Pc128us-2 Sebm018419 PDF

SEBM018419
Shop
Manual
PC128US-2
PC138US-2
PC138USLC-2E0
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
PC128US-2
5001 - 7730 avance
PC128US-2
7731 and up GALEO
PC138US-2
4501 and up GALEO
PC138USLC-2E0 1001 and up GALEO
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu

Printed in U.S.A.
Komatsu America Corp.
January 2005
CONTENTS
No. of page
01
GENERAL ............................................................................................................ 01-1
10
STRUCTURE AND FUNCTION
20
TESTING AND ADJUSTING
30
DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40
MAINTENANCE STANDARD ............................................................... 40-1
90
OTHERS
00-2
4
........................................................... 10-1
................................................................ 20-1
............................................................................................................... 90-1
PC128US-2
The affected pages are indicated by the use of the

following marks. It is requested that necessary
actions be taken to these pages according to the
table below.
Mark
Indication
Action required
Page to be newly added
Add
Page to be replaced
Replace
( )
Page to be deleted
Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Mark
Page
q 00-1
q
q
q
q
q
00-2
00-2-1
00-2-2
00-2-3
00-2-4
00-2-5
00-3
00-4
00-5
00-6
00-7
00-8
00-9
00-10
00-11
00-12
00-13
00-14
00-15
00-16
00-17
00-18
00-19
00-20
00-21
00-22
01-1
01-2
01-3
01-4
01-4-1
01-4-2
01-4-3
01-4-4
01-4-5
01-4-6
01-4-7
01-4-8
01-5
PC128US-2
Revision Mark
number
(19)
(4)
(19)
(19)
(19)
(19)
(19)
(10)
(10)
(10)
(10)
(10)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
Page
Revision Mark
number
01-6
01-7
01-8
01-9
01-10
01-10-1
01-10-2
01-10-3
01-10-4
01-10-5
01-10-6
01-10-7
01-10-8
01-10-9
01-10-10
01-10-11
01-10-12
01-10-13
01-10-14
01-10-15
01-11
01-12
01-13
01-14
01-14-1
01-14-2
01-14-3
01-14-4
01-14-5
01-14-6
01-14-7
01-14-8
01-14-9
01-14-10
01-15
01-16
(15)
(11)
(11)
(15)
(15)
(15)
(15)
(11)
(11)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(11)
10-1
10-2
10-3
10-4
(15)
(15)
Page
10-4-1
10-4-2
10-5
10-6
10-7
10-7-1
10-8
10-8-1
10-9
10-10
10-11
10-12
10-13
10-13-1
10-13-2
10-14
10-14-1
10-15
10-15-1
10-15-2
10-16
10-16-1
10-17
10-18
10-19
10-20
10-21
10-22
10-22-1
10-23
10-24
10-25
10-26
10-27
10-27-1
10-27-2
10-27-3
10-28
10-29
10-30
10-31
Revision Mark
number
(15)
(15)
(15)
(15)
(15)
(10)
(15)
(7)
(10)
(4)
(15)
(11)
(15)
(15)
(10)
(15)
(15)
(15)
(15)
(10)
(7)
(10)
(15)
(10)
(15)
(10)
(18)
Page
10-32
10-33
10-34
10-35
10-36
10-37
10-37-1
10-38
10-39
10-40
10-41
10-42
10-43
10-44
10-45
10-45-1
10-45-2
10-45-3
10-45-4
10-45-5
10-45-6
10-45-7
10-45-8
10-45-9
10-45-10
10-45-11
10-46
10-47
10-48
10-49
10-50
10-51
10-52
10-53
10-54
10-55
10-56
10-57
10-58
10-59
10-60
Revision Mark
number
(18)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(10)
(5)
(5)
(15)
(15)
(5)
(15)
(15)
(15)
(15)
(15)
Page
10-61
10-62
10-63
10-64
10-65
10-66
10-67
10-68
10-69
10-70
10-71
10-72
10-73
10-74
10-75
10-76
10-77
10-78
10-79
10-80
10-81
10-82
10-83
10-84
10-85
10-86
10-87
10-88
10-89
10-90
10-91
10-92
10-93
10-94
10-95
10-96
10-97
10-98
10-99
10-100
10-101
Revision
number
(18)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(11)
(11)
(10)
(18)
(2)
(2)
(18)
00-2-1
(19)
Mark
Page
10-102
10-103
10-104
10-105
10-106
10-107
10-108
10-109
10-110
10-111
10-112
10-113
10-114
10-115
10-116
10-117
10-117-1
10-118
10-119
10-120
10-121
10-122
10-122-1
10-122-2
10-122-3
10-122-4
10-122-5
10-122-6
10-122-7
10-122-8
10-122-9
10-123
10-123-1
10-123-2
10-124
10-125
10-126
10-127
10-128
10-128-1
10-128-2
10-129
10-130
10-131
10-132
10-132-1
10-132-2
10-132-3
10-132-4
10-132-5
10-132-6
00-2-2
(19)
Revision
number Mark
(13)
(7)
(7)
(15)
(15)
(15)
(15)
(15)
(13)
(15)
(7)
(7)
(7)
(15)
(13)
(18)
(13)
(10)
(18)
(18)
(10)
(15)
(10)
(15)
(10)
(15)
(15)
(10)
(10)
(10)
(10)
(15)
(7)
(15)
(15)
(15)
(15)
Page
10-132-7
10-133
10-133-1
10-134
10-134-1
10-135
10-136
10-136-1
10-136-2
10-136-3
10-136-4
10-136-5
10-137
10-138
10-138-1
10-138-2
10-138-3
10-138-4
10-138-5
10-139
10-139-1
10-140
10-141
10-142
10-142-1
10-142-2
10-143
10-143-1
10-143-2
10-143-3
10-143-4
10-143-5
10-144
10-144-1
10-144-2
10-144-3
10-144-4
10-144-5
10-144-6
10-144-7
10-145
10-146
10-146-1
10-146-2
10-147
10-147-1
10-147-2
10-147-3
10-147-4
10-147-5
10-147-6
Revision
number Mark
(15)
(15)
(15)
(10)
(15)
(10)
(10)
(10)
(15)
(11)
(15)
(15)
(10)
(7)
(15)
(18)
(15)
(15)
(7)
(10)
(15)
(10)
(18)
(18)
(15)
(7)
(10)
(15)
(15)
(15)
(15)
(15)
(10)
(15)
(15)
(15)
(15)
(15)
(15)
(18)
(15)
(18)
(11)
(15)
(10)
(10)
(10)
(15)
(7)
(15)
(15)
q
q
q
q
q
q
q
Page
Revision
number Mark
10-147-7
10-148
10-149
10-149-1
10-150
10-151
10-151-1
10-151-2
10-151-3
10-152
10-153
(15)
(15)
(10)
(15)
(18)
(7)
(15)
(15)
(11)
20-1
20-2
20-2-1
20-3
20-4
20-5
20-6
20-7
20-8
20-8-1
20-8-2
20-8-3
20-8-4
20-8-5
20-8-6
20-8-7
20-8-8
20-8-9
20-8-10
20-8-11
20-8-12
20-9
20-10
20-11
20-12
20-13
20-14
20-15
20-16
20-17
20-18
20-19
20-20
20-21
20-22
20-101
20-102
20-103
20-104
(1)
(17)
(17)
(10)
(14)
(14)
(7)
(18)
(7)
(17)
(17)
(19)
(19)
(18)
(17)
(17)
(17)
(19)
(19)
(17)
(17)
(7)
(7)
(18)
(10)
(1)
(1)
(1)
(17)
(7)
(7)
(17)
(17)
(17)
(17)
(17)
(19)
(19)
(19)
Page
20-105
20-106
20-107
20-108
20-108-1
20-108-2
20-108-3
20-108-4
20-108-5
20-108-6
20-108-7
20-108-8
20-108-9
20-109
20-110
20-111
20-112
20-113
20-114
20-115
20-116
20-117
20-118
20-119
20-120
20-121
20-122
20-123
20-124
20-125
20-126
20-127
20-128
20-129
20-130
20-131
20-132
20-133
20-134
20-135
20-136
20-137
20-138
20-201
20-202
20-203
20-204
20-205
20-206
20-207
20-208
Revision
number Mark
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(7)
(1)
(1)
(1)
(9)
(7)
(18)
(7)
(18)
(7)
(7)
(7)
(7)
(1)
(1)
(7)
(10)
(1)
(1)
(1)
(17)
(1)
(1)
(1)
(14)
(14)
(17)
(17)
(17)
(17)
(14)
(1)
(1)
(17)
(17)
(17)
(17)
(17)
q
q
q
Q
Page
Revision
number
20-209
20-210
20-211
20-212
20-214
20-215
20-216
20-217
20-218
20-218-2
20-218-3
20-218-4
20-218-5
20-218-6
20-218-8
20-218-9
20-218-10
20-218-11
20-218-12
20-219
20-220
20-221
20-222
20-223
20-224
20-225
20-226
20-227
20-228
20-229
20-230
20-230-1
20-230-2
20-230-3
20-230-4
20-230-5
20-230-6
20-230-7
20-230-8
20-230-9
20-230-10
20-230-11
20-230-12
20-230-13
20-231
20-232
20-233
