02547-01
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PC138US, USLC-8
SEN02548-01
Machine model
Serial number

Hydraulic system, Part 1
Hydraulic equipment layout drawing ............................................................................................................... 2 Valve control ................................................................................................................................................... 4 Hydraulic tank and filter .................................................................................................................................. 6 Hydraulic pump ............................................................................................................................................... 8
PC138US, USLC-8
SEN02548-01
Hydraulic equipment layout drawing

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Bucket cylinder Arm cylinder Control valve Solenoid valve Accumulator (for PPC circuit) Boom cylinder Hydraulic tank Swing motor Hydraulic pump R.H. travel motor Oil cooler L.H. travel motor L.H. work equipment PPC valve Blade PPC valve R.H. work equipment PPC valve Center swivel joint Travel PPC valve Attachment PPC valve (Machine ready for attachment) 19. Blade cylinder (blade specification)
PC138US, USLC-8
SEN02548-01
PC138US, USLC-8
SEN02548-01
Valve control
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connecting valve Solenoid valve Accumulator (for PPC circuit) Control valve Blade PPC valve (blade specification) R.H. work equipment control lever (for boom and bucket control) Blade control lever (blade specification) L.H. work equipment control lever (for arm and swing control) L.H. work equipment PPC valve
10. 11. 12. 13. 14. 15.
Lock lever R.H. work equipment PPC valve Travel lever Travel pedal Travel PPC valve Attachment PPC valve (Machine ready for attachment) 16. Attachment control pedal (Machine ready for attachment) 17. Lock pin
PC138US, USLC-8
SEN02548-01
PC138US, USLC-8
SEN02548-01
Hydraulic tank and filter
1. 2. 3. 4. 5. 6. 7.
Hydraulic tank Suction strainer Filter element Bypass valve Drain plug Sight gauge Oil filler cap combined with breather
Specifications
Hydraulic tank capacity (l) Oil level in hydraulic tank (l) Bypass valve set pressure (MPa{kg/cm}) 99 69 0.15 0.03 {1.53 0.3}
PC138US, USLC-8
SEN02548-01
Breather
1. 2. 3. 4. 5.
Filter element Bottom plate Gasket Seam valve Spring
Prevention of negative pressure in tank q The hydraulic tank is enclosed and pressurized. When the oil level in the hydraulic tank drops, negative pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) is opened to draw the atmosphere to the tank. (Intake valve set pressure: 0 0.49 kPa {0 0.005 kg/cm}) Prevention of pressure rise in tank q When the hydraulic circuit is operating, the pressure in the hydraulic tank increases as the hydraulic cylinder operates and the oil level and temperature increase in the tank. If the pressure in the tank rises above the set value, bottom plate (2) is pushed up to release the pressure in the tank. (Exhaust valve set pressure: 16.7 6.86 kPa {0.17 0.07 kg/cm})
PC138US, USLC-8
SEN02548-01
Hydraulic pump
Type: HPD56+56
PC138US, USLC-8
SEN02548-01
Outline q This pump consists of a variable-displacement swash plate type piston pump, PC valve, LS valve and EPC valve. Features of double pump system The common single pump system makes much loss in the pressure compensation valve. Accordingly, the machine travel speed is reduced much when the machine is steered. q The double pump system does not make much loss in the pressure compensation valve, since the right and left travel circuits are independent from each other. Accordingly, the machine travel speed is less reduced when the machine is steered. q The double pump has simpler structure than the tandem pump.
q
BMP : Breather mounting port IM : PC mode selector current OCP : Oil level check port P1T : Travel deviation control orifice P2T : Travel deviation control orifice PA1 : Pump discharge port PA1C : Pump discharge pressure pickup port PA2 : Pump discharge port PA2C : Pump discharge pressure pickup port PB : Pump pressure input port PD1 : Case drain port PD2 : Drain plug PEN : Control pressure pickup port PEPB : EPC basic pressure pickup port PEPC: EPC basic pressure input port PLS : Load pressure input port PLSC : Load pressure pickup port PM : PC mode selector pressure pickup port PS : Pump suction port 1. 2. 3. 4. 5. 6. 7. Main pump LS valve PC valve PC-EPC valve Shuttle valve No. 1 check valve No. 2 check valve
PC138US, USLC-8
SEN02548-01
1. 2. 3. 4. 5. 6.
Shaft Cradle Case Rocker cam Shoe Piston
7. 8. 9. 10. 11.
Cylinder block Valve plate End cap Servo piston PC valve
10
PC138US, USLC-8
SEN02548-01
Function q The pump converts the engine rotation and torque transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle. Structure Cylinder block (7) is supported to shaft (1) by spline (10). q Shaft (1) is supported by front and rear bearings (11). q Tip of piston (6) is shaped as a concave ball and shoe (5) is caulked to it to form one unit. q Piston (6) and shoe (5) constitute the spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement.
q
q q q
Rocker cam (4) conducts high pressure oil to the cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside the respective cylinder chambers of cylinder block (7) is suctioned and discharged through valve plate (8).
PC138US, USLC-8
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SEN02548-01
Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the ax ial di rec tio n of cy li nder b loc k (7) changes. q (a) is named the swash plate angle.
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
q q
With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) suctions and discharges the oil by the amount (F) (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.
12
PC138US, USLC-8
SEN02548-01
Control of delivery q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b ec o me s l ar g er a nd pu m p d el i v e r y ( Q ) increases. q Servo piston (12) is used for changing swash plate angle (a). q Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. q This linear movement is transmitted to rocker cam (4) via slider (13). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. Main pump discharge pressure (check valve output pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
PC138US, USLC-8
13
SEN02548-01
LS valve
PA PDP PLP PLS PP PPL
: Pump port : Drain port : LS control pressure output port : LS pressure input port : Pump port : Control pressure input port
1. 2. 3. 4. 5. 6.
Sleeve Piston Spool Spring Sheet Sleeve
7. Plug 8. Locknut
Function q The LS (load sensing) valve detects the load and controls the delivery. q This valve controls main pump delivery (Q) according to differential pressure ( PLS) [= (PP) (PLS)], called the LS differential pressure (the difference between main pump pressure (PP) and control valve outlet port pressure (PLS)). q Main pump pressure (PP), pressure (PLS) (called the LS pressure) coming from the control valve output enters this valve.
14
PC138US, USLC-8
SEN02548-01
Operation
1. When the control valve is situated at neutral
The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the outlet port of the control valve brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery pressure (check valve output pressure) (PP) determine the position of spool (6). Before the engine is started, servo piston (12) is pushed to the left. (See the diagram on the right) If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool) Spool (6) is pushed to the left, and port (C) and port (D) will be connected.
q q q
Pump pressure (PP) is conducted to the larger diameter end from the port (K). The same pump pressure (PP) is conducted to the smaller diameter end from the port (J). According to the difference in the areas on servo piston (12), the pressure moves in such that the swash plate angle may be minimized.
PC138US, USLC-8
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2. Action for the direction of maximizing the pump delivery
When the difference between the main pump pressure (PP) and LS pressure (PLS), in other words, LS differ ential press ure ( P LS) becomes smaller [for example, when the area of opening of the control valve becomes larger and pump pressure (PP) drops], spool (6) is pushed to the right by the combined force of LS pressure (PLS) and the force of spring (4). When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve. The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT). (The operation of the PC valve is explained later.) The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT), and pump pressure (PP) enters port (J) at the small diameter end, so servo piston (12) is pushed to the right side. Therefore, the swash plate is moved in the direction to make the delivery larger. PC138US, USLC-8
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SEN02548-01
3. Action for the direction of minimizing the pump delivery
When LS differential pressure ( PLS) becomes larger [for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises] because of the leftward move (it reduces delivery) of servo piston (12), pump pressure (PP) pushes spool (6) to the left. When spool (6) moves, main pump pressure (PP) flows from port (C) to port (D) and from port (K), it enters the large diameter end of the piston. Main pump pressure (PP) also enters port (J) of the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end on servo piston (12), it is pushed to the left. As the result, the servo piston (12) moves into the direction of reducing the swash plate angle.
PC138US, USLC-8
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SEN02548-01
4. When servo piston is balanced
Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) (PP) = (A1) (PEN), servo piston (12) will stop in that position. The swash plate of the pump will be held at the intermediate position. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] At this point, the relationship between the pressure receiving areas across servo piston (12) is (A0) : (A1) = 1 : 2, so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 2 : 1.
Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when (PP) (PLS) = 2.2 MPa {22.5 kg/cm2} at the median of the specified value.
18
PC138US, USLC-8
SEN02548-01
PC valve
PA : Pump port PA2 : Pump pressure pilot port PDP : Drain port PM : Mode selector pressure pilot port PPL : PC control pressure output port PPL2: LC control pressure output port
1. 2. 3. 4. 5. 6. 7. 8.
Plug Servo piston assembly Pin Spool Retainer Sheet Cover Wiring
Function q When the pump discharge pressure (PP1) (check valve output pressure) and (PP2) (shuttle valve output pressure) are high, the PC valve controls the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it may not exceed the engine hose power. q If the pump discharge pressure (PP1) increases due to increased load during operation, this valve decreases the pump delivery. q And if the pump delivery pressure goes low, it increases the pump delivery. q In this case, relation between the mean average discharge pressure of the pump [(PP1) + (PP2)]/2 and the pump delivery (Q) will becomes as shown in the diagram if the relation is represented as the parameter of the current value to be given to PC-EPC valve solenoid. q The controller continues counting the actual engine speed. q If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed. PC138US, USLC-8
If the engine speed goes below the specified value because of increased load, the controller sends a command current to PC-EPC valve solenoid in order to reduce the slope angle in proportion to reduction in the engine speed.
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SEN02548-01
Operation
1. When pump controller is normal

1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) q Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller. q This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston (2). q Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4) and (6) as well as the pump pressures (PP1) (check valve output pressure) and (PP2) (shuttle valve output pressure).
The pressure [port (C) pressure] output from PC valve is changed depending on the above position. The size of command current (X) is determined by the nature of the operation (lever operation), the selected working mode, and the set value and actual value of the engine speed.
20
PC138US, USLC-8
SEN02548-01
PC138US, USLC-8
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SEN02548-01
Action of spring q Load of springs (4) and (6) on the PC valve is determined by the swash plate position. q As servo piston (9) moves to left, spring (6) is retracted. q If the servo piston moves further, it will be contacted again seat (5) and spring (6) will be fixed. q After that, spring (4) alone will operate. q The spring load is changed by servo piston (9) as it extends or compresses springs (4) and (6). q If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2).
q q
Spring load of springs (4) and (6) is also affected by the command current (X) to PCEPC valve solenoid. Port (C) of the PC valve is connected to port (E) of the LS valve. Check valve output pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and shuttle valve output pressure (PP2) enters port (A). When pump pressures (PP1) and (PP2) are small, spool (3) will be positioned in the right side. Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
22
PC138US, USLC-8
SEN02548-01
q q
If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes drain pressure (PT), and servo piston (9) moves to the right side. The pump delivery will be set to the increasing trend. Accompanied with move of servo piston (9), springs (4) and (6) will be expanded and the spring force becomes weaker. As the spring force is weakened, spool (3) moves to the left, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are connected. As a result, the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the rightward move of servo piston (9) is stopped. Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the pressures (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve generates and the pushing force of springs (4) and (6) are balanced.
PC138US, USLC-8
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SEN02548-01
2)
When load on actuator is large and pump discharge pressure is high
Outline q When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the left becomes larger and spool (3) will be moved to the position shown in above figure. q Part of the pressure to be conducted from port (C) to LS valve flows from port (A) to port (C) and (D) through LS valve. At the end this flow, level of this pressure becomes approximately half of the main pump pressure (PP).
Operation q When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of servo piston (9), stopping servo piston (9). q If main pump pressure (PP) increases further and spool (3) moves further to the left, main pump pressure (PP1) flows to port (C) and acts to make the pump delivery the minimum. q When servo piston (9) moves to the left, springs (4) and (6) are compressed and push back spool (3). q When spool (3) moves to the right, the opening of port (C) and port (D) becomes larger.
24
PC138US, USLC-8
SEN02548-01
As a result, the pressure on port (C) (= J) is decreased and the rightward move of servo piston (9) is stopped. The position in which servo piston (9) stops at this time is further to the left than the position when pump pressures (PP1) and (PP2) are low. The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their positions can be represented by the broken line in the figure because springs (4) and (6) form the double springs. The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q) becomes as shown below.
If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/ 2, and pump delivery (Q) is proportional to the force of the PC-EPC valve solenoid and moves in parallel. Namely, the force of PC-EPC valve solenoid (1) is added to the pushing force to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased.
PC138US, USLC-8
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SEN02548-01
2. As the emergency pump drive switch is turned on due to failure on the pump controller
1) When the main pump is under light load
If there is a failure in the pump controller, the emergency pump drive switch is turned on to hand the control to the resistor side. In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the resistor is set in between to control the current flowing to PC-EPC valve solenoid (1). The current becomes constant, so the force pushing piston (2) is also constant.
If the main pump pressures (PP1) and (PP2) are low, the combined force of the pump pressure and the PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the right. The port (C) is connected to the drain pressure of the port (D), and the large diameter end of the servo piston (9) also becomes the drain pressure (PT) through the LS valve. Since the pressure on the small diameter end of the piston is large, servo piston (9) moves in the direction to make the delivery larger.
26
PC138US, USLC-8
SEN02548-01
2)
When the main pump is under heavy load
q q
If the emergency pump drive switch is turned on in the same way as in above, the command current (X) sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. If main pump pressures (PP1) and (PP2) increase, spool (3) moves further to the left than when the main pump load is light, and is balanced at the position in the figure above. In this case, the pressure from port (A) flows to port (C), so servo piston (9) moves to the left (smaller pump delivery) and stops at a position to the further to the left then when the load on the pump is light.
PC138US, USLC-8
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SEN02548-01
When the emergency pump drive switch is turned on, too, the pump pressure (PP) and pump delivery (Q) have a relationship as shown with the curve in the figure corresponding to the current sent to the PC-EPC valve solenoid through the resistor. The curve resulting when the emergency pump drive switch is ON is situated further to the left (B) than when the pump controller is normal (A).
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PC138US, USLC-8
SEN02548-01
PC-EPC valve
C : To PC valve P : From self pressure reducing valve T : To tank 1. 2. 3. 4. 5. 6. 7. Connector Coil Body Spring Spool Rod Plunger
PC138US, USLC-8
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SEN02548-01
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the PC valve.
Operation
1. When signal current is 0 (coil is deenergized)

q
q q
When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. Spool (5) is pushed to the left by spring (4). Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the PC valve. The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).
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PC138US, USLC-8
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2. When signal current is very small (coil is energized)

q
3. When signal current is maximum (coil is energized)

q q
q q
q q q
When a very small signal current flows to coil (2), coil (2) is energized, and a propulsion force is generated on the right side of plunger (7). Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C). Pressure on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become larger than the propulsion force of plunger (7). Spool (5) is pushed to the left, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (5) moves up and down so that the propulsion force of plunger (7) may be balanced with pressure of port (C) + spring load of spring (4). The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the size of the signal current.
q q
As the signal current flows to coil (2), coil (2) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (7) is also at its maximum. Spool (5) is pushed toward right side by rod (6). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and PC valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the tank.
PC138US, USLC-8
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Check valve
PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP1: Output pressure of check valve Function q A set of 2 check valves is used to select and output the higher discharge pressure of the 2 main pumps.
1. 2.
Poppet valve Poppet valve
Operation
1. When (PA1) > (PA2)

q
Discharge pressures (PA1) and (PA2) of the main pumps are applied to poppet valves (1) and (2). Since (PA1) > (PA2), however, poppet valve (2) is kept closed and (PA1) is output to (PP1). Reversely to 1., poppet valve (1) is kept closed and (PA2) is output to (PP1).
2. When (PA1) < (PA2)

q
32
PC138US, USLC-8
SEN02548-01
Shuttle valve
PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP2: Output pressure of shuttle valve 1. 2. 3. Poppet valve Poppet valve Pin Operation q The discharge pressures (PA1) and (PA2) of the 2 main pumps are applied to poppet valves (1) and (2) respectively. q Since poppet valves (1) and (2) push each other through pin (3), either one of them receiving higher pressure is closed and the other one receiving lower pressure is opened. q Accordingly, lower discharge pressure of the 2 main pumps is output.
Function q The shuttle valve selects and outputs the lower discharge pressure of the 2 main pumps.
PC138US, USLC-8
33
SEN02548-01
34
PC138US, USLC-8
SEN02549-02
Machine model
Serial number

Control valve ................................................................................................................................................... 2 CLSS............................................................................................................................................................. 14 Functions and operation by valve ................................................................................................................. 18
PC138US, USLC-8
SEN02549-02
Control valve
Outline The control valves of the following types are set. q 6-spool valve (Without service valve) q 7-spool valve (6-spool valve + service valve) q 7-spool valve (Blade) q 8-spool valve (Blade + service valve) q 8-spool valve (6-spool valve + 2 service valves) q 9-spool valve (Blade + 2 service valves) The appearance and section of only the 8-spool valve (blade + service valve) are shown here. A1 : To swing motor A2 : To blade cylinder bottom A3 : To left travel motor A4 : To right travel motor A5 : To boom cylinder bottom A6 : To arm cylinder head A7 : To bucket cylinder head A8 : To attachment B1 : To swing motor B2 : To blade cylinder head B3 : To left travel motor B4 : To right travel motor B5 : To boom cylinder head B6 : To arm cylinder bottom B7 : To bucket cylinder bottom B8 : To attachment LS : To pump LS valve P1 : From main pump P2 : From main pump PP : To main pump PR : To solenoid valve, EPC valve PS : From solenoid valve of merge-divider valve TB : To tank TC : To oil cooler BP1: From boom raise PPC valve LS1: LS1 pressure pickup port LS2: LS2 pressure pickup port 1. 2. 3. 4. 5. 6. 7. 8. Cover Service valve Bucket valve Arm valve Boom valve Right travel valve Left travel valve Blade valve LS3 : LS3 pressure pickup port PA1 : From swing left PPC valve PA2 : From blade lower PPC valve PA3 : From left travel forward PPC valve PA4 : From right travel forward PPC valve PA5 : From boom raise PPC valve PA6 : From arm dump PPC valve PA7 : From bucket dump PPC valve PA8 : From service PPC valve PB1 : From swing right PPC valve PB2 : From blade raise PPC valve PB3 : From left travel reverse PPC valve PB4 : From right travel reverse PPC valve PB5 : From boom lower PPC valve PB6 : From arm in PPC valve PB7 : From bucket curl PPC valve PB8 : From attachment PPC valve PMAX: Pressure sensor port PP1 : PP1 pressure pickup port PP2 : PP2 pressure pickup port PPI1 : Pump 1 pressure pickup port PPI2 : Pump 2 pressure pickup port PRI : PR pressure pickup port PST : From travel junction solenoid valve TS1 : To tank PS2 : To tank TSW : To swing motor 9. 10. 11. 12. 13. 14. 15. 16. Swing valve Block Swing bleeding valve LS check valve Travel junction valve + LS check valve Arm regeneration valve Boom hydraulic drift prevention valve Merge-divider valve block
PC138US, USLC-8
SEN02549-02
PC138US, USLC-8
SEN02549-02
PC138US, USLC-8
SEN02549-02
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Suction safety valve (Service) Suction valve (Bucket) Suction valve (Arm) Suction valve (Boom) Lift check valve Suction valve (Right travel) Suction valve (Left travel) Suction valve (Blade) Suction safety valve (Blade) Suction valve (Left travel) Suction valve (Right travel) Main relief valve Suction valve (Boom) Suction valve (Arm)
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Suction valve (Bucket) Suction safety valve (Service) Suction safety valve Spool (Service) Spool (Bucket) Spool (Arm) Spool (Boom) Spool (Right travel) Spool (Left travel) Spool (Blade) Spool (Swing) Unload valve Unload valve
Unit: mm No. Check item Standard size 28 Suction valve spring Free length Outside diameter 46.8 7.5 29 Piston return spring 30 Suction valve spring 31 Spool return spring 32 Spool return spring 33 Spool return spring 34 Spool return spring 35 Spool return spring 36 Spool return spring 37 Spool return spring 38 Spool return spring 39 Spool return spring 72.7 20.6 39.2 4.45 41.8 19 41.44 19.3 27.14 25.8 32.4 11 76.78 20.9 45.7 28 42.4 28 45.6 28 45.81 28 Installed length 40.6 42.5 33.5 38.5 38.5 25.5 31.4 70 43 39 43 43 Installed load 5.49 N {0.56 kg} 135 N {13.8 kg} 5.1 N {0.52 kg} 141 N {14.4 kg} 137 N {13.96 kg} 55.9 N {5.7 kg} 60.2 N {6.137 kg} 423 N {43.1 kg} 221 N {22.55 kg} 222 N {22.6 kg} 230 N {23.5 kg} 203 N {20.7 kg} Criteria Repair limit Free length Installed load 4.41 N {0.45 kg} 108 N {11.0 kg} 4.12 N {0.42 kg} 113 N {11.5 kg} 110 N {11.2 kg} 44.7 N {4.56 kg} 48.2 N {4.91 kg} 338 N {34.5 kg} 177 N {18.04 kg} 178 N {18.1 kg} 184 N {18.8 kg} 163 N {16.6 kg} If damaged or deformed, replace spring Remedy
PC138US, USLC-8
SEN02549-02
PC138US, USLC-8
SEN02549-02
1 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. F: R:
No.
LS selector valve Cooler bypass valve Pressure compensation valve R (Service) Pressure compensation valve R (Bucket) Pressure compensation valve R (Arm) Pressure compensation valve R (Boom) Pressure compensation valve R (Right travel) Pressure compensation valve R (Left travel) Pressure compensation valve R (Blade) Pressure compensation valve R (Swing) Pressure compensation valve F (Swing) Pressure compensation valve F (Blade) Pressure compensation valve F (Left travel) Pressure compensation valve F (Right travel) Merge-divider valve spool Pressure compensation valve F (Boom) Pressure compensation valve F (Arm) Pressure compensation valve F (Bucket) Pressure compensation valve F (Service) Flow control valve Pressure reducing valve
Unit: mm Check item Standard size Free length x Outside diameter 41.5 x 8.5 Criteria Repair limit Installed load 5.88 N {0.6 kg} 2.94 N {0.3 kg} Free length Installed load 4.71 N {0.48 kg} 2.35 N {0.24 kg} Remedy
20 Check valve spring
Installed length 31.5 16
If damaged or deformed, replace spring
20.3 x 13.7
PC138US, USLC-8
SEN02549-02
PC138US, USLC-8
SEN02549-02
1.
LS selector valve
Swing valve 2. Pressure compensation valve F 3. Spool 4. Pressure compensation valve R 5. Swing bleed valve Blade valve 6. Suction safety valve 7. Suction valve 8. Spool 9. Pressure compensation valve R 10. Pressure compensation valve F L.H. travel valve 11. Pressure compensation valve F 12. Suction valve 13. Suction valve 14. Spool 15. Pressure compensation valve R 16. LS check valve F: R: Flow control valve Pressure reducing valve
Unit: mm No. Check item Standard size 17 Check valve spring Free length x Outside diameter 23.3 12.5 18 Check valve spring 19 Retainer spring 21.9 5 9.1 4.2 Installed length 23 15.8 7.4 Installed load 3.92 N {0.4 kg} 1.96 N {0.2 kg} 0.98 N {0.1 kg} Criteria Repair limit Free length Installed load 3.14 N {0.32 kg} 1.57 N {0.16 kg} 0.78 N {0.08 kg} If damaged or deformed, replace spring Remedy
PC138US, USLC-8
SEN02549-02
10
PC138US, USLC-8
SEN02549-02
R.H. Travel valve 1. Pressure compensation valve F 2. Suction valve 3. Suction valve 4. Spool 5. Pressure compensation valve R 6. Travel junction valve + LS check valve 7. 8. 9. 10. 11. 12. Unload valve LS bypass valve Merge-divider valve spool Main relief valve Cooler bypass valve Lift check valve
Boom valve 13. Pressure compensation valve F 14. Suction valve 15. Hydraulic drift prevention valve 16. Suction valve 17. Spool 18. Pressure compensation valve R F: R: Flow control valve Pressure reducing valve
Unit: mm No. Check item Standard size 19 Spool return spring Free length x Outside diameter 19.26 7.5 20 Check valve spring 21 Valve return spring 22 Spool return spring 23 Check valve spring 24 Spool return valve spring 21.9 5 58.9 13 49.8 18.8 16.4 8.9 72.7 20.6 Installed length 14 15.8 53 33 11.5 42.5 Installed load 15.7 N {1.6 kg} 1.96 N {0.2 kg} 83.4 N {8.5 kg} 98.1 N {10 kg} 13.7 N {1.4 kg} 135 N {13.8 kg} Criteria Repair limit Free length Installed load 12.6 N {1.28 kg} 1.57 N {0.16 kg} 66.7 N {6.8 kg} 78.5 N {8 kg} 11.0 N {1.12 kg} 108 N {11 kg} If damaged or deformed, replace spring Remedy
PC138US, USLC-8
11
SEN02549-02
12
PC138US, USLC-8
SEN02549-02
Arm valve 1. Pressure compensation valve F 2. Suction valve 3. Suction valve 4. Spool 5. Pressure compensation valve R 6. Regeneration valve Bucket valve 7. Pressure compensation valve F 8. Suction valve 9. Suction valve 10. Spool 11. Pressure compensation valve R Service valve 12. Pressure compensation valve F 13. Suction safety valve 14. Suction safety valve 15. Spool 16. Pressure compensation valve R 17. Suction safety valve 18. Pressure release plug F: R: Flow control valve Pressure reducing valve
Unit: mm No. Check item Standard size 19 Valve spring Free length Outside diameter 41.5 8.5 Installed length 31.5 Installed load 5.88 N {0.6 kg} Criteria Repair limit Free length Installed load 4.71 N {0.48 kg} If damaged or deformed, replace spring Remedy
PC138US, USLC-8
13
SEN02549-02
CLSS
Outline of CLSS
1
1
Features CLSS stands for Closed center Load Sensing System, which has the following characteristics:
q q q
Fine control not influenced by load Controllability enabling digging even with fine control Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations Energy saving using variable pump control
Configuration q CLSS is configured with variable capacity piston pumps, control valves, and respective actuators. q The hydraulic pump is configured with pump body, PC valve and LS valve.
14
PC138US, USLC-8
SEN02549-02
Basic principle
1. Pump swash plate angle control
q
1
q
The pump swash plate angle (pump delivery) is controlled so that LS differential pressure ( P L S ) ( t h e d i ff e r e n c e b e t w e e n p u m p pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. [LS differential pressure ( PLS) = Pump discharge pressure (PP) LS pressure (PLS)]
The pump swash plate angle shifts toward the maximum position if LS differential pressure ( PLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high). If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate angle shifts toward the minimum position.
LS differential pressure ( PLS) and pump swash plate angle
For details of functions, see the "Hydraulic pump" paragraph.
PC138US, USLC-8
15
SEN02549-02
2. Pressure compensation control
A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When actuators are operated together, the p r e s s u r e d i ff e r e n c e ( P ) b e t w e e n t h e upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve.
16
PC138US, USLC-8
SEN02549-02
PC138US, USLC-8
17
SEN02549-02
Functions and operation by valve

Hydraulic circuit diagram and the name of valves
1
1
18
PC138US, USLC-8
SEN02549-02
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
Swing valve Blade valve Left travel valve Right travel valve Boom valve Arm valve Bucket valve Service valve Swing spool Blade spool Left travel spool Right travel spool Boom spool Arm spool Bucket spool Service spool Pressure compensation valve Suction valve LS service valve Merge-divider valve Arm regeneration valve Self pressure reducing valve Travel junction valve Lift check valve Cooler bypass valve Boom hydraulic drift prevention valve Swing bleeding valve Suction safety valve Set pressure: 36.8 MPa {375 kg/cm} Suction safety valve Set pressure: 24.5 MPa {250 kg/cm} Suction safety valve Set pressure: 35.8 MPa {365 kg/cm} Main relief valve Set pressure: 34.8 MPa {355 kg/cm} Unload valve
PC138US, USLC-8
19
SEN02549-02
Unload valve
1. When control valve is at HOLD
Function q When the control valve is at HOLD, pump delivery (Q) discharged by the minimum swash plate angle is released to the tank circuit. At this time, pump discharge pressure (P1) and (P2) is set by spring (2) in the valve. [LS pressure (LS1) and (LS2) = 0 MPa {0 kg/cm}] q Since the pump merge-divider valve is at the merge position, pump discharge pressures (P1) and (P2) are merged. LS pressures (LS1), (LS2), and (LS3) are also merged. Operation Pump discharge pressures (P1) and (P2) are applied to pump pressure receiving (SA) face of unload spool (1). q LS pressures (LS1) and (LS2) are applied to LS pressure receiving (SB) face. [(P1) = (P2), (LS1) = (LS2)]
q
When the control valve is at HOLD, LS pressures (LS1) and (LS2) are not generated, so only pump discharge pressures (P1) and (P2) act, and (P1) and (P2) are set by only the load of spring (2). As pump discharge pressure (P1) and (P2) rises and reaches the load of spring (2), spool (1) is moved to the left. Pump discharge pressures (P1) and (P2) are connected to tank circuit (T) through the notch of spool (1).
20
PC138US, USLC-8
SEN02549-02
2. When work equipment valve is operated
Function q When any work equipment valve is operated if the demand flow for the actuator becomes greater than the pump discharge from the minimum swash plate angle, the oil flow to tank circuit (T) is cut off, and all pump delivery (Q) flows to the actuator circuit. q Since the pump merge-divider valve is at the merge position, pump discharge pressures (P1) and (P2) are merged. LS pressures (LS1), (LS2), and (LS3) are also merged.
Operation q When any work equipment valve is operated for a long stroke, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of unload spool (1) [(P1) = (P2), (LS1) = (LS2)]. q For this reason, the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). q As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump delivery (Q) flows to the actuator circuit.
PC138US, USLC-8
21
SEN02549-02
3. During fine control of both travel valves
Function q When the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) reaches the load of spring (2), unload spool (1) opens, so excessive oil (maximum pump delivery - demand flow) flows into the tank circuit. q Since the pump merge-divider valve is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve.)
Operation q When fine control is carried out on both travel valves, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of spool (1) [(P1), (P2), (LS1), and (LS2) are separated]. q When the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) reaches the load of spring (2), spool (1) moves to the left, and pump discharge pressures (P1) and (P2) are connected to tank circuit (T) and the excessive oil (maximum pump delivery - demand flow) flows. q In other words, the excessive oil (maximum pump delivery - demand flow) above the strokes of both travel valves flows into tank circuit (T).
22
PC138US, USLC-8
SEN02549-02
4. When both travel valves are operated
Function q During operation of both travel valves, when the demand flow becomes maximum, the oil flow to tank circuit (T) is cut off, and all pump delivery (Q) flows to both travel circuits. q Since the pump merge-divider spool is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve .)
Operation q When both travel valves are operated to the stroke ends, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of unload spool (1) [(P1), (P2), (LS1), and (LS2) are separated]. q The area of the openings of both travel valve spools is large, so LS pressures (LS1) and (LS2) are not so different from pump discharge pressures (P1) and (P2). q For this reason, the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). q As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump delivery (Q) flows to the actuator circuit.
PC138US, USLC-8
23
SEN02549-02
5. When either travel valve is operated
Function q The demand flow decided by the valve stroke is sent to the travel circuit on the operated travel valve side and the all pump delivery is sent to the tank circuit on the non-operated travel valve side. q Since the pump merge-divider valve is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve.) Operation When left travel valve is operated to stroke end and right one is at HOLD. q When the left travel valve is operated to the stroke end, LS pressure (LS1) is generated and acts on the face (SB) of unload spool (1).
The area of the openings of left travel valve spool is large, so LS pressures (LS1) is not so different from pump discharge pressures (P1). For this reason, the difference between pump discharge pressure (P1) and LS pressure (LS1) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). As a result, pump discharge pressures (P1) and tank circuit (T) are shut off, and all pump delivery (QP1) on the (P1) side flows to the left travel circuit. Since the right travel valve is at HOLD, LS pressure (LS2) is not generated, so only pump discharge pressure (P2) acts. When pump discharge pressure (P2) reaches the load of spring (2), spool (1) moves to the left, and all pump delivery (QP2) on the (P2) side flows into tank circuit (T).
24
PC138US, USLC-8
SEN02549-02
PC138US, USLC-8
25
SEN02549-02
Merge-divider valve
1. When oil is merged: (PS) = 0 kg/cm2
Function q Pump discharge pressures (P1) and (P2) are merged in pump merge-divider spool (3). (LS1), (LS2), and (LS3) are also merged. q At this time, (P1) = (P2) and (LS1) = (LS2) = (LS3) and the pump swash plate is controlled by the difference between (P) and (LS).
26
PC138US, USLC-8
SEN02549-02
2. When oil is divided: (PS) = 30 kg/cm2
Function q Pump discharge pressures (P1) and (P2) are divided in pump merge-divider spool (3). (LS1), (LS2), and (LS3) are also divided. q At this time, higher one of (P1) and (P2) is applied through pump merge-divider spool (3) to the output port of the LS pressure. q As a result, there is not difference between (P) and (LS) and the pump swash plate is set to the maximum position.
PC138US, USLC-8
27
SEN02549-02
Introduction of LS pressure
1. Work equipment valve
Function q The LS pressure is the actuator load pressure at the outlet port end of the control valve. q Actually, pump discharge pressure (PP) is reduced by reducing valve (3) of the pressure compensation valve to the same pressure as actuator circuit pressure (A) and sent to LS circuit (PLS). q In the travel valve, actuator circuit pressure (A) is directly introduced to LS circuit (PLS). Operation When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit (A). q At the same time, reducing valve (3) also moves to the right, so pump discharge pressure (PP) is reduced by the pressure loss at notch (c). It goes to LS circuit (PLS), and then goes to spring chamber (PLSS).
q
When this happens, LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4) (See the section on the LS bypass valve). The areas at both ends of reducing valve (3) are the same [(SA) = (SLS)], and actuator circuit pressure (PA) acts on the (SA) end. The reduced pump discharge pressure (PP) acts on (SLS) at the other end. As a result, reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of spring chamber (PLSS) are the same. Pump discharge pressure (PP) reduced at notch (c) becomes actuator pressure (A) and is introduced into LS circuit (PLS).
28
PC138US, USLC-8
SEN02549-02
2. Travel valve
Operation q When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit (A). q Actuator circuit pressure (PA) (= A) is introduced through the check valve (5) into LS circuit (PLS). a The travel circuit is different from the work equipment circuit: actuator circuit pressure (PA) is directly introduced into LS circuit (PLS).
PC138US, USLC-8
29
SEN02549-02
LS bypass valve
1. When work equipment valve is operated (including compound operation of work equipment + travel)
Function q The LS bypass valve releases the remaining pressure of LS pressure (PLS). q This lowers the rising speed of LS pressure (PLS). In addition, the discarded throttled flow causes a pressure loss in the throttled flow in the reducing valve, and that lowers the effective LS differential pressure to improve the stability.
Operation q Since pump merge-divider spool (1) is at the merge position, the hydraulic oil in LS circuits (PLS1), (PLS2), and (PLS3) flows from tip filter (a) of LS bypass valve (2) through orifice (b) to tank circuit (T).
30
PC138US, USLC-8
SEN02549-02
2. When either or both travel valves are operated (Including operation of only one travel valve)
Operation q Since pump merge-divider spool (1) is at the separate position, LS circuits (PLS1) and (PLS2) are separated. q The hydraulic oil (PLS1) flows from tip filter (a) of LS bypass valve (2) through orifice (b) to tank circuit (T).
The hydraulic oil (PLS2) flows from tip filter (c) of LS bypass valve (3) through orifice (d) to tank circuit (T).
PC138US, USLC-8
31
SEN02549-02
Pressure compensation valve
32
PC138US, USLC-8
SEN02549-02
Function q When the load pressure becomes lower than another actuator and the flow is going to increase during a compound operation, this valve compensates the load pressure. [At the time, the load pressure of another actuator under compound operation (the upper side) is higher than that of the actuator on this side (the lower side)]. Operation When the load pressure (Ab) of another actuator side (the upper side) rises during a compound operation, the flow in the actuator circuit (Aa) on this side (the lower side) is apt to increase. q In this case, the LS pressure (PLS) of another actuator is applied to the spring chamber (PLS1) and pushes the pressure reducing valve (1) and the flow control valve (2) to the left side. q The flow control valve (2) throttles the opening area between the pump circuit (PP) and the spool upstream (PPA) and causes a pressure loss between (PP) and (PPA). q The flow control valve (2) and the pressure reducing valve (1) balance each other where the pressure difference between (PA) applied to the both end faces of the pressure reducing valve (1) and (PLS) becomes the same as the pressure loss between (PP) before and after the flow control valve (2) and (PPA). q So, the pressure differences between the upstream pressures (PPA) and the downstream pressures (PA) of the both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch (a).
q
PC138US, USLC-8
33
SEN02549-02
Area ratio of pressure compensation valve
Function q The pressure compensation valve slightly adjusts the ratio (S2) and (S1) of the area (S1) on the left side of the flow control valve (2) and the area (S2) on the right side of the pressure reducing valve (1) to suite the characteristics of each actuator and determines the compensation characteristics. S1 : Area of the flow control valve (2) area of the piston (3) S2 : Area of the pressure reducing valve (1) area of the piston (3)
Area ratio (S1) : (S2) and compensation characteristics q When the ratio is 1.00 : The expression [Pump (discharge) pressure (PP) Spool notch upstream pressure (PPB)] C [LS circuit pressure (PLS) Actuator circuit pressure (PA) (= A)] can be held, and the flow is distributed as per the spool opening area ratio. q When the ratio is more than 1.00: The expression (PP) (PPB) > (PLS) (PA) (= A) can be held, and the flow is distributed less than the spool opening area ratio. q When the ratio is less than 1.00: The expression (PP) (PPB) < (PLS) (PA) (= A) can be held, and the flow is distributed more than the spool opening area ratio.
34
PC138US, USLC-8
SEN02549-02
Boom regeneration circuit

1. At boom lower and own weight fall
Function q When the boom is lowered and falls due to its own weight because the bottom pressure (A) in the cylinder (1) is higher than the head pressure (B), this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed. Operation When the boom is lowered and falls due to its own weight, the bottom side pressure (A) in the boom cylinder (1) will rise above the head side pressure (B).
At the time, part of the return flow on the bottom side passes through the regeneration passage (a) of the boom spool (2), pushes the check valve (3) to open it and flows to the head side. This increases the boom lower speed.
PC138US, USLC-8
35
SEN02549-02
2. At boom lower load process
Function q When the head pressure (B) of the cylinder (1) is higher than the bottom pressure (A) while the boom is lowered and the boom is in the load process, the check valve (3) will be closed, and the circuits on the head side and the bottom side will be interrupted. Operation q When the boom is lowered and is in the load process, the head side pressure (B) of the boom cylinder (1) rises above the bottom side pressure (A).
At the time, the head side pressure (B) and the spring (4) close the check valve (3), and the circuits on the head side and the bottom side are interrupted.
36
PC138US, USLC-8
SEN02549-02
Arm regeneration circuit

1. At arm in and own weight fall
A : Head circuit B : Bottom circuit PP : Pump circuit Function q When the arm falls due to its own weight because the head pressure (A) in the arm cylinder (1) is higher than the bottom pressure (B) during arm digging, this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed. Operation When the arm falls for digging due to its own weight, the head side pressure (A) in the arm cylinder (1) will rise above the bottom side pressure (B).
1. 2. 3.
q
Arm cylinder Arm spool Check valve At the time, part of the return flow on the head side passes through the regeneration passage (a) of the arm spool (2), pushes the check valve (3) to open it and flows to the bottom side. This increases the arm digging speed.
PC138US, USLC-8
37
SEN02549-02
2. At arm in process
A : Head circuit B : Bottom circuit PP : Pump circuit Function q When the bottom pressure (B) of the cylinder (1) rises above the head pressure (A) and the arm enters the digging process, the check valve (3) will be closed and the circuits on the head side and the bottom side will be interrupted. Operation When the arm is in the digging process, the bottom side pressure (B) of the arm cylinder (1) will rise, close the check valve (3) and interrupt the circuits on the head side and the bottom side.
1. 2. 3.
Arm cylinder Arm spool Check valve
38
PC138US, USLC-8
SEN02549-02
Hydraulic drift prevention valve

1. When boom is raised
Function q While the boom lever is not operated, the hydraulic drift prevention valve prevents pressurized oil from leaking from the boom bottom through spool (1) to prevent the boom from drifting hydraulically.
Operation q If the boom is raised out, the main pressure from the control valve pushes up poppet (5). As a result, the main pressure from the control valve flows through the valve into the boom cylinder bottom.
PC138US, USLC-8
39
SEN02549-02
2. When boom and arm are set in neutral
Operation q If the control lever is returned to the neutral position while the boom is raised out, the holding pressure in the boom cylinder bottom and arm cylinder head is blocked by poppet (5) and the pressurized oil flowing in through orifice (a) is blocked by pilot spool (3). Accordingly, the boom is held.
40
PC138US, USLC-8
SEN02549-02
3. When boom is lowered
Operation q If the boom is lowered, pilot pressure (P1) from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber (b) in the poppet is drained. q The pressurized oil in port (Ab) is raised by the pressurized oil from the boom cylinder bottom, but the pressurized oil in chamber (b) is lowered by orifice (a). q If the pressure in chamber (b) is lowered below the pressure in port (Aa), poppet (5) opens and the pressurized oil from port (Ab) flows through port (Aa) into the control valve.
PC138US, USLC-8
41
SEN02549-02
Swing bleeding valve
Function q When the machine swings, the bleeding valve installed to the pressure reducing valve works so that the LS pressure rises gradually and the machine swings smoothly. Operation (In fine control operation) q The pressure reducing valve moves to the right and notch (a) connects to the LS circuit. As a result, pump circuit (PP), bleed-off circuit, and LS circuit are connected through piston (2). q Bleeding spool (3) moves to the left in proportion as swing PPC pressure (PA) rises. In the fine control area, notch (b) chokes the bleedoff circuit and determines the intermediate pressure before the lowered pressure is applied to pump discharge pressure (PP) and LS pressure (PLS).
Accordingly, the intermediate pressure is set lower than pump discharge pressure (PP) and raised as bleeding spool (3) moves. As a result, LS pressure (PLS) rises gradually. When the lever is in neutral or operated fully, the bleed-off circuit is closed.
42
PC138US, USLC-8
SEN02549-02
LS select valve
1. During normal operation
Function q At the time of simultaneous operation of swing + boom RAISE, this valve prevents high swing LS pressure from entering the LS circuit (PLS) and also prevents the boom RAISE speed from reducing by securing the pump flow at the time of swing drive. Operation The pilot pressure is not generally applied to the pilot port (BP) except for boom RAISE operation. q In this state, the pump discharge pressure (PP) pushes the valve (1) to open it and is led to the pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure (PLS) suitable for the load pressure, and the pressure is led to the pump LS valve.
q
PC138US, USLC-8
43
SEN02549-02
2. At simultaneous operation of swing + boom RAISE
Operation q At the simultaneous operation of swing + boom RAISE, the signal pressure of the PPC circuit is led to the pilot port (BP). q When this pilot pressure (BP) is applied to the piston (2) and reaches a pressure that is stronger than the spring (3), the piston (2) will be pushed to the left side, the valve (1) will close and the pump discharge pressure (PP) will not come to flow to the pressure reducing valve (4) of the swing valve. q Then, the swing pressure does not cause LS pressure (PLS), but the LS pressure (PLS) caused by the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. q The pilot pressure (BP) depends on the control lever stroke.
44
PC138US, USLC-8
SEN02549-02
Travel junction valve
Function q This valve connects both travel circuits to each other so that hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. q When the machine is steered, outside pilot pressure (PST) closes the travel junction valve to secure high steering performance.
Operation When pilot pressure is turned ON q If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (2), travel junction spool (1) moves to the left stroke end and the junction circuit between port (PTL) (Left travel circuit) and (PTR) (Right travel circuit) is closed.
PC138US, USLC-8
45
SEN02549-02
Self pressure reducing valve
Function q The self pressure reducing valve lowers the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valves, PPC valves, etc. Operation If the (PR) pressure rises higher than the set level, poppet (1) opens and the hydraulic oil flows from port (PR) through orifice (a) in spool (4) and opening of poppet (1) into seal drain port (TS). q Accordingly, differential pressure is generated over orifice (a) in spool (4) and spool (4) moves in the direction to close the opening between ports (P) and (PR). The (P) pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio at this time and supplied as the (PR) pressure.
q
When abnormally high pressure is generated q If the (PR) pressure of the self pressure reducing valve is raised abnormally, ball (6) separates from the seat against the force of spring (5). As a result, the hydraulic oil flows from output port (PR) to (TS) and the (PR) pressure lowers. q Accordingly, the devices receiving the oil pressure (PPC valves, solenoid valves, etc.) are protected from abnormally high pressure.
46
PC138US, USLC-8
SEN02549-02
Lift check valve and cooler bypass valve
Lift check valve Function q The lift check valve generates back pressure in the drain circuit to prevent negative pressure on each actuator (motor, cylinder, etc.) Operation q Drain circuit pressure (PA) of the control valve acts on the left side of piston (2) to move the piston to the right. q The piston is so balanced that the back pressure will be as follows. q (PA) (PB) = Force of spring (3) / Area of piston (2) at diameter (d1) [(PB) C 0 kg/cm]
Cooler bypass valve Function The cooler bypass valve protects oil cooler (4) from breakage when the return flow rate from the control valve increases and oil cooler inlet pressure (PB) increases. q The cooler bypass valve returns the return oil to the tank directly without passing it through oil cooler (4).
q
Operation q Oil cooler inlet pressure (PB) acts on the underside of piston (1) to push up the piston. q Piston (1) is so balanced that oil cooler inlet pressure (PB) will be as follows. q (PB) (PT) = Force of spring (5) / Area of piston (1) at diameter (d2) [(PT) C 0 kg/cm]
PC138US, USLC-8
47
SEN02549-02
48
PC138US, USLC-8
SEN02550-01
Machine model
Serial number

PPC valve ....................................................................................................................................................... 2 Swing motor .................................................................................................................................................. 19 Travel motor .................................................................................................................................................. 27 Center swivel joint......................................................................................................................................... 36 Solenoid valve............................................................................................................................................... 40 PPC accumulator .......................................................................................................................................... 44 Holding valve ................................................................................................................................................ 46 Multi-control valve ......................................................................................................................................... 51
PC138US, USLC-8
SEN02550-01
PPC valve
Work equipment and swing PPC valve 1
P P1 P2 P3 P4 T
: From self pressure reducing valve : L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port : L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port : L.H. PPC valve: Swing LEFT port/R.H PPC valve: Bucket CURL port : L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port : To tank
PC138US, USLC-8
SEN02550-01
PC138US, USLC-8
SEN02550-01
1. 2. 3. 4. 5. 6. 7. 8. 9.
Spool Piston Disc Nut (for lever connection) Joint Plate Retainer Body Filter
Unit: mm No. Check item Standard size Centering spring 10 (for ports P3 and P4) Criteria Repair limit Free length Installation Installation Installation Free length Outside length load load diameter 42.48 15.5 11 Centering spring (for ports P1 and P2) 44.45 15.5 26.9 8 34 34 24.9 17.7 N {1.8 kg} 29.4 N {3 kg} 16.7 N {1.7 kg} 14.1 N {1.44 kg} 23.5 N {2.40 kg} 13.3 N {1.36 kg} Remedy
If damaged or deformed, replace spring.
12 Metering spring
PC138US, USLC-8
SEN02550-01
Operation
1. When in neutral
q
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.
2. During fine control (Neutral o fine control)

q
When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).
PC138US, USLC-8
SEN02550-01
3. During fine control (When control lever is returned)

q
4. At full stroke
q q
When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).
PC138US, USLC-8
SEN02550-01
Travel PPC valve
P P1 P2 P3 P4 T
: From self pressure reducing valve : L.H. reverse : L.H. forward : R.H. reverse : R.H. forward : To tank
PC138US, USLC-8
SEN02550-01
PC138US, USLC-8
SEN02550-01
1. 2. 3. 4. 5. 6.
Plate Body Piston Seal Valve Damper

Unit: mm
No.
Check item Standard size
Criteria Repair limit
Remedy
Centering spring
Free length Installation Installation Installation Outside Free length length load load If damaged or diameter deformed, 48.57 108 N 86.3 N replace spring. 32.5 15.5 {11 kg} {8.8 kg} 26.53 8.15 24.9 16.7 N {1.7 kg} 13.3 N {1.36 kg}
Metering spring
PC138US, USLC-8
SEN02550-01
Operation
1. When in neutral
q
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.
2. During fine control (Neutral o fine control)

q
When piston (4) is pushed by lever (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1).
10
PC138US, USLC-8
SEN02550-01
3. During fine control (When control lever is returned)

q
4. At full stroke
q q
When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).
PC138US, USLC-8
11
SEN02550-01
Blade PPC valve
For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
12
PC138US, USLC-8
SEN02550-01
P P1 P2 T
: From self pressure reducing valve : To blade valve : To blade valve : To tank
1. 2. 3. 4. 5. 6. 7.
Spool Piston Lever Plate Retainer Body Filter

Unit: mm
No.
Remedy
Centering spring
Free length Installation Installation Installation Outside Free length length load load If damaged or diameter deformed, 42.36 147 N 118 N replace spring. 32.5 15.5 {15 kg} {12.0 kg} 22.73 8.1 22 16.7 N {1.7 kg} 13.3 N {1.36 kg}
Metering spring
PC138US, USLC-8
13
SEN02550-01
Attachment PPC valve (with EPC valve)
For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
14
PC138US, USLC-8
SEN02550-01
P P1 P2 T
: From self pressure reducing valve : To service valve : To service valve : To tank
1. 2. 3. 4. 5. 6. 7. 8.
Spool Piston Lever Plate Retainer Block Body EPC valve

Unit: mm
No.
Remedy
Centering spring
Free length Installation Installation Installation Outside Free length length load load If damaged or diameter deformed, 125 N 100 N replace spring. 33.9 15.3 28.4 {12.7 kg} {10.2 kg} 22.7 8.10 22 .0 16.7 N {1.70 kg} 13.3 N {1.36 kg}
10 Metering spring
PC138US, USLC-8
15
SEN02550-01
1. EPC valve
C: P: T: 1. 2.
To control valve From self pressure reducing valve To hydraulic tank Body Plug
3. 4. 5. 6. 7.
Spool Push pin Coil Plunger Connector
Unit: mm No. Check item Standard size 8 Return spring Free length 9.0 Criteria Repair limit Remedy
If damaged or Installation Installation Installation Free length deformed, length load load replace EPC 3.1 N valve assembly. 8.4 {0.32 kg}
16
PC138US, USLC-8
SEN02550-01
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the control valve.
Operation
1) When signal current is 0 (coil is de-energized)

q
q q q
When there is no signal current flowing from the controller to coil (14), coil (14) is de-energized. Spool (11) is pushed to the right by spring (12). Port (P) closes and the pressurized oil from the front pump does not flow to the control valve. The pressurized oil from the control valve is drained to the tank via port (C) and port (T).
PC138US, USLC-8
17
SEN02550-01
2) When signal current is very small (coil is energized)

q
3) When signal current is maximum (coil is energized)

q q
q q
When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated on the left side of plunger (6). Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port (P) to port (C). Pressures on port (C) increases and the force to act on surface (a) of spool (2) and the spring load on spring (3) become larger than the propulsion force of plunger (6). Spool (2) is pushed to the right, port (P) is shut off from port (C) and ports (C) and (T) are connected. Spool (2) moves up and down so that the propulsion force of plunger (6) may be balanced with pressure of port (C) + spring load of spring (3). The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current.
q q
As the signal current flows to coil (5), coil (5) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. Spool (2) is pushed to the left by push pin (4). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and the control valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the hydraulic tank.
18
PC138US, USLC-8
SEN02550-01
Swing motor
Type: KMF45ABE-5
B: From swing holding brake solenoid valve MA: From control valve MB: From control valve S: From control valve T: To tank 1. 2. Reverse prevention valve Safety valve
Specifications Type Theoretical displacement Safety valve set pressure Rated speed Brake release pressure
: KMF45ABE-5 : 143.8 cm/rev : 27.1 MPa {276 kg/cm} : 2,111 rpm : 1.1 MPa {11 kg/cm}
PC138US, USLC-8
19
SEN02550-01
20
PC138US, USLC-8
SEN02550-01
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

No.
Brake spring Drive shaft Spacer Case Disc Plate Brake ring Brake piston Housing Piston Cylinder block Valve plate Center shaft Center spring Check valve Shuttle valve
Unit: mm Check item Standard size Criteria Repair limit Remedy
Free length Installation Installation Installation Outside Free length length load load If damaged or diameter deformed, 6.96 N 5.59 N replace spring. 66.5 25.6 45.0 {0.71 kg} {0.57 kg} 24.5 11.6 14.5 7.45 N {0.76 kg} 5.98 N {0.61 kg}
18 Shuttle valve spring
PC138US, USLC-8
21
SEN02550-01
Swing holding brake

1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation q As the swing holding brake solenoid valve is de-energized, the pressurized oil from the self pressure reducing valve is shut off. q Port (B) is connected to tank circuit (T). q Brake piston (8) is pushed down by brake spring (1). q Disc (5) and plate (6) are pushed together, and the brake is applied.
Operation q As the swing holding brake solenoid valve is energized, the valve is switched. q The pressurized oil from the self pressure reducing valve is conducted brake chamber (a) via port (B). q After entering chamber (a), the pressurized oil compresses brake spring (1) and pushes brake piston (8) up. q Disc (5) is separated from plate (6), releasing the brake.
22
PC138US, USLC-8
SEN02550-01
Relief valve portion

Outline q The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function q When the machine is in the swing holding mode, control valve (6) closes the motor outlet circuit, but the motor rotation is continued by inertial force. q The motor output, therefore, is abnormally increased, resulting in damaging the motor. q In order to prevent the motor damages, the relief valve relieves the abnormally high pressure to port (S) from the motor outlet side (high-pressure side) of the motor. Operation 1. When starting swing q When the swing control lever is operated to the right- swing, the pressurized oil from the pump is supplied to port (MA) via control valve (6). q The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. q The pressurized oil from the outlet port of the motor passes from port (MB) through the control valve (6) and returns to the tank. 2.
q
q q q
q q
When swing is stopped When the swing control lever is returned to neutral, the supply of pressurized oil from the pump to port (MA) is stopped. The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (6). Thus, pressure on port (MB) increases. Rotation resistance is generated on the motor and hence the brake starts working. Shuttle valve (4) is pressed as pressure on port (MB) goes above port (MA). The pressure on chamber (C) is increased to the se t pr es sur e of r el ief va lv e ( 1) an d becomes the same as that of port (MB). A high braking torque works on the motor, thereby stopping the motor. When relief valve (1) is being actuated, the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) via check valve (3). Above prevents cavitation on port (MA).
PC138US, USLC-8
23
SEN02550-01
Reverse prevention valve
24
PC138US, USLC-8
SEN02550-01
MA: MB: T1: T2:
From control valve From control valve To tank To tank
1. 2. 3. 4. 5. 6. 7.
Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)
Explanatory drawing of effects
PC138US, USLC-8
25
SEN02550-01
Function q This valve reduces the swing back generation in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. q The valve contributes in preventing collapsing of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, enabling you to proceed to the next work quicker than ever). Operation 1.
q q
2.
q
q q
q q
q q
When port (MB) brake pressure is generated Pressure (MB) is conducted to chamber (d) via notch (g). The pressure compresses spring (6) by use of the difference in areas of circles (D1 > D2) of spool (5) and moves spool (5) to the left side. Port (MB) o chamber (e) will be interconnected. Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is kept in. Thus the braking force is ensured.
When motor is stopped temporarily The motor rotation is reversed by the closing pressure generated at port (MB). (1st time: reverse rotation) Reversing pressure is generated on port (MA). Pressure (MA) is conducted to chamber (a). The pressure compresses spring (3) by use of the difference in areas of circles (D3 > D4) of spool (2) and moves spool (2) to the right side. Port (MA) o chamber (b) will be interconnected. Ports (b) and (f) will be interconnected through the drilled hole (h) on spool (5). This interconnection bypasses the reversing pressure on port (MA) to port (T), thereby preventing the reverse rotation of the 2nd time.
26
PC138US, USLC-8
SEN02550-01
Travel motor
A:
B:
D: P: 1. 2. 3.
From center swivel joint, port B2 (L.H. travel motor) From center swivel joint, port C2 (R.H. travel motor) From center swivel joint, port D2 (L.H. travel motor) From center swivel joint, port A2 (R.H. travel motor) To center swivel joint, port DR2 From center swivel joint, port E2 Oil filler plug Oil level plug Drain plug
PC138US, USLC-8
27
SEN02550-01
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Plug Check valve Counterbalance valve Sleeve Relief valve End cover Brake piston Disc Plate Swash plate Pivot Bearing Hub Planetary pinion B Planetary pinion A
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Cover Sun gear A Carrier A Sun gear B Carrier B Regulator piston Shaft Piston Floating seal Spindle Cylinder Timing plate Regulator valve Check valve Piston
28
PC138US, USLC-8
SEN02550-01
Specifications
Type Stroke volume (cm/rev) Rated speed (rpm) Brake releasing pressure (MPa{kg/cm}) Hi-Lo switching pressure (MPa{kg/cm}) Reduction ratio Hi Lo Hi Lo GM21VA-A 44.2 79.1 2,609 1,486 0.76 {7.71} 2.94 {30} 54.0
Outline
1.
Final drive Consists of 2-stage planetary gear mechanism. Reduces the hydraulic motor speed from high speed to low speed high torque. Hydraulic motor Swash plate type axial piston motor mechanism. Converts oil pressure from the hydraulic pump into rotary motion. Brake valve Consists of various valves. Provides the following functions: stops the hydraulic motor smoothly, prevents runway of hydraulic motor, prevents generation of abnormally high pressure when the hydraulic motor is stopped suddenly.
4.
2nd travel speed selector mechanism Consists of the regulator valve and regulator piston. Changes the rotation speed in 2 stages by changing the stroke volume of the hydraulic motor. Parking brake Multiple disc type brake mechanism. Forms a unit with the hydraulic motor.
2.
5.
3.
PC138US, USLC-8
29
SEN02550-01
Operation Operation of motor At low speed (the motor swash plate angle is maximized.)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
2nd travel speed select solenoid valve Regulator valve Spring Check valve Regulator piston Swash plate Parking brake piston Hydraulic pump Travel control valve Pump merge-divider valve Self pressure reducing valve Brake valve
q q
Since 2nd travel speed select solenoid valve (1) is de-energized, the pressurized oil from self pressure reduction valve (11) is not fed to port (P). Regulator valve (2) is pushed down with spring (3) reaction force. The main pressurized oil, sent from the control valve through check valve (4), is controlled by regulator valve (2) and used to shuts off the circuit to regular piston (5). The pressurized oil in control chamber (C) is drained from port (D) through oil passage (e) of regulator valve (2). Swash plate (7) reaches its maximum tilt angle, and the machine travels at low speed with the maximum motor capacity.
30
PC138US, USLC-8
SEN02550-01
At high speed (the motor swash plate angle is minimized.)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
2nd travel speed select solenoid valve Regulator valve Spring Check valve Regulator piston Swash plate Parking brake piston Hydraulic pump Travel control valve Pump merge-divider valve Self pressure reducing valve Brake valve
q q
When 2nd travel speed select solenoid valve (1) is energized, the pressurized oil from self pressure reduction valve (11) is fed to port (P). Regulator valve (2) is pushed up with the pressurized oil that is sent to port (P). The main pressurized oil from the control valve passes through check valve (4), and passes through oil passage (F) in regulator valve (2) to control chamber (C), and is used to push to regular piston (5) to the left. Swash plate (7) reaches its minimum tilt angle, and the machine travels at high speed with the minimum motor capacity.
PC138US, USLC-8
31
SEN02550-01
Brake valve Operation when pressure oil is supplied Operation when pressure is shut off
When the travel lever is operated, the pressurized oil from the control valve is fed to port (A) and check valve (1) is opened. The oil is further sent from port (C) to port (D) through the motor. At the same time, when the pressure of the hydraulic oil that entered in chamber (G) through orifice (f) exceeds spring (3) reaction force, counterbalance valve (2) moves to the right, opening ports (D) and (B), and the motor becomes ready to rotate. As ports (A) and (E) also open, parking brake piston (4) is pressed down by the hydraulic pressure. This releases the parking brake and the motor starts to rotate.
When the travel lever is returned to its neutral position, the hydraulic oil circuit from the control valve is closed. And counterbalance valve (2) starts to return to the left by spring (3) reaction force. The hydraulic oil in chamber (G) tends to flow to port (A) through orifice (f). However, the back pressure is generated by closing of orifice (f), controlling the return speed of counterbalance valve (2) to the right. The motor tends to rotate by inertia even when the hydraulic oil from the control valve is stopped.During this time, the oil return circuit is gradually closed by controlling the movement speed of counterbalance valve (2) and by using its cutout portion. By this, the motor is smoothly stopped.
32
PC138US, USLC-8
SEN02550-01
Brake operation at travelling downhill
If the machine is going to run away when traveling downhill, the motor idles and the hydraulic pressure at port (C) drops. The pressure of hydraulic oil that is sent to chamber (G) through orifice (f) also drops. When the hydraulic oil pressure in chamber (G) goes below spring (3) reaction force, counterbalance valve (2) starts to return to the left. The hydraulic oil in chamber (J) tends to flow to port (B) through orifice (h). However, the back pressure is generated by closing of orifice (h), controlling the return speed of counterbalance valve (2) to the right. When ports (D) and (B) are closed and when the hydraulic pressure at port (D) increases, a resistance is generated in motor rotation to protect the machine from running away. Counterbalance valve (2) is moved to the position where the hydraulic pressure at port (B) is well balanced with the pressure by the weight of machine itself and the pressure at port (A). The motor speed is controlled according to the pump delivery by controlling the opening of hydraulic oil output circuit.
PC138US, USLC-8
33
SEN02550-01
Relief valve When starting When stopping
The pressurized oil from the control valve is fed from port (A) to port (C). As port (C) is connected to the motor, the pressure drives the motor to rotate. When the hydraulic pressure at port (C) exceeds the specified value, relief valve (1a) is pushed up and the hydraulic oil is fed to port (D).However, relief valve (1b) is kept closed independent from the hydraulic pressure at port (C). The hydraulic oil is fed from port (C) to chamber (E) through the oil passages of relief valve (1a) and sleeve (2a). By this pressure, piston (3) is moved to the right. When piston (3) reaches its stroke end position, the hydraulic pressure from relief valve (1a) to chamber (E) increases. Therefore, ports (C) and (D) are closed by relief valve (1a). The hydraulic pressure at port (C) at the inlet side is controlled so that the motor is smoothly started to rotate.
When the hydraulic oil from the control valve is stopped, ports (A) and (C) are closed. At the same time, ports (D) and (B) are closed, but the motor continues to rotate by the inertia. When the hydraulic pressure at port (D) exceeds the specified value, relief valve (1b) is pushed up and the hydraulic oil is fed to port (C).The hydraulic pressure applied to port (D) at the outlet side is fed to port (C) at the inlet side, and it is used to prevent the oil cavitation. The hydraulic oil from port (D) passes through the oil passages of relief valve (1b) and sleeve (2b), and sent to chamber (F). By this pressure, piston (3) is moved to the left. When piston (3) reaches its stroke end position, the hydraulic pressure from relief valve (1b) to chamber (F) increases. Therefore, ports (D) and (C) are closed by relief valve (1b). The hydraulic pressure at port (D) at the outlet side is controlled so that the motor is smoothly stopped.
34
PC138US, USLC-8
SEN02550-01
PC138US, USLC-8
35
SEN02550-01
Center swivel joint

Standard specification
A1: B1: C1: D1: E1: DR1: 1. 2. 3.
From control valve (R.H. travel FORWARD) From control valve (L.H. travel FORWARD) From control valve (R.H. travel REVERSE) From control valve (L.H. travel REVERSE) From 2nd travel speed select solenoid valve To hydraulic tank
A2: B2: C2: D2: E2: DR2: 4. 5.
To R.H. travel motor port B To L.H. travel motor port A To R.H. travel motor port A To L.H. travel motor port B To L.H. and R.H. travel motor port P From L.H. and R.H. travel motor port D
Cover Body Slipper seal
O-ring Shaft
36
PC138US, USLC-8
SEN02550-01
Unit: mm No. 1 Item Clearance between rotor and shaft Standard size 80 Criteria Standard clearance 0.056 0.105 Clearance limit 0.111 Remedy Replace
PC138US, USLC-8
37
SEN02550-01
Blade specification (if equipped)
A1: B1: C1: D1: E1: F1: G1: DR1: 1. 2. 3.
From control valve (R.H. travel REVERSE) From control valve (L.H. travel FORWARD) From control valve (R.H. travel FORWARD) From control valve (L.H. travel REVERSE) From 2nd travel speed select solenoid valve From control valve (blade LOWER) From control valve (blade RAISE) To hydraulic tank
A2: B2: C2: D2: E2: F2: G2: DR2: 4. 5.
To R.H. travel motor port A To L.H. travel motor port A To R.H. travel motor port B To L.H. travel motor port B To L.H. and R.H. travel motor port P To L.H. and R.H. blade cylinder bottom To L.H. and R.H. blade cylinder head From L.H. and R.H. travel motor port D
Cover Body Slipper seal
Dust seal Shaft
38
PC138US, USLC-8
SEN02550-01
Unit: mm No. 1 Item clearance between rotor and shaft Standard size 80 Criteria Standard clearance 0.056 0.105 Clearance limit 0.111 Remedy Replace
PC138US, USLC-8
39
SEN02550-01
Solenoid valve
40
PC138US, USLC-8
SEN02550-01
P1 A1 A2 A3 A4 A5 T ACC 1. 2. 3. 4. 5.
: From self pressure reducing valve : To PPC valve : To center swivel joint, port E1 : To swing motor, port B : To control valve, port PS : To control valve, port PST : To hydraulic tank : To accumulator (for PPC circuit)
Operation Check valve
PPC lock solenoid valve 2nd travel speed select solenoid valve Swing holding brake solenoid valve Pump merge-divider solenoid valve Travel junction solenoid valve
Solenoid valve 6. Coil (ON/OFF type) 7. Push pin 8. Valve spool 9. Sleeve 10. Block 11. Plug Check valve 12. Plunger 13. Plug
Installed between port (P) and PPC solenoid valve. When the engine is stopped, plunger (1) is pushed back to the left with spring (2) reaction force, and ports (ACC) and (P) are closed to maintain the pressure in the accumulator. When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P), and ports (P) and (ACC) are interconnected.
PC138US, USLC-8
41
SEN02550-01
Solenoid valve When solenoid valve is de-energized (circuit is closed) When solenoid valve is energized (circuit is connected)
q q q
Coil (1) is de-energized when no signal current is supplied to coil (1). Spool (2) is pushed back to the left with spring (3) reaction force. As ports (P) and (A) are closed, the pilot pressure is not fed to the actuator through port (A). At the same time, port (T) is opened, allowing the oil from the actuator to drain to the hydraulic tank.
q q q
Coil (1) is energized when signal current is supplied to coil (1). Spool (2) is pushed to the right with push pin (4). As ports (P) and (A) are opened, the pilot pressure is fed to the actuator through port (A). At the same time, port (T) is closed, shutting off the oil from the actuator to the hydraulic tank.
42
PC138US, USLC-8
SEN02550-01
PC138US, USLC-8
43
SEN02550-01
PPC accumulator
For PPC circuit 1. 2. 3. 4. 5. 6. Gas plug Shell Poppet Holder Bladder Oil port
Outline q Mounted on the solenoid valve. If the engine is stopped with the work equipment is kept at an elevated position, the pilot pressure is supplied to the control valve by the pressure of the compressed nitrogen gas in the accumulator. Therefore, the spool can be operated to lower the work equipment by its own weight. Specifications Gas to be used: Nitrogen gas Gas capacity: 300 cc Sealed gas pressure: 1.18 MPa {12 kg/cm} (at 80C) Maximum operating pressure: 6.86 MPa {70 kg/cm}
44
PC138US, USLC-8
SEN02550-01
For breaker (Machine ready for attachment) For low pressure
For high pressure
1. 2. 3. 4. 5. 6. 7.
Cap Core Guard rubber Ring Lid Bladder Shell
1. 2. 3. 4. 5. 6.
Cap Core Locknut Gas port Bladder Shell
Outline q Connected to the attachment piping. When the breaker operates, the oil pulsation is absorbed by the pressure of compressed nitrogen gas of the accumulator, to protect the hydraulic system devices and piping. Specifications Gas to be used: Nitrogen gas Gas capacity: 480 cc Sealed gas pressure: 0.1 MPa {1 kg/cm} (at 80C) Maximum operating pressure: 0.69 MPa {7 kg/cm}
Outline q Connected to the attachment piping. When the breaker operates, the oil pulsation is absorbed by the pressure of compressed nitrogen gas of the accumulator, to protect the hydraulic system devices and piping. Specifications Gas to be used: Nitrogen gas Gas capacity: 500 cc Sealed gas pressure: 5.88 MPa {60 kg/cm} (at 80C) Maximum operating pressure: 20.6 MPa {210 kg/cm}
PC138US, USLC-8
45
SEN02550-01
Holding valve
(For boom and arm)
46
PC138US, USLC-8
SEN02550-01
CY : To work equipment cylinder PCY: For pressure pickup port and equalizer circuit PI : From PPC valve T : To tank V : From control valve 1. 2. 3.
No.
Pilot spool Safety valve Check valve

Unit: mm Check item Standard size Criteria Repair limit Free length Installation Installation Installation Outside Free length length load load diameter 20.8 12.2 13.5 35.0 41.0 12.7 N {1.3 kg} 58.8 N {6.0 kg} 78.5 N {8.0 kg} 10.2 N {1.04 kg} 47.1 N {4.8 kg} 62.8 N {6.4 kg} Remedy
Check valve spring
If damaged or deformed, replace spring.
5 6
Spool return spring Spool return spring
41.1 9.6 41.9 25.8
PC138US, USLC-8
47
SEN02550-01
Function q Prevents the pressurized oil from reversing from the work equipment cylinder in order to prevents sudden drift of the work equipment at breaking of the piping between the control valve and the work equipment cylinder. Operation 1. When the work equipment lever is in neutral When the piping is free of breakage Check valve (5) is closed under the holding pressure of the cylinder led from port (CY) to chamber (b). q At the neutral, pilot pressure led to port (PI) from the PPC valve is 0 MPa {0 kg/cm}. q Spool (1) is pressed to the left by the force of springs (2) and (3). q Chambers (a) and (b) are shut off. q No pressurized oil flows between the control valve and the work equipment cylinder. q Accordingly, the work equipment is held in position. q If the work equipment cylinder has abnomally high pressure, safety valve (4) is actuated by the holding pressure of the work equipment cylinder. q Chambers (b) of L.H. and R.H. holding valve for the boom are interconnected by port (PCY). q Chambers (b) will have the same pressure if the L.H. and R.H. holding valves have a difference in leakage.
q
If the piping is bursted q If piping (A) is broken between the control valve and the work equipment cylinder, chambers (a) and (b) are shut off in the same way as the piping is free from damages. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment.
48
PC138US, USLC-8
SEN02550-01
2.
When pressurized oil flows from the main valve to the cylinder
When the piping is free of breakage q Pressurized oil led to chamber (a) from the control valve becomes higher than the combined force of pressure from work equipment cylinder circuit chamber (b) and spring (6). q Check valve (5) opens and chambers (a) and (b) are interconnected. q Pressurized oil flows from the control valve to the work equipment cylinder. If the piping is bursted If piping (A) between the control valve and the work equipment cylinder is broken, pressurized oil in chamber (a) flows outside from the damaged portion. q Pressure force in chamber (a) drops. q Pressure force in chamber (a) drops lower than the combined pressure force of chamber (b) and spring (6). q Check valve (5) closes and chambers (a) and (b) are cut off. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment.
q
PC138US, USLC-8
49
SEN02550-01
3.
When returning pressurized oil to the main valve from the work equipment cylinder If the piping is bursted q If piping (A) bursts between the control valve and the work equipment cylinder. q Pressurized oil in chamber (a) flows out to the bursted portion but resupplied from chamber (b). q Since pressurized oil flows via opening (c) of spool (1), a sudden drop of the cylinder is prevented.
When the piping is free of burst q Holding pressure of the work equipment cylinder is led to chamber (b) and check valve (5) closes. q Pilot pressure from the PPC valve is led to port (PI) and reaches [Pilot Pressure > Force of Spring (3)] (area of d). q Spool (1) moves to the right to the standby position.(1st stage stroke) q At this point, chambers (a) and (b) are not interconnected. q Pilot pressure further rises, and reaches [Pilot pressure > Force of spring (2)] (area of d). q Spool (1) moves further to the right, and chambers (a) and (b) are interconnected. (2nd stage stroke) q Pressurized oil returns to the control valve from the work equipment cylinder.
50
PC138US, USLC-8
SEN02550-01
Multi-control valve
(if equipped)
(1) JIS pattern
(2) Backhoe pattern
Control pattern switching diagram (Port names correspond to the marks on the above figures.)
PC138US, USLC-8
51
SEN02550-01
52
PC138US, USLC-8
SEN02551-00
Machine model
Serial number