20-234
20-235
20-236
20-237
(17)
(1)
(1)
(17)
(10)
(10)
(10)
(7)
(7)
(17)
(7)
(17)
(7)
(7)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(19)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(19)
(19)
(19)
(19)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
PC128US-2
Mark
q
q
q
q
Page
20-238
20-239
20-240
20-241
20-242
20-243
20-244
20-245
20-246
20-246-1
20-246-2
20-246-3
20-246-4
20-246-5
20-247
20-248
20-250
20-251
20-252
20-253
20-254
20-255
20-256
20-257
20-258
20-259
20-301
20-301-1
20-301-2
20-302
20-303
20-304
20-305
20-306
20-307
20-308
20-309
20-310
20-311
20-312
20-313
20-314
20-315
20-316
20-317
20-318
20-319
20-320
20-321
20-322
20-323
PC128US-2
Revision
number Mark
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(19)
(19)
(17)
(17)
(19)
(19)
(10)
(7)
(10)
(7)
(17)
(7)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(7)
(9)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
Page
20-324
20-325
20-326
20-327
20-328
20-329
20-330
20-331
20-332
20-334
20-335
20-336
20-338
20-339
20-340
20-341
20-401
20-402
20-403
20-403-1
20-403-2
20-404
20-405
20-406
20-407
20-408
20-409
20-410
20-411
20-412
20-413
20-414
20-416
20-417
20-418
20-419
20-420
20-421
20-422
20-423
20-501
20-502
20-503
20-504
20-505
20-506
20-507
20-508
20-509
20-510
20-511
Revision
number Mark
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(7)
(10)
(1)
(10)
(7)
(1)
(7)
(1)
(1)
(1)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(7)
(10)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
Page
20-512
20-513
20-514
20-515
20-516
20-517
20-551
20-552
20-554
20-555
20-556
20-557
20-558
20-559
20-560
20-561
20-562
20-563
20-564
20-565
20-566
20-567
20-568
20-569
20-570
20-571
20-572
20-573
20-574
20-575
20-576
20-577
20-578
20-579
20-580
20-581
20-582
20-583
20-584
20-585
20-586
20-587
20-588
20-589
20-601
20-602
20-603
20-701
20-702
20-703
20-704
Revision
number Mark
(1)
(1)
(1)
(1)
(1)
(1)
(17)
(17)
(7)
(7)
(17)
(7)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(7)
(7)
Page
20-705
20-706
20-707
20-708
20-709
20-710
20-711
20-712
20-713
20-714
20-715
20-716
20-717
20-718
20-719
20-720
20-721
20-722
20-723
20-724
20-725
20-726
20-727
20-728
20-801
20-802
20-804
20-805
20-806
20-807
20-808
20-809
20-810
20-811
20-812
20-813
20-814
20-815
20-816
20-817
20-818
20-819
20-820
20-821
20-822
20-823
20-824
20-825
20-826
20-827
20-828
Revision
number Mark
(7)
(7)
(7)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(7)
(7)
(7)
(7)
(7)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
Page
Revision
number
20-829
20-830
20-831
20-832
20-833
20-834
20-835
20-836
20-837
20-838
20-839
20-840
20-841
20-901
20-902
20-903
20-904
20-905
20-906
20-907
20-908
20-909
20-910
20-911
20-912
20-913
20-914
20-915
20-916
20-917
20-918
20-919
20-920
20-921
20-922
20-951
20-952
20-953
20-954
20-955
20-956
20-957
20-958
20-959
20-960
20-961
20-962
20-963
20-964
20-965
20-966
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(17)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
00-2-3
(19)
Mark
q
q
Page
Revision
number Mark
20-967
20-968
20-969
20-970
20-971
20-972
20-973
20-974
(14)
(14)
(14)
(14)
(14)
(14)
(14)
(14)
30-1
30-2
30-3
30-4
30-5
30-6
30-7
30-8
30-9
30-10
30-11
30-12
30-13
30-14
30-15
30-16
30-17
30-18
30-19
30-20
30-21
30-22
30-23
30-24
30-25
30-26
30-27
30-28
30-29
30-30
30-31
30-32
30-33
30-34
30-35
30-36
30-37
30-38
30-39
30-40
30-41
30-42
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(19)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(19)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(19)
(19)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
00-2-4
(19)
Page
30-43
30-44
30-45
30-46
30-47
30-48
30-49
30-50
30-51
30-52
30-53
30-54
30-55
30-56
30-57
30-58
30-59
30-60
30-61
30-62
30-63
30-64
30-65
30-66
30-67
30-68
30-69
30-70
30-71
30-72
30-73
30-74
30-75
30-76
30-77
30-78
30-79
30-80
30-81
30-82
30-83
30-84
30-85
30-86
30-87
30-88
30-89
30-90
30-91
30-92
30-94
Revision
number Mark
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
q
q
q
q
q
q
q
q
q
Page
30-95
30-96
30-97
30-98
30-99
30-100
30-101
30-102
30-103
30-104
30-105
30-106
30-107
30-108
30-109
30-110
30-111
30-112
30-113
30-114
30-115
30-116
30-117
30-118
30-119
30-120
30-121
30-122
30-123
30-124
30-125
30-126
30-127
30-128
30-129
30-130
30-131
30-132
30-133
30-134
30-135
30-136
30-137
30-138
30-139
30-140
30-141
30-142
30-143
30-144
30-145
Revision
number Mark
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(19)
(19)
(19)
(19)
(19)
(16)
(19)
(19)
(19)
(19)
q
q
q
q
q
q
q
q
Page
Revision
number Mark
30-146
30-147
30-148
30-149
30-150
30-151
30-152
30-153
30-154
30-155
30-156
30-157
(19)
(19)
(19)
(19)
(16)
(19)
(19)
(19)
(19)
(16)
(16)
(16)
40-1
40-2
40-3
40-3-1
40-3-2
40-4
40-5
40-5-1
40-6
40-6-1
40-6-2
40-7
40-8
40-9
40-10
40-11
40-12
40-13
40-14
40-15
40-15-1
40-15-2
40-15-3
40-15-4
40-16
40-17
40-17-1
40-17-2
40-18
40-18-1
40-19
40-20
40-21
40-22
40-23
40-24
40-25
40-26
(15)
(15)
(14)
(15)
(15)
(14)
(15)
(10)
(10)
(11)
(15)
(11)
(15)
(11)
(15)
(15)
(10)
(7)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
Page
Revision
number
40-26-2
40-26-3
40-26-4
40-26-5
40-26-6
40-26-7
40-26-8
40-26-9
40-26-10
40-27
40-28
40-29
40-30
40-31
40-32
40-33
40-34
40-34-1
40-35
40-35-1
40-36
40-37
40-37-1
40-37-2
40-38
40-39
40-40
40-41
40-42
40-43
40-44
40-45
40-45-1
40-45-3
40-45-4
40-45-5
40-45-7
40-45-8
40-45-9
40-46
40-47
40-47-1
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
(15)
90-1
90-2
90-3
90-5
90-5-2
90-7
90-7-2
90-9
(15)
(15)
(10)
(15)
(11)
(11)
(15)
(15)
(15)
(15)
(15)
(13)
(15)
(15)
(2)
(15)
(15)
(11)
(2)
(10)
(15)
(10)
(10)
(15)
(10)
(10)
(15)
(15)
(11)
(10)
(10)
(10)
PC128US-2
Mark
Page
90-9-2
90-11
90-11-2
90-13
90-13-2
90-13-4
90-13-6
90-13-8
90-13-10
90-15
90-17
90-17-2
90-17-4
90-17-6
90-17-8
90-17-10
90-17-12
90-17-14
90-17-16
90-17-18
90-19
90-21
90-23
90-25
90-27
90-29
90-31
90-33
90-35
PC128US-2
Revision
number Mark
Page
Revision
number Mark
Page
Revision
number Mark
Page
Revision
number Mark
Page
Revision
number
(15)
(10)
(15)
(10)
(15)
(10)
(15)
(10)
(15)
(10)
(10)
(10)
(10)
(11)
(11)
(15)
(15)
(15)
(15)
(15)
(10)
(10)
(10)
(10)
(15)
(15)
(15)
(15)
(15)
00-2-5
(19)
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is 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

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.
GENERAL PRECAUTIONS
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 precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
Always wear safety glasses when hitting

parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two 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 signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. 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 or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety 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.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.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 machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.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, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places.

Replace any damaged parts 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 being
operated.
20.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. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.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.
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
(
....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models
REVISIONS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
123
Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol
Item
Remarks
Safety
Special safety precautions

are necessary when performing the work.
Caution
Special technical precautions or other precautions

for preserving standards
are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary

when selecting hoisting
wire, or when working posture is important, etc.
Tightening
torque
Places that require special

attention for the tightening
torque during assembly.
Coat
Places to be coated with

adhesives and lubricants,
etc.
Oil, water
Places where oil, water or

fuel must be added, and
the capacity.
Drain
Places where oil or water

m u s t b e d r a i n e d , a nd
quantity to be drained.
4
3
2
5
6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one 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.
4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Before carrying out the following work, release

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from 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.
Disconnection
1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),
press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.
(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
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. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
Type 1
FOREWORD
Type 3
1) Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push

until cover (3) contacts contact surface a of
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
Disassembly
Type 2
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of
adhesive and
hardening
agent)
Adhesive:
1 kg
Hardenin
g
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr
Used to prevent rubber gaskets,

rubber cushions, and cock plug
from coming out.
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
Features: Resistance to heat and

chemicals
Used for anti-loosening and sealant purpose for bolts and plugs.
Used as adhesive or sealant for

metal, glass and plastic.
Used as sealant for machined

holes.
Used as heat-resisting sealant for

repairing engine.
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength after 30 minutes)
Used mainly for adhesion of rubbers, plastics and metals.
Resistance to heat, chemicals

Used at joint portions subject to
high temperatures.
Used as adhesive or sealant for

gaskets and packing of power
train case, etc.
Used as sealant for various

threads, pipe joints, flanges.
Used as sealant for tapered
plugs, elbows, nipples of hydraulic piping.
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread.
mab Used as sealant for oil pan,
final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Adhesives
Molybdenum
disulphide
lubricant
LM-P
09940-00040
200 g
Used as heat-resisting sealant for

repairing engine.
Used as lubricant for sliding portion (to prevent from squeaking).
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
Various
Molybdenum
disulphide
lubricant
SYG2-400M
400 g
(10 per
case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type