Work equipment
Work equipment .............................................................................................................................................. 2 Dimensions of components............................................................................................................................. 4 Hydraulic cylinder............................................................................................................................................ 8
PC138US, USLC-8
SEN02551-00
Work equipment
Unit: mm No. Item Clearance between mounting pin and bushing of boom and revolving frame Clearance between mounting pin and bushing of boom and arm Clearance between mounting pin and bushing of arm and bucket Clearance between mounting pin and bushing of arm and link Clearance between mounting pin and bushing of link and link Clearance between mounting pin and bushing of link and bucket Clearance between mounting pin and bushing of blade and track frame Standard size 70 Shaft -0.030 -0.100 -0.030 -0.100 -0.030 -0.080 -0.030 -0.080 -0.030 -0.080 -0.030 -0.080 -0.030 -0.100 Criteria Tolerance Hole +0.143 +0.063 +0.145 +0.065 +0.129 +0.074 +0.133 +0.075 +0.132 +0.075 +0.130 +0.078 +0.190 +0.090 Standard clearance 0.093 0.245 0.095 0.245 0.104 0.209 0.105 0.213 0.105 0.212 0.108 0.210 0.120 0.290 Clearance limit 0.8 Remedy
70
0.8
60
0.8 Replace pin and bushing 0.8 0.8
4 5
60 65
60
0.8
70
1.5
PC138US, USLC-8
SEN02551-00
PC138US, USLC-8
SEN02551-00
Dimensions of components
Arm
PC138US, USLC-8
SEN02551-00
Unit: mm PC138US-8, PC138USLC-8 No. Measurement point Arm side Cylinder head side Boom side 3 Arm side 4 5 6 7 8 9 10 11 12 13 14 15 Link side Bucket side 17 Arm side 18 Bucket side 19 Min. Max. 274 1,378 2,263 226 70 264 213.5 640.6 2,491 2,101.9 290.4 487 415 374.9 1,241.3 60 259 261 60 226 -0.030 -0.080 0 -0.5 +2.0 0 -0.030 -0.080 0 -1.0 1.0 +0.200 0 -0.030 -0.100 2.0 1.0 0.5 1.5 0.5 0.2 0.5 +0.200 0 Standard size 70 81.5 80 226 Tolerance Shaft -0.030 -0.100 +1.0 0 1.2 +0.5 0 -0.2 -0.7 +0.100 0 Hole +0.100 0
16
PC138US, USLC-8
SEN02551-00
Bucket
PC138US, USLC-8
SEN02551-00
Unit: mm No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 PC138US-8, PC138USLC-8 Measurement point Standard size 371.3 51.6 97.9 374.9 1,226.6 190.2 5 0 60 64 80 261 50 85 380 18 110 130 132 108 274 51 34 100.5 115.3 74 65 Tolerance 0.5 0.5 +0.2 0 +0.25 0 1.0 +1.0 0 +2.0 0
PC138US, USLC-8
SEN02551-00
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
PC138US, USLC-8
SEN02551-00
Blade cylinder
Unit: mm No. Item Cylinder name Boom 1 Clearance between piston rod and bushing Arm Bucket Blade Boom Clearance between piston rod support shaft and bushing Arm Bucket Blade Boom Clearance between cylinder bottom support shaft and bushing Arm Bucket Blade Standard size 70 75 65 75 70 70 65 70 70 70 65 70 Shaft -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.100 -0.030 -0.100 -0.030 -0.080 -0.030 -0.100 -0.030 -0.100 -0.030 -0.100 -0.030 -0.080 -0.030 -0.100 Criteria Tolerance Hole +0.259 +0.063 +0.279 +0.065 +0.250 +0.055 +0.279 +0.065 +0.190 +0.090 +0.190 +0.090 +0.170 +0.070 +0.190 +0.090 +0.190 +0.090 +0.190 +0.090 +0.170 +0.070 +0.190 +0.090 Standard clearance 0.093 0.335 0.095 0.355 0.085 0.326 0.095 0.355 0.120 0.290 0.120 0.290 0.100 0.250 0.120 0.290 0.120 0.290 0.120 0.290 0.100 0.250 0.120 0.290 Clearance limit 0.435 0.455 0.426 0.455 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Replace bushing Remedy
PC138US, USLC-8
SEN02551-00
10
PC138US, USLC-8
SEN02552-01
Machine model
Serial number

Cab and its attachments
Air conditioner ................................................................................................................................................. 2
PC138US, USLC-8
SEN02552-01
Air conditioner
Air conditioner piping diagram
PC138US, USLC-8
SEN02552-01
A: B: C: D: E: F: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Front warm/cool air outlet Rear warm/cool air outlet Foot warm/cool air outlet Defroster warm/cool air outlet Internal air flow outlet External air flow outlet Sunlight sensor Machine monitor Refrigerant piping Compressor Condenser (with built-in receiver) Air conditioner controller Sight glass External air filter Air conditioner unit Internal air filter Dual pressure switch Hot water take-out piping Ambient temperature sensor Hot water return piping
Dual pressure switch q If abnormally low or high pressure was generated in the refrigerant circulation circuit, this switch releases the magnet clutch of the compressor to protect a series of cooler-related equipment. High-pressure OFF: 3.14 0.20 MPa {32 2 kg/cm} Low-pressure OFF: 0.20 0.02 MPa {2 0.2 kg/cm}
Specifications
Refrigerant to be used Refrigerant capacity (g) R134a 800
PC138US, USLC-8
SEN02552-01
1. 2. 3.
Engine Compressor Condenser 3a. Receiver 4. Sight glass 5. Air conditioner unit 6. Dual pressure switch Table of tightening torque for refrigerant piping adapter
Unit: Nm{kgm} No. 7 8 9 Item Compressor refrigerant piping lock bolt Condenser refrigerant piping lock bolt Air conditioner unit refrigerant piping connector lock bolt Criteria 7.85 11.8 {0.8 1.2} (Screw size: M6 1.0) 3.92 6.86 {0.4 0.7} (Screw size: M6 1.0) 7.85 11.8 {0.8 1.2} (Screw size: M6 1.0) Retighten Remedy
PC138US, USLC-8
SEN02552-01
PC138US, USLC-8
SEN02552-01
Air conditioner unit
PC138US, USLC-8
SEN02552-01
A: B: C: D: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
From condenser To compressor Hot water inlet Hot water outlet Evaporator Heater core Expansion valve Blower motor Air mix damper actuator Air mix damper Mode selector damper actuator Mode selector damper Internal/external air changeover damper actuator Internal/external air changeover damper Power transistor Evaporator temperature sensor Internal air temperature sensor Internal air filter
Outline q The horizontal air conditioner unit on which evaporator (1) and heater core (2) is arranged in parallel. Blower motor (4) is driven to to generate cool and hot air. q Selecting the temperature on the machine monitor controls air mix damper (6) to adjust the spurting out temperature. Cooler The cooler circulates refrigerant through evaporator (1) to cause heat exchange (dehumidification and cooling). q Air taken in by blower motor (4) is cooled with evaporator (1) and then blown out from the duct and grill.
q
Heater q The heater circulates engine coolant in heater core (2) to cause heat exchange (heating). q Air taken in by blower motor (4) is heated with heater core (2) and then blown out through the duct and grill.
PC138US, USLC-8
SEN02552-01
Functions of major components Evaporator q Evaporator fin is cooled by the low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air from the blower motor is cooled and dehumidified when passing through the fin. Heater core Fin of the heater core is heated by the hot water (coolant) being sent from the engine. Air from the blower motor is heated as it passes through the fin.
Internal/external air changeover damper actuator q It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the internal/external air flow selector damper through the link mechanism. q The motor rotating direction is determined by selecting internal/external air flow on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned OFF. Evaporator temperature sensor In order to prevent freezing of the evaporator, it senses the evaporator temperature and sends necessary signals to the air conditioner controller.The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.
Expansion valve q This valve converts high-pressure, high-temperature liquid refrigerant from the condenser to low-pressure, low-temperature misty refrigerant through the throttling function. It controls flow rate of refrigerant by changing level of throttling depending on the thermal load in the operator's cab. Blower motor It suctions air by rotating the fin installed on the blower motor. And it is also used for sending air to the evaporator and heater core.
Air mix damper actuator q It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the air mix damper through the link mechanism. q The motor rotating direction is determined as the air conditioner controller reads the position of the potentiometer being built in the actuator. This reading is done as the target temperature is set on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned OFF. Mode selector damper actuator It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the mode selector damper through the link mechanism. q The motor rotating direction is determined as the air conditioner controller reads the position of the potentiometer being built in the actuator. This reading is done as the mode is selected on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned OFF.
q
Internal air temperature sensor q It senses the internal air temperature and sends necessary signals to the air conditioner controller.The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.
PC138US, USLC-8
SEN02552-01
Air conditioner controller
Input and output signals

AMP040-36P Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NC Air mix dumper actuator potentiometer signal Actuator potentiometer power supply Dual pressure switch NC Back-up power supply Blower feedback signal Power transistor control signal Mode selector actuator potentiometer signal NC Internal air temperature sensor Evaporator temperature sensor External air temperature sensor NC Sunlight sensor GND Signal name Input and output signals Input Output Input Input Input Output Input Input Input Input Input Output Pin No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 CAN_H CAN_L Internal/external air changeover dumper actuator (A) Internal/external air changeover dumper actuator (B) Air mix dumper actuator (A) Air mix dumper actuator (B) Mode selector actuator (A) Mode selector actuator (B) Relay power supply NC GND (sensor) NC NC Test terminal RAM monitor (for switching display) RAM monitor I/F RAM monitor output NC Compressor clutch relay Blower main relay Signal name Input and output signals Input/ output Input/ output Output Output Output Output Output Output Output Input Input Input
PC138US, USLC-8
SEN02552-01
Compressor
A: B:
From air conditioner unit To condenser
Function q Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator to high-pressure, high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature. q Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure. Specifications
Number of cylinders - bore x stroke (mm) Piston capacity (cc/rev) Allowable maximum speed (rpm) Refrigerant oil to be used Refrigerant oil capacity (cc) 10-32 x 20.8 129.2 6,000 Denso: ND-OIL 8 180
10
PC138US, USLC-8
SEN02552-01
Condenser
A: B: 1. 2.
From compressor To air conditioner unit Core Receiver
Specifications
Fine pitch (mm) Total heat dissipation surface (m) Max. pressure used (MPa{kg/cm}) Weight of desiccating agent (g) 4.0 3.58 3.53 {36} 290
Function q It cools and liquefies the high-pressure and high-temperature misty refrigerant from the compressor. q The receiver holds high-pressure, high-temperature liquid refrigerant.It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent.
a
If the fin crushes or is clogged with dusts, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.
PC138US, USLC-8
11
SEN02552-01
Sensor
Sunlight sensor
External air temperature sensor
Outline q The sunlight sensor is installed on top of the machine monitor of the air duct. q It senses intensity of the sun light and sends signals to the air conditioner controller. The signal sent to the air conditioner controller is used to control the blower motor and compressor. Output characteristics
Outline q The external air temperature sensor is installed in the battery room at the rear left of the machine. q It senses the external air temperature and sends signals to the air conditioner controller. The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.
12
PC138US, USLC-8
SEN02552-01
PC138US, USLC-8
13
SEN02552-01
14
PC138US, USLC-8
SEN02553-01
Machine model
Serial number

Electrical system
Electronic control system ................................................................................................................................ 2 Monitor system.............................................................................................................................................. 35 KOMTRAX system........................................................................................................................................ 49 Sensor........................................................................................................................................................... 51
PC138US, USLC-8
SEN02553-01
Electronic control system

Machine control system diagram
PC138US, USLC-8
SEN02553-01
PC138US, USLC-8
SEN02553-01
Engine control function
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Battery Battery relay Fusible link Fuse box Starting switch Engine controller Lock lever PPC lock switch Starting motor cut-out relay (for PPC lock) Starting motor cut-out relay (for personal code) Fuel control dial Safety relay Starting motor Fuel supply pump Sensors Engine controller power cut-off relay A Engine controller power cut-off relay B Machine monitor KOMTRAX terminal
Function 1. The neutral safety circuit is employed to secure safety when the engine is started. q The engine does not start until the lock lever is set in the LOCK position. The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX terminal receives an engine cut command issued through external operation.
2.
PC138US, USLC-8
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Starting engine q When starting switch (5) is turned ON, engine controller (6) sends command current to fuel supply pump (14). For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an electrical failure occurs. q When starting switch (5) is turned to START with lock lever (7) set in the LOCK position, a starting current is supplied to starting motor (13) causing the engine to start. However, as the neutral safety mechanism is provided, the engine will not start if lock lever (7) is set in the FREE position at this time; starting motor cut-out relay (9) cuts off the starting current to starting motor (13). q Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the signal to machine monitor (18). Machine monitor (18) causes starting motor cut-out relay (10) to cut off the starting current to starting motor (13), therefore the engine does not start. Engine speed control Upon receipt of a fuel control dial (11) control signal, engine controller (6) sends a command current to fuel supply pump (14) to adjust the fuel injection amount to control the engine speed.
Stopping engine q When starting switch (5) is turned OFF, the current from the ACC terminal of starting switch (5) to engine controller (6) is cut off, and consequently the command current to fuel supply pump (14) is cut off. Fuel supply pump (14) stops fuel feed, causing the engine speed to go down and the engine stops.
PC138US, USLC-8
SEN02553-01
Pump and engine mutual control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Fuel supply pump 12. Sensors 13. Pump oil pressure sensor 14. Oil pressure sensor 15. Oil pressure switch 16. Hydraulic pump 16a. Servo 16b. LS valve 16c. PC valve 17. Control valve 17a. Pump merge-divider valve 17b. Self pressure reducing valve 18. PC-EPC valve
Input and output signals a. Constant power supply b. CAN signal c. PC-EPC valve drive signal d. Solenoid valve GND e. Oil pressure sensor signal f. Oil pressure switch signal g. Throttle signal h. Fuel supply pump control signal i. Sensor signals
PC138US, USLC-8
SEN02553-01
Function q A function that selects working mode with the working mode selector switch in the machine monitor. 5 modes (P, E, L, ATT, B) are available, allowing the operator to select appropriate engine torque (T) and pump absorption torque depending on the work. In the default setting of the service mode, only 3 modes (P, E, L) are available in which Without is selected for the attachment. q According to the pump absorption torque set at each mode, based on the engine governor set speed with the fuel control dial and the actual engine speed, the controller controls so that the pump absorbs all torques at each engine output point. q When the engine speed is lowered, the controller prevents the engine from stopping by throttling the pump absorption torque.
PC138US, USLC-8
SEN02553-01
Control method in each mode P mode, E mode, and ATT mode q Matching point:
Working mode Travel P, ATT Working (At arm digging) Working (Except arm digging) E
q
Matching point 68.4 kW/2,200 rpm {91.7 HP/2,200 rpm} 64.4 kW/2,050 rpm {86.4 HP/2,050 rpm} 66.3 kW/2,050 rpm {88.9 HP/2,050 rpm} 60.0 kW/1,980 rpm {80.5 HP/1,980 rpm}
In P, E, or ATT mode, engine speed is always controlled so that it is kept around the matching point specified for each mode. When a load to the pump increases and the pressure rises, the engine speed (N) lowers. At the time, the controller reduces the pump delivery (Q) to increase the engine speed to the matching point. If the pressure drops, the controller increases the pump delivery to increase the engine speed to the matching point.
PC138US, USLC-8
SEN02553-01
Modes B and L
Working mode B L
q
Partial output 75% 70%
Matching point:
Working mode B L Matching point 50.9 kW/1,870 rpm {68.2 HP/1,870 rpm} 47.8 kW/1,640 rpm {64.1 HP/1,640 rpm}
q q
In B or L mode, engine output is controlled to a constant level. The controller controls the pump absorption torque to decrease the engine speed while keeping the engine torque at a constant level along the equal engine horsepower curve. The controller controls pump delivery (Q) so that the engine torque can be kept at a constant level along the equal engine horsepower curve.
PC138US, USLC-8
SEN02553-01
Control function during travel q Traveling the machine in P or ATT mode increases engine speed (N). q Traveling the machine in E, L or B mode does not change engine speed (N) or pump absorption torque.
Control function with emergency pump drive switch ON q If the controller gets out of order and no work is possible because the hydraulic pump does not work properly, operating emergency pump drive switch (1) temporarily enables to maintain functions of the machine with absorption torques quite similar to those in the Mode E. In this case, a constant current flows from the battery to the PC-EPC valve, and the valve detects the oil pressure only. a. Emergency b: Normal a Emergency pump drive switch (1) is of the alternative type. If the machine is operated after the switch is set to Emergency (a) even though the machine is normal, the user code E02 will be shown on the display.
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PC138US, USLC-8
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Auto-decelerator function
1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Fuel supply pump 6. Sensors 7. Oil pressure sensor 8. Oil pressure switch 9. Hydraulic pump 10. Control valve 10a. Pump merge-divider valve 10b. Self pressure reducing valve 11. PPC lock solenoid valve
Input and output signals a. CAN signal b. Oil pressure sensor signal c. Oil pressure switch signal d. Throttle signal e. Fuel supply pump control signal f. Sensor signals
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PC138US, USLC-8
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Function q When all the control levers are set to NEUTRAL for waiting for a dump track or work, the engine speed is automatically reduced to a control speed, and fuel consumption and noise are lowered. q When any control lever is operated, the engine speed returns immediately to the speed that is set with the fuel control dial. Operation When control levers are set in neutral q If all the control levers are set to NEUTRAL for 4 seconds or more with the engine speed exceeding approx. 1,400 rpm, the engine speed lowers down to the control speed (approx. 1,400 rpm) and is held until the control lever is operated again. When any control lever is operated With the engine speed at the control speed (approx. 1,400 rpm), when any control lever is operated, the engine speed increases immediately to the speed that is set with the fuel control dial.
A : All work equipment control levers in NATURAL B : All work equipment control levers OPERATED C: Fuel control dial set speed D: Engine control speed (approx. 1,400 rpm) E : 4 sec. F : Max. 2 sec. G: Max. 0.2 sec.
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Engine automatic warm-up function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Fuel supply pump 12. Sensors 13. Hydraulic oil temperature sensor 14. Hydraulic pump 14a. Servo 14b. LS valve 14c. PC valve 15. Control valve 15a. Pump merge-divider valve 15b. Self pressure reducing valve 16. PC-EPC valve
Input and output signals a. CAN signal b. PC-EPC valve drive signal c. Solenoid valve GND d. Hydraulic oil temperature signal e. Throttle signal f . Fuel supply pump control signal g. Sensor signals
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Function q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after start-up of the engine.
Operational conditions (all required)
Coolant temperature: Max. 30C Fuel control dial: Max. 70% of full rotation
Operation o
Engine speed: 1,300 rpm
O Release conditions (either one required)

Automatic Manual Coolant temperature: Min. 30C Duration of automatic warming-up: Min. 10 minutes Fuel control dial: Held at Min. 70% of full rotation for Min. 3 seconds
Release o
Engine speed: Any
Overheat prevention function

a
q
See Engine automatic warm-up function for system circuit diagram. Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil temperature becomes too high.
Operational conditions Operation and actions taken o Sends torque control signal to
lower the pump absorption torque and reduce the engine load. Engine speed: Remains same
Release conditions
Coolant temperature: Max. 95C
Working mode: P, ATT Coolant temperature: Min. 95C Hydraulic oil temperature: Min. 95C Traveling status check: OFF
o Hydraulic oil temperature: Max. 95C
The original conditions are restored if above requirements are met (automatic restoration).
Operational conditions
Working mode: P, ATT Coolant temperature: Min. 98C Hydraulic oil temperature: Min. 98C Traveling status check: ON
Operation and actions taken o Engine speed: Remains same

Travel speed: Down
Release conditions
Coolant temperature: Max. 98C
o Hydraulic oil temperature: Max. 98C
Working mode: P, ATT Coolant temperature: Min. 100C Hydraulic oil temperature: Min. 100C Traveling status check: Any
Operation and actions taken o Sends torque control signal to

lower the pump absorption torque and reduce the engine load. Engine speed: Remains same
Release conditions Coolant temperature: Max. 100C o Hydraulic oil temperature: Max. 100C
Working mode: P, ATT, E, B Coolant temperature: Min. 102C Hydraulic oil temperature: Min. 102C Traveling status check: Any
Operation and actions taken Engine speed: Remains same
Release conditions
Coolant temperature: Max. 102C Alarm monitor: ON o o Hydraulic oil temperature: Max. 102C The original conditions are restored if Sends torque control signal to above requirements are met (autolower the pump absorption torque matic restoration). and reduce the engine load.
Working mode: Any Coolant temperature: Min. 105C Hydraulic oil temperature: Min. 105C Traveling status check: Any
Operation and actions taken
Release conditions Coolant temperature: Max. 105C

Hydraulic oil temperature: Max. 105C o Fuel control dial: Returns to low idle (MIN) position. The original conditions are restored if above requirements are met (man-
o Engine speed: Low idle Alarm monitor: ON Alarm monitor: Sounds
ual restoration).
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Turbocharger protection function

a
q q
See Engine automatic warm-up function for system circuit diagram. When the engine is started at low temperatures and the engine speed is increased sharply, the turbocharger may be seized. Controlling the engine speed prevents this problem. Duration of engine speed control depends on the coolant temperature.
Operational conditions Operating o
Turbocharger protection (See the following figure)
Engine oil pressure: Max. 50 kPa {0.51 kg/cm2}
A: B: C: D: E: F:
Start engine Duration of turbocharger protection (approx. 0 20 sec) Modulating time (approx. 1.5 sec) 500 rpm 1,100 rpm 2,300 rpm (*1)
*1. Working mode: Mode P Fuel control dial: Full rotation (MAX) position Travel lever operated
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PC138US, USLC-8
SEN02553-01
Swing control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Swing holding brake release switch 6. Swing lock switch 7. Pump controller 8. Machine monitor 9. Oil pressure switch 10. Hydraulic pump 11. Control valve 11a. Pump merge-divider valve 11b. Self pressure reducing valve 12. Swing motor 13. Swing holding brake solenoid valve
Input and output signals a. Swing holding brake release signal b. Swing holding brake solenoid valve drive signal c. CAN signal d. Solenoid valve GND e. Oil pressure switch signal
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Function Swing lock and swing holding brake functions q Turning swing lock switch (1) to ON locks the swing lock (manual lock) at any position. q Interlocked with the swing operation, the swing holding brake (auto lock) prevents hydraulic drift from occurring after the swing stops. q Interlocked with the arm retract operation, the swing holding brake is released to reduce the load on the swing equipment during excavation work.
Swing lock switch Swing lock monitor Function
OFF OFF Swing holding brake
ON ON Swing lock
When the L.H. work The swing holding brake works to equipment control lock the swing. lever is set to NEUTRAL, the swing Even if the L.H. holding brake works work equipment in 5 sec. control lever is operated for When the L.H. work swing, the swing equipment control Operation holding brake lever is operated for cannot be swing or the arm released, and no lever is operated for swing is possible. retract, the swing holding brake is released allowing free swing operation.
A: B: C: D:
L.H. work equipment control lever SWING (Swing holding brake RELEASE) L.H. work equipment control lever NEUTRAL Swing holding brake OPERATED 5 sec
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PC138US, USLC-8
SEN02553-01
Swing holding brake release function q If the controller gets out of order and no swing is possible because the swing holding brake does not work properly, operating swing holding brake release switch (2) releases the swing holding brake and allows swing operation. a: Release (Emergency) b: Normal
Swing holding brake release switch Swing lock switch Swing brake Release (when the controller is out of order) Normal (when the controller is in order)
ON
OFF Swing holding brake is released. (*1)
ON
OFF Swing holding brake works.
Swing lock works.
Swing lock works.
*1: Hydraulic brake by the safety valve.

a
Even if the swing holding brake release switch is set to RELEASE, the swing holding brake is not be released while the swing lock switch is set to ON. When the swing holding brake is released, only the hydraulic brake with the safety valve is effective for swing. So, note that, when the swing stops on a slope, a hydraulic drift may occur. Swing holding brake release switch (2) is of the alternator type. When the switch is turned to RELEASE (a) position, the swing lock monitor in the machine monitor will blink.
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Travel control function
1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Fuel supply pump 6. Sensors 7. Pump oil pressure sensor 8. Oil pressure sensor 9. Travel alarm buzzer 10. Hydraulic pump 11. Control valve 11a. Pump merge-divider valve 11b. Self pressure reducing valve 11c. Travel junction valve 11d. Pump merge-divider valve 12. Travel motor 13. 2nd travel speed select solenoid valve 14. Travel junction solenoid valve 15. Pump merge-divider solenoid valve
Input and output signals a. Oil pressure sensor signal b. CAN signal c. Pump merge-divider solenoid valve drive signal d. Travel junction solenoid valve drive signal e. 2nd travel speed select solenoid valve drive signal f . Oil pressure sensor signal g. Travel alarm buzzer operation signal h. Throttle signal i . Fuel supply pump control signal j . Sensor signals
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PC138US, USLC-8
SEN02553-01
Function Travel speed select function 1.

q
Travel speed Manual change Turning the travel speed selector switch Hi and Lo changes the motor capacity and allows the machine to select travel speed.
Lo (low speed) 79.1 2.9 Max. Hi (high speed) 44.2 5.1 Min.
Travel speed selector switch Motor capacity (cc/rev.) Travel speed (km/h) Travel motor swash plate angle
2.
Travel speed Automatic change 1) Automatic selection corresponding to engine speed q When the engine speed is lowered to below 1,500 rpm with the fuel control dial, the travel speed changes to Lo automatically. 2) Automatic selection corresponding to pump discharge pressure q If the travel pressure increases on an uphill with the travel speed selector switch in Hi, and the travel hydraulic pressure exceeding 32.4 MPa {330 kg/cm} continues for 0.02 seconds or more, the travel motor capacity is switched to low speed (corresponds to Lo) automatically (the travel speed switch position is remain Hi). q If the travel pressure decreases on a flat or downhill with low speed (caused by the automatic gear shifting due to high pressure), and the travel hydraulic pressure below 17.7 MPa {180 kg/cm} continues for 0.1 seconds or more, the travel motor capacity is switched back to the set speed of Hi automatically.
A: B: C: D:
17.7 MPa {180 kg/cm} 32.4 MPa {330 kg/cm} Min. 0.1 sec. Min. 0.02 sec.
Pump control function during travel a See Pump and engine mutual control function for details. Travel junction function When the travel lever is operated, detects the pilot pressure and judges whether it is for straight-travel or for steering. q For straight-travel, a signal is sent to the travel junction solenoid valve, controlling the pump flow between the right and left to be equal, to prevent travel deviation and improve straight line stability. q When steering, the signal to the travel junction solenoid valve is cut-off, separating the pump flow between the right and left, to improve steering stability.
q
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Pump merge-divider function q When the travel lever is operated, detects the pilot pressure and judges if it is for straight-travel. q For straight-travel, a signal is sent to the pump merge-divider solenoid valve, dividing the pump delivery, to improve travel performance.
Pattern Criterion of travel operation Stop or travel at very low speed (All of following conditions are satisfied) P1 = Min. 1.6 {16} P2 = Min. 1.6 {16} P3 = Min. 1.6 {16} P4 = Min. 1.6 {16} (All of following conditions are satisfied) Work equipment is not operated (Work equipment PPC pressure switch is Straight travel operation "OFF"). (All of following conditions Blade is not operated (P5 = Max. 0.3 are satisfied) P1 P2 absolute value = {3}). Max. 0.3 {3} (One of following conditions is satisfied) P3 P4 absolute value = Work equipment is operated (Work Max. 0.3 {3} equipment PPC pressure switch is "ON"). Blade is operated (P5 = Min. 0.5 {5}). Travel at normal speed (One of following conditions is satisfied) P1 = Min. 1.8 {18} P2 = Min. 1.8 {18} P3 = Min. 1.8 {18} P4 = Min. 1.8 {18} (All of following conditions are satisfied) Work equipment is not operated (Work equipment PPC pressure switch is "OFF"). Blade is not operated deeply (P5 = Max. 2.0 {20}). Pivot turn is not made. Example) Right forward pivot turn (P1 = Max. 2.0 {20} or P2, P4 = Min. 0.5 {5}) (One of following conditions is satisfied) Work equipment is operated (Work equipment PPC pressure switch is "ON"). Blade is operated deeply (P5 = Max. 2.2 {22}) Pivot turn is made. Example) Right forward pivot turn (P1 = Max. 2.2 {22} and P2, P4 = Max. 0.3 {3}) Criterion of steering operation Criterion of work equipment and blade operation Mergedivider valve
Merge
Divide
Merge
(*1) 4
Divide
Steering operation (One of following conditions is satisfied) P1 P2 = Min. 0.5 {5} P3 P4 = Min. 0.5 {5}
Merge
*1. If the work equipment etc. is operated in pattern 4, the pump merge-divider valve is set to the merge mode of pattern 5. Even if the work equipment operation is stopped after the pump merge-divider valve is set in pattern 5, the pump merge-divider valve is not returned to pattern 4. P1: Left forward PPC pressure (MPa {kg/cm2}) P2: Right forward PPC pressure (MPa {kg/cm2}) P3: P1: Left reverse PPC pressure (MPa {kg/cm2}) P4: Right reverse PPC pressure (MPa {kg/cm2}) P5: Blade PPC pressure (MPa {kg/cm2})
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PC138US, USLC-8
SEN02553-01
PPC lock function
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery Battery relay Fusible link Fuse box Starting switch Lock lever PPC lock switch Hydraulic pump Control valve 9a. Pump merge-divider valve 9b. Self pressure reducing valve 10. PPC lock solenoid valve
Function Interlocked with the lock lever, the PPC lock switch is turned OFF when operating the lock lever to LOCK position. q When the PPC lock switch is turned OFF, the current to the PPC lock solenoid valve is cutoff, causing neither the work equipment nor machine moves even if levers or pedal is operated.
q
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Oil flow adjuster function for attachment

(Machine ready for attachment)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Pump controller Engine controller Machine monitor Fuel control dial Fuel supply pump Sensors Emergency pump drive switch Oil pressure switch Hydraulic pump 9a. Servo 9b. LS valve 9c. PC valve 10. Control valve 10a. Pump merge-divider valve 10b. Self pressure reducing valve 11. PPC lock solenoid valve 12. Oil flow adjuster EPC valve for attachment 13. PC-EPC valve 14. Attachment circuit selector valve 15. Attachment
Input and output signals a. Oil flow adjuster EPC valve drive signal for attachment b. Oil pressure switch signal c. CAN signal d. PC-EPC valve drive signal e. Solenoid valve GND f . Throttle signal g. Fuel supply pump control signal h. Sensor signals Function Setting of the working mode and oil flow rate on the machine monitor controls the oil flow to the attachment when the attachment control pedal is depressed all the way.
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System components
Engine controller
Input and output signals q The following is the list of the symbols used for signal classification in the input/output signal chart. A: Power supply B: Input C: Ground/shield/return D: Output E: Communication
DTP-4P [CN-CE03] Pin No. 1 2 3 4 Signal name GND NC Constant power supply (24 V) NC Signal classification C A
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DRC-60P(1) [CN-CE01] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Signal name NC NC NC NC NC NC NC NC NC Fuel supply pump regulator (+) Boost temperature sensor NC NC Fuel supply pump regulator () NC NC NC NC Boost pressure sensor Ambient pressure sensor NC NC NC NC NC Crankshaft speed sensor (5 V) NC NC Common rail pressure sensor NC Signal classification B B C B B A B Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Signal name NC Engine oil pressure switch NC NC NC Sensor power supply (5 V) Camshaft speed sensor NC NC NC NC Crankshaft speed sensor NC Crankshaft speed sensor GND Injector #2 (+) NC Coolant temperature sensor GND Sensor GND Coolant temperature sensor NC Injector #4 () NC Injector #1 () NC Injector #3 (+) Injector #4 (+) Injector #1 (+) Injector #2 () Injector #3 () NC Signal classification B A B B C D C C D C C D D D C C
DRC-60P(2) [CN-CE02] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 CAN(+) NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC CAN () NC NC NC NC NC Fuel control dial (5 V) Fuel control dial () NC NC Signal name Signal classification E E A C Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Signal name NC Engine controller power cut-off relay GND NC NC Fuel control dial (+) NC NC NC NC NC NC NC NC NC Starting switch ACC signal NC NC NC NC NC NC NC NC NC Engine controller power cut-off relay NC NC NC NC NC Signal classification C B B D
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Pump controller
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AMP-81P [CN-C01] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name Constant power supply (24 V) GND Window washer Constant power supply (24 V) GND NC NC Potentiometer power supply (5 V) Potentiometer power supply (5 V) NC Arm angle sensor NC L.H. travel REVERSE oil pressure sensor Boom LOWER oil pressure switch Arm OUT pressure switch Swing oil pressure switch Arm IN pressure switch GND (analog signal) Swing lock switch NC Model select 2 NC NC Starting switch ACC signal NC NC NC NC Hydraulic oil temperature sensor NC Boom cylinder bottom oil pressure sensor Blade RAISE oil pressure sensor NC Bucket DUMP oil pressure switch NC R.H. travel REVERSE oil pressure sensor GND (digital signal) Swing holding brake cancel switch Model select 5 Model select 1 Input/output signal Input Input Output Input Input Output Output Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Pin No. 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 Input/output signal NC NC Starting switch ACC signal Input GND (pulse signal) Input CAN_H Input/output GND (analog signal) Input GND (analog signal) Input NC Pump oil pressure sensor Input NC Blade LOWER oil pressure sensor Input Attachment oil pressure switch Input Boom RAISE oil pressure switch Input NC R.H. travel FORWARD oil pressure sensor Input Wiper motor reverse (W) Input Cab front window open limit switch Input Model select 4 Input NC Starting switch C signal Input NC External start signal Input NC CAN_L Input/output NC NC Boom angle sensor Input NC L.H. travel FORWARD oil pressure sensor Input GND (analog signal) Input NC NC Bucket CURL oil pressure switch Input NC Wiper motor stop (P) Input Blade specification signal Input Model select 3 Input Overload alarm enable signal Input Starting switch ACC signal Input NC GND (digital signal) Input Signal name Input/output signal Output Output Output Output Output Input Input Input Input Output Input Input
AMP-40P [CN-C02] Pin No. 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 Input/output signal NC NC NC NC NC 2nd travel speed select solenoid Output NC NC NC NC NC Arm crane relay drive signal Output Bucket DUMP operation lock solenoid Output NC PC-EPC Output Oil flow adjuster EPC for attachment Output NC NC NC Swing holding brake solenoid Output Signal name Pin No. 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 Signal name NC NC NC NC NC Travel and swing alarm buzzer Battery relay drive NC Travel junction solenoid NC Pump merge-divider solenoid NC Wiper motor () GND (solenoid) Solenoid power supply GND (solenoid) Solenoid power supply Wiper motor (+) GND (solenoid) Solenoid power supply
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Fuel control dial
1. 2. 3. 4. 5. 6.
Knob Dial Spring Ball Potentiometer Connector
Function q Installed in the right console box. Potentiometer (5) is installed inside knob (1). Turning knob (1) causes potentiometer (5) shaft to rotate. q This rotation changes the resistance of the variable resistor within potentiometer (5), and a throttle signal is sent to the controller. q The hatched areas in the graph are error detection areas. If the throttle voltage is within the area, the engine drops down to low idle.
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Resistor
1. 2.
Resistance Connector
Specifications For PC-EPC valve: 30 z Function q Sends an electric current to each EPC valve that is appropriate for each condition, when the emergency pump drive switch is turned to ON. a No electric current flows in the normal condition.
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Engine oil pressure switch
1. 2. 3.
Connector Sensor O-ring
Specifications Contact type: Normal close Function q Installed in the cylinder block. Detects engine oil pressure, and turns the switch ON when the pressure goes below the specified value.
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PPC oil pressure switch
1. 2. 3.
Plug Switch Connector
Specifications Contact type: Normal open Operating pressure to make contact point ON: 490 98.1 kPa {5.0 1.0 kg/cm2} Operating pressure to break contact point OFF: 294 49.0 kPa {3.0 0.5 kg/cm2} Function q Installed (8 places) in the connecting valve. Detects the PPC oil pressure when each actuator is operated, and turns the switch ON when the pressure exceeds the specified value.
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Monitor system
1. 2. 3. 4. 5. 6. 7. 8.
Machine monitor Battery Pump controller Engine controller Air conditioner controller KOMTRAX terminal Sensors, switches Wiper motor, window washer motor
Input and output signals a. Power supply b. CAN signal c. Sensor and switch signals d. Drive signal
Outline The monitor system keeps the operator informed of all machine functions, by monitoring the machine conditions using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor. The information displayed on the machine monitor falls into the following types: 1. Alarm when an error occurs 2. Machine status display (coolant temperature, hydraulic oil temperature and fuel level) q The switches on the machine monitor controls the machine.
q
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Machine monitor
Outline q The machine monitor provides monitor display function, mode selection function and switch function of the electrical equipment etc. Also it provides an alarm buzzer. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The machine monitor consists of display and switches: the display is of LCD type, and the switches are of flat sheet switch. q If an error occurs in the machine monitor itself, controller or wiring circuit between monitor and controller, the monitor does not display properly.
Precautions on the machine monitor display q The LCD panel may have black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, it does not indicate a failure or a defect. q When the engine is started, the battery voltage may drop suddenly depending on ambient temperatures and battery conditions. In this case, the machine monitor may go off for a moment. However, this phenomenon is not a failure. q After the machine monitor is used continuously, blue points (points which do not go off) may be seen on the black background. This phenomenon does not indicate a failure or a defect. Blue points can never be a problem as the screen has usually blue or white background. (White in the LCD is made up of red, green and blue.)
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PC138US, USLC-8
SEN02553-01

070-18P(1) [CN-CM01] Pin No. 1 2 3 4 5 6 7 8 9 Signal name Constant power supply (24 V) Constant power supply (24 V) GND (constant power supply) GND (constant power supply) Wake-up Starting motor cut-out relay (for personal code) GND (machine signal) Hydraulic oil temperature Fuel level Input/output signal Input Input Input/output Output Input Input Input/output signal Input Input Input Input Input Input Input/output signal Input Input Input Output Output Output Input Pin No. 10 11 12 13 14 15 16 17 18 Signal name Engine coolant temperature Battery level GND (machine analog signal) Lamp switch Starting switch ACC signal Starting switch C signal Preheat USB power supply (5 V) GND (USB power supply) Input/output signal Input Input Input Input Input Input Output Input/output signal Input/output Input/output Input/output Input/output Input/output signal Input Input Input Output Output Output Input Output
070-12P(1) [CN-CM02] Pin No. 1 2 3 4 5 6 Signal name Engine oil pressure sensor Engine oil level sensor Radiator coolant level sensor Air cleaner clogging sensor Swing lock switch Spare Pin No. 7 8 9 10 11 12 Signal name GND (machine signal) CAN terminal signal CAN_H CAN_L USB data () USB data (+)
070-18P(2) [CN-CM03] Pin No. 1 2 3 4 5 6 7 8 9 Signal name For communication terminal, RS232C CD For communication terminal, RS232C RXD For communication terminal, RS232C SG GND (communication terminal control signal) Communication terminal selection signal For communication terminal, RS232C RTS For communication terminal, RS232C TXD For communication terminal, RS232C DTR For communication terminal, RS232C DSR Pin No. 10 11 12 13 14 15 16 17 18 Signal name For communication terminal, RS232C CTS For communication terminal, RS232C RI GND (communication terminal power supply) Communication terminal status signal CH1 Communication terminal power supply control signal Communication terminal control signal CH1 Communication terminal control signal CH2 Communication terminal status signal CH2 Communication terminal power supply (12 V)
070-12P(2) [CN-CM04] Pin No. 1 2 3 4 5 6 Signal name GND (peripheral equipment power supply) Peripheral equipment control signal GND (for peripheral equipment, RS232C) For peripheral equipment, RS232C TXD For peripheral equipment, RS232C RXD Reserved Input/output signal Output Output Input Pin No. 7 8 9 10 11 12 Reserved Reserved Reserved Reserved Reserved Peripheral equipment power supply (12 V) Signal name Input/output signal Output
B60-8P [CN-CM05] Pin No. 1 2 3 4 Signal name Camera power supply (8 V) Camera NTSC signal 1 Camera NTSC signal 2 Camera NTSC signal 3 Input/output signal Output Input Input Input Pin No. 5 6 7 8 Signal name GND (Camera power supply) GND (Camera signal 1) GND (Camera signal 2) GND (Camera signal 3) Input/output signal
PC138US, USLC-8
37
SEN02553-01
Display
A: B:
C:
Normal operation screen All indicators light-up screen q When monitor items (14) to (16) are faulty after starting the engine, monitor items are displayed on the screen in chronological order from the upper left. q If the hydraulic oil temperature goes High or Low while the hydraulic oil temperature gauge is displayed at the center of the screen, the screen displays only hydraulic oil temperature monitor (2b). Screen with maintenance interval reminder
38
PC138US, USLC-8
SEN02553-01
No. Classification
Display item
1a
Gauge
(*1) Coolant temperature
1b
Caution
2a
Gauge
(*1) Hydraulic oil temperature
2b
Caution
3a
Gauge
(*1) Fuel level
3b 4
Caution ECO gauge
Description Display Tempera- Background location ture (C) color W1 105 Red W2 102 Red W3 100 Blue W4 85 Blue W5 60 Blue W6 30 White See the column Gauge. Display Tempera- Background location ture (C) color H1 105 Red H2 102 Red H3 100 Blue H4 85 Blue H5 40 Blue H6 20 White See the column Gauge. Display Background Quantity (l) location color F1 139 Blue F2 116 Blue F3 96 Blue F4 66 Blue F5 52 Blue F6 33 Red See the column Gauge. Segment Load level Light to Green 18 medium Orange 9,10 Heavy 00000 h 99999 h
Remarks
Indicates corresponding temperature range. Alarm buzzer sounds when the temperature exceeds 105C. If the monitor background appears white, warm-up the engine.
Indicates corresponding temperature range. Alarm buzzer sounds when the temperature exceeds 105C. If the monitor background appears white, warm-up the hydraulic components.
Indicates corresponding fuel level.
Indicates average load per minute on a scale of 1 to 10. (Indicates when Default (ECO display setting) of the service mode is ON.) Indicates accumulated engine operating hours (the alternator is generating). (F4 switch changes for clock display.)
Service meter 5 Clock
Message
12-hour display (AM/PM) Displays time. (F4 switch changes for service meter.) 24-hour display Background Status (If KOMTRAX is equipped.) color Displays message status. Green There is unread message. (OFF when no message is available.) Blue There is unsent message. Light ON: ON Light OFF: OFF INT: Intermittent ON: Continuous Light OFF: Stop Swing lock Swing holding brake switch release switch OFF OFF ON OFF OFF ON ON ON Indicates air conditioner and air blower operating status. Indicates front glass wiper operating status. Monitor display OFF ON Blink Blink Indicates swing lock operating status.
7 8
Air conditioner Wiper
Pilot
Swing lock
*1: If the gauge signal is not available due to disconnection of CAN communication line, the gauge pointer goes off. PC138US, USLC-8
39
SEN02553-01
No. Classification
Display item
10
Preheat
Description Remarks Elapsed time after turning Monitor disthe starting switch to play HEAT (preheat). Indicates preheat operating status. 0 30 sec. ON 30 40 sec. Blink 40 sec. or more OFF Indicates auto-decelerator operating status.
11
Pilot
Auto-decelera- Light ON: ON tor Light OFF: OFF P: Heavy-duty operation E: Low-fuel consumption operation Working mode L: Fine operation B: Breaker operation ATT: Compound attachment operation Lo: Low speed Travel speed Hi: High speed (*2) Engine oil level (*2) Engine oil pressure Light ON: Abnormal range (below the specified value) Light OFF: Normal range Light ON: Abnormal range (below the specified value) Light OFF: Normal range Light ON: Defective battery charge (Charge voltage < Battery voltage) Light OFF: Normal range Background color Status
12
Displays working mode.
13
Displays travel speed setting. When an error is detected with the engine running, the monitor lights up on the screen and the alarm buzzer sounds at the same time. When an error is detected with the engine stopped, the monitor lights up on the screen. When an error is detected with the engine running, the monitor lights up on the screen.
14
15
16
Caution
(*2) Battery level
17
Maintenance interval
Yellow
Red
The display changes depending on the time to/after the maintenance. There is a maintenance item which is 30 hours or After the starting switch is turned ON, less left before next mainthe monitor turns ON if the monitor tenance. light-up conditions are met, and then There is a maintenance turns OFF in 30 seconds. overdue item.
*2: Included in the star-up check. After the staring switch is turned ON, the monitor turns ON for 2 seconds, and changes to a normal operation screen if no error is found.
40
PC138US, USLC-8
SEN02553-01
PC138US, USLC-8
41
SEN02553-01
Switches
No. 1
Name Auto-decelerator switch [Numeric keypad: 1] (*1) Working mode selector switch [Numeric keypad: 2] Travel speed selector switch [Numeric keypad: 3]
Function Turns the auto-decelerator function ON/ OFF. Light ON: ON Light OFF: OFF Displays the working mode selector screen. Changes the travel speed. Lo light ON: Low speed Hi light ON: High speed
Operation When the working mode is in L, the autodecelerator does not work. OFF i o ON P: Heavy-duty operation E: Low-fuel consumption operation L: Fine operation B: Breaker operation ATT: Compound attachment operation Lo (low speed) i o Hi (high speed) Stops the alarm buzzer. The alarm buzzer resumes when another error is detected. o INT o ON o OFF o I (Intermittent) (Continuous) (Stop) O i i i ON: Washer fluid is sprayed and wiper works continuously. [When wiper is not working] OFF: Wiper works twice and stops after the switch is released. [When wiper is working intermittently] OFF: Wiper works twice continuously and returns to intermittent operation after the switch is released.
Stops the alarm buzzer. Buzzer cancel switch (Some alarm buzzer does not stop even if [Numeric keypad: 4] the switch is pressed.) Wiper switch [Numeric keypad: 5] Operates the front glass wiper. INT: Intermittent ON: Continuous Light OFF: Stop
Window washer switch [Numeric keypad: 6]
Sprays washer fluid onto the front glass.
*1: When the working mode is changed, the auto-decelerator function turns ON.
42
PC138US, USLC-8
SEN02553-01
No. 7
Name Fan switch (Up) [Numeric keypad: 7]
Function Controls the fan speed of the air conditioner in 6 levels. (Low, Medium 1, Medium 2, Medium 3, Medium 4, High)
Operation The air flow increases immediately after the air conditioner adjustment screen appears. The air flow decreases immediately after the air conditioner adjustment screen appears. The temperature control increases immediately after the air conditioner adjustment screen appears. The temperature control decreases immediately after the air conditioner adjustment screen appears. Automatically controls the fan speed, air outlet port, internal/external air flow according to the temperature setting, immediately after the air conditioner adjustment screen appears. Switches to the air conditioner adjustment screen, and pressing it again switches ON/ OFF. OFF i o ON Switches to the air conditioner adjustment screen, and pressing it again switches internal/external air flow. RECIRC i o FRESH Switches to the air conditioner adjustment screen, and pressing it again switches air outlet mode. Mode 1, 5 and 6 are not available with auto mode. o 1 o 2 o 3 o 4 o 5o 6 o I O i i i i i i i Turns the fan and air conditioner OFF.
7a
Fan switch (Down) Temperature control switch (Up) [Numeric keypad: 8] Temperature control switch (Down) [Numeric keypad: 0]
Controls the temperature inside the cab. (18.0C 32.0C: Aailable at every 0.5C)
8a
(*2) Auto switch [Numeric keypad: 9]
Auto-runs the air conditioner and air blower. AUTO light ON: Auto run
10
(*3) Air conditioner switch
Turns the air conditioner ON/OFF. A/C ON lights-up: Manual operation Light OFF: Stop
11
FRESH/RECIRC selector switch
Changes the FRESH/RECIRC.
12
Vent selector switch
Selects the air vent mode from 6 modes. 1. Front 2. Front and rear 3. Front and rear-foot 4. Foot 5. Foot and defroster 6. Defroster Turns the fan and air conditioner OFF. Light OFF: OFF a See Guidance icon and function switch.
13
OFF switch
14a Guidance icon 14b Function switch
*2: When the temperature is set at 18.0C or 32.0C, the fan speed is kept at High. Even if the set temperature is reached, the fan speed remains the same. *3: When the fan is set at Stop, the air conditioner does not start even if the switch is pressed.
PC138US, USLC-8
43
SEN02553-01
Guidance icon and function switch q Functions available with the function switch depend on the guidance icon displayed above the switch. q No function is available if no guidance icon appears above the function switch. q The following is the list of guidance icons and the functions displayed above the function switches.
Function switch
Guidance icon 1 2 3 Clear
Item
Function Clears selected/displayed item. Moves selection down one page. (To the top page from the bottom page.) Sets function. Starts function. (Used for starting measurement of spilt fuel consumption.) Stops function. (Used for stopping measurement of spilt fuel consumption.) Sets selected item back to default. (Used for screen adjustment.) Moves selection up one page. (To the bottom page from the top page.) Clears selected/displayed item. Switches to camera image. Moves selection down one item. (To the top item from the bottom item.) Releases holding of the monitor. Moves selection to the left. (To the rightmost item from the leftmost item.) Switches clock/service meter display. Moves selection up one item. (To the bottom item from the top item.) Holds the monitor. Moves selection to the right. (To the leftmost item from the rightmost item.)
Move selection Set Start
F1 4
5 1 F2 2 3 1 F3 2 3 1 F4 2 3
Stop Default Move selection Clear Camera image Move selection Move selection Switching clock/service meter Move selection Move selection
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PC138US, USLC-8
SEN02553-01
Function switch F5 F6
Guidance icon 1 2 1 2 Return
Item Selecting maintenance screen Selecting user mode screen Fix
Function Selects maintenance screen. Returns to the previous screen or condition. Selects user mode screen. Fixes selected/displayed item.
PC138US, USLC-8
45
SEN02553-01
Operator mode function

q
The functions in this mode are displayed in normal operation. Display and setting of these functions are available from the operator's switch operations. Display and setting of some functions require special operation of the switch. Items available in the operator mode are as follows:
Item Display of KOMATSU logo Display of inputting password Display of start-up check Display of warning after start-up check Display of overdue maintenance Display of check of working mode and travel speed Display of normal operation screen Display of end screen Selection of auto-decelerator Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Operation to display clock/service meter Check of maintenance information Setting and display of user mode Breaker/attachment setting Display of message (including KOMTRAX messages for user) Screen adjustment Clock adjustment Language setting Economy mode adjustment Display of energy-saving guidance Display of caution monitor Display of user code and failure code Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing attachment/maintenance password Display order (*2) W X Y Z 1 1 1 1 2 3 2 2 2 3 3 4 3 4 4 5 4 5 5
Category (*1)
*1: The items available in the operator mode fall into the following categories. A: Display from the time starting switch is turned ON until the ordinary screen appears. Display after the starting switch is turned OFF. B: Display when the switch of machine monitor is operated. C: Display when a certain condition is satisfied D: Display when special switch operation is necessary. *2: For the category A, the order in which items are displayed varies depending on the setting and conditions of the machine as follows: W: When the engine start lock is set on X: When the engine start lock is set off Y: When an error is detected during start-up check. Z: When a maintenance overdue is detected.
a a
For how to operate the operator mode functions, see the Operation and Maintenance Manual or Special functions of machine monitor in Testing and adjusting. For how to set the engine start lock on/off, see Password setting/cancel manual.
46
PC138US, USLC-8
SEN02553-01
Oil flow setting for breaker
Oil flow setting for attachment
q q
Oil flow for the breaker can be changed in the Breaker/attachment setting of the user mode. Oil flow level can be set as follows:
Oil flow level 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Quantity (l/min) 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Default Remarks
Oil flow for the compound attachment can be changed in the Breaker/attachment setting of the user mode. Oil flow level can be set as follows:
Oil flow level 1 2 3 4 5 6 7 8 Quantity (l/min) 30 85 105 130 155 175 200 225 Default Remarks
Language setting
The language used in the machine monitor can be changed in the Language setting of the user mode. The available languages are as follows: English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian and Thai
PC138US, USLC-8
47
SEN02553-01
Service mode function

q
The functions in this mode are not accessible from the normal operation screen. Display and setting of these functions are available by the serviceman's special operations of the switch. This mode is used for special setting, testing, adjusting or troubleshooting. Items available in the service mode are as follows:
Mechanical systems
Monitoring Abnormality record Maintenance record Change of maintenance mode Setting of telephone No. Working mode with key ON Selection of units of measure Default With/Without attachment Setting of attachment/maintenance password Setting of camera Setting of ECO display Adjustment No injection cranking Display of fuel consumption Setting condition of KOMTRAX terminal Display of KOMTRAX setting Condition of positioning and communication Modem IP address (Model TH201) Modem S/N (Model TH300) Display of KOMTRAX message Pump absorption torque Cylinder cut-out operation Electrical systems Air conditioner system
For how to operate the service mode functions, see Special functions of machine monitor in Testing and adjusting.
48
PC138US, USLC-8
SEN02553-01
KOMTRAX system
The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, machine monitor and GPS antenna. This system sends various information of the machine via wireless communication. It allows operators of the KOMTRAX to obtain the machine information from the office and to provide various services with the customers. The information available from the KOMTRAX system are as follows: 1. Operation map 2. Service meter 3. Machine location 4. Error record To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
PC138US, USLC-8
49
SEN02553-01
KOMTRAX terminal
TH300
The KOMTRAX system uses satellite communication technology. Communication antenna connection Machine harness connection (AMP-14P) Machine harness connection (AMP-10P)

AMP-14P [CN-CK01] Pin No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 Signal name Power supply (5 V) NC NC Selection of power supply voltage NC NC GND GND NC NC NC NC NC NC Input/output signal Input Output Input Input
1. 2. 3.
Outline q The KOMTRAX terminal sends various machine information based on the network signals and input signals obtained through the machine monitor, as well as GPS position data, via wireless communication. The KOMTRAX terminal can sends information via communication antenna. q Conditions of the KOMTRAX terminal can be checked with the Display of KOMTRAX setting in the service mode of the machine monitor. q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
AMP-10P [CN-CK02] Pin No. B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 Signal name RS232C DCD RS232C RXD RS232C TXD RS232C DTR RS232C SGND RS232C DSR NC NC NC NC Input/output signal Output Output Input Input Input Output
50
PC138US, USLC-8
SEN02553-01
Sensor
Atmospheric pressure sensor
1. 2.
Connector Pressure inlet port
Function q Installed in the bracket on the side face of the cylinder block. Detects the ambient pressure and outputs variable voltage. Boost pressure, temperature sensor
1. 2. 3.
Function Installed in the intake manifold. Detects the boost pressure and boost temperature, and outputs signal as a variable voltage for pressure, and a resistance change for temperature.
PC138US, USLC-8
51
SEN02553-01
Coolant temperature sensor
1. 2. 3.
Function q Installed in the water pump. Detects the temperature change and outputs signal as a resistance change. Crankshaft speed sensor Camshaft speed sensor
1. 2. 3.
Function The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is installed in the gear of the camshaft. Each of the sensors outputs a pulse voltage according to the gear rotation.
52
PC138US, USLC-8
SEN02553-01
Common rail pressure sensor
1. 2. 3.
Common rail Sensor Connector
Function q Installed in the common rail. Detects the fuel pressure and outputs variable voltage. Engine oil level sensor
1. 2.
Connector Bracket
3. 4.
Float Switch
Function The engine oil level sensor is installed to the side of the oil pan. If the oil level lowers below the specified level, the float lowers and the switch is turned OFF.
PC138US, USLC-8
53
SEN02553-01
Fuel level sensor
1. 2. 3. 4.
Connector Float Arm Body
5. 6. 7.
Spring Contact Spacer
Function q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the fuel level. The float moves the variable resistor through the arm. The resistance changes according to the operating angle and signal voltage is generated from the source voltage according to the change of the resistance.
54
PC138US, USLC-8
SEN02553-01
Hydraulic oil temperature sensor
1. 2. 3.
Connector Plug Thermistor
Function q Installed in the suction pipe of the hydraulic pump. Detects the temperature change and outputs signal as a resistance change of the thermistor. Pump oil pressure sensor
1. 2. 3.
O-ring Sensor Connector
Output characteristics
Function The pump oil pressure sensor is installed in the control valve. Detects the pump discharge pressure and outputs variable voltage.
PC138US, USLC-8
55
SEN02553-01
PPC oil pressure sensor (For travel and blade operation)
1. 2. 3.
O-ring Sensor Connector
Output characteristics
Function q The PPC oil pressure sensor is installed in the control valve connecting part of the pilot circuit for travel and blade operation. Detects the pilot pressure and outputs variable voltage.
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PC138US, USLC-8
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PC138US, USLC-8
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SEN02553-01
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PC138US, USLC-8
SEN02457-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
20 Standard value table

Standard service value table
Standard value table for engine related parts ................................................................................................. 2 Standard value table for chassis related parts ................................................................................................ 3
PC138US, USLC-8
SEN02457-01
Standard value table for engine related parts

Applicable model Engine Category Item Test conditions High idle Engine speed Coolant temperature: operating range Low idle Rated speed At sudden acceleration At high idle Intake valve Exhaust valve Unit rpm rpm rpm % % mm mm MPa {kg/cm2} PC138US-8 SAA4D95LE-5 Standard value for new machine 2,300 60 1,100 50 2,200 Max. 30 Max. 10 0.35 0.50 Min. 2.9 {Min. 30} Max. 0.59 {Max. 60} 0.34 0.59 {3.5 6.0} MPa {kg/cm2} 0.29 0.49 {3.0 5.0} Min. 0.18 {Min. 1.8} Min. 0.15 {Min. 1.5} C 80 115 Service limit value 30 20 2.0 {20} 0.98 {100} 0.25 {2.5} 0.2 {2.1} 0.15 {1.5} 0.13 {1.3} 120
Exhaust gas color
Coolant temperature: operating range
Valve clearance
Normal temperature
Compression pressure Blow-by pressure
Oil temperature: 40 60C Engine speed: 320 360 rpm SAE0W30E0S
Engine
Coolant temperature: operating kPa range {mmH2O} Arm IN relief At sudden acceleration SAE30 Oil SAE10W Oil SAE30 Oil Low idle SAE10W Oil
Oil pressure (Hydraulic oil temperature: Min. 80C)
Oil temperature
Whole speed range (inside oil pan) Between fan pulley and alternator pulley Deflection when pressed with finger force of approx. 60 N {6.1 kg} Between fan pulley and compressor pulley Deflection when pressed with finger force of approx. 60 N {6.1 kg}
Fan belt tension
mm
6 10
Air conditioner compressor belt tension
mm
12 15
12 15
PC138US, USLC-8
SEN02457-01
Standard value table for chassis related parts

Applicable model Category Engine speed Item Test conditions Hydraulic oil temperature: 45 55C Engine oil pressure: Within operating range Engine water temperature: Within operating range Center of lever knob Tip of pedal Read max. value to end of travel Engine stopped No RAISE, LOWER N o IN, OUT No CURL, DUMP No LEFT, RIGHT No RAISE, LOWER N o FORWARD, REVERSE (LEFT, RIGHT) Work equipment, swing Travel Boom control lever Operating effort of control lever Arm control lever Bucket control lever Swing control lever Blade control lever Travel control lever Travel pedal Hydraulic oil temperature: 45 55C Engine at high idle MPa Working mode: P mode {kg/cm2} Hydraulic pump output pressure with all control levers in NEUTRAL position Hydraulic oil temperature: MPa 45 55C {kg/cm2} Engine at high idle Pump discharge pressure Target Relieve only circuit to be tested value (Range) Engine at high idle Oil temperature: 45 55C Fit push-pull scale to center of control lever knob to test Fit push-pull scale to tip of control pedal to test Test max. value to end of travel N {kg} mm Unit PC138US-8 Standard value for new machine Service limit value
At 1-pump relief
rpm
2,050 100
Boom control lever Arm control lever Travel of control levers Bucket control lever Swing control lever Blade control lever Travel control lever
100 11 85 11 100 11 85 11 53 6 115 12 35 10 3 16.7 3.3 {1.7 0.3} 16.7 3.3 {1.7 0.3} 13.7 2.7 {1.4 0.3} 13.7 2.7 {1.4 0.3} 25.5 6.9 {2.6 0.7} 24.5 5.9 {2.5 0.6} 74.5 18.6 {7.6 1.9}
100 21 85 21 100 21 85 21 Min. 47 Max. 59 Min. 103 Max. 127 58 10 5 Max. 25.5 {Max. 2.6} Max. 25.5 {Max. 2.6} Max. 22.6 {Max. 2.3} Max. 22.6 {Max. 2.3} Max. 32.4 {Max. 3.3} Max. 39.2 {Max. 4.0} Max. 107.6 {Max. 11}
Play of control lever
Hydraulic pressure
Unload pressure
4.9 6.9 {50 70}
4.9 6.9 {50 70}
Boom relief Arm relief Bucket relief
34.8 1.0 {355 10} 34.8 1.0 {355 10} 34.8 1.0 {355 10}
34.8 1.0 {355 +20 10 } 34.8 1.0 {355 +20 10 } 34.8 1.0 {355 +20 10 }
+2.0 +2.0
+2.0
PC138US, USLC-8
SEN02457-01
Applicable model Category Item Swing relief Blade RAISE Blade LOWER Travel relief Hydraulic pressure Control circuit source pressure Servo piston input pressure Test conditions Hydraulic oil temperature: 45 55C Engine at high idle Pump discharge pressure Relieve only circuit to be tested Unit
PC138US-8 Standard value for new machine 27.1 1.0 {276 10} 34.8 +0 {355 +20 +0 } 34.8 1.5 {355 15} 34.8 1.0 {355 10}
+2.0
Service limit value 27.1 2.5 {276 +15 25 } 34.8 1.0 {355 +20 10 } 34.8 2.5 {355 25} 34.8 2.0 {355 20} 3.2 0.5 {33 5} 3.4 1.0 {35 10} 16.0 2.5 {163 25}
+2.0 +1.5
MPa 2 Hydraulic oil Control levers at {kg/cm } temperature: HOLD Target 45 55C At pump relief value Engine at (normal actuation) (Range) high idle Hydraulic oil temperature: 45 55C Engine at high idle a LS differential pressure = pump outlet port pressure LS pressure All levers at HOLD
3.2 0.2 {33 2} 3.4 1.0 {35 10} 16.0 1.5 {163 15}
2.75 0.98 {28 10}
{}
LS differential pressure
Travel rotating under no load Travel lever at half-way position
2.2 0.1 {22.5 1}
{}
Overrun when stopping swing
For testing posture, see Swing 1 Engine at high idle Hydraulic oil temperature: 45 55C Stop after swinging one turn and test distance that swing circle moves Figure in ( ) shows movement at outside of swing circle For testing posture, see Swing 1 Engine at high idle 90 Hydraulic oil temperature: 45 55C Time taken to swing 90 and 180 from starting position 180 Figure in ( ) shows time when bucket is at rated load For testing posture, see Swing 1 Engine at high idle Hydraulic oil temperature: 45 55C Swing one turn, and test time taken to swing next 5 turns
Deg. (mm)
Max. 60 (Max. 580)
Max. 70 (Max. 676)
Swing
2.8 0.3 {3.4 0.3} sec. 4.0 0.4 {4.9 0.5}
Max. 3.5 (Max. 4.0)
Time taken to start swing
Max. 6.2 (Max. 6.4)
Time taken to swing
sec.
27.3 2
27.3 4
PC138US, USLC-8
SEN02457-01
Applicable model Category Item Test conditions For testing posture, see Swing 2 Engine stopped Hydraulic oil temperature: 45 55C Bucket at rated load (450 kg) Set machine on 15 slope, and set upper structure at an uphill angle of 45. Make match marks on swing circle outer race and track frame. Test distance that match marks move apart after 15 minutes. Engine at high idle Hydraulic oil temperature: 45 55C Relieve swing circuit. For testing posture, see Travel 1 Lo Engine at high idle Hydraulic oil temperature: 45 55C Raise track on one side at a time, rotate one turn, then Hi test time taken for next 5 turns with no load. For testing posture, see Travel 2 Lo Engine at high idle Hydraulic oil temperature: 45 55C Run up for at least 10 m, and test time taken to travel Hi next 20 m on flat ground. For testing posture, see Travel 2 and 3 Engine at high idle Hydraulic oil temperature: 45 55C Run up for at least 10 m, and test deviation when traveling next 20 m on flat ground. a Use a hard horizontal surface. For testing posture, see Travel 4 Engine stopped Hydraulic oil temperature: 45 55C Stop machine on 12 slope with sprocket facing straight up the slope. Test the distance the machine moves in 5 minutes. Unit
PC138US-8 Standard value for new machine Service limit value
Hydraulic drift of swing Swing
Deg. (mm)
0 (0)
0 (0)
Leakage from travel motor
l/min
Max. 3
Max. 6
Max. 39.5 sec. Max. 22.3
49
Travel speed (without load)
27
Max. 24.8 sec. Max. 14.1
Max. 30
Travel speed (actual run)
Max. 17
Travel Travel deviation
mm
Max. 200
220
Hydraulic drift of travel
mm
PC138US, USLC-8
SEN02457-01
Applicable model Category Travel Item Test conditions Engine at high idle Hydraulic oil temperature: 45 55C Lock shoes and relieve travel circuit. Unit
Leakage from travel motor
l/min
Max. 1.1
Max. 1.7
Hydraulic drift of work equipment
Total work For testing posture, see Work equipment equipment 1 (hydraulic drift at Place in above posture and test tip of bucket extension or retraction of each teeth) cylinder and downward movement at tip of bucket teeth. Boom cylinder (amount of Horizontal, flat ground retraction of Bucket: Rated load (450 kg) cylinder) Levers at HOLD Engine stopped Arm cylinder Hydraulic oil temperature: (amount of extension of 45 55C cylinder) Start testing immediately after setting. Bucket cylinder Test hydraulic drift every 5 (amount of minutes, and judge from results retraction of cylinder) for 15 minutes. Engine stopped Hydraulic oil temperature: Blade (hydraulic 45 55C drift at tip of Set blade at maximum lifting blade) height and test downward movement at edge of blade for 15 minutes. Boom Bucket teeth in contact with ground I O Cylinder fully extended Arm Cylinder fully retracted I O Fully extended Bucket Cylinder fully retracted I O Fully extended For testing posture, see Work equipment 2 Engine at high idle Hydraulic oil temperature: 45 55C RAISE
Max. 310
Max. 460
Max. 15
Max. 23
Max. 50 mm Max. 40
Max. 75
Max. 60
Max. 31
Max. 47
Work equipment
3.8 0.3 (Until touching cushion) 3.1 0.3 3.2 0.3 (Until touching cushion) 2.7 0.3 (Until touching cushion) 2.9 0.3
Max. 4.4 (Until touching cushion) Max. 4.2 Max. 4.0 (Until touching cushion) Max. 3.7 (Until touching cushion) Max. 3.7
Work equipment speed
OUT DUMP CURL
For testing posture, see Work equipment 3 Engine at high idle Hydraulic oil temperature: 45 55C For testing posture, see Work equipment 4 Engine at high idle Hydraulic oil temperature: 45 55C
IN sec.
LOWER
2.3 0.2
Max. 2.9
LOWER RAISE
Blade For testing posture, see Blade in contact Work equipment 5 with ground Engine at high idle I Hydraulic oil temperature: O 45 55C Blade fully raised
1.2 0.3
Max. 2.5
1.3 0.3
Max. 2.5
PC138US, USLC-8
SEN02457-01
Applicable model Category Item Test conditions For testing posture, see Work equipment 6 Engine at low idle Hydraulic oil temperature: 45 55C Fully retract arm and bucket cylinders, then lower boom from maximum height and test time taken from point where bucket contacts ground to point where chassis rises from ground. For testing posture, see Work equipment 7 Engine at low idle Hydraulic oil temperature: 45 55C Set top surface of boom horizontal, retract bucket cylinder fully, then extend arm cylinder and test time taken for arm to start moving again after stopping at bottom. For testing posture, see Work equipment 8 Engine at low idle Hydraulic oil temperature: 45 55C Set top surface of boom horizontal, retract arm cylinder fully, then extend bucket cylinder and test time taken for bucket to start moving again after stopping at bottom. For testing posture, see Work equipment 9 Engine at low idle Hydraulic oil temperature: 45 55C Lower blade from maximum height and test time taken from point where blade contacts ground to point where chassis rises from ground. Hydraulic oil temperature: 45 55C Engine at high idle Circuit to be tested is relieved. Unit
Boom
Max. 3
Max. 3
Arm
Max. 2
Max. 2
Time lag
sec.
Work equipment
Bucket
Max. 2
Max. 2
Blade
Max. 2
Max. 2
Internal leakage level
Each cylinder
Max. 3.5 cc/min Max. 10
Max. 15
Center swivel joint
Max. 50
PC138US, USLC-8
SEN02457-01
Pump performance curve
q q
TVC current: 0.4 A Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)
Check point Test pump discharge pressure (MPa {kg/cm2}) P1 Discharge pressure of other pump (MPa {kg/cm2}) P2 Average pressure (MPa {kg/cm2}) P1 + P2 2 Standard value for discharge amount Q (l/min) See graph Judgement standard lower limit Q (l/min) See graph
As desired
a a a
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when testing. The error is large near the point where the graph curves, so avoid testing at this point. When testing with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of test, and use them as a base for calculating the pump discharge amount at the specified speed. Pump delivery Q in the graph is the delivery from 1 side of the pump. PC138US, USLC-8
SEN02457-01
Posture of machine for testing performance and test procedure Swing 1: Swing brake angle, time taken to start swing, time taken to swing
Travel 2: Travel speed (actual run), travel deviation
Travel 3: Travel deviation Swing 2: Hydraulic drift of swing
Travel 4: Hydraulic drift of travel Travel 1: Travel speed (without load)
PC138US, USLC-8
SEN02457-01
Work equipment 1: Hydraulic drift of work equipment
Work equipment 4: Bucket speed
Work equipment 5: Blade speed Work equipment 2: Boom speed
Work equipment 6: Boom time lag Work equipment 3: Arm speed
10
PC138US, USLC-8
SEN02457-01
Work equipment 7: Arm time lag
Work equipment 8: Bucket time lag
Work equipment 9: Blade time lag
PC138US, USLC-8
11
SEN02457-01
12
PC138US, USLC-8
SEN02458-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
30 Testing and adjusting

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3 Testing engine speed ...................................................................................................................................... 6 Testing exhaust temperature........................................................................................................................... 7 Checking exhaust gas color............................................................................................................................ 8 Adjusting valve clearance ............................................................................................................................... 9 Testing compression pressure .......................................................................................................................11 Testing blow-by pressure .............................................................................................................................. 13 Testing engine oil pressure ........................................................................................................................... 14 Handling fuel system parts............................................................................................................................ 15 Releasing residual pressure from fuel system .............................................................................................. 15 Testing fuel pressure..................................................................................................................................... 16 Testing fuel return rate and fuel leakage....................................................................................................... 17 Bleeding air from fuel circuit.......................................................................................................................... 19 Checking fuel circuit for leakage ................................................................................................................... 21 Testing and adjusting alternator belt tension................................................................................................. 22 Testing swing circle bearing clearance ......................................................................................................... 23
PC138US, USLC-8
SEN02458-01
Checking and adjusting air conditioner compressor belt tension .................................................................. 24 Checking and adjusting track shoe tension................................................................................................... 25 Testing and adjusting oil pressure in work equipment, swing, and travel circuits ......................................... 27 Testing control circuit basic pressure ............................................................................................................ 30 Testing and adjusting oil pressure in pump PC control circuit....................................................................... 31 Testing and adjusting oil pressure in pump LS control circuit ....................................................................... 34 Testing solenoid valve output pressure ......................................................................................................... 38 Testing PPC valve output pressure ............................................................................................................... 39 Adjusting play of work equipment and swing PPC valves............................................................................. 41 Checking parts which cause hydraulic drift of work equipment..................................................................... 42 Testing and adjusting travel deviation ........................................................................................................... 44 Releasing residual pressure from hydraulic circuit........................................................................................ 46 Testing oil leakage......................................................................................................................................... 47 Bleeding air from each part ........................................................................................................................... 50 Checking cab tipping stopper........................................................................................................................ 52 Adjusting mirrors ........................................................................................................................................... 52
PC138US, USLC-8
SEN02458-01
Tools for testing, adjusting, and troubleshooting