Used as sealant for flywheel
housing, intake manifold, oil an,
thermostat housing, etc.
General purpose type
Used for normal temperature,

light load bearing at places in contact with water or steam.
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter
of bolt
Width across
flats
mm
mm
6
8
10
12
14
10
13
17
19
22
16
18
20
22
24
24
27
30
32
36
27
30
33
36
39
41
46
50
55
60
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
6
8
10
12
10
13
14
27
7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85
Nm
kgm
0 0.15
0 0.3
0 0.7
01
02
28.5 0 3
39 0 4
56 0 6
76 0 8.5
94.5 0 10.5
135 0 15
175 0 20
225 0 25
280 0 30
335 0 35
0 1.4
03
07
0 10
0 19
279 0 30
382 0 39
549 0 59
745 0 83
927 0 103
1320 0 140
1720 0 190
2210 0 240
2750 0 290
3290 0 340
1.35
3.2
6.7
11.5
18
13.2
31
66
113
177
kgm
0
0
0
0
0.8
1.9
4.1
8.4
0 0.2
0 0.5
0 0.6
0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
5 2
8 2
14 3
18 3
20 5
25 5
30 5
00-12
Tightening torque
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7 6.8
112 9.8
279 29
0
0
0
6.7 0.7
11.5 1
28.5 3
0
0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
14
20
24
33
42
Varies depending
on type of
connector.
34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3
Norminal No.
02
03, 04
05, 06
10, 12
14
kgm
0
0
0
0
0
0 0.5
01
02
06
0 13.5
3.5
9.5
14.5
43
89.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
n
36
n
n
7.35 1.47
11.27 1.47
17.64 1.96
22.54 1.96
29.4 4.9
39.2 4.9
49 4.9
68.6 9.8
107.8 14.7
127.4 19.6
151.9 24.5
210.7 29.4
323.4 44.1
0
0
0
0
0
0
0
0
0
0
0
0
0
0.75 0.15
1.15 0.15
1.8 0.2
2.3 0.2
3 0.5
4 0.5
5 0.5
7 1
11 1.5
13 2
15.5 2.5
21.5 3
33 4.5
Norminal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
0
0
0
0
0
0
0
0
0
0
0
0
0
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
10 2
24 4
43 6
77 12
kgm
0
0
0
0
1.02
2.45
4.38
7.85
0 0.20
0 0.41
0 0.61
0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
14
8 2
10 2
12 2
24 4
36 5
kgm
0
0
0
0
0
0.81
1.02
1.22
2.45
3.67
0 0.20
0 0.20
0 0.20
0 0.41
0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter
Tightening torque
inch
Nm
1 / 16
1/8
1/4
3/8
1/2
3/4
1
3 1
8 2
12 2
15 2
24 4
36 5
60 9
kgm
0
0
0
0
0
0
0
0.31
0.81
1.22
1.53
2.45
3.67
6.12
0 0.10
0 0.20
0 0.20
0 0.41
0 0.41
0 0.51
0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm})
Nominal size Width across
of hose
flats
Taper seal
type
Face seal type
Nominal thread
Root diameter
Thread size size - Threads per
(mm) (Reference)
(mm)
inch, Thread series
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
14
9
- 18UNF
16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
11
- 16UN
16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13
- 16UN
16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3
1 - 12UNF
16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal

etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm 2)
0.85
11
0.32
26
CLASSIFICATION BY COLOR AND CODE

Circuits
Priority
Classification
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2
Color White & Red
Code
WB
3
Color White & Black
Code
4
Auxiliary
WL
Color White & Blue

Code
WG
5
Color White & Green
Code
6
Color
n
n
n
n
n
n
n
n
n
n
n
n
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
RY
Black & Red Red & Yellow
n
n
n
n
RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
Red & Blue Yellow & White Green & Blue
n
n
00-15
FOREWORD
CONVERSION TABLE
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 , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide 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.
A
B
B
Millimeters to inches
1 mm = 0.03937 in
00-16
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
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
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
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 or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses {
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
}.
01
GENERAL
General assembly drawing ..........................

Specifications ....... ;. ......................................
Weight table ..................................................
List of lubricants and water.. .......................
PC 128US-2
Ol- 2
Ol- 5
01-11
01-15
01-l
GENERAL ASSEMBLY DRAWING
GENERAL
SPECIFICATION DIMENSIONAL DRAWING

PC128US-2 Serial No.: 7731 and up
Item
Machine weight
PC128US-2
Unit
12,950
Standard specification
Blade specification
7731 and up
kg
13,450
Bucket capacity
m3
0.45
Engine type
Komatsu S4D102E-1 Diesel engine
kW{HP}/rpm
64 {85.8}/2,200
mm
7,220
Blade specification
mm
7,955
B Overall height
mm
2,850
C Overall width
mm
2,515
D Shoe width
mm
500
Engine rated output

A
Overall length
A'
Trail swing radius
mm
1,480
Crawler overall length
mm
3,480
G Distance between tambler center
mm
2,750
H Cab height
mm
2,810
Minimum ground clearance
mm
390
Traveling speed (Low/High)
km/h
3.2/5.1
Continuous swing speed
rpm
11.0
PC128US-2
01-4-3
(15)
GENERAL
Item
Machine weight
PC138US-2
Unit
Blade specification
4501 and up
13,400
kg
14,050
Bucket capacity
m3
0.50
Engine type
Komatsu SAA4D95LE-3-A Diesel engine
kW{HP}/rpm
66.2 {88.7}/2,200
mm
7,220
Blade specification
mm
7,955
B Overall height
mm
2,850
C Overall width
mm
2,515
D Shoe width
mm
500
Engine rated output

A
Overall length
A'
Trail swing radius
mm
1,480
mm
3,610
mm
2,880
H Cab height
mm
2,815
mm
395
km/h
2.9/5.1
rpm
11.0
01-4-4
(15)
PC128US-2
GENERAL
PC138USLC-2 Serial No.: 1001 1500
Item
PC138USLC-2
Unit
Machine weight
Blade specification
0.50
Engine type
Komatsu S4D102E-1 Diesel engine
kW{HP}/rpm
64 {85.8}/2,200
Overall length
D Shoe width
mm
Blade specification
7,395
8,035
mm
Overall width
mm
Blade specification
Overall height
C
C'
14,370
m3
14,000
kg
Bucket capacity
Engine rated output
A'
1001 1500
2,850
2,590
2,515
mm
Blade specification
600
500
Trail swing radius
mm
1,480
mm
3,880
mm
3,140
Cab height
mm
2,815
mm
395
km/h
2.9/4.7
rpm
11.0