Testing/Adjusting item Exhaust temperatures Checking exhaust gas color Symbol R A Part No. Part name Q'ty Remarks
799-101-1502 Digital thermometer 1 799-201-9001 Handy smoke checker 2 1 Commercially Smoke meter available 795-799-1131 Gear Commercially Thickness gauge available
1 -99.9 1,299C 1 Bosch index: 0 9 1 1 1 Intake: 0.35 mm Exhaust: 0.57 mm
Adjusting valve clearance
1 795-502-1590 Compression gauge Testing compression presC 795-471-1420 Adapter sure 2 6261-11-3880 Gasket Testing blow-by pressure D 1 799-201-1504 Blow-by checker 799-101-5002 Hydraulic tester Testing engine oil pressure 1 E 799-261-1204 Digital hydraulic tester 2 799-401-2320 Gauge 799-101-5002 Hydraulic tester 1 Testing fuel pressure F 2 790-261-1204 Digital hydraulic tester 795-471-1450 Adapter 07005-00812 Washer
1 0 6.9 MPa {0 70 kg/cm2} 1 1 For 95E-5 engine
1 0 5 kPa {0 500 mmH2O} 1 1 1 1 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge:58.8 MPa {600 kg/cm2} Pressure gauge:0.98 MPa {10 kg/cm2} Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge:58.8 MPa {600 kg/cm2}
1 Size: 8 x 1.25 mm 1 1 Pressure gauge:0.98 MPa {10 kg/cm2}
3 799-401-2320 Gauge 1 6151-51-8490 Spacer 2 6164-81-5750 Joint 3 4 Testing fuel return rate and leakage G 5 6 7 Testing swing circle bearing clearance H 07042-20108 Plug Commercially Hose available Commercially Hose available Commercially Measuring cylinder available Commercially Stopwatch available Commercially Dial gauge available 799-101-5002 Hydraulic tester Testing and adjusting oil pressure in work equipment, swing, and travel circuits 1 J 2 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring
1 14 1 14 1 1 Internal dimensions: Approx. 6 mm 1 Internal dimensions: Approx. 12 mm 1 1 1 1 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
2 Size: 10 x 1.25 mm 2
PC138US, USLC-8
SEN02458-01
Testing/Adjusting item
Symbol
Q'ty
Part No.
Part name
Remarks Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
799-101-5002 Hydraulic tester Testing basic pressure of control circuit 1 K 2 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester 1 Testing and adjusting oil pressure in pump PC con- L 790-261-1204 Digital hydraulic tester trol circuit 2 799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester 1 Testing and adjusting oil pressure in pump LS con- M trol circuit 790-261-1204 Digital hydraulic tester 2 799-401-2701 3 Differential pressure gauge
1 1
2 Size: 10 x 1.25 mm 2 1 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
2 Size: 10 x 1.25 mm 2 1 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
1 49 MPa {500 kg/cm2} 2 Size: 10 x 1.25 mm 2 1 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2} Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester
1 Testing solenoid valve outN put pressure
790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter 799-101-5002 Hydraulic tester Testing PPC valve output pressure P 1 790-261-1204 Digital hydraulic tester 2 799-401-3100 Adapter Testing oil leakage Q Commercially Measuring cylinder available 799-601-4100 or T-adapter assembly 799-601-4200 799-601-4130 T-adapter 799-601-4160 T-adapter Troubleshooting for engine controller/sensors/ actuators S 799-601-4220 T-adapter 799-601-4240 Socket 799-601-4190 Socket 799-601-4340 Socket 795-799-5530 Socket 799-601-4380 Socket 799-601-4390 Socket
1 Size: 02 1 1
1 Size: 02 1 1 1 CAM 1 Ne sensor 1 Engine controller 1 For ambient pressure sensor 1 Common rall pressure sensor 1 Injector 1 Engine water temprature sensor 1 Boost pressure sensor 1 Engine controller
PC138US, USLC-8
SEN02458-01
Testing/Adjusting item
Symbol
Q'ty
Part No.
Part name
Remarks
799-601-4100 or 799-601-4200 or T-adapter assembly 799-601-9000 or 799-601-9200 799-601-9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9050 Adapter for DT Troubleshooting for chassis sensors/wiring harnesses T 799-601-9110 Adapter for DT 799-601-9220 Adapter for HD30 799-601-7000 or 799-601-7100 or T-adapter kit 799-601-7400 or 799-601-8000 799-601-7050 Adapter for SWP 799-601-7090 Adapter for M 799-601-7110 Adapter for M Testing coolant temperature and oil temperature Testing operating effort and depressing force Testing stroke and hydraulic drift Testing work equipment speed Testing voltage and resistance 799-101-1502 Digital thermometer 79A-264-0021 Push-pull scale 79A-264-0091 Push-pull scale Commercially Ruler available Commercially Stopwatch available Commercially Circuit tester available
1 For DT2P 1 1 1 1 For DT3P (Does not include 799-6014100 and 799-601-4200) For DT6P (Does not include 799-6014100 and 799-601-4200) For DT12P (Does not include 799601-4100 and 799-601-4200) For HD30P (Does not include 799601-4100 and 799-601-4200)
For SW6P (Does not include 799601-8000)
1 For M2P 1 For M3P 1 -99.9 1,299C 1 1 1 1 1
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Troubleshooting (General information on troubleshooting), List of T-boxes and T-adapters".
PC138US, USLC-8
SEN02458-01
Testing engine speed

a a
4.
Test the engine speed with the monitoring function of the machine monitor. Test the engine speed under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range Preparation work Operate the machine monitor so that the engine speed can be monitored. a For the operating method of the machine monitor, see Special functions of machine monitor. a Monitoring code: 01002 Engine speed 5.
Testing pump relief speed 1) Start the engine and operate the arm cylinder to the IN stroke end. 2) Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P). 3) Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and test the engine speed. Testing auto-deceleration speed 1) Start the engine, set the fuel control dial in the high idle position (MAX), and turn the auto-decelerator ON. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed when the auto-decelerator operates. a The engine speed lowers to a certain level about 5 seconds after all the levers and pedals are set in neutral. This level is the auto-deceleration speed.
1.
2.
Testing low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed. Testing high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the working mode in the power mode (P) and turn the auto-decelerator OFF. 3) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed.
3.
PC138US, USLC-8
SEN02458-01
Testing exhaust temperature

a
4.
Testing tools for exhaust temperature

Part No. 799-101-1502 Part name Digital thermometer R
Run the engine and test the exhaust temperature over the speed range.
Symbol
k
Install or remove the testing instrument after the exhaust manifold temperature has lowered. Remove the engine compartment side cover and exhaust manifold cover. Remove exhaust temperature pickup plug (1) from the side of the center of the exhaust manifold.
1.
2.
5.
After finishing test, remove the testing instrument and return the removed parts.
3.
Install sensor [1] of digital thermometer R and connect it to thermometer [2].
PC138US, USLC-8
SEN02458-01
Checking exhaust gas color

a
Checking tools for exhaust gas color

Part No. 799-210-9001 Commercially available Part name Handy smoke checker Smoke meter 1
Symbol A
k k
Stop the machine on a level ground and lower the work equipment to the ground. Be careful not to touch any hot part when removing or installing the checking tools. Check the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range If an air source and an electric power source are not available in the field, use handy smoke checker A1. When recording official data, use smoke meter A2. Testing with handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Start the engine and accelerate it suddenly or run it at high idle and operate the handle of smoke checker A1 so that the filter paper will absorb the exhaust gas. a Absorbing time: 1.4 0.2 sec
2)
3)
1.
4)
5)
Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter A2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. Connect the power cable to an AC receptacle. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of smoke meter A2.
6) 4) 5) 2. Remove the filter paper and compare it with the attached scale. After finishing checking, remove the testing tools and return the removed parts.
7)
Checking with smoke meter A2 1) Insert probe [1] of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip.
8)
Start the engine and accelerate it suddenly or run it at high idle and depress the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing checking, remove the checking tools and return the removed parts.
PC138US, USLC-8
SEN02458-01
Adjusting valve clearance

a
3.
Adjusting tools for valve clearance

Part No. 795-799-1131 Commercially available Gear Thickness gauge Part name 1
Remove plate (5) on the starting motor and insert gear B1.
Symbol B
k
Stop the machine on a level ground and lower the work equipment to the ground. Adjust the valve clearance under the following condition. q Engine coolant temperature: Normal temperature Open the engine hood and remove air intake hose (1), air conditioner compressor hose clamp (2) and heater hose clamp (3). 4. Remove compression top dead center TDC check plug (6) from the flywheel housing. Rotate the crankshaft forward with gear B1 and set it so that you can see the white mark of the flywheel.
1.
2.
Remove cylinder head cover (4).

a
When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn.
PC138US, USLC-8
SEN02458-01 Adjust the valve clearances marked with q in the valve arrangement drawing according to the following procedure.
5.
7.
After finishing adjustment, remove the adjusting tools and return the removed parts. k Take care not to forget remove gear B1. 3 Cylinder head cover mounting nut: 8.82 0.98 Nm {0.9 0.1 kgm}
1) 2)
3)
While fixing adjustment screw (1), loosen locknut (2). Insert thickness gauge B2 in the clearance between rocker arm (3) and valve stem (4) and adjust the valve clearance with adjustment screw (1). a With the thickness gauge inserted, turn the adjustment screw to a degree that you can move the thickness gauge lightly. While fixing adjustment screw (1), tighten locknut (2). 3 Locknut: 24 4 Nm {2.45 0.41 kgm} a After tightening the locknut, check the valve clearance again.
6.
Rotate the crankshaft forward 1 turn according to step 4 to set the No. 4 cylinder to the compression top dead center and adjust the valve c l ea r a nc e s m a r k ed wi th Q i n t he va l v e arrangement drawing similarly to those marked with q.
10
PC138US, USLC-8
SEN02458-01
Testing compression pressure

a
Testing tools for compression pressure

Part No. 795-502-1590 795-471-1420 6261-11-3880 Adapter Gasket Part name Compression gauge 1
Symbol C
k
When testing the compression pressure, take care not to burn you rself on t he exhaust manifold or muffler or get caught in a rotating part. Test the compression pressure after the engine is warmed up. (Engine oil temperature: 40 60C) Remove the injector of the cylinder to be tested according to the following procedure. a Test of the No. 1 cylinder is explained below as an example. 1) Remove wiring harness connector (2) from injector (1). 2) Move fuel scatter prevention cover (3) from the joint. 3) Remove clamp (4) and high-pressure pipe (5). 4) Pull spill hose connector (6) out of injector (1).
2.
1.
Install adapter C2 to the injector mounting part with holder (7) and connect compression gauge C1. a Fit the gasket to the adapter end without fail.
3
Holder mounting bolt: 27 30 Nm {2.8 3.1 kgm} Tighten the mounting bolt after the fulcrum of the holder is seated perfectly.
5)
Remove holder (7) and injector (1). a If the injector is stuck and is not removed easily, pass a wire under the fuel inlet and pull it up to remove the injector. a Do not apply an external force to the terminal at the injector top.
PC138US, USLC-8
11
SEN02458-01
3.
Disconnect CE03 connector (5) of the engine controller. k If the connector is not disconnected, the engine may starts during test and that is dangerous. Accordingly, be sure to disconnect the connector. k Since the CE03 connector is the power supply circuit of the engine controller, cover the connector on the machine side with a vinyl sheet etc. to prevent leak and ground fault.
4.
Rotate the engine with the starting motor and test the compression pressure. a Test the compression pressure when the gauge pointer is stabilized. After finishing test, remove the testing instruments and return the removed parts. a Install the injector and spill hose connector according to the following procedure. 1) Fit O-ring (8) and gasket (9) to injector (1). a Do not fit O-ring (8) to groove (a).
5.
12
PC138US, USLC-8
SEN02458-01
Testing blow-by pressure

a
D
k
Testing tools for blow-by pressure

Part No. 799-201-1504 Part name Blow-by checker 1
Symbol
Stop the machine on a level ground and lower the work equipment to the ground. Test the blow-by pressure under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range Remove the undercover of the hydraulic pump. Install tool and adapter [1] of blow-by checker D1 to breather hose (1) and connect gauge [2].
5.
1. 2.
After finishing test, remove the testing tools and return the removed parts.
3.
Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON. a If the swing lock switch is turned ON, the main relief valve is set for high-pressure relief. While running the engine at high idle, relieve the arm circuit and test the blow-by pressure. a Read the gauge when the pointer is stabilized.
4.
PC138US, USLC-8
13
SEN02458-01
Testing engine oil pressure

a
Testing tools for engine oil pressure

Part No. 799-101-5002 790-261-1204 799-401-2320 Part name Hydraulic tester Digital hydraulic tester Gauge
Symbol E
k
1 2
Stop the machine on a level ground and lower the work equipment to the ground. Test the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range Remove the engine compartment side cover and oil pressure pickup plug (1) from the engine block.
5.
1.
After finishing test, remove the testing tools and return the removed parts. 3 Oil pressure pickup plug: 20 22 Nm {2.0 2.2 kgm}
2.
Install nipple [1] of hydraulic tester E1 and connect hydraulic tester E2.
3. 4.
Start the engine and turn the auto-decelerator OFF. Run the engine and test the engine oil pressure at high idle and low idle.
14
PC138US, USLC-8
SEN02458-01
Handling fuel system parts

a
Precautions for checking and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When checking and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
Releasing residual pressure from fuel system 1

a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump Fuel main filter Supply pump High-pressure circuit: Supply pump Common rail Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is checked and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before checking the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
PC138US, USLC-8
15
SEN02458-01
Testing fuel pressure

a
1
Part name
Testing tools for fuel pressure

Part No. 799-101-5002 790-261-1204 795-471-1450 07005-00812 799-401-2320 Hydraulic tester Digital hydraulic tester Adapter (8 x 1.25 mm) O-ring Gauge
Symbol 1 F 2 3
k
Stop the machine on a level ground and lower the work equipment to the ground. Test only the fuel pressure in the low-pressure circuit from the priming pump through the fuel main filter to the supply pump and the return circuit from the supply pump/common rail/ injector to fuel tank. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be tested. Testing pressure in fuel low-pressure circuit 1) Open the engine hood and remove fuel pressure pickup plug (1) from the fuel main filter.
3)
Run the engine at high idle and test the pressure in the fuel low-pressure circuit. a If the pressure in the fuel low-pressure circuit is in the following range, it is normal.
Engine speed At high idle Fuel pressure -49 0 kPa {-0.5 0 kg/cm2}
1.
4)
After finishing test, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 7.8 9.8 Nm {0.8 1.0 kgm}
2)
Install adapter F2 and nipple [1] of hydraulic tester F1 and connect them to oil pressure gauge [2] a Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.
16
PC138US, USLC-8

a
SEN02458-01
Testing fuel return rate and fuel leakage 1

a
Lay test hose G4 so that it will not slacken and put its end in the oil pan.
Testing tools for fuel return rate and fuel leakage

Part No. 6151-51-8490 6164-81-5750 07042-20108 Commercially available Commercially available Commercially available Commercially available Spacer Joint Plug Hose Hose Measuring cylinder Part name 1 2 3 4
Symbol
5 6 7
6)
Stopwatch
Remove spill hose connector joint (5) and install plug G3.
Prepare an oil pan of about 20 l to receive the fuel flowing out during the test. Preparation work 1) Remove tube (3) and spill hose (4) between common rail (1) and return block (2).
1.
The above is the preparation work for test of the leakage from the pressure limiter and return rate from the injector.
2)
3)
4) 5)
Insert spacer G1 on return block (2) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the spacer. Insert joint G2 on common rail (1) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose G4 to the end of joint G2. Connect test hose G5 to connector (6) side of spill hose (4). a Bind the connecting part of the test hose with a wire etc. to prevent it from coming off.
PC138US, USLC-8
17
SEN02458-01
2.
Testing leakage from pressure limiter 1) Lay test hose G4 so that it will not slacken and put its end in the oil pan. 2) Start the engine and keep its speed at 1,600 rpm with no load. 3) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder G6. a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following standard range, it is normal.
Engine speed (rpm) 1,600 Leakage (cc/min) Max. 20
3.
Testing return rate from injector a While testing the return rate from the injector, keep the test hose on the pressure limiter side connected and keep its end in the oil pan. 1) Run the engine at the rated output. 2) After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder G6. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump pressure is low, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following standard range, it is normal.
Rated output speed (rpm) 1,600 1,700 1,800 1,900 2,000 Limit of return rate (spill) (cc/min) 190 200 210 220 230
4)
After finishing test, stop the engine.
3) 4.
After finishing test, stop the engine.
After finishing test, remove the testing tools and return the removed parts. 3 Joint bolt: 3.9 6.9 Nm {0.4 0.7 kgm}
18
PC138US, USLC-8
SEN02458-01
Bleeding air from fuel circuit

a
k
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. Stop the machine on a level ground and lower the work equipment to the ground. Fill the fuel tank with fuel. a Add fuel until the float of the sight gauge reaches the maximum position. Open the side cover of the pump room. Loosen knob (1) of the feed pump and pull it out, and then operate it forward and backward. a Move the knob until it becomes heavy. a The plug at the top of the fuel main filter does not need to be removed.
1.
2. 3.
4.
After bleeding air, push in and tighten knob (1).
PC138US, USLC-8
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SEN02458-01
a
Air bleeding route of fuel circuit Fuel tank o Pre-filter o Main filter o Feed pump o Metering unit o Fuel tank
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Fuel tank Priming pump Pre-filter with water separator Main filter Feed pump IMV (Inlet Metering Valve) Overflow valve Rail Injector Safety valve High pressure pump
20
PC138US, USLC-8
SEN02458-01
Checking fuel circuit for leakage 1

k
9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After checking the fuel system or removing its parts, check it for fuel leakage according to the following procedure. Stop the machine on a level ground and lower the work equipment to the ground. Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2. Run the engine at low idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2. Run the engine at high idle. Check the fuel piping and devices for fuel leakage. a Check around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2. Run the engine at high idle and load it. a Relieve the arm circuit at the IN stroke end.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2. a If no fuel leakage is detected, check is completed.
1.
2. 3.
4. 5.
6. 7.
8.
PC138US, USLC-8
21
SEN02458-01
Testing and adjusting alternator belt tension 1

Testing 1. Remove the engine compartment side cover and air intake pipe (1).
Adjusting a If the deflection is out of the standard range, adjust the belt tension according to the following procedure. 1. Loosen alternator fixing bolts (1) and (2). a Loosen fixing bolt (2) from the rear side of the engine.
Press the intermediate point of the belt between the alternator pulley and fan pulley with a finger and test deflection (a) of the belt. a Pressing force: Approx. 60 Nm {Approx. 6.1 kg} a Deflection (a): 6 10 mm
2.
Adjust the tension of alternator belt (4) by turning adjustment bolt (3). a Do not loosen double nut (5) at the adjustment bolt end. (If you have loosened it, apply LOCTITE (LT-2) to it when tightening.) Reference: If adjustment bolt (3) is tightened (turned to the right), the alternator belt (4) is loosened. If the former is turned to the left, the latter is tightened.
3.
After adjusting the belt tension, tighten alternator fixing bolts (1) and (2). Check again that the tension of alternator belt (4) is in the standard range.
4.
22
PC138US, USLC-8
SEN02458-01
Testing swing circle bearing clearance

a
Symbol H Part No. Commercially available Part name Dial gauge
4.
Testing tools for swing circle bearing clearance
Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats. a At this time the front of the upper structure rises and the rear lowers. Under this condition, read dial gauge H. a The value indicated by dial gauge H is the clearance of the bearing. a For the standard value, see Structure, function and maintenance standard, "Swing circle".
5.
a
k k
When testing the swing circle bearing clearance installed to the machine, perform the following procedure. Stop the machine on a level ground and lower the work equipment to the ground. Do not put your hands or feet under the undercarriage during test. Fix dial gauge H to the track frame and apply the probe to the lower end of the outer race.
1.
6.
Return the machine to the condition of step 2 and check that dial gauge H indicates 0. a If the dial gauge does not indicate 0, repeat steps 2 through 5.
2.
Set the work equipment to the maximum reach position and set the bucket tip to the height of the under side of the revolving frame. a At this time the front of the upper structure lowers and the rear rises. Set dial gauge H to the 0 point.
3.
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SEN02458-01
Checking and adjusting air conditioner compressor belt tension

k
Adjusting a If the belt deflection is abnormal, adjust it according to the following procedure. 1. 2. Loosen bolts (1) and (2) and locknut (6). Move compressor (3) and bracket (4) as a set with adjustment bolt (5) to adjust the belt tension. After positioning compressor (3), tighten bolts (1) and (2) and locknut (6). a Check each pulley for breakage, wear of the V-groove, and contact of the V-belt and V-groove. a If the V-belt is so lengthened that the adjustment allowance is eliminated or it has a cut or a crack, replace it. a If the belt is replaced, adjust their tension again after operating the machine for 1 hour. a After tightening the bolts, check the belt tension again according the above procedure.
Stop the machine on a level ground and lower the work equipment to the ground.
Checking 1. Open the engine hood, press the intermediate point of the belt between the fan pulley and compressor pulley with a finger, and test deflection (a) of the belt. q Belt pressing force: 60 N {6.1 kg}
3.
4.
After finishing test, return the removed parts.
24
PC138US, USLC-8
SEN02458-01
Checking and adjusting track shoe tension
Checking 1. Run the engine at low idle and drive the machine forward by the length of track on ground, and then stop slowly. 2. Place square bar [3] longer than the distance between idler (1) and carrier roller (2) on the track shoe. a As the steel bar, use an angle steel, etc. which will be deflected less. Test maximum clearance (a) between steel bar [3] and track shoe. q Standard maximum clearance (a): 10 30 mm
Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1. Increasing tension 1) Add grease through grease fitting (2) with a grease gun. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track shoe tension again according to the above procedure.
3.
You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. If the tension is still low, the pins and bushings are worn much. In this case, reverse or replace the pins and bushings.
PC138US, USLC-8
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SEN02458-01
2.
Decreasing tension 1) Loosen valve (1) to discharge grease, and then tighten it. k Do not loosen the valve more than 1 turn. If it is loosened more, it may jump out because of the highpressure grease in it. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track shoe tension again according to the above procedure.
26
PC138US, USLC-8
SEN02458-01
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 1
a
Testing and adjusting tools for oil pressure in work equipment, swing, and travel circuits
Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023 Part name Hydraulic tester Digital hydraulic tester Nipple (10 1.25 mm) O-ring
Symbol 1 J 2
k
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit".
2)
Install nipples J2 and connect oil pressure gauges [1] of hydraulic tester J1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.
Testing a The oil pressure in the work equipment, swing, and travel circuits (pump discharge pressure) can be checked with monitoring function of the machine monitor, too (For details, see "Special functions of machine monitor"). q Monitoring code: 01100 pump pressure a Test the oil pressure in the work equipment, swing, and travel circuits under the following condition. q Hydraulic oil temperature: Within operating range 1. Preparation work 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure port (1) check plug q (2): Pump discharge pressure port (2) check plug 2. Testing unload pressure 1) Start the engine, set the working mode in the power mode (P), and turn the autodecelerator OFF. 2) Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure. a The pressure tested when the unload valve is unloaded is indicated.
PC138US, USLC-8
27
SEN02458-01
3.
Testing work equipment relief pressure 1) Start the engine and move the cylinder to be tested to the stroke end. 2) Set the working mode in the power mode (P). 3) Run the engine at high idle, operate the right and left work equipment control levers to relieve the cylinder, and test the oil pressure. a The pressure tested when the main relief valve is relieved is indicated (If t he boo m is l owe r ed si ng ly, t he safety-suction valve of the control valve for lowering the boom is relieved). Testing swing relief pressure 1) Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON. 2) Run the engine at high idle, operate the left work equipment control lever to relieve the swing motor, and test the oil pressure. a The pressure tested when the swing motor relief valve is relieved is indicated. a The swing relief pressure is lower than the main relief pressure. Testing travel relief pressure 1) Run the engine and lock the travel mechanism. k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely.
2) 3)
Set the working mode in the power mode (P). Run the engine at high idle, operate the travel lever and pedal to relieve the travel motor, and test the oil pressure. k Before operating the travel lever and pedal, check the position and locking direction of the locked sprocket again. a The pressure tested when the main relief valve of the control valve is relieved is indicated. The travel circuit is always relieved at high pressure.
6.
4.
Work after finishing test After finishing test, remove the testing tools and return the removed parts. 3 Oil pressure pickup plug: 20 27 Nm {2.0 2.8 kgm}
5.
28
PC138US, USLC-8
SEN02458-01
Adjusting a The unload valve and safety-suction valve for lowering the boom cannot be adjusted. 1. Adjusting work equipment and travel relief pressure a If the relief pressure of the work equipment circuit and travel circuit is abnormal, adjust main relief valves (3) according to the following procedure. q (3): Main relief valve a When adjusting the main relief valves, remove the side cover of the control valve.
2.
Adjusting swing relief pressure a If the swing relief pressure is abnormal, adjust safety valve (6) of the swing motor according to the following procedure.
1) 2)
1) 2) 3)
4)
Remove the control valve left side cover. While fixing holder (4), loosen locknut (5). Turn holder (4) to adjust the set pressure. a If the holder is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} While fixing holder (4), tighten locknut (5). 3 Locknut: 49 58.8 Nm {5 6 kgm}
3)
While fixing adjustment screw (7), loosen locknut (8). Turn adjustment screw (7) to adjust the pressure. a If the adjustment screw is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of adjustment screw: Approx. 6.7 MPa {Approx. 68.4 kg/cm2} While fixing adjustment screw (7), tighten locknut (8). 3 Locknut: 78 103 Nm {8 10.5 kgm}
4)
After finishing adjustment, check again that the oil pressure is normal according to the above described test procedure.
5)
After finishing adjustment, check again that the oil pressure is normal according to the above described test procedure.
PC138US, USLC-8
29
SEN02458-01
Testing control circuit basic pressure

a
Symbol 1 K 2
k
3.
1
4.
Testing tools for control circuit basic pressure

Start the engine, set the working mode in the power mode (P), and turn the auto-decelerator OFF. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure.
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Test the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range Remove the control valve cover and oil pressure pickup plug (1). 5.
a
1.
After finishing test, remove the testing tools and return the removed parts. The control circuit basic pressure may be tested with oil pressure pickup plug (2) on the hydraulic pump side.
2.
Install nipple K2 and connect oil pressure gauge [1] of hydraulic tester K1. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.
Do not adjust the relief valve for control circuit basic pressure.
30
PC138US, USLC-8
SEN02458-01
Testing and adjusting oil pressure in pump PC control circuit 1

a
Testing and adjusting tools for oil pressure in pump PC control circuit
Symbol 1 L 2
k
2)
Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1.
Testing a Before testing the oil pressure in the PC control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure of the control circuit are normal. a Test the oil pressure in the pump PC control circuit under the following condition. q Hydraulic oil temperature: Within operating range 1. Testing PC valve output pressure (servo piston inlet pressure) a Test the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): PC valve output pressure pickup plug
a
Install nipple L2 to the inspection part of plug (2) and connect it to oil pressure gauge [1] by hose [2] of hydraulic tester L1. Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.
3) 4)
Start the engine and move the arm cylinder to the IN stroke end. Set the working mode in the power mode (P).
PC138US, USLC-8
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SEN02458-01
5)
Run the engine at high idle, operate the left work equipment control lever to relieve the arm circuit at the IN stroke end, and test the oil pressure.
2)
Install nipples L2 and connect them to oil pressure gauges [1]. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.
Testing condition and method of judgment: If the pressures are in the following ratio, the PC valve is normal.
Tested oil pressure Operation of lever Arm IN relief Ratio of oil pressures 1 Approx. 0.6 (Approx. 3/5)
3) 4)
Pump discharge pressure PC valve output pressure
Start the engine and set the working mode in the power mode (P). Run the engine at high idle and low idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed.
6) 2.
If the PC valve or the servo piston is abnormal, the PC valve output pressure (servo piston inlet pressure) is "the same as the pump discharge pressure" or "almost 0". After finishing test, remove the testing tools and return the removed parts.
Testing PC-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup plugs (3). (3): PC-EPC valve output pressure pickup plug
Testing condition and method of judgment: If the output pressures are in the following ratio, the PC-EPC valve is normal.
Operation of lever All control levers and pedals in neutral Output pressure Approx. 2.9 MPa {Approx. 30 kg/cm2} Approx. 3.4 MPa {Approx. 35 kg/cm2}
Engine Low idle High idle
5)
32
PC138US, USLC-8
SEN02458-01
Adjusting Adjusting pump PC valve a If the following phenomenon occurs and PC valve (4) seems to be defective, adjust PC valve (4) according to the following procedure. q As the working load increases, the engine speed lowers remarkably. q The engine speed is normal but the work equipment speed is low. a The width across flats of the PC valve locknut is 13 mm and that of the adjustment screw (inside width) is 4 mm. Do not turn any other locknuts or adjustment screws since they affects the hydraulic pump performance.
4.
After finishing adjustment, check again that the PC valve output pressure (servo piston inlet pressure) is normal according to the above described test procedure.
1.
Loosen locknut (5). a Before loosening the locknut, make counter mark at the adjustment screw end so that you can see the position of the locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse). Turn adjustment screw (6) clockwise or counterclockwise to adjust. a Turn the adjustment screw q Clockwise when the work equipment s pee d i s low ( to i nc re ase pu mp absorption torque) and q Counterclockwise when the engine speed lowers (to decrease pump absorption torque). Tighten locknut (5). 3 Locknut: 27 34 Nm {2.8 3.5 kgm}
2.
3.
PC138US, USLC-8
33
SEN02458-01
Testing and adjusting oil pressure in pump LS control circuit 1

a
Testing and adjusting tools for oil pressure in pump LS control circuit
Part No. 799-101-5002 790-261-1204 799-401-2701 799-101-5220 07002-11023 Part name Hydraulic tester Digital hydraulic tester Differential pressure gauge Nipple (10 1.25 mm) O-ring
Symbol 1 M 2 3
k
2)
Install nipple M3 and connect it to oil pressure gauge [1] of hydraulic tester M1.
Testing a Before testing the oil pressure in the LS control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure of the control circuit are normal. a Test the oil pressure in the pump LS control circuit under the following condition. q Hydraulic oil temperature: Within operating range 1. Testing LS valve output pressure (servo piston inlet pressure) a Test the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): LS valve output pressure pickup plug
a
Install nipple M3 to the inspection part of plug (2) and connect it to oil pressure gauge [1] by hose [2] of hydraulic tester M1. Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.
3)
Start the engine and push up the track shoe on the side to be tested with the work equipment and prepare for running the track shoe idle. k Since the raised track shoe will be run idle during test, secure a sufficient working area.
34
PC138US, USLC-8
SEN02458-01
4) 5)
Set the working mode in the power mode (P) and set the travel speed in the High position. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed. Then, operate the travel lever to run the track shoe idle and test the oil pressure. k While checking the safety around the machine extremely, run the track shoe pushed up idle. a Do not operate the travel lever to the stroke end (but stop it halfway).
2)
Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): LS pressure pickup plug
3)
Testing condition and method of judgment: If the pressures are in the following ratio, the LS valve is normal.
Operation of lever and ratio of oil pressures Tested oil pressure All control Travel lever levers and moved halfpedals in neu- way (Track tral shoe run idle) 1 Almost same Approx. 0.6 (Approx. 3/5)
Pump discharge pressure LS valve output pressure
Install nipples M3 and connect it to differential pressure gauge M2 or the oil pressure gauge [1] of hydraulic tester M1. a When using differential pressure gauge M2: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12V power source, connect it to a battery. a When using oil pressure gauge (in M1): Use the oil pressure gauge of 58.8 MPa {600 kg/cm2} having the unit of 0.98 MPa {10 kg/cm2}. Since the differential pressure is about 3.9 MPa {40 kg/cm 2 } at maximum, test it by installing the same gauge to the pickup plugs alternately. q The figure shows the pump discharge pressure side.
6) 2.
Testing LS differential pressure a Test the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the difference between them. 1) Remove connector V5 (Port A4) of the solenoid valve. Purpose: Remove the connector to set the merge-divider valve in the constant merge state and stabilize the LS differential pressure.
PC138US, USLC-8
35
SEN02458-01
a
The figure shows the LS pressure side.
Testing condition and method of judgment: If the pressures are in the following ratio, the LS valve is normal.
Operation of levers LS differential pressure 2.8 1.0 MPa {28 10 kg/cm2} 2.2 0.1 MPa {22.5 1 kg/cm2}
All control levers and pedals in neutral Travel lever moved halfway (No-load travel operation of one side)
7)
4)
5) 6)
Run the engine, push up the track shoe on the side to be tested with the work equipment, and prepare for running track shoe idle. q When testing P1 circuit: Right track shoe q When testing P2 circuit: Left track shoe k Since the raised track shoe will be run idle during test, secure a sufficient working area. Set the working mode in the power mode (P) and set the travel speed in the High position. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed. Then, operate the travel lever to run the track shoe idle and test the oil pressure. k While checking the safety around the machine extremely, run the track shoe pushed up idle. a Do not operate the travel lever to the stroke end (but stop it halfway).
After finishing test, remove the testing tools and return the removed parts. Insert the removed connector V5 of the solenoid valve in its original position.
36
PC138US, USLC-8
SEN02458-01
Adjusting Adjusting LS valve a If the LS differential pressure is abnormal, adjust the LS valve according to the following procedure. q (3): Pump LS valve
1. 2.
While fixing adjustment screw (4), loosen locknut (5). Turn adjustment screw (4) to adjust the differential pressure. a If the adjustment screw is q Turned to the right, the differential pressure is increased. q Turned to the left, the differential pressure is decreased. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. 1.1 MPa {Approx. 10.8 kg/cm2} While fixing adjustment screw (4), tighten locknut (5). 3 Locknut: 49 68.6 Nm {5 7 kgm}
3.
4.
After finishing adjustment, check again that the LS differential pressure is normal according to the above described test procedure.
PC138US, USLC-8
37
SEN02458-01
Testing solenoid valve output pressure

a
Symbol N
k
2.
1
3.
Install adapter N2 and connect the disconnected hose again. Install nipple [1] of hydraulic tester N1 and connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. a The figure shows the testing tools connected to outlet hose (1) of the PPC lock solenoid valve.
Testing tools for solenoid valve output pressure

Part No. 799-101-5002 790-261-1204 799-401-3100 Part name Hydraulic tester Digital hydraulic tester Adapter (Size: 02)
1 2
a a
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Before testing the solenoid valve output pressure, check that the basic pressure of the control circuit is normal. Test the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range Remove the control valve left side cover and disconnect outlet hoses (1) (5) of the solenoid valve to be checked. 4. 5. Start the engine. Run the engine at high idle, operate the control levers and switches to turn the solenoid valve ON or OFF, and test the oil pressure. a For the conditions for turning the solenoid valve ON and OFF, see the operation table of each solenoid valve. a The operating condition of the solenoid valve can be checked with the monitoring function of the machine monitor (For details, see "Special functions of machine monitor"). q Monitoring code: 02300 Solenoid 1 a If the output pressure is as follows, the solenoid valve is normal.
Solenoid valve OFF (Demagnetization) ON (Excitation) Output pressure 0 MPa {0 kg/cm2} 2.9 MPa {30 kg/cm2}
1.
No. 1 2 3 4 5
Solenoid valve to be tested PPC lock solenoid valve Travel speed shifting solenoid valve Swing holding brake solenoid valve Merge-divider valve Travel junction solenoid valve
When testing with hose (1), remove the undercover (rear side) of the operator's cab.
6.
38
PC138US, USLC-8

a
SEN02458-01
Testing PPC valve output pressure

Connecting points of PPC piping
Testing tools for PPC valve output pressure

Part No. 799-101-5002 790-261-1204 799-401-3100 Part name Hydraulic tester Digital hydraulic tester Adapter (Size: 02)
Symbol P
k
1 2
a a a
The above figure shows the connecting points of the PPC piping on the control valve of 1 attachment installation specification. The colors in ( ) are the colors of the bands installed for distinction of the pipes. The figure at right shows the check points of the steering signal voltage of the travel PPC valve. When testing the steering signal voltage, remove the undercover of the operator's cab (front side).
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Before testing the PPC valve output pressure, check that the basic pressure of the control circuit is normal. Test the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range Disconnect the hose of the PPC circuit to be tested. a For the hose to be disconnected, see "Connecting points of PPC piping". Install adapter P2 and connect the disconnected hose again. Install nipple [1] of hydraulic tester P1 and connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. a The figure shows the testing tools connected to the hose of the bucket dump PPC circuit.
1.
2. 3.
PC138US, USLC-8
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SEN02458-01
4. 5.
Start the engine and set the working mode in the power mode (P). Run the engine at high idle and test the oil pressure with the control lever in neutral and moved to the stroke end.
If the output pressure is as follows, the PPC valve is normal.

Operation of lever Neutral Stroke end Output pressure 0 MPa {0 kg/cm2} Almost same as control circuit basic pressure (See standard values table)
6.
40
PC138US, USLC-8
SEN02458-01
Adjusting play of work equipment and swing PPC valves 1

a
If the right and left work equipment levers have large play, adjust them according to the following procedure. Remove the work equipment and swing PPC valve assembly. Remove bellows (1). Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4). Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 93.1 112.7 Nm {9.5 11.5 kgm} Install bellows (1). Install the work equipment and swing PPC valve assembly.
1. 2. 3. 4.
5. 6.
PC138US, USLC-8
41
SEN02458-01
Checking parts which cause hydraulic drift of work equipment1

a
2.
If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylind e r pa c k i n g s i d e o r c o n t r o l v a l v e s i d e according to the following procedure. Checking boom cylinder and bucket cylinder 1) Set the machine in the position for testing hydraulic drift and stop the engine. a Fill the bucket with a rated load or with dirt and sand.
Checking arm cylinder 1) Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine.
1.
2)
When checking the boom cylinder, set the boom control lever in the RAISE position. When checking the bucket cylinder, set the bucket control lever in the CURL position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator.
Operate the arm control lever in the IN position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator. [Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2) As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then the lowering speed is lowered. 3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.
2)
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3.
Checking PPC valve While the pressure in the accumulator is high, set the lock lever in the LOCK/FREE position and test the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator. a If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).
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Testing and adjusting travel deviation
Inspection 1. Run the engine and heighten the hydraulic oil temperature to the operating range and set the machine in the travel posture. a To set the machine in the travel posture, extract the bucket cylinder and arm cylinder fully and set the boom angle to 45. 2. Set the working mode to P and travel speed to Lo. Run up for 10 m with the engine speed at high idle and continue travel under the same condition for 20 m and measure the deviation (a). a Install an oil pressure gauge and check that the P1 and P2 discharge pressures of the hydraulic pump are even.
3.
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Adjustment a If the machine deviates, it can be corrected by partially draining the oil discharged more from the pump through the travel deviation adjusting plug. (If the travel deviation is corrected by this method, however, the pump discharge is reduced. As a result, the travel speed, work equipment speed in compound operation, and relief pressure may lower.) a If the machine deviates in the same direction regardless of the travel direction, correct it according to the following procedure. (If the deviating direction of the machine depends on the travel direction, the cause of deviation may not be in the hydraulic pump. In this case, carry out troubleshooting.) a Only when the travel deviation is 200 mm or less, it can be corrected by the following method. k If the adjusting plug is loosened more than the adjustment limit, high-pressure oil will spout out. Take care extremely. k Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the residual pressure from the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 1. Check the deviating direction and the locations of travel deviation adjusting plugs (1) and (2). q (1): Right deviation adjusting plug (P1 pump) q (2): Left deviation adjusting plug (P2 pump) a Loosen only the plug on either side for adjustment. Do not loosen the plugs on both sides.
2.
Fixing plug (3) with a hexagonal wrench (Width across flats: 4 mm), loosen locknut (4). a If the locknut is sealed with a vinyl tape, remove that tape. a Before loosening the locknut, make match marks on it and pump case. q Loosening angle of locknut: Approx. 90 180
3.
Loosen plug (3) to adjust the travel deviation. q Quantity of adjustment of deviation per turn of plug: 150 mm (Reference) a The plug is fully tightened when shipped. Adjust the deviation by the loosening angle of the plug from the fully tightened position. a If the plug is turned together with the locknut, tighten it fully again, then start adjustment. a The plug can be loosened by 2 turns (720) from the fully tightened position. Fixing plug (3) with a hexagonal wrench, tighten locknut (4). 3 Locknut: 2.9 4.9 Nm {0.3 0.5 kgm} a After tightening the locknut, seal its hole with a vinyl tape. After finishing adjustment, check travel deviation again according to the procedure for inspection described above.
4.
5.
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Releasing residual pressure from hydraulic circuit 1

1. Releasing residual pressure from hydraulic tank k Since the hydraulic tank is enclosed and pressurized, release the residual pressure from it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable position and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank. 3.
4)
Repeat steps 2) and 3) above 2 3 times, and the residual pressure in the piping is released completely.
Releasing residual pressure from swing motor circuit The residual pressure in the swing motor circuit can be released by performing the operation for "Releasing residual pressure from hydraulic cylinder circuit" (Operate the lever in the swing direction only, however). Releasing residual pressure from travel motor circuit Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by performing "Releasing residual pressure from hydraulic tank".
4.
2.
Releasing residual pressure from hydraulic cylinder circuit k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the residual pressure from the piping according to the following procedure. 1) Lower the work equipment and release the residual pressure from the hydraulic tank. For details, see "Releasing residual pressure from hydraulic tank". a Keep the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch ON and set the lock lever in the FREE position, and then operate the right and left work equipment control levers forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up, however, after the control valve is operated 2 3 times. 3) Run the engine at low idle for 5 seconds to heighten the pressure in the accumulator. a The engine does not start until the lock lever is set in the LOCK position once.
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Testing oil leakage

a
1
Part name
2.
Testing tools for oil leakage

Part No. Commercially available
Symbol Q
Measuring cylinder
Test the oil leakage under the following condition. q Hydraulic oil temperature: Within operating range Testing oil leakage from boom cylinder 1) Move the boom cylinder to the RAISE stroke end and stop the engine. k Release the residual pressure from the piping on the boom cylinder head side. For details, see "Releasing residual pressure from hydraulic circuit" (Operate the lever in the boom RAISE direction only, however). 2) Disconnect hose (1) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-00640 (Flange #06)
1.
Testing oil leakage from arm cylinder 1) Move the arm cylinder to the IN stroke end and stop the engine. k Release the residual pressure from the piping on the arm cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the arm IN direction only, however). 2) Disconnect hose (2) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70522 (Plug #05)
3)
4) 5)
Run the engine at high idle and relieve the arm circuit by moving the arm IN. k Take care not to "move the arm OUT". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.
3) 4) 5)
Run the engine at high idle and relieve the boom circuit by raising the boom. k Take care not to "lower the boom". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.
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3.
Testing oil leakage from bucket cylinder 1) Move the bucket cylinder to the CURL stroke end and stop the engine. k Release the residual pressure from the piping on the bucket cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the bucket CURL direction only, however). 2) Disconnect hose (3) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70422 (Plug #04)
4.
Testing oil leakage from swing motor 1) Disconnect 2 drain hoses (4) and block the hose side with plugs. a Use the following parts to block the hose side. 07376-70315 (Plug #03)
2) 3)
4) 3) 4) 5) Run the engine at high idle and relieve the bucket circuit by curling the bucket. k Take care not to "dump the bucket". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.
Turn the swing lock switch ON. Run the engine at high idle and relieve the swing circuit by swinging. a Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. a After testing 1 time, swing 180, and then test again. After finishing test, return the removed parts.
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5.
Testing oil leakage from travel motor 1) Remove the travel motor cover. 2) Run the engine, lock the travel mechanism, and stop the engine. k Put pin [1] between the sprocket and track frame to lock the travel mechanism securely.
5)
After finishing test, return the removed parts.
3)
Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Use the following part to block the hose side. 07376-70422 (Plug #04)
4)
Run the engine at high idle, relieve the travel circuit, and test the oil leakage. k Before operating the travel lever, check the position and locking direction of the locked sprocket again. k Wrong operation of the lever can cause an accident. Accordingly, make signs and checks securely. a Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. a Test several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time.
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Bleeding air from each part

Air bleeding item 1 Bleeding air from hydraulic pump q
1
Air bleeding procedure 2 Starting engine q q 3 4 5 6 Checking oil level and starting operation q q q
Contents of work Replacing hydraulic oil Cleaning strainer Replacing return filter element Replacing and repairing hydraulic pump Removing suction piping Replacing and repairing control valve Removing control valve piping Replacing and repairing cylinder Removing cylinder piping Replacing and repairing swing motor Removing swing motor piping Replacing and repairing travel motor Removing travel motor piping Replacing and repairing swivel joint Removing swivel joint piping
Bleeding air Bleeding air Bleeding air from swing from travel from cylinder motor motor q o q q (See note) o o q (See note) o o
q q q
q q o
o o q
o o o
q q q
q q
o o
o o
q o
q q
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1. Bleeding air from hydraulic pump 1) Loosen air bleeder (1) and check that oil oozes out through the air bleeder. 2) After the oil oozes out, tighten air bleeder (1). 3 Air bleeder: 7.8 9.8 Nm {0.8 1.0 kgm} a Do not use an impact wrench to tighten the air bleeder. 2. Starting engine When running the engine after performing step 1, keep its speed at low idle for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset). Bleeding air from cylinder a If a cylinder is replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idle for about 5 minutes. 2) While running the engine at low idle, raise and lower the boom 4 5 times. a Stop the piston rod about 100 mm b efo re e ac h s tr ok e en d. Do no t relieve the oil.
3.
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3) 4)
5) 4.
While running the engine at high idle, perform step 2). While running the engine at low idle, move the piston rod to the stroke end and relieve the oil. Bleed air from the arm cylinder and bucket cylinder according to steps 2) 4).
6.
Checking oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.
Bleeding air from swing motor 1) Turn the swing lock switch "ON" and run the engine at low idle for 5 minutes. a Bleed air from the swing motor by applying the S-port pressure. 2) Remove the swing motor top cover, disconnect hose (1) from the swing motor, and block the hose with a plug. a Use the following plug to block the hose. 07379-70628 (Plug #06) 2) Check the oil level by sight gauge (3) on the rear side of the hydraulic tank. a If the oil level is below line L, it is insufficient. Add oil. a The oil level changes according to the oil temperature. Add oil when the oil level is out of the following standard ranges. q When oil temperature is 10 30C: Between line H and line L q When oil temperature is 50 80C: Near line H
3)
4) 5.
Run the engine at low idle and check that oil flows out of elbow (2). a If no oil flows out of the elbow, perform step 1) again. Connect hose (1) under its normal condition.
Bleeding air from travel motor 1) Remove the travel motor cover and disconnect motor drain hose (2). 2) Run the engine at low idle and check that oil flows out of nipple (3).
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Checking cab tipping stopper
Adjusting mirrors
Adjusting mirrors (a1) and (b1) Loosen bolts (1) and (2) of the mirrors and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator's seat. a Adjust the mirrors so that the operator can see persons (or things 1 m high and about 30 cm in diameter) at the right and left rear of the machine.
Check the cab tipping stopper according to the following procedure. Remove the side lower cover of the operator's cab. a Perform this step only when the additional undercover is installed. Check the tightening torque of the mounting bolt (2) of the lock plate (1). 3 Bolt (2): 98 123 Nm {10 12.5 kgm}
1.
2.
[Reference] q The tightening torque of mounting bolt (4) of cab tipping stopper (3) is different from that of a common bolt 30 mm in diameter. Take care. 3 Bolt (4): 245 309 Nm {25 31.5 kgm}
Adjusting mirrors (c1) and (d1) Adjust the mirrors so that the operator can see the ground at 1 m around the machine from the operator's seat. a If the mirror is hard to move for adjustment, loosen bolts (3) and (4).
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HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number

Special functions of machine monitor ............................................................................................................. 2
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Special functions of machine monitor

Air conditioner specification
PC138US, USLC-8
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Upper section of machine monitor (Display section) (a): Multi-display a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Auto-decelerator switch [2]: Numeral 2 input switch/Working mode selector switch [3]: Numeral 3 input switch/Travel speed shifting switch [4]: Numeral 4 input switch/Alarm buzzer cancel switch [5]: Numeral 5 input switch/Wiper switch [6]: Numeral 6 input switch/Windshield washer switch [7]: Numeral 7 input switch/Air conditioner or heater switch [8]: Numeral 8 input switch/Air conditioner or heater switch [9]: Numeral 9 input switch/Air conditioner or heater switch [0]: Numeral 0 input switch/Air conditioner or heater switch Switch having no numerals: Air conditioner or heater switch a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multidisplay.
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t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page 6p 6p 7p 7p 7p 7p 8p 8p 8p O (Special operation) 8p 9p 10p 10p 10p 10p 11p 11p 12p 12p 13p 14p 14p 14p Monitoring Mechanical Systems Abnormality Electrical Systems Record Air-conditioning System Maintenance Record Maintenance Mode Change Phone Number Entry Key-on Mode Unit Default With/Without Attachment Attachment/Maintenance Password Camera ECO Display Adjustment Pump Absorption Torque Attachment Flow Adjustment Page 19p 20p 25p 26p 32p 33p 34p 36p 37p 38p 39p 40p 41p 42p 43p 44p 45p 46p 48p 49p 50p 51p 52p 53p
t Operator mode (Outline) A Display of KOMATSU logo A Display of inputting password A Display of check before starting A Display of warning after check before starting A Display of ending of maintenance interval A Display of check of working mode and travel speed A Display of ordinary screen A Display of end screen B Selection of auto-deceleration B Selection of working mode B Selection of travel speed B Operation to stop alarm buzzer B Operation of windshield wiper B Operation of window washer B Operation of air conditioner/heater B Operation to display camera mode B Operation to display clock and service meter B Check of maintenance information B Setting and display of user mode (Including KOMTRAX messages for user)
Service mode
Cylinder Cut-Out No Injection Fuel Consumption Terminal Status KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300) MODEM IP Address (TH200/201) Display of KOMTRAX message
C Display of energy-saving guidance C Display of caution monitor C Display of user code and failure code O (Special operation) D Function of checking display of LCD (Liquid Crystal Display)
16p 16p 17p
D Function of checking service meter D Function of changing attachment/maintenance password
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Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch
PC138US, USLC-8
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Operator mode (Outline) Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see the Structure, function and maintenance standard, or Operation and Maintenance Manual. The following are the displays or functions of the operator mode explained in this section (including some items which need special operations).
Display pattern A B C D E Display of KOMATSU logo Display of inputting password Display of check before starting Display of warning after check before starting Display of ending of maintenance interval Display of check of working mode and travel speed Display of ordinary screen Display of end screen Selection of auto-deceleration Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user) Display of energy-saving guidance Display of caution monitor Display of user code and failure code O (Special operation) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing attachment/maintenance password 1 1 1 1 1 2 3 2 3 2 2 3 3 4 3 4 4 4 5 4 5 5 5
Display pattern of operator mode The contents of display from the time when starting switch is turned ON to time when screen changes to ordinary screen depends on the setting and condition of the machine. A : When engine start lock is set effective B : When engine start lock is set ineffective C : When working mode at start is set to breaker mode (B) D : When there is abnormal item in checkbefore-starting items E : When there is maintenance item which is not maintained after specified interval
Display of KOMATSU logo When the s tarting switch is turned ON, the KOMATSU logo is displayed for 2 seconds. a After the KOMATSU logo is displayed for 2 seconds, the screen changes to "Display of inputting password", or "Display of check before starting".
a a
The following screen may be displayed instead of the above Display of inputting password screen. If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.
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Display of inputting password After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective. a If the password is input normally, the screen changes to "Display of check before starting". a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.
Display of warning after check before starting If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the engine oil level monitor (a) is warning of low of engine oil level.
Display of check before starting When the screen changes to the check-beforestarting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of ending of maintenance interval". a If no abnormality is detected by the check before starting, the screen changes to "Display of check of working mode and travel speed". a The monitors (3 pieces) displayed on the screen are the items under the check before starting.
Display of ending of maintenance interval When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode. a After display of this screen is finished, the screen changes to "Display of check of working mode and travel speed".
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Display of check of working mode and travel speed If the check before starting is finished normally, the screen to check the working mode and travel speed is displayed for 2 seconds. a After display of check of the working mode and travel speed is finished, the screen changes to "Display of ordinary screen".
Display of end screen When the starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.
Display of ordinary screen If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a ECO gauge (b) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).
Selection of auto-deceleration While the ordinary screen is displayed, if the autodeceleration switch is pressed, large auto-deceleration monitor (a) is displayed for 2 seconds and the setting of the auto-deceleration is changed. a Each time the auto-deceleration switch is pressed, the auto-deceleration is turned ON and OFF alternately. a If the auto-deceleration is turned ON, large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously. a If the auto-deceleration is turned OFF, autodeceleration monitor (b) goes off.
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Selection of working mode Select a working mode according to the following procedure. 1. While the ordinary screen is displayed, press the working mode selector switch, and the working mode selection screen is displayed. a The following figure is the working mode selection screen displayed when "With attachment" is set (If "With attachment" is not set in the service mode, the attachment mode [ATT] is not displayed).
3.
When the ordinary screen is displayed again, large working mode monitor (a) is displayed for 2 seconds, and then the setting of the working mode is changed. a When large monitor (a) is displayed, the display of working mode monitor (b) is changed, too.
2.
Operate the function switches or working mode selector switch to select and confirm the working mode which you will use. Function switches q [F3]: Move to lower working mode q [F4]: Move to upper working mode q [F5]: Cancel selection and return to ordinary screen q [F6]: Confirm selection and return to ordinary screen Working mode selector switch q Press: Move to lower working mode q Hold down:Confirm selection and return to ordinary screen a If you do not touch any of the function switches and working mode selector switch for 5 seconds, the selection is confirmed and the screen changes to the ordinary screen.
<Precautions for selecting breaker mode [B]> q If breaker mode [B] is selected, both of the control of the hydraulic pump and the setting of the hydraulic circuit are changed. q If an attachment other than the breaker is used, the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged.
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Selection of travel speed While the ordinary screen is displayed, if the travel speed shifting switch is pressed, large travel speed monitor (a) is displayed for 2 seconds and the setting of the travel speed is changed. a Each time the travel speed shifting switch is pressed, the travel speed is changed to Lo, Hi, and Lo again in order. a When large monitor (a) is displayed, the display of travel speed monitor (b) is changed, too.
Operation of windshield wiper While the ordinary screen is displayed, if the wiper switch is pressed, large wiper monitor (a) is displayed for 2 seconds and the windshield wiper starts or stops. a Each time the wiper switch is pressed, the windshield wiper setting is changed to INT, ON, OFF, and INT again in order. a When large monitor (a) is displayed, the display of wiper monitor (b) is changed or turned OFF, too. a If the windshield wiper is turned OFF, large monitor (a) is not displayed.
Operation to stop alarm buzzer While the alarm buzzer is sounding, if the alarm buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the alarm buzzer cancel switch is pressed, the screen does not change.
Operation of window washer While the ordinary screen is displayed, if the window washer switch is pressed, the washing liquid is splashed only while the switch is held down. a Even if the window washer switch is pressed, the screen does not change.
10
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Operation of air conditioner/heater While the ordinary screen is displayed, press the air conditioner switch and the air conditioner adjustment screen is displayed. a While the air conditioner adjustment screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the ordinary screen. a Air conditioner specification
Operation to display camera mode When a camera is installed, if [F3] is pressed, the multi-display changes to the camera image (Set the connection of the camera in the service mode).
If a caution is generated in the camera mode, the caution monitor is displayed at the left upper of the screen (The low hydraulic oil temperature caution is not displayed there, however). When an error that there is a user code occurs in the camera mode, if you do not touch any control lever for 10 seconds, the screen changes to the ordinary screen and displays the error information.
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Operation to display clock and service meter While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function.
Check of maintenance information While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.
To reset the time left after finishing maintenance, more operations are necessary.
12
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Setting and display of user mode (Including KOMTRAX messages for user) While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.
[KOMTRAX message] q There are 2 types of KOMTRAX message; 1 is for the user and the other is for the service. q For user: A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is displayed on the ordinary screen. To see the contents of the message, operate "User Message" in the above user menu. q For service: A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed on the ordinary screen. To see the contents of the message, operate "KOMTRAX message" display in the service menu.
There are following items in the user menu.

Breaker/Attachment Settings User Message Screen Adjustment Clock Adjustment Language Economy Mode Adjustment
The breaker/attachment setting menu is displayed only when "With attachment" is set in the service mode.
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Display of energy-saving guidance When the machine is set in a certain operating condition, the energy-saving guidance screen is displayed automatically to urge the operator to the energy-saving operation. a The energy-saving guidance is displayed when the following condition is satisfied while the display setting is set effective in the service mode. a Condition for display: Engine is running + All levers have been in neutral for 5 minutes + Caution (Note) or user code is not generated (Note) Note: Excluding hydraulic oil low temperature caution a If any lever or pedal is operated, or [F5] is pressed, the screen returns to the ordinary screen.
Display of user code and failure code If an abnormality which displays a user code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a): User code (3 digits) (b): Failure code (5 or 6 digits) (c): Telephone mark (d): Telephone No. a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the abnormality record in the service mode, check the details in the service mode.
Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor flashes at the left upper of the screen when the caution is generated.
When the caution monitor is also displayed, the telephone mark is not displayed.
14
PC138US, USLC-8
SEN02459-00
Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual)
Failure mode Pump control system error Action When emergency pump drive switch is at the up (emergency) position, normal operations become possible, but have inspection carried out immediately. Move the swing brake cancel switch up to release the brake. When applying the swing brake, operate the swing lock switch manually. Depending on the cause of the problem, it may not be possible to release it. In any case, have inspection carried out immediately.
User code E02
E03
Swing brake system error
E10 E11 E14 E15 E20 E0E
Engine controller power source error Engine controller drive system circuit error Have inspection carried out immediately. (engine stopped) Engine controller system error Output reduced to protect engine Abnormality in throttle system Engine sensor (coolant temperature, fuel pressure, oil pressure) system error Abnormality in travel system Network error Operate machine to a safe posture and have inspection carried out immediately. Operate machine to a safe posture and have inspection carried out immediately. Operations are possible, but have inspection carried out immediately. Operations are possible, but have inspection carried out immediately. Operate machine to a safe posture and have inspection carried out immediately.
PC138US, USLC-8
15
SEN02459-00
Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.
Function of checking service meter To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.
16
PC138US, USLC-8
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Function of changing attachment/maintenance password When changing the attachment/maintenance password used for the attachment setting function and maintenance setting function, follow these procedures. 1. While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [5] o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.
3.
After the New password input screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. a Set a new password of 4 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral
4.
2.
After the Attachment/Maintenance PASSWORD screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.
After the New password input screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.
PC138US, USLC-8
17
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5.
If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully.
18
PC138US, USLC-8
30 Testing and adjusting t Service mode To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1. Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a This operation of the switches is accepted only while the ordinary screen is displayed. a
SEN02459-00
The items which can be selected in the service menu are as follows (including some items which need special operations).
01 Monitoring Mechanical Systems 02 Abnormality Electrical Systems Record Air-conditioning System 03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Unit With/Without Attachment 06 Default Attachment/Maintenance Password Camera ECO Display 07 Adjustment Pump Absorption Torque Attachment Flow Adjustment
08 Cylinder Cut-Out 09 No Injection 10 Fuel Consumption Terminal Status 11 KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300) MODEM IP Address (TH200/201)
2.
Selection of service menu When the Service menu screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].
PC138US, USLC-8
19
SEN02459-00
Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1. Selecting menu Select "Monitoring" on the service menu screen.
3.
2.
Selecting monitoring items After the "Monitoring selection menu screen" is displayed, select items to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Reset input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.
Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.
20
PC138US, USLC-8
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4.
Executing monitoring After the "Executing monitoring screen" is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be set to SI unit, metric unit, or inch unit with the Initialization function in the service mode.
6.
Changing machine setting mode To change the setting of the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished.
5.
Holding monitoring information The monitoring information can be held and reset with the function switches. q [F3]: Reset holding q [F4]: Hold information (displayed data) q [F5]: Return to monitoring selection menu screen
PC138US, USLC-8
21
SEN02459-00
Monitoring items table

Unit (Initial setting: ISO) Code No. 00200 00201 01002 01601 01100 07102 07103 07104 07105 07106 07107 04107 04401 01300 01700 03200 03203 04300 36400 37400 18500 36500 36700 18700 03000 04200 04105 04402 37401 18501 36501 36401 17500 31701 31706 18600 36200 36300 37300 01602 13113 15900 Monitoring item (Display on screen) Controller model select Machine ID Engine speed 2nd eng. speed command Pump pressure Travel FW L PPC pressure Travel FW R PPC pressure Travel BW L PPC pressure Travel BW R PPC pressure Blade raise PPC pressure Blade lower PPC pressure Coolant temperature Hyd oil temperature PC-EPC sol current Attachment sol current Battery voltage Battery power supply Battery charge vol. Rail pressure Ambient pressure Charge temperature Charge pressure-abs Engine torque ratio Engine output torque Fuel dial pos sens volt Fuel level sensor volt Coolant temp sens volt Hyd temp sens volt Ambient press sens volt Charge temp sens volt Charge press sens volt Rail pressure sens volt Engine power mode Throttle position Final throttle position Inject fueling command Rail press command Injection timing command Fuel rate 2nd eng. speed command Main pump absorb torque Boom bottom pressure Swing Boom lower Pressure switch 1 Boom raise Arm curl Arm dump ISO meter rpm rpm kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 C C mA mA V V V kg/cm2 kg/cm2 C kg/cm2 inch Component in charge PUMP ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP ENG PUMP PUMP PUMP PUMP ENG MON ENG ENG ENG ENG ENG ENG ENG MON ENG PUMP ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP Remarks
r/min r/min MPa MPa MPa MPa MPa MPa MPa C C mA mA V V V MPa kPa C kPa % Nm V V V V V V V V
rpm rpm psi psi psi psi psi psi psi F F mA mA V V V psi psi F psi
All items (including the ambient pressure) are indicated by absolute values.
01900
% % kgm lbft V V V V V V V V V V V V V V V V % % % % % % mg/st mg/st mg/st MPa kg/cm2 psi CA CA CA l/h l/h gal/h % % % Nm kgm lbft MPa kg/cm2 psi ONOFF ONOFF ONOFF ONOFF ONOFF
22
PC138US, USLC-8
SEN02459-00
Unit (Initial setting: ISO) Code No. Monitoring item (Display on screen) Bucket curl Pressure switch 2 Bucket dump Attachment Travel junction Swing brake Solenoid valve 1 Merge-divide Travel speed Swing release sw Switch input 1 Swing brake sw Blade spec Switch input 2 Overload alarm Switch input 3 Key switch Window limit sw. Switch input 5 P limit sw. W limit sw. Controller output 2 Travel alarm Key switch Start Monitor input 1 Preheat Light Eng. oil level Monitor input 2 Battery charge Monitor input 3 Swing brake sw. F1 F2 F3 Monitor function switches F4 F5 F6 SW1 SW2 Monitor 1st & 2nd SW3 row switches SW4 SW5 SW6 SW7 SW8 Monitor 3rd & 4th SW9 row switches SW10 SW11 SW12 SW13 Monitor 5th row SW14 switches SW15 ECM build version ECM calibration data ver ECM internal temp ECM serial No Monitor ass'y P/N Monitor serial No ISO meter ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF ONOFF C inch
01901
02300
02200 02201 02202 02204 03701 04500
04501 04502
04503
04504
04505
04506 20216 20217 18900 20400 20227 20402
Component in charge PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON ENG ENG ENG ENG MON MON
Remarks
PC138US, USLC-8
23
SEN02459-00
Unit (Initial setting: ISO) Code No. 20228 20229 20403 20230 Monitoring item (Display on screen) Monitor prog. P/N Pump con ass'y P/N Pump con serial No Pump con. prog P/N ISO meter inch
Component in charge MON PUMP PUMP PUMP
Remarks
a a
Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen. Unit The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in Initialization of the service menu). "CA" in the display unit is an abbreviation for crankshaft angle. "mg/st" in the display unit is an abbreviation for milligram/stroke. Component in charge MON: The machine monitor is in charge of detection of monitoring information. ENG: The engine controller is in charge of detection of monitoring information. PUMP: The pump controller is in charge of detection of monitoring information.
24
PC138US, USLC-8
SEN02459-00
Abnormality Record (Mechanical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning system or heater system. To check the mechanical system abnormality record, perform the following procedures. 1. Selecting menu Select "Abnormality Record" on the "Service Menu" screen.
3.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "Mechanical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heaterless specification.
Information displayed on "abnormality record" screen On the "Mechanical Systems" screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to abnormality record screen a If no abnormality record is recorded, "No abnormality record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table in "Abnormality Record (Electrical Systems)".
PC138US, USLC-8
25
SEN02459-00
4.
Resetting abnormality record The contents of the mechanical system abnormality record cannot be reset.
Abnormality Record (Electrical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning system. To check the electrical system abnormality record, perform the following procedures. 1. Selecting menu Select "Abnormality Record" on the "Service Menu" Screen. 3. Information displayed on "abnormality record" screen On the "Electrical Systems" screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "abnormality record" screen a If no abnormality record is recorded, "No abnormality record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heaterless specification.
26
PC138US, USLC-8
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4.
Resetting abnormality record 1) While the "Electrical Systems" screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3]
3)
After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to "Electrical systems" screen (Reset mode) q [F6]: Execute reset a The following figure shows the screen displayed when the items are reset one by one (which is a little different from the screen displayed when all the items are reset together).
2)
Check that the screen is set in the reset mode, and then reset the items one by one or together with the function switches. a If the screen is set in the reset mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Reset all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to abnormality record screen q [F6]: Reset selected item a To reset items one by one: Select the item to be reset with [F3] or [F4] and press [F6]. a To reset all items together: Press [F2], and all the items are reset, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the resetting operation is accepted but the information is not reset.
4)
If the screen to notify completion of reset is displayed and then the "Electrical Systems" (reset mode) screen is displayed, the reset of the abnormality record is completed. a After a while, the screen returns to the "Electrical Systems" screen.
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27
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Failure codes table

User code Failure code 989L00 989M00 989N00 AB00KE B@BAZG B@BAZK B@BCNS B@HANS E10 E10 E11 E11 E14 E14 E15 E15 E15 E15 E15 E11 E11 E15 CA111 CA115 CA122 CA123 CA131 CA132 CA144 CA145 CA153 CA154 CA187 CA221 CA222 CA227 CA234 E15 E10 E10 E11 E11 E11 E11 CA238 CA271 CA272 CA322 CA324 CA331 CA332 Trouble (Displayed on screen) Engine controller lock caution 1 Engine controller lock caution 2 Engine controller lock caution 3 Charge voltage low Eng oil press. low Eng oil level low Eng coolant overheat Hydr oil overheat ECM critical internal failure Eng. Ne and Bkup speed sensor error Charge air press sensor high error Charge air press sensor low error Throttle sensor high error Throttle sensor low error Coolant temp. sensor high error Coolant temp. sensor low error Charge air temp. sensor high error Charge air temp. sensor low error Sensor sup. 2 volt. low error Ambient air press. sensor high error Ambient air press. sensor low error Sensor sup. 2 volt. high error Eng. overspeed Ne speed sensor sup. volt. error IMV/PCV1 short error IMV/PCV1 open error Injector #1 (L #1) system open/short error Injector #3 (L #3) system open/short error Injector #2 (L #2) system open/short error Injector #4 (L #4) system open/short error q q q q q q q e e q q q q q q q q q q q q q q e Alarm buzzer Component Category of in charge record MON MON MON MON ENG MON ENG PUMP ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
28
PC138US, USLC-8
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User code E10 E15 E15 E15 E10 E10 E11 E11 E11 E15 E15 E15 E15 E10 E15 E0E E14 E14 E11 E11
Failure code CA351 CA352 CA386 CA435 CA441 CA442 CA449 CA451 CA452 CA553 CA559 CA689 CA731 CA757 CA778 CA1633 CA2185 CA2186 CA2249 CA2311 D110KB
Trouble (Displayed on screen) Inj. drive circuit error Sensor sup. 1 volt. low error Sensor sup. 1 volt. high error Abnormality in engine oil pressure switch Battery voltage low error Battery voltage high error Rail press. very high error Rail press. sensor high error Rail press. sensor low error Rail press. high error Rail press. low error Eng. Ne speed sensor error Eng. Bkup speed sensor phase error All persistent data lost error Eng. Bkup speed sensor error KOMNET datalink timeout error Throttle sens. sup. volt. high error Throttle sens. sup. volt. low error Rail press. very low error Abnormality in IMV solenoid Battery relay drive short Personal code relay abnormality GPS antenna discon Pump solenoid power low error 5V sensor 1 power abnormality 5V sensor 2 power abnormality CAN discon (Pump con detected) Short circuit in camera power supply GPS module error CAN discon (Monitor detected)
Alarm buzzer q q q q q q q q q q q q q q q q q q q q
E01
D19JKZ D862KA
E0E
DA22KK DA25KP DA26KP
E0E
DA2RMC DAF8KB DAFGMC
E0E
DAFRMC
Component Category of in charge record Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical PUMP system Electrical KOM system Electrical KOM system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical MON system Electrical KOM system Electrical MON system
PC138US, USLC-8
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SEN02459-00
User code
Failure code DGH2KB DHPAMA
Trouble (Displayed on screen) Hydr oil sensor short Pump press sensor abnormality Travel left forward PPC press sensor abnormality Travel right forward PPC press sensor abnormality Travel left reverse PPC press sensor abnormality Travel right reverse PPC press sensor abnormality Blade raise PPC press sensor abnormality Blade lower PPC press sensor abnormality Overload sensor abnormality (Analog) Travel alarm S/C Travel speed sol discon Travel speed sol short Swing brake sol discon Swing brake sol short Travel junction sol discon Travel junction sol short Merge-divider sol discon Merge-divider sol short PC-EPC sol discon PC-EPC sol short Service current EPC discon Service current EPC short Wiper working abnormality Wiper parking abnormality Washer drive discon Washer drive short Wiper drive (for) short Wiper drive (rev) short
Alarm buzzer
E20 E20 E20 E20
DHSFMA DHSGMA DHSHMA DHSJMA DHSKMA DHSLMA DHX1MA DV20KB DW43KA DW43KB
q q q q
E03 E03
DW45KA DW45KB DW91KA DW91KB DWJ0KA DWJ0KB
q q
E02 E02
DXA8KA DXA8KB DXE4KA DXE4KB DY20KA DY20MA DY2CKA DY2CKB DY2DKB DY2EKB
q q
Component Category of in charge record Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system
30
PC138US, USLC-8
30 Testing and adjusting a a
SEN02459-00
Entry order of items in table The items are entered in the order of their failure codes (incremental order). User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the abnormality. Alarm buzzer q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). e : Since the caution monitor is also turned ON, its function sounds the buzzer. Component in charge MON: The machine monitor is in charge of detection of abnormality. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. ENG: The engine controller is in charge of detection of abnormality. PUMP: The pump controller is in charge of detection of abnormality. Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record.
PC138US, USLC-8
31
SEN02459-00
Abnormality Record (Air-conditioning System) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning abnormalities. To check the air-conditioning abnormality record or heater abnormality record, perform the following procedures. 1. Selecting menu Select "Abnormality Record" on the "Service Menu" screen.
3.
Information displayed on "abnormality record" screen On the "Air-conditioning System" screen, the following information is displayed. (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) q [F2]: Reset abnormality record q [F5]: Return to abnormality record screen If [E] is displayed on the left of a condition, the abnormality is still occurring or resetting of it has not been confirmed. If CAN disconnection is displayed in Communication condition, communication cannot be carried out normally. Accordingly, the conditions of other items are turned OFF.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "Air-conditioning System" or "Heater System" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].
4.
Resetting abnormality record While the "abnormality record" screen is displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.
32
PC138US, USLC-8
SEN02459-00
Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section. 1. Selecting menu Select "Maintenance Record" on the "Service Menu" screen.
The following items can be selected in the maintenance record.

01 Engine oil change 02 Engine oil filter change 03 Fuel main filter change 41 Fuel pre-filter change 04 Hydraulic oil filter change 05 Hydraulic tank breather change 06 Corrosion resistor change 07 Damper case service 08 Final drive case oil change 09 Machinery case oil change 10 Hydraulic oil change
3.
Items displayed on maintenance record screen The following items are displayed. (a) : Maintenance items (b) : Number of times of replacement up to now (c) : Service meter reading (SMR) at previous replacement
2.
Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.
PC138US, USLC-8
33
SEN02459-00 a
Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set replacement interval (by items) q Initialize all set replacement intervals 1. Selecting menu Select of "Maintenance Mode Change" on the "Service Menu" screen.
The following items can be selected on the Change of maintenance mode screen.
00 Maintenance mode on/off 01 Engine oil change int. 02 Engine oil filter change int. 03 Fuel main filter change int. 41 Fuel pre filter change int. 04 Hyd oil filter change int. 05 Hyd tank breather change int. 06 Corrosion resistor change int. 07 Damper case service int. 08 Final drive case oil change int. 09 Machinery case change int. 10 Hydraulic oil change int. 99 Initialize all items
3.
2.
Selecting sub menu After the "Maintenance Mode Change" screen is displayed, select an item to change the setting with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].
Contents of setting of Maintenance mode on/ off After selecting "Maintenance Mode On/Off", if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode change screen q [F6]: Confirm selection and return to Maintenance mode change screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.
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4.
Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches. q Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). q Set value: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 50 hours). q ON: Maintenance function of this item is set effective in operator mode. q OFF: Maintenance function of this item is set ineffective in operator mode. q [F3]: Select Reduce set value (Upper) or OFF (Lower). q [F4]: Select Increase set value (Upper) or ON (Lower). q [F5]: Cancel setting before confirmation and return to Maintenance mode change screen. q [F6]: Confirm setting of upper or lower line. a After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode change screen with [F5], the setting is effective. a If the set value of an item set to "ON" is changed after 1 or more operating hours since the start of setting, the change is recognized as a resetting operation.
5.
Function of initializing all items After selecting "All Default Value", if the screen is displayed, set with the function switches. q If this operation is executed, the set values of all the maintenance items are initialized. q [F5]: Return to Maintenance mode change screen q [F6]: Execute initialization a A while after [F6] is pressed, the initialization completion screen is displayed. Then, if the "Maintenance Mode Change" screen is displayed, initialization is completed.
PC138US, USLC-8
35
SEN02459-00 a
Phone Number Entry The telephone No. displayed when the user code/ failure code is displayed in the operator mode can be input and changed according to the following procedure. If a telephone No. is not input with this function, no telephone No. is displayed in the operator mode. 1. Selecting menu Select "Phone Number Entry" on the "Service Menu" screen.
If [F6] is pressed without inputting a digit, there is not information of telephone No. Accordingly, no telephone No. is displayed in the operator mode.
2.
Registering and changing telephone No. After the "Phone Number Entry" screen is displayed, register or change the telephone No. q [F2]: Reset all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Reset input digit/Return to service menu q [F6]: Confirm input
a a
Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (orange background) and overwrite it with the correct digit.
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PC138US, USLC-8
SEN02459-00
Default (Key-on Mode) Check or change various settings related to the machine monitor and machine by "Default". The function of working mode with key ON is used to set the working mode displayed on the machine monitor when the starting switch is turned ON. 1. Selecting menu Select "Default" on the "Service Menu" screen.
q q q q
a a a
Mode at Previous Key-off: Final mode in previous operation is displayed when key is ON [F3]: Move to lower item [F4]: Move to upper item [F5]: Cancel selection and return to "Default" screen [F6]: Confirm selection and return to "Default" screen When the machine is delivered, Mode at previous key-OFF is set. If "With attachment" is not set, the attachment mode cannot be selected. While Attachment mode [ATT] is selected, if "Without attachment" is set, Power mode [P] is displayed when the key is turned ON. If the engine is stopped while breaker mode [B] is selected in the operator mode, Breaker mode [B] is always displayed, regardless of the above setting.
2.
Selecting sub menu After the "Default" screen is displayed, select "Key-on Mode" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set with the function switches. q Power Mode: [P] is displayed when key is ON q Economy Mode: [E] is displayed when key is ON q Lifting Mode: [L] is displayed when key is ON q Breaker Mode: [B] is displayed when key is ON q Attachment Mode: [ATT] is displayed when key is ON
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37
SEN02459-00 a
Default (Unit) Check or change various settings related to the machine monitor and machine by "Default". The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1. Selecting menu Select "Default" on the "Service Menu" screen.
When the machine is delivered, the SI unit system is set.
2.
Selecting sub menu After the "Default" screen is displayed, select "Unit" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting unit After the "Unit" screen is displayed, select the unit to be set with the function switches. q [F3]: Move to lower unit q [F4]: Move to upper unit q [F5]: Cancel selection and return to "Default" screen q [F6]: Confirm selection and return to "Default" screen
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PC138US, USLC-8
SEN02459-00
Default (With/Without Attachment) Check or change various settings related to the machine monitor and machine by "Default". The "With/Without attachment" function is used to set an installed or a remove attachment. 1. Selecting menu Select "Default" on the "Service Menu" screen.
When an attachment is installed, if this setting is not carried out normally, the attachment cannot be set in the operator mode. As a result, the attachment may not work normally or the hydraulic components may have trouble.
2.
Selecting sub menu After the "Default" screen is displayed, select "With/Without Attachment" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting With/Without After the "With/Without Attachment" screen is displayed, select the setting with the function switches. q Without Attachment: When attachment is not installed q With Attachment: When attachment is installed q [F3] : Move to lower item q [F4] : Move to upper item q [F5] : Cancel selection and return to Default screen q [F6] : Confirm selection and return to Default screen
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SEN02459-00
Default (Attachment/Maintenance Password) Check or change various settings related to the machine monitor and machine by "Default". The function of setting attachment/maintenance password is used to set the display of the password screen when the functions related to the attachment and maintenance are used in the operator mode. 1. Selecting menu Select "Default" on the "Service Menu" screen.
3.
Selecting Disable/Enable After the Attachment/Maintenance Password screen is displayed, select the setting with the function switches. q Disable : Password screen is not displayed q Enable : Password screen is displayed q [F3] : Move to lower item q [F4] : Move to upper item q [F5] : Cancel selection and return to "Default" screen q [F6] : Confirm selection and return to "Default" screen
2.
Selecting sub menu After the "Default" screen is displayed, select "Attachment/Maintenance Password" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
4.
Displaying attachment/maintenance password screen When the following operation is performed, the password screen is displayed in the operator mode. q Maintenance mode: The Maintenance table screen is changed to the Maintenance interval reset screen. q User mode: On the User menu screen, the Breaker/Attachment setting menu is selected and the screen is changed to the Attachment setting menu screen. Changing attachment/maintenance password The password can be changed by operating the switches specially in the operator mode. a See Attachment/Maintenance password changing function in the operator mode. a Default password: [000000] a If the password setting is changed from Enable to Disable, the password is reset to the default. When Enable is set again, be sure to set a new password. a The attachment/maintenance password is different from the engine start lock password.
5.
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PC138US, USLC-8
SEN02459-00
Default (Camera) Check or change various settings related to the machine monitor and machine by "Default". The camera setting function is used to set installation and removal of a camera. 1. Selecting menu Select "Default" on the "Service Menu" screen.
3.
2.
Selecting sub menu After the "Default" screen is displayed, select "Ca mer a" with the fu ncti on s witc hes or numeral input switches. a Select this item similarly to an item on the "Service Menu" Screen.
Selecting camera setting After the "Camera" setting screen is displayed, select the setting with the function switches. q OFF: Camera is not used q Original Image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse Image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to "Default" screen q [F6]: Confirm selection in each line a After "Camera" screen is displayed, camera 1 can be always set. a After confirming the setting of each line with [F6], return to the "Default" screen with [F5], and the setting is effective. a If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a When a camera is installed, check that the displayed image is not inverted horizontally.
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41
SEN02459-00 a
Default (ECO Display) Check or change various settings related to the machine monitor and machine by "Default". The ECO display setting function is used to set the display of the ECO gauge and energy saving guidance. 1. Selecting menu Select "Default" on the "Service Menu" screen.
If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen. Even if the energy saving guidance is turned ON, however, it is not displayed if the condition for display is not satisfied on the ordinary screen.
Display of ECO gauge (a)
2.
Selecting sub menu After the "Default" screen is displayed, select "ECO Display" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
Display of energy saving guidance
3.
Selecting display setting After the "ECO Display" screen is displayed, select the setting with the function switches. q ON : Display ECO q OFF: Do not display ECO q [F3] : Move to left item q [F4] : Move to right item q [F5] : Cancel setting before confirmation and return to "Default" screen q [F6] : Confirm selection in each line a After confirming the setting of the upper and lower lines with [F6], return to the "Default" screen with [F5], and the setting is effective.
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PC138US, USLC-8
SEN02459-00
Adjustment (Pump Absorption Torque) The operator can adjust various items related to the machine with the machine monitor. The pump absorption torque function is used to finely adjust the absorption torque on the hydraulic pump. 1. Selecting menu Select "Adjustment" on the "Service Menu" screen.
3.
Selecting absorption torque After the "Pump Absorption Torque" screen is displayed, select a set value on the right side with the function switches. q Set value: For actual torque adjustment value, see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.
2.
Selecting sub menu After the "Adjustment" screen is displayed, select "Pump Absorption Torque" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
Relationship between set value torque adjustment value

Code Set value 000 001 002 003 004 005 006 007 008
and
Torque adjustment value +39.2 Nm {+4 kgm} +29.4 Nm {+3 kgm} +19.6 Nm {+2 kgm} +9.8 Nm {+1 kgm} 0 Nm {0 kgm} 9.8 Nm {1 kgm} 19.6 Nm {2 kgm} 29.4 Nm {3 kgm} 39.2 Nm {4 kgm}
022
PC138US, USLC-8
43
SEN02459-00
Adjustment (Attachment Flow Adjustment) The operator can adjust various items related to the machine with the machine monitor. The function of "Attachment Flow Adjustment" is used to finely adjust the oil flow to the attachment in compound operation. 1. Selecting menu Select "Adjustment" on the "Service Menu" screen.
3.
Selecting distribution of oil flow After the screen of "Attachment Flow Adjustment" is displayed, select a set value on the right side with the function switches. q Set value: For actual distribution of flow, see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.
2.
Selecting sub menu After the "Adjustment" screen is displayed, select "Attachment Flow Adjustment" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
Relationship between set value and distribution of flow to attachment

Code Set value 000 001 002 003 Distribution of flow to attachment 50 % 70 % 100 % 40 %
037
44
PC138US, USLC-8
SEN02459-00
Cylinder Cut-Out The operator can perform "Cylinder Cut-Out" operation with the machine monitor. "Cylinder Cut-Out" operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1. Selecting menu Select "Cylinder Cut-Out" on the "Service Menu" screen. 3. Resetting Cut-Out cylinder When changing a cylinder to be Cut-Out or when Cylinder Cut-Out operation is finished, select a Cut-Out cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset. a If the machine monitor resets a Cut-Out cylinder but the engine controller cannot reset that Cut-Out cylinder, the background (a) of the cylinder No. becomes red. a The Cut-Out operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the cylinder cut-out operation is finished. Function of holding displayed information If [F4] is pressed during the cylinder Cut-Out operation, the displayed information is newly held (c) (The real-time information is kept displayed on the left side). While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the reduced cylinder mode operation.
2.
Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be Cut-Out with the function switches. q [F1]: Move selection mark (R) to left q [F2]: Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to service menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is Cut-Out. a If the machine monitor Cut-Out a cylinder but the engine controller cannot Cut-Out that cylinder, the background (a) of the cylinder No. becomes yellow. a One or more cylinders can be Cut-Out. a In the cylinder Cut-Out operation, the auto-deceleration function can be selected. If the auto-deceleration is turned ON, auto-deceleration monitor (b) is displayed.
4.
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45
SEN02459-00
[Reference] q If a normally operating cylinder is Cut-Out, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.
No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the no-injection cranking while the engine is stopped. 1. Selecting menu Select "No Injection" on the "Service Menu" screen.
2.
Displaying check screen If the "No injection" screen is displayed, the machine monitor asks the operator if no injection cranking should be performed. Answer with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform a While the screen is changing to the following screen, the screen of "Communication between controllers is being checked" is displayed.
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3.
Starting no injection cranking If no injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of "Setting is being prepared" is displayed. a Limit the cranking time to 20 seconds to protect the starting motor.
5.
Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running, the message that the engine is running is displayed and the no injection cranking is not set effective. a This function can be selected even while the engine is running. If the no injection cranking is performed, however, the message of "Engine is running" is displayed on the screen.
4.
Finishing no injection cranking After completing the no injection cranking operation, press [F6], and finish of no injection cranking is displayed and the screen returns to the "Service Menu" screen automatically.
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Fuel Consumption This function calculates the hourly fuel consumption from the actual fuel consumption in a testing period and indicates it. 1. Selecting menu Select "Fuel Consumption" on the "Service Menu" screen.
3.
Display and function during test Clock mark (a) flashes during test. a While the fuel consumption is being tested, the operator can work with the operator mode and other functions. Test is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is tested only while the engine is running).
2.
Starting test After the screen of "Fuel Consumption" is displayed, start test with the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to Service menu screen a When the screen of Fuel consumption is displayed, if a data is indicated, it is the data of the previous test. This data is not an obstacle to new test and can be reset by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and test starts.
4.
Finishing test Press [F1], and test is finished and the data are displayed on the finishing date and time side. Displaying fuel consumption If the test is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.
5.
The display unit of the fuel changes according to the unit set with the default (unit setting) function. SI and meter: l/h inch: gal/h
48
PC138US, USLC-8
SEN02459-00
KOMTRAX Settings (Terminal Status) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX setting. Setting condition of terminal is used to check the setting condition of the KOMTRAX terminal. 1. Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.
3.
Contents of display of terminal status On the "Terminal Status" screen, the following items are displayed. q Terminal type: Model name of KOMTRAX communication MODEM q KOMTRAX communication: Executing condition of station opening inspection q GMT time: Greenwich Meant Time q [F5]: Return to KOMTRAX settings screen
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Terminal Status" with the function switches or numeral input switches. a Select this item similarly to an item on the Service menu screen. a The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is displayed.
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SEN02459-00
KOMTRAX Settings (GPS & Communication Status) The setting condition and operating condition of KOMTRAX can be checked with "KOMTRAX Settings". GPS & communication status is used to check the condition of positioning and communication of the KOMTRAX terminal. 1. Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.
3.
Contents of display of GPS & communication status On the screen of "GPS & Communication Status", the following items are displayed. q Positioning: Positioning condition of GPS q Communication: Communication environment of communication MODEM and connecting condi tion of c ommunication MODEM q Number of message not yet sent: Number of mails which are saved in machine monitor and not transmitted yet q [F5]: Return to KOMTRAX settings screen
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select GPS & communication status with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen. a The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is displayed.
50
PC138US, USLC-8
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KOMTRAX Setting (MODEM S/N: TH300) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX setting. MODEM S/N is used to check the serial No. of the KOMTRAX communication MODEM. 1. Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.
3.
Contents of display of Modem S/N The serial No. of TH300 Modem is displayed. q [F5]: Return to KOMTRAX settings screen
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
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51
SEN02459-00
KOMTRAX Settings (IP Address: TH200/201) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX settings. IP address is used to check the IP address of the KOMTRAX communication MODEM. 1. Selecting menu Select "KOMTRAX Settings" on the service menu screen.
3.
Contents of display of IP address The telephone No. and IP address (2 systems) of TH200 MODEM are displayed. q [F5]: Return to KOMTRAX setting screen a The IP address is a No. specific to each MODEM which is required when communication is made between the MODEM and the server.
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "IP Address" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
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PC138US, USLC-8
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Display of KOMTRAX message Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this function. If there is setting in a message, a return mail can be sent by using numeral input switches. 1. Operation to display menu Select "Service message" on the service menu screen.
3.
Display of message (with return mail function) If a box to enter a value with the numeral keys is displayed under the message, enter a proper number with the numeral input switches and function switches and confirm it, and the information is returned to the KOMTRAX base station. q [F5]: Return to service menu screen q [F6]: Confirm and return input value a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
2.
Display of message (Read-only) If there is a message, its contents are displayed. If there is not a message, "No message" is displayed. q [F5]: Return to service menu screen a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
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53
SEN02459-00
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PC138US, USLC-8
SEN02460-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number

Handling voltage circuit of engine controller ................................................................................................... 2 Preparation work for troubleshooting of electrical system .............................................................................. 3 Procedure for testing diodes ........................................................................................................................... 8 Pm Clinic service ............................................................................................................................................ 9
PC138US, USLC-8
SEN02460-01
Handling voltage circuit of engine controller 1

1. Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF. If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
2.
PC138US, USLC-8
SEN02460-01
Preparation work for troubleshooting of electrical system

a
3)
When carrying out troubleshooting of an electric circuit related to the machine monitor, e n g i n e c o n t r o l l e r, p u m p c o n t r o l l e r, o r KOMTRAX communication MODEM, expose the related connectors according to the following procedure. Disconnect and connect the connectors having special locking mechanisms according to the procedure shown below. Machine monitor 1) Remove 2 mounting bolts and cover (1). a One of the mounting bolts is installed in the cover on the right of the daylight sensor. a While removing the mounting bolts, disconnect connector P31 of the daylight sensor. a The following figure shows the model of the arm crane specification equipped with a level. If the machine which you are working on has the arm crane specification, remove level (2).
Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM03 of machine monitor (4). a Connectors CM02 and CM03 are of the same type. When returning them, check the mark plates of the mounting brackets and take care not to make a wrong connection.
1.
2.
Engine controller 1) Open the engine hood. a The engine controller is mounted on the engine (on the counterweight side). 2) Insert or connect troubleshooting T-adapters in or to connectors CE01, CE02, and CE03 of engine controller (5). a Connectors CE01 and CE02 are fixed with screws. When disconnecting them, loosen the screws. a When returning connectors CE01 and CE02, tighten the screws to the specified torque. 3 Screw: 3 1 Nm {0.3 0.1 kgm}
2)
Remove 1 mounting bolt and duct (3).
PC138US, USLC-8
SEN02460-01
3.
Pump controller 1) Slide the operator's seat and seat stand to the forward end.
2)
Connect the troubleshooting adapters to connectors C01 and C02 of pump controller (12). a Install the adapters to only the wiring harness side.
The pump controller connector has a special locking mechanism. Disconnect it according to procedures (a) ( c ) s ho wn be lo w a nd c on ne ct i t according to procedures (d) (f). Disconnection : (a) Unlock (b) Slide lever (c) Disconnect connector. Connection: (d) Position connector (e) Slide lever (f) Lock.
PC138US, USLC-8
SEN02460-01
4.
KOMTRAX communication module 1) Slide the operator's seat and seat stand to the forward end.
2)
Connect troubleshooting T-adapters to connectors CK01 and CK02 of KOMTRAX communication module (13). a Cable (14) is for the communication antenna.
5.
Engine Ne speed sensor (Crank sensor) Engine Bkup speed sensor (Cam sensor) Engine oil pressure switch (Oil pressure switch) a Disconnection and connection of connectors The connectors of the engine Ne speed s ens or, eng ine Bku p sp eed s ens or, engine oil pressure switch have a special locking mechanism. Disconnect them according to steps (a) (c) and connect them according to steps (d) (f) as shown below. Disconnection : (a) Slide lever (b) Unlock (c) Disconnect connector. Connection: (d) Connect connector (e) Lock (f) Slide lever.
Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. See "Tools for testing, adjusting, and troubleshooting".
PC138US, USLC-8
SEN02460-01
6.
Boost pressure and temperature sensor (Boost press & IMT) a Disconnection and connection of connector The connector of the boost pressure and temperature sensor has a special locking mechanism. Disconnect it according to steps (a) (b) and connect it according to steps (c) (d) as shown below. Disconnection: (a) Unlock (b) Disconnect connector. Connection: (c) Connect connector (d) Lock.
7.
Supply pump IMV solenoid (Fuel regulator) a Disconnection and connection of connector The connector of the supply pump IMV solenoid has a special locking mechanism. Disconnect it according to steps (a) (b) and connect it according to steps (c) (d) as shown below. Disconnection: (a) Unlock (b) Disconnect connector. Connection: (c) Connect connector (d) Lock.
a a
Removal and installation of sensor A torque wrench is necessary for removal and installation of the boost pressure and temperature sensor. See "Tools for testing, adjusting, and troubleshooting".
Precautions for disconnecting connector The direction of the lock of the connector varies with the tightened position of the sensor and the lock may be in a direction in which it is difficult to reset (on the underside or engine side). In this case, pinch the lock in direction (a) with bent-nose nippers [1] (commercially available), and the lock is reset. Since the lock clicks when it is reset, disconnect the connector after a click is heard.
PC138US, USLC-8

a
SEN02460-01
Precautions for connecting connector Take care not to connect the connector reversely. Engage lock (e) on the wiring harness side with triangular notch (f) on the sensor side (Do not engage lock (e) with square guide (g) on the opposite side of triangular notch (f)).
9.
Engine coolant temperature sensor (Coolant temp) a Disconnection and connection of connector The connector of the engine coolant temperature sensor has a special locking mechanism. Disconnect it according to steps (a) (b) and connect it according to steps (c) (d) as shown below. Disconnection: (a) Unlock (b) Disconnect connector. Connection: (c) Connect connector (d) Lock.
8.
Common rail pressure sensor (Fuel rail press) a Disconnection and connection of connector The connector of the common rail pressure sensor has a special locking mechanism. Disconnect it according to steps (a) (b) and connect it according to steps (c) (d) as shown below. Disconnection: (a) Unlock (b) Disconnect connector. Connection: (c) Connect connector (d) Lock.
Removal and installation of sensor A deep socket is necessary for removal and installation of the engine coolant temperature sensor. See "Tools for testing, adjusting, and troubleshooting".
PC138US, USLC-8
SEN02460-01
Procedure for testing diodes

a a
Test the assembled-type diode (8-pin) and the single diode (2-pin) according to the following procedure. The conductive directions of the assembledtype diode are as follows.
2.
The conductive direction of the single diode is indicated on the surface of the diode.
1.
When using digital circuit tester 1) Set the tester in the diode range and check the indicated value. a When an ordinary circuit tester is used, the voltage of the internal battery is indicated. 2) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black () lead to the cathode (N) side and check the indicated value. 3) Judge the condition of the diode by the indicated value. q The indicated value does not change: The diode does not have conductivity (Defective). q The indicated value changes: The diode has conductivity (Normal). Note: In the case of a silicon diode, a value in the range from 460 to 600 is indicated.
When using analog circuit tester 1) Set the tester in the resistance range. 2) Apply the leads of the tester as explained below and check the movement of the pointer. i) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black () lead to the cathode (N) side. ii) Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black () lead to the anode (P) side. 3) Judge the condition of the diode by the movement of the pointer. q The pointer does not move in i) but moves in ii): The diode is normal (The moving range (resistance) depends on the type and selected range of the tester, however). q The pointer moves in both i) and ii): The diode is defective (Internal short circuit). q The pointer moves in neither of i) and ii): The diode is defective (Internal disconnection).
PC138US, USLC-8
SEN02460-01
Pm Clinic service
Model name T PC138US-8 User's name
1
Serial No. Date of execution / / Service meter h Inspector
Specifications Main components Boom Arm Bucket T Standard T ( T Standard T ( T Standard T ( ) ) ) T Breaker T( T( Check of oil/coolant level T Radiator coolant T Engine oil T Hydraulic oil When necessary T Damper case oil T Final drive case oil T Machinery case oil T( Altitude m Operator's opinion ) Attachments ) ) T 500 mm T 600 mm T 700 mm Shoe width T( )
Ambient temperature C
Result of visual inspection
Mechanical equipment system fault history 989EKX AB00KE B@BAZG B@BAZK B@BCNS B@HANS CA234 times/1st time times/1st time times/1st time times/1st time times/1st time times/1st time times/1st time h/last h/last h/last h/last h/last h/last h/last h h h h h h h
Electrical equipment system fault history times/1st time times/1st time times/1st time times/1st time times/1st time times/1st time times/1st time h/last h/last h/last h/last h/last h/last h/last h h h h h h h
Max. range of engine coolant temperature gauge
Max. range of hydraulic oil temperature gauge
PC138US, USLC-8
SEN02460-01
Check sheet (PC138US-8)

Model Serial No. Service meter User's name Date of execution / / Inspector
1.
Engine
Checking condition Fuel control dial MAX P MIN OFF All levers in neutral Work- Autoing decelmode eration Standard value for new machine Good Good Good Service limit value Measured value Bad Bad Bad
No.
Check item
Operation of work equipment
Unit
1 2 3 4
Engine speed Engine oil pressure Engine speed Engine oil pressure All levers in neutral
rpm
2,090 2,210 2,090 2,210 0.25 {2.5}
MPa 0.34 0.59 {kg/cm2} {3.47 6.02} rpm MPa {kg/cm2} Min. 0.10 {Min. 1.0}
1,050 1,150 1,050 1,150 0.07 {0.7}
2.
Work equipment speed

Checking condition Fuel control dial Working mode Standard value for new machine 3.5 4.1 2.9 3.5 2.4 3.0 2.6 3.2 25.3 29.3 Max. 39.5 Max. 22.3 Service limit value Max. 4.4 Max. 4.0 Max. 3.7 Max. 3.7 23.3 31.3 Max. 49 Max. 27 Measured value
No.
Check item
Checking posture, etc. Work equipment extended fully Boom top horizontal Boom top horizontal Arm cylinder retracted fully Work equipment extended fully Swing right and left One side of track pushed up and turned forward and backward LO STD HI STD
Unit
1 2 3 4 5
Boom RAISE Arm IN Arm OUT Bucket CURL Swing (5 turns) Travel (5 idle turns) MAX P
sec sec sec sec sec sec sec
3.
Hydraulic drift of work equipment

Checking condition Fuel control dial Working mode Standard value for new machine Service limit value Measured value
No.
Check item
Checking posture, etc. Boom top horizontal Arm cylinder retracted fully Bucket loaded
Unit
Hydraulic drift of Engine stopped bucket tip
mm/ 15 min
Max. 310
Max. 460
10
PC138US, USLC-8
SEN02460-01
4.
Hydraulic circuit
Checking condition [1] 600K Pump main 1 B C1 D1 D1 E E B C1 C2 D2 D2 [2] 600K Pump main 2 [3] 600K Pump LS 1 C2 [4] 600K Pump LS 2 [5] Good Good Bad Bad 60K Control A
No.
Checked part
Fuel control dial
Working mode
1 2 3
Self pressure reducing valve Main relief valve Unload valve
All lever in neutral Arm out relief All levers in neutral Right track driven idle Lever moved halfway Left track driven idle Lever moved halfway MAX P Swing lock Right swing relief Swing lock Left swing relief Right travel lock Right forward relief E E F F
LS valve
Swing motor safety valve
F F
Main relief valve Travel motor Safety valve Travel junction valve
Right travel lock Right reverse relief Left travel lock Left forward relief Left travel lock Left reverse relief
Checked oil pressure Standard value A (Control circuit basic pressure) B (Work equipment relief pressure) C (Unload pressure) D (LS differential pressure) E (Swing relief pressure) F (Travel relief pressure)
Unit
Standard value for new machine 3.0 3.4 {31 35} 33.8 35.8 {345 365} 1.8 3.8 {18 38} 2.1 2.3 {21.5 23.5} 28.2 30.2 {288 308} 33.8 35.8 {345 365}
Service limit value 2.7 3.7 {28 35} 33.8 36.8 {345 375} 1.8 3.8 {18 38} 2.1 2.3 {21.5 23.5} 26.7 30.7 {273 313} 32.8 36.8 {335 375}
MPa {kg/cm2}
* Gauge changing work: Change hoses of gauges [3] and [4].

Checking condition No. Check item Fuel control dial MAX Working mode P [1] 600K F pump main H1 [2] 600K R pump main H1 [3a] 600K F pump servo H2 [4a] 600K R pump servo H2 [5] 60K Control
Servo piston
Arm out relief
Standard value
Checked oil pressure H (Servo control pressure)
Unit
Standard value for new machine H1 : H2 = 1 : 0.6 (Oil pressure ratio)
Service limit value
PC138US, USLC-8
11
SEN02460-01
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
Checking condition No. Check item Fuel control dial MIN P 8 PC-EPC valve MAX L B E All levers in neutral Working mode [1] 600K F pump main [2] 600K R pump main [3b] 60K F pump (F) J1 J2 J3 J4 J5 [4b] 60K R pump (R) J1 J2 J3 J4 J5 [5a] Good Bad 60K LS-EPC
Checked oil pressure

Standard value J1 (PC-EPC valve output pressure 1) J2 (PC-EPC valve output pressure 2) J3 (PC-EPC valve output pressure 3) J4 (PC-EPC valve output pressure 4) J5 (PC-EPC valve output pressure 5)
Unit
Standard value for new machine
Service limit value
Approx. 1.7 {Approx. 18} MPa {kg/cm2} Approx. 0.3 {Approx. 3} Approx. 0.5 {Approx. 5} Approx. 0.4 {Approx. 5} Approx. 0.4 {Approx. 5}
12
PC138US, USLC-8
SEN02460-01
PC138US, USLC-8
13
SEN02460-01
14
PC138US, USLC-8
SEN02461-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2 Fuse locations................................................................................................................................................. 6
PC138US, USLC-8
SEN02461-01
40 Troubleshooting
Failure code table

User code Failure code 989L00 989M00 989N00 AB00KE
1
Alarm buzzer Component Category of Reference in charge record documents No. MON MON MON MON e ENG MON e e q q q q q q q q q q q q q q ENG PUMP ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG q q q q q ENG ENG ENG ENG ENG Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical Troubleshooting system by failure code, Part 1 Electrical SEN02463-00 system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system
Trouble (Displayed on screen) Engine controller lock caution 1 Engine controller lock caution 2 Engine controller lock caution 3 Charge voltage low
B@BAZG Eng oil press. low B@BAZK Eng oil level low B@BCNS Eng coolant overheat B@HANS Hydr oil overheat E10 E10 E11 E11 E14 E14 E15 E15 E15 E15 E15 E11 E11 E15 CA111 CA115 CA122 CA123 CA131 CA132 CA144 CA145 CA153 CA154 CA187 CA221 CA222 CA227 CA234 E15 E10 E10 E11 E11 CA238 CA271 CA272 CA322 CA324 ECM critical internal failure Eng. Ne and Bkup speed sensor error Charge air press sensor high error Charge air press sensor low error Throttle sensor high error Throttle sensor low error Coolant temp. sensor high error Coolant temp. sensor low error Charge air temp. sensor high error Charge air temp. sensor low error Sensor sup. 2 volt. low error Ambient air press. sensor high error Ambient air press. sensor low error Sensor sup. 2 volt. high error Eng. overspeed Ne speed sensor sup. volt. error IMV/PCV1 short error IMV/PCV1 open error Injector #1 (L #1) system open/short error Injector #3 (L #3) system open/short error
PC138US, USLC-8
40 Troubleshooting
SEN02461-01
User code E11 E11 E10 E15 E15 E15 E10 E10 E11 E11 E11 E15 E15 E15 E15 E10 E15 E0E E14 E14 E11 E11
Failure code CA331 CA332 CA351 CA352 CA386 CA435 CA441 CA442 CA449 CA451 CA452 CA553 CA559 CA689 CA731 CA757 CA778 CA1633 CA2185 CA2186 CA2249 CA2311 D110KB
Trouble (Displayed on screen) Injector #2 (L #2) system open/short error Injector #4 (L #4) system open/short error Inj. drive circuit error Sensor sup. 1 volt. low error Sensor sup. 1 volt. high error Abnormality in engine oil pressure switch Battery voltage low error Battery voltage high error Rail press. very high error Rail press. sensor high error Rail press. sensor low error Rail press. high error Rail press. low error Eng. Ne speed sensor error Eng. Bkup speed sensor phase error All persistent data lost error Eng. Bkup speed sensor error KOMNET datalink timeout error Throttle sens. sup. volt. high error Throttle sens. sup. volt. low error Rail press. very low error Abnormality in IMV solenoid Battery relay drive short Personal code relay abnormality GPS antenna discon Pump solenoid power low error 5V sensor 1 power abnormality 5V sensor 2 power abnormality CAN discon (Pump controller detected) Short circuit in camera power supply
Alarm buzzer q q q q q q q q q q q q q q q q q q q q q q
E01
D19JKZ D862KA
E0E
DA22KK DA25KP DA26KP
E0E
DA2RMC DAF8KB
Component Category of in charge record Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical PUMP system Electrical KOM system Electrical KOM system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical MON system
Reference documents No. Troubleshooting by failure code, Part 1 SEN02463-00
Troubleshooting by failure code, Part 2 SEN02464-00
PC138US, USLC-8
SEN02461-01
40 Troubleshooting
User code
Failure code DAFGMC
Trouble (Displayed on screen) GPS module error CAN discon (Monitor detected) Hydr oil sensor short Pump press sensor abnormality Travel left forward PPC press sensor abnormality Travel right forward PPC press sensor abnormality Travel left reverse PPC press sensor abnormality Travel right reverse PPC press sensor abnormality Blade raise PPC press sensor abnormality Blade lower PPC press sensor abnormality Overload sensor abnormality (Analog) Travel alarm S/C Travel speed sol discon Travel speed sol short Swing brake sol discon Swing brake sol short Travel junction sol discon Travel junction sol short Merge-divider sol discon Merge-divider sol short PC-EPC sol discon PC-EPC sol short Service current EPC discon Service current EPC short Wiper working abnormality Wiper parking abnormality Washer drive discon Washer drive short Wiper drive (for) short Wiper drive (rev) short
Alarm buzzer
E0E
DAFRMC DGH2KB DHPAMA
E20 E20 E20 E20
DHSFMA DHSGMA DHSHMA DHSJMA DHSKMA DHSLMA DHX1MA DV20KB DW43KA DW43KB
q q q q
E03 E03
DW45KA DW45KB DW91KA DW91KB DWJ0KA DWJ0KB
q q
E02 E02
DXA8KA DXA8KB DXE4KA DXE4KB DY20KA DY20MA DY2CKA DY2CKB DY2DKB DY2EKB
q q
Component Category of in charge record Electrical KOM system Electrical MON system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system
Reference documents No.
PC138US, USLC-8
40 Troubleshooting
a a
SEN02461-01
Entry order of items in table The items are entered in the order of their failure codes (incremental order). User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the abnormality. Alarm buzzer q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). e : Since the caution monitor is also turned ON, its function sounds the buzzer. Component in charge MON: The machine monitor is in charge of detection of abnormality. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. ENG: The engine controller is in charge of detection of abnormality. PUMP: The pump controller is in charge of detection of abnormality. Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record.
PC138US, USLC-8
SEN02461-01
40 Troubleshooting
Fuse locations
Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally.
Type of power supply Fusible link Fuse No. 1 Switch power supply F02 (45A) 2 3 4 5 6 Switch power supply F02 (45A) 7 8 9 10 11 Switch power supply F02 (45A) 12 13 14 15 Constant power supply F03 (45A) 16 17 18 Switch power supply Starting switch ACC 19 20 Fuse capacity 10A 30A 15A 10A 10A 5A 10A 20A 10A 5A 20A 10A 10A 10A 5A 10A 20A 30A 5A 5A Solenoid valve Cigarette lighter Windshield washer Horn Working lamp relay, horn relay Rotary lamp (If equipped) Working lamp Radio, speaker Air conditioner Air conditioner unit Optional power supply (1) Optional power supply (2), power supply of 12 volt Spare Air conditioner Radio backup, room lamp Machine monitor, pump controller, starting switch Engine controller Engine controller PPC oil pressure lock solenoid Destination of power Emergency operating circuit
PC138US, USLC-8
40 Troubleshooting
SEN02461-01
Locations of fusible links
Location of fuse box and fuse Nos.
PC138US, USLC-8
SEN02461-01
40 Troubleshooting
PC138US, USLC-8
SEN02462-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2 Sequence of events in troubleshooting........................................................................................................... 3 Checks before troubleshooting ....................................................................................................................... 4 Classification and procedures for troubleshooting .......................................................................................... 5 Information in troubleshooting table................................................................................................................ 6 Phenomena looking like troubles and troubleshooting Nos. ........................................................................... 8 Wiring table for connector pin numbers .........................................................................................................11 T-adapter box and T-adapter table................................................................................................................ 44
PC138US, USLC-8
SEN02462-00
40 Troubleshooting
Points to remember when troubleshooting

k k k k k k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative () terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Is there any sign of irregularities of the machine? 2) Make checks before starting day's work. 3) Make checks of other items. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4.
Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of failure, then use the troubleshooting table or troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.To prevent this, always investigate why the problem occurred. Then, remove the root cause.
5.
2.
6.
3.
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
Sequence of events in troubleshooting
PC138US, USLC-8
SEN02462-00
40 Troubleshooting
Checks before troubleshooting

Item 1. Check of level and type of fuel 2. Check of fuel for foreign matter 3. Check of fuel filter 4. Check of hydraulic oil level Lubricating oil/Coolant 5. Check of hydraulic oil strainer 6. Check of swing machinery oil level 7. Check of level and type of engine oil (in oil pan) 8. Check of coolant level 9. Check of dust indicator for clogging 10. Check of hydraulic oil filter 1. Check of battery terminals and wiring for looseness and corrosion Electrical equipment 2. Check of alternator terminals and wiring for looseness and corrosion 3. Check of starting motor terminals and wiring for looseness and corrosion Hydraulic/ Mechanical equipment 1. Check for abnormal noise and smell 2. Check for oil leakage 3. Bleeding air 1. Check of battery voltage (with engine stopped) 2. Check of electrolyte level 3. Check of wires for discoloration, burn, and removal of cover Electric, electrical equipment 4. Check for released wire clamp and drooping wire 5. Check of wires for wetness (Check connectors and terminals for wetness, in particular) 6. Check of fuse for disconnection and corrosion 7. Check of alternator voltage (while engine speed is at middle or higher) 8. Check of battery relay for operating sound (when starting switch is turned ON or OFF) Criterion 20 30 V After operating for several minutes: 27.5 29.5 V Remedy Add fuel Clean and drain Replace Add fuel Clean and drain Add fuel Add fuel Add coolant Clean or replace Replace
Retighten or replace Retighten or replace Retighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect the connectors and dry Replace Replace Replace
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
Classification and procedures for troubleshooting

Classification for troubleshooting
Mode Display of code E-mode H-mode S-mode Troubleshooting by failure code Troubleshooting of electrical system Troubleshooting of hydraulic and mechanical system Troubleshooting of engine Contents
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1. Procedure for troubleshooting to be taken when user code and failure code are displayed on machine monitor: If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for the corresponding "Display of code" according to the displayed failure code. When electrical system error code or mechanical system error code is recorded in abnormality record: If a user code and a failure code are not displayed on the machine monitor, check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according to the recorded code. a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is still detected. a An error code of the mechanical system cannot be deleted. a If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the abnormality record function, carry out the corresponding troubleshooting in E-mode. When user code and failure code is not displayed and no failure code is recorded in abnormality record: If a user code and failure code are not displayed on the machine monitor and no failure code is recorded in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode".
2.
3.
PC138US, USLC-8
SEN02462-00
40 Troubleshooting
Information in troubleshooting table

a
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
User code Failure code Trouble Trouble name displayed in abnormality record machine monitor
Display on Display on machine machine monimonitor tor Contents of trouble
Contents of trouble detected by machine monitor or controller
Action of Action taken by machine monitor or controller to protect system or devices when engine conmachine monitroller detects trouble tor or controller Problem that appears on machine Related information Problem that appears on machine as result of action taken by machine monitor or controller (shown above) Information related to detected trouble or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting <Contents of description> Standard value in normal state to judge possible causes Remarks on judgment <Troubles in wiring harness> Disconnection Connector is connected imperfectly or wiring harness is broken. Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. Short circuit Independent wiring harnesses are in contact with each other abnormally.
Possible causes and standard value in normal state
Possible causes of trouble 3 (Given numbers are reference numbers, which do not <Precautions for troubleshooting> (1) Method of indicating connector No. and handling of Tindicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. If connector No. has no marks of male and female, disconnect connector and insert T-adapters in both male 4 side and female side. If connector No. has marks of male and female, disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative () lead of tester as explained below for troubleshooting, unless otherwise specified. 5 Connect positive (+) lead to pin No. or wiring harness entered on front side. Connect negative () lead to pin No. or harness entered on rear side.
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

q q
Connector No.: Indicates (Model Number of pins) and (Color). Connector No. and pin No. from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. Arrow ( ): Roughly shows the location on the machine.
PC138US, USLC-8
SEN02462-00
40 Troubleshooting
Phenomena looking like troubles and troubleshooting Nos.

Troubleshooting No. Phenomena looking like troubles Display of code E-mode H-mode
S-mode
Phenomena related to user code/failure code User code and failure code are displayed on ordinary screen of machine monitor According to disWhen abnormality record is checked, failure code is displayed in 2 played mechanical system abnormality record code When abnormality record is checked, failure code is displayed in 3 electrical system abnormality record 1 4 When abnormality record is checked, failure code is displayed in air conditioner or heater abnormality record Phenomena related to engine 5 Starting performance is poor 6 Engine does not start (Engine does not turn) 7 Engine does not pick up smoothly 8 Engine stops during operations 9 Engine does not rotate smoothly 10 Engine lacks output (or lacks power) 11 Exhaust smoke is black (incomplete combustion) 12 Oil consumption is excessive (or exhaust smoke is blue) 13 Oil becomes contaminated quickly 14 Fuel consumption is excessive 15 Oil is in coolant (or coolant spurts back or coolant level goes down) 16 Oil pressure drops 17 Oil level rises (Entry of coolant or fuel) 18 Coolant temperature becomes too high (overheating) 19 Abnormal noise is made 20 Vibration is excessive 21 Preheater does not operate 22 Automatic warm-up system does not operate (in cold season) 23 Auto-decelerator does not operate normally Phenomena related to work equipment/swing/travel 24 All work equipment, swing, and travel mechanism do not move or cannot be locked E-6 H-3 H-1 H-2 E-16 H-4 H-5 H-6 H-7 H-8 H-9 S-6 E-4 E-5 E-15 E-3 S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 E-22
25 Speed or power of all work equipment, swing, and travel are low 26 Engine speed sharply drops or engine stalls 27 Working mode does not change 28 Abnormal noise is heard from around hydraulic pump 29 Fine control mode does not function Phenomena related to work equipment 30 Speed or power of boom is low 31 Speed or power of arm is low 32 Speed or power of bucket is low 33 Work equipment does not move in its single operation
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
Troubleshooting No. Phenomena looking like troubles Display of code E-mode H-mode H-10 H-11 H-26 S-mode
34 Hydraulic drift of work equipment is large 35 Time lag of work equipment is large 36 Flow rate in attachment circuit cannot be adjusted (when attachment is installed) Phenomena related to compound operation 37 Work equipment loaded more is slower during compound operation 38 39 Boom RAISE speed is low in compound operation of swing + boom RAISE Travel speed lowers largely during compound operation of work equipment/swing + travel Phenomena related to travel 40 Machine deviates during travel 41 Travel speed is low 42 Machine cannot be steered easily or steering power is low 43 Travel speed does not change or it is kept low or high 44 Track does not move (Only either side) 45 Travel alarm does not sound or does not stop sounding Phenomena related to swing 46 Machine does not swing 47 Swing acceleration or swing speed is low 48 Excessive overrun when stopping swing 49 When upper structure stops swinging, it makes large shock 50 When upper structure stops swinging, it makes large sound 51 Swing holding brake does not operate normally Hydraulic drift of swing is large Phenomena related to machine monitor 52 When starting switch turned ON, machine monitor displays nothing 53 When starting switch turned ON (before starting engine), basic check item lights up E-1 E-2 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-18 E-19 E-22 E-23 E-24 E-25 E-20 E-21 E-17
H-12 H-13 H-14
H-15 H-16 H-17 H-18 H-19
H-20 H-21 H-22 H-23 H-24 H-25
54 Precaution lights up while engine is running 55 Emergency stop item lights up while engine is running 56 Engine coolant temperature gauge does not indicate normally 57 Hydraulic oil temperature gauge does not indicate normally 58 Fuel level gauge does not indicate normally 59 Contents of display by machine monitor are different from applicable machine
60 Machine monitor does not display some items 61 Function switch does not work 62 Alarm buzzer cannot be stopped 63 Windshield wiper and window washer do not operate 64 Air conditioner does not operate normally (including air conditioner abnormality record)
65 While starting switch is in OFF position, service meter is not displayed 66 Machine monitor cannot be set in service mode 67 Monitoring function does not display lever control signal normally
PC138US, USLC-8
SEN02462-00
40 Troubleshooting
Troubleshooting No. Phenomena looking like troubles Other phenomena 68 KOMTRAX system does not operate normally E-26 Display of code E-mode H-mode S-mode
10
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
Wiring table for connector pin numbers

a
(Rev. 2006.11)
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
PC138US, USLC-8
11
SEN02462-00
40 Troubleshooting
12
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
13
SEN02462-00
40 Troubleshooting
14
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
15
SEN02462-00
40 Troubleshooting
16
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
17
SEN02462-00
40 Troubleshooting
18
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
19
SEN02462-00
40 Troubleshooting
20
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
21
SEN02462-00
40 Troubleshooting
22
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
23
SEN02462-00
40 Troubleshooting
24
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
25
SEN02462-00
40 Troubleshooting
26
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
27
SEN02462-00
40 Troubleshooting
28
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
29
SEN02462-00
40 Troubleshooting
30
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
31
SEN02462-00
40 Troubleshooting
32
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
33
SEN02462-00
40 Troubleshooting
34
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
35
SEN02462-00
40 Troubleshooting
36
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
37
SEN02462-00
40 Troubleshooting
38
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
39
SEN02462-00
40 Troubleshooting
40
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
41
SEN02462-00
40 Troubleshooting
42
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
PC138US, USLC-8
43
SEN02462-00
40 Troubleshooting
T-adapter box and T-adapter table

a
(Rev. 2006.11) 1
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
Number of pins T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4100 799-601-4200 Identification symbol Out of kit q 24 24 17 17 5 10 5 17 19 14 5 13 17 21 9 2 3 4 8 8 12 16 MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5S MS-17P MS-19P MS-14P MIC-5P MIC-13P MIC-17P MIC-21P MIC-9P ECONO2P ECONO3P ECONO4P ECONO8P DLI-8P DLI-12P DLI-16P q q q q q q q q q q q q q q q q q X2P X3P X4P SW6P SW8P SW12P SW14P SW16P q M2P M3P q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q 50 1 2 3 4 6 8 12 14 16 1 2 3 DRC50 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-2600 T-box (for ECONO) 799-601-3100 T-box (for MS) 799-601-3200 T-box (for MS) 799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS) 799-601-3420 Adapter for BENDIX (MS) 799-601-3430 Adapter for BENDIX (MS) 799-601-3440 Adapter for BENDIX (MS) 799-601-3450 Adapter for BENDIX (MS) 799-601-3460 Adapter for BENDIX (MS) 799-601-3510 Adapter for BENDIX (MS) 799-601-3520 Adapter for BENDIX (MS) 799-601-3530 Adapter for BENDIX (MS) 799-601-2910 Adapter for BENDIX (MS) 799-601-3470 Case 799-601-2710 Adapter for MIC 799-601-2720 Adapter for MIC 799-601-2730 Adapter for MIC 799-601-2740 Adapter for MIC 799-601-2950 Adapter for MIC 799-601-2750 Adapter for ECONO 799-601-2760 Adapter for ECONO 799-601-2770 Adapter for ECONO 799-601-2780 Adapter for ECONO 799-601-2790 Adapter for ECONO 799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI 799-601-2840 Extension cable (ECONO type) 799-601-2850 Case 799-601-4210 Adapter for DRC 799-601-7010 Adapter for X (T-adapter) 799-601-7020 Adapter for X 799-601-7030 Adapter for X 799-601-7040 Adapter for X 799-601-7050 Adapter for SWP 799-601-7060 Adapter for SWP 799-601-7310 Adapter for SWP 799-601-7070 Adapter for SWP 799-601-7320 Adapter for SWP 799-601-7080 Adapter for M (T-adapter) 799-601-7090 Adapter for M 799-601-7110 Adapter for M
21 37 37
q q
12 ECONO12P q q
12 ECONO12P q q
44
PC138US, USLC-8
40 Troubleshooting
SEN02462-00
Number of pins
T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4100 799-601-4200 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-7120 Adapter for M 799-601-7130 Adapter for M 799-601-7340 Adapter for M 799-601-7140 Adapter for S 799-601-7150 Adapter for S (White) 799-601-7160 Adapter for S (Blue) 799-601-7170 Adapter for S (Blue) 799-601-7330 Adapter for S (White) 799-601-7350 Adapter for S (White) 799-601-7180 Adapter for AMP040 799-601-7190 Adapter for AMP040 799-601-7210 Adapter for AMP040 799-601-7220 Adapter for AMP040 799-601-7230 Short connector for X 799-601-7240 Case 799-601-7270 Case 799-601-7510 Adapter for 070 799-601-7520 Adapter for 070 799-601-7530 Adapter for 070 799-601-7540 Adapter for 070 799-601-7550 Adapter for 070 799-601-7360 Adapter for relay 799-601-7370 Adapter for relay 799-601-7380 Adapter for JFC 799-601-9010 Adapter for DTM 799-601-9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9040 Adapter for DT 799-601-9050 Adapter for DT 799-601-9060 Adapter for DT (Gray) 799-601-9070 Adapter for DT (Black) 799-601-9080 Adapter for DT (Green) 799-601-9090 Adapter for DT (Brown) 799-601-9110 Adapter for DT (Gray) 799-601-9120 Adapter for DT (Black) 799-601-9130 Adapter for DT (Green) 799-601-9140 Adapter for DT 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24-pin)
4 6 8 8 10 12 16 16 12 8 12 16 20 2
M4P M6P M8P S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P
q q q q q q
q q
10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31
07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P
q q q q q
PC138US, USLC-8
45
SEN02462-00
40 Troubleshooting
Number of pins
T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4100 q q q q HST16A HST16B HST26A q q q 799-601-4200 Identification symbol Out of kit q q q q q q q q q q q q q q ITT3N FCIN FCIG FCIB 4160 4180 1,2,3L 1,2,3,4C 1,2,3A 1,2,3B 1,2,3,G 2,PA 1,2,3,4T DTP4 DRC50 DRC60 q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-9320 T-box (for DT/HD) 799-601-9330 Case 799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL 799-601-9430* Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
12
q q q q
40 24 2 3 2 3 2 2 2 3 3 3 4 3 3 3 2 3 3 4 3 3 3 2 4 4 50 60 60 121 16 16 26
DRC-40 DRC-24 G A3 P 1,2,3 S C A
q q
799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor 795-799-5540* Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM 799-601-4140 Adapter for engine (CRI-T3) Atomosphere pressure Adapter for engine (CRI-T3) Oil pressure switch Socket for engine (CRI-T3) Commonrail pressure Socket for engine (CRI-T3) Air intake pressure/temperature
799-601-4150 Adapter for engine (CRI-T3) POIL 799-601-4160
799-601-4180 Adapter for engine (CRI-T3) PEVA 799-601-4190* 799-601-4230*
799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator 799-601-4380* Socket for engine (CRI-T3)(95) Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 799-601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280 Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9370 Adapter for controller (HST)
* Shows not T-adapter but socket.
46
PC138US, USLC-8
SEN02462-00
40 Troubleshooting
48
PC138US, USLC-8
SEN02463-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Troubleshooting by failure code, Part 1
Failure code [989L00] Engine controller lock caution 1 .................................................................................. 3 Failure code [989M00] Engine controller lock caution 2 ................................................................................. 3 Failure code [989N00] Engine controller lock caution 3.................................................................................. 4 Failure code [AB00KE] Charge voltage low.................................................................................................... 6 Failure code [B@BAZG] Eng oil press. low .................................................................................................... 8 Failure code [B@BAZK] Eng oil level low ....................................................................................................... 8 Failure code [B@BCNS] Eng coolant overheat .............................................................................................. 9 Failure code [B@HANS] Hydr oil overheat ..................................................................................................... 9 Failure code [CA111] ECM critical internal failure ......................................................................................... 10 Failure code [CA115] Eng. Ne and Bkup speed sensor error ....................................................................... 13 Failure code [CA122] Charge air press sensor high error ............................................................................ 14 Failure code [CA123] Charge air press sensor low error.............................................................................. 16 Failure code [CA131] Throttle sensor high error........................................................................................... 18 Failure code [CA132] Throttle sensor low error ............................................................................................ 20 Failure code [CA144] Coolant temp. sensor high error................................................................................. 21 Failure code [CA145] Coolant temp. sensor low error .................................................................................. 22
PC138US, USLC-8
SEN02463-01
40 Troubleshooting
Failure code [CA153] Charge air temp. sensor high error ............................................................................ 23 Failure code [CA154] Charge air temp. sensor low error.............................................................................. 24 Failure code [CA187] Sensor sup. 2 volt. low error....................................................................................... 24 Failure code [CA221] Ambient air press. sensor high error .......................................................................... 26 Failure code [CA222] Ambient air press. sensor low error............................................................................ 28 Failure code [CA227] Sensor sup. 2 volt. high error ..................................................................................... 30 Failure code [CA234] Eng. overspeed .......................................................................................................... 32 Failure code [CA238] Ne speed sensor sup. volt. error ................................................................................ 34 Failure code [CA271] IMV/PCV1 short error ................................................................................................. 36 Failure code [CA272] IMV/PCV1 open error ................................................................................................. 37 Failure code [CA322] Injector #1 (L #1) system open/short error ................................................................. 38 Failure code [CA324] Injector #3 (L #3) system open/short error ................................................................. 40 Failure code [CA331] Injector #2 (L #2) system open/short error ................................................................. 42 Failure code [CA332] Injector #4 (L #4) system open/short error ................................................................. 44
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Failure code [989L00] Engine controller lock caution 1

User code Contents of trouble Failure code 989L00 Trouble Engine controller lock caution 1 (Machine monitor system)
Engine controller lock is detected (Factor 1).
Action of None in particular. machine monitor If cause of failure disappears, system resets itself. Problem that appears on machine Related information Engine cannot be started. If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. Method of reproducing failure code: Turn starting switch ON. Cause 1 Replacement of machine monitor Standard value in normal state/Remarks on troubleshooting This trouble may be caused by replacement of machine monitor.
Failure code [989M00] Engine controller lock caution 2

User code Contents of trouble Failure code 989M00 Trouble Engine controller lock caution 2 (Machine monitor system)
Action of None in particular. machine monitor If cause of failure disappears, system resets itself. Problem that appears on machine Related information Engine cannot be started. If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. Method of reproducing failure code: Turn starting switch ON. Cause Possible causes and standard value in normal state 1 Replacement of machine monitor Standard value in normal state/Remarks on troubleshooting This trouble may be caused by replacement of machine monitor. If this failure code is displayed while machine monitor is not replaced, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
2 Defective machine monitor
PC138US, USLC-8
SEN02463-01
40 Troubleshooting
Failure code [989N00] Engine controller lock caution 3

User code Contents of trouble Failure code 989N00 Trouble Engine controller lock caution 3 (Machine monitor system)
Action of Tries automatic resetting. machine monitor If cause of failure disappears, system resets itself. Problem that appears on machine Related information Possible causes and standard value in normal state Method of reproducing failure code: Failure code is not reproduced since system is reset automatically. Cause 1 Defective engine controller Standard value in normal state/Remarks on troubleshooting If this failure code is displayed repeatedly, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
SEN02463-01
40 Troubleshooting
Failure code [AB00KE] Charge voltage low

User code Contents of trouble Failure code AB00KE Trouble Charge voltage low (Machine monitor system)
While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
Action of Displays charge level monitor on machine monitor. machine monitor Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information If machine is operated as it is, battery may not be charged. Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage) Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. E12 (male) Between (1) chassis ground Engine speed Min. medium speed Voltage 27.5 29.5 V
Defective charge of alternator (when system is normal)
If cause 1 is not detected, charge level monitor system may be Defective charge level monidefective. Carry out troubleshooting for "E-7 Caution item flashes tor while engine is running" in E-mode.
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Circuit diagram related
PC138US, USLC-8
SEN02463-01
40 Troubleshooting
Failure code [B@BAZG] Eng oil press. low

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code B@BAZG Trouble Engine oil pressure low (Engine controller system)
While engine was running, signal circuit of engine oil pressure switch detected low engine oil pressure (sensor contact opened). Displays engine oil pressure monitor on machine monitor. If cause of failure disappears, system resets itself. If machine is operated as it is, engine may be damaged. Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor. Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting Engine oil pressure may be low. Check it and remove cause if it is low.
Lowering of engine oil pres1 sure (when system is normal) 2
Defective engine oil pressure If cause 1 is not detected, engine oil pressure switch system may switch system be defective. Carry out troubleshooting for failure code [CA435].
Failure code [B@BAZK] Eng oil level low

User code Contents of trouble Failure code B@BAZK Trouble Engine oil level low (Machine monitor system)
When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch detected low engine oil level (sensor contact opened).
Action of Displays engine oil level monitor on machine monitor. machine monitor Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information If machine is operated as it is, engine may be damaged. Engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2) Method of reproducing failure code: Turn starting switch ON. Cause Possible causes and standard value in normal state 1 Lowering of engine oil level (when system is normal) Standard value in normal state/Remarks on troubleshooting Engine oil level may be low. Check it and add new oil if it is low. If cause 1 is not detected, engine oil level monitor system may be defective. Carry out troubleshooting for "E-2 Basic check item lights up when starting switch is turned ON (but engine is not started)" in E-mode.
Defective engine oil level 2 monitor system
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Failure code [B@BCNS] Eng coolant overheat

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code B@BCNS Trouble Engine coolant overheat (Engine controller system)
While engine was running, signal circuit of engine coolant temperature sensor detected overheating of engine coolant (above about 102C). Displays engine coolant temperature monitor with red on machine monitor. If cause of failure disappears, system resets itself. If machine is operated as it is, engine may be seized. Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor. Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature) Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting
Overheating of engine Engine coolant may be overheating. Check it and remove cause if 1 coolant (when system is norit is overheating. mal) 2 Defective engine coolant temperature sensor system If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].
Failure code [B@HANS] Hydr oil overheat

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code B@HANS Trouble Hydraulic oil overheat (Pump controller system)
While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of hydraulic oil (above about 102C). Displays hydraulic oil temperature monitor with red on machine monitor. If cause of failure disappears, system resets itself. If machine is operated as it is, engine may be seized. Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine monitor. Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature) Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting Hydraulic oil may be overheating. Check it and remove cause if it is overheating. If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for "E-10 Hydraulic oil temperature gauge does not work normally" in E-mode.
Overheating of hydraulic oil 1 (when system is normal) 2 Defective hydraulic oil temperature gauge system
PC138US, USLC-8
SEN02463-01
40 Troubleshooting
Failure code [CA111] ECM critical internal failure

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Cause 1 Defective fuse Standard value in normal state/Remarks on troubleshooting Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) Failure code CA111 Trouble ECM critical internal failure (Engine controller system)
Abnormality occurred in controller. None in particular. Engine runs normally but it may stop during operation or may not be able to start.
Defective power supply cut2 out relay
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) (32) Resistance 185 265 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) R23 (1) Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between CE02 (female) (55) R24 (1) Wiring harness between CE02 (female) (32) R23 (2) Wiring harness between CE02 (female) (32) R24 (2) Wiring harness between CE03 (female) (1) T12 Wiring harness between CE03 (female) (3) R23 (5) Wiring harness between CE03 (female) (3) R24 (5) Wiring harness between R23 (female) (3) battery (+) Wiring harness between R24 (female) (3) battery (+) Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
10
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) R23 (1) and chassis ground Wiring harness between CE02 (female) (55) R24 (1) and chassis ground Wiring harness between CE02 (female) (32) R23 (2) and chassis ground Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
Ground fault in wiring harWiring harness between CE02 (female) (32) 4 ness (Short circuit with GND R24 (2) and chassis ground circuit) Wiring harness between CE03 (female) (3) R23 (5) and chassis ground Wiring harness between CE03 (female) (3) R24 (5) and chassis ground Wiring harness between R23 (female) (3) battery (+) and chassis ground Wiring harness between R24 (female) (3) battery (+) and chassis ground
5 Defective engine controller
a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. CE03 Between (3) (1) Voltage 20 30 V
PC138US, USLC-8
11
SEN02463-01
40 Troubleshooting
12
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Failure code [CA115] Eng. Ne and Bkup speed sensor error

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Causes 1 2 Possible causes and standard value in normal state 3 4 5 Defective Ne speed sensor system Defective Bkup speed sensor system Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA689]. Carry out troubleshooting for failure code [CA778]. Failure code CA115 Trouble Eng. Ne and Bkup speed sensor error (Engine controller system)
Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously. None in particular. Engine cannot be started (if engine has been stopped). Engine stops (if engine has been running).
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, internal of flywheel, etc.) Defective mount of Bkup speed sensor Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defecconnection) tive connection (wrong connection). If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
13
SEN02463-01
40 Troubleshooting
Failure code [CA122] Charge air press sensor high error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA122 Trouble Charge air press sensor high error (Engine controller system)
High voltage was detected in charge pressure sensor circuit. Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation. Acceleration performance of engine drops. Signal voltage of charge pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage). Method of reproducing failure code: Turn starting switch ON. Causes Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble1 ply system shooting for it first. Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective charge pressure 2 sensor (Internal trouble) PTIM Between (2) (4) Power supply Voltage 4.75 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between CE01 (female) (19) PTIM (female) (1) Wiring harness between CE01 (female) (36) PTIM (female) (2) Wiring harness between CE01 (female) (48) PTIM (female) (4)
Resistance Resistance Resistance
Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between CE01 (female) (19) PTIM (female) (1) and chassis ground Wiring harness between CE01 (female) (36) PTIM (female) (2) and chassis ground Wiring harness between CE01 (female) (48) PTIM (female) (4) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
14
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (19) PTIM (female) (1) and wiring harness between CE01 (female) (36) PTIM (female) (2) Wiring harness between CE01 (female) (19) PTIM (female) (1) and wiring harness between CE01 (female) (48) PTIM (female) (4) Chassis ground between CE01 (female) (36) PTIM (female) (2) and chassis ground between CE01 (female) (48) PTIM (female) (4) Resistance Min. 1 Mz
Short circuit in wiring harness 5 (With another wiring harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. CE01 Between (36) (48) Power supply Voltage 4.75 5.25 V
PC138US, USLC-8
15
SEN02463-01
40 Troubleshooting
Failure code [CA123] Charge air press sensor low error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA123 Trouble Charge air press sensor low error (Engine controller system)
Low voltage was detected in charge pressure sensor circuit. Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation. Acceleration performance of engine drops. Signal voltage of charge pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage). Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA122].
16
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
17
SEN02463-01
40 Troubleshooting
Failure code [CA131] Throttle sensor high error

User code E14 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA131 Trouble Throttle sensor high error (Engine controller system)
High voltage was detected in fuel control dial circuit. Sets throttle angle with signal other than fuel control dial signal and continues operation (depending on each model) Engine speed cannot be controlled with fuel control dial. Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) Method of reproducing failure code: Turn starting switch ON. Causes Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA2185] or [CA2186] is indicated, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective fuel control dial (Internal trouble) P20 (male) Between (1) (3) Between (2) (1) Between (2) (3) Resistance 4.0 6.0 kz 0.25 5.0 kz 0.25 5.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between CE02 (female) (27) P20 (female) (1) Wiring harness between CE02 (female) (35) P20 (female) (2) Wiring harness between CE02 (female) (28) P20 (female) (3) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between CE02 (female) (27) P20 (female) (1) and chassis ground Wiring harness between CE02 (female) (35) P20 (female) (2) and chassis ground Wiring harness between CE02 (female) (28) P20 (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller CE02 Between (27) (28) Between (35) (28) Power supply Signal Voltage 4.75 5.25 V 0.5 4.5 V
18
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
19
SEN02463-01
40 Troubleshooting
Failure code [CA132] Throttle sensor low error

User code E14 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA132 Trouble Throttle sensor low error (Engine controller system)
Low voltage was detected in fuel control dial circuit. Sets throttle angle with signal other than fuel control dial signal and continues operation (depending on each model) Engine speed cannot be controlled with fuel control dial. Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA131].
20
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Failure code [CA144] Coolant temp. sensor high error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Engine coolant temperature sensor voltage) Method of reproducing failure code: Turn starting switch ON. Cause Defective coolant temperature sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting Failure code CA144 Trouble Coolant temp. sensor high error (Engine controller system)
High voltage was detected in coolant temperature sensor circuit. Fixes coolant temperature (90C) and continues operation.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male) Between (1) (2) Coolant temperature 10 100C Resistance 0.6 20 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (47) 2 or defective contact in con- TWTR (female) (1) nector) Wiring harness between CE01 (female) (49) TWTR (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (49) Resiscircuit) Min. 1 Mz TWTR (female) (2) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CE01 (female) Between (47) (49) Coolant temperature 10 100C Resistance 0.6 20 kz
PC138US, USLC-8
21
SEN02463-01
40 Troubleshooting
Failure code [CA145] Coolant temp. sensor low error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Engine coolant temperature sensor voltage) Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA144]. Failure code CA145 Trouble Coolant temp. sensor low error (Engine controller system)
Low voltage was detected in coolant temperature sensor circuit. Fixes coolant temperature (90C) and continues operation.
22
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Failure code [CA153] Charge air temp. sensor high error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Signal voltage of charge temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Failure code CA153 Trouble Charge air temp. sensor high error (Engine controller system)
High voltage was detected in charge temperature sensor circuit. Fixes charge temperature (intake air temperature) (70C) and continues operation.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective charge temperature sensor (Internal trouble) PTIM (male) Between (3) (4) Between (3) chassis ground Intake air temperature 10 100C All range Resistance 0.5 20 kz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring ing without turning starting switch ON. harness Wiring harness between CE01 (female) (11) Resis2 (Disconnection in wiring or Max. 1 z PTIM (female) (3) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z PTIM (female) (4) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (11) Resiscircuit) Min. 1 Mz PTIM (female) (3) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller CE01 (female) Between (11) (48) Intake air temperature 10 100C Resistance 0.5 20 kz
PC138US, USLC-8
23
SEN02463-01
40 Troubleshooting
Failure code [CA154] Charge air temp. sensor low error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Signal voltage of charge temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA153]. Failure code CA154 Trouble Charge air temp. sensor low error (Engine controller system)
Low voltage was detected in charge temperature sensor circuit. Fixes charge temperature (intake air temperature) (70C) and continues operation.
Failure code [CA187] Sensor sup. 2 volt. low error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Failure code CA187 Trouble Sensor sup. 2 volt. low error (Engine controller system)
Low voltage was detected in sensor power supply 2 (5 V) circuit. Operates Bkup speed sensor with signals of Ne speed sensor. Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. Output drops. Method of reproducing failure code: Turn starting switch ON.
Causes
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA227].
24
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
25
SEN02463-01
40 Troubleshooting
Failure code [CA221] Ambient air press. sensor high error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA221 Trouble Ambient air press. sensor high error (Engine controller system)
High voltage was detected in ambient pressure sensor circuit. Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Output drops. Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) Method of reproducing failure code: Turn starting switch ON. Causes Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective atmospheric pres2 sure sensor (Internal trouble) PAMB Between (1) (3) Between (2) (3) Power supply Signal Voltage 4.75 5.25 V 0.3 4.7 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between CE01 (female) (36) PAMB (female) (1) Wiring harness between CE01 (female) (20) PAMB (female) (2) Wiring harness between CE01 (female) (48) PAMB (female) (3) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between CE01 (female) (36) PAMB (female) (1) and chassis ground Wiring harness between CE01 (female) (20) PAMB (female) (2) and chassis ground Wiring harness between CE01 (female) (48) PAMB (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
26
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) PAMB (female) (1) and wiring harness between CE01 (female) (20) PAMB (female) (2) Wiring harness between CE01 (female) (36) PAMB (female) (1) and wiring harness between CE01 (female) (48) PAMB (female) (3) Wiring harness between CE01 (female) (20) PAMB (female) (2) and wiring harness between CE01 (female) (48) PAMB (female) (3) Resistance Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller CE01 Between (36) (48) Between (20) (48) Voltage 4.75 5.25 V 0.3 4.7 V
PC138US, USLC-8
27
SEN02463-01
40 Troubleshooting
Failure code [CA222] Ambient air press. sensor low error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA222 Trouble Ambient air press. sensor low error (Engine controller system)
Low voltage was detected in ambient pressure sensor circuit. Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Output drops. Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) Method of reproducing failure code: Turn starting switch ON. Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA221].
28
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
29
SEN02463-01
40 Troubleshooting
Failure code [CA227] Sensor sup. 2 volt. high error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA227 Trouble Sensor sup. 2 volt. high error (Engine controller system)
High voltage was detected in sensor power supply 2 (5 V) circuit. Operates Bkup speed sensor with signals of Ne speed sensor. Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. Output drops. Method of reproducing failure code: Turn starting switch ON.
Causes 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective sensor (Internal trouble)
Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.
Bkup speed sensor Atmospheric pressure sensor Charge pressure sensor
CAM connector PAMB connector
PTIM connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between CE01 (female) (36) Resis3 (Disconnection in wiring or Max. 1 z each sensor (female) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z each sensor (female) tance Ground fault in wiring harness 4 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) each sensor (female) and chassis ground Wiring harness between CE01 (female) (48) each sensor (female) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) each sensor (female) and Wiring harness between CE01 (female) (48) each sensor (female) Resistance Min. 1 Mz
Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE01 Between (36) (48) Voltage 4.75 5.25V
30
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
31
SEN02463-01
40 Troubleshooting
Failure code [CA234] Eng. overspeed

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA234 Trouble Eng. overspeed (Engine controller system)
Engine speed is above operating range. Limits fuel injection rate until engine speed lowers to operating range. Engine speed fluctuates. Engine speed can be checked with monitoring function. (Code: 01002 Engine speed) Method of reproducing failure code: Run engine at high idle. Cause Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Way of use may be improper. Teach proper way of use to operator. If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
1 Defective related system 2 Improper way of use 3 Defective engine controller
32
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
33
SEN02463-01
40 Troubleshooting
Failure code [CA238] Ne speed sensor sup. volt. error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA238 Trouble Ne speed sensor sup. volt. error (Engine controller system)
Abnormality occurred in Ne speed sensor power supply (5 V) circuit. Controls Ne speed sensor with signals of Bkup speed sensor. Running engine stops (when Bkup speed sensor is also abnormal). Stopped engine cannot be started (when Bkup speed sensor is also abnormal). Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective Ne speed sensor (Internal trouble)
Ne speed sensor
NE connector
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (26) 2 or defective contact in con- NE (female) (1) nector) Wiring harness between CE01 (female) (44) NE (female) (2)
Ground fault in wiring harWiring harness between CE01 (female) (26) 3 ness (Short circuit with GND NE (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (44) NE (female) (2) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (26) NE (female) (1) and between CE01 (female) (44) NE (female) (2) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE01 Between (26) (44) Voltage 4.75 5.25 V
34
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
35
SEN02463-01
40 Troubleshooting
Failure code [CA271] IMV/PCV1 short error

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Method of reproducing failure code: Turn starting switch ON. Failure code CA271 Trouble IMV/PCV1 short error (Engine controller system)
There is short circuit in IMV circuit of supply pump. None in particular.
Causes
Defective supply pump IMV (Internal trouble)
PREG (male) Between (1) (2) Between (1), (2) chassis ground
Resistance 2.3 5.3 z Min. 1 Mz
Ground fault in wiring harness 2 (Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (10) PREG (female) (2) Wiring harness between CE01 (female) (14) PREG (female) (1) Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Hot short (Short circuit with Wiring harness between CE01 (female) (10) 24V circuit) in wiring harness PREG (female) (2) and chassis ground Wiring harness between CE01 (female) (14) PREG (female) (1) and chassis ground Voltage Voltage Max. 1V Max. 1V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller CE01 (female) Between (10) (14) Between (10), (14) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
36
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
Failure code [CA272] IMV/PCV1 open error