H
PC128US-2
01-4-5
(15)
GENERAL
PC138USLC-2 Serial No.: 1501 and up
Item
PC138USLC-2
Unit
Machine weight
Blade specification
0.50
Engine type
Komatsu SAA4D95LE-3-E Diesel engine
kW{HP}/rpm
66.2 {88.7}/2,200
Overall length
Overall width
D Shoe width
mm
Blade specification
7,390
8,035
mm
mm
Blade specification
Overall height
C'
14,370
m3
14,000
kg
Bucket capacity
Engine rated output
A'
1501 and up
2,850
2,590
2,515
mm
Blade specification
600
500
Trail swing radius
mm
1,480
mm
3,870
mm
3,140
Cab height
mm
2,815
mm
395
km/h
2.9/5.1
rpm
11.0

H
01-4-6
(15)
PC128US-2
GENERAL
WORKING RANGE DRAWING

PC128US-2
Serial No.: 7731 and up
PC128US-2
Working range (mm)
7731 and up
Maximum digging radius
8,230
Maximum digging depth
5,405
Maximum digging height
9,260
Maximum vertical wall digging depth
4,860
Maximum dumping height
6,910
Minimum swing radius of work equipment
1,980
Maximum reach at ground level
8,110
Maximum raising distance of blade
470
Maximum lowering distance of blade
530
PC128US-2
01-4-7
(15)
GENERAL
PC138US-2
Working range (mm)
PC138US-2
PC138USLC-2
4501 and up
1001 and up
Maximum digging radius
8,300
Maximum digging depth
5,480
Maximum digging height
9,340
Maximum vertical wall digging depth
4,900
Maximum dumping height
6,840
Minimum swing radius of work equipment
1,980
Maximum reach at ground level
8,180
Maximum raising distance of blade
Maximum lowering distance of blade
01-4-8
(15)
470
525
490
PC128US-2
SPECIFICATIONS
GENERAL
SPECIFICATIONS
FOR STD SPEC.
PC128US-2 Serial No.: 5001 7730
PC128US-2
Machine model
Without blade
Serial No.
5001 7730
Bucket capacity (SAE)
m3
0.45
0.45
Operating weight
kg
12,950
13,450
Max. digging depth
mm
5,445
5,445
Max. digging depth of cut for

2,440 mm 8' level
mm
5,235
5,235
Working ranges
Performance
With blade
Max. vertical wall depth
mm
4,900
4,900
Max. digging reach

Max. reach st ground level
mm
mm
8,230
8,110
8,230
8,110
Max. digging height

Max. dumping height
mm
mm
9,220
6,870
9,220
6,870
Max. blade lifting amount

Max. blade lowering amount
mm
mm
470 [535]
530 [465]
KN {kg}
93.2 {9,500}
93.2 {9,500}
Serial No. 6457 and up
rpm
11.0
11.0
Serial No. 5001 6456
rpm
12
12
Swing max. slope angle
deg.
19
19
Travel speed (Hi/Lo)
km/h
5.1/3.2
5.1/3.2
Gradeability
deg.
35
35
kPa {kg/cm2}
42.2 {0.43}
43.1 {0.44}
Overall length (for transport)
mm
7,220
7,955
Overall width
mm
2,490
2,490
Overall width of undercarrige
mm
2,490
2,490
Overall height (for transport)
mm
2,850 [2,890]
2,850 [ 2,890]
Overall height to top of cab
mm
2,730 [2,795]
2,730 [2,795]
Ground clearance of counterweight
mm
855 [920]
855 [920]
Min. ground clearance
mm
390 [455]
390 [455]
Tail swing radius
mm
1,480
1,480
Min. swing radius of work euipment
mm
1,980
1,980
Height of work equipment at

min. swing radius
mm
6,725 [6,790]
6,725 [6,790]
Length of track on ground
mm
2,750
2,750
Track gauge
mm
1,990
1,990
Overall height of machine cab
mm
1,935 [2,000]
1,935 [2,000]
Blade width x height
mm
2,490 x 590
Max. digging force (bucket)

Swing speed
Dimension
Ground pressure
fl The values shown in the [ ] are those for the machines when the road liner shoe is equipped.
PC128US-2
01-5
(15)
SPECIFICATIONS
GENERAL
PC128US-2
Machine model
Without blade
Serial No.
5001 7730
Model
S4D102E-1
4-cycle, water-cooled, in-line, vertical,
direct injection, with turbochatger
No. of cylinders-bore x stroke
mm
4 102 x 120
Piston displacement
{cc}
3.920 {3,920}
Rated horsepower
kW/rpm{HP/rpm}
64/2,200 {87/2,200}
Max. torpue
Nm/rpm{kgm/rpm}
329/1,300 {33.5/1,300}
High idling speed
rpm
2,400
Low idling speed
rpm
950
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type
Min. fuel consumption ratio

Starting motor
24V, 4.5 kw
Alternator
24V, 25A
Undercarriage
Battery
Radiator type
CF19-4
Carrier roller
1 on each side
Track roller
7 on each side
Asembly-type triple grouster, 42 on each side
Hydraulic pump
(road liner)
Hydraulic motor control

valve
Hydraulic system
12V, 64 Ah x 2
Track shoe (iron shoe)
Road liner, 42 on each side

HPV95 (for 105cc/rev.)
Type x no.
Variable displacement piston type x 1

/min
Discharge
Set pressure (at operation)
(at traveling)
Type x no.
Control method
226 (at 2,200rpm)

2
MPa {kg/cm }
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM18VL-J
Variable displacement piston type
(with brake valve, holding brake) x 2
Swing motor
KMF40ABE-3
Fixed displacement piston type
(with shockless safety valve, holding brake) x 1
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic cooler
01-6
(15)
With blade
Air cooled (CF40-1)
PC128US-2
SPECIFICATIONS
GENERAL
PC128US-2
Machine model
STD (without blade)
Serial No.
5001 7730
Boom cylinder
Type
105
105
Piston rod diameter
mm
70
70
Stroke
mm
1,055
1,055
Max. length betwiin pins
mm
2,555
2,555
Min. length betwiin pins
mm
1,500
1,500
Reciprocating piston tipe
Arm cylinder
Cylinder inner diameter
mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
mm
95
95
Piston rod diameter
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
Blade cylinder
mm
Type
Bucket cylinder
Work equipment cylinder
Hydraulic system
Type
PC128US-2
OPT (with blade)
mm
115
Piston rod diameter
mm
75
Stroke
mm
181
mm
870
mm
689
01-7
A
SPECIFICATIONS
GENERAL
FOR NORTH AMERICA SPEC.

PC128US-2 Serial No.: 5001 7730
PC128US-2
Machine model
STD (without blade)
Serial No.
5001 7730
m3
0.45
0.45
Operating weight
kg
13,100
13,600
Max. digging depth
mm
5,445
5,445

2,440 mm 8' level
mm
5,235
5,235
Working ranges
Performance
OPT (with blade)
mm
4,900
4,900
Max. digging reach
mm
8,230
8,230
mm
8,110
8,110
Max. digging height
mm
9,220
9,220
Max. dumping height
mm
6,870
6,870
mm
470 [535]
mm
530 [465]
KN {kg}
93.2 {9,500}
93.2 {9,500}
rpm
11.0
11.0
rpm
12
12
deg.
19
19
km/h
5.1/3.2
5.1/3.2
Gradeability
deg.
35
35
kPa {kg/cm2}
35.6 {0.36}
37.0 {0.38}
mm
7,220
7,955
Overall width
mm
2,590
2,590
mm
2,590
2,590
mm
2,850 [2,890]
2,850 [2,890]
mm
2,730 [2,795]
2,730 [2,795]
mm
855 [920]
855 [920]
mm
390 [455]
390 [455]
Tail swing radius
mm
1,480
1,480
mm
1,980
1,980

min. swing radius
mm
6,725 [6,790]
6,725 [6,790]
mm
2,750
2,750
Track gauge
mm
1,990
1,990
mm
1,935 [2,000]
1,935 [2,000]
mm
2,490 x 590

Swing speed
Dimension
Ground pressure
fl The values shown in the [
01-8
A
] are those for the machines when the road liner shoe is equipped.
PC128US-2
SPECIFICATIONS
GENERAL
PC128US-2
Machine model
Without blade
Serial No.
5001 7730
Model
S4D102E-1
mm
4 102 x 120
Piston displacement
{cc}
3.92 {3,920}
Flywheel horsepower
kW/rpm{HP/rpm}
64/2,200 {87/2,200}
Maximum torpue
Nm/rpm{kgm/rpm}
329/1,300 {33.5/1,300}
High idling speed
rpm
2,400
Low idling speed
rpm
950
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type

Starting motor
24V, 4.5 kw
Alternator
24V, 25A
12V, 72Ah x 2
Radiator type
CF19-4
Carrier roller
1 on each side
Track roller
7 on each side
[Road liner, 42 on each side]
Track shoe
Hydraulic motor
control
valve
Hydraulic pump
Undercarriage
Battery
Hydraulic system
With blade

Type x no.
Discharge
(at traveling)
Type x no.
Control method
/min
226 (at 2,200rpm)
MPa {kg/cm2}
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM18VL-J
(with brake valve, parking brake) x 2
Swing motor
KMF40ABE-3
(with shockless safety valve, parking brake) x 1
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic oil filter
Air cooled (CF40-1)
PC128US-2
01-9
(15)
GENERAL
SPECIFICATIONS
PC128US-2
Machine model
Without blade
Serial No.
5001 7730
Boom cylinder
Type

mm
105
105
Piston rod diameter
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
Blade cylinder
mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
95
95
Piston rod diameter
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
(15)
Type
01-10
With blade
mm
115
Piston rod diameter
mm
75
Stroke
mm
181
mm
870
mm
689
PC128US-2
SPECIFICATIONS
GENERAL
FOR KUK SPEC.

PC128US-2 Serial No.: 5001 7730
PC128US-2
Machine model
Without blade
Serial No.
5001 7730
m3
0.36
0.36
Operating weight
kg
12,750
13,250
Max. digging depth
mm
5,945
5,945

2,440 mm 8' level
mm
5,760
5,760
mm
5,385
5,385
Max. digging reach
mm
8,720
8,720
mm
8,600
8,600
Working ranges
Performance
With blade
Max. digging height
mm
9,655
9,655
Max. dumping height
mm
7,305
7,305
mm
470 [535]
mm
530 [465]
KN {kg}
88.3 {9,000}
88.3 {9,000}
rpm
11.0
11.0
rpm
12
12
deg.
19
19
km/h
5.1/3.2
5.1/3.2
Gradeability
deg.
35
35
kPa {kg/cm }
42.2 {0.43}
43.1 {0.44}
mm
7,120
7,855
Overall width
mm
2,490
2,490
mm
2,490
2,490
mm
3,190 [3,230]
3,190 [3,230]
mm
2,730 [2,795]
2,730 [2,795]
mm
855 [920]
855 [920]
mm
390 [455]
390 [455]
Tail swing radius
mm
1,480
1,480
mm
2,250
2,250

min. swing radius
mm
6,725 [6,790]
6,725 [6,790]
mm
2,750
2,750
Track gauge
mm
1,990
1,990
mm
1,935 [2,000]
1,935 [2,000]
mm
2,490 x 590

Swing speed
Dimension
Ground pressure
fl The above values are for the machines equipped with the long arm and 0.36 m3 bucket.
PC128US-2
01-10-1
(15)
GENERAL
SPECIFICATIONS
PC128US-2
Machine model
Without blade
Serial No.
5001 7730
Model
S4D102E-1
mm
4 102 x 120
Piston displacement
{cc}
3.92 {3,920}
Flywheel horsepower
kW/rpm{HP/rpm}
64/2,200 {87/2,200}
Maximum torpue
Nm/rpm{kgm/rpm}
329/1,300 {33.5/1,300}
High idling speed
rpm
2,400
Low idling speed
rpm
950
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type

Starting motor
24V, 4.5 kw
Alternator
24V, 35A
12V, 64Ah x 2
Radiator type
CF19-4
Carrier roller
1 on each side
Track roller
7 on each side
[Road liner, 42 on each side]
Track shoe
Hydraulic motor
control
valve
Hydraulic pump
Undercarriage
Battery
Hydraulic system
With blade

Type x no.
Discharge
(at traveling)
Type x no.
Control method
/min
226 (at 2,200rpm)
MPa {kg/cm2}
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM18VL-J
(with brake valve, parking brake) x 2
Swing motor
KMF40ABE-3
(with shockless safety valve, parking brake) x 1
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic oil filter
01-10-2
(15)
Air cooled (CF40-1)
PC128US-2
GENERAL
SPECIFICATIONS
PC128US-2
Machine model
STD (without blade)
Serial No.
5001 7730
Boom cylinder
Type

mm
105
105
Piston rod diameter
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
mm
95
95
Piston rod diameter
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
Blade cylinder
Type
Bucket cylinder
Hydraulic system
Type
PC128US-2
OPT (with blade)
mm
115
Piston rod diameter
mm
75
Stroke
mm
181
mm
870
mm
689
01-10-3
A
SPECIFICATIONS
GENERAL