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Method of reproducing failure code: Turn starting switch ON. Failure code CA272 Trouble IMV/PCV1 open error (Engine controller system)
There is disconnection in IMV circuit of supply pump. None in particular.
Causes
Defective supply pump IMV (Internal disconnection)
PREG (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness ResisWiring harness between CE01 (female) (10) 2 (Disconnection in wiring or Max. 1 z PREG (female) (2) tance defective contact in connecWiring harness between CE01 (female) (14) Resistor) Max. 1 z PREG (female) (1) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (10) PREG (female) (2) and chassis ground Wiring harness between CE01 (female) (14) PREG (female) (1) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller CE01 (female) Between (10) (14) Between (10) (14) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
PC138US, USLC-8
37
SEN02463-01
40 Troubleshooting
Failure code [CA322] Injector #1 (L #1) system open/short error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA322 Trouble Injector #1 (L #1) system open/short error (Engine controller system)
There is disconnection or short circuit in injector #1 circuit. None in particular. Output drops. Rotation is unstable. Method of reproducing failure code: Start engine.
Causes
Defective injector #1 (Internal trouble)
CN1 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness ResisWiring harness between CE01 (female) (57) 2 (Disconnection in wiring or Max. 1 z CN1 (female) (1) tance defective contact in connecWiring harness between CE01 (female) (53) Resistor) Max. 1 z CN1 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) Defective injector or wiring harness of another cylinder a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (57) CN1 (female) (1) and chassis ground Wiring harness between CE01 (female) (53) CN1 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
If another failure code for injector abnormality is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
CE01 (female) Between (57) (53) Between (57), (53) chassis ground
38
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
39
SEN02463-01
40 Troubleshooting

Cause
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (55) 2 or defective contact in con- CN3 (female) (1) nector) Wiring harness between CE01 (female) (59) CN3 (female) (2)
Ground fault in wiring harWiring harness between CE01 (female) (55) 3 ness (Short circuit with GND CN3 (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (59) CN3 (female) (2) and chassis ground 4 Defective injector or wiring harness of another cylinder
40
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
41
SEN02463-01
40 Troubleshooting

Cause
42
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
43
SEN02463-01
40 Troubleshooting

Cause
44
PC138US, USLC-8
40 Troubleshooting
SEN02463-01
PC138US, USLC-8
45
SEN02463-01
40 Troubleshooting
46
PC138US, USLC-8
SEN02464-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Failure code [CA351] Inj. drive circuit error..................................................................................................... 3 Failure code [CA352] Sensor sup. 1 volt. low error ........................................................................................ 6 Failure code [CA386] Sensor sup. 1 volt. high error ....................................................................................... 8 Failure code [CA435] Abnormality in engine oil pressure switch .................................................................. 10 Failure code [CA441] Battery voltage low error .............................................................................................11 Failure code [CA442] Battery voltage high error ............................................................................................11 Failure code [CA449] Rail press. very high error .......................................................................................... 12 Failure code [CA451] Rail press. sensor high error ...................................................................................... 14 Failure code [CA452] Rail press. sensor low error ....................................................................................... 16 Failure code [CA553] Rail press. high error.................................................................................................. 16 Failure code [CA559] Rail press. low error ................................................................................................... 17 Failure code [CA689] Eng. Ne speed sensor error ....................................................................................... 20 Failure code [CA731] Eng. Bkup speed sensor phase error......................................................................... 22 Failure code [CA757] All persistent data lost error ....................................................................................... 22 Failure code [CA778] Eng. Bkup speed sensor error ................................................................................... 24 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 26
PC138US, USLC-8
SEN02464-01
40 Troubleshooting
Failure code [CA2185] Throttle sens. sup. volt. high error............................................................................ 28 Failure code [CA2186] Throttle sens. sup. volt. low error ............................................................................. 30 Failure code [CA2249] Rail press. very low error.......................................................................................... 30 Failure code [CA2311] Abnormality in IMV solenoid ..................................................................................... 31 Failure code [D110KB] Battery relay drive short ........................................................................................... 32 Failure code [D19JKZ] Personal code relay abnormality .............................................................................. 34 Failure code [D862KA] GPS antenna discon ................................................................................................ 36 Failure code [DA22KK] Pump solenoid power low error ............................................................................... 38 Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................................... 40 Failure code [DA26KP] 5V sensor 2 power abnormality ............................................................................... 43
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Failure code [CA351] Inj. drive circuit error

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA351 Trouble Inj. drive circuit error (Engine controller system)
Abnormality occurred in injector drive circuit. Limits output and continues operation (Limits common rail pressure). Output drops. Method of reproducing failure code: Start engine.
Cause 1 Defective related system 2 Defective fuse
Standard value in normal state/Remarks on troubleshooting If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it. Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) (32) Resistance 185 265 z
Defective power supply cutout relay
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector) Wiring harness between CE02 (female) (55) R23 (1) Wiring harness between CE02 (female) (55) R24 (1) Wiring harness between CE02 (female) (32) R23 (2) Wiring harness between CE02 (female) (32) R24 (2) Wiring harness between CE03 (female) (1) T12 Wiring harness between CE03 (female) (3) R23 (5) Wiring harness between CE03 (female) (3) R24 (5) Wiring harness between R23 (female) (3) battery (+) Wiring harness between R24 (female) (3) battery (+) Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
PC138US, USLC-8
SEN02464-01
40 Troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) R23 (1) and chassis ground Wiring harness between CE02 (female) (55) R24 (1) and chassis ground Wiring harness between CE02 (female) (32) R23 (2) and chassis ground Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
Ground fault in wiring harWiring harness between CE02 (female) (32) 5 ness (Short circuit with GND R24 (2) and chassis ground circuit) Wiring harness between CE03 (female) (3) R23 (5) and chassis ground Wiring harness between CE03 (female) (3) R24 (5) and chassis ground Wiring harness between R23 (female) (3) battery (+) and chassis ground Wiring harness between R24 (female) (3) battery (+) and chassis ground
a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. CE03 Between (3) (1) Voltage 20 30 V
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
SEN02464-01
40 Troubleshooting
Failure code [CA352] Sensor sup. 1 volt. low error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Failure code CA352 Trouble Sensor sup. 1 volt. low error (Engine controller system)
Low voltage was detected in sensor power supply 1 (5 V) circuit. Limits output of common rail pressure sensor and continues operation (Limits common rail pressure). Output drops. Method of reproducing failure code: Turn starting switch ON.
Causes
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
SEN02464-01
40 Troubleshooting
Failure code [CA386] Sensor sup. 1 volt. high error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA386 Trouble Sensor sup. 1 volt. high error (Engine controller system)
High voltage was detected in sensor power supply 1 (5 V) circuit. Limits output of common rail pressure sensor and continues operation (Limits common rail pressure). Output drops. Method of reproducing failure code: Turn starting switch ON.
Causes 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective sensor (Internal 2 trouble)
Common rail pressure sensor
PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between CE01 (female) (36) Resis3 (Disconnection in wiring or Max. 1 z PFUEL (female) (1) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z PFUEL (female) (3) tance Ground fault in wiring harness 4 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) PFUEL (female) (1) and chassis ground Wiring harness between CE01 (female) (48) PFUEL (female) (3) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) PFUEL (female) (1) and wiring harness between CE01 (female) (48) PFUEL (female) (3) Resistance Min. 1 Mz
Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE01 Between (36) (48) Voltage 4.75 5.25V
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
SEN02464-01
40 Troubleshooting
Failure code [CA435] Abnormality in engine oil pressure switch

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA435 Trouble Abnormality in engine oil pressure switch (Engine controller system)
Abnormality occurred in engine oil pressure switch signal circuit. None in particular. Engine oil pressure switch-based engine protection function does not function. Engine oil pressure monitor does not display normally. Method of reproducing failure code: Turn starting switch or start engine. Causes Defective engine oil pressure switch Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. POIL (Male) Between (1) chassis ground Resistance Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshootness ing without turning starting switch ON. 2 (Disconnection in wiring or Resisdefective contact in connec- Wiring harness between CE01 (female) (32) Max. 1 z POIL (female) (1) tance tor) a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Short circuit in wiring harness Wiring harness among all pins between (With another wiring harness) CE01 (female) (32) CE01 (female) (With all connectors of wiring harness disconnected) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CE01 (Female) Between (32) chassis ground Resistance Max. 1 z
10
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Failure code [CA441] Battery voltage low error

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Failure code CA441 Trouble Battery voltage low error (Engine controller system)
Low voltage was detected in controller power supply voltage circuit. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start. Method of reproducing failure code: Turn starting switch ON.
Cause
Failure code [CA442] Battery voltage high error

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Failure code CA442 Trouble Battery voltage high error (Engine controller system)
High voltage was detected in controller power supply voltage circuit. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start. Method of reproducing failure code: Turn starting switch ON.
Cause
PC138US, USLC-8
11
SEN02464-01
40 Troubleshooting
Failure code [CA449] Rail press. very high error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA449 Trouble Rail press. very high error (Engine controller system)
Common rail pressure sensor circuit detected abnormally high pressure (level 2). Limits output and continues operation (Limits common rail pressure). Output drops. Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine. Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA553].
12
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
13
SEN02464-01
40 Troubleshooting
Failure code [CA451] Rail press. sensor high error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA451 Trouble Rail press. sensor high error (Engine controller system)
High voltage was detected in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure). Output drops. Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) Method of reproducing failure code: Turn starting switch ON. Causes 1 Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA352] or [CA386] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
Defective common rail pres2 sure sensor (Internal trouble)
PFUEL Between (1) (3) Between (2) (3) Power supply Signal
Voltage 4.75 5.25 V 0.25 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between CE01 (female) (36) PFUEL (female) (1) Wiring harness between CE01 (female) (29) PFUEL (female) (2) Wiring harness between CE01 (female) (48) PFUEL (female) (3) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between CE01 (female) (36) PFUEL (female) (1) and chassis ground Wiring harness between CE01 (female) (29) PFUEL (female) (2) and chassis ground Wiring harness between CE01 (female) (48) PFUEL (female) (3) and chassis ground Resistance Resistance Resistance Min.1 Mz Min.1 Mz Min.1 Mz
14
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) PFUEL (female) (1) and wiring harness between CE01 (female) (29) PFUEL (female) (2) Wiring harness between CE01 (female) (36) PFUEL (female) (1) and wiring harness between CE01 (female) (48) PFUEL (female) (3) Wiring harness between CE01 (female) (29) PFUEL (female) (2) and wiring harness between CE01 (female) (48) PFUEL (female) (3) Resistance Min.1 Mz
Resistance
Min.1 Mz
Resistance
Min.1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller CE01 Between (36) (48) Between (29) (48) Voltage 4.75 5.25 V 0.25 4.6 V
PC138US, USLC-8
15
SEN02464-01
40 Troubleshooting
Failure code [CA452] Rail press. sensor low error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA452 Trouble Rail press. sensor low error (Engine controller system)
Low voltage was detected in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure). Output drops. Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) Method of reproducing failure code: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA451].
Failure code [CA553] Rail press. high error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA553 Trouble Rail press. high error (Engine controller system)
Common rail pressure sensor circuit detected abnormally high pressure (level 1). None in particular. Output drops. Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine. Causes 1 Defective related system 2 Use of improper fuel Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Check fuel used directly (for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out common rail pressure sensor troubleshooting for failure code [CA451].
Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve 6 Clogging of overflow piping 7 Defective pressure limiter Check overflow valve directly for broken spring, worn seat, and stuck ball. Check overflow piping directly for clogging. Check pressure limiter directly for mechanical defect.
16
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Failure code [CA559] Rail press. low error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA559 Trouble Rail press. low error (Engine controller system)
Supply pump does not feed fuel (level 1). Limits common rail pressure. Output drops. Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine. Causes 1 Defective related system 2 Use of improper fuel 3 Clogging of fuel filter Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Check fuel used directly (for high viscosity). a If a fuel filter is clogged, replace it. a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel pressure". Pressure in fuel low-pressure circuit (At high idle or rated load) -49 0 kPa {-0.5 0 kg/cm2}
Defective low-pressure circuit device
5 6 Possible causes and standard value in normal state
Defective electrical system of Supply pump IMV may have electric trouble. Carry out troublesupply pump IMV shooting for following failure codes [CA271], [CA272]. Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor ness for damage. a For testing of leakage from pressure limiter, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector". Leakage from pressure limiter *: Max. 20 cc/min (*) A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)".
7 Defective pressure limiter
a For testing of return rate (spill) from injector, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector". Speed at rated operation 8 Defective injector 1,600 rpm 1,700 rpm 1,800 rpm 1,900 rpm 2,000 rpm 9 Defective supply pump Return (Spill) limit from injector 190 cc/min 200 cc/min 210 cc/min 220 cc/min 230 cc/min
If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet> Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed. Note 1: Check the low-pressure circuit parts for the following items. 1) Fuel level 2) Clogging of fuel tank breather 3) Sticking and wear of feed pump and clogging of filter 4) Leakage through and clogging of low-pressure fuel piping 5) Clogging of fuel filter PC138US, USLC-8
17
SEN02464-01
40 Troubleshooting
Check sheet for no-pressure feed

Model Machine serial No. Engine Engine serial No. A. Visual check 1 2 Fuel leakage to outside Clogging of fuel tank breather
Good NG
Work No. # # Date of check Service meter Worker's name

Good NG
/ h
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3 Check of failure code Check of monitoring information Code Displayed item Low idle *1 Engine speed High idle Equivalent to rating *2 *3 4 *4 *5 Throttle opening degree Fuel injection command Common rail pressure command Common rail fuel pressure Fuel injection timing command Boost pressure Engine coolant temperature Fuel temperature Low idle High idle Equivalent to rating Equivalent to rating Equivalent to rating Low idle High idle Equivalent to rating Equivalent to rating Low idle Low idle Checking condition Unit rpm rpm rpm % % mm3 MPa MPa CA CA CA kPa C C Standard value (Reference value) Standard value (Reference value) -49 0 kPa {-0.5 0 kg/cm2} Measured value Standard value (Reference value) 1,100 50 2,300 60 2,200 0 100 Measured value / / / /
Good NG
*6 *7 *8 *9
Check of reduced cylinder mode operation (Engine speed)

Function
Reduced cylinder No. 1 cylinder Low idle Low idle Low idle Low idle
Checking condition
Unit rpm rpm rpm rpm
Measured value
Good NG
5 *10
No. 2 cylinder No. 3 cylinder No. 4 cylinder
C. Check of fuel circuit pressure 6
Checking condition
Unit MPa {kg/cm2}
Good NG
Fuel low-pressure circuit pressure High idle or rated load
D. Check of strainers and filters 7 Visual check of fuel filter Checking condition Equivalent to rating Equivalent to rating 1,600 rpm Equivalent to rating 1,700 rpm 9 Return rate from injector Equivalent to rating 1,800 rpm Equivalent to rating 1,900 rpm Equivalent to rating 2,000 rpm Unit cc/min cc/min cc/min cc/min cc/min cc/min Standard value (Reference value) Max. 20 (*) 190 200 210 220 230 Return rate: Speed: Measured value
Good NG
E.Check of leakage and return rate 8 Leakage through pressure limiter
Good NG
18
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
*1 *10: See Testing and adjusting, "Special functions of machine monitor", Monitoring items table. *: A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)". Rating or equivalent: Relieve the circuit under the following condition. 1) Engine: Full throttle 2) Mode: P 3) Boom: Raise
PC138US, USLC-8
19
SEN02464-01
40 Troubleshooting
Failure code [CA689] Eng. Ne speed sensor error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA689 Trouble Eng. Ne speed sensor error (Engine controller system)
Abnormality occurred in engine Ne speed sensor circuit. Operates with signals of Bkup speed sensor. Running engine stops (when Bkup speed sensor is also abnormal). Stopped engine cannot be started (when Bkup speed sensor is also abnormal). Method of reproducing failure code: Start engine.
Causes 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between CE01 (female) (26) NE (female) (1) Wiring harness between CE01 (female) (44) NE (female) (2) Wiring harness between CE01 (female) (42) NE (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state Wiring harness between CE01 (female) (26) NE (female) (1) and chassis ground Wiring harness between CE01 (female) (44) NE (female) (2) and chassis ground Wiring harness between CE01 (female) (42) NE (female) (3) and chassis ground Resistance Resistance Resistance Min.1 Mz Min.1 Mz Min.1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (26) NE (female) (1) and wiring harness between CE01 (female) (44) NE (female) (2) Wiring harness between CE01 (female) (26) NE (female) (1) and wiring harness between CE01 (female) (42) NE (female) (3) Wiring harness between CE01 (female) (44) NE (female) (2) and wiring harness between CE01 (female) (42) NE (female) (3) Resistance Min.1 Mz
Resistance
Min.1 Mz
Resistance
Min.1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (crankshaft pulley) part directly for defect. 6 Defective engine Ne speed sensor If causes 1 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
20
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Causes 7 Defective engine controller
Standard value in normal state/Remarks on troubleshooting If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
21
SEN02464-01
40 Troubleshooting
Failure code [CA731] Eng. Bkup speed sensor phase error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA731 Trouble Eng. Bkup speed sensor phase error (Engine controller system)
Engine Bkup speed sensor circuit detected abnormality in phase. Controls with signals of engine Ne speed sensor. Running engine stops (when Ne speed sensor is also abnormal). Stopped engine cannot be started (when Ne speed sensor is also abnormal). Method of reproducing failure code: Start engine.
Cause 1 2 Defective engine Ne speed sensor system Defective engine Bkup speed sensor system
Standard value in normal state/Remarks on troubleshooting Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA698]. Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
Failure code [CA757] All persistent data lost error

User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Failure code CA757 Trouble All persistent data lost error (Engine controller system)
All data in engine controller are lost. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start. Method of reproducing failure code: Turn starting switch ON.
Cause
22
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
23
SEN02464-01
40 Troubleshooting
Failure code [CA778] Eng. Bkup speed sensor error

User code E15 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA778 Trouble Eng. Bkup speed sensor error (Engine controller system)
Abnormality occurred in engine Bkup speed sensor circuit. Operates with signals of Ne speed sensor. Running engine stops (when Ne speed sensor is also abnormal). Stopped engine cannot be started (when Ne speed sensor is also abnormal). Method of reproducing failure code: Start engine.
Causes 1
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between CE01 (female) (36) CAM (female) (1) Wiring harness between CE01 (female) (48) CAM (female) (2) Wiring harness between CE01 (female) (37) CAM (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state Wiring harness between CE01 (female) (36) CAM (female) (1) and chassis ground Wiring harness between CE01 (female) (48) CAM (female) (2) and chassis ground Wiring harness between CE01 (female) (37) CAM (female) (3) and chassis ground Resistance Resistance Resistance Min.1 Mz Min.1 Mz Min.1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) CAM (female) (1) and between CE01 (female) (48) CAM (female) (2) Wiring harness between CE01 (female) (36) CAM (female) (1) and between CE01 (female) (37) CAM (female) (3) Wiring harness between CE01 (female) (48) CAM (female) (2) and between CE01 (female) (37) CAM (female) (3) Resistance Resistance Resistance Min.1 Mz
Min.1 Mz
Min.1 Mz
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly part for defect. 6 Defective engine Bkup speed sensor If causes 1 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
24
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
25
SEN02464-01
40 Troubleshooting
Failure code [CA1633] KOMNET datalink timeout error

User code E0E Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA1633 Trouble KOMNET datalink timeout error (Engine controller system)
Engine controller detected communication error in KOMNET communication circuit between pump controller and machine monitor. Continues operation in default mode. If cause of failure disappears, system resets itself. Information may not transmitted normally by KOMNET communication and machine may not operate normally. (Trouble phenomenon depends on failed section.) Method of reproducing failure code: Turn starting switch ON.
Cause
Disconnection in wiring harness (Disconnection in wiring 1 or defective contact in connector)
Wiring harness between CM02 (female) (8), (9) C01 (female) (45), CE02 (female) (1), K02 (female) (A) Wiring harness between CM02 (female) (10) C01 (female) (64), CE02 (female) (21), K02 (female) (B)
Resistance Resistance
Max. 1 z
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CM02 (female) (8), Ground fault in wiring har(9) C01 (female) (45), CE02 (female) 2 ness (Short circuit with GND (1), K02 (female) (A), N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) C01 (female) (64), CE02 (female) (21), K02 (female) (B), N08 (male) (10) Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) C01 (female) (45), CE02 (female) 3 24V circuit) in wiring harness (1), K02 (female) (A), N08 (male) (3) Wiring harness between CM02 (female) (10) C01 (female) (64), CE02 (female) (21), K02 (female) (B), N08 (male) (10) Defective CAN terminal 4 resistance (Internal short circuit or disconnection) Voltage Max. 5.5 V Max. 5.5 V
Voltage
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. K02 (male) Between (A) (B) Resistance 120 12 z
5 Defective pump controller
If causes 1 4 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
26
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
27
SEN02464-01
40 Troubleshooting
Failure code [CA2185] Throttle sens. sup. volt. high error

User code E14 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA2185 Trouble Throttle Sens. sup. volt. high error (Engine controller system)
High voltage was detected in throttle sensor power supply (5 V) circuit. Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model). Engine speed cannot be controlled with fuel control dial. Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective fuel control dial (Internal trouble)
Fuel control dial
P20 connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE02 (female) (27) Resis2 Max. 1 z or defective contact in con- P20 (female) (1) tance nector) Wiring harness between CE02 (female) (28) ResisMax. 1 z P20 (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Min.1 Mz Min.1 Mz
Ground fault in wiring harWiring harness between CE02 (female) (27) 3 ness (Short circuit with GND P20 (female) (1) and chassis ground circuit) Wiring harness between CE02 (female) (28) P20 (female) (3) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (27) P20 (female) (1) and between CE02 (female) (28) P20 (female) (3) Resistance Min.1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE02 Between (27) (28) Voltage 4.75 5.25 V
28
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
29
SEN02464-01
40 Troubleshooting
Failure code [CA2186] Throttle sens. sup. volt. low error

User code E14 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Failure code CA2186 Trouble Throttle sens. sup. volt. low error (Engine controller system)
Low voltage was detected in throttle sensor power supply (5 V) circuit. Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model). Engine speed cannot be controlled with fuel control dial. Method of reproducing failure code: Turn starting switch ON.
Cause
Failure code [CA2249] Rail press. very low error

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA2249 Trouble Rail press. very low error (Engine controller system)
Supply pump does not feed fuel (level 2). Limits common rail pressure. Output drops. Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA559].
30
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Failure code [CA2311] Abnormality in IMV solenoid

User code E11 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA2311 Trouble Abnormality in IMV solenoid (Engine controller system)
Resistance in supply pump actuator is abnormally high or low. None in particular. Engine output drops. Method of reproducing failure code: Start engine. Causes 1 Defective related system Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective supply pump actuator PREG (Male) Between (1) (2) Between (2) chassis ground Disconnection in wiring harness Wiring harness between CE01 (female) (10) 3 (Disconnection in wiring or PREG (female) (2) defective contact in connecWiring harness between CE01 (female) (14) tor) PREG (female) (1) Resistance Max. 1 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between CE01 (female) (14) ResisMin.1 Mz PREG (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller CE01 (Female) Between (14) (10) Between (14) chassis ground Resistance Max. 1 z Min. 1 Mz
PC138US, USLC-8
31
SEN02464-01
40 Troubleshooting
Failure code [D110KB] Battery relay drive short

User code Contents of trouble Action of controller Problem that appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting Failure code D110KB Trouble Battery relay drive short (Pump controller system)
Abnormal current flowed at output to battery relay drive circuit. Turns output to battery relay drive circuit OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Engine does not stop.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective battery relay (Internal defect) Battery relay Between BR (terminal BR) RE (terminal E) Between BR (terminal BR) chassis ground Ground fault in wiring harness 2 (Short circuit with GND circuit) Resistance There is continuity Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (108) D02 J06 BR (terminal BR) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective pump controller C02 (female) Between (108) chassis ground Turn starting switch OFF. ON o OFF Voltage 20 30 V (4 7 sec.)
32
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
33
SEN02464-01
40 Troubleshooting
Failure code [D19JKZ] Personal code relay abnormality

User code E01 Contents of trouble Action of controller Problem that appears on machine Related information This failure code is displayed only when engine lock function is effective. Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble cannot be reproduced on machine (Short circuit). Cause 1 Defective fuse No. 20 Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 4). Failure code D19JKZ Trouble Personal code relay abnormality (KOMTRAX system in machine monitor)
Disconnection or short circuit was detected in personal code relay circuit. None in particular (when disconnection is detected). Turns output to personal code relay OFF (when short circuit is detected). If cause of failure disappears, system resets itself (when disconnection is detected). Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF (when disconnection is detected).
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (Troubleshooting for relay unit) R07 (male) Resistance Defective personal code Between (1) (2) (300 600 z) 2 relay (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON or short circuit) and carry out troubleshooting. (Troubleshooting by replacement) Replace personal code relay (R07) with another relay and perform reproducing operation. If "E" of failure code goes off at this time, replaced relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (20) R07 Resis3 Max. 1 z or defective contact in con- (female) (1) tance nector) Wiring harness between R07 (female) (2) ResisMax. 1 z CM01 (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Min. 1 Mz Min. 1 Mz
Ground fault in wiring harWiring harness between F01 (20) R07 4 ness (Short circuit with GND (female) (1) circuit) Wiring harness between R07 (female) (2) CM01 (female) (6) 5 Defective machine monitor (KOMTRAX section)
If causes 1 4 are not detected, machine monitor (KOMTRAX) may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
34
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
35
SEN02464-01
40 Troubleshooting
Failure code [D862KA] GPS antenna discon

User code Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Failure code D862KA Trouble GPS antenna disconnection (KOMTRAX system in machine monitor)
Disconnection was detected in GPS antenna circuit. None in particular. If cause of failure disappears, system resets itself. GPS cannot measure position. Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defective GPS antenna or antenna cable
Standard value in normal state/Remarks on troubleshooting Possible causes are defective GPS antenna, disconnection or short circuit in antenna cable, and defective connection of antenna cable connector (GPS).
Configuration drawing
36
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
37
SEN02464-01
40 Troubleshooting
Failure code [DA22KK] Pump solenoid power low error

User code E0E Contents of trouble Action of controller Problem that appears on machine Related information Failure code DA22KK Trouble Lowering of solenoid power supply voltage (Pump controller system)
Solenoid power supply voltage of controller is below 20 V. While this failure code is displayed, detection of failure codes (disconnection/short circuit) of all the solenoid systems is stopped. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Since no solenoid valve is driven normally, machine does not operate normally. Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defective fuse F01
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See Cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between C02 (female) (116), (118), (121) F01-2 Wiring harness between F01-1A F02 (male) (2) Wiring harness between F02 (male) (1) RM
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (116), Ground fault in wiring har(118), (121) F01-2 3 ness (Short circuit with GND Wiring harness between F01-1A F02 circuit) (male) (2), circuit branch end Wiring harness between F02 (male) (1) RM Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective pump controller C01 (female), C02 (female) Between C02 (116), (118), (121) C01 (2), (5) Voltage 20 30 V
38
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
PC138US, USLC-8
39
SEN02464-01
40 Troubleshooting
Failure code [DA25KP] 5V sensor 1 power abnormality

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DA25KP Trouble 5V sensor power supply output 1 abnormality (Pump controller system)
Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V. Turns output of 5V sensor power supply output 1 OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Automatic gear shifting function does not work (pump pressure sensor system). Auto-decelerator keeps working and is not reset or fine control performance of work equipment is lowered (PPC pressure sensor system). Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Bucket DUMP PPC pressure switch Boom RAISE PPC pressure switch P01 P03 P04 P05 P07 P08 P25
Defective pressure sensor 1 (Internal short circuit)
Disconnect sensors at right in order and carry out operation to reproduce trouble. If "E" of failure code goes off when a sensor is disconnected, that sensor is defective.
Bucket CURL PPC pressure switch Arm IN PPC pressure switch Swing RIGHT PPC pressure switch Swing LEFT PPC pressure switch Pump pressure sensor
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C01 (female) (34) P01 (female) (2), P01 (female) (1) J03 ground (T08) [Bucket DUMP PPC pressure switch system] Wiring harness between C01 (female) (53) P03 (female) (2), P03 (female) (1) J03 ground (T08) [Boom RAISE PPC pressure switch system] Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C01 (female) (73) P04 (female) (2), P04 (female) (1) J03 circuit) ground (T08) [Bucket CURL PPC pressure switch system] Wiring harness between C01 (female) (17) P05 (female) (2), P05 (female) (1) J03 ground (T08) [Arm IN PPC pressure switch system] Wiring harness between C01 (female) (16) P07 (female) (2), P07 (female) (1) J03 ground (T08) [Swing RIGHT PPC pressure switch system]
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
40
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Cause
Standard value in normal state/Remarks on troubleshooting Resistance Resistance Min. 1 Mz
Wiring harness between C01 (female) (16) P08 (female) (2), P08 (female) (1) J03 ground (T08) Ground fault in wiring har2 ness (Short circuit with GND [Swing LEFT PPC pressure switch system] circuit) Wiring harness between C01 (female) (9) J07 P25 (female) (3) [Pump pressure sensor system]
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between C01 (female) (34) P01 (female) (2), P01 (female) (1) J03 ground (T08) [Bucket CURL PPC pressure sensor system] Wiring harness between C01 (female) (53) P03 (female) (2), P03 (female) (1) J03 ground (T08) [Swing LEFT PPC pressure sensor system] Possible causes and standard value in normal state 3 Wiring harness between C01 (female) (73) P04 (female) (2), P04 (female) (1) J03 ground (T08) [Arm IN PPC pressure sensor system] Hot short (Short circuit with Wiring harness between C01 (female) (17) 24V circuit) in wiring harness P05 (female) (2), P05 (female) (1) J03 ground (T08) [Bucket DUMP PPC pressure sensor system] Wiring harness between C01 (female) (16) P07 (female) (2), P07 (female) (1) J03 ground (T08) [Boom RAISE PPC pressure sensor system] Wiring harness between C01 (female) (16) P08 (female) (2), P08 (female) (1) J03 ground (T08) [Swing RIGHT PPC pressure sensor system] Wiring harness between C01 (female) (9) J07 P25 (female) (3) [Pump pressure sensor system] 4 Defective pump controller
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
If causes 1 3 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
41
SEN02464-01
40 Troubleshooting
42
PC138US, USLC-8
40 Troubleshooting
SEN02464-01
Failure code [DA26KP] 5V sensor 2 power abnormality

User code Contents of trouble Action of controller Problem that appears on machine Related information Method of reproducing failure code: Turn starting switch ON. Failure code DA26KP Trouble 5V sensor power supply output 2 abnormality (Pump controller system)
Voltage of 5V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V. Turns output of 5V sensor power supply output 2 OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Cause
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 1 ness (Short circuit with GND Wiring harness between C01 (female) (8) Resiscircuit) Min. 1 Mz A08 (female) (3) (6) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between C01 (female) (8) Voltage Max. 1 V A08 (female) (3) (6) 3 Defective pump controller If causes 1 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
43
SEN02464-01
40 Troubleshooting
44
PC138US, USLC-8
SEN02465-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Failure code [DA2RMC] CAN discon (Pump controller detected)................................................................... 4 Failure code [DAF8KB] Short circuit in camera power supply ........................................................................ 6 Failure code [DAFGMC] GPS module error.................................................................................................... 8 Failure code [DAFRMC] CAN discon (Monitor detected).............................................................................. 10 Failure code [DGH2KB] Hydr oil sensor short .............................................................................................. 12 Failure code [DHPAMA] Pump press sensor abnormality............................................................................. 14 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality ................................................. 16 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality .............................................. 18 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality ................................................ 20 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................................... 22 Failure code [DHSKMA] Blade raise PPC press sensor abnormality ........................................................... 24 Failure code [DHSLMA] Blade lower PPC press sensor abnormality........................................................... 26 Failure code [DHX1MA] Overload sensor abnormality (Analog)................................................................... 28 Failure code [DV20KB] Travel alarm S/C...................................................................................................... 29 Failure code [DW43KA] Travel speed sol discon.......................................................................................... 30 Failure code [DW43KB] Travel speed sol short ............................................................................................ 31
PC138US, USLC-8
SEN02465-01
40 Troubleshooting
Failure code [DW45KA] Swing brake sol discon........................................................................................... 32 Failure code [DW45KB] Swing brake sol short ............................................................................................. 34 Failure code [DW91KA] Travel junction sol discon ....................................................................................... 36 Failure code [DW91KB] Travel junction sol short.......................................................................................... 37 Failure code [DWJ0KA] Merge-divider sol discon......................................................................................... 38 Failure code [DWJ0KB] Merge-divider sol short ........................................................................................... 39
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
SEN02465-01
40 Troubleshooting
Failure code [DA2RMC] CAN discon (Pump controller detected)

User code E0E Contents of trouble Action of controller Problem that appears on machine Related information Failure code DA2RMC Trouble CAN disconnection (Pump controller detected) (Pump controller system)
Pump controller detected communication error in CAN communication circuit between machine monitor and engine controller. Continues operation with information of CAN communication just before detection of error. If cause of failure disappears, system resets itself. Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble phenomenon depends on failed section.) Method of reproducing failure code: Turn starting switch ON.
Cause
Max. 1 z
Max. 1 z
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) C01 (female) (45), CE02 (female) 3 24V circuit) in wiring harness (1), K02 (female) (A), N08 (male) (3) Wiring harness between CM02 (female) (10) C01 (female) (64), CE02 (female) (21), K02 (female) (B), N08 (male) (10) Defective CAN terminal 4 resistance (Internal short circuit or disconnection) 5 Defective pump controller Voltage Max. 5.5 V Max. 5.5 V
Voltage
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
SEN02465-01
40 Troubleshooting
Failure code [DAF8KB] Short circuit in camera power supply

User code Contents of trouble Failure code DAF8KB Trouble Short circuit in camera power supply (Machine monitor system)
Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above 10 V.
Action of Turns output power supply voltage (Rating: 8 V) to camera OFF. machine monitor Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information Camera image is not displayed on monitor screen. Method of reproducing failure code: Turn starting switch ON.
Cause Defective camera (Internal 1 short circuit)
Standard value in normal state/Remarks on troubleshooting a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Disconnect camera and perform failure reproduction operation. If failure code disappears at this time, camera is defective.
a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Ground fault in wiring har(Disconnect camera and check that it is not defective in 2 ness (Contact with GND ciradvance.) cuit) Between CM05 (female) (1) CAMERA Voltage Min. 6 V (female) (F) wiring harness and ground a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Disconnect camera and check that it is not defective in advance.) Between CM05 (female) (1) CAMERA (female) (F) wiring harness and ground 4 Defective machine monitor Voltage Max. 10 V
Hot short (Contact with 24V circuit) in wiring harness
If causes 1 3 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
SEN02465-01
40 Troubleshooting
Failure code [DAFGMC] GPS module error

User code Contents of trouble Failure code DAFGMC Trouble GPS module operation error (KOMTRAX system in machine monitor)
Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication MODEM in 50 seconds after KOMTRAX is started.
Action of None in particular. machine monitor If cause of failure disappears, system resets itself. Problem that appears on machine Related information Possible causes and standard value in normal state Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting switch is turned ON). Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting GPS module of machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
SEN02465-01
40 Troubleshooting
Failure code [DAFRMC] CAN discon (Monitor detected)

User code E0E Contents of trouble Failure code DAFRMC Trouble CAN disconnection (Monitor detected) (Machine monitor system)
Machine monitor detected communication error in CAN communication circuit between pump controller and engine controller.
Action of If cause of failure disappears, system resets itself. machine monitor Problem that appears on machine Related information Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble phenomenon depends on failed section.) Method of reproducing failure code: Turn starting switch ON.
Cause
Max. 1 z
Max. 1 z
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) C01 (female) (45), CE02 (female) 3 24V circuit) in wiring harness (1), K02 (female) (A), N08 (male) (3) Wiring harness between CM02 (female) (10) C01 (female) (64), CE02 (female) (21), K02 (female) (B), N08 (male) (10) Defective CAN terminal 4 resistance (Internal short circuit or disconnection) Voltage Max. 5.5 V Max. 5.5 V
Voltage
10
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
11
SEN02465-01
40 Troubleshooting
Failure code [DGH2KB] Hydr oil sensor short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DGH2KB Trouble Hydraulic oil temperature sensor short (Pump controller system)
Ground fault was detected in hydraulic oil temperature sensor circuit. Controls pump in normal mode (as when hydraulic oil temperature is 20C to below 95C). (Overheat prevention function does not work.) While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from top of white range (bottom of green range). Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function. (Code: 04402 Hydraulic oil temperature sensor voltage) Method of reproducing failure code: Start engine. Cause Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P22 (male) Between (1) (2) Between (2) chassis ground Resistance 3.5 90 kz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND ResisWiring harness between C01 (female) (29) circuit) Min. 1 Mz P22 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller C01 (female) Between (29) (46) Between (29) chassis ground Resistance 3.5 90 kz Min. 1 Mz
12
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
13
SEN02465-01
40 Troubleshooting
Failure code [DHPAMA] Pump press sensor abnormality

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DHPAMA Trouble Pump pressure sensor abnormality (Pump controller system)
Signal voltage of pump pressure sensor circuit is below 0.3 V or above 4.4 V. Fixes pump pressure at 0 MPa {0 kg/cm2} and continues control. If cause of failure disappears, system resets itself. Automatic gear shifting function does not work. Straight travel performance or steering performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. Pump pressure can be checked with monitoring function. (Code: 01100 Pump pressure) Method of reproducing failure code: Turn starting switch ON or start engine. Cause Defective 5V sensor power 1 supply 1 system Standard value in normal state/Remarks on troubleshooting a If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. Defective pump pressure 2 sensor (Internal defect) P25 Between (3) (1) Between (2) (1) Power supply Signal Voltage 4.5 5.5 V 0.3 4.5 V
If voltage is abnormal, check failure code. (If "E" of failure code goes off at this time, pump pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) P25 (female) (1) Wiring harness between C01 (female) (49) P25 (female) (2) Wiring harness between C01 (female) (9) J07 P25 (female) (3) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (49) Resiscircuit) Min. 1 Mz P25 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (49) Voltage Max. 1 V P25 (female) (2) 6 Defective pump controller If causes 1 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
14
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
15
SEN02465-01
40 Troubleshooting
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality
User code E20 Contents of trouble Action of controller Problem that appears on machine Related information Failure code DHSFMA Trouble Travel left forward PPC pressure sensor abnormality (Pump controller system)
Signal voltage of travel left forward PPC pressure sensor circuit is below 0.3 V or above 4.5 V. Fixes travel left forward PPC pressure at 0 MPa {0 kg/cm2} and continues control. If cause of failure disappears, system resets itself. Automatic decelerator cannot be reset. Travel left forward performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. Travel left forward PPC pressure can be checked with monitoring function. (Code: 07102 Travel left forward PPC pressure) Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P10 Defective travel left forward 2 PPC pressure sensor (Internal defect) Between (3) (1) Between (2) (1) Power supply Signal Voltage 4.5 5.5 V 0.3 4.5 V
If voltage is abnormal, replace travel left forward PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel left forward PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between C01 (female) (18) P10 (female) (1) Wiring harness between C01 (female) (69) P10 (female) (2) Wiring harness between C01 (female) (9) J07 P10 (female) (3)
16
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
17
SEN02465-01
40 Troubleshooting
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality
User code E20 Contents of trouble Action of controller Problem that appears on machine Related information Failure code DHSGMA Trouble Travel right forward PPC pressure sensor abnormality (Pump controller system)
Signal voltage of travel right forward PPC pressure sensor circuit is below 0.3 V or above 4.5 V. Fixes travel right forward PPC pressure at 0 MPa {0 kg/cm2} and continues control. If cause of failure disappears, system resets itself. Automatic decelerator cannot be reset. Travel right forward performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. Travel right forward PPC pressure can be checked with monitoring function. (Code: 07103 Travel right forward PPC pressure) Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P09 Defective travel right forward 2 PPC pressure sensor (Internal defect) Between (3) (1) Between (2) (1) Power supply Signal Voltage 4.5 5.5 V 0.3 4.5 V
If voltage is abnormal, replace travel right forward PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel right forward PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
18
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
19
SEN02465-01
40 Troubleshooting
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality
User code E20 Contents of trouble Action of controller Problem that appears on machine Related information Failure code DHSHMA Trouble Travel left reverse PPC pressure sensor abnormality (Pump controller system)
Signal voltage of travel left reverse PPC pressure sensor circuit is below 0.3 V or above 4.5 V. Fixes travel left reverse PPC pressure at 0 MPa {0 kg/cm2} and continues control. If cause of failure disappears, system resets itself. Automatic decelerator cannot be reset. Travel left reverse performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. Travel left reverse PPC pressure can be checked with monitoring function. (Code: 07104 Travel left reverse PPC pressure) Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P27 Defective travel left reverse 2 PPC pressure sensor (Internal defect) Between (3) (1) Between (2) (1) Power supply Signal Voltage 4.5 5.5 V 0.3 4.5 V
If voltage is abnormal, replace travel left reverse PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel left reverse PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
20
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
21
SEN02465-01
40 Troubleshooting
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality
User code E20 Contents of trouble Action of controller Problem that appears on machine Related information Failure code DHSJMA Trouble Travel right reverse PPC pressure sensor abnormality (Pump controller system)
Signal voltage of travel right reverse PPC pressure sensor circuit is below 0.3 V or above 4.5 V. Fixes travel right reverse PPC pressure at 0 MPa {0 kg/cm2} and continues control. If cause of failure disappears, system resets itself. Automatic decelerator cannot be reset. Travel right reverse performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. Travel right reverse PPC pressure can be checked with monitoring function. (Code: 07105 Travel right reverse PPC pressure) Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P26 Defective travel right reverse 2 PPC pressure sensor (Internal defect) Between (3) (1) Between (2) (1) Power supply Signal Voltage 4.5 5.5 V 0.3 4.5 V
If voltage is abnormal, replace travel right reverse PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel right reverse PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
22
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
23
SEN02465-01
40 Troubleshooting
Failure code [DHSKMA] Blade raise PPC press sensor abnormality

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DHSKMA Trouble Blade raise PPC pressure sensor abnormality (Pump controller system)
Signal voltage of blade raise PPC pressure sensor circuit is below 0.3 V or above 4.5 V. Fixes blade raise PPC pressure at 0 MPa {0 kg/cm2} and continues control. If cause of failure disappears, system resets itself. Automatic decelerator cannot be reset. Blade raise performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. Blade raise PPC pressure can be checked with monitoring function. (Code: 07106 Blade raise PPC pressure) Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P28 Defective blade raise PPC 2 pressure sensor (Internal defect) Between (3) (1) Between (2) (1) Power supply Signal Voltage 4.5 5.5 V 0.3 4.5 V
If voltage is abnormal, replace blade raise PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, blade raise PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (32) Resiscircuit) Min. 1 Mz P28 (female) (2) tance Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (32) P28 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Max. 1 V
24
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
25
SEN02465-01
40 Troubleshooting
Failure code [DHSLMA] Blade lower PPC press sensor abnormality

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DHSLMA Trouble Blade lower PPC pressure sensor abnormality (Pump controller system)
Signal voltage of blade lower PPC pressure sensor circuit is below 0.3 V or above 4.5 V. Fixes blade lower PPC pressure at 0 MPa {0 kg/cm2} and continues control. If cause of failure disappears, system resets itself. Automatic decelerator cannot be reset. Blade lower performance lowers. a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. Blade lower PPC pressure can be checked with monitoring function. (Code: 07107 Blade lower PPC pressure) Method of reproducing failure code: Turn starting switch ON or start engine. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P11 Defective blade lower PPC 2 pressure sensor (Internal defect) Between (3) (1) Between (2) (1) Power supply Signal Voltage 4.5 5.5 V 0.3 4.5 V
If voltage is abnormal, replace blade lower PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, blade lower PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (51) Resiscircuit) Min. 1 Mz P11 (female) (2) tance Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (51) P11 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Max. 1 V
26
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
27
SEN02465-01
40 Troubleshooting
Failure code [DHX1MA] Overload sensor abnormality (Analog)

User code Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Method of reproducing failure code: Turn starting switch ON. Failure code DHX1MA Trouble Overload sensor (Analog) (Pump controller system)
Monitor which is not set to be displayed (Overload alarm monitor) is displayed. None in particular. If cause of failure disappears, system resets itself.
Cause 1 Defective pump controller
Standard value in normal state/Remarks on troubleshooting Pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
28
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
Failure code [DV20KB] Travel alarm S/C

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DV20KB Trouble Travel alarm S/C (Pump controller system)
Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit. Power to the travel alarm circuit is switched OFF. Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF. The travel alarm does not sound. Operation of the travel alarm (ON or OFF) can be checked in the monitoring function. (Code: 03701 Controller output 2) Cause Standard value in normal state/Remarks on troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. Travel alarm defective 1 (Internal defect) M14 (female) Between (1) and (2) Travel lever Neutral Operated Voltage Max. 1 V 20 30 V
If the above voltage is normal but the travel alarm does not operate, the travel alarm is defective. a Turn the engine starting switch OFF for the preparations, and Grounding fault of wiring harhold it in the OFF position during the troubleshooting. ness 2 (Contact with grounding cir- Between wiring harness between C02 ResisMin. 1 Mz (female) (107) and M14 (female) (1) and cuit) tance grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 3 Pump controller defective C02 Between (107) chassis ground Travel lever Neutral Operated Voltage Max. 1 V 20 30 V
PC138US, USLC-8
29
SEN02465-01
40 Troubleshooting
Failure code [DW43KA] Travel speed sol discon

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DW43KA Trouble Travel speed solenoid system disconnection (Pump controller system)
When output to travel speed shifting solenoid was turned ON, disconnection was detected in circuit. None in particular. (Since no current flows, solenoid does not operate.) If cause of failure disappears, system resets itself. Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle). Operating condition of travel speed shifting solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. Cause Defective travel speed shift1 ing solenoid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V02 (male) Between (1) (2) Resistance 20 60 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (87) 2 or defective contact in con- V02 (female) (2) nector) Wiring harness between C02 (female) (115), (117), (120) V02 (female) (1)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller C01 (female) Between (87) (115), (117), (120) Resistance 20 60 z
30
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
Failure code [DW43KB] Travel speed sol short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DW43KB Trouble Travel speed solenoid system short (Pump controller system)
When output to travel speed shifting solenoid was turned ON, short circuit was detected in circuit. Turns output to travel speed shifting solenoid OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle). Operating condition of travel speed shifting solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. Cause Defective travel speed shift1 ing solenoid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V02 (male) Between (1) (2) Between (2) chassis ground Resistance 20 60 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND ResisWiring harness between C02 (female) (87) circuit) Min. 1 Mz V02 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller C02 (female) Between (87) (115), (117), (120) Between (87) chassis ground Resistance 20 60 z Min. 1 Mz
PC138US, USLC-8
31
SEN02465-01
40 Troubleshooting
Failure code [DW45KA] Swing brake sol discon

User code E03 Contents of trouble Action of controller Problem that appears on machine Failure code DW45KA Trouble Swing holding brake solenoid system disconnection (Pump controller system)
When output to swing holding brake solenoid was turned OFF, disconnection was detected in circuit. None in particular. (Since no current flows, solenoid does not operate.) If cause of failure disappears, system resets itself. Machine cannot swing (Swing holding brake is not reset). If solenoid and wiring harness are normal, operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work, however, when machine stops). Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. Operating condition of swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Turn starting switch ON. Cause Defective swing holding 1 brake solenoid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V03 (male) Between (1) (2) Resistance 20 60 z
Related information
Defective assembled-type 2 diode D01 (Internal disconnection)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D01 (male) Between (7) (3) Digital circuit tester Diode mode Continuity There is continuity
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Possible causes and standard value in normal state Defective swing lock switch (Internal disconnection) S04 (male) Between (3) (4) Swing lock switch OFF ON Resistance Max. 1 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between D01 (female) (3) 4 or defective contact in con- J04 S04 (female) (3) nector) Wiring harness between S04 (female) (4) V03 (female) (2) Wiring harness between C02 (female) (101) D01 (female) (7) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Wiring harness between C02 (female) (115), (117), (120) V03 (female) (1)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective pump controller C02 (female) Between (101) (115), (117), (120) Disconnect D01 and connect pins (3) and (7) on female side directly. Resistance 20 60 z
32
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
33
SEN02465-01
40 Troubleshooting
Failure code [DW45KB] Swing brake sol short

User code E03 Contents of trouble Action of controller Problem that appears on machine Failure code DW45KB Trouble Swing holding brake solenoid system short (Pump controller system)
When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit. Turns output to swing holding brake solenoid OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Machine cannot swing (Swing holding brake is not reset). If solenoid and wiring harness are normal, operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work, however, when machine stops). Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. Operating condition of swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine + Swing with left work equipment control lever. Cause Defective swing holding 1 brake solenoid (Internal short circuit or ground fault) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V03 (male) Between (1) (2) Between (1) chassis ground Resistance 20 60 z Min. 1 Mz
Related information
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. ness (Disconnection in wiring 2 Wiring harness between C02 (female) (101) or defective contact in conResisMin. 1 Mz D01 J04 S04 V03 (female) (2), S25 nector) tance (female) (14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C02 (female) 3 Defective pump controller Between (101) (115), (117), (120) Between (101) chassis ground Disconnect D01 and connect pins (3) and (7) on female side directly. Resistance 20 60 z Min. 1 Mz
34
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
PC138US, USLC-8
35
SEN02465-01
40 Troubleshooting
Failure code [DW91KA] Travel junction sol discon

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DW91KA Trouble Travel junction solenoid system disconnection (Pump controller system)
When output to travel junction solenoid was turned ON, disconnection was detected in circuit. None in particular. (Since no current flows, solenoid does not operate.) If cause of failure disappears, system resets itself. Machine is not steered easily during travel. Operating condition of travel junction solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. Cause Defective travel junction 1 solenoid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V04 (male) Between (1) (2) Resistance 20 60 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (110) 2 or defective contact in con- V04 (female) (2) nector) Wiring harness between C02 (female) (115), (117), (120) V04 (female) (1)
36
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
Failure code [DW91KB] Travel junction sol short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DW91KB Trouble Travel junction solenoid system short (Pump controller system)
When output to travel junction solenoid was turned ON, short circuit was detected in circuit. Turns output to travel junction solenoid OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Machine is not steered easily during travel. Operating condition of travel junction solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. Cause Defective travel junction 1 solenoid (Internal short circuit or ground fault) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V04 (male) Between (1) (2) Between (2) chassis ground Resistance 20 60 z Min. 1 Mz
PC138US, USLC-8
37
SEN02465-01
40 Troubleshooting
Failure code [DWJ0KA] Merge-divider sol discon

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DWJ0KA Trouble Merge-divider solenoid disconnection (Pump controller system)
When merge-divider EPC solenoid was driven, disconnection was detected in circuit. None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, system resets itself. Single operation speed of work equipment and swing is high in lifting mode (L). Method of reproducing failure code: Turn starting switch ON.
Cause Defective merge-divider EPC 1 solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V05 (male) Between (1) (2) Resistance 7 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (112) Resis2 Max. 1 z or defective contact in con- V05 (female) (2) tance nector) Wiring harness between C02 (female) (115), ResisMax. 1 z (117), (120) V05 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller C02 (female) Between (112) (115), (117), (120) Resistance 7 14 z
38
PC138US, USLC-8
40 Troubleshooting
SEN02465-01
Failure code [DWJ0KB] Merge-divider sol short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DWJ0KB Trouble Merge-divider solenoid short (Pump controller system)
When merge-divider EPC solenoid was driven, short circuit was detected in circuit. Turns output to merge-divider EPC solenoid OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Single operation speed of work equipment and swing is high in lifting mode (L). Method of reproducing failure code: Turn starting switch ON.
Cause Defective merge-divider EPC 1 solenoid (Internal short circuit or ground fault) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V05 (male) Between (1) (2) Between (2) chassis ground Resistance 7 14 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C02 (female) (112) Resiscircuit) Min. 1 Mz V05 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller C02 (female) Between (112) (115), (117), (120) Between (112) chassis ground Resistance 7 14 z Min. 1 Mz
PC138US, USLC-8
39
SEN02465-01
40 Troubleshooting
40
PC138US, USLC-8
SEN02466-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Failure code [DXA8KA] PC-EPC sol discon ................................................................................................... 2 Failure code [DXA8KB] PC-EPC sol short...................................................................................................... 4 Failure code [DXE4KA] Service current EPC discon ...................................................................................... 6 Failure code [DXE4KB] Service current EPC short ........................................................................................ 7 Failure code [DY20KA] Wiper working abnormality ........................................................................................ 8 Failure code [DY20MA] Wiper parking abnormality ...................................................................................... 10 Failure code [DY2CKA] Washer drive discon ............................................................................................... 12 Failure code [DY2CKB] Washer drive short.................................................................................................. 14 Failure code [DY2DKB] Wiper drive (for) short ............................................................................................. 16 Failure code [DY2EKB] Wiper drive (rev) short ............................................................................................ 18
PC138US, USLC-8
SEN02466-00
40 Troubleshooting
Failure code [DXA8KA] PC-EPC sol discon

User code E02 Contents of trouble Action of controller Problem that appears on machine Related information Failure code DXA8KA Trouble PC-EPC solenoid system disconnection (Pump controller system)
When PC-EPC solenoid was driven, disconnection was detected in circuit. None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, system resets itself. If pump load increases, engine speed lowers largely and engine may stall. Drive current of PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current) Method of reproducing failure code: Turn starting switch ON. Cause Defective PC-EPC solenoid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male) Between (1) (2) Resistance 7 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump 2 drive switch (Internal disconnection) S25 (male) Between (3) (2) Between (6) (5) Emergency pump drive switch Normal Emergency Normal Emergency Resistance Max. 1 z Min. 1 Mz Max. 1 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between S25 (female) (2) 3 or defective contact in con- V11 (female) (1) nector) Wiring harness between C02 (female) (115), (117), (120) S25 (female) (6) Wiring harness between S25 (female) (5) V11 (female) (2) Wiring harness between C02 (female) (96) S25 (female) (3) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z
PC138US, USLC-8
40 Troubleshooting
SEN02466-00
PC138US, USLC-8
SEN02466-00
40 Troubleshooting
Failure code [DXA8KB] PC-EPC sol short

User code E02 Contents of trouble Action of controller Problem that appears on machine Related information Failure code DXA8KB Trouble PC-EPC solenoid system short (Pump controller system)
When PC-EPC solenoid was driven, short circuit was detected in circuit. Turns output to PC-EPC solenoid OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. If pump load increases, engine speed lowers largely and engine may stall. Drive current of PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current) Method of reproducing failure code: Turn starting switch ON. Cause Defective PC-EPC solenoid 1 (Internal short circuit or ground fault) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male) Between (1) (2) Between (1) chassis ground Resistance 7 14 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump 2 drive switch (Internal short circuit or ground fault) S25 (male) Between (2), (3) (4) Between (2), (3) chassis ground Normal Emergency pump drive switch Resistance Min. 1 Mz Min. 1 Mz
Ground fault in wiring harWiring harness between C02 (female) (96) 3 ness (Contact with GND cir S25 (female) (3) cuit) Wiring harness between S25 (female) (5) V11 (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller C02 (female) Between (96) (115), (117), (120) Between (96) chassis ground Resistance 7 14 z Min. 1 Mz
PC138US, USLC-8
40 Troubleshooting
SEN02466-00
PC138US, USLC-8
SEN02466-00
40 Troubleshooting
Failure code [DXE4KA] Service current EPC discon

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DXE4KA Trouble Service current EPC solenoid disconnection (Pump controller system)
When service EPC solenoid was driven, disconnection was detected in circuit. None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, system resets itself. Attachment does not operate. Drive current of service EPC solenoid can be checked with monitoring function. (Code: 01700 Service solenoid current) Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective service EPC sole1 noid (Internal disconnection) V30 (male) Resistance Between (1) (2) Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (97) 2 or defective contact in con- V30 (female) (1) nector) Wiring harness between C02 (female) (115), (117), (120) V30 (female) (2) 7 14 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Max. 1 z Max. 1 z
PC138US, USLC-8
40 Troubleshooting
SEN02466-00
Failure code [DXE4KB] Service current EPC short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DXE4KB Trouble Service current EPC solenoid short (Pump controller system)
When service EPC solenoid was driven, short circuit was detected in circuit. Turns output to service EPC solenoid OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Attachment does not operate. Drive current of service EPC solenoid can be checked with monitoring function. (Code: 01700 Service EPC solenoid current) Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause Defective service EPC sole1 noid (Internal short circuit or ground fault) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V30 (male) Between (1) (2) Between (1) chassis ground Resistance 7 14 z Min. 1 Mz
PC138US, USLC-8
SEN02466-00
40 Troubleshooting
Failure code [DY20KA] Wiper working abnormality

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DY20KA Trouble Wiper working abnormality (Pump controller system)
When windshield wiper works, W signal of working ends is not input. Turns working output to wiper motor OFF. If cause of failure disappears, system resets itself. Wiper motor does not work. Condition of W contact signal of wiper working area can be checked with monitoring function. (Code: 02204 Switch input 5) Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective wiper motor (Inter1 nal disconnection) M05 (female) Between (6) (5) Between (1) (3) Wiper blade Operating range top Other than operating range top All range Resistance Max. 1 z Min. 1 Mz Max. 20 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between M05 (female) (5) 2 or defective contact in con- J01 chassis ground (T09) nector) Wiring harness between C02 (female) (114) M05 (male) (1) Wiring harness between C02 (female) (119) M05 (male) (3) Wiring harness between C01 (female) (56) M05 (male) (6) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C01 (female) 3 Defective pump controller Wiper blade Operating range top Resistance Max. 1 z Min. 1 Mz Max. 20 z
Between (56) chasOther than operating sis ground range top Between (114) (119) All range
PC138US, USLC-8
40 Troubleshooting
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PC138US, USLC-8
SEN02466-00
40 Troubleshooting
Failure code [DY20MA] Wiper parking abnormality

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DY20MA Trouble Wiper parking abnormality (Pump controller system)
When windshield wiper parks, P signal of storage area is not input. Turns parking output to wiper motor OFF. If cause of failure disappears, system resets itself. Wiper motor does not park. Condition of P contact signal of wiper parking area can be checked with monitoring function. (Code: 02204 Switch input 5) Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female) Defective wiper motor (Inter1 nal disconnection) Between (4) (5) Between (1) (3) Wiper blade Storage area Working area All range Resistance Max. 1 z Min. 1 Mz Max. 20 z Resistance Resistance Max. 1 z Max. 1 z
Wiring harness between C02 (female) (114) M05 (male) (1) Wiring harness between C02 (female) (119) M05 (male) (3) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between M05 (female) (5) 2 or defective contact in con- J01 chassis ground (T09) nector) Wiring harness between C02 (female) (114) M05 (male) (1) Wiring harness between C02 (female) (119) M05 (male) (3) Wiring harness between C01 (female) (75) M05 (male) (4) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller C01 (female) Between (75) chassis ground Between (114) (119) Wiper blade Storage area Working area All range Resistance Max. 1 z Min. 1 Mz Max. 20 z
10
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PC138US, USLC-8
11
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40 Troubleshooting
Failure code [DY2CKA] Washer drive discon

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DY2CKA Trouble Window washer drive system disconnection (Pump controller system)
When output to window washer drive system was turned OFF (when ground circuit was connected), disconnection was detected in circuit. None in particular (Since no current flows, washer motor does not operate). If cause of failure disappears, system resets itself. Window washer does not operate. Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defective fuse No. 4
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective washer motor 2 (Internal short circuit or ground fault)
M06 (male) Between (1) (2) Between (1), (2) chassis ground
Resistance 5 20 z Min. 1 Mz
Defective assembled-type 3 diode D02 (Internal short circuit) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D02 (female) Between (3) (7) Continuity (Resistance) No continuity (Min. 1 Mz)
Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (4) J05 4 or defective contact in con- M06 (female) (1) nector) Wiring harness between C01 (female) (3) J01 M06 (female) (2)
Ground fault in wiring harWiring harness between F01 (4) J05 5 ness (Short circuit with GND M06 (female) (1), D02 (female) (3) circuit) Wiring harness between C01 (female) (3) J01 M06 (female) (2), D02 (female) (7)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C01 (female) Between (3) chassis ground Voltage 20 30 V
12
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PC138US, USLC-8
13
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40 Troubleshooting
Failure code [DY2CKB] Washer drive short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DY2CKB Trouble Window washer drive system short (Pump controller system)
When output to window washer drive system was turned ON (ground circuit was disconnected), short circuit was detected in circuit. Turns output to washer motor OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Window washer does not operate. Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
Cause Defective washer motor 1 (Internal short circuit) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M06 (male) Between (1) (2) Resistance 5 20 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between C01 (female) (3) Voltage Max. 1 V J01 M6 (female) (2), D02 (female) (7) 3 Defective pump controller If causes 1 and 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
14
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15
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Failure code [DY2DKB] Wiper drive (for) short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DY2DKB Trouble Wiper motor drive forward system short (Pump controller system)
When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit. Turns output to wiper motor drive forward side OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Windshield wiper does not operate. Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
Cause Defective wiper motor (Inter1 nal short circuit or ground fault)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female) Between (3) (1) Between (3) chassis ground Resistance There is continuity Min. 1 Mz
Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (119) circuit) M05 (male) (3) 3 Defective pump controller
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Min. 1 Mz
If causes 1 and 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
16
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Failure code [DY2EKB] Wiper drive (rev) short

User code Contents of trouble Action of controller Problem that appears on machine Related information Failure code DY2EKB Trouble Wiper motor drive reverse system short (Pump controller system)
When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit. Turns output to wiper motor drive reverse side OFF. Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Windshield wiper does not operate. Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
Cause Defective wiper motor (Inter1 nal short circuit or ground fault)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female) Between (1) (3) Between (1) chassis ground Continuity/Resistance There is continuity Min. 1 Mz
Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (114) circuit) M05 (male) (1) 3 Defective pump controller
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Min. 1 Mz
If causes 1 and 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 3 Information in troubleshooting table................................................................................................................ 5 E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 6 E-2 When starting switch turned ON (before starting engine), basic check item lights up.............................. 8 E-3 Engine does not start (Engine does not turn) ........................................................................................... 9 E-4 Preheater does not operate.................................................................................................................... 12 E-5 Automatic warm-up system does not operate (in cold season).............................................................. 14 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ........................... 16 E-7 Precaution lights up while engine is running .......................................................................................... 18 E-8 Emergency stop item lights up while engine is running.......................................................................... 21 E-9 Engine coolant temperature gauge does not indicate normally ............................................................. 22 E-10 Hydraulic oil temperature gauge does not indicate normally................................................................ 23 E-11 Fuel level gauge does not indicate normally ........................................................................................ 25 E-12 Contents of display by machine monitor are different from applicable machine .................................. 27
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E-13 Machine monitor does not display some items..................................................................................... 27 E-14 Function switch does not work ............................................................................................................. 27 E-15 Auto-decelerator does not operate normally ........................................................................................ 28 E-16 Working mode does not change ........................................................................................................... 29 E-17 Travel speed does not change ............................................................................................................. 30 E-18 Alarm buzzer cannot be stopped.......................................................................................................... 31 E-19 Windshield wiper and window washer do not operate.......................................................................... 32 E-20 Swing holding brake does not operate normally................................................................................... 36 E-21 Travel alarm does not sound or does not stop sounding...................................................................... 38 E-22 Air conditioner does not operate normally (including air conditioner abnormality record) .................... 39 E-23 While starting switch is in OFF position, service meter is not displayed .............................................. 51 E-24 Machine monitor cannot be set in service mode .................................................................................. 51 E-25 Monitoring function does not display lever control signal normally....................................................... 52 E-26 KOMTRAX system does not operate normally..................................................................................... 68
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Before carrying out troubleshooting of electrical system
Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally.
Type of power supply Fusible link Fuse No. 1 Switch power supply F02 (45A) 2 3 4 5 6 Switch power supply F02 (45A) 7 8 9 10 11 Switch power supply F02 (45A) 12 13 14 15 Constant power supply F03 (45A) 16 17 18 Switch power supply Starting switch ACC 19 20 Fuse capacity 10A 30A 15A 10A 10A 5A 10A 20A 10A 5A 20A 10A 10A 10A 5A 10A 20A 30A 5A 5A Solenoid valve Cigarette lighter Windshield washer Horn Working lamp relay, horn relay Rotary lamp (If equipped) Working lamp Radio, speaker Air conditioner Air conditioner unit Optional power supply (1) Optional power supply (2), power supply of 12 volt Spare Air conditioner Radio backup, room lamp Machine monitor, pump controller, starting switch Engine controller Engine controller PPC oil pressure lock solenoid Destination of power Emergency operating circuit
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Locations of fusible links
Location of fuse box and fuse Nos.
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Information in troubleshooting table

a
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Related information Trouble which occurred in the machine Information related to detected trouble or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Contents of description> Standard value in normal state to judge possible causes Remarks on judgment 1 <Troubles in wiring harness> Disconnection Connector is connected imperfectly or wiring harness is broken. Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. Hot short Wiring harness which is not connected to power source (24 2 V) circuit is in contact with power source (24 V) circuit. Short circuit Independent wiring harnesses are in contact with each other abnormally. Possible causes of trouble (Given numbers are refer- <Precautions for troubleshooting> ence numbers, which do 1) Method of indicating connector No. and handling of Tnot indicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. If connector No. has no marks of male and female, 3 disconnect connector and insert T-adapters in both male side and female side. If connector No. has marks of male and female, disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative () lead of tester as explained below for troubleshooting, unless otherwise specified. 4 Connect positive (+) lead to pin No. or wiring harness entered on front side. Connect negative () lead to pin No. or harness entered on rear side.
Related circuit diagram

This drawing is a part of the circuit diagram related to troubleshooting. Connector No.: Indicates (Model Number of pins) and (Color). Connector No. and pin No. from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. Arrow ( ): Roughly shows the location on the machine.
PC138US, USLC-8
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40 Troubleshooting
E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble Related information When starting switch turned ON, machine monitor displays nothing. When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password (if set), screen to check breaker mode (if set), screen of check before starting, screen to check working mode and travel speed, and ordinary screen in order. When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Low charge level of battery Battery voltage (2 pieces) Min. 24 V 2 3 Defective fusible link F03 or fuse No. 17 Electrolyte specific gravity (1 piece) Min. 1.26
If fusible link or fuse is broken, circuit probably has ground fault. (See Cause 5.)
Wrong connection of connec- Machine monitor connector may be connected wrongly. Check it tor directly. (Check mounting bracket plate with connector.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery () chassis ground Wiring harness between battery (+) RB F03 (male) (1) Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Disconnection in wiring harness (Disconnection in wiring 4 or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between F03 (male) (2) F01-15D Wiring harness between F01-17 J07 CM01 (female) (1), (2) Wiring harness between CM01 (female) (3), (4) chassis ground (T09) Wiring harness between F01-17 H15 (female) (1) Wiring harness between H15 (female) (5) J05 CM01 (female) (14)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (+) RB F03 (male) (1) Wiring harness between F03 (male) (2) Ground fault in wiring harF01-15D 5 ness (Short circuit with GND Wiring harness between F01-17 J07 circuit) CM01 (female) (1), (2) Wiring harness between F01-17 H15 (female) (1) Wiring harness between H15 (female) (5) J05 CM01 (female) (14) Resistance Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then hold starting switch OFF and ON and carry out troubleshooting in each case. CM01 6 Defective machine monitor Between (1), (2) (3), (4) Between (14) (3), (4) Starting switch OFF ON Voltage 20 30 V 20 30 V
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E-2 When starting switch turned ON (before starting engine), basic check item lights up
Trouble Related information Engine oil level monitor lights up red. Condition of engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2) Cause 1 Lowering of engine oil level (When system is normal) Standard value in normal state/Remarks on troubleshooting Engine oil level may be low. Check it and add oil if necessary.
Defective engine oil level 2 switch (Internal disconnection) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P44 (male) Between (1) chassis ground Engine oil level Between H L Below L Resistance Max. 1 z Min. 1 Mz
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 3 or defective contact in con- Wiring harness between CM02 (female) (2) ResisMax. 1 z nector) P44 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective machine monitor CM02 Between (2) chassis ground Engine oil level Between H L Below L Voltage Max. 1 V 20 30 V
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E-3 Engine does not start (Engine does not turn)

Trouble Related information Engine does not start (Engine does not turn). Engine starting circuit has following 2 start lock mechanisms. 1) Start lock with password of machine monitor 2) Start lock with lock lever Cause Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Low charge level of battery Battery voltage (2 pieces) Min. 24 V 2 Defective fuse No. 20 Electrolyte specific gravity (1 piece) Min. 1.26
If fuse is broken, circuit probably has ground fault. (See cause 10.) a Prepare with starting switch OFF, then keep starting switch OFF and turn it to START and carry out troubleshooting in each case. H15 (male) Between (1) (4) Starting switch OFF START Resistance Min. 1 Mz Max. 1 z
Defective starting switch (Internal disconnection)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective lock lever switch (Internal disconnection) S14 (female) Between (1) (3) Lock lever Free Lock Resistance Min. 1 Mz Max. 1 z
Defective starting motor cutout relay R06 or R07 (Inter5 nal disconnection or short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R06 (male), R07 (male) Between (1) (2) Between (3) (4) Between (3) (5) Resistance 300 600 z Max. 1 z Min. 1 Mz
a Prepare with starting switch OFF (with only terminal C disconnected), then turn starting switch to START and carry out troubleshooting. Safety relay terminal Between B E 6 Defective starting motor safety relay (Internal defect) Between R (R17-2) E Between S (R17-1) E Between C (R18) E Power supply Generation input Starting input Starting output Voltage 20 30 V Max. 1 V 20 30 V 20 30 V
If power supply, generation input, and starting input are normal but starting output is not normal, starting motor safety relay is defective. a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Starting motor terminals 7 Defective starting motor (Internal defect) Between B chassis ground Between C (E10) chassis ground Power supply Starting input Voltage 20 30 V 20 30 V
If power supply and starting input are normal but starting motor does not turn, starting motor is defective.
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40 Troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Alternator Between L (AR-1) chassis ground Generation output Voltage Max. 1 V
Defective alternator (Internal short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between H15 (male) (4) R06 (female) (5) Wiring harness between R06 (female) (3) R07 (female) (4) Wiring harness between R07 (female) (3) R17 (female) (1) Wiring harness between starting motor Disconnection in wiring har- safety relay B heater relay battery relay ness (Disconnection in wiring B 9 or defective contact in conWiring harness between starting motor nector) safety relay E chassis ground Wiring harness between starting motor safety relay C starting motor C (E10) Possible causes and standard value in normal state Wiring harness between F01-20 S14 (male) (1) Wiring harness between S14 (male) (3) R06 (female) (1) Wiring harness between R06 (female) (2) J02 chassis ground (T08) Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between H15 (male) (4) R06 (female) (5), circuit branch end Wiring harness between R06 (female) (3) R07 (female) (4) Wiring harness between R07 (female) (3) R17 (female) (1) Ground fault in wiring har10 ness (Short circuit with GND Wiring harness between starting motor circuit) safety relay B heater relay battery relay B Wiring harness between starting motor safety relay C starting motor C (E10) Wiring harness between F01-20 S14 (male) (1) Wiring harness between S14 (male) (3) R06 (female) (1) 11 Resistance Resistance Resistance Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between R17 (female) (2) Voltage Max. 1 V alternator L (AR-1), circuit branch end
10
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E-4 Preheater does not operate

Trouble
Related information
(1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash. Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds after to notify completion of preheating (It stops flashing about 10 seconds after). If engine coolant temperature is below 20C, automatic warm-up system operates and preheating monitor lights up for up to 30 seconds. Condition of starting switch (preheating) signal can be checked with the monitoring function. (Code: 04500 Monitor input 1) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. 1 Defective starting switch (Internal disconnection) H15 (female) Between (1) (3) Starting switch OFF Resistance Min. 1 Mz
HEAT Max. 1 z Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) ResisMax. 1 z nector) (16) J04 H15 (female) (3) tance a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. 3 Defective machine monitor CM01 Between (16) chassis ground Starting switch OFF HEAT Voltage Max. 1 V 20 30 V
Trouble Related information
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm. Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-1 Engine does not start (Engine does not turn)). Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF (with wiring harness connected), then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. Continuity/ResisHeater relay Starting switch tance Defective heater relay (Inter1 nal disconnection) Between R15 OFF There is continuity chassis ground Between power supply terminal HEAT Max. 1 z R16 a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting in each case. E01 Starting switch Voltage Between terminal chassis ground HEAT 20 30 V Cause
Defective intake air heater (Internal disconnection)
If voltage is normal but heater mounting part does not become warm, intake air heater is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisDisconnection in wiring har- Wiring harness between H15 (female) (3) Max. 1 z tance ness (Disconnection in wiring J04 heater relay R15 3 or defective contact in con- Wiring harness between battery relay RM ResisMax. 1 z nector) heater relay contact terminal (F04) tance Wiring harness between heater relay R16 intake air heater E01 Resistance Max. 1 z
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E-5 Automatic warm-up system does not operate (in cold season)
Trouble Automatic warm-up system does not operate (in cold season).
Related information
When engine coolant temperature is below 30C automatic warm-up system raises engine speed to 1,300 rpm. If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after engine is started, automatic warm-up system is turned OFF. (Automatic warm-up system stops automatically after operating for 10 minutes.) If engine coolant temperature is below 10C turbocharger protection function operates to keep the engine speed at low idle. Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting. Monitoring code Engine coolant temperature 105C 102C 04107 Engine coolant temperature 100C 85C 60C 30C Coolant temperature level 6 (a: Red) 5 (a: Red) 4 (a: Blue) 3 (a: Blue) 2 (a: Blue) 1 (a: White)
Defective engine coolant 1 temperature signal system
If level of coolant temperature gauge is different from actual coolant temperature, carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally. 2 Defective engine controller If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Engine coolant temperature gauge and engine coolant temperature monitor
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E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 1
Trouble Related information Cause 1 Defective fuse No. 20 Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective lock lever switch (Internal disconnection) S14 (female) Between (1) (2) Lock lever Lock Free Resistance Min. 1 Mz Max. 1 z (1) All work equipment, swing, and travel mechanism do not move.
Defective PPC lock solenoid 3 (Internal disconnection or short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V01 (male) Between (1) (2) Between (1) chassis ground Resistance 20 60 z Min. 1 Mz
Defective assembled-type 4 diode D01 (Internal short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D01 (male) Between (4) (8) Resistance (Continuity) Min. 1 Mz (No continuity)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 5 or defective contact in connector) Wiring harness between F01-20 S14 (male) (1) Wiring harness between S14 (male) (2) V01 (female) (2) Wiring harness between V01 (female) (1) chassis ground (T08) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
Ground fault in wiring harWiring harness between F01-20 S14 6 ness (Short circuit with GND (male) (1), circuit branch end circuit) Wiring harness between S14 (male) (2) V01 (female) (2), D01 (female) (4)
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(2) All work equipment, swing, and travel mechanism cannot be locked.
Cause
Defective lock lever switch (Internal short circuit)
S14 (female) Between (1) (2)
Lock lever Lock Free
Resistance Min. 1 Mz Max. 1 z
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between S14 (male) (2) V01 (female) (2), D01 (female) (4)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Max. 1 V
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E-7 Precaution lights up while engine is running

Trouble Related information (1) Charge level monitor lights up red. Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage) Cause Defective generation by 1 alternator (when system is normal) Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. AR (male) Between (L) chassis ground Engine speed Middle or higher Voltage 27.5 29.5 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) ResisMax. 1 z nector) (11) J06 AR (female) (1) tance Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CM01 (female) circuit) (11) J06 AR (female) (1), circuit branch end a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective machine monitor CM02 Between (11) chassis ground Engine Running Voltage Min. 7.8 V
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(2) Fuel level monitor lights up red. Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting
1 2
Low fuel level (when system Fuel level may be low (below about 41 l). Check it and add fuel if is normal) necessary. Defective fuel level gauge system If cause 1 is not detected, fuel level gauge system may be defective. Carry out troubleshooting for E-11 Fuel level gauge does not indicate normally.
(3) Engine coolant temperature monitor lights up white. Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause Standard value in normal state/Remarks on troubleshooting If monitor lights up white, engine coolant temperature may be low (below about 30C). Warm up engine. Lighting up white: Engine coolant temperature is low. Lighting up blue: Engine coolant temperature is proper. If cause 1 is not detected, engine coolant temperature gauge system may be defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally.
Insufficient warm-up of 1 machine (when system is normal) 2 Defective engine coolant temperature gauge system
(4) Hydraulic oil temperature monitor lights up white. Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause Standard value in normal state/Remarks on troubleshooting If monitor lights up white, hydraulic oil temperature may be low (below about 20C). Warm up engine. Lighting up white: Hydraulic oil temperature is low. Lighting up blue: Hydraulic oil temperature is proper. If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally.
Insufficient warm-up of 1 machine (when system is normal) 2 Defective hydraulic oil temperature gauge system
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E-8 Emergency stop item lights up while engine is running

Trouble Related information (1) Engine coolant temperature monitor lights up red.
Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause Standard value in normal state/Remarks on troubleshooting
If monitor lights up red, engine coolant temperature may be high (above about 102C). Cool down engine coolant (Run engine at low idle). Overheating of engine cool- Lighting up red: Engine coolant temperature is high 1 (overheating). ant (when system is normal) Lighting up blue: Engine coolant temperature is proper. Carry out troubleshooting for S-14 Coolant temperature becomes too high (overheating). 2 Defective engine coolant temperature gauge system If cause 1 is not detected, engine coolant temperature gauge system may be defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally.
(2) Hydraulic oil temperature monitor lights up red. Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause Standard value in normal state/Remarks on troubleshooting If monitor lights up red, hydraulic oil temperature may be high (above about 102C). Cool down hydraulic oil (Run engine at low idle). Lighting up red: Hydraulic oil temperature is high (overheating). Lighting up blue: Hydraulic oil temperature is proper. If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally.
Overheating of hydraulic oil (when system is normal)
Defective hydraulic oil temperature gauge system
(3) Engine oil pressure monitor lights up red. Signals of engine oil pressure switch are input to engine controller and then transmitted to machine monitor through communication system. Cause Standard value in normal state/Remarks on troubleshooting Engine oil pressure may be low. If it is low, carry out troubleshooting for S-12 Oil pressure lowers.
Lowering of engine oil pres1 sure (when system is normal) 2
Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may switch system be defective. Carry out troubleshooting for failure code [CA435].
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E-9 Engine coolant temperature gauge does not indicate normally

Trouble
(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C). (2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H). Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause Standard value in normal state/Remarks on troubleshooting If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145]. If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Related information
Defective engine coolant temperature sensor system
Trouble
(3) Display of coolant temperature gauge is different from actual engine coolant temperature. (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor. Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.
Related information
Engine coolant temperature 105C 1 Defective machine monitor 102C 100C 85C 60C 30C
Coolant temperature Color of monitor light level (a) 6 5 4 3 2 1 White Blue Red
Engine coolant temperature gauge and engine coolant temperature monitor
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E-10 Hydraulic oil temperature gauge does not indicate normally

Trouble (1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C). (2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H). Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting
Related information
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P22 (male) Between (1) (2) Between (2) chassis ground Resistance 3.5 90 kz Min. 1 Mz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (29) 2 or defective contact in con- P22 (female) (2) nector) Wiring harness between C01 (female) (46) P22 (female) (1) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (29) Resiscircuit) Min. 1 Mz P22 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (29) Voltage Max. 1 V P22 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective pump controller C01 (female) Between (29) (46) Between (29) chassis ground 6 Defective machine monitor Resistance 3.5 90 kz Min. 1 Mz
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Trouble
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor. Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.
Related information
Hydraulic oil temperature 105C 1 Defective machine monitor 102C 100C 85C 40C 20C
Hydraulic oil temper- Color of monitor light ature level (a) 6 5 4 3 2 1 White Blue Red
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
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E-11 Fuel level gauge does not indicate normally

Trouble Related information (1) While fuel is added, fuel level gauge does not rise from red range (E). (2) While fuel level is low, fuel level gauge does not lower from green range top (F) Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor voltage) Cause Defective fuel level sensor 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P21 (male) Between (1) chassis ground Fuel level FULL EMPTY Resistance 7 11 z 85 95 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) (9) ResisMax. 1 z nector) P21 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CM01 (female) (9) Resiscircuit) Min. 1 Mz P21 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between CM01 (female) (9) Voltage Max. 1 V P21 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective machine monitor CM01 (female) Between (9) chassis ground Fuel level FULL EMPTY Resistance 7 11 z 85 95 z
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(3) Display of fuel level gauge is different from actual fuel level. (4) Display of fuel level gauge is different from display of fuel level monitor. Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.
Quantity of fuel 139 l 1 Defective machine monitor 116 l 96 l 66 l 52 l 33 l
Reading of fuel level Color of monitor light gauge (a) 6 5 4 3 2 1 Red Blue
Fuel level gauge and fuel level monitor
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E-12 Contents of display by machine monitor are different from applicable machine
Trouble Related information Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Contents of display by machine monitor are different from applicable machine.
a Turn starting switch ON and carry out troubleshooting (with monitoring function). 1 Defective model code signal Monitoring code 00200 Controller model code 2 Defective machine monitor Normal display Blade spec Not blade spec PC128/138US-a PC128/138US-a BL
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
E-13 Machine monitor does not display some items

Trouble Related information Machine monitor does not display some items.
The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting. Defective machine monitor 1 (LCD panel) Defective machine monitor (body) When following switches are operated, if all LCD panel is lighted up (all surface becomes white), LCD panel is normal. Operation of switches: [4] + [F2] (Press simultaneously) If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
E-14 Function switch does not work

Trouble Related information Possible causes and standard value in normal state Function switch does not work. Condition of signal of function switch can be checked with monitoring function. (Code: 04503 Monitor function switch) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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E-15 Auto-decelerator does not operate normally

Trouble Related information Possible causes and standard value in normal state
(1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off. Condition of signal of auto-decelerator switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) Auto-decelerator is not operated or reset with lever. Set speed of auto-decelerator is 1,400 rpm. If fuel control dial is not set above this speed, autodecelerator is not operated or reset. Cause Standard value in normal state/Remarks on troubleshooting a Start engine and carry out troubleshooting (with monitoring function). Monitoring code Item Swing Travel 01900 Pressure switch 1 1 Boom lower Boom raise Arm curl Arm dump Bucket curl 01901 Pressure switch 2 Bucket dump Service When lever is operated: ON When lever is in neutral: OFF When lever is operated: ON When lever is in neutral: OFF Normal display
Defective PPC pressure signal
If display of monitoring is abnormal, carry out troubleshooting for E-26 Monitoring function does not display lever control signal normally. 2 Defective machine monitor 3 Defective pump controller 4 Defective engine controller If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If cause 1 is not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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E-16 Working mode does not change

Trouble Related information Possible causes and standard value in normal state (1) When working mode switch is operated, working mode selection screen is not displayed. Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Cause 1 Defective machine monitor 2 Defective pump controller
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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E-17 Travel speed does not change

Trouble Related information Possible causes and standard value in normal state (1) When travel speed switch is operated, travel speed monitor does not change. Condition of signal of travel speed switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When travel speed is shifted, actual travel speed does not change. If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo. Cause Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between C02 (female) (87) Voltage Max. 1 V V02 (female) (2) 2 Defective machine monitor 3 Defective pump controller If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If cause 1 is not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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E-18 Alarm buzzer cannot be stopped

Trouble Related information Possible causes and standard value in normal state Alarm buzzer cannot be stopped. Condition of signal of alarm buzzer cancel switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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E-19 Windshield wiper and window washer do not operate

Trouble Related information Possible causes and standard value in normal state (1) When wiper switch is operated, wiper monitor does not light up or go off. Condition of wiper switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When wiper switch is operated, wiper does not operate. Condition of window rear limit switch signal can be checked with monitoring function. (Code: 02204 Switch input 5) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective window rear limit switch (Internal short circuit) W03 (male) Front window When installed to front When retracted to rear Resistance Min. 1 Mz Max. 1 z
Between (1) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective wiper motor (Inter2 nal disconnection) M05 (female) Continuity Between (1) (3) There is continuity a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Max. 1 z Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (119) 3 or defective contact in con- M05 (male) (3) nector) Wiring harness between C02 (female) (114) M05 (male) (1)
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Resiscircuit) C01 (female) (57) W03 (female) (1) Min. 1 Mz tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective pump controller (Rear limit switch system) 5 C01 (female) Between (57) chassis ground Front window When installed to front When retracted to rear Resistance Min. 1 Mz Max. 1 z
Defective pump controller (Wiper motor system)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C02 (female) Between (119) (114) Continuity There is continuity
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(3) When window washer switch is operated, window washer does not operate. Condition of window washer switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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E-20 Swing holding brake does not operate normally

Trouble Related information (1) When swing lock switch is operated, swing lock monitor does not light up or go off. Condition of swing lock switch signal can be checked with monitoring function. (Machine monitor system code: 04502 Monitor input 3) (Pump controller system code: 02200 Switch input 1) Cause Defective swing lock switch 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (male) Between (5) (6) Swing lock switch OFF Resistance Min. 1 Mz
ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (5) Resis2 Max. 1 z or defective contact in con- J01 S04 (female) (5) tance nector) Wiring harness between S04 (female) (6) ResisMax. 1 z J02 chassis ground (T08) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CM02 (female) (5) Resiscircuit) J01 S04 (female) (5), C01 (female) Min. 1 Mz tance (19) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CM02 Swing lock switch Voltage Between (5) chassis ground OFF ON 20 30 V Max. 1 V
(2) When swing lock switch is turned ON, swing lock does not operate. (Hydraulic drift of swing occurs on slope.)
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (male) Between (3) (4) Swing lock switch OFF Resistance Min. 1 Mz
Defective swing lock switch (Internal short circuit)
Defective swing holding 2 brake release switch (Internal short circuit)
ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Swing holding brake S25 (male) Resistance release switch Between (13) (14) Lock Release Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Hot short (Short circuit with Wiring harness between D01 (female) (3) 24V circuit) in wiring harness J04 S04 (female) (3), S25 (female) (14) Wiring harness between S04 (female) (4) V03 (female) (2), D03 (female) (3) Voltage Voltage Max. 1 V Max. 1 V
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E-21 Travel alarm does not sound or does not stop sounding
Trouble Related information Cause Standard value in normal state/Remarks on troubleshooting Alarm does not sound during travel. Alarm does not stop sounding while machine is stopped.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (107) Resis1 Max. 1 z or defective contact in con- M14 (female) (1) tance nector) Wiring harness between C02 (female) (115) ResisMax. 1 z (117) (120) M14 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C02 (female) (107) Resiscircuit) Min. 1 Mz M14 (female) (1) tance Defective travel alarm (Inter3 If causes 1, 2 are not detected, travel alarm is defective. nal defect)
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E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble Related information Possible causes and standard value in normal state (1) When air conditioner switch is operated, air conditioner control screen is not displayed. Condition of air conditioner switch signal can be checked with monitoring function. (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When air conditioner switch is operated, air conditioner does not operate at all.
Cause 1 Defective fuse No. 15 2 Defective fuse in unit
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 4.) If fuse in unit is broken, circuit in unit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Max. 1 z Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01-15 fuse in 3 or defective contact in con- unit ACW (wiring side) (6) nector) Wiring harness between ACW (wiring side) (16) chassis ground (T14) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har4 ness (Short circuit with GND Wiring harness between F01-15 fuse in Resiscircuit) Min. 1 Mz unit ACW (wiring side) (6), circuit branch tance end a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective air conditioner controller ACW (wiring side) Between (6) (16) Voltage 20 30 V
If above voltage is normal, air conditioner controller may be defective. 6 Defective machine monitor If causes 1 5 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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(3) Air does not come out (Air flow is insufficient).
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side). R20 (male) Resistance
Between (1) (3) 140 340 z Defective blower relay (Intera Prepare with starting switch OFF, then turn starting switch ON nal disconnection) and carry out troubleshooting (contact side). R20 Between (4) chassis ground Air conditioner switch Air blow position Voltage 20 30 V
Defective power transistor (Internal defect)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch Operate between Low and Medium and High. If air flow changes according to operation of fan switch, power transistor is normal.
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state 3 Defective blower motor (Internal defect) MB (wiring side) Between (1) (2) Air conditioner switch Air blow position Voltage 20 30 V
If above voltage is normal and blower motor does not revolve, blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-10 fuse in unit R20 (female) (1) Wiring harness between R20 (female) (3) ACW (wiring side) (36) Disconnection in wiring harness (Disconnection in wiring Wiring harness between R20 (female) (2) 4 or defective contact in con- MB (wiring side) (1) nector) Wiring harness between MB (wiring side) (2) PTR (wiring side) (3) Wiring harness between PTR (wiring side) (1) chassis ground (T14) Wiring harness between PTR (wiring side) (2) ACW (wiring side) (8) Wiring harness between PTR (wiring side) (4) ACW (wiring side) (7) Wiring harness between F01-11 R20 (female) (4) Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
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Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between R20 (female) (3) ACW (wiring side) (36) Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
Ground fault in wiring harWiring harness between R20 (female) (2) 5 ness (Short circuit with GND MB (wiring side) (1) circuit) Wiring harness between MB (wiring side) (2) PTR (wiring side) (3) Wiring harness between PTR (wiring side) (2) ACW (wiring side) (8) 6
If causes 1 5 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.) If causes 1 5 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume of Shop Manual, Air tem conditioner, Troubleshooting.
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(4) Air is not cooled (Cooling performance is insufficient).
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side). R21 (male) Resistance 140 340 z Between (1) (3)
Defective compressor relay (Internal disconnection)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (contact side). R21 Between (2) chassis ground Air conditioner switch Cooling position Voltage 20 30 V
2 Defective internal air sensor 3 4 5 Possible causes and standard value in normal state
Internal air sensor may be defective. Carry out troubleshooting for Abnormality in internal air sensor.
Defective high and low pres- High and low pressure switches may be defective. Carry out trousure switches bleshooting for Abnormality in refrigerant. Defective compressor clutch Compressor clutch may be defective. Check it directly. (Internal defect) Defective compressor (InterCompressor may be defective. Check it directly. nal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between R21 (female) (3) 6 or defective contact in con- ACW (wiring side) (35) nector) Wiring harness between F01-11 R21 (female) (4) Wiring harness between R21 (female) (2) AC02 (female) (1)
Wiring harness between F01-10 fuse in unit R21 (female) (1)
Resistance Resistance Resistance Resistance
Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Ground fault in wiring harWiring harness between R21 (female) (3) 7 ness (Short circuit with GND ACW (wiring side) (35) circuit) Wiring harness between R21 (female) (2) AC02 (female) (1) 8
If causes 1 7 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.) If causes 1 7 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume of Shop Manual, Air tem conditioner, Troubleshooting.
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Trouble
(5) Air conditioner abnormality record: Communication condition CAN disconnection, Communication condition Abnormal While abnormality in communication is being detected, CAN disconnection is displayed. If abnormality in communication has been detected and reset, Abnormality is displayed. If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, condition of other items is not displayed. Method of reproducing abnormality record: Turn starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting
Related information
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between N10 (female) (1) Resis1 Max. 1 z or defective contact in con- CM02 (female) (8), (9) tance nector) Wiring harness between N10 (female) (2) ResisMax. 1 z CM02 (female) (10) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between N10 (male) (1) CM02 (female) (8), (9), C01 (female) (45), Ground fault in wiring har CE02 (female) (1), K02 (female) (A), 2 ness (Short circuit with GND N08 (male) (3) circuit) Wiring harness between N10 (female) (2) CM02 (female) (10), C01 (female) (64), CE02 (female) (21), K02 (female) (B), N08 (male) (10) Resistance Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 24V circuit) in wiring harness N10 (male) (1) CM02 (female) (8), (9), C01 (female) (45), CE02 (female) (1), K02 (female) (A), N08 (male) (3) Wiring harness between N10 (female) (2) CM02 (female) (10), C01 (female) (64), CE02 (female) (21), K02 (female) (B), N08 (male) (10) Voltage Max. 5.5 V
Voltage
Max. 5.5 V
Defective CAN terminal 4 resistance (Internal short circuit or disconnection)
If causes 1 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be 5 troller carried out.) 6 Defective machine monitor If causes 1 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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SEN02467-00
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(6) Air conditioner abnormality record: Setting condition Abnormality If setting of air conditioner controller model is different from setting of machine monitor model, Abnormality is displayed. If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Method of reproducing abnormality record: Turn starting switch ON. Cause 1 Standard value in normal state/Remarks on troubleshooting
Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in troller system, troubleshooting cannot be carried out.) Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(7) Air conditioner abnormality record: Internal air sensor Abnormality If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective internal air sensor 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (device side) Between (1) (2) Resistance 300 z 430 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side) 2 or defective contact in con- (11) THI (wiring side) (2) nector) Wiring harness between ACW (wiring side) (27) THI (wiring side) (1)
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND ResisWiring harness between ACW (wiring side) circuit) Min. 1 Mz tance (11) THI (wiring side) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between ACW (wiring side) Voltage Max. 1 V (11) THI (wiring side) (2) 5 If causes 1 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
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40 Troubleshooting
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(8) Air conditioner abnormality record: External air sensor Unused External air sensor is not used in air conditioner system of this machine. If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Cause 1 Normal display Standard value in normal state/Remarks on troubleshooting Since external air sensor is not used in air conditioner system of this machine, above display is normal.
(9) Air conditioner abnormality record: Air flow sensor Abnormality If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective air flow sensor 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THF (device side) Between (1) (2) Resistance 100 z 115 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side) 2 or defective contact in con- (12) THF (wiring side) (2) nector) Wiring harness between ACW (wiring side) (27) THF (wiring side) (1)
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND ResisWiring harness between ACW (wiring side) circuit) Min. 1 Mz tance (12) THF (wiring side) (2) Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ACW (wiring side) (12) THF (wiring side) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Max. 1 V
If causes 1 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
PC138US, USLC-8
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SEN02467-00
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(10) Air conditioner abnormality record: Daylight sensor Abnormality If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1 Defective daylight sensor (Internal defect) Standard value in normal state/Remarks on troubleshooting Daylight sensor may be defective.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side) Max. 1 z 2 tance or defective contact in con- (36) P31 (female) (1) nector) ResisWiring harness between ACW (wiring side) Max. 1 z (15) P31 (female) (2) tance Possible causes and standard value in normal state a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Min. 1 Mz Min. 1 Mz
Ground fault in wiring harWiring harness between ACW (wiring side) 3 ness (Short circuit with GND (3) P31 (female) (1), circuit branch end circuit) Wiring harness between ACW (wiring side) (15) P31 (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Hot short (Short circuit with Wiring harness between ACW (wiring side) 24V circuit) in wiring harness (3) P31 (female) (1), circuit branch end Wiring harness between ACW (wiring side) (15) P31 (female) (2) 5 Voltage Voltage Max. 1 V Max. 1 V
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(11) Air conditioner abnormality record: Air outlet damper Abnormality If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1 Defective air outlet servomotor (Internal defect) Standard value in normal state/Remarks on troubleshooting Air outlet servomotor may be defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV1 (wiring side) (1) ACW (wiring side) (27) Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Wiring harness between MV1 (wiring side) (3) ACW (wiring side) (3) Wiring harness between MV1 (wiring side) (5) ACW (wiring side) (9) Wiring harness between MV1 (wiring side) (6) ACW (wiring side) (23) Wiring harness between MV1 (wiring side) (7) ACW (wiring side) (24) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV1 (wiring side) (1) ACW (wiring side) (27), circuit branch end Possible causes and standard value in normal state Wiring harness between MV1 (wiring side) Ground fault in wiring har(5) ACW (wiring side) (9), circuit branch 3 ness (Short circuit with GND end circuit) Wiring harness between MV1 (wiring side) (6) ACW (wiring side) (23), circuit branch end Wiring harness between MV1 (wiring side) (7) ACW (wiring side) (24), circuit branch end Resistance Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between MV1 (wiring side) (1) ACW (wiring side) (27), circuit branch end Wiring harness between MV1 (wiring side) Hot short (Short circuit with (5) ACW (wiring side) (9), circuit branch 4 24V circuit) in wiring harness end Wiring harness between MV1 (wiring side) (6) ACW (wiring side) (23), circuit branch end Wiring harness between MV1 (wiring side) (7) ACW (wiring side) (24), circuit branch end 5 Voltage Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
PC138US, USLC-8
47
SEN02467-00
40 Troubleshooting
(12) Air conditioner abnormality record: A/M damper Abnormality If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1 Standard value in normal state/Remarks on troubleshooting
Defective air mix servomotor Air mix servomotor may be defective. (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MAM (wiring side) (1) ACW (wiring side) (27) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Wiring harness between MAM (wiring side) (3) ACW (wiring side) (3) Wiring harness between MAM (wiring side) (5) ACW (wiring side) (2) Wiring harness between MAM (wiring side) (6) ACW (wiring side) (21) Wiring harness between MAM (wiring side) (7) ACW (wiring side) (22)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MAM (wiring side) (3) ACW (wiring side) (3), circuit branch end Possible causes and standard value in normal state Wiring harness between MAM (wiring side) Ground fault in wiring har(5) ACW (wiring side) (2), circuit branch 3 ness (Short circuit with GND end circuit) Wiring harness between MAM (wiring side) (6) ACW (wiring side) (21), circuit branch end Wiring harness between MAM (wiring side) (7) ACW (wiring side) (22), circuit branch end Resistance Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between MAM (wiring side) (3) ACW (wiring side) (3), circuit branch end Wiring harness between MAM (wiring side) Hot short (Short circuit with (5) ACW (wiring side) (2), circuit branch 4 24V circuit) in wiring harness end Wiring harness between MAM (wiring side) (6) ACW (wiring side) (21), circuit branch end Wiring harness between MAM (wiring side) (7) ACW (wiring side) (22), circuit branch end 5 Voltage Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
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PC138US, USLC-8
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(13) Air conditioner abnormality record: Refrigerant Abnormality If CAN disconnection is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1 Insufficient refrigerant (gas) (when system is normal) Standard value in normal state/Remarks on troubleshooting Refrigerant (gas) may be insufficient. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P17 (male) Between (1) (2) Resistance Max. 1 z
Defective high and low pres2 sure switches (Internal disconnection)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side) Max. 1 z 3 tance or defective contact in con- (4) P17 (female) (1) nector) Wiring harness between P17 (female) (2) ResisMax. 1 z chassis ground (T08) tance 4 If causes 1 3 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
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40 Troubleshooting
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E-23 While starting switch is in OFF position, service meter is not displayed
Trouble Related information When starting switch is turned OFF, service meter is not displayed. While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] + [1] (Press simultaneously) Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting
When starting switch is turned ON, if machine monitor displays Defective backup power sup- nothing, backup power supply system may be defective. In this 1 ply system case, carry out troubleshooting for E-1 When starting switch turned ON, machine monitor displays nothing. 2 Defective machine monitor If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
E-24 Machine monitor cannot be set in service mode

Trouble Related information Possible causes and standard value in normal state Machine monitor cannot be set in service mode. If following switches are operated, machine monitor is set in service mode. Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8
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SEN02467-00
40 Troubleshooting
E-25 Monitoring function does not display lever control signal normally 1
Trouble Related information (1) Boom raise operation is not displayed normally by monitoring function. Monitoring code: 01900 Pressure switch 1 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective boom raise PPC 1 pressure switch (Internal disconnection or short circuit) P03 (male) Between (1) (2) Right work equipment control lever Neutral Boom raise Resistance Min. 1 Mz Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (53) 2 or defective contact in con- P03 (female) (2) nector) Wiring harness between P03 (female) (1) chassis ground (T08)
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (53) Resiscircuit) Min. 1 Mz P03 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (53) Voltage Max. 1 V P03 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller C01 (female) Between (53) chassis ground Right work equipment control lever Neutral Boom raise Resistance Min. 1 Mz Max. 1 z
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53
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40 Troubleshooting
(2) Arm curl operation is not displayed normally by monitoring function. Monitoring code: 01900 Pressure switch 1 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective arm curl PPC pres1 sure switch (Internal disconnection or short circuit) P05 (male) Between (1) (2) Left work equipment control lever Neutral Arm curl Resistance Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (17) Resiscircuit) Min. 1 Mz P05 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (17) Voltage Max. 1 V P05 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller C01 (female) Between (17) chassis ground Left work equipment control lever Neutral Arm curl Resistance Min. 1 Mz Max. 1 z
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(3) Bucket curl operation is not displayed normally by monitoring function. Monitoring code: 01901 Pressure switch 2 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective bucket curl PPC 1 pressure switch (Internal disconnection or short circuit) P04 (male) Between (1) (2) Right work equipment control lever Neutral Bucket curl Resistance Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (73) Resiscircuit) Min. 1 Mz P04 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (73) Voltage Max. 1 V P04 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller C01 (female) Between (73) chassis ground Right work equipment control lever Neutral Bucket curl Resistance Min. 1 Mz Max. 1 z
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(4) Bucket dump operation is not displayed normally by monitoring function. Monitoring code: 01901 Pressure switch 2 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective bucket dump PPC 1 pressure switch (Internal disconnection or short circuit) P01 (male) Between (1) (2) Right work equipment control lever Neutral Bucket dump Resistance Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (34) Resiscircuit) Min. 1 Mz P01 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (34) Voltage Max. 1 V P01 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller C01 (female) Between (34) chassis ground Right work equipment control lever Neutral Bucket dump Resistance Min. 1 Mz Max. 1 z
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(5) Boom lower operation is not displayed normally by monitoring function. Monitoring code: 01900 Pressure switch 1 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective boom lower PPC 1 pressure switch (Internal disconnection or short circuit) P06 (male) Between (1) (2) Right work equipment control lever Neutral Boom lower Resistance Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (14) Resiscircuit) Min. 1 Mz P06 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (14) Voltage Max. 1 V P06 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller C01 (female) Between (14) chassis ground Right work equipment control lever Neutral Boom lower Resistance Min. 1 Mz Max. 1 z
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(6) Arm dump operation is not displayed normally by monitoring function. Monitoring code: 01900 Pressure switch 1 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective arm dump PPC 1 pressure switch (Internal disconnection or short circuit) P02 (male) Between (1) (2) Left work equipment control lever Neutral Arm dump Resistance Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (15) Resiscircuit) Min. 1 Mz P02 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (15) Voltage Max. 1 V P02 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller C01 (female) Between (15) chassis ground Left work equipment control lever Neutral Arm dump Resistance Min. 1 Mz Max. 1 z
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(7) Swing operation is not displayed normally by monitoring function. Monitoring code: 01900 Pressure switch 1 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective swing PPC pres1 sure switch (Internal disconnection or short circuit) P07 (male) P08 (male) Between (1) (2) Left work equipment control lever Neutral Swing left Swing right Resistance Min. 1 Mz Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (16) 2 or defective contact in con- P07 (female) (2) or P08 (female) (2) nector) Wiring harness between P07 (female) (1) or P08 (female) (2) chassis ground (T08)
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (16) Resiscircuit) Min. 1 Mz P07 (female) (2) or P08 (female) (2) tance Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (16) P07 (female) (2) or P08 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller C01 (female) Between (16) chassis ground Left work equipment control lever Neutral Swing left Swing right Resistance Min. 1 Mz Max. 1 z
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(8) Service operation is not displayed normally by monitoring function. Monitoring code: 01901 Pressure switch 2 Cause Defective service front PPC 1 pressure switch (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. P14 (male) Between (1) (2) Service pedal Neutral Forward Resistance Min. 1 Mz Max. 1 z
Defective service rear PPC 2 pressure switch (Internal disconnection or short circuit)
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. P15 (male) Between (1) (2) Service pedal Neutral Reverse Resistance Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (52) P14 (female) (1), P15 (female) (1) Wiring harness between P14 (female) (2) chassis ground (T08) Wiring harness between P15 (female) (2) chassis ground (T08) Resistance Resistance Resistance
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (52) Resiscircuit) Min. 1 Mz P14 (female) (1), P15 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (52) Voltage Max. 1 V P14 (female) (1), P15 (female) (1) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 6 Defective pump controller C01 (female) Between (52) chassis ground Service pedal Neutral Forward or reverse Resistance Min. 1 Mz Max. 1 z
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E-26 KOMTRAX system does not operate normally

Trouble Related information KOMTRAX system does not operate normally.
If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry out following troubleshooting. Even if KOMTRAX system has trouble, it does not particularly appear on machine. Carry out all troubleshooting on service menu screen of machine monitor. Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and check Setting condition or terminal screen. Check item Communication start check Normal display Completion
1 Defective communication 1
a Turn starting switch ON and check Condition of positioning and communication screen. Check item 2 Defective GPS Possible causes and standard value in normal state Positioning Normal display N ###,##,## (Latitude) E ###,##,## (Longitude) In positioning If latitude and longitude are not displayed in 5 minutes on open ground, notify KOMTRAX service hot line. a Turn starting switch ON and check Condition of positioning and communication screen. 3 Defective communication environment Check item Communication Normal display Zone level 1 Zone level 3
If zone level 1 3 is not displayed within communication zone of ORBCOMM, notify KOMTRAX service hot line. a Turn starting switch ON and check Condition of positioning and communication screen. Check item Number of items not transmitted Normal display 0 9 (Normally 0)
4 Defective communication 2
Select Terminal Status from 12 Display of KOMTRAX setting in the service menu of the machine monitor.
Select GPS & Communication Status from 12 Display of KOMTRAX setting in the service menu of the machine monitor.
68
PC138US, USLC-8
SEN02467-00
40 Troubleshooting
70
PC138US, USLC-8
SEN02468-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-mode)
Information contained in troubleshooting table ............................................................................................... 3 System chart for hydraulic and mechanical systems ...................................................................................... 4 H-1 Speed or power of all work equipment, swing, and travel are low ........................................................... 6 H-2 Engine speed sharply drops or engine stalls............................................................................................ 7 H-3 No work equipment, travel and swing move ............................................................................................ 8 H-4 Abnormal noise is heard from around hydraulic pump............................................................................. 8 H-5 Fine control mode does not function ........................................................................................................ 9 H-6 Speed or power of boom is low .............................................................................................................. 10 H-7 Speed or power of arm is low..................................................................................................................11 H-8 Speed or power of bucket is low ............................................................................................................ 12 H-9 Work equipment does not move in its single operation.......................................................................... 13 H-10 Hydraulic drift of work equipment is large ............................................................................................ 14 H-11 Time lag of work equipment is large..................................................................................................... 15 H-12 Work equipment loaded more is slower during compound operation .................................................. 15
PC138US, USLC-8
SEN02468-01
40 Troubleshooting
H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE....................................... 15 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel ............... 16 H-15 Machine deviates during travel............................................................................................................. 17 H-16 Travel speed is low............................................................................................................................... 18 H-17 Machine cannot be steered easily or steering power is low ................................................................. 19 H-18 Travel speed does not change or it is kept low or high ........................................................................ 20 H-19 Track does not move (Only either side)................................................................................................ 20 H-20 Machine does not swing....................................................................................................................... 21 H-21 Swing acceleration or swing speed is low ............................................................................................ 22 H-22 Excessive overrun when stopping swing.............................................................................................. 23 H-23 When upper structure stops swinging, it makes large shock ............................................................... 24 H-24 When upper structure stops swinging, it makes large sound ............................................................... 24 H-25 Hydraulic drift of swing is large............................................................................................................. 25 H-26 Flow rate in attachment circuit cannot be adjusted .............................................................................. 26
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
Information contained in troubleshooting table

a
Troubleshooting table collectively carry the following information. Carry out troubleshooting work after fully grasping their contents.
Trouble Related information Phenomena occurring on machine Information on occurred failures and troubleshooting
Cause 1
2 Possible causes and standard value in normal state Cause for presumed failure (The attached No. for 3 filing and reference purpose only. It does not stand for any priority) 4 <Contents> The standard values in normalcy by which to judge "good" or "no good" about presumed causes. References for making judgement of "good" or "no good"
PC138US, USLC-8
SEN02468-01
40 Troubleshooting
System chart for hydraulic and mechanical systems
PC138US, USLC-8
40 Troubleshooting
a
SEN02468-01
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.
PC138US, USLC-8
SEN02468-01
40 Troubleshooting
H-1 Speed or power of all work equipment, swing, and travel are low
Trouble Related information Speed or power of all work equipment, swing, and travel are low. Conduct the troubleshooting in working mode P. Cause a 1 Malfunction of unload valve Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers All levers in NEUTRAL Unload pressure 2.8 1.0 MPa {28 10 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control lever Main relief pressure 34.8 {355
+2.0 1.0 MPa +20 2 10 kg/cm }
Defective adjustment or operation of main relief valve
Arm relieved in IN direction
If the oil pressure cannot be set normally by adjustment, the main relief valve may be malfunction or may have an internal defect. Check the main relief valve directly. a 3 Malfunction of self-pressure reducing valve Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers All levers in NEUTRAL Possible causes and standard value in normal state 4 Defective adjustment or operation of PC valve a Control circuit basic pressure 3.2 0.5 MPa {33 5 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Measured oil pressure Pump discharge pressure PC valve output pressure Measurement conditions Swing lock: ON Arm: Relieved in IN direction Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the PC valve may be malfunction or may have an internal defect. Check the PC valve directly. Measured oil pressure Defective adjustment or 5 operation of LS valve Pump discharge pressure LS valve output pressure Oil pressure ratio All levers in NEUTRAL Almost same pressure Bucket curled (Lever at stroke end) 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the LS valve may be malfunction or may have an internal defect. Check the LS valve directly. 6 Malfunction of servo piston 7 Piston pump defective The servo piston may have malfunction. Check it directly. If there is none of the causes listed above, the piston pump may have problems of lowering of performance, malfunction, internal defect, etc.
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-2 Engine speed sharply drops or engine stalls

Trouble Related information Engine speed sharply drops or the engine stalls. Conduct the troubleshooting in working mode P. Cause a Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control lever Main relief pressure 34.8 {355
+2.0 1.0 MPa +20 2 10 kg/cm }
Defective adjustment or operation of main relief valve
Arm relieved in IN direction
If the oil pressure cannot be set normally by adjustment, the main relief valve may be malfunction or may have an internal defect. Check the main relief valve directly. a Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Measured oil pressure Possible causes and standard value in normal state 2 Defective adjustment or operation of PC valve Pump discharge pressure PC valve output pressure Measurement conditions Swing lock: ON Arm: Relieved in IN direction Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the PC valve may be malfunction or may have an internal defect. Check the PC valve directly. Measured oil pressure Defective adjustment or 3 operation of LS valve Pump discharge pressure LS valve output pressure Oil pressure ratio All levers in NEUTRAL Almost same pressure Bucket curled (Lever at stroke end) 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the LS valve may be malfunction or may have an internal defect. Check the LS valve directly. 4 Orifice or filter in servo equipment clogged The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself. The servo piston may have malfunction. Check it directly.
5 Malfunction of servo piston
PC138US, USLC-8
SEN02468-01
40 Troubleshooting
H-3 No work equipment, travel and swing move

Trouble Related information No work equipment, travel and swing move. Set the working mode at P mode for the troubleshooting. Cause a Malfunction of PPC lock solenoid valve Standard value in normal state/Remarks on troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idle. Work equipment lock lever Locked Released Solenoid output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
a 2 Malfunction of self reducing pressure valve
Stop engine for preparations. Start troubleshooting at engine high idle. Control lever All control levers in NEUTRAL position Control circuit source pressure 3.2 0.5 MPa {33 5 kg/cm2}
3 Piston pump defective
The piston pump is suspected of malfunction or an internal failure. Diagnose it in the following manner. Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal condition. It is presumed that the pump shaft does not rotate due to some internal failure of the dumper. Check the damper itself.
4 Damper defective
H-4 Abnormal noise is heard from around hydraulic pump

Trouble Related information An abnormal noise is heard from around the hydraulic pump. Cause 1 Hydraulic oil level lowered 2 Quality of hydraulic oil bad Possible causes and standard value in normal state 3 Hydraulic tank cap breather clogged Hydraulic tank strainer clogged Standard value in normal state/Remarks on troubleshooting Make a visual check. Air may have get mixed with the oil. Make a visual check.
It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside the tank. Make a visual check. It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction circuit. Make a visual check. The piston pump is suspected of an internal failure. Check the pump itself.
5 Piston pump defective
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-5 Fine control mode does not function

Trouble Related information Fine control mode does not function. Set the working mode at P mode for the troubleshooting. Cause 1 Orifice in LS circuit clogged Standard value in normal state/Remarks on troubleshooting
The orifice in the LS circuit is presumed to be clogged. Check the orifice itself. a Stop engine for preparations. Start troubleshooting at engine high idle. Oil pressure ratio At bucket CURL (Control lever full stroke) 1 Approx. 0.6 (Approx. 3/5)
Oil pressure to be measured 2 Defective adjustment or malfunction of LS valve Pump delivery pressure LS valve output pressure
All control levers in NEUTRAL Nearly equal oil pressure
If the oil pressure does not return to normalcy even after the adjustment, malfunction of the LS valve or its internal failure is suspected. In that case, check the valve itself. 3 Malfunction of servo piston Malfunction of the servo piston is suspected. Check the piston itself.
PC138US, USLC-8
SEN02468-01
40 Troubleshooting
H-6 Speed or power of boom is low

Trouble Related information Speed or power of boom is low. Conduct the troubleshooting in working mode P. Cause a Malfunction of right PPC valve (boom circuit) Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
Right work equipment control lever NEUTRAL Boom RAISE position Boom LOWER position a
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers All levers in NEUTRAL Position for travel only (On either or both sides) Solenoid output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
Malfunction of pump mergedivider solenoid valve
3 Possible causes and standard value in normal state 4
Malfunction of pump merge- The pump merge-divider valve of the control valve may have a divider valve malfunction. Check it directly. Malfunction of boom control valve (spool) The spool of the boom control valve may have a malfunction. Check it directly (Including stroke limiting mechanism on RAISE side). The pressure compensation valve of the boom control valve may have a malfunction. Check it directly. The lock valve of the boom control valve may have a malfunction. Check it directly.
Malfunction of boom control 5 valve (pressure compensation valve) 6 Malfunction of boom control valve (lock valve)
Malfunction or defective The safety-suction valve of the boom control valve (on the head 7 sealing of boom control valve side) may have a malfunction or its sealing may be defective. (safety-suction valve) Check it directly. Malfunction or defective The suction valve of the boom control valve (on the bottom side) 8 sealing of boom control valve may have a malfunction or its sealing may be defective. Check it (suction valve) directly. Malfunction or defective The centralized safety-suction valve of the control valve may have 9 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 10 Boom cylinder defective Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Boom cylinder Relieved in RAISE direction Leakage from cylinder 15 cc/min
10
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-7 Speed or power of arm is low

Trouble Related information Speed or power of arm is low. Conduct the troubleshooting in working mode P. Cause a Malfunction of left PPC valve (arm circuit) Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever NEUTRAL Arm IN position Arm OUT position PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
a 2 Malfunction of pump mergedivider solenoid valve
3 4
Malfunction of pump merge- The pump merge-divider valve of the control valve may have a divider valve malfunction. Check it directly. Malfunction of arm control valve (spool) The spool of the arm control valve may have a malfunction. Check it directly (Including stroke limiting mechanisms on IN side and OUT side). The pressure compensation valve of the arm control valve may have a malfunction. Check it directly. The safety-suction valves of the arm control valve (on the bottom side and head side) may have a malfunction or their sealing may be defective. Check them directly.
Malfunction of arm control 5 valve (pressure compensation valve) Malfunction or defective 6 sealing of arm control valve (safety-suction valves)
Malfunction or defective The centralized safety-suction valve of the control valve may have 7 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 8 Arm cylinder defective Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Arm cylinder Relieved in IN direction Leakage from cylinder 15 cc/min
PC138US, USLC-8
11
SEN02468-01
40 Troubleshooting
H-8 Speed or power of bucket is low

Trouble Related information Speed or power of bucket is low. Conduct the troubleshooting in working mode P. Cause a Malfunction of right PPC valve (bucket circuit) Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
Right work equipment control lever NEUTRAL Bucket CURL position Bucket DUMP position a
Malfunction of pump mergedivider solenoid valve
3 4
Malfunction of pump merge- The pump merge-divider valve of the control valve may have a divider valve malfunction. Check it directly. Malfunction of bucket control The spool of the bucket control valve may have a malfunction. valve (spool) Check it directly.
Malfunction of bucket control The pressure compensation valve of the bucket control valve may 5 valve (pressure compensahave a malfunction. Check it directly. tion valve) Malfunction or defective The safety-suction valves of the bucket control valve (on the bot6 sealing of bucket control tom side and head side) may have a malfunction or their sealing valve (safety-suction valves) may be defective. Check them directly. Malfunction or defective The centralized safety-suction valve of the control valve may have 7 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 8 Bucket cylinder defective Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Bucket cylinder Relieved in CURL direction Leakage from cylinder 15 cc/min
12
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-9 Work equipment does not move in its single operation
Trouble
(1) The boom does not move when operated independently. Work equipment does not move in its sin- (2) The arm does not move when operated indepengle operation dently. (3) The bucket does not move when operated independently. Set the working mode at P mode for the troubleshooting. Cause a Standard value in normal state/Remarks on troubleshooting Stop engine for preparations. Start troubleshooting at engine high idle. PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2} NEUTRAL Operation 2 Malfunction of work equipment control valve (spool)
Related information
1 Malfunction of PPC valve
Work equipment control lever
The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
PC138US, USLC-8
13
SEN02468-01
40 Troubleshooting
H-10 Hydraulic drift of work equipment is large

Trouble Related information Hydraulic drift of work equipment is large. Conduct the troubleshooting in working mode P. Cause a Possible causes and standard value in normal state 1 Boom cylinder defective Standard value in normal state/Remarks on troubleshooting (1) Hydraulic drift of boom is large.
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Boom cylinder Relieved in RAISE direction Leakage from cylinder 15 cc/min
2 3
Defective sealing of boom control valve (lock valve) Defective sealing of centralized safety-suction valve
Sealing of the lock valve of the boom control valve may be defective. Check it directly. Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly. (2) Hydraulic drift of arm is large.
Hydraulic drift of work equipment is large. Conduct the troubleshooting in working mode P. Cause a 1 Arm cylinder defective
Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Arm cylinder Relieved in IN direction Leakage from cylinder 15 cc/min
Defective sealing of arm con- Sealing of the spool of the arm control valve may be defective. 2 trol valve (spool) Check it directly. 3 4 Defective sealing of arm con- Sealing of the suction valve of the arm control valve (on the bottom trol valve (suction valve) side) may be defective. Check it directly. Defective sealing of centralized safety-suction valve Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly. (3) Hydraulic drift of bucket is large.
Hydraulic drift of work equipment is large. Conduct the troubleshooting in working mode P. Cause a 1 Bucket cylinder defective
Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Bucket cylinder Relieved in CURL direction Leakage from cylinder 15 cc/min
Defective sealing of bucket 2 control valve (spool) 3 4 Defective sealing of bucket control valve (suction valve) Defective sealing of centralized safety-suction valve
Sealing of the spool of the bucket control valve may be defective. Check it directly. Sealing of the suction valve of the bucket control valve (on the bottom side) may be defective. Check it directly. Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.
14
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-11 Time lag of work equipment is large

Trouble Related information Time lag of work equipment is large. Conduct the troubleshooting in working mode P. Cause Possible causes and standard value in normal state Malfunction of control valve 1 (regeneration valve) [Boom and arm] 2 Malfunction of control valve (suction valve) Standard value in normal state/Remarks on troubleshooting The regeneration valve of the control valve may have a malfunction. Check it directly.
The suction valve of the control valve (on the head side) may have a malfunction. Check it directly.
H-12 Work equipment loaded more is slower during compound operation

Trouble Related information Work equipment loaded more is slower during compound operation. Cause Standard value in normal state/Remarks on troubleshooting The pressure compensation valve of the work equipment loaded less may have a malfunction. Check it directly. Compound operation Possible causes and standard value in normal state Boom RAISE + Arm IN Malfunction of pressure com1 pensation valve of work equipment loaded less Boom RAISE + Arm OUT Boom RAISE + Bucket CURL Arm IN + Bucket CURL Boom LOWER + Arm OUT More loaded side Boom Arm Boom Arm Arm Less loaded side Arm Boom Bucket Bucket Boom
H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE
Trouble Related information Possible causes and standard value in normal state Boom RAISE speed is low in compound operation of swing + boom RAISE.
If the speed of single operation of the boom RAISE speed is slow, conduct troubleshooting for H-7 first. Cause 1 Malfunction or defective sealing of LS selector valve Standard value in normal state/Remarks on troubleshooting The LS selector valve of the control valve may have a malfunction or its sealing may be defective. Check it directly.
PC138US, USLC-8
15
SEN02468-01
40 Troubleshooting
H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel 1
Trouble Related information Travel speed lowers largely during compound operation of work equipment/swing + travel. Conduct the troubleshooting in working mode P. Cause a 1 Malfunction of pump mergedivider solenoid valve Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers All levers in NEUTRAL Position for travel only (On either or both sides) Possible causes and standard value in normal state 2 Solenoid output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly.
Malfunction of work equipThe pressure compensation valve of the work equipment control 3 ment control valve (pressure valve may have a malfunction. Check it directly. compensation valve) Malfunction of swing control 4 valve (pressure compensation valve) Malfunction of travel control 5 valve (pressure compensation valve) The pressure compensation valve of the swing control valve may have a malfunction. Check it directly. The pressure compensation valve of the travel control valve may have a malfunction. Check it directly.
16
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-15 Machine deviates during travel

Trouble Related information Machine deviates during travel. Conduct the troubleshooting in working mode P. Cause a 1 Malfunction of self-pressure reducing valve Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers All levers in NEUTRAL Control circuit basic pressure 3.2 0.5 MPa {33 5 kg/cm2}
a Malfunction of travel PPC valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever Forward or reverse position Difference in above output between both sides PPC valve output pressure Above 2.7 MPa {Above 28 kg/cm2} Below 0.4 MPa {Below 4 kg/cm2}
a 3 Malfunction of pump mergedivider valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever All levers in NEUTRAL Position for travel only (On either or both sides) Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
a Possible causes and standard value in normal state 4 Malfunction of travel junction solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever All levers in NEUTRAL Position for travel only on either side Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
a 5 Malfunction of unload valve
6 7 8
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly. Malfunction of travel junction The travel junction valve may have a malfunction. Check it directly. valve Malfunction of travel control lever (spool) The spool of the travel control lever may have a malfunction. Check it directly. a Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever Travel circuit relieved Leakage from travel motor 1.65 l/min
9 Travel motor defective
10 Final drive defective Defective adjustment of 11 travel deviation adjustment plug
The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.) Adjust travel deviation adjustment plug. For details, see Testing and adjusting, "Testing and adjusting travel deviation".
PC138US, USLC-8
17
SEN02468-01
40 Troubleshooting
H-16 Travel speed is low

Trouble Related information Travel speed is low. Conduct the troubleshooting in working mode P. Cause a 1 Malfunction of self-pressure reducing valve Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers All levers in NEUTRAL Control circuit basic pressure 3.2 0.5 MPa {33 5 kg/cm2}
a Malfunction of travel PPC valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever Forward or reverse position Difference in above output between both sides PPC valve output pressure Above 2.7 MPa {Above 28 kg/cm2} Below 0.4 MPa {Below 4 kg/cm2}
a 3 Possible causes and standard value in normal state Malfunction of pump mergedivider valve
a 4 Malfunction of unload valve
5 6
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly. Malfunction of travel control lever (spool) The spool of the travel control lever may have a malfunction. Check it directly. The pressure compensation valve of the travel control lever may have a malfunction. Check it directly. The suction valve of the travel control lever may have a malfunction. Check it directly. a Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever Travel circuit relieved Leakage from travel motor 1.65 l/min
Malfunction of travel control 7 lever (pressure compensation valve) 8 Malfunction of travel control lever (suction valve)
9 Travel motor defective
10 Final drive defective
The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
18
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-17 Machine cannot be steered easily or steering power is low

Trouble Related information Machine cannot be steered easily or steering power is low. Conduct the troubleshooting in working mode P. Cause a 1 Malfunction of travel PPC valve Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever In NEUTRAL on both sides Operated on either side PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
a 2 Malfunction of pump mergedivider valve
a 3 Possible causes and standard value in normal state Malfunction of travel junction solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever All levers in NEUTRAL Position for travel only on either side Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
4 5 6 7 8
Malfunction of hydraulic pump (check valve) Malfunction of hydraulic pump (shuttle valve)
The check valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly. The shuttle valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly.
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly. Malfunction of travel junction The travel junction valve may have a malfunction. Check it directly. valve Malfunction of travel control lever (spool) The spool of the travel control lever may have a malfunction. Check it directly. The pressure compensation valve of the travel control lever may have a malfunction. Check it directly. The suction valve of the travel control lever may have a malfunction. Check it directly. The safety and check valve of the travel motor may have a malfunction. Check it directly. (It may be checked by exchanging the front and rear motors or the right and left motors and checking change of the phenomenon.)
Malfunction of travel control 9 lever (pressure compensation valve) 10 Malfunction of travel control lever (suction valve)
Malfunction of travel motor 11 (safety and check valve)
PC138US, USLC-8
19
SEN02468-01
40 Troubleshooting
H-18 Travel speed does not change or it is kept low or high

Trouble Related information Travel speed does not change or it is kept low or high. Conduct the troubleshooting in working mode P. Cause a Possible causes and standard value in normal state Malfunction of travel speed selector solenoid valve Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel speed Lo Hi Travel lever In NEUTRAL Operated Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
Malfunction of travel motor (speed-changer unit)
The speed-changer unit of the travel motor may have a malfunction. Check it directly.
H-19 Track does not move (Only either side)

Trouble Related information Track does not move (only either side). Conduct the troubleshooting in working mode P. Cause 1 Standard value in normal state/Remarks on troubleshooting
Defective seat of travel con- The suction valve seat of the travel control lever may be defective. trol valve (suction valve) Check it directly.
Defective seat of travel conThe safety and check valve seat of the travel control lever may be 2 trol valve (safety and check defective. Check it directly. valve) 3 Malfunction of travel motor (counterbalance valve) The counterbalance valve of the travel motor may have a malfunction. Check it directly. a 4 Travel motor defective Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever Travel circuit relieved 5 Final drive defective Leakage from travel motor 1.65 l/min
The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
20
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-20 Machine does not swing

Trouble Related information Machine does not swing. (1) Machine does not swing in either direction. Conduct the troubleshooting in working mode P. Cause a Malfunction of swing holding brake solenoid valve Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
Right work equipment control lever In NEUTRAL Operated for swing
Malfunction of swing motor (holding brake)
The holding brake of the swing motor may have a malfunction. Check it directly. a Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever Swing circuit relieved Leakage from swing motor Below 6 l/min
3 Swing motor defective
4 Swing machinery defective
The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
Machine does not swing.
(2) Machine does not swing in only one direction.
Conduct the troubleshooting in working mode P. Cause a Malfunction of swing PPC valve Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever In NEUTRAL Operated for swing PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
Malfunction of swing control valve (spool)
The spool of the swing control valve may have a malfunction. Check it directly. a Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment Swing relief pressure control lever (Pump pressure) Swing circuits relieved (separately on both sides) 29.2 1.5 MPa {298 15 kg/cm2}
Defective adjustment or mal3 function of swing motor (safety valve)
Swing lock switch ON
Defective sealing of swing motor (suction valve)
Sealing of the suction valve of the swing motor may be defective. Check it directly.
PC138US, USLC-8
21
SEN02468-01
40 Troubleshooting
H-21 Swing acceleration or swing speed is low

Trouble Related information Swing acceleration or swing speed is low. (1) Swing acceleration or swing speed is low in both directions.
Conduct the troubleshooting in working mode P. Cause Malfunction of swing control 1 valve (pressure compensation valve) Standard value in normal state/Remarks on troubleshooting The pressure compensation valve of the swing control valve may have a malfunction. Check it directly. The holding brake of the swing motor may have a malfunction. Check it directly. a 3 Swing motor defective Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever Swing circuit relieved 4 Swing machinery defective Leakage from swing motor Below 6 l/min
Malfunction of swing motor (holding brake)
The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
Swing acceleration or swing speed is low.
(2) Swing acceleration or swing speed is low in only one direction.
Conduct the troubleshooting in working mode P. Cause a Malfunction of swing PPC valve Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever In NEUTRAL Operated for swing PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
Malfunction of swing control valve (spool)
The spool of the swing control valve may have a malfunction. Check it directly. a Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment Swing relief pressure control lever (Pump pressure) Swing circuits relieved (separately on both sides) 29.2 1.5 MPa {298 15 kg/cm2}
4 5
Defective sealing of swing motor (suction valve) Malfunction of swing motor (reverse prevention valve)
Sealing of the suction valve of the swing motor may be defective. Check it directly. Sealing of the reverse prevention valve of the swing motor may be defective. Check it directly.
22
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-22 Excessive overrun when stopping swing

Trouble Related information Excessive overrun when stopping swing. (1) Overrun of upper structure is large in both directions.
Conduct the troubleshooting in working mode P. Cause Standard value in normal state/Remarks on troubleshooting a 1 Swing motor defective Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever Swing circuit relieved Leakage from swing motor Below 6 l/min
Excessive overrun when stopping swing.
(2) Overrun of upper structure is large in only one direction.
Conduct the troubleshooting in working mode P. Cause a Malfunction of swing PPC valve Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever In NEUTRAL Operated for swing 2 PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
The swing PPC slow return valves may be clogged. Check them Clogging of swing PPC slow directly. (They may be checked by exchanging with each other return valves and checking change of the phenomenon.) Malfunction of swing control valve (spool) The spool of the swing control valve may have a malfunction. Check it directly. a Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment Swing relief pressure control lever (Pump pressure) Swing circuits relieved (separately on both sides) 29.2 1.5 MPa {298 15 kg/cm2}
5 6
Defective sealing of swing motor (suction valve) Malfunction of swing motor (reverse prevention valve)
Sealing of the suction valve of the swing motor may be defective. Check it directly. Sealing of the reverse prevention valve of the swing motor may be defective. Check it directly.
PC138US, USLC-8
23
SEN02468-01
40 Troubleshooting
H-23 When upper structure stops swinging, it makes large shock

Trouble Related information When upper structure stops swinging, it makes large shock. Conduct the troubleshooting in working mode P. Cause a Malfunction of swing PPC valve Standard value in normal state/Remarks on troubleshooting
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever In NEUTRAL Operated for swing PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
2 3
Malfunction of swing PPC slow return valves Malfunction of swing motor (safety valve)
The swing PPC slow return valves may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.) The safety valve of the swing motor may have malfunction. Check it directly.
H-24 When upper structure stops swinging, it makes large sound

Trouble Related information When upper structure stops swinging, it makes large sound. Conduct the troubleshooting in working mode P. Cause 1 Possible causes and standard value in normal state 2 3 Malfunction of back pressure check valve Malfunction of swing motor (safety valve) Malfunction of swing motor (suction valves) Standard value in normal state/Remarks on troubleshooting
The back pressure check valve may have a malfunction. Check it directly. The swing motor (safety valves) may have a malfunction. Check the valves directly. The swing motor (suction valves) may have a malfunction. Check the valves directly. (They may be checked by exchanging with each other and checking change of the phenomenon.) The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
4 Swing machinery defective
24
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
H-25 Hydraulic drift of swing is large

Trouble Related information Hydraulic drift of swing is large. (1) When swing holding brake is operated
If the swing lock switch is turned ON or the swing holding brake release switch is in the normal position, the swing holding brake operates and the disc brake holds the upper structure. Conduct the troubleshooting in working mode P. Cause a Standard value in normal state/Remarks on troubleshooting Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 3.43 MPa {29 35 kg/cm2}
Malfunction of swing holding brake solenoid valve
Right work equipment control lever In NEUTRAL Operated for swing
Malfunction or internal defect The holding brake of the swing motor may have a malfunction or 2 of swing motor (holding an internal defect. Check it directly. brake)
Hydraulic drift of swing is large.
(2) When swing holding brake is released
If the swing holding brake release is in the emergency position, the swing holding brake is released and the upper structure is held with only hydraulic pressure. Conduct the troubleshooting in working mode P. Cause 1 Defective sealing of swing control valve (spool) Defective sealing of swing motor (safety valve) Defective sealing of swing motor (suction valve) Standard value in normal state/Remarks on troubleshooting Sealing of the spool of the swing control valve may have a malfunction. Check it directly. The safety valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.) The suction valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.) The reverse prevention valve of the swing motor may have a malfunction or its sealing may be defective. Check it directly.
Malfunction or defective 4 sealing of swing motor (reverse prevention valve)
PC138US, USLC-8
25
SEN02468-01
40 Troubleshooting
H-26 Flow rate in attachment circuit cannot be adjusted

When attachment is installed
Trouble Related information Flow rate in attachment circuit cannot be adjusted. If an attachment is installed, the flow rate in the service circuit changes according to the selected working mode. How to adjust the flow rate in modes B and ATT is different from that in mode B. For details, see Operation manual. Cause Malfunction of attachment 1 flow rate adjustment EPC valve Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly. a
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Wiring harness connector Service pedal In NEUTRAL Operated PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.7 MPa {Above 28 kg/cm2}
Malfunction of service PPC 2 valve
Disconnect connector V30 of attachment flow rate adjustment EPC valve.
26
PC138US, USLC-8
40 Troubleshooting
SEN02468-01
PC138US, USLC-8
27
SEN02468-01
40 Troubleshooting
28
PC138US, USLC-8
SEN02469-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
40 Troubleshooting
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 4 S-1 Starting performance is poor .................................................................................................................... 8 S-2 Engine does not start ............................................................................................................................... 9 S-3 Engine does not pick up smoothly.......................................................................................................... 12 S-4 Engine stops during operations .............................................................................................................. 13 S-5 Engine does not rotate smoothly ............................................................................................................ 14 S-6 Engine lacks output (or lacks power) ..................................................................................................... 15 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17 S-9 Oil becomes contaminated quickly ......................................................................................................... 18 S-10 Fuel consumption is excessive............................................................................................................. 19 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20 S-12 Oil pressure drops ................................................................................................................................ 21 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 23
PC138US, USLC-8
SEN02469-01
40 Troubleshooting
S-15 Abnormal noise is made ....................................................................................................................... 24 S-16 Vibration is excessive ........................................................................................................................... 25
PC138US, USLC-8
40 Troubleshooting
SEN02469-01
PC138US, USLC-8
SEN02469-01
40 Troubleshooting
Method of using troubleshooting chart
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. Questions Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. Check items Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the right. Causes Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. Troubleshooting Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w. E : Causes to be referred to for questions and check items Q : Causes related to questions and check items w : Causes highly probable among ones marked with Q a When narrowing the "causes", apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
PC138US, USLC-8
40 Troubleshooting
SEN02469-01
PC138US, USLC-8
SEN02469-01
40 Troubleshooting
<Example of troubleshooting> Exhaust gas is black Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].
PC138US, USLC-8
40 Troubleshooting
SEN02469-01
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in the [Causes] section. The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is explained according to Step 1 Step 3 shown below.
PC138US, USLC-8
SEN02469-01
40 Troubleshooting
S-1 Starting performance is poor

Leaking or clogged fuel piping, entry of air Clogged air breather hole of fuel tank cap Defective contact of valve and valve seat Defective alternator (generator section)
q
1
Causes Defective alternator (regulator section)
q q
Stuck, seized supply pump plunger
Defective intake air heater system
Confirm recent repair history Degree of use of machine Operated for long period Starting performance Questions Became worse gradually Engine starts easily when warm
Q Q Q w w w w w w w w w Q w w w w Q Q Q w Q w q q q q q q q q w Q w Q Q E Q w w E Q w w E
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally During operation, charge level monitor indicates abnormal charge Dust indicator is red Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly While engine is cranked with starting motor, If air bleeding plug of fuel filter is removed, fuel does not flow out If spill hose from injector is disconnected, little fuel spills
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner directly When compression pressure is measured, it is found to be low When air is bled from fuel system, air comes out Inspect fuel filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 30 V between alternator terminal B and terminal E with engine at low idle? Yes No Replace Replace Replace Replace Replace
Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, they are low Replace Replace Replace Replace Clean Remedy Clean
*1: Displayed failure codes [CA559] and [CA2249]
PC138US, USLC-8
Replace
Defective or deteriorated battery
Clogged air cleaner element
Worn piston ring, cylinder
Clogged fuel filter
Defective injector
General causes why starting performance is poor q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.
40 Troubleshooting
SEN02469-01
S-2 Engine does not start

Defective connection of battery terminal Defective starting motor (motor section)
w w Q q Q Q q q
1
Causes
Defective or deteriorated battery
Questions
Confirm recent repair history Degree of use of machine Condition of horn when starting switch is turned ON Battery electrolyte is low Battery terminal is loose When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out
Q Q w w
Operated for long period Horn does not sound Horn volume is low
E E Q w w w w Q w Q w
Check items
Speed of rotation is low When starting switch is turned to START, starting pinion moves out, but Makes grating noise Soon disengages again Makes rattling noise and does not turn Inspect flywheel ring gear directly When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 30 V) between battery relay terminal B and terminal E When terminal B and terminal C of starting switch are connected, engine starts Turn starting switch OFF, connect cord, and carry out troubleshooting at ON When terminal B and terminal C at safety relay outlet are connected, engine starts Even if terminal B and terminal C at safety relay outlet are connected, engine does not start When terminal at safety switch and terminal B at starting motor are connected, engine starts Replace
Troubleshooting
q q q
Replace
Replace
Replace
Replace
Remedy
Replace
Correct
PC138US, USLC-8
Carry out troubleshooting on E-mode
Defective steering circuit wiring
a) Engine does not turn General causes why engine does not turn q Seized parts inside engine o See S-4 Engine stops during operations q Defective electrical system
Broken flywheel ring gear
Defective starting switch
Defective battery relay
Defective safety relay
SEN02469-01
40 Troubleshooting
Defective operation of overflow valve (Does not close)

q
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Defective common rail pressure limiter

q
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)
Causes
Seized, abnormally worn feed pump
Defective supply pump MPROP
Broken supply pump shaft
Insufficient fuel in tank
Confirm recent repair history Degree of use of machine Questions Operated for long period
w w w w w Q E w w w w Q Q Q Q q q q q q q w Q w w w Q E E E Q E E w Q w w E
Exhaust smoke suddenly stopped coming out (when starting again) Fuel other than specified one is used Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed, there is not fuel in it
Check items
Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills When air is bled from fuel system, air comes out Inspect fuel filter directly Inspect feed pump directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code Carry out troubleshooting according to Abnormality in supply pump IMV (*2) indicated by code Inspect overflow valve directly Engine can be started in reduced cylinder mode Fuel flows out when pressure limiter return piping is disconnected Replace
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA271] and [CA272]
10
PC138US, USLC-8
Replace
Correct
Clean
Add
Defective fuel injector

q
Use of improper fuel
Clogged fuel filter
40 Troubleshooting
SEN02469-01
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

Q q
Leaking or clogged fuel system, entry of air
Confirm recent repair history Degree of use of machine Questions Suddenly failed to start Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally Dust indicator is red Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed, there is not fuel in it Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly When engine is cranked, abnormal sound is generated around cylinder head Check items If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Inspect air cleaner directly Inspect dynamic valve system directly When compression pressure is measured, it is found to be low Troubleshooting When air is bled from fuel system, air comes out Inspect fuel filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code Engine can be started in reduced cylinder mode When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally When starting switch is turned to HEAT, intake air heater mount does not become warm Replace Replace Replace Replace Replace Replace Replace Replace Remedy Correct Clean Clean
q q q q q q q q q w Q w w w w w w Q w w Q w w w w w
Operated for long period

w
E w
E Q Q
*1: Displayed failure codes [CA559] and [CA2249] PC138US, USLC-8
11
Replace
Defective intake air heater system
Clogged injector, defective spray
Defective, deteriorated battery
c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel
Causes
Clogging of fuel filter
Use of improper fuel
SEN02469-01
40 Troubleshooting
S-3 Engine does not pick up smoothly

Seized turbocharger, interference of turbocharger
1
Causes
Defective contact of valve and valve seat

q
Confirm recent repair history Degree of use of machine Questions Operated for long period
E E w E Q Q E Q w w w w w w w w w w Q Q w w w Q w w Q Q w q q q q q q q w Q Q w w w
Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Oil must be added more frequently Dust indicator is red Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Color of exhaust gas is
Blue under light load Black
When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, interference sound is generated around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner directly When compression pressure is measured, it is found to be low
Troubleshooting
Inspect valve clearance directly When turbocharger is rotated by hand, it is found to be heavy When air is bled from fuel system, air comes out Inspect fuel filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
Replace
Replace
Replace
Remedy
12
PC138US, USLC-8
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clogged injector, defective spray

q
General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
Improper valve clearance
40 Troubleshooting
SEN02469-01
S-4 Engine stops during operations

Broken dynamic valve system (valve, rocker arm, etc.) Broken auxiliary equipment (pump, compressor, etc.)
1
Causes
Defective engine controller power supply wiring

q
Broken, seized piston, connecting rod
Broken, seized crankshaft bearing
Clogging feed pump gauze filter
Confirm recent repair history Degree of use of machine Operated for long period Abnormal noise was heard and engine stopped suddenly Questions Condition when engine stopped Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Fuel level monitor indicates low level When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Rust and water are found when fuel tank is drained Check items Metal particles are found when oil pan is drained Does not turn at all When engine is cranked by hand Turns in opposite direction Moves by amount of gear backlash Supply pump shaft does not turn Engine turns, but stops when load is applied to machine Inspect dynamic valve system directly Inspect piston, connecting rod directly Inspect crankshaft bearing directly Inspect gear train directly Troubleshooting Inspect fuel filter directly Inspect feed pump gauge filter directly Inspect feed pump directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Check controller power supply wiring Check starting switch wiring Replace Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Clean Remedy Clean Add
q q q q q q q q q w w w w w w w w w w w w w w w Q Q w w w w w Q w w Q Q Q Q Q Q Q Q Q w w Q E E Q w Q w Q Q Q Q Q w
Carry out troubleshooting on applicable machine

q
PC138US, USLC-8
13
Correct
Defective starting switch wiring
Leaking, clogged fuel piping
General causes why engine stops during operations q Internal parts of engine seized q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine
Broken, seized feed pump
Broken supply pump shaft
Defective hydraulic pump
Broken, seized gear train
SEN02469-01
40 Troubleshooting
S-5 Engine does not rotate smoothly

Clogged injector, defective spray (dirt in injector)
q q
1
Causes Defective Bkup speed sensor, wiring harness
q
Confirm recent repair history Degree of use of machine Questions Operated for long period Occurs at a certain speed range Hunting Occurs at low idle Occurs even when speed is raised Occurs on slopes Replacement of filters has not been carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Check items Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When air is bled from fuel system, air comes out Inspect fuel filter directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to Abnormality in Ne speed sensor (*1) indicated by code Carry out troubleshooting according to Abnormality in Bkup speed sensor (*2) indicated by code Replace Replace Replace Replace Remedy Clean Add
w w Q q q w w Q w w Q E Q Q Q Q Q Q Q Q Q
Troubleshooting
Defective Ne speed sensor, wiring harness
General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)
*1: Displayed failure code [CA689] *2: Displayed failure code [CA778]
14
PC138US, USLC-8
Replace
40 Troubleshooting
SEN02469-01
S-6 Engine lacks output (or lacks power)

Seized turbocharger, interference of turbocharger Air leakage from air intake piping and aftercooler Clogged injector, defective spray (dirt in injector) Defective boost pressure sensor, wiring harness
q
1
Causes Defective installation of boost pressure sensor (air leakage)
Defective drive of injector (signal, solenoid)
Leaking, clogged fuel piping
Confirm recent repair history Degree of use of machine Questions Power was lost Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Oil must be added more frequently Dust indicator is red Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Color of exhaust gas is Black Blue under light load
w w w w w w w w Q Q w w w q q q q q q q q q q q q q q q w Q Q Q Q Q w Q Q w Q Q w w w w w Q Q
Operated for long period Suddenly Gradually
E Q w Q
E Q
E Q
E Q Q Q Q Q Q w Q Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items When engine is cranked, interference sound is generated around turbocharger When engine is cranked, abnormal sound is generated around cylinder head High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner directly Inspect air intake piping directly When boost pressure is measured, it is found to be low When compression pressure is measured, it is found to be low Inspect valve clearance directly Troubleshooting Inspect fuel piping Inspect fuel filter directly Inspect spill port check valve directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Inspect charge pressure sensor mount directly Carry out troubleshooting according to Abnormality in charge pressure sensor (*2) indicated by code Replace Replace Replace Replace
Replace
Replace
Replace
Remedy
PC138US, USLC-8
15
Replace
Correct
Correct
Correct
Correct
Adjust
Clean
Clean
Clogged fuel spill piping
General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See S-14 Coolant temperature becomes too high (Overheating) q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
SEN02469-01
40 Troubleshooting
S-7 Exhaust smoke is black (incomplete combustion)