PC128US-2
Machine model
STD (without blade)

7731 and up
m3
0.45
0.45
Operating weight
kg
12,950
13,450
Max. digging depth
mm
5,405
5,405

2,440 mm 8' level
mm
5,195
5,195
mm
4,860
4,860
Max. digging reach
mm
8,230
8,230
mm
8,110
8,110
Max. digging height
mm
9,260
9,260
Max. dumping height
mm
6,910
6,910
mm
470 [535]
mm
530 [465]
KN {kg}
93.2 {9,500}
93.2 {9,500}
Swing speed
rpm
11.0
11.0
deg.
19
19
km/h
5.1/3.2
5.1/3.2
Gradeability
deg.
35
35
kPa {kg/cm2}
42.2 {0.43}
43.1 {0.44}
mm
7,220
7,955
Overall width
mm
2,515
2,515
mm
2,490
2,490
mm
2,850 [2,890]
2,850 [ 2,890]
mm
2,810 [2,875]
2,810 [2,875]
mm
895 [960]
895 [960]
mm
390 [455]
390 [455]
Tail swing radius
mm
1,480
1,480
mm
1,980
1,980

min. swing radius
mm
6,765 [6,830]
6,765 [6,830]
mm
2,750
2,750
Track gauge
mm
1,990
1,990
mm
1,975 [2,040]
1,975 [2,040]
mm
2,490 x 590
Working ranges
Persormance
Serial No.
Ground pressure
Dimension
OPT (with blade)
01-10-4
A
PC128US-2
SPECIFICATIONS
GENERAL
PC128US-2
Machine model
Without blade
Serial No.
7731 and up
Model
S4D102E-1
mm
4 102 x 120
Piston displacement
{cc}
3.920 {3,920}
Rated horsepower
kW/rpm{HP/rpm}
64/2,200 {87/2,200}
Max. torpue
Nm/rpm{kgm/rpm}
329/1,300 {33.5/1,300}
High idling speed
rpm
2,400
Low idling speed
rpm
950
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type

Starting motor
24V, 4.5 kw
Alternator
24V, 25A
(For KUK spec.)
24V, 35A
Battery
12V, 64 Ah x 2
12V, 72 Ah x 2
Radiator type
CF19-4
Carrier roller
1 on each side
Track roller
7 on each side

(road liner)
Hydraulic motor
Control
valve
Hydraulic pump
Undercarriage
(For North America spec.)
Hydraulic system
With blade

Type x no.
Discharge
(at traveling)
Type x no.
Control method
/min
226 (at 2,200rpm)
MPa {kg/cm2}
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM18VL-J
Swing motor
KMF40ABE-3
Hydraulic tank
Hydraulic filter
Hydraulic cooler
PC128US-2
Box-shaped, open
Tank return side
Air cooled (CF40-1)
01-10-5
(15)
GENERAL
SPECIFICATIONS
PC128US-2
Machine model
Without blade
Serial No.
7731 and up
Boom cylinder
Type

mm
105
105
Piston rod diameter
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
Blade cylinder
mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
95
95
Piston rod diameter
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
(15)
Type
01-10-6
With blade
mm
115
Piston rod diameter
mm
75
Stroke
mm
181
mm
870
mm
689
PC128US-2
SPECIFICATIONS
GENERAL

PC138US-2
Machine model
Without blade
m3
0.50
0.50
Operating weight
kg
13,400
14,050
Max. digging depth
mm
5,480
5,480

2,440 mm 8' level
mm
5,265
5,265
mm
4,900
4,900
Max. digging reach
mm
8,300
8,300
mm
8,180
8,180
Max. digging height
mm
9,340
9,340
Max. dumping height
mm
6,840
6,840
mm
470 [535]
mm
525 [460]
KN {kg}
93.2 {9,500}
93.2 {9,500}
Swing speed
rpm
11.0
11.0
deg.
19
19
km/h
5.1/2.9
5.1/2.9
Gradeability
deg.
35
35
kPa {kg/cm2}
42.2 {0.43}
44.1 {0.45}
mm
7,260
7,955
Overall width
mm
2,515
2,515
mm
2,490
2,490
mm
2,850 [2,890]
2,850 [ 2,890]
mm
2,815 [2,880]
2,815 [2,880]
mm
900 [965]
900 [965]
mm
395 [460]
395 [460]
Tail swing radius
mm
1,480
1,480
mm
1,980
1,980

min. swing radius
mm
6,770 [6,835]
6,770 [6,835]
mm
2,880
2,880
Track gauge
mm
1,990
1,990
mm
1,980 [2,045]
1,980 [2,045]
mm
2,490 x 590
Ground pressure
Dimension
4501 and up
Working ranges
Persormance
Serial No.
With blade
PC128US-2
01-10-7
(15)
SPECIFICATIONS
GENERAL
PC138US-2
Machine model
Without blade
Serial No.
4501 and up
Model
SAA4D95LE-3-A
direct injection, with turbochatger, after cooler
mm
4 95 x 115
Piston displacement
{cc}
3.260 {3,260}
Rated horsepower
kW/rpm{HP/rpm}
66.2/2,200 {88.7/2,200}
Max. torpue
Nm/rpm{kgm/rpm}
353/1,500 {36.0/1,500}
High idling speed
rpm
2,400
Low idling speed
rpm
1,100
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type

Starting motor
24V, 3.0 kw
Alternator
24V, 25A
(For KUK spec.)
24V, 35A
Battery
12V, 64 Ah x 2
12V, 72 Ah x 2
Radiator type
Corrugated aluminum (4-line)
Carrier roller
1 on each side
Track roller
7 on each side

(road liner)
Hydraulic motor
Control
valve
Hydraulic pump
Undercarriage
(For North America spec.)
Hydraulic system
With blade

Type x no.
Discharge
(at traveling)
Type x no.
Control method
/min
226 (at 2,200rpm)
MPa {kg/cm2}
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM20VL2-P
Swing motor
KMF40ABE-3
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic cooler
Air cooled (CF40)
01-10-8
(15)
PC128US-2
GENERAL
SPECIFICATIONS
PC138US-2
Machine model
Without blade
Serial No.
4501 and up
Boom cylinder
Type

mm
105
105
Piston rod diameter
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder

mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
mm
100
100
Piston rod diameter
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
Blade cylinder
Type
Bucket cylinder
Hydraulic system
Type
PC128US-2
With blade
mm
115
Piston rod diameter
mm
75
Stroke
mm
181
mm
870
mm
689
01-10-9
(15)
SPECIFICATIONS
GENERAL

PC138USLC-2
Machine model
Without blade
m3
0.50
0.50
Operating weight
kg
14,000
14,370
Max. digging depth
mm
5,480
5,480

2,440 mm 8' level
mm
5,265
5,265
mm
4,900
4,900
Max. digging reach
mm
8,300
8,300
mm
8,180
8,180
Max. digging height
mm
9,340
9,340
Max. dumping height
mm
6,840
6,840
mm
470
mm
490
KN {kg}
93.2 {9,500}
93.2 {9,500}
Swing speed
rpm
11.0
11.0
deg.
19
19
km/h
4.7/2.9
4.7/2.9
Gradeability
deg.
35
35
kPa {kg/cm }
33.6 {0.35}
42.2 {0.43}
mm
7,395
8,035
Overall width
mm
2,590
2,515
mm
2,590
2,490
mm
2,850
2,850
mm
2,815
2,815
mm
900
900
mm
395
395
Tail swing radius
mm
1,480
1,480
mm
1,980
1,980

min. swing radius
mm
6,770
6,770
mm
3,140
3,140
Track gauge
mm
1,990
1,990
mm
1,980
1,980
mm
2,490 x 590
Ground pressure
Dimension
1001 1500
Working ranges
Performance
Serial No.
With blade
01-10-10
(15)
PC128US-2
SPECIFICATIONS
GENERAL
PC138USLC-2
Machine model
Without blade
Serial No.
1001 1500
Model
S4D102E-1
mm
4 102 x 120
Piston displacement
{cc}
3.920 {3,920}
Rated horsepower
kW/rpm{HP/rpm}
64/2,200 {87/2,200}
Max. torpue
Nm/rpm{kgm/rpm}
329/1,300 {33.5/1,300}
High idling speed
rpm
2,400
Low idling speed
rpm
950
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type

Starting motor
24V, 4.5 kw
Alternator
24V, 25A
12V, 72 Ah x 2
Radiator type
CF19-4
Carrier roller
2 on each side
Track roller
8 on each side
Control Hydraulic pump

valve
Hydraulic motor
Undercarriage
Battery
Hydraulic system
With blade

Type x no.

/min
Discharge
(at traveling)
Type x no.
Control method
226 (at 2,200rpm)

2
MPa {kg/cm }
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM20VL-P
Swing motor
KMF40ABE-3
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic cooler
PC128US-2
Air cooled (CF40-1)
01-10-11
(15)
GENERAL
SPECIFICATIONS
PC138USLC-2
Machine model
Without blade
Serial No.
1001 1500
Boom cylinder
Type

mm
105
105
Piston rod diameter
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
100
100
Piston rod diameter
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Blade cylinder
Type
(15)
Type
01-10-12
With blade
mm
115
Piston rod diameter
mm
75
Stroke
mm
181
mm
870
mm
689
PC128US-2
SPECIFICATIONS
GENERAL

PC138USLC-2
Machine model
Without blade
m3
0.50
0.50
Operating weight
kg
14,000
14,370
Max. digging depth
mm
5,480
5,480

2,440 mm 8' level
mm
5,265
5,265
mm
4,900
4,900
Max. digging reach
mm
8,300
8,300
mm
8,180
8,180
Max. digging height
mm
9,340
9,340
Max. dumping height
mm
6,840
6,840
mm
470
mm
490
KN {kg}
93.2 {9,500}
93.2 {9,500}
Swing speed
rpm
11.0
11.0
deg.
19
19
km/h
5.1/2.9
5.1/2.9
Gradeability
deg.
35
35
kPa {kg/cm }
33.6 {0.35}
42.2 {0.43}
mm
7,390
8,035
Overall width
mm
2,590
2,515
mm
2,590
2,490
mm
2,850
2,850
mm
2,815
2,815
mm
900
900
mm
395
395
Tail swing radius
mm
1,480
1,480
mm
1,980
1,980

min. swing radius
mm
6,770
6,770
mm
3,140
3,140
Track gauge
mm
1,990
1,990
mm
1,980
1,980
mm
2,490 x 590
Ground pressure
Dimension
1501 and up
Working ranges
Performance
Serial No.
With blade
PC128US-2
01-10-13
(15)
SPECIFICATIONS
GENERAL
PC138USLC-2
Machine model
Without blade
Serial No.
1501 and up
Model
SAA4D95LE-3-A
direct injection, with turbochatger, after cooler
mm
4 95 x 115
Piston displacement
{cc}
3.260 {3,260}
Rated horsepower
kW/rpm{HP/rpm}
66.2/2,200 {88.7/2,200}
Max. torpue
Nm/rpm{kgm/rpm}
353/1,500 {36.0/1,500}
High idling speed
rpm
2,400
Low idling speed
rpm
1,100
g/kWh{g/HPh}
224 {165}
Performance
Engine
Type

Starting motor
24V, 3.0 kw
Alternator
24V, 25A
12V, 72 Ah x 2
Radiator type
Corrugated aluminum (4-line)
Carrier roller
2 on each side
Track roller
8 on each side
Control Hydraulic pump

valve
Hydraulic motor
Undercarriage
Battery
Hydraulic system
With blade

Type x no.

/min
Discharge
(at traveling)
Type x no.
Control method
226 (at 2,200rpm)

2
MPa {kg/cm }
31.9 {325}
34.8 {355}
6-spool type x 1
Hydraulic type
Travel motor
GM20VL2-P
Swing motor
KMF40ABE-3
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic cooler
Air cooled (CF40)
01-10-14
(15)
PC128US-2
GENERAL
SPECIFICATIONS
PC138USLC-2
Machine model
Without blade
Serial No.
1501 and up
Boom cylinder
Type

mm
105
105
Piston rod diameter
mm
70
70
Stroke
mm
1,055
1,055
mm
2,555
2,555
mm
1,500
1,500
Arm cylinder
mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
mm
2,877
2,877
mm
1,702
1,702
Type
Bucket cylinder
Hydraulic system
mm
100
100
Piston rod diameter
mm
65
65
Stroke
mm
885
885
mm
2,263
2,263
mm
1,378
1,378
Type
Blade cylinder
Type
PC128US-2
With blade
mm
115
Piston rod diameter
mm
75
Stroke
mm
181
mm
870
mm
689
01-10-15
(15)
GENERAL
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling component.
FOR STD SPEC.

PC128US-2 Serial