Leakage of air between turbocharger and cylinder head
1
Causes Defective coolant temperature sensor, wiring harness
q q q
Seized turbocharger, interference of turbocharger
Confirm recent repair history Degree of use of machine Color of exhaust gas is Non-specified fuel is being used Oil must be added more frequently Power was lost Dust indicator is red Muffler is crushed Air leaks between turbocharger and cylinder head, clamp is loosened Engine is operated in low-temperature mode at normal temperature When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items When engine is cranked, interference sound is generated around turbocharger When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive If spill hose from injector is disconnected, abnormally much fuel spills Inspect air cleaner directly When turbocharger is rotated by hand, it is fount to be heavy When compression pressure is measured, it is found to be low Troubleshooting Inspect valve clearance directly When muffler is removed, exhaust sound improves Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) indicated by code Confirm with monitoring function Replace Replace Replace Replace Replace Replace Correct Remedy Correct Adjust Clean
q q q q q q q q q Q Q w Q Q Q w w Q Q w w w Q Q w w Q Q Q w w Q w w Q Q Q Q Q Q
Operated for long period Suddenly became black Gradually became black Blue under light load
E w w
E w Q
E Q Q Q Q
Questions
w Q Q
Suddenly Gradually
Replace
Replace
Improper fuel injection pressure
Crushed, clogged muffler
Abnormally worn injector
Improper injection timing
Clogged, seized injector
General causes why exhaust smoke is black q Insufficient intake of air q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See S-14 Coolant temperature becomes too high (Overheating) q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
16
PC138US, USLC-8
Replace
40 Troubleshooting
SEN02469-01
S-8 Oil consumption is excessive (or exhaust smoke is blue)

Worn, damaged valve (stem, guide, seal)
1
Oil leakage from oil pan, cylinder head, etc. Correct
Dust sucked in from intake system
Clogged breather, breather hose
Confirm recent repair history Questions Degree of use of machine Operated for long period
E E E w w Q Q w w w w w w w w Q w w w w w Q Q w q q q q q q q q q q q q q q w w E Q Q
Oil consumption suddenly increased Oil must be added more frequently Oil becomes contaminated quickly Outside of engine is dirty with oil There are loose piping clamps in intake system Inside of turbocharger intake outlet pipe is dirty with oil Inside of turbocharger exhaust outlet pipe is dirty with oil
Check items
There is oil in coolant Oil level in clutch chamber or damper chamber is high Exhaust smoke is blue under light load Amount of blow-by gas Excessive None
When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found to be dirty abnormally Troubleshooting Excessive play of turbocharger shaft Check breather and breather hose directly When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC138US, USLC-8
Correct
Clean
Oil leakage from oil drain plug
Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping
Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter
General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of pats in lubrication system
Causes Turbocharger
Broken piston ring
Broken oil cooler
17
SEN02469-01
40 Troubleshooting
S-9 Oil becomes contaminated quickly

Clogged turbocharger lubrication drain tube
Q w q q q q q q q q
1
Causes Defective seal at turbocharger turbine end
Clogged breather, breather hose
Defective oil filter safety valve Replace
General causes why oil becomes contaminated quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load
Worn valve, valve guide
Questions
Confirm recent repair history Degree of use of machine Operated for long period
E E E Q w Q Q w w w w Q Q w w Q
Non-specified fuel is being used Oil must be added more frequently Metal particles are found when oil filter is drained Inside of exhaust pipe is dirty with oil Engine oil temperature rises quickly Blue under light load Black Excessive None
Check items
Color of exhaust gas is Amount of blow-by gas
Excessive play of turbocharger shaft Troubleshooting When compression pressure is measured, it is found to be low Check breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly
Replace
Replace
Replace
Replace
Replace
Clean
Remedy
Clean
18
PC138US, USLC-8
See S-7
Exhaust smoke is bad
Clogged oil cooler
Clogged oil filter
40 Troubleshooting
SEN02469-01
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive q Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc. Causes
1
Defective coolant temperature sensor, wiring harness
q q q
Defective common rail pressure
Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Q Q q
Defective feed pump oil seal
Defective spray by injector

E Q w w q
Confirm recent repair history Questions Degree of use of machine Condition of fuel consumption Operated for long period More than for other machines of same model Gradually increased Suddenly increased There is external leakage of fuel from engine Combustion is irregular Engine oil level rises and oil smells of diesel fuel Check items When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idle speed is high Torque converter stall speed or pump relief speed is high Color of exhaust gas is Black White
Q q q q Q Q w w Q Q w Q E E Q Q Q Q
Remove head cover and inspect directly Troubleshooting Inspect feed pump oil seal directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) indicated by code When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change If spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) indicated by code Confirm with monitoring function
Replace
Replace
Replace
Replace
Replace
Replace
Improper injection timing
Q Q
Remedy
PC138US, USLC-8
19
Replace
Correct
Correct
SEN02469-01
40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
Broken cylinder head, head gasket
1
Causes
Confirm recent repair history Questions Degree of use of machine Oil level Operated for long period Suddenly rose Gradually rose
Q Q Q Q Q Q Q w w q q q q E E Q
Hard water is being used as coolant Oil level has risen and oil is milky
Check items
There are excessive air bubbles in radiator, coolant spurts back
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage Inspect cylinder block, liner directly Pressure-tightness test of oil cooler shows there is leakage
Replace
Replace
Replace
Remedy
20
PC138US, USLC-8
Replace
Broken oil cooler core, O-ring
General causes why oil is in coolant q Internal leakage in lubrication system q Internal leakage in cooling system
Cracks inside cylinder block
Holes caused by pitting
40 Troubleshooting
SEN02469-01
S-12 Oil pressure drops

Leaking, crushed, clogged hydraulic piping
w w w w q Q
1
Causes Defective oil level sensor, wiring harness
Q w q
Clogged, broken pipe in oil pan
General causes why oil pressure drops q Leakage, clogging, wear or lubrication system q Defective oil pressure control q Improper selection of fuel (improper viscosity) q Deterioration of oil due to overheating
Clogged strainer in oil pan Worn journal of bearing
Defective regulator valve

w q
Lack of oil in oil pan
Defective oil pump

E q
Coolant, fuel in oil
Confirm recent repair history Questions Degree of use of machine Operated for long period
E Q E Q w Q w w Q w w w w w w Q
Oil pressure monitor indicates low oil pressure Non-specified oil is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual Indicates pressure drop at low idle Oil pressure monitor (if installed) Indicates pressure drop at low, high idle Indicates pressure drop on slopes Sometimes indicates pressure drop Oil level monitor indicates oil level drop Oil level in oil pan is low External hydraulic piping is leaking, crushed Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained Metal particles are found when oil filter is drained Metal particles are found in oil filter
Troubleshooting
Check items
Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged Inspect oil filter directly If oil level sensor is replaced, oil level monitor indicates normally Replace
See S-13
Inspect oil pan strainer, pipe directly
q q
Replace
Replace
Replace
Clogged oil filter

q
Remedy
PC138US, USLC-8
21
Replace
Correct
Clean
Clean
Add
SEN02469-01
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)

General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant
Causes
1
Defective seal of auxiliary equipment (pump, compressor)
E w Q w w Q w Q Q Q Q w w q q q q q q q q
Broken oil cooler core, O-ring Replace
Worn, damaged rear oil seal Replace
Cracks inside cylinder block
Questions
Confirm recent repair history Degree of use of machine Operated for long period
Q E w Q Q Q Q E E
Fuel must be added more frequently Coolant must be added more frequently There is oil in coolant Oil smells of diesel fuel Oil is milky When engine is started, drops of water come from muffler
Check items
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w or coolant spurts back Exhaust smoke is white Oil level in damper chamber is low Oil level in hydraulic tank is low When compression pressure is measured, it is found to be low
Troubleshooting
Remove injector and inspect O-ring. Inspect cylinder block, liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly Replace
Replace
Replace
Replace
Replace
Defects in supply pump
Broken injector, O-ring
Remedy
22
PC138US, USLC-8
Replace
40 Troubleshooting
SEN02469-01
S-14 Coolant temperature becomes too high (overheating)

Defective radiator cap (pressure valve) Defective coolant temperature gauge
w w w Q w w w w w w w w w w w q
Defective operation of thermostat
Slipping fan belt, worn fan pulley
Confirm recent repair history Questions Degree of use of machine Condition overheating Coolant temperature gauge Operated for long period Sudden overheated Always tends to overheat Rises quickly Does not go down from red range
Q E E Q w Q w w w E E Q Q
Radiator coolant level monitor indicates drop of coolant level Engine oil level has risen, oil is milky Fan belt tension is low When fan pulley is turned, it has play Milky oil is floating on coolant There are excessive air bubbles in radiator, coolant spurts back Check items When light bulb is held behind radiator core, no light passes through Radiator shroud, inside of underguard side are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps Coolant flows out from radiator overflow hose Fan belt whines under sudden acceleration Hydraulic oil temperature enters red range faster than engine coolant temperature When compression pressure is measured, it is found to be low Inspect cylinder liner directly Inspect oil cooler directly Troubleshooting Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is carried out, it does not open at cracking temperature Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt, pulley directly When coolant temperature is measured, it is found to be normal Replace Replace Replace
q q q
q q q q q q
Replace
Replace
Replace
Remedy
Replace
Correct
Correct
Correct
Add
PC138US, USLC-8
Carry out troubleshooting on H-mode
Rise in hydraulic oil temperature
Clogged, crushed radiator fins
General causes why coolant temperature becomes too high q Lack of cooling air (deformation, damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system
Causes
Clogged, broken oil cooler
Clogged radiator core
Broken water pump
Lack of coolant
23
SEN02469-01
40 Troubleshooting
S-15 Abnormal noise is made

Deformed cooling fan, loose fan belt, interference of fan belt Defective inside of muffler (dividing board out of position)
1
Causes
Leakage of air between turbocharger and cylinder head
Confirm recent repair history Questions Degree of use of machine Condition of abnormal noise Operated for long period Gradually occurred Suddenly occurred
Q Q w w w w w w w Q w Q w Q w Q w q q q q q q q q q q q q Q Q Q w w E Q Q Q Q
Non-specified fuel is being used Oil must be added more frequently Metal particles are found when oil filter is drained Air leaks between turbocharger and cylinder head When engine is cranked, interference sound is generated around turbocharger When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, beat noise is generated around muffler
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is Blue under light load Black
Engine does not pick up smoothly and combustion is irregular Abnormal noise is loud when engine is accelerated Blow-by gas is excessive When turbocharger is rotated by hand, it is found to be heavy Inspect dynamic valve system directly When muffler is removed, abnormal noise disappears Troubleshooting Inspect valve clearance directly When compression pressure is measured, it is found to be low Inspect gear train directly Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Abnormal noise is heard only when engine is started Confirm with monitoring function Replace Replace Replace Replace Replace Replace Replace
Replace
Replace
Remedy
24
PC138US, USLC-8
Replace
Correct
Adjust
Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)
Broken dynamic valve system (valve, rocker lever)
Interference of turbocharger, seized turbocharger
Excessive wear of piston ring, cylinder
Improper gear train backlash
Removed, seized bushing
Clogged, seized injector
Dirt caught in injector
General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 3 seconds. This does not indicate abnormality, however.
40 Troubleshooting
SEN02469-01
S-16 Vibration is excessive

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)
1
Causes
General causes why vibration is excessive q Defective parts (abnormal wear, breakage) q Misalignment between engine and chassis q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.
Stuck dynamic valve system (valve, rocker lever) Worn main bearing, connecting rod bearing
Loose engine mounting bolts, broken cushions

E Q q
Confirm recent repair history Questions Degree of use of machine Condition of vibration Operated for long period Suddenly increased Gradually increased
Q Q Q w w Q Q w q q q q q q Q Q Q w w Q Q Q Q Q E E Q
Non-specified oil is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Check items Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Inspect dynamic valve system directly Troubleshooting Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Confirm with monitoring function Inspect engine mounting bolts and cushions directly Inspect output shaft or inside of damper directly Replace
Replace
Replace
Replace
Replace
Replace
Remedy
PC138US, USLC-8
25
Replace
Broken output shaft, parts in damper
Improper gear train backlash
Worn camshaft bushing
SEN02469-01
40 Troubleshooting
26
PC138US, USLC-8
SEN02709-00
Machine model
Serial number
50 Disassembly and assembly1

General information on disassembly and assembly
How to read this manual ................................................................................................................................. 2 List of adhesives ............................................................................................................................................. 4 Special tool list ................................................................................................................................................ 7 Sketche of special tool ...................................................................................................................................11
PC138US, USLC-8
SEN02709-00
50 Disassembly and assembly
How to read this manual
1
Removal The "Removal" section contains procedures and precautions for implementing the work, know how and the amount of oil or coolant to be drained. q Various symbols used in the "Removal" section are explained and listed below. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. [*1] : This mark shows that there are instructions or precautions for installing parts. 6 : This mark shows the amount of oil or coolant to be drained. 4 : Weight of part or component
q
1. Removal and installation of assemblies

Special tools q Special tools which are deemed necessary for removal or installation of parts are described as A1 ,X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts ).
* *** ****
Installation q Except where otherwise instructed, installation of parts is done in the reverse order of removal. q Instructions and precautions for installing parts are shown with [*1] mark in the "Removal" section, identifying which step the instructions are intended for. q Marks shown in the "Installation" section stand for the following. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque
5
: Quantity of oil or coolant to be added
General tools that are necessary for removal or installation are described as [1], [2]etc. and their part names, part numbers and quantities are not described.
Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.
PC138US, USLC-8
SEN02709-00
2. Disassembly and assembly of assemblies

Special tools q Special tools which are deemed necessary for disassembly and assembly of parts are described as A1,X1 etc. and their part names, part numbers and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They respectively have a new part number. R : Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts ). Disassembly In "Disassembly" section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant drained are described. q The meanings of the symbols used in "Disassembly" section are as follows. k : Precautions related to safety in execution of work. a: This mark gives guidance or precautions when doing the procedure. 6: Quantity of oil or coolant drained
q
Assembly q In "Assembly" section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q The meanings of the symbols used in "Assembly" section are as follows. k : Precautions related to safety in execution of work a: This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque
5
: Quantity of oil or coolant to be added
* *** ****
Sketches of special tools Various special tools are illustrated for the convenience of local manufacture.
General tools that are necessary for disassembly and assembly are described as [1], [2]etc. and their part names, part numbers and quantities are not described.
PC138US, USLC-8
SEN02709-00
List of adhesives
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code LT-1A Part No. 790-129-9030 Q'ty 150 g 20 g (2 pcs.) 50 g Container Tube Polyethylene container Main features and applications Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out. Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
LT-1B
790-129-9050
LT-2
09940-00030
Polyethylene Features: Resistance to heat and chemicals. container Used to fix and seal bolts and plugs. Can Used to stick and seal metal, glass, and plastics.
LT-3 Adhesive
790-129-9060 Adhesive: (Set of 1 kg adhesive and Hardener: hardener) 500 g 790-129-9040 790-129-9120 250 g 75 g
LT-4 Holtz MH 705
Polyethylene Used to seal plugs. container Tube Heat-resistant seal used to repair engines.
ThreeBond 790-129-9140 1735
50 g
Quick-setting adhesive. Polyethylene Setting time: Within 5 sec. to 3 min. container Used mainly to stick metals, rubbers, plastics, and woods. Quick-setting adhesive. Polyethylene Quick-setting type. container (max. strength is obtained after 30 minutes) Used mainly to stick rubbers, plastics, and metals. Polyethylene Features: Resistance to heat and chemicals. container Used for fitted portions used at high temperatures. Tube Used to stick or seal gaskets and packings of power train case, etc.
Aron-alpha 790-129-9130 201 Loctite 648-50 LG-1 79A-129-9110 790-129-9010
2g
50 cc 200 g
LG-5
790-129-9080
1 kg
Used to seal various threaded portions, pipe joints, Polyethylene and flanges. container Used to seal tapered plugs, elbows, and nipples of hydraulic piping. Tube Features: Silicon-based heat and cold-resistant sealant. Used to seal flange surfaces and threaded portions. Used to seal oil pan, final drive case, etc. Features: Silicon-based quick-setting sealant. Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Gasket sealant used to repair engine. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Used to seal transfer case, etc.
Gasket sealant
LG-6
790-129-9020
200 g
LG-7
790-129-9070
1 kg 100 g 100 g
Tube Tube Tube
ThreeBond 790-129-9090 1211 ThreeBond 419-15-18131 1207B
PC138US, USLC-8
SEN02709-00
Category Lubricant with molybdenum disulfide
Komatsu code LM-G
Part No.
Q'ty
Container
Main features and applications To be sed as lubricant (anti squeaking) for sliding part. To be used for press fit, shrink fit and preventing scratching or seizure of thread. To be used as lubricant for linkage and bearing etc..
09940-00051
60 g
Can
LM-P
09940-00040 SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG0-400LI-A (*) SYG0-16CNLI (*) SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
200 g
Tube
G2-LI G0-LI(*) * For cold region
Various kinds
Various kinds Versatile type
G2-CA
Various kinds
Various kinds
To be used for the place where the bearing designed for normal temperature and low load condition is used and contacts water and steam. Used for parts under heavy load. Caution: Do not use this grease for ball bearings such as swing circle bearing. Apply this grease to work equipment pins only when installing but do not use it after then. Higher anti seizure and heat resistance than grease with molybdenum disulphide Body dirt is not distinctive due to white color.
Grease with molybdenum disulphide LM-G(G2-M) Hyper white grease G2-T G0-T(*) *: For cold region Biological grease G2-B G2-BT(*) *: For heat resistance and heavy load Sunstar primer for painting plane 580 super Sunstar primer for glass 580 super Sunstar primer for painting plane 435-95 Sunstar primer for glass 435-41 Sunstar primer for sash GP-402
Grease
400 g x 10 Bellows type 400 g x 20 16 kg Can
400 g 16 kg
Bellows type Can
400 g 16 kg
Bellows type Can
To be shortly dissolved by a bacteria in nature so that the influence to microorganism and animals and plants is suppressed to the minimum.
20 ml 417-926-3910
Glass container
To be used as primer for cab side. (Term of validity: 4 months after manufacturing) To be used as primer for glass side. (Term of validity: 4 months after manufacturing) To be used as primer for painting plane of cab side. (Term of validity: 4 months after manufacturing) To be used as primer for black ceramic coated plane of glass side and polycarbonate hard coat plane. (Term of validity: 4 months after manufacturing) To be used as primer for sash (Alumite surface treatment) (Term of validity: 4 months after manufacturing)
Primer
22M-54-27230
20 ml
Glass container
22M-54-27240
150 ml
Steel can
22M-54-27250
20 ml
Glass container
For adhesion of cab glass
20 ml
Glass container
PC138US, USLC-8
SEN02709-00
Category
Komatsu code Sunstar penguin seal 580 super "S" or "W" Sika Ltd, Japan Sika Flex 256HV Sunstar pengiun super 560 Sunstar pengiun seal No. 2505 Sekisui silicone sealant GE Toshiba Silicones Tosseal 381
Part No.
Q'ty
Container
Main features and applications "S" and "W" are used as glass adhesive compound in high temperature (April October) and in low temperature (October -April ) respectively. (Term of validity: 4 months after manufacturing) For adhesion of cab glass To be used as glass adhesive compound. (Term of validity: 6 months after manufacturing) To be used as glass adhesive compound. (Term of validity: 6 months after manufacturing) To be used as seal for joints of glass. (Term of validity: 4 months after manufacturing) To be used for seal of front window. (Term of validity: 6 months after manufacturing) To be used as seal for joints of glass. semi-transparent white seal (Term of validity: 12 months after manufacturing)
Adhesive compound
417-926-3910
320 ml
Polyethylene container
20Y-54-39850
310 ml
Polyethylene container ECOCART (special container) Polyethylene container Polyethylene container
22M-54-27210
320 ml
Coaking compound
417-926-3920
320 ml
20Y-54-55130
333 ml
22M-54-27220
333 ml
Cartridge
PC138US, USLC-8
SEN02709-00
Special tool list
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity : t . . . . . . Cannot be substituted, must always be installed (used) : q . . . . . . Extremely useful if available or, can be substituted with commercially available
part.
a New/Remodel: N. . . . . . Tools with new part numbers, newly developed for this model.
: R. . . . . . Tools with upgraded part numbers, remodeled from items already available for other models. : Blank . . Tools already available for other models, can be used without any modification a Tools marked with Q in the Sketch column are tools introduced in the sketches of the special (See Sketches of special tools).
New/remodel
790-101-5201 Engine front oil seal 1 790-101-5271 790-101-5221 01010-51225 Engine rear oil seal A 2 795-931-1100 790-101-5401 Engine rear oil seal 3 790-101-5431 790-101-5421 01010-51240 Hydraulic oil tank D 1 796-460-1210 795-799-1131 790-201-2750 790-101-5201 790-101-2510 790-101-2550 790-101-2560 2 790-101-2570 790-101-3101 790-101-4200 Swing machinery F 790-101-1102 790-101-5401 790-101-5461 3 790-101-5441 790-101-5421 01010-51240 4 5 6 790-201-2850 790-201-2750 790-201-2680
Push tool (Kit) Plate Grip Bolt
1 1 1 1 1 1 1 1 1 Instllation rear oil seal Removal rear oil seal Instllation front oil seal
Seal puller assembly q Push tool (Kit) Plate Grip Bolt Oil stopper Adapter Spacer Push puller (Kit) Block Leg Nut Plate Bearing puller Puller (294 kN {30 ton}) Hydraulic oil pump Push tool (Kit) (C) Plate Plate Grip Bolt Spacer Spacer Plate t t t q q q q q q q t q t
1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 Q
Sketch
Component
Symbol
Necessity
Part No.
Part Name
Nature of work, remarks
Qty
Stop oil supply from hydraulic tank Removal split collar
Removal bearing
Instllation Bearing outer race For main bearing For sub bearing
Instllation Bearing inner race Instllation oil seal
796T-426-1140 Push tool
PC138US, USLC-8
SEN02709-00
791-675-1510 791-600-2001 or 791-685-8006 791-635-3160
Installer Compressor (A) Compressor (B) Extension Spacer Cylinder (686 kN {70 ton}) Pump Push tool (Kit) Plate (Periphery 74) Plate (Periphery 79) Grip Bolt Installer Oil pump Frame Plate Plate Guide Adapter Push Push Guide Bolt Washer Bolt Washer Cylinder (297 kN {30 ton}) Pump Push puller Block Screw Washer Nut Leg Washer Nut Adapter
t t t t t t q
1 1 1 1 1 1 1 1 1 1 1 1
Sketch Q
Component
Symbol
New/remodel
Necessity
Part No.
Part Name
Qty
Application of floating seal
790-201-2770 790-101-1600
Compression of spring
Disassembly, assembly L of idler recoil spring
790-101-1102 790-201-1500 790-201-1590 3 790-201-1610 790-101-5021 01010-50816
Press fit of piston dust seal
1 Disassembly, assembly M of track roller 2
790-434-1650 791-601-1000 791-616-1110 791-616-1121 791-616-1131 791-616-1150 791-616-1160 791-620-3530
t q t t t t t t t t t t t t t t t q
1 1 1 1 1 1 1 1 1 1 1 2 2 3 3 1 1 1 1 1 1 1 2 4 2 2
Application of floating seal 88 Sealing of oil and checking of air leak
791T-616-1280 Adapter Expansion, installation of track shoe 791-620-3260 791-620-3270 01011-62260 01643-62260 01011-61455 01643-31445 790-105-1100 790-101-1102 790-101-2501 790-101-2510 790-101-2520 790-101-2540 Disassembly of center swivel joint T 791-112-1180 790-101-2630 790-101-2570 790-101-2560 791-112-2650
Removal, pressfit of master pin
Disconnection of rotor from shaft
PC138US, USLC-8
SEN02709-00
1 2
790-502-1003 790-101-1102 790-102-4300 790-201-4310 790-201-1702 790-201-1791 790-101-5021 01010-50816 790-201-1702 790-201-1811 790-101-5021 01010-50816 790-201-1702 790-201-1821 790-101-5021 01010-50816 790-201-1500 790-201-1610 790-101-5021 01010-50816 790-201-1500 790-201-1620 790-101-5021 01010-50816 790-201-1500 790-201-1630 790-101-5021 01010-50816
Repair stand Pump Wrench assembly Pin Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Expander Ring Clamp Remover Adapter Puller (490 kN {50 ton}) Pump Lifter (Suction cup) Adapter
t t t t t
1 1 1 1 1 1 1 1
Sketch
Component
Symbol
Part No.
Part Name
New/remodel
Necessity
Qty
Disassembly, assembly of cylinder Removal, installation of piston
Press fit of bucket cylinder roll bushings
1 1 1 1 Press fit of boom cylinder roll bushings
1 1 1 1 Press fit of arm and blade cylinder roll bushings
Disassembly, assembly U of hydraulic cylinder
1 1 1 1 Press fit of bucket cylinder dust seal
1 1 1 1 Application of boom cylinder dust seal
1 1 1 1 Application of arm and blade cylinder dust seal
5 6
790-720-1000 796-720-1660 07281-01159 792-785-1100
t t t t
1 1 1 1 1 1 1
Extension of piston ring Bucket cylin- Removal, der installation of Arm, boom, piston ring blade cylinder
Removal, installation, of work equipment and V 1 boom
796-270-1110 790-101-4000 790-101-1102
Removal of boom foot pin
Operators cab glass (stuck glass)
1 2
793-498-1210 20Y-54-13180
t t
2 2
Removal and installation operatiors cab glass (stuck glass)
PC138US, USLC-8
SEN02709-00
799-703-1200 Floor frame assembly airconditioner compressor assembly airconditioner condenser assembly airconditioner unit assembly 799-703-1100 X 3 799-703-1111 790-703-1121 799-703-1401
Service tool (Kit) Vacuum pump (100V) Vacuum pump (220V) Vacuum pump (240V) Gas leak detector
t t t t t
1 1 1 1 1 Charging of air-conditioning gas
10
Sketch
Component
Symbol
New/remodel
Necessity
Part No.
Part Name
Qty
PC138US, USLC-8
SEN02709-00
Sketche of special tool
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. F6 Push tool
Unless otherwise specified, there shall be on burrs or flushes at the corner.
R Adapter
PC138US, USLC-8
11
SEN02709-00
12
PC138US, USLC-8
SEN02710-00
Machine model
Serial number

Engine and cooling system
Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of fuel injector assembly ......................................................................................... 4 Removal and installation of front oil seal ........................................................................................................ 7 Removal and installation of rear oil seal ......................................................................................................... 9 Removal and installation of cylinder head assembly .................................................................................... 12 Removal and installation of radiator assembly ............................................................................................. 19 Removal and installation of aftercooler assembly......................................................................................... 21 Removal and installation of work equipment oil cooler assembly ................................................................. 23 Removal and installation of engine and work equipment pump assembly ................................................... 26 Removal and installation of fuel tank assembly ............................................................................................ 31
PC138US, USLC-8
SEN02710-00
Removal and installation of fuel supply pump assembly 1

Removal
k
6) 7) 8)
Disconnect the negative () terminal of the battery beforehand. Remove the counterweight, referring to "Removal and installation of counterweight." Disconnecting engine controller and frame assembly 1) Remove engine controller mounting bolts (1) from the upper frame (2). 2) Remove 4 lower frame mounting bolts (3). 3) Disconnect the engine controller frame assembly (4).
Loosen sleeve nuts (12) and (13) and remove high pressure pipe (14). [*2] Remove the pin and disconnect spill hose (15). Remove joint bolts (16), (17) and (18) and remove fuel tubes (19) and (20). [*3]
1. 2.
4.
Removal of supply pump and pump holder assembly 1) Remove 4 mounting bolts (21) from the gear case. 2) Loosen mounting bolts (22) completely from the pump holder side. [*4] a At this stage, mounting bolts (22) cannot be removed between the supply pump and the pump holder. 3) Remove supply pump and pump holder assembly (23).
3.
Disconnecting wiring and piping 1) Disconnect pump regulator sensor connector PREG (5). 2) Disconnect wiring clamps (6), (7) and (8). 3) Disconnect clamp (10) from fuel hoses (9). 4) Disconnect fuel hose (9) from the fuel filter. 5) Remove two boots (11) from the injector and supply pump. [*1]
PC138US, USLC-8
SEN02710-00
5.
Removal of supply pump assembly 1) Loosen nut (24) and pull out supply pump gear (25) using gear puller [1]. [*5]
Installation
q
Carry out the installation in the reverse order of removal.
[*1] a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. [*2]
k k
2)
Remove 3 nuts (26) and remove supply pump (27) from pump holder (28).
Never bens a high-pressure pipe for the convenience sake. The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Be sure to install the boot to the sleeve nut after installing the high-pressure pipe. Before installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2 mm inside the tip). No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).
3 3
Sleeve nut (12) on the common rail side: 25.5 29.4 Nm {2.6 3.0 kgm} Sleeve nut (13) on the supply pump side: 18 23 Nm {1.9 2.3 kgm} Joint bolts (16) and (17): 24.5 34.3 Nm {2.5 3.51 kgm} Joint bolt (18): 19.6 17.7 Nm {2.0 1.8 kgm}
[*3]
3 3
[*4] a For mounting bolt (22), install M6 bolt with LT2A. [*5]
3
Pump gear mount nut: 65 75 Nm {6.6 7.6 kgm}
PC138US, USLC-8
SEN02710-00
Removal and installation of fuel injector assembly 1

Removal
k
3.
Disconnect the negative () terminal of the battery beforehand. Open engine hood (1).
1.
Removal of the high-pressure pipe a The following indicates the removal of injector assembly of cylinder No. 1 for example. 1) Remove clamp (5) from the high-pressure pipe. 2) Remove boot (6) from the injector and common rail sides. [*1]
2.
Disconnection of air conditioner compressor hose clamp and aftercooler hose a When removing injector assemblies No. 3 and No. 4, completing the following procedures in advance makes the work for Procedure 3 and onward easier. 1) Disconnect air conditioner compressor hose clamps (2) and (3) and keep the hose out of the way. 2) Disconnect aftercooler hose (4) on the side of the air intake connector and keep it out of the way.
3)
4) 5)
Remove injector wiring connector (7). Connector No. Cylinder No. 1: CN1 Cylinder No. 2: CN2 Cylinder No. 3: CN3 Cylinder No. 4: CN4 Remove pin (8) and disconnect spill hose (9). Loosen sleeve nut (10) both on the injector side and common rail side and remove high-pressure pipe (11). [*2]
PC138US, USLC-8
SEN02710-00
4.
Removal of injector assembly 1) Remove holder mounting bolt (12) and remove holder (13). [*3] 2) Remove injector assembly (14). [*4]
Installation
q
[*1] a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. [*2]
k k
Never bend a high-pressure pipe for the convenience sake. The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. Be sure to install the boot to the sleeve nut after installing the high-pressure hose. Before Installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2mm inside the tip). No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).
Sleeve nut (11): 25.5 29.4 Nm {2.6 3.0 kgm} Holder mounting bolt (13): 27 30 Nm {2.8 3.1 kgm}
[*3]
PC138US, USLC-8
SEN02710-00
[*4]
q
When reusing injector, always replace Oring (15) and gasket (16) with new ones.
PC138US, USLC-8
SEN02710-00
Removal and installation of front oil seal 1

Special tools
Symbol Part No. Part name New/Remodel Necessity
3. 4. 5. 6.
Loosen fan belt adjust bolt (3) and remove fan belt (4). [*1] Remove engine speed sensor connector (5). Remove speed sensor mounting bolt (6) and remove speed sensor (7). [*2] Remove crankshaft pulley mounting bolt (8) and remove crankshaft pulley (9). [*3]
790-101-5201 A 1 790-101-5271 790-101-5221 01010-51225
Push tool (kit) Plate Grip Bolt
t 1 1 1 1
Removal
1. 2. Remove the engine assembly, referring to "Removal and installation of engine assembly." Remove fan mounting bolt (1) and remove fan (2). 7. Remove front oil seal (10).
Q'ty
PC138US, USLC-8
SEN02710-00
Installation
1. Use tool A1 (outside diameter of 80 mm) to press front oil seal (10) in gear case (11). 1) Check the crankshaft end corner and the oil seal lip sliding surface for flaws, burrs, scars, or rust, before installing the oil seal. 2) Fill about 2 cc of grease to between the oil seal lips. 2 Front oil seal: grease (G2-LI)
2.
Install the crankshaft pulley. a Align key (a) of crankshaft (12) with key groove (b) of crankshaft pulley (9) and install the pulley.
3.
For the rest of the installation work, carry out the installation in the reverse order of removal.
[*1] Confirm the direction of the fan. [*2]

2
Speed sensor mounting bolt (6): 7.0 11 Nm {0.7 1.1 kgm} Crankshaft pulley mounting bolt (8): 343 402 Nm {35 41 kgm}
[*3]
PC138US, USLC-8
SEN02710-00
Removal and installation of rear oil seal 1

Special tools
2) 3)
Temporarily lift flywheel (3). Remove 7 flywheel mounting bolts (4) except one. [*2]
2 A 3
795-931-1100 790-101-5401 790-101-5431 790-101-5421 01010-51240
Seal puller assemq 1 bly Push tool (kit) Plate Grip Bolt t 1 1 1 1
Q'ty
4)
Removal
k
Disconnect the negative () terminal of the battery beforehand. Remove the work equipment pump assembly, referring to "Removal and Installation of Work Equipment Pump Assembly." Removal of the flywheel 1) Remove coupling mounting bolt (1) and remove coupling (2). [*1]
5) 6) 7)
1.
2.
Loosen flywheel mounting bolt (4). k Leave 3 threads or 4 engaged to prevent the flywheel from suddenly shooting out in the following procedure. Pull out the flywheel by prying with a bar, etc. Checking that flywheel (3) is manually removable, remove the flywheel mounting bolt (4). Lift flywheel (3) and remove it. 4 Flywheel: 25 kg
PC138US, USLC-8
SEN02710-00
3.
Removal of the rear oil seal 1) Screw the tip of tool A4 into the metal ring of seal (5) and pull it out with the impact of a slide hammer [1]. a For the ease of pulling out the seal, slightly hammer it in to unfasten it from the housing before pulling it out. a Do not use a drill as chips may enter the engine.
Installation
1. Rear oil seal mounting procedure Use tool A3 (outside diameter of 120 mm) to install rear oil seal to flywheel housing. a Fill about 3 cc of grease to between the rear oil seal lips. 2 Front oil seal: grease (G2 LI)
2. (Photo shows work on a single unit of engine, but the procedures are the same.) [*1]
For the following installation work, carry out the installation in the reverse order of removal. Coupling mounting bolt: 98 122.6 Nm (10 12.5 Kgm)
[*2]
q
Tighten the flywheel mounting bolts according to the following procedure: 1) Apply engine oil EO#30 to the bolt threads. 2 Mounting bolt threads: Engine oil (EO30) 2) Tighten the bolts in the order of 1 to 6 as shown in the diagram (CPP14824). 3) Tighten the bolts each in two actions by applying torque as specified in the order of item 2) above. 3 Mounting bolt:
Unit: Nm{kgm} target 88.2 {9.0} range 58.7 117.7 {6.0 12.0}
procedure 1st time
2nd time 191.3 {19.5} 186.4 196.2 {19.0 20.0}
10
PC138US, USLC-8
SEN02710-00
[*3]
q
Measuring radial runout of flywheel 1) Install dial gauge [2] to the flywheel housing. 2) Set the probe of the dial gauge at right angles to the spigot joint (a) or the outer periphery of the flywheel. 3) Rotate the crank shaft one full turn and measure the difference of the maximum values of runout of the needle. a Check that the position of needle remains in its original position after the flywheel is rotated one full turn. Radial runout: Max. 0.15 mm Measuring face runout of flywheel 1) As with the measurement of radial runout, set the probe of the dial gauge at right angles to end face (b) close to the outer periphery of the flywheel. a For measurement, move the crank shaft forward or backward to prevent error caused by an end play. 2) Rotate the crank shaft one full turn and measure the difference of the maximum values of runout of the needle. Face runout: Max. 0.25 mm
PC138US, USLC-8
11
SEN02710-00
Removal and installation of cylinder head assembly

Removal
k
4.
Disconnect aftercooler hose (11) from the air intake connector (12) side.
Disconnect the negative () terminal of the battery beforehand. Remove the counterweight assembly, referring to "Removal of counterweight assembly." Removal of engine controller frame assembly 1) Remove engine controller mounting bolts (1) from the upper frame (2). 2) Remove 4 lower frame mounting bolts (3). 3) Disconnect engine controller frame assembly (4).
1. 2.
5. 6.
Remove 4 mounting bolts (13) and remove the air conditioner compressor mounting bracket. Remove bolts (14) and (15) and remove fuel filter (18). [*1] a Bolt (14) tightens the clamp of wiring to the air conditioner compressor together. a Bolt (15) tightens bracket (19) together. Remove bolts (16) to (18) and remove bracket (19). [*2] a Bolt (18) tightens the clamp of wiring to the injector together.
7.
3.
Removal of air conditioner compressor 1) Disconnect wiring connector AC02 (5). 2) Disconnect air conditioner hose clamps (6) at two locations. a Do not disconnect the air conditioner hoses. 3) Remove air conditioner compressor drive belt protective cover (7). 4) Loosen air conditioner compressor mounting bolts (8) and remove drive belt (9). 5) Remove air conditioner compressor mounting bolts (8) and remove air conditioner compressor (10). (Keep the compressor out of the way.)
12
PC138US, USLC-8
SEN02710-00
8.
Disconnection of wiring 1) Disconnect heater wiring E01 (20). 2) Disconnect injector wiring CN1 to CN4 (21). 3) Disconnect boost pressure sensor connector PTIM (22).
6)
Remove 8 air intake manifold mounting bolts (37) and remove air intake manifold (38). [*7]
9.
Removal of air intake connector and electrical intake air heater assembly 1) Remove 4 bolts (23) to (26) and remove air intake connector (27). [*3] a Because oil level gauge pipe bracket (28) is tightened together with bolt (24), tie the disconnected oil level gauge pipe with a string to keep it out of the way. a Bolt (25) tightens grounding (29) together. 2) Remove electrical intake air heater assembly (30). [*4]
11. Removal of injector assembly 1) Remove 4 injector mounting bolts (39) and remove 4 holders (40). [*8] 2) Remove injector assembly (41). [*9]
12. Removal of muffler 1) Remove upper covers (42) and (43).
10. Removal of high-pressure pipe and air intake manifold 1) Remove coolant temperature sensor wiring clamp (31). 2) Remove spill hose mounting pin (32) and disconnect spill hose (33). 3) Remove high-pressure pipe clamps (34) at 2 locations. 4) Remove 8 boots (35) both from the cylinder head side and common rail side. [*5] 5) Loosen the sleeve nuts and remove 4 high-pressure pipes (36). [*6] PC138US, USLC-8
13
SEN02710-00
2)
Remove 2 clamp mounting bolts (44) and remove clamp (45). [*10]
13. Removal of turbocharger and exhaust manifold assembly 1) Remove cover (52).
3) 4)
Remove divider board (46). Remove rubber covers (47) and (48).
2) 3)
Disconnect blowby tube (53). Remove 3 mounting nuts (54) and remove cylinder head cover (55). [*11]
5) 6) 7)
Remove muffler drain tube (49). a Remove the lower clamp in advance. Remove 4 bracket mounting bolts (50). Lift muffler bracket assembly (51) and remove it. 4 Muffler bracket assembly: 22 kg
14
PC138US, USLC-8
SEN02710-00
4) 5)
6)
7) 8)
Remove mounting bolts (56) and disconnect turbocharger lubricant inlet port tube (57). [*12] Remove 2 mounting bolts (58) and disconnect turbocharger lubricant return tube (59). Remove 3 mounting bolts (60) and disconnect connector (61) between the turbocharger and aftercooler hose from the turbocharger. Remove 8 exhaust manifold mounting bolts (62). [*13] Lift turbocharger and exhaust manifold assembly (63) and remove them. 4 Turbocharger and exhaust manifold assembly: 15 kg
14. Removal of water pump 1) Disconnect coolant temperature sensor connector TWTR (64). 2) Disconnect radiator upper hose (65), heater hoses (66) and (67) and radiator lower hose (68). 3) Remove fan belt (69). 4) Remove 6 fan pulley mounting bolts (70). 5) Remove fan pulley assembly (71).
6) 7)
Remove 3 water pump mounting bolts (72). [*14] Remove water pump (73).
PC138US, USLC-8
15
SEN02710-00
15. Removal of rocker arm assembly 1) Loosing lock nut (74) and fully loosen adjustment screw (75). [*15] a Loosen the air intake and exhaust adjustment screws on all cylinders. 2) Remove 8 mounting bolts (76) and remove rocker arm assembly (77). [*16]
Installation
q
[*1] [*2] a When installing fuel filter mounting bolts (14), tighten wiring clamp (81) for the air conditioner compressor together. a When installing bracket mounting bolts (18), tighten wiring clamp (21) for the injector together.
16. Removal of cylinder head assembly 1) Pull out 8 push rods (78). 2) Remove 17 cylinder head mounting bolts (79). [*17]
q
3)
Lift cylinder head assembly (80) and remove it. 4 Cylinder head assembly: 30 kg
[*3] [*4] When installing air intake connector (27) and electrical intake air heater (30), pay attention to the following matters: a When installing the air intake connector and electrical intake air heater, replace the gasket with new one. a When installing air intake connector mounting bolts (24), tighten it together with oil level gauge pipe bracket (28). a When installing air intake connector mounting bolts (25), tighten it together with oil level gauge pipe bracket (29). a If grounding (29) is removed from electrical intake air heater (30) by removing grounding mounting bolt (81), install the grounding mounting bolt (82) with the following torque: 3 Grounding mounting bolt (82): 4.9 5.9 Nm {0.5 0.6 kgm}
16
PC138US, USLC-8
SEN02710-00
[*5] [*6] q Precautions when installing high-pressure piping k Never bend a high-pressure pipe for the convenience sake. k The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. k Be sure to install the boot to the sleeve nut after installing the high-pressure hose. a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. a Before Installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. q No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2mm inside the tip). q No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).
[*7] a Apply gasket sealant to the air intake manifold before installation. Apply gasket sealant for about 1 mm of wire diameter. 2 Mounting face: Gasket sealant (LG 7) [*8] [*9] q Injector mounting procedure: 1) Install seal (82) to injector (41). 2) Install copper gasket (84) to injector (41). 3) Insert injector (41) to the cylinder head. 4) Install holder (40) to injector (41). 5) Tighten holder (40) with mounting bolt (39). a Before tightening the bolt, check that holder (40) is securely installed to groove(a)of injector (41). 3 Holder mounting bolt: 27 30 Nm {2.8 3.1 kgm}
3 3
Sleeve nut on the supply pump side: 18 23 Nm {1.9 2.3 kgm} Sleeve nut on the common rail side: 25.5 29.4 Nm { 2.6 3.0 kgm}
[*10] q Install the clamp mounting bolts between the turbocharger and muffler according to the following procedure: 3 Clamp mounting bolt: 1st time: 39.2 49 Nm {4 5 kgm} 2nd time: 68.6 - 122.5 Nm {7 12.5 kgm} [*11]
3
Cylinder head cover mounting nut: 7.84 9.8 Nm {0.8 1.0 kgm} Lubricant inlet port tube mounting bolt: 34.3 53.9 Nm {3.5 5.5 kgm}
[*12]
[*13] q Exhaust manifold mounting procedure: 1) Attach the guide bolt to the cylinder head and set the gasket. a Install the manifold with the gasket face stamped 6205 on the side of the manifold.
PC138US, USLC-8
17
SEN02710-00
2)
Install the exhaust manifold and tighten the mounting bolt. 3 Exhaust manifold mounting bolt: 9.8 12.7 Nm {1.0 1.3 kgm}
[*14] a One (1) of the water pump mounting bolts is tightened together with the alternator mounting bracket. [*15] [*16] a Before installing rocker arm assembly (77), loosen lock nut (74) and fully loosen adjustment screw (75). a When installing rocker arm assembly (77), tighten the mounting bolts alternately by checking that the adjustment screw ball fits to the push rod socket. 3 Rocker arm mounting bolt (76): 19.6 29.4 Nm {2.0 3.0 kgm} q For adjustment of the valve clearance, refer to "Adjusting valve clearance" in Testing and adjusting.
(In the diagram, (F) indicates the front of engine, (R) the rear and (b) a plastic region turning angle tightening bolt.)
(In the diagram, (p1) indicates a cylinder head marking and (p2) the bolt head.)
[*17] Tightening procedure for the cylinder head mounting bolt Apply molybdenum disulphide lubricant (LM-P) to the threads of cylinder head mounting bolt, and tighten the bolts in the order shown in the diagram. 3 Cylinder head mounting bolt: 1st time: 68.6 9.8 Nm {7.0 1.0 kgm} 2nd time: 107.8 4.9 Nm {11.0 0.5 kgm} 3rd time: Mark the bolt head and cylinder head, and turn the cylinder head by 90 (+30/0) to tighten. a After tightening, stamp a punch mark (n), indicating the number of tightening, on the bolt head. a If a bolt has 5 punch marks, do not reuse. Replace it with a new one.
18
PC138US, USLC-8
SEN02710-00
Removal and installation of radiator assembly

Removal
k
6.
Open covers (9) and (10).
Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative () terminal of the battery beforehand. Remove lower cover (1).
1.
7. 8. 9.
Disconnect radiator overflow hose (11). Disconnect radiator upper hose (12). [*3] Remove 2 plate mounting bolts (13) and remove plate (14).
10. Remove 2 radiator mounting bolts (15).
2.
Open the coolant drain valve (2) to drain. [*1] 6 Coolant: 12.4 l Remove 2 plate (3) mounting bolts (4) and remove the cover. Disconnect radiator lower hose (5). [*2]
3. 4.
11. Lift radiator assembly (16) and remove it.[*4] 4 Radiator assembly: 10 kg
5.
Remove 4 cover mounting bolts (6) and remove covers (7) and (8).
PC138US, USLC-8
19
SEN02710-00
Installation
q

5
[*1]
Coolant: 12.4 l
[*2] [*3] 3 Radiator hose clamp bolt: (Both upper and lower hoses) 8.8 0.5 Nm {0.9 0.05 kgm} [*4] a When installing the radiator assembly, align the convex portion (a) on the bottom of the radiator assembly with the concave portion (b) on the machine.
20
PC138US, USLC-8
SEN02710-00
Removal and installation of aftercooler assembly

Removal
k
4.
1
5.
Loosen 2 clamps (6) and disconnect the air aftercooler upper hose (7). Remove 2 mounting bolts (8) and remove plate (9). Remove 2 air aftercooler mounting bolts (10).
Disconnect the negative () terminal of the battery beforehand. Remove lower cover (1).
6.
1.
7. 2. 3. Remove 2 mounting bolts (2) and disconnect the air aftercooler lower hose (3). Remove 2 mounting bolts (4) and remove plate (5).
Pull out air aftercooler (11). [*1] a Take care not to damage sponge around the aftercooler.
PC138US, USLC-8
21
SEN02710-00
Installation
q
[*1] a Take care not to damage sponge on the sides when installing the aftercooler. a When installing the radiator assembly, align the convex portion (a) on the bottom of the air aftercooler with the concave portion (b) on the machine.
22
PC138US, USLC-8

a
SEN02710-00
Removal and installation of work equipment oil cooler assembly 1

Special tools
When using tool D to stop oil, remove the hydraulic oil tank strainer in advance.
796-460-1210 795-799-1131
Oil stopper Adapter
q 1 q 1
Removal
k
k k
Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative () terminal of the battery beforehand. Loosen the hydraulic oil tank cap gradually to release the pressure in the tank. Fasten tags to respective piping for identification to prevent any mistakes when re-installing. Remove the radiator assembly referring to "Removal and Installation of Radiator Assembly." Remove the air aftercooler assembly referring to "Removal and Installation of Air Aftercooler Assembly." Loosen hydraulic oil drain plug (1) to drain the work equipment oil. [*1] 6 Hydraulic tank: 69 l (Specified capacity: 120 l)
Q'ty
4.
Remove lower cover (2).
1.
2.
5.
Remove 2 oil cooler lower mounting bolts (3) and disconnect lower hose (4).
3.
PC138US, USLC-8
23
SEN02710-00
6.
Remove air cleaner (5).
11. Pull out oil cooler assembly (11). [*2]
7. 8.
Remove connector (6). Remove air cleaner hose clamp (7).
9.
Remove 2 hose mounting bolts (8) and disconnect oil cooler upper hose (9).
10. Remove 2 oil cooler mounting bolts (10).
24
PC138US, USLC-8
SEN02710-00
Installation
q
Carry out the installation in the reverse order of removal. Hydraulic oil drain plug (13): 58.8 78.4 Nm {6 8 kgm} Target: 68.6 Nm {7 kgm} Hydraulic tank: 69 l (Specified capacity: 120 l)
[*1]
PC138US, USLC-8
25
SEN02710-00
Removal and installation of engine and work equipment pump assembly 1

Special tools
3.
Open fuel drain valve (3) to drain fuel.
796-460-1210 795-799-1131
Oil stopper Adapter
q 1 q 1
Q'ty
Removal
k
4.
k k
Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative () terminal of the battery beforehand. Loosen the hydraulic oil tank cap gradually to release the pressure in the tank. Remove lower cover (1).
Loosen hydraulic oil drain plug (4) to drain the work equipment oil. [*2] 6 Hydraulic tank: 69 l (Quantity of oil in hydraulic tank )
1.
2.
Drain coolant from the coolant drain port (2). [*1] 6 Coolant: 12.4 l
26
PC138US, USLC-8
SEN02710-00
5. 6.
Remove covers (5), (6) and (7). Open covers (8) and (9).
8)
Remove frame mounting bolts (20), (21) and (22).
9) 7. 8. Remove the counterweight, referring to "Removal and Installation of Counterweight." Removal of frame cover assembly 1) Temporarily lift the frame cover assembly. 2) Remove lock pin (10). 3) Disconnect air conditioner hose mounting clamp (12).
Lift frame cover assembly (23) and remove it.
9.
Removal of the engine upper hoses 1) Remove air conditioner hose mounting clamp (24). 2) Remove wiring clamp (25). 3) Remove air hose (26) between the turbocharger and air cleaner. [*3] 4) Remove after cooler hose (27). [*4] 5) Disconnect radiator hose (28). [*5]
4) 5)
6) 7)
Disconnect wiring (13) to (16) from the frame. Disconnect wiring (17) to the engine controller. (Disconnect connector CE02 from engine controller (p).) a Keep wiring (17) out of the way. Disconnect resistor connector K02 (18). Remove bracket mounting bolt (19) and disconnect the wiring mounting bracket.
10. Removal of air conditioner compressor 1) Disconnect wiring connector AC02 (29). 2) Remove drive belt protective cover (30). 3) Loosen drive belt adjusting and mounting bolts (31), and remove the drive belt (32).
PC138US, USLC-8
27
SEN02710-00
4)
Remove adjustment and mounting bolts (31) and remove air conditioner compressor (33). a Do not disconnect the air conditioner hoses.
6) 7) 8) 9)
Disconnect starting motor wiring terminals (42) and (42a). [*7] Remove wiring bracket mounting bolt (43) and disconnect bracket (44). Disconnect wiring (45) from the engine block and keep it out of the way. Disconnect grounding wire (46).
11. Disconnecting hoses and wiring from the L.H. side of the engine 1) Remove heater hose clamp (34) and disconnect heater hose (35). 2) Remove radiator lower hose clamp (35) and disconnect radiator lower hose (37). [*6]
12. Disconnecting hoses and wiring from the R.H. side of the engine 1) Disconnect alternator wiring (47). 2) Remove 3 bolts (48) and remove hose mounting connector (49) between the after cooler and turbocharger.
3) 4) 5)
Disconnect electrical intake air heater connector E01 (38). Disconnect clamps (40) at 2 locations on wiring (39) and disconnect wiring (39) from the engine. Disconnect fuel hose (41) from the fuel tank.
3)
Disconnect engine oil temperature sensor wiring connector (50).
28
PC138US, USLC-8
SEN02710-00
13. Remove 4 bracket mounting bolts (51) and disconnect engine oil filter and bracket assembly (52). a Tie the assembly with a string to keep it out of the way.
3)
Disconnect 6 hoses (56) to (61).
4)
Remove 4 bolts (62) and disconnect suction tube (63).
14. Disconnecting work equipment pump wiring and hoses 1) Remove rubber cover (53).
15. Remove 4 engine mounting bolts (64). [*8]
2)
Disconnect oil temperature sensor wiring connector P22 (53) and EPC solenoid wiring connector A11 (54).
PC138US, USLC-8
29
SEN02710-00
16. Lift engine and work equipment pump assembly (65) and remove it. 4 Engine and work equipment pump assembly: 470 kg
Installation
q

5
[*1]
Coolant: 12.4 l Hydraulic oil drain plug (13): 58.8 78.4 Nm {6 8 kgm} Target: 68.6 Nm {7 kgm} Hydraulic tank: 69 l (Specified capacity: 120 l) Hose clamps between the turbocharger and air cleaner: 10.8 1 Nm {1.1 0.1 kgm} Aftercooler hose clamp: 10.8 0.5 Nm {1.1 0.05 kgm}
[*2]
[*3]
[*4]
[*5][*6] 3 Radiator hose clamp bolt: (Both upper and lower hoses) 8.8 0.5 Nm {0.9 0.05 kgm} [*7]
3 3 3
Starting motor wiring terminal (42): 17.7 24.5 Nm {1.8 2.5 kgm} Starting motor wiring terminal (42a): 2.6 4.6 Nm {0.27 0.47 kgm} Connector mounting bolt: 10 2 Nm {1.02 0.2 kgm} Engine mounting bolt: 245 309 Nm {25 31.5 kgm}
[*8]
30
PC138US, USLC-8
SEN02710-00
Removal and installation of fuel tank assembly 1

Removal
k
7.
Removal of exterior parts 1) Remove hand rail (7). 2) Remove covers (8) to (11).
Stop the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative () terminal of the battery beforehand. Open the inspection cover on the rear R.H. side, and open fuel drain valve (1) to drain fuel. Fuel (When fuel tank is full): 195 l
1.
8.
Removal of fuel tank mounting bracket and mounting bolts 1) Remove fuel tank rear mounting brackets (12).
2. 3. 4. 5. 6.
Disconnect fuel level sensor connector P21 (2). Disconnect fuel level sensor wiring (3). Disconnect hose (4) from the radiator. Disconnect water assembly (5). separator and bracket 2) 3) Disconnect reservoir tank (6). Remove wiring and hose mounting brackets (13). Remove fuel tank front mounting brackets (14).
PC138US, USLC-8
31
SEN02710-00
4) 5)
Disconnect hoses (15) and (16). Remove 4 fuel tank front mounting bolts (17).
Installation
q
Carry out the installation in the reverse order of removal. Fuel tank mounting bolt: liquid adhesive (LT2) Fuel tank mounting bolt: 235 285 Nm {23.5 29.5 kgm}
[*1]
2 3
9.
Lift fuel tank assembly (18) and remove it. [*1] 4 Fuel tank assembly: 95 kg
32
PC138US, USLC-8
SEN02710-00
PC138US, USLC-8
33
SEN02710-00
34
PC138US, USLC-8
SEN02711-00
Machine model
Serial number

Power train
Removal and installation of travel motor and final drive assembly ................................................................. 2 Removal and installation of swing motor and swing machinery assembly ..................................................... 4 Disassembly and assembly of swing machinery assembly ............................................................................ 6 Removal and installation of swing circle assembly ....................................................................................... 12
PC138US, USLC-8
SEN02711-00
Removal and installation of travel motor and final drive assembly 1

Removal
1. Remove track shoe assembly. For details, see "Removal of track shoe assembly". Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Swing work equipment 90, then push up chasis with work equipment and set block [1] between track frame and track shoe. Lift off sprocket (1). [*1] 3 Sprocket : 40 kg
2.
3.
4. 5. 6.
Remove travel motor cover. Disconnect 4 travel motor hoses (2). Lift off travel motor and final drive assembly. [*2] a Be extremely careful not to damage the nipple tool surface of the hose mount. 4 Travel motor and final drive assembly: 150 kg
PC138US, USLC-8
SEN02711-00
Installation
q
Carry out installation in the reverse order to removal. Thread of travel motor mounting bolt : Thread tightener (LT-2) Sprocket mounting bolt : 323.6 362.8 Nm {33 37 kgm}
[*1]
2 3
[*2]
Thread of travel motor and final drive assembly mounting bolt : Thread tightener (LT-2) 3 Travel motor and final drive assembly mounting bolt : 235 285 Nm {23.5 29.5 kgm} a Bleed the air from the travel motor. For details, see Testing and adjusting, "Bleeding air from travel motor". Refilling with oil (hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
PC138US, USLC-8
SEN02711-00
Removal and installation of swing motor and swing machinery assembly 1

Removal
k
4. 5.
Remove mounting bolt (9). Remove swing motor and swing machinery assembly (10) from the machine using forcing screw [1].
Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative () terminal of the battery beforehand. Fasten tags to respective piping for identification to prevent any mistakes when reinstalling. Disconnect oil level pipe clamp (1). Remove covers (2) and (3).
6.
1. 2.
Lift and remove swing motor and swing machinery assembly (10). a Lift the assembly carefully to prevent interference with the surrounding hoses. 4 Swing motor and swing machinery assembly: 95 kg
3.
Disconnect hoses (4) to (8).
PC138US, USLC-8
SEN02711-00
Installation
q
Carry out the installation in the reverse order of removal. Refilling oil (Hydraulic tank) a Fill oil up to the specified level, start the engine to circulate oil in the pipe and check the oil level again. Bleeding air a Bleed air from the piping, referring to "Bleeding air from each part" in Testing and adjusting. Wing machinery mounting bolt: 277 31.9 Nm {28.25 3.25 kgm}
[*1]
PC138US, USLC-8
SEN02711-00
Disassembly and assembly of swing machinery assembly

Special tools
Necessity Symbol 1 New/Remodel
790-201-2750 790-101-5201 790-101-2510 790-101-2550 790-101-2560 790-101-2570 790-101-3101 790-101-4200
Spacer Push puller (Kit) Block Leg Nut Plate Bearing puller
t 1 q 1 1 1 2 4 q 1
Sketch
Part No.
Part name
Q'ty
4) 5)
Disconnect swing motor assembly (4) using forcing screw [1]. Lift and remove swing motor assembly (4).
Puller q 1 (294 kN {30 ton}) Hydraulic oil pump Plate Plate Grip Bolt Spacer Spacer Plate q 1
790-101-1102 790-101-5401 790-101-5461 3 790-101-5441 790-101-5421 01010-51240 4 5 6 790-201-2850 790-201-2750 790-201-2680
Push tool (Kit) (C) q 1 1 1 1 1 t 1 t 1 t 1 q 1 Q
3.
796T-426-1140 Push tool
Carrier No. 1 and Sun gear No. 2 assembly 1) Remove sun gear No. 1 (5). 2) Remove carrier No. 1 and sun gear No. 2 assembly (6).
Disassembly
1. Oil drain Remove the drain plug and drain oil from the swing machinery. 6 Swing machinery case: 2.5 l Swing motor assembly 1) Remove oil level pipe (1). 2) Remove hose (2). 3) Remove 15 swing motor mounting bolts (3).
2.
PC138US, USLC-8
SEN02711-00
3)
ub-disassembly of carrier No. 1 and sun gear No. 2 assembly 1] Remove snap ring (7) and remove thrust washer (8), gear (9), bearing (10) and thrust washer (11).
3)
Sub-disassembly of carrier No. 2 assembly. 1] Press pin (20) in and punch out shaft (21) from carrier (22). a Remove the shaft, then remove pin (20). 2] Remove thrust washer (23), gear (24), bearing (25) and thrust washer (26).
2]
3]
Drive pin (12) in and punch out shaft (13). a Remove the shaft, then remove pin (12). Remove snap ring (14) and remove sun gear No. 2 (15) from carrier (16).
6.
Retainer and collar 1) Remove retainer (27). 2) Set the shaft and case assembly to the press, and push 2-piece collar (28) using a push tool to press bearing (29). 3) Remove 2-piece collar (28).
4. 5.
Ring gear Remove ring gear (17). Carrier No. 2 assembly 1) Remove spacer (18). 2) Remove carrier No. 2 assembly (19).
PC138US, USLC-8
SEN02711-00
7.
Shaft assembly 1) Set the shaft and case assembly (30) to block [2], and remove shaft assembly (31) with the press using push tool [3]. 2) Remove bearing (29).
2)
Use puller [4] to remove bearing outer races (37) and (38) from case (36).
3)
Use tool F2 to remove bearing (32) and collar (33) from shaft (34).
8.
Oil seal and bearing outer race 1) Remove oil seal (35) from case (36).
PC138US, USLC-8
SEN02711-00
Assembly
1. Bearing outer race Use push tool F3 to press outer races (37) and (38) to case (36).
5) 6)
Install 2-piece collar (28). Screw in bolt (12 mm, P=1.75) to the case. Using push-pull scale [5] to measure the tangential force in the direction of rotation. a Tangential force: Max. 176.4 N {18kg} a Tangential force refers to a maximum value at the start of rotation.
2.
Shaft assembly 1) Install O-ring to inside collar (33) and install to shaft (34). 2) Use push tool F4 to press bearing (32) with the press.
3.
Oil seal Using tool F6 to press oil seal (35). a Replace the oil seal with a new one. 2 Circumference of oil seal: LG-6 a Be careful not to allow LG-6 to attach to the lip and shaft. 2 Oil seal lip portion: Grease (G2-LI)
3) 4)
Set case (39) to shaft assembly (31). Use push tool F5 to press bearing (29) with the press to the position where the 2piece collar can be entered. a Press-fit force: 11,760 N {1,200kg} a Press the bearing gradually by rotating the case.
4.
Retainer Install retainer (27).
PC138US, USLC-8
SEN02711-00
5.
Carrier No. 2 assembly 1) Sub-disassembly of carrier No. 2 assembly 1] Assemble bearing (25) to gear (24). 2] Install thrust washer (23) and (26) and set gear assembly to carrier (22).
6.
Ring gear Install O-ring (40) to the shaft and case assembly, and install ring gear (17).
3]
4]
Align the shaft to the carrier pin hole position, and install shaft (21) by lightly hammering with a plastic hammer, etc. a Install the shaft by turning the planetary gear. Be careful not to damage the thrust washer. Insert pin (20). a Insert the pin, then caulk the pin of the carrier. 7. Carrier No. 1 and sun gear No. 2 assembly 1) Sub-disassembly of carrier No. 1 and sun gear No. 2 assembly 1] Install carrier No. 1 (16) to sun gear No. 2 (15) and Install snap ring (14). 2] Align the shaft to the carrier pin hole position, and install shaft (21) by lightly hammering with a plastic hammer, etc. 3] Insert pin (12). a Insert the pin, then caulk the pin of the carrier. a Check that difference (a) between the shaft and carrier is 0.2 mm or less.
2) 3)
Install carrier No. 2 assembly (19) to the shaft and case assembly. Install spacer (18).
10
PC138US, USLC-8
SEN02711-00
4]
Install thrust washer (11), bearing (10), gear (9) and thrust washer (8), and install snap ring (7). a Use new snap ring. a ?hen installing the snap ring, do not allow the mating space to expand wider than 11 mm to prevent the snap ring from deforming. a After installation, check that the snap ring is firmly in place.
8.
Swing motor assembly 1) Install swing motor assembly (4). 2) Install 15 swing motor mounting bolts (3). 3 Swing motor mounting bolt: 110.3 12.3 Nm {11.25 1.25 kgm} 3) Install hose (2). 4) Install oil level pipe (1).
9.
Refilling with oil Tighten the drain plug, and refill engine oil E030 from the oil filler port.
5
2) 3)
Install carrier No. 1 and sun gear No.2 assembly (6) to the shaft case assembly. Install sun gear No. 1 (5).
Swing machinery case: 2.5 l
PC138US, USLC-8
11
SEN02711-00
Removal and installation of swing circle assembly

Removal
k
Installation
Installation is performed in the opposite way to removal. Swing circle mounting bolt: Liquefied adhesive (LT-2) Swing circle mounting bolt : 245 308.9 Nm {25 31.5 kgm}
Gradually loosen the hydraulic oil tank cap to bleed the air from the tank after grounding the work equipment and stopping the engine and lock the safety lock lever. Remove the revolving frame assembly by referring to "Removal of revolving frame assembly". Temporarily lift swing circle assembly (1) to remove the 38 mounting bolts. [*1] Remove swing circle assembly (1). [*2] 4 Swing circle assembly : 155 kg
[*1]
2 3
1.
2. 3.
[*2] a Lift swing circle assembly (1) and install it on the track frame with the inner wheel soft zone (S) symbol of the inner race facing the right side of the body as shown in the figure. 2 Amount of circle grease sealed: 9.1 l grease (G2-LI)
12
PC138US, USLC-8
SEN02711-00
PC138US, USLC-8
13
SEN02711-00
14
PC138US, USLC-8
SEN02712-00
Machine model
Serial number

Undercarriage and frame
Disassembly and assembly of track roller....................................................................................................... 2 Disassembly and assembly of idler assembly ................................................................................................ 5 Disassembly and assembly of recoil spring .................................................................................................... 8 Removal and installation of of track shoe assembly ......................................................................................11 Removal and installation of sprocket ............................................................................................................ 13 Removal and installation of revolving frame assembly ................................................................................. 14 Removal and installation of counterweight assembly (Machine without add-on weight) .............................. 16 Removal and installation of counterweight assembly (Machine with add-on weight) ................................... 18
PC138US, USLC-8
SEN02712-00
Disassembly and assembly of track roller

Special tools
Symbol 1 2 Part No. Part name
3.
1
New/Remodel
Pull out roller (4) from shaft (5). a It is filled with 75 85 cc of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. Remove floating seal (6) (on opposite side) from roller (4) and shaft (5).
4.
Necessity
790-434-1650 791-601-1000
Installer Oil pump
t 1 q 1
Disassembly
1. Remove pin (1), then remove collar (2).
Q'ty
5. 6.
Remove collar (8) from shaft (5). Remove bushings (9) and (10) from roller (4).
5 6 10 4 9 3 1 2 11
CLP00790
2.
Remove floating seal (3) from collar (2) and roller (4).
PC138US, USLC-8
SEN02712-00
Assembly
1. 2. 3. Using push tool [1], press fit bushings (9) and (10) to roller (4). Assemble collar (8) to shaft (5). Using tool M1, install floating seal (6) to shaft (5). a When assembling the floating seal, clean the contact surface of O-ring (6c) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal.
6. 7.
Turn over roller (4) and shaft (5) assembly. Using tool M1, install floating seal (3) to collar (2). a For details of the precautions when installing floating seals (3a) and (3c), see the precautions marked a for Step 3.
8.
Assemble collar (2) to shaft (5), and install pin (1).
4.
Using tool M1, install floating seals (6) and (3) to roller (4). a For details of the precautions when installing floating seals (6b) and (6d), and (3b) and (3d), see the precautions marked a for Step 3. Assemble shaft (5) to roller (4). 9.
5.
CLP00867
Using tool M2, apply standard pressure to roller oil filler port and check air leakage. a Standard pressure: 0.1 MPa {1 kg/cm} a Method of checking: The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.
PC138US, USLC-8
SEN02712-00
10. Using tool M2, fill track roller assembly with oil, then tighten plug (11).
5
Track roller oil: 75 85 cc (EO30-CD)
PC138US, USLC-8
SEN02712-00
Disassembly and assembly of idler assembly

Special tools
Symbol L 1 Part No. Part name
1
New/Remodel
Necessity
791-675-1510
Installer
t 1
Disassembly
1. 2. 3. Remove dowel pin (1), then remove support (2). Remove floating seal (3) from support (2) and idler (4). Pull out idler (4) from shaft (5) and support assembly (7). a It is filled with approx. 90 cc of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. Remove floating seal (6) (on opposite side) from idler (4) and shaft (5) and support assembly (7). 5. 6. Remove dowel pin (8), then remove support (7) from shaft (5). Remove bushings (9) and (10) from idler (4).
4.
Q'ty
PC138US, USLC-8
SEN02712-00
Assembly
1. Press fit bushings (9) and (10) to idler (4).
4.
Assemble shaft (5) and support assembly (7) to idler (4).
2. 3.
Fit O-ring and install support (7) to shaft (5) with dowel pin (8). Using tool L1, install floating seal (6) to idler (4) and shaft (5) and support assembly (7). a Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. a Remove all grease and oil from the contact surface of the O-ring and the floating seal.
5.
Add oil between shaft (5) and idler (4).

5
Oil: 90 105 cc (EO30)
6.
Using tool L1, install floating seal (3) to idler (4) and support (2). a Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. a Remove all grease and oil from the contact surface of the O-ring and the floating seal.
PC138US, USLC-8
SEN02712-00
7.
Install O-ring, then install support (2) with dowel pin (1).
PC138US, USLC-8
SEN02712-00
Disassembly and assembly of recoil spring

Special tools
791-600-2001 or 791-685-8006 791-635-3160 L 2 790-201-2770 790-101-1600 790-101-1102
Compressor (A) t Compressor (B) Extension Spacer Cylinder (686 kN {70 ton}) Pump
t 1 t 1 t 1 t 1
Disassembly
1.
Remove lock plate (1), then remove seat (2) and valve (3). a Do not remove grease fitting (17) from the valve (3). Remove yoke piston assembly (5) from recoil spring assembly (4). Disassembly of recoil spring assembly (4) 1) Set recoil spring assembly (4) to tool L2. k The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. a Installed load of spring: 84,300 N {8,600 kg}
2. 3.
Q'ty 1 1
PC138US, USLC-8
SEN02712-00
2)
3) 4) 4.
Apply hydraulic pressure slowly to compress spring, then remove nut (6). a Compress the spring to a point where the nut becomes loose. a Release the hydraulic pressure slowly to remove the spring tension. Remove pilot (8), and spring (7). Remove snap ring (10), dust seal (11) and bush (12) from cylinder (9).
Disassembly of yoke piston (5) assembly 1) Remove snap ring (14), then remove Upacking (15). 2) Remove wear ring (16) from yoke piston (13).
PC138US, USLC-8
SEN02712-00
Assembly
1.
Assembly of yoke piston assembly 1) Assemble wear ring (16) to yoke piston (13). 2) Assemble U-packing (15) and secure with snap ring (14). Assembly of recoil spring assembly 1) Using tool [1], press fit bush (12) to cylinder (9). 2) Using tool (L3), press fit dust seal (11) to cylinder (9).
2.
5) 3.
Remove recoil spring assembly (4) from tool L2.
Assemble yoke piston assembly (5) to recoil spring assembly (4). 2 Yoke piston sliding portion wear ring : Grease (G2-LI) Fit valve (3) and seat (2), and secure with lock plate (1). a Install the valve so that the direction of the fitting (17) is to the outside. Fill inside of cylinder with a approximately 120 cc of grease. 2 Inside cylinder: Grease (G2-LI)
4. 3) 4) Assemble cylinder (9) and pilot (8) to spring (7), and set to tool L2. Apply hydraulic pressure slowly to compress spring, and tighten nut (6) so that installed length of spring is dimension (a). a Installed length (a) of spring: 390 mm
5.
10
PC138US, USLC-8
SEN02712-00
Removal and installation of of track shoe assembly

Special tools
2.
1
3.
New/Remodel
Move machine forward so that position of master pin is at front of idler, and set block [1] in position. Using tool R, pull out master pin. [*2] Remove tool R, pull out temporary pin, and remove dust seal, then drive machine in reverse to lay out track (2). [*3]
Symbol
Part No.
Part name
Necessity
4.
791-616-1110 791-616-1121 791-616-1131 791-616-1150 791-616-1160 791T-616-1280 791-620-3530 R 791-620-3260 791-620-3270 01011-62260 01643-62260 01011-61455 01643-31445 790-105-1100 790-101-1102
Frame Plate Plate Guide Adapter Adapter Push Push Guide Bolt Washer Bolt Washer Cylinder (297 kN {30 ton}) Pump
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 2 t 2 t 3 t 3 t 1 t 1
Removal
1. Lower work equipment to ground, then loosen lubricator (1), and relieve track tension. [*1] k The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.
Q'ty
PC138US, USLC-8
11
SEN02712-00
Installation
[*1] a Adjust the track tension. For details, see Testing and adjusting, "Testing and adjusting track tension". [*2] a Use tool R and press fit the master pin so that the protrusion of the master pin is dimension (a). Protrusion (a) of master pin: 5.5 2 mm [*3] a When assembling the dust seal, coat the bushing contact surface with grease (G2-LI).
a
If the rubber of the road liner (rubber pad type) becomes worn or broken and the head of the mounting bolt becomes damaged, replace the shoe with a new part immediately. If the head of the mounting bolt becomes fla ttened, it will be impossible to remove it.
12
PC138US, USLC-8
SEN02712-00
Removal and installation of sprocket

Removal
1. 2.
Installation
Carry out installation in the reverse order to removal. Threads of sprocket mounting bolt: Adhesive (LT-2) Sprocket mounting bolt: 323.6 362.8 Nm {33 37 kgm}
Expand the track shoe assembly. For details, see Expansion of track shoe assembly. Swing the work equipment by 90 and push up the machine with it, and then set blocks [1] between the track frame and track shoe.
[*1]
2 3
3.
Remove the 15 mounting bolts and lift off sprocket (1). [*1] 4 Sprocket: 35 kg
PC138US, USLC-8
13
SEN02712-00
Removal and installation of revolving frame assembly

Removal
k
7.
1
8.
Disconnect drain hose (8) and hoses (9) and (10) between control valve and left travel motor from center swivel joint. Disconnect hoses (11) and (12) between control valve and right travel motor. Disconnect hoses (13) between solenoid valve (Boost) and both travel motors.
Disconnect the negative () terminal of the battery. Remove the work equipment assembly by referring to "Removal of work equipment assembly". Disconnect boom cylinder hoses (1) (right) and (2) (left). a Be sure to apply the blind plug to the disconnected hose. Remove covers (3) and (4). Temporarily lift the boom cylinder to remove pins (5) on the bottom. a Check the number and position of the shims mounted. [*1]
1.
9.
10. Disconnect plate (14) from revolving frame.
2.
3. 4.
11. Remove mounting bolts (15), leaving one each at front and rear. [*2]
5.
Lift boom cylinder assembly (6) to remove it. 4 Boom cylinder assembly: 120 kg Remove operator cab assembly (7) by referring to "Removal of operator cab assembly".
6.
14
PC138US, USLC-8
SEN02712-00
12. Lift revolving frame assembly (16) to loosen remaining bolts (15). a Carefully remove the remaining bolts by balancing them using the crane. a Carefully lift and remove them to prevent them from coming in contact with the center swivel joint or other parts. 4 Revolving frame assembly: 6,100 kg
Installation
q
Installation is performed in the opposite way to removal. Surface inside bushing during pin assembly: Hyper white grease (G2-T) Greasing after pin assembly: Hyper white grease (G2-T)
[*1]
2 2
Never put your finger in the pin hole when adjusting the position. Adjust the clearance between the mount on the boom cylinder bottom and the frame using the shims so that it becomes 1mm or less. Swing circle contacting face: Liquefied gasket (LG-1) Revolving frame mounting bolt screw: Liquefied adhesive (LT-2) Revolving frame mounting bolt: 277.5 32.4 Nm {28.3 3.3 kgm}
[*2]
2 2 3
Supplying oil (hydraulic oil tank) Supply oil from the oil filler port to the specified level, start the engine to circulate oil in the piping and recheck the oil level. Bleeding air Bleed the air. For details , see Testing and adjusting, "Bleeding air from each part".
PC138US, USLC-8
15
SEN02712-00
Removal and installation of counterweight assembly (Machine without add-on weight) 1

Removal
k
5.
Demporarily lift the counterweight, and remove 3 mounting bolts (9). [*1]
Stop the machine on a level ground, stop the engine, and lower the work equipment to the ground. Disconnect the cable from the negative (-) terminal of the battery. Remove monitor camera wiring protection cover (1). Remove engine upper covers (2) to (5). 6. Lift and remove counterweight assembly (10). a Shift the counterweight horizontally to backward before lifting so that it will not interfere with the machine main body. 4 Counterweight assembly : 3,300 kg (standard specification) : 2,900 kg (Blade specification)
1. 2.
3.
Disconnect monitor camera wiring (7).
4.
Disconnect flywheel case lubrication hose (8).
16
PC138US, USLC-8
SEN02712-00
Installation
q
Carry out installation in the reverse order to removal. Counterweight mounting bolt: Adhesive (LT-2) Counterweight mounting bolt: 3,430 4,212 Nm {350 430 kgm} Target: 3,626 Nm {370 kgm}
[*1]
2 3
PC138US, USLC-8
17
SEN02712-00
Removal and installation of counterweight assembly (Machine with add-on weight)

Removal
k
6.
Sling the counterweight and remove 3 mounting bolts (5). [*2]
Stop the machine on a level ground, stop the engine, and lower the work equipment to the ground. Disconnect the cable from the negative (-) terminal of the battery. Perform steps 1 4 of "Removal and installation of counterweight assembly (Machine without add-on weight) Remove the 2 monitor camera mounting bolts to remove the monitor camerai1j. Remove mounting bolt (2) on the top of the add-on weight. Sling add-on weight (3) and remove 2 mounting bolts (4) from its side. Lift off add-on weight (3). [*1] 4 Add-on weight: 510 kg 7. Lift off counterweight assembly (6). a First, move the counterweight assembly horizontally toward the rear so that it will not interfere with the machine body, and then lift it up. 4 Counterweight assembly : 3,300 kg (Standard specification) : 2,900 kg (Blade specification)
1.
2. 3. 4. 5.
18
PC138US, USLC-8
SEN02712-00
Installation
q
Carry out installation in the reverse order to removal.
[*1] Installation procedure for add-on weight 1) Put faces (X) and (Y) to the insert boss of the counterweight. 2) Install top bolt (2) and tighten it lightly. 2 Add-on weight mounting bolt: Adhesive (LT-2) 3) Adjust clearance (a) to 10 3 and install side bolts (4). 2 Add-on weight mounting bolt: Adhesive (LT-2) 3 Add-on weight mounting bolt: 1,860 3,040 Nm {190 310 kgm} 4) Tighten the top bolt. 3 Add-on weight mounting bolt: 1,860 3,040 Nm {190 310 kgm}
[*2]
2 3
Counterweight mounting bolt: Adhesive (LT-2) Counterweight mounting bolt: 3,430 4,212 Nm {350 430 kgm} Target: 3,626 Nm {370 kgm}
PC138US, USLC-8
19
SEN02712-00
20
PC138US, USLC-8
SEN02713-00
Machine model
Serial number

Hydraulic system
Removal and installation of center swivel joint assembly ............................................................................... 2 Disassembly and assembly of center swivel joint assembly........................................................................... 4 Removal and installation of hydraulic tank assembly...................................................................................... 5 Removal and installation of hydraulic pump assembly ................................................................................... 8 Removal and installation of control valve assembly ..................................................................................... 12 Disassembly and assembly of control valve assembly ................................................................................. 17 Disassembly and assembly of work equipment PPC valve assembly .......................................................... 27 Disassembly and assembly of travel PPC valve assembly........................................................................... 30 Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 32
PC138US, USLC-8
SEN02713-00
Removal and installation of center swivel joint assembly 1

Removal
k
Gradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine. Disconnect the negative () terminal of the battery. Remove cover (1), (2) at rear of boom. Remove filter and bracket assembly (3). (for attachment specification) 9. Disconnect hoses (for changing the speed) (18) and (19) between both travel motors and swivel joint.
1. 2.
3. 4.
Disconnect hoses (4) (9) between travel motor and swivel joint. Remove elbow (10).
10. Remove mounting bolts and lift off center swivel joint assembly (20). [*1] a Sling the joint assembly temporarily, then remove the bolts. 4 Center swivel joint assembly : 30 kg (Standard specification) : 45 kg (Blade specification)
5. 6. 7. 8.
Disconnect drain hose (11). Disconnect hoses (12) (15) between control valve and swivel joint. Disconnect hose (16) from solenoid valve. Remove plate (17).
PC138US, USLC-8
SEN02713-00
Installation
q
Installation is performed in the opposite way to removal. Mounting bolt screw: Liquefied adhesive (LT-2) Mounting bolt: 98.1 123.0 Nm {10.0 12.5 kgm}
[*1]
2 3
Bleeding air Bleed air from the swing motor. For details, see Testing and adjusting, "Bleeding air from each part".
PC138US, USLC-8
SEN02713-00
Disassembly and assembly of center swivel joint assembly

Special tools
790-101-2501 790-101-2510 790-101-2520 790-101-2540 T 791-112-1180 790-101-2630 790-101-2570 790-101-2560 791-112-2650
Push puller Block Screw Washer Nut Leg Washer Nut Adapter
q 1 1 1 1 1 2 4 2 2
Sketch
Q'ty
Assembly
1. 2. Fit slipper seals (7) and O-rings (6) to swivel rotor. Set swivel shaft (5) to block, then fit it by using push tool and hitting swivel rotor (4) lightly with plastic hammer. 2 Contact surfaces of rotor and shaft : Grease (G2-LI) a When installing the rotor, take care not to damage the slipper seals and O-rings. Install ring (3) and secure with snap ring (2). Fit O-ring and install cover (1). 3 Swivel joint mounting bolt : 31.3 2.9 Nm {3.2 0.3 kgm}
Disassembly
1. 2. 3. 4. Remove cover (1). Remove snap ring (2). Using tool T, pull out swivel rotor (4) and ring (3) from swivel shaft (5). Remove O-rings (6) and slipper seals (7) from swivel shaft (5). 3. 4.
PC138US, USLC-8

a
SEN02713-00
Removal and installation of hydraulic tank assembly

Special tools
796-460-1210 795-799-1131
Oil Stopper Adapter
q 1 q 1
Removal
k
Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative () terminal of the battery beforehand. Loosen hydraulic drain plug(1) and drain the hydraulic oil. [*1] 6 Hydraulic oil tank: 69 l (Capacity: 120 l)
Sketch
Q'ty
2.
Removal of exterior parts 1) Removal handrail(2) 2) Removal cover(3) (6).
1.
3.
Tank rear wiring, hose and clamps 1) Disconnect drain hose (7). 2) Disconnect hydraulic pump suction hose (8).
PC138US, USLC-8
SEN02713-00
3) 4) 5)
Remove engine oil filter bracket (9). a Move the filter assembly close to the engine. Disconnect hose (10) from radiator. Disconnect fuel level sensor wire (11).
7.
Removal of hydraulic oil tank mounting bracket and mounting bolts. 1) Remove fuel tank rear mounting brackets (23).
2) 4. Disconnect 8 return hoses (12) to (19) in front of the tank. a Record the installed position of respective hoses. 3)
Remove wiring and hose mounting brackets (24). Remove fuel tank front mounting brackets (25).
5. 6.
Disconnect swing machinery oil level pipe clamp (20). Disconnect 2 drain hoses (21) and clamps (22).
4)
Remove 4 hydraulic oil front mounting bolts (26). [*2]
PC138US, USLC-8
SEN02713-00
8.
Lift and remove hydraulic oil tank assembly (27). 4 Hydraulic oil tank assembly: 95 kg
Installation
q
Carry out the installation in the reverse order of removal. Drain plug (1): 58.8 78.4 Nm {6 8kgm} Target: 68.6 Nm {7 kgm} Hydraulic oil tank: 69 l (Capacity: 120 l) Thread of hydraulic oil tank mounting bolt: Adhesive (LT-2) Hydraulic oil tank mounting bolt (27): 245 309 Nm {25 31.5 kgm}
[*1]
3 5
[*2]
2 3
PC138US, USLC-8
SEN02713-00
a
Removal and installation of hydraulic pump assembly

Special tools
796-460-1210 795-799-1131
Oil Stopper Adapter
q 1 q 1
Removal
k
Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative (-) terminal of the battery beforehand. Loosen hydraulic drain plug(1) and drain the hydraulic oil. [*1] 6 Hydraulic oil tank: 69 l (Capacity: 120 l)
Sketch
Q'ty
2.
Remove covers (2) and (3).
1.
3. 4. 5.
Remove radiator sub tank (4). Disconnect water assembly (6). separator and bracket
Remove engine oil filter bracket (5). a Move the filter assembly close to the engine.
PC138US, USLC-8
SEN02713-00
6. 7.
Disconnect damper case oil filler hose(7). Removal of muffler assembly 1) Remove divider boards (8) and rubber covers (9) and (10).
4)
Disconnect 6 hoses(17) to (22). a Record the installed position of respective hoses.
9. 2) 3) 4) Remove muffler drain tube (11). Remove 4 muffler mounting bolts (12). Lift and remove muffler assembly (13).
Disconnection hydraulic pump 1) Temporarily lift the pump (23) and remove mounting bolts (24). a Temporarily lift the pump by the engine side using chain block [1] and by the near side using wire rope [2]. 2) Lift and disconnect hydraulic pump (23) from engine. 4 Hydraulic pump assembly: 110 kg
8.
Disconnecting wiring and hoses 1) Disconnect EPC solenoid wiring connector V11(14) and hydraulic oil temperature sensor wiring connector P22 (15). 2) Removes suction tube (16) from hydraulic pump.
PC138US, USLC-8
SEN02713-00
10. Removal procedures of work equipment pump Remove work equipment pump by pulling it toward the front according to the following procedures. 1) Shift the pump closer to the front end until wire rope [2] almost makes contact with the counterweight.
4)
Install wire rope [2] to the work equipment pump from outside the counterweight. a Apply rubber plates or cloth [3] to the counterweight to prevent it from being damaged by wire rope.
5) 6) 2) 3) Pull chain block [1] up and loosen wire rope [2]. Disconnect wire rope [2] from the work equipment pump.
Lower chain block [1] and hold the work equipment pump in level state. Shift the pump closer to the front end until chain block [1] almost makes contact with the counterweight.
7)
Lower the chain block [1] and loosen chain block [1].
10
PC138US, USLC-8
SEN02713-00
8)
Disconnect chain block from the work equipment pump, shift the work equipment pump (23) forward to the front and remove it.
Installation
q
PC138US, USLC-8
11
SEN02713-00
a
Removal and installation of control valve assembly

Special tools
When using tool D to stop oil, remove the hydraulic tank strainer in advance.
796-460-1210 795-799-1131
Oil Stopper Adapter
q 1 q 1
Removal
k
Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." Disconnect the negative () terminal of the battery beforehand. The following procedure explain about "Attachment and multi-pattern specifications." Fasten tags to respective connecters and piping for identification to prevent any mistakes when re-installing. Loosen hydraulic drain plug(1) and drain the hydraulic. [*1] 6 Hydraulic oil tank: 69 l (Capacity: 120 l)
Sketch
Q'ty
2.
Removal of exterior parts 1) Removal handrail(2) 2) Removal cover (3) and (6).
a a
1.
3.
Removal of solenoid valve frame 1) Disconnect hoses (5) to (12). (Index No. , Color band , Hose Name) (5); (Red-Green) PPC basic pressure (6); (Red) Travel HI/LO (7); (Red-Red) Swing paring brake (8); () Merge-divider valve selection signal (9); () Travel junction valve (10); () P1Pilot pressure (11); () Travel junction valve (12); () Pilot pressure #3
12
PC138US, USLC-8
SEN02713-00
2)
Disconnect connectors (13) to (23). (13): V10 (Bucket dump solenoid) (14): M14 (ravel alarm buzzer)
4.
Removal of pressure switch connector 1) Disconnect wiring connectors (26) to (32). (26): P01 (Bucket dump switch) (27): P02 (Arm dump switch) (28): P03 (Boom raise switch) (29): P04 (Bucket digging switch) (30): P05 (Boom digging switch) (31): P06 (Boom lower switch) (32): P07 (Right swing switch) 2) Remove pressure switch mounting bracket (33).
3) 4)
V1 (PPC Basic pressure) V2 (Travel HI/LO) V3 (Swing paring brake) V4 (Travel junction valve) V5 (Merge-divider valve selection signal) (20): P25 (Pump pressure sensor) (21): P26 (Travel right rear pressure sensor) (22): P27 (Travel left rear pressure sensor) (23): P29 (Dummy) Disconnect clamp (24) from solenoid valve frame. Remove solenoid valve frame assembly (25).
(15): (16): (17): (18): (19):
5.
Disconnection of multi-valve assembly wiring and hose (for machines installed with the assembly) 1) Disconnect connectors (34) and (35). (34): (P08) Left swing switch (35): (P67) Right swing switch a Connector P67 is connected to connector P07. a For a machine without the multi-valve assembly, connector P08 is positioned under P07 of the pressure switch connector mounting bracket.
PC138US, USLC-8
13
SEN02713-00
2)
Disconnect hoses (36) to (39). (Index No. , Color band , Hose Name) (36); (Orange) Arm dump (37); (White) Swing left (38); (Red) Bucket dump (39); (Red-Yellow) Boom raise
6.
Disconnection of control valve connectors and hoses (Connectors) 1) Disconnect connectors (40) to (42) from right side of control valve. (40): P64 (Bucket digging switch) (41): P65 (Arm digging switch) (42): P66 (Boom lower switch)
2)
Disconnect connectors (43) to (47) from left side (operator cab side) of control valve. (43): P61 (Bucket dump switch) (44): P62 (Arm dump switch) (45): P63 (Boom raise switch) (46): P09 (Right travel forward switch) (47): P10 (Left travel forward switch)
(Hoses) 3) Disconnect 15 hoses (48) to (62) right and front side of control valve. (48); () (49); (Blue) (50); (Blue) (51); (Green) (52); (Green) (53); (Black) (54); (Black) (55); () (56); (Yellow) (57); (Yellow) (58); (Brown) (59); () (60); () (61); (Black) (62); (Black)
14
PC138US, USLC-8
SEN02713-00
(78); (79); (80); (81); (82); (83);
(Yellow- Black) (Yellow- Green) (Yellow- Brown) (Yellow- Orange) (White) (Brown)
4)
Disconnect 5 hoses (63) to (67) left side (operator cab side) of control valve. (63); () (64); (Red- Red) (65); (Red) (66); (Black- Yellow) (67); (Brown- Yellow)
7.
Disconnect attachment select valve connecting hose (84).
5)
Disconnect all of hoses (68) to (83) back side(engine side) of control valve. (68); (White) (69); (Brown) (70); (Red) (71); (Blue) (72); (Orange) (73); (Green) (74); () (75); (Black) (76); () (77); ()
8.
Remove 3 multi-valve mounting bolts (85) and remove multi-valve assembly (86).
PC138US, USLC-8
15
SEN02713-00
9.
Remove bracket mounting bolt (87) and r emov e multi - val ve as sem bly m ounti ng bracket (88).
Installation
q
10. Loosen 4 control valve mounting bolt(89) and lift and remove control valve assembly (90). 4 Control valve assembly: 95 kg
16
PC138US, USLC-8
SEN02713-00
Disassembly and assembly of control valve assembly

Assembly
PC138US, USLC-8
17
SEN02713-00
The appearance and section of only the 8-spool valve (blade + service valve) are shown here. A1 : To swing motor A2 : To blade cylinder bottom A3 : To left travel motor A4 : To right travel motor A5 : To boom cylinder bottom A6 : To arm cylinder head A7 : To bucket cylinder head A8 : To attachment B1 : To swing motor B2 : To blade cylinder head B3 : To left travel motor B4 : To right travel motor B5 : To boom cylinder head B6 : To arm cylinder bottom B7 : To bucket cylinder bottom B8 : To attachment LS : To pump LS valve P1 : From main pump P2 : From main pump PP : To main pump PR : To solenoid valve, PPC valve and EPC valve PS : From solenoid valve of merge-divider valve TB : To tank TC : To oil cooler BP1: From boom raise PPC valve LS1: LS1 pressure pickup port LS2: LS2 pressure pickup port 1. 2. 3. 4. 5. 6. 7. 8. 9. Cover Service valve Bucket valve Arm valve Boom valve Right travel valve Left travel valve Blade valve Swing valve LS3 : LS3 pressure pickup port PA : From swing left PPC valve PA2 : From blade lower PPC valve PA3 : From left travel forward PPC valve PA4 : From right travel forward PPC valve PA5 : From boom raise PPC valve PA6 : From arm dump PPC valve PA7 : From bucket dump 1 PPC valve PA8 : From service PPC valve PB1 : From swing right PPC valve PB2 : From blade raise PPC valve PB3 : From left travel reverse PPC valve PB4 : From right travel reverse PPC valve PB5 : From boom lower PPC valve PB6 : From arm in PPC valve PB7 : From bucket curl PPC valve PB8 : From service PPC valve PMAX: Pressure sensor port PP1 : PP1 pressure pickup port PP2 : PP2 pressure pickup port PPI1 : Pump 1 pressure pickup port PPI2 : Pump 2 pressure pickup port PRI : PR pressure pickup port PST : From travel junction solenoid valve TS1 : To tank PS2 : To tank TSW : To swing motor TSW : To swing motor 10. 11. 12. 13. 14. 15. 16. 17. 18. Block Swing bleed valve LS check valve Travel junction valve + LS check valve Arm regeneration valve Boom hydraulic drift prevention valve Merge-divider valve block Nut Bolt
18
PC138US, USLC-8

a
SEN02713-00
In this section, only the precautions for assembling the control valve assembly are described. Before assembling the parts, apply engine oil to their sliding surfaces. 2 Mating face: Liquid sealant (Sealend 242 or equivalent) The tightening torque of the parts and the precautions are shown below (in random order). Install cover (1): Tighten the 4 nuts (17) in the diagonal order ([1] [4]) according to the following procedure. 1st time: 3 58.8 68.6 Nm {6 7 kgm} 2nd time: 3 78.5 88.3 Nm {8 9 kgm} 3rd time: 3 98.1 113 Nm {10 11.5 kgm} The height of the stud top above the nut top: 0.5 3 mm Assembling block (10): Tighten the 4 bolts (18) in the diagonal order ([1] [4]) according to the following procedure. 1st time: 3 19.6 29.4 Nm {2 3 kgm} 2nd time: 3 39.2 49.0 Nm {4 5 kgm} 3rd time: 3 58.8 73.5 Nm {6 7.5 kgm} Degrease and dry up the threads of the plugs and female screws in advance. Do not apply pressure for 2 hours after tightening them.
PC138US, USLC-8
19
SEN02713-00
20
PC138US, USLC-8
SEN02713-00
PC138US, USLC-8
21
SEN02713-00
22
PC138US, USLC-8
SEN02713-00
PC138US, USLC-8
23
SEN02713-00
24
PC138US, USLC-8
SEN02713-00
AA1. AA2. AA3. AA4. AA5. AA6. AA7. AA8. AA9. AA10. AA11. AA12. AA13. AA14. CC1 CC2. DD3. DD4. DD5. DD6. DD7.
Safety-suction valve (Service) Suction valve (Bucket) Suction valve (Arm) Suction valve (Boom) Lift check valve Suction valve (Right travel) Suction valve (Left travel) Suction valve (Blade) Safety-suction valve (Blade) Suction valve (Left travel) Suction valve (Right travel) Main relief valve Suction valve (Boom) Suction valve (Arm)
AA15. AA16. AA17. BB18. BB19. BB20. BB21. BB22. BB23. BB24. BB25. BB26. BB27.
Suction valve (Bucket) Safety-suction valve (Service) Safety-suction valve Spool (Service) Spool (Bucket) Spool (Arm) Spool (Boom) Spool (Right travel) Spool (Left travel) Spool (Blade) Spool (Swing) Unload valve Unload valve
LS selector valve Cooler bypass valve Pressure compensation valve R (Service) Pressure compensation valve R (Bucket) Pressure compensation valve R (Arm) Pressure compensation valve R (Boom) Pressure compensation valve R (Right travel) DD8. Pressure compensation valve R (Left travel) DD9. Pressure compensation valve R (Blade) DD10. Pressure compensation valve R (Swing) FF1. FF2. FF3. FF4. FF5. FF6. FF7. FF8. FF9. FF10. LS selector valve Pressure compensation valve F (Swing) Spool (Swing) Pressure compensation valve R (Swing) LS bleed valve Safety-suction valve (Blade) Suction valve (Blade) Spool (Blade) Pressure compensation valve R (Blade) Pressure compensation valve F (Blade)
DD11. Pressure compensation valve F (Swing) DD12. Pressure compensation valve F (Blade) DD13. Pressure compensation valve F (Left travel) DD14. Pressure compensation valve F (Right travel) DD15. Merge-divider valve spool DD16. Pressure compensation valve F (Boom) DD17. Pressure compensation valve F (Arm) DD18. Pressure compensation valve F (Bucket) DD19. Pressure compensation valve F (Service)
FF11. FF12. FF13. FF14. FF15. FF16. F: R:
Pressure compensation valve R (Left travel) Suction valve (Left travel) Suction valve (Left travel) Spool (Left travel) Pressure compensation valve F (Left travel) LS check valve
Flow control valve Pressure reducing valve
PC138US, USLC-8
25
SEN02713-00
JJ1. JJ2. JJ3. JJ4. JJ5. JJ6. JJ7. JJ8.
Pressure compensation valve F (Right travel) Suction valve (Right travel) Suction valve (Right travel) Spool (Right travel) Pressure compensation valve R (Right travel) Travel junction valve + LS check valve Unload valve LS bypass valve
JJ9. JJ10. JJ11. JJ12. JJ13. JJ14. JJ15. JJ16. JJ17. JJ18.
Merge-divider valve spool Main relief valve Cooler bypass valve Lift check valve Pressure compensation valve F (Boom) Suction valve (Boom) Hydraulic drift prevention valve (Boom) Suction valve (Boom) Spool (Boom) Pressure compensation valve R (Boom)
NN1. Pressure compensation valve F (Arm) NN2. Suction valve (Arm) NN3. Suction valve (Arm) NN4. Spool (Arm) NN5. Pressure compensation valve R (Arm) NN6. Hydraulic drift prevention valve (Arm) NN7. Pressure compensation valve F (Bucket) NN8. Suction valve (Bucket) NN9. Suction valve (Bucket) NN10. Spool (Bucket) NN11. Pressure compensation valve R (Bucket)
NN12. Pressure compensation valve F (Service) NN13. Safety-suction valve NN14. Safety-suction valve NN15. Spool (Service) NN16. Pressure compensation valve (Service) NN17. Safety-suction valve NN18. Pressure release plug F: R: Flow control valve Pressure reducing valve
26
PC138US, USLC-8
SEN02713-00
Disassembly and assembly of work equipment PPC valve assembly (For boom, bucket, arm, swing control)
Disassembly
1. 2.
Remove nut (13), then remove disc (12), nut (11) and boot (15). Remove bolts, then remove plate (5). a Do not remove joint (10) unless it is to be replaced. Remove seal (16) and collar (17). Pull out piston (8), and remove retainer (18), springs (7), (6) and (5), and shim (4). a Spring (6), (5) and spring (7), (5) consists of each one of two types of springs with different installed loads in four places, so check the mounting position (oil pressure port) and mark with tags to prevent mistakes when installing. Pull out valve (19) from body (1). a Do not remove plugs (2), (3).
3. 4.
5.
PC138US, USLC-8
27
SEN02713-00
Assembly
a
When assembling, clean and inspect the parts closely and take care fully so that dirt, rust, flaw, etc. will not cause a trouble. When installing plug (2) to body (1), take care that its tip will not enter the hole of the body 20 mm in diameter. 3 Plug (2): 4 9 Nm {0.4 0.9 kgm} The head of plug (3) must not be projected from the body surface. 3 Plug (3): 6 11 Nm {0.6 1.1 kgm} When installing piston (8), apply grease (G2LI) to its outside and the inside of the body hole. Install spring (5) with its small diameter side on the shim (4) side. q Diameter of spring (Inside diameter) Small diameter side: 4.9, Large diameter side: 5.4 When installing springs (6) and (7), note that they are different and they must be installed to different hydraulic ports. q Installed height: 34 mm (Common to both springs) q Installed load: Spring (6) (P1, P2): 29 N {3 kg} Spring (7) (P3, P4): 17.7 N {1.8 kg} 3 Bolt (9): 11.8 14.7 Nm {1.2 1.5 kgm}
1.
2.
3.
4.
5.
28
PC138US, USLC-8
SEN02713-00
6.
When installing joint (10) to body (1), apply LOCTITE as shown below. 1) When installing the joint, apply 1 drop (approx. 0.02 g) of LOCTITE (No. 262) each to 2 places of the female screw (A) of the body. Before installing the joint, thoroughly degrease and dry its male screw and the female screw of the body with DRYSOL. 2) Drop LOCTITE to the following positions. 2 Female screw (A) of body: LOCTITE No. 262 3 Joint (10): 39 49 Nm {4 5 kgm}
9.
Installation of disc (12) 1) Install disc (12) so that each bolt (9) will be the center of each side of disc (12) and they will not interfere with each other during compound operation. (Error: 3 ) 2) When installing disc (12), adjust it so that the play of the lever end will be 0.5 3 mm (at 200 mm from the center of rotation of the lever). 3) Fixing disc (12) with [1], tighten nut (13). a At this time, give play to body (1) or plate (14) and lock with [2]. 3 Nut (13): 93.1 112.7 Nm {9.5 11.5 kgm}
7.
Install nut (11). 2 Apply 1 drop (about 0.02 g) of LOCTITE No. 641 to each of the points shown below. Apply grease (G2-LI) to the rocking part of joint (10) and the contact surfaces of disc (12) and piston (8). 2 Quantity of grease (G2-LI) 1) Rocking part of joint: 2 4 cc/periphery 2) Contact surfaces of disc and piston: 0.3 0.8 cc/place
8.
PC138US, USLC-8
29
SEN02713-00
Disassembly and assembly of travel PPC valve assembly

Disassembly
1. 2. 3. 4. 5. 6. Remove screw (13) to remove lever (9).
Remove pin (5) from plate (8), and remove the plate (8) from the lever (9). Remove mounting bolt (15) to remove case shaft assembly (17). Remove shaft (6) from the case. Remove lever (7), bushing (4) and pin (5) from the case. Remove mounting bolt (16) to remove plate (18) together with damper assembly (19). a Check the thickness and the mounting position of washer (10). Remove mounting bolt (12) to remove damper assembly (19) from plate (18). Remove seal (20) and collar (21). Remove piston (1) to remove retainer (22), springs (23) and (2) and shim (3). a Store shim (3) after checking the thickness and the number of shims at each mounting position.
7. 8. 9.
10. Remove valve (24) from body (25). a Do not remove plug (11).
30
PC138US, USLC-8
SEN02713-00
Assembly
a
When assembling, clean and inspect the parts closely and take care fully so that dirt, rust, flaw, etc. will not cause a trouble. When installing piston (1), apply grease (G2LI) to its outside and the inside of the body hole. Install spring (2) with its small diameter side on the shim (3) side. q Diameter of spring (Inside diameter) Small diameter side: 4.9, Large diameter side: 5.55 Use the insertion jig to insert bushing (4). (Do not drive in the bushing with impact loads of a hammer, etc.) Use the insertion jig to insert pin (5). (Do not drive in the pin with impact loads of a hammer, etc.) Apply grease (G2-LI) to the rocking part of shaft (6) and the contact surfaces of lever (7) and piston (1) and the contact surfaces of plate (8) and pin of lever (9). 2 Quantity of grease (G2-LI) Rocking part of shaft: 4 8 cc/periphery Contact surfaces of lever and piston: 0.3 0.8 cc/place Contact surfaces of plate and pin: 0.3 0.8 cc/place Install plate (8) with the cut part on the outside of the PPC assembly. Install washer (10) 1.6 mm thick first. If the difference between both sides at the stroke end of the lever exceeds 0.7, change the washer thickness to reduce the difference to below 0.7. (If the washer thickness is reduced by 0.3 mm, the stroke end angle is increased by 0.39.) q Thickness of washer t: 1.0, 1.3, 1.6 Tighten each part to the following torque. Plug (11): 6 11 Nm {0.6 1.1 kgm} q Bolt (12): 3.9 4.9 Nm {0.4 0.5 kgm} (Apply LOCTITE #262.) q Screw (13): 7.8 9.8 Nm {0.8 1.0 kgm} q Plug (14): 4 9 Nm {0.4 0.9 kgm} q Bolt (15): 25 30 Nm {2.5 3.2 kgm} q Bolt (16): 27 34 Nm {2.8 3.5 kgm}
q
1.
2.
3.
4.
5.
6. 7.
8.
PC138US, USLC-8
31
SEN02713-00
Disassembly and assembly of hydraulic cylinder assembly

Special tools
Disassembly
This section explains how to disassemble and assemble the boom, arm, bucket and blade cylinders. For how to disassemble and assemble the offset cylinder, refer to "Disassembly and assembly of offset cylinder assembly". Piston rod assembly 1) Remove the piping from the cylinder assembly. 2) Remove the mounting bolt to disconnect head assembly (1). 3) Remove piston rode assembly (2). a Place an oil pan or the like under the cylinder to receive oil. 4) Disassemble the piston rod assembly with the following procedure. 1] Set piston rod assembly (2) on tool U1.
1 2
790-502-1003 790-101-1102 790-102-4300 790-201-4310 790-201-1702 790-201-1791 790-101-5021 01010-50816 790-201-1702 790-201-1811 790-101-5021 01010-50816 790-201-1702 790-201-1821 790-101-5021 01010-50816 790-201-1500 790-201-1610 790-101-5021 01010-50816 790-201-1500 790-201-1620 790-101-5021 01010-50816 790-201-1500 790-201-1630 790-101-5021 01010-50816
Repair stand Pump Pin Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Push tool (Kit) Push tool Grip Bolt Expander Ring Clamp
t 1 t 1 t 1 t 1 1 1 1 t 1 1 1 1 t 1 1 1 1 q 1 1 1 1 q 1 1 1 1 q 1 1 1 1 t 1 t 1 t 1
Wrench assembly t 1
5 6
790-720-1000 796-720-1660 07281-01159
32
Sketch
1.
Q'ty
PC138US, USLC-8
SEN02713-00
2]
Remove piston assembly lock screw (3). Screw size M12 x 1.75 pitch: Boom, arm and blade M10 x 1.5 pitch: Bucket
6]
Remove the head assembly (7).
7]
If screw (3) is caulked too tightly to be removed, force the screw in once and then tap it to remove it.
Remove cap (8) to remove eleven balls (9) and cushion plunger (10). q For the arm cylinder only. a Since cap (8) is made of nylon, tighten a screw into it and pull it out with pliers.
2. 3] Use tool U2 to remove piston assembly (4). q If tool (U2) is not used, use the four drill holes (diameter = 10) to loosen the piston assembly. Remove plunger (5). q Arm cylinder and boom cylinder. Remove collar (6). q Arm cylinder and boom cylinder.
Sub-disassembly of piston assembly 1) Remove ring (11). 2) Remove wear ring (12). 3) Remove piston ring (13). 4) Remove the O-ring and backup ring (14).
4] 5]
PC138US, USLC-8
33
SEN02713-00
3.
Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).
Assembly
a a
Be careful not to damage the packing, the dust seal, the O-ring or the like Do not forcibly insert the backup ring but make it warm with hot water (50 to 60C) before insertion. Sub-assembly of cylinder head assembly 1) Press fit bushing (20) using tool (U3). 2) Engage buffer ring (19). 3) Engage rod packing (18). 4) Mount dust seal (17) using tool (U4) and fix it with snap ring (16). 5) Mount the backup ring and O-ring (15).
1.
34
PC138US, USLC-8
SEN02713-00
2.
Sub-assembly of piston assembly 1) Expand piston ring (13) using tool (U5). a Set the piston ring on tool (U5) and expand it by rotating the handle eight to ten times. 2) Reduce piston ring (13) using tool (U6).
2) 3) 4)
Assemble head assembly (7). Fit O-ring and backup ring to collar (6), and assemble. q Arm cylinder and boom cylinder. Assemble plunger (5). q Arm cylinder and boom cylinder. a Check that there is a small amount of play at the tip of the plunger.
3) 4) 5)
Mount the backup ring and O-ring (14). Engage wear ring (12). Engage ring (11). a Be careful not to expand the ring abutment joint too much. 2 Ring groove: Grease (G2-LI)
5)
6)
3.
Piston rod assembly 1) Set piston rod assembly (2) on tool (U1).
Set cushion plunger (10) on the piston rod and engage 11 balls (9) and fix them using cap (8). q For the arm cylinder only. Assemble piston assembly (4) in the following procedure. q When the rod and piston assembly (2) are reused a Completely wash them and clear them of cut powder or dust. 1] Screw piston assembly (4) and tighten it using tool U2 until the screw hole position completely fits. a Eliminate screw burrs using a file or the like. 2] Tighten screw (3). 2 Screw (3): LOCTITE No. 262 3 Screw (3) : Boom, arm and blade : 66.2 7.35 Nm {6.75 0.75 kgm} Bucket: 30.9 3.4 Nm {3.15 0.35 kgm}
PC138US, USLC-8
35
SEN02713-00
2]
Drill a hole for mounting screw (3). a Engage the drill with the screw Vshaped grooves of piston (4) and rod (2) for horizontal processing. a Process the bottom cushionequipped cylinder (arm cylinder) on other part than the cap hole (8).
Tap drill diameter 10.3 8.5 Tap drill depth Tap used 27 27 12 x 1.75 10 x 1.5 Tap depth 20 20
Cylinder Boom, arm and blade Bucket
3]
Caulk the screw at two points through punching.
3] 4]
When new rod or/and piston assembly (2) is/are used a For the bottom cushion-equipped rod, mark the cap hole (8) on the rod end surface. q For the arm cylinder only. 5]
Clear it of cut powder and dust and completely wash it after processing. Tighten screw (3). 2 Screw thread: LOCTITE No. 262 3 Screw (3) : Boom, arm and blade : 66.2 7.35 Nm {6.75 0.75 kgm} Bucket: 30.9 3.4 Nm {3.15 0.35 kgm} Caulk the screw at four points through punching.
1]
Screw piston assembly (4) until it comes in contact with rod (2) end surface (a). 3 Piston assembly (4): 294 29.4 Nm {30 3.0 kgm}
a
q
After tightening the piston, make sure that there is some play with plunger. For the boom and arm cylinders only.
36
PC138US, USLC-8
SEN02713-00
7)
Engage piston rod assembly (2) 2 Seal: Grease (G2-LI) a Set the ring abutment joint horizontally and align the axes of the piston rod assembly and the cylinder tube to insert them. a After insertion, make sure that the ring is not damaged or dropped and completely push the piston rod.
8)
Mount head assembly (1) and tighten it with the mounting bolt. 3 Mounting bolt :
Cylinder Bucket Arm Boom Blade Tightening torque 172 25 Nm {17.5 2.5 kgm} 270 39 Nm {27.5 4.0 kgm} 172 25 Nm {17.5 2.5 kgm} 270 39 Nm {27.5 4.0 kgm}
9)
Mount the piping.
PC138US, USLC-8
37
SEN02713-00
38
PC138US, USLC-8
SEN02714-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number

Work equipment Body
Removal and installation of work equipment assembly .................................................................................. 2
PC138US, USLC-8
SEN02714-00
Removal and installation of work equipment assembly 1

Special tools
Symbol Part No. Part name New/Remodel Necessity Q'ty
3. 4. 5.
Disconnect working lamp wiring connector (6) and clamp (7). Remove guard (8). Disconnect hoses (9) (Arm cylinder bottom), (10) (Bucket cylinder bottom), (11) (Arm cylinder head), and (12) (Bucket cylinder head). a Since the engine will be started, be sure to plug the disconnected hoses.
792-785-1100 796-270-1110 V 1 790-101-4000 790-101-1102
Remover Adapter Puller (490 kN {50 ton}) Pump
t 1 1 1 1
Removal
k
Fully extend the work equipment and set a block at the arm end and lower the bucket tip to the ground. Disconnect the cable from the negative () terminal of the battery. Remove handrail (1), then remove covers (2) and (3). Remove undercovers (4) and (5) from boom mounting section.
6. 7. 8.
Disconnect grease tube (13). Remove lock bolt (14). [*1] Remove plate and push out pin (15) to the opposite side until it is removed from cylinder head. [*2] a Check the number and location of the shims. Lower boom cylinder (16) onto block [1]. a Connect the cable of the negative () terminal of the battery and start the engine and retract the boom cylinder. a Disconnect the cable from the negative () terminal of the battery again.
1. 2.
9.
10. Remove plug (17) from boom foot pin (19). 11. Remove mounting bolts to remove lock plate (18).
PC138US, USLC-8
SEN02714-00
12. Set tool V to boom foot pin (19).
Installation
q
[*1] a When tightening the locknut, tighten so that the clearance (a) between the plate and nut is 0.5 1.5 mm.
13. Sling work equipment assembly(20) slightly,then remove pin(19) by using tool V. [*3] a Lift off work equipment assembly from revolving frame by using crane. 4 Work equipment assembly: 1,860 kg [*2]
Inside surface of bushing when assembling pin: Molybdenum disulphide lubricant (LM-P) 2 Grease after assembling pin : Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust the shim thickness so that clearance (b) between cylinder rod (21) and plate (22) is less than 1 mm. a Standard shim thickness: 1.0 mm
PC138US, USLC-8
SEN02714-00
[*3]
Inside surface of bushing when assembling pin : Molybdenum disulphide lubricant (LM-P) 2 Grease after assembling pin : Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust the shim thickness so that clearance (c) between boom (23) and bracket (24) is less than 0.5 mm. a Standard shim thickness: 0.5, 1.0, 2.0 mm
Bleeding air Bleed the air. For details, see Testing and adjusting, "Bleeding air from hydraulic cylinder". Refilling with oil (hydraulic tank) Run the engine to circulate the oil through the system. Then add oil to the specified level.
PC138US, USLC-8
SEN02714-00
PC138US, USLC-8
SEN02714-00
PC138US, USLC-8
SEN02715-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number

Cab and its attachments
Removal and installation of operator cab assembly ....................................................................................... 2 Removal and installation of operator's cab glass (stuck glass)....................................................................... 4 Removal and installation of front window assembly ..................................................................................... 13 Removal and installation of floor frame assembly ........................................................................................ 14
PC138US, USLC-8
SEN02715-00
Removal and installation of operator cab assembly

Removal
k
7.
Remove cover (11).
Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative () terminal of the batterybeforehand. Remove floor mat (1). Remove machine monitor (2), referring to "Removal and installation of machine monitor assembly." Remove covers (3) to (6). a When removing cover (5), simultaneously remove cigar lighter wiring connector that attached to the back of the cover. Remove ducts (7) and (8). Loosen R.H. console (9) and shift toward the inside.
1. 2.
8. 9.
Remove cover (12) and duct (13). Disconnect cover (14).
3.
10. Remove cover (15).
4. 5.
11. Disconnect KOMTRAX antenna cable (16). 12. Disconnect wiring connectors (17) to (21).
6.
Disconnect window washer hose (10).
PC138US, USLC-8
SEN02715-00
13. Removal of operator cab mounting bolts and nuts. 1) Remove 6 mounting bolts (22b) (marked with *) and 4 nuts (22n) (marked with #) from inside the operator cab. a Nuts (22n) tightens floor frame together.
14. Lift and remove operator cab assembly (27). a Before removing the operator cap assembly, make sure that all wiring and piping are disconnected. 4 Operator cab assembly: 380 kg
Installation
2) Remove L.H. side cover (23).
q
3) 4)
Remove lock plate mounting bolt (24) and remove plate (25). Remove cab tip-over stopper mounting bolt (26).
PC138US, USLC-8
SEN02715-00
Removal and installation of operator's cab glass (stuck glass)
Amoung the panes of window glass on the 4 sides of the operators cab, 5 panes (1) (5) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (5), remove front window assembly (6). (It is impossible to replace only the front window glass while the front window assembly is installed to the operators cab.) For the procedure for replacing the front window assembly, see "Removal and installation of front window assembly".
( 1 ): Right side window glass ( 2 ): Left side rear window glass ( 3 ): Door upper window glass ( 4 ): Door lower window glass ( 5 ): Front window glass ( 6 ): Front window assembly (Front window glass + Front frame) ( 7 ): Both-sided adhesive tape (16): Center trim seal
PC138US, USLC-8

a
New/Remodel Necessity
SEN02715-00
Special tools
Symbol 1 2 Part No. Part name
Q'ty
If the window glass is broken finaly, it may be removed with knife [4] and a screwdriver. Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4].
793-498-1210 20Y-54-13180
Lifter (Suction cup) t 2 Adapter t 2
(The figure shows the operators cab of a wheel loader.)
Removal
a
Remove the window glass to be replaced accoring to the following procedure. Using seal cutter [1], cut the adhesive between broken window glass (7) and operators cab (metal sheet) (8).
1.
2.
Remove the window glass.
If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.
(The figure shows the operators cab of a wheel loader.)
PC138US, USLC-8
SEN02715-00
Installation
1. Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operators cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfac e s. (If th e pai nt ed s urf ac es are scratched, adhesion will be lowered.) (The figure shows the operators cab of a wheel loader.) 3. Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Disc ar d t h e p r i m e r 2 4 ho u r s a ft e r i t i s packed.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a dry before stirring it. (If the primer is unpacked just after taken out of the refrigertor, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.
2.
Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all back part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry.
PC138US, USLC-8

a
SEN02715-00
3)
Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operators cab (8) which will be coated with the adhesive. 2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPER or equivalant a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
a a
As for right side window glass (1), apply the primer to only the periphery of the glass to stick the both-sided adhesive tapes and the areas out of it to apply the adhesive. q Part (b) After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. Never apply wring primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
a
q
Parts to be coated with primer: Apply the primer all over dimension (a). Dimension to apply primer (a): 25 mm
4)
Evenly apply glass primer to the sticking surfaces of window glass (9). 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER or equivalant a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
PC138US, USLC-8
SEN02715-00
a a
a a
Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (7) and operators cab (8). Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. After applying the primer, leave it for at least 5 minutues (within 8 hours) to dry. Never apply wring the primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
1)
When sticking both-sided adhesive tape (7) around a frame, do not lap its finishing end over the starting end but make clearance e of about 5 mm between them. Stick both-sided adhesive tape (7) for right side window glass (1) as shown in the figure.
a
q
Stick both-sided adhesive tape (7a) additionally for right side window glass (1). Positions to stick additional both-sided adhesive tape for right side window glass. (f) : 140 mm (g): 500 mm
4.
Stick both-sided adhesive tape (7) along the inside edge of the glass sticking section. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before stiking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.
2)
Stick both-sided adhesive tape (7) for left side rear window glass (2) as shown in the figure.
PC138US, USLC-8
SEN02715-00
3)
Stick both-sided adhesive tape (7) for door upper window glass (3) and lower window glass (4) as shown in the figure. (The figure shows the door upper window glass.)
Details of the sticking positions are as follows. (h): Stick to inside end of right and left front frames (17). (j) : Retract by "3.0 mm" from the end of front frame (17).
(The figure shows the door lower window glass.)
5.
4)
Stick both-sided adhesive tape (7) for front window glass (5) as shown i the figure. a Both-sided adhesive tape: 1,004 mm 2 pieces
Possition the new window glass. 1) Check the clearance between the window glass and the operators cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operators cab (8) and draw positioning line (n). a Stick tapes [6] to the right, left, and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. 3) Cut the tape between window glass (9) and operators cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator s cab before installing the window glass.
PC138US, USLC-8
SEN02715-00
a
When positioning front window glass (5), set its horizontal and vertical positions as shown below. Part (m) (Right side): Project by "3.8 mm" from the frame end. Part (o) (Upper side): Retract by "3.0 mm" from the frame end.
1)
Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
2)
Cut the tip of the adhesive nozzle (14) so that dimension (q) and r will be as follows. q Dimension (q): 10 mm q Dimension (r) : 15 mm
3) 6. Apply adhesive. a Use either of the 2 types of the adhesive. 2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S" 2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER "W" a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperaure is below 25C. a Never heat the adhesive higher than 30C. a When reusing the adhesive, remove the all hardened part from the nozzle tip.
Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.
10
PC138US, USLC-8
SEN02715-00
4) 5)
Remove the release tape of the bothsided adhesive tape on the glass side. Apply adhesive (15) to the outside of bothsided adhesive tape (7) of the operators cab.
7.
a a
Apply adhesive (15) to dimensions s and t of both-sided adhesive tape (7) of operators cab (8). q Dimension (s): 10 mm q Dimension (t) : 15 mm Apply adhesive (15) higher than bothsided adhesive tape (7). Apply the adhesive evenly.
Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. a Sine the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly. a You can perform this work efficiently by pulling window glass (9) from inside of the operators cab with suction cup X1. (The figure shows the operator's cab of PC200-7.)
As for the right side window glass, apply the adhesive to the outside of the both-sided adhesive tape on the periphery of the glass.
PC138US, USLC-8
11
SEN02715-00
a
After installing front window glass (5), install the center trim seal to its bottom. Then, apply caulking material all a r ou nd t he g la s s to fi ll par t ( U) between the glass and center trim seal. a When caulking, neatly arrange the form of the adhesive at the right and left ends with a rubber spatula. 2 Adhesive: Sikaflex 256HV manufactured by Sika Japan
(The figure shows the operator's cab of PC2007.)
2)
Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape of fit them completely. (The figure shows the operator's cab of PC2007.)
9.
8.
Fix the window glass. 1) After installing right window glass (1) to the operators cab, insert stopper rubbers X2 to 2 places (v) at the bottom of the glass to fix the glass. (The figure shows the operator's cab of PC2007.)
After installing the window glass, remove the primer and adhesive from the operators cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact to it.
10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene form blocks, and rubber bands installed for 10 hours (at temperature of 20C and humidity of 60%). 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually.
12
PC138US, USLC-8
SEN02715-00
Removal and installation of front window assembly 1

k
Lower the work equipment to the ground and stop the engine. To replace the front window glass, the front window assembly must be removed from the operators cab. The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below.
Removal
1. Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides). [*1] Remove left lower block (1) and right lower block (2). [*2]
2.
3. 4.
Reset the lock at the rear of the cab. Lower front window assembly (3) carefully a little. Put out rollers (4) and (5) under the right and left sides of the front window through the portion from which the right and left lower blocks were removed in step 2 (the bottom of the rails). Twist front window assembly (3) to the right and left to remove right and left upper rollers (6) and (7) from the rails, and then remove front window assembly (3). a For (6) and (7), see the figure above.
Installation
q
5.
PC138US, USLC-8
13
SEN02715-00
Removal and installation of floor frame assembly 1

Special tools
1.
Remove lower cover (1).
799-703-1200 799-703-1100 X 3 799-703-1111 799-703-1121 799-703-1401
t 1 t 1 t 1
Q'ty
2.
t 1 t 1
Open the coolant drain valve (2) and drain coolant. 6 Coolant: 12.4 l
Removal
k
Park the machine on a level place and lower the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in Testing and adjusting. Disconnect the negative () terminal of the battery beforehand. Fasten tags to respective connecters and piping for identification to prevent any mistakes when re-installing. 3. Removal of exterior parts 1) Remove handrail (2). 2) Remove covers (3) and (4).
14
PC138US, USLC-8
SEN02715-00
3)
Remove covers (111), (112) and (113).
2)
4.
Disconnecting wiring and hoses around the solenoid valve 1) Disconnect bucket damp solenoid wiring connector V10 (5) and travel alarm M14 (6).
3)
4)
Disconnect wiring connectors (8) to (16) around the solenoid valves connected to wring (7). (8) : V01 (PPC basic pressure) (9) : V02 (Travel HI/LO) (10): V03 (Swing paring brake) (11) : V04 (Travel junction valve) (12): V05 (Merge-divider valve selection signal) (13): P25 (Pump pressure sensor) (14): P26 (Travel right rear pressure sensor) (15): P27 (Travel left rear pressure sensor) (16): P29 (Dummy) Remove wiring mounting clamp and disconnect wiring (7) from solenoid valve mounting frame assembly (17). Disconnect PPC basic pressure hose (18) (color band: Red-Green).
PC138US, USLC-8
15
SEN02715-00
5.
Disconnecting pressure switch and pressure sensor connector wiring 1) Disconnect wiring connectors (20) to (29) connected to wiring (19). (20): P01 (Bucket dump switch) (21): P02 (Arm dump switch) (22): P03 (Boom raise switch) (23): P04 (Bucket digging switch) (24): P05 (Boom digging switch) (25): P06 (Boom lower switch) (26): P07 (Right swing switch) (27): P08 (Left swing switch) (Multi-valve-installed machine) (28): P67 (Right swing switch) (Multi-valve-installed machine) a Connector P67 is connected to connector P07. a For a machine without the multivalve, connector P08 is positioned under P07 of the pressure switch connector mounting bracket. (29): P12 (Pressure sensor) 2) Remove wiring mounting clamps and disconnect wiring (19) from the pressure switch connector mounting bracket (30).
6.
Disconnection of control valve assembly wiring and hoses (R.H. side of control valve-inspection cover side-) 1) Disconnect hose (31) to the attachment. (Machine with the attachment) (Band color: Blue-Blue) 2) Disconnect wiring connectors (32) to (34). (32): P64 (Bucket digging switch) (33): P65 (Arm digging switch) (34): P66 (Boom lower switch)
3)
4)
Disconnect wiring connectors (35) and (36). (35): P26 (Right travel reverse) (36): P27 (Left travel reverse) Disconnect hoses (37) and (38). (37): (Yellow-Green) (Right travel reverse) (38): (Yellow-Orange) (Left travel reverse)
16
PC138US, USLC-8
SEN02715-00
(Operator cab side) 5) Disconnect wiring connectors (39) to (41). (39): P61 (Bucket dump switch) (40): P62 (Arm dump switch) (41): P63 (Boom raise switch) 6) Disconnect hose (42) to the attachment. (Machine with the attachment) (Color band: Red-Red)
7.
7)
8)
Disconnect travel switch connectors (38) and (39). (43): (Black-Yellow) (44): (Brown-Yellow) Disconnect travel motor hoses (40) and (41). (Color band) (45): (Black-Yellow) (46): (Brown-Yellow)
Disconnect 8 hoses (47) to (54) from the operation pattern select valve assembly. (Machine with the select valve) (From the upper side of operator cab) (47): Brown (Swing right) (48): Green (Arm digging) (49): White (Swing left) (50): Orange (Arm dump) (From the upper side of the hydraulic tank) (51): Yellow (Boom raise) (52): Black (Boom lower) (53): Red (Bucket dump) (54): Blue (Bucket digging) a For a machine without the operation pattern select valve, disconnect 8 hoses installed in the following order from the top to the solenoid valve installation frame as s hown i n Procedure 4- 4 (Photo No. CPP15287). Red (Bucket dump) Orange (Arm dump) Yellow (Boom raise) Blue (Bucket digging) Green (Arm digging) Black (Boom lower) White (Swing left) Brown (Swing right)
PC138US, USLC-8
17
SEN02715-00
8.
Disconnect PPC drain hose (55).
12. Disconnect buzzer wiring connector (60). 13. Disconnect buzzer wiring clamp (61) and disconnect the buzzer wiring.
9.
Disconnect wiring A13 (56) and A08 (57).

a
How to remove clamp (61) Hold a flat-head screwdriver [1] to section (a) and push it downward. Simultaneously br ing whole clamp (61) upwar d and unhook it from plate (b).
10. Disconnect boom bottom pressure sensor connector P46 (58). 11. Disconnect wiring clamp (59) and disconnect the wiring.
18
PC138US, USLC-8
SEN02715-00
14. Remove operator cab assembly, referring to "Removal of operator cab assembly." 15. Disconnecting floor lower wiring and clamps 1) Disconnect wiring and hose clamps (62) to (73).
2) 3) 4)
Disconnect air conditioner Hi-Lo pressure switch wiring connector (74). Disconnect air conditioner hoses (75) and (76). Disconnect heater hoses (77) and (78).
5)
Pull out wiring lock pad (79) and draw out wiring (80).
PC138US, USLC-8
19
SEN02715-00
6)
Disconnect grounding wire (81).
Installation
q
16. Lift and remove floor frame assembly (82). a Before lifting the floor frame assembly, check that every wiring connector and clamp is disconnected. a Pull out the control valve wiring while lifting floor frame assembly (82) little by little. a When pulling out the wiring on the control valve side, it may catch obstacles on the way to resist smooth removal. Do not pull by force. Manage to evade obstacles patiently. 4 Floor frame assembly: Approx. 210 kg
[*1] a Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. a Make sure that O-ring is installed to the pipe joint section of the air conditioner hoses before installing a Check the O-ring for scratches or degradation. a When installing O-ring, apply the compressor oil (Denso: ND-OIL8 or ZEXEL: ZXL100PG (PAG46 or equivalent)). 3 Mounting bolt: 8 12 Nm {0.8 1.2 kgm}
q
Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a). a Filling capacity: 800 (+50/0) g
20
PC138US, USLC-8
SEN02715-00
PC138US, USLC-8
21
SEN02715-00
22
PC138US, USLC-8
SEN02716-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number

Electrical system
Removal and installation of air compressor assembly .................................................................................... 2 Removal and installation of air conditioner condenser ................................................................................... 3 Removal and installation of air compressor unit assembly ............................................................................. 4 Removal and installation of machine monitor assembly ................................................................................. 7 Removal and installation of pump controller assembly ................................................................................... 8 Removal and installation of engine controller assembly ................................................................................. 9 Removal and installation of KOMTRAX communications module ................................................................ 10
PC138US, USLC-8
SEN02716-00
Removal and installation of air compressor assembly

Special tools
Installation
1
New/Remodel
Carry out the installation in the reverse order of removal. Precautions when installing piping Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. When jointing the air conditioner piping, apply compressor oil (Denso ND-01L8 equivalent) to the threaded portions. 3 Mounting bolt: 8 12 Nm {0.8 1.2 kgm} Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a). Air compressor mounting bolt: 24.5 29 Nm {2.5 3.0 kgm}
[*1]
q
Symbol
Part No.
Part name
Necessity
a a
799-703-1200 799-703-1100 X 3 799-703-1111 799-703-1121 799-703-1401
t 1 t 1 t 1 t 1 t 1
Q'ty
[*2]
Removal
k
k k
Stop the machine on a level place and lower the work equipment to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative () terminal of the battery beforehand. Bleed the air conditioner gas using the special tool. Disconnect wiring connector AC02 (1). Disconnect air conditioner pipes (2) and (3). [*1] Loosen drive belt tension adjust bolt (4). Remove drive belt protective cover (6). Remove drive belt protective cover (6). Remove drive belt (7). Remove mounting bolts (8) and remove air compressor assembly (9). [*2]
1. 2. 3. 4. 5. 6. 7.
PC138US, USLC-8
SEN02716-00
Removal and installation of air conditioner condenser

Special tools
Symbol Part No. Part name
4.
1
5.
New/Remodel
Disconnect 2 hoses (3). a Put blind caps to prevent the entry of dirt or water into hoses and compressor. Remove 4 bolts and remove condenser (4).
Necessity
799-703-1200 799-703-1100 X 3 799-703-1111 799-703-1121 799-703-1401
t 1 t 1 t 1 t 1 t 1
Removal
k k
Lower the work equipment to the ground completely. Remove the negative () terminal from the battery. Collect air conditioner gas (R134a) from air conditioner circuit. Remove air cleaner cover (1) and remove the element. Loosen bolts and remove the wire harness clamp (2).
1. 2. 3.
Q'ty
Installation
q
Carry out installation in reverse oder to remaval. Filling air-conditioning gas Using tool X3, charge air conditioner gas (R134a) to air conditioner circuit.
PC138US, USLC-8
SEN02716-00
Removal and installation of air compressor unit assembly

Special tools
2.
1
3.
New/Remodel
Disconnect wiring connector (2) of the air conditioner high and low pressure switch. Disconnect air conditioner hoses (3) and (4). Disconnect heater hoses (5) and (6).
4.
Symbol
Part No.
Part name
Necessity
799-703-1200 799-703-1100 X 3 799-703-1111 799-703-1121 799-703-1401
t 1 t 1 t 1 t 1 t 1
Q'ty
Removal
k
5. 6.
Remove floor mat (7). Remove machine monitor (8), referring to "Removal and installation of machine monitor assembly." Remove covers (9) to (12). a When removing cover (11), simultaneously remove cigar lighter wiring connector that attached to the back of the cover. Remove ducts (13) and (14).
k k
Park the machine on a level place and lower the work equipment to the ground. Stop the engine and set the lock lever to locked position. Disconnect the negative () terminal of the battery beforehand. Bleed the air conditioner gas using the special tool. Remove side cover (1).
7.
1.
8.
PC138US, USLC-8
SEN02716-00
9.
Remove cover (15).
14. Remove cover (23).
10. Remove cover (16). 11. Remove duct (17). 12. Remove covers (18) and (19).
15. Remove 3 cover mounting bolts (24) on the left and right.
16. Lift cover (25) using 3 forcing bolts [1]. 17. Remove 3 air conditioner unit mounting bolts (26) in front and rear, and remove air conditioner unit (27).
13. Disconnect connectors (20), (21) and (22) and disconnect the wiring clamps.
PC138US, USLC-8
SEN02716-00
Installation
q
Carry out the installation in the reverse order of removal. Precautions when installing piping Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a). a Filling capacity: 800 (+50/-0) g
[*1]
q
PC138US, USLC-8
SEN02716-00
Removal and installation of machine monitor assembly

Removal
k
3.
Disconnect connector (3) to (5). Remove 3 mounting bolts (6) and remove machine monitor assembly (7).
4.
Disconnect the negative () terminal of the battery beforehand. Remove the 2 mounting bolts and cover (1). a One of the mounting bolts is installed inside the cap on the right of the daylight sensor. a While removing cover (1), simultaneously disconnect wiring connector P31 of the daylight sensor. a A level gauge is installed to the top of the monitor panel on the machine of arm crane specifications. Remove the level gauge.
1.
Installation
q
2.
Remove duct (2).
PC138US, USLC-8
SEN02716-00
Removal and installation of pump controller assembly 1

Removal
k
5.
Disconnect wiring (5) and (6). a Pull each connector lever (a) and (b) inward. Remove 4 mounting bolts (7) and 2 mounting bolts (8), and remove pump controller assembly (9).
Disconnect the negative () terminal of the battery beforehand. Remove cover (1).
6.
1.
2. 3. 4.
Remove cover (2). Remove duct (3). Remove cover (4).
Installation
q
PC138US, USLC-8
SEN02716-00
Removal and installation of engine controller assembly

Removal
k
Installation
Carry out the installation in the reverse order of removal. Screw: 3 1 Nm {0.3 0.1 kgm}
Disconnect the negative () terminal of the battery beforehand. Open the engine hood. DReferring to "Removal and installation of air compressor assembly," disconnect air conditioner compressor (1). a Do not disconnect the air conditioner hoses from the air conditioner compressor. Remove wiring connectors CE01 (2), CE02 (3) and CE03 (4). [*1] Remove mounting bolts (5) and remove engine controller (6).
[*1]
1. 2.
3.
4.
PC138US, USLC-8
SEN02716-00
Removal and installation of KOMTRAX communications module

Removal
k
5.
Disconnect wiring connector CK02 (5), CK01 (6) and antenna (7). Remove 4 mounting bolts (8) and remove KOMTRAX communications module (9).
6.
Disconnect the negative () terminal of the battery beforehand. Remove cover (1).
1.
Installation
q
2. 3. 4.
Remove cover (2). Remove duct (3). Remove cover (4).
10
PC138US, USLC-8
SEN02716-00
PC138US, USLC-8
11
SEN02716-00
12
PC138US, USLC-8
SEN01980-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number
90 Diagrams and drawings

Hydraulic circuit diagram
Hydraulic circuit diagram................................................................................................................................. 3
PC138US, USLC-8

PC138US-8
Hydraulic circuit diagram PC138US-8
SEN01980-00
PC138US, USLC-8

PC138US-8 (Blade specification and machine ready for attachment)
Hydraulic circuit diagram PC138US-8 (Blade specification and machine ready for attachment)
SEN01980-00
PC138US, USLC-8

PC138USLC-8 (KA specification) (Blade specification and machine ready for attachment)
Hydraulic circuit diagram PC138USLC-8 (KA specification) (Blade specification and machine ready for attachment)
SEN01980-00
PC138US, USLC-8

PC138US-8 (KUK specification) (Blade specification and machine ready for attachment)
Hydraulic circuit diagram PC138US-8 (KUK specification) (Blade specification and machine ready for attachment)
SEN01980-00
PC138US, USLC-8
SEN01980-00
12
PC138US, USLC-8
SEN01981-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
Machine model
Serial number

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3 Connectors table and arrangement drawing................................................................................................... 5
PC138US, USLC-8
SEN01981-01
PC138US, USLC-8
Electrical circuit diagram
PC138US, USLC-8
Electrical circuit diagram PC138US, USLC-8
SEN01981-01 PC138US, USLC-8
Connectors table and arrangement drawing

Connector No. A08 A13 AB AC01 AC02 ACC AR B BNC BR BR C C01 C02 CAN CE01 CE02 CE03 CK01 CK02 CM01 CM02 CM03 CM05 CN1 CN2 CN3 CN4 D01 D02 D03 D10 D11 E01 E10 F01 F02 F03 F04 F05 F06 GT5 H08 H09 H15 H16 J01 J02 J03 J04 J05 J06 J07 K01 K02 L01 L03 M01 M02 M03 M04 M05 M06 M07 M09 M10 M11 M12 M13 M14 M40 M41 N08 N10 NE P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 P17 P20 P21 P22 P25 P26 P27 P28 P29 P31 Model DT-T DT-T Terminal YAZAKI X Terminal SUMITOMO Terminal Terminal Terminal Terminal AMP AMP
FRAMA TOME
PC138US, USLC-8
Address F-9 F-9 H-9 AB-4 J-9 H-9 L-7 Z-4 Z-5 AF-1 AE-9 K-9 L-8 AB-7 AA-7 O-6 O-6 O-5 AF-9 AF-9 AG-9 AG-9 AA-7 Z-6 Z-6 AB-7 AB-7 I-9 I-9 X-9 L-6 L-6 L-4 K-1 L-4 F-1 Y-5 Y-5 T-9 Y-3 T-9 U-9 U-9 U-9 V-9 V-9 V-9 Z-7 K-9 B-9 I-9 X-2 J-9 I-9 O-6 "E-1,O-5" K-1 E-1 S-9 W-2 D-9 G-9 E-9 X-9 AB-3 AF-1 A-6 A-5 A-5 A-5 A-5 A-5 A-4 A-4 C-1 D-1 D-1 B-1 R-1 Q-1 Q-1 T-1 Q-9 F-9 G-9 A-6 A-6 A-6 A-1 A-7 O-6 Connector No. P32 P44 P61 P62 P63 P64 P65 P66 P67 PAMB PFUEL POIL PREG PTIM R1 R05 R06 R07 R10 R14 R15 R16 R17 R18 R19 R20 R21 R23 R24 RB RE RM S02 S04 S07 S10 S14 S21 S22 S25 T01 T02 T03 T04 T05 T06 T07 T08 T09 T10 T11 T12 T14 TNC TWTR V01 V02 V03 V04 V05 V10 V11 V30 W03 Model YAZAKI DT-T X X X X X X X AMP BOSCH
FRAMA TOME
Connectors table and arrangement drawing PC138US, USLC-8
Type of connector 6 2 1 10 1 1 3 1 1 1 1 1 81 39 3 60 60 4 14 10 18 12 18 8 2 2 2 2 8 8 8 2 2 1 1 20 2 2 1 1 1 1 4 8 22 12 20 20 20 20 20 20 20 2 3 2 2 9 2 2 2 6 2 2 2 2 4 2 2 2 2 2 12 4 3 2 2 2 2 2 2 2 2 3 3 3 6 2 2 2 2 3 1 2 3 3 3 3 6 2
Component name Intermediate connector Intermediate connector Alternator (Terminal B) Air conditioner unit Air conditioner compressor electromagnetic clutch Starter switch Alternator Starter switch Orbcomm Starter switch Battery relay Starter switch CH700 controller CH700 controller Engine Bkup speed sensor Engine controller Engine controller Engine controller KOMTRAX communication module KOMTRAX communication module Machine monitor Machine monitor Machine monitor Machine monitor Injector #1 Injector #2 Injector #3 Injector #4 Battery relay Ribbon heater relay/washer motor Monitor light switch Diode Diode Ribbon heater Starting motor Fuse Fuse(45A) Fuse(450A) Fuse Fuse(50A) Fuse(120A) Antenna Intermediate connector Intermediate connector Intermediate connector Intermediate connector Junction connector (Pink) Junction connector (Pink) Junction connector (Pink) Junction connector (Black) Junction connector (Green) Junction connector (Black) Junction connector (Pink) Pump resistor CAN terminal resistance Working lamp (Boom) Cab light Radio Speaker(left) Speaker(right) Cigar lighter Wiper motor Window washer motor Horn (High tone) Optional power supply connector (1) Optional power supply connector (2) DC/DC converter 12V outlet Optional power supply connector (12 V) Travel alarm Head light(STD) Head light(OPT) Service coneeector Air conditioner unit NE sensor Pressure switch(Buket dump) Pressure switch(Arm dump) Pressure switch(Boom UP) Pressure switch(Buket digging) Pressure switch(Arm digging) Pressure switch(Boom down) Pressure switch(Left swing) Pressure switch(Right swing) Intermediate connector Intermediate connector Pressure switch(Service) Pressure switch(Service) A/C HI/LO pressure switch Fuel dial Fuel level sensor Hydraulic oil temperature sensor Pump pressure sensor Intermediate connector Sunshine sensor
Type of connector 2 2 2 2 2 2 2 2 2 3 3 1 2 4 1 5 5 5 5 1 1 1 2 1 1 4 4 5 5 1 1 1 6 6 6 2 3 5 5 16 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 8
Component name Air conditioner daylight sensor Engine oil level sensor Pressure switch(Buket dump) Ambient pressure sensor Common rall pressure sensor Engine oil pressure switch (Low pressure) Supply pump solenoid (IMV) Boost pressur/temp. Starter switch Relay for light Relay for Starter cut(Ppc lock) Relay for Starter cut(Personal cood) Relay for OPT. light Ribon heater relay Ribon heater relay Ribon heater relay Blower relay Compressor relay Relay for CM2100(1) Relay for CM2100(2) Battery relay Battery relay Battery relay Light switch Swing lock switch Beacon Right knob switch PPC hydraulic lock switch Emergency pump drive switch Emergency swing parking brake release Intermediate connector Floor frame Cab GND GND Floor frame Revolving frame GND GND Revolving frame Revolving frame Revolving frame Revolving frame Revolving frame Revolving frame FOMA Engine water temperature sensor PPC lock solenoid valve Travel speed shifting solenoid valve Swing holding brake solenoid valve Travel junction solenoid valve Confluece solenoid valve Bucket dump lock solenoid valve PC-EPC valve Att current Limit switch Rear view camera
Address H-1 H-9 AF-5 AG-5 AD-6 AD-7 AD-8 X-9 Z-5 Z-4 Y-8 M-5 N-5 N-5 H-1 J-1 J-1 AB-4 AB-5 AB-4 AB-4 L-7 L-6 L-7 R-8 R-8 S-8 Q-7 W-9 Y-8 Y-8 AA-7 W-1 L-5 X-2 G-1 G-1 AF-5 AE-5 I-1 I-1 I-1 H-1 H-1 V-1 L-5 AE-9 C-9 C-9 C-9 B-8 A-8 E-9 G-9 Q-1 J-9 -
BOSCH BOSCH Terminal RELAY RELAY RELAY RELAY Terminal Terminal Terminal X Terminal Terminal RELAY RELAY RELAY RELAY Terminal Terminal Terminal SWP SWP SWP Y090 M 090 Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal PACKARD DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T M TAJIMI
DRC DRC DTP AMP AMP 070 070 070 B60 DT DT DT DT SWP SWP SWP Terminal Terminal L L Terminal Terminal Terminal M M S090 S SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO M DT-T M PA M M M KES 090 M M M M M DT-T X X DT-T SUMITOMO
FRAMA TOME
X X X X X X X X AMP AMP AMP DT-T X X X S 090 M X DT-T AMP AMP AMP AMP DT-T YAZAKI
SEN01981-01
PC138US, USLC-8
SEN01981-01
PC138US, USLC-8
SEN01981-01
PC138US, USLC-8

10795750-DKP8P8EM-Download Komatsu Pc138us-8 Pc138uslc-8 Excavator Manual

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SEN01968-02

PC138US- 20001 PC138USLC- 20001

00 Index and foreword

00 Index and foreword

Composition of shop manual

00 Index and foreword

00 Index and foreword

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PC138US, USLC-8 Hydraulic excavator Form No. SEN01977-02

2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (02)

00 Index and foreword

00 Index and foreword

6 Safety check before starting work 7 8

9 Good physical condition and preparation 10

00 Index and foreword

13) 14) 15)

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00 Index and foreword

Example of O-ring (Fitted to every joint of hoses and tubes)

00 Index and foreword

How to read the shop manual

00 Index and foreword

00 Index and foreword

Explanation of terms for maintenance standard

Example: Standard size 120 a

Tolerance 0.022 0.126

Example: Standard size 60 Tolerance Shaft Hole 0.030 +0.046 0.076 +0

00 Index and foreword

00 Index and foreword

Handling of electric equipment and hydraulic component

00 Index and foreword

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00 Index and foreword

Connection (Example of incomplete setting of (a))

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00 Index and foreword

Handling of connectors newly used for engines

00 Index and foreword

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How to read electric wire code

Heat-resistant low-voltAEX age wire for automobile

00 Index and foreword

8 50/0.45 7.95 3.7 5.5 5.3

15 84/0.45 13.36 4.8 7.0 7.0

20 41/0.80 20.61 6.0 8.2 8.2

30 70/0.80 35.19 8.0 10.8 10.8

40 85/0.80 42.73 8.6 11.4 11.4

f of nominal No. denotes flexible.

00 Index and foreword

Color codes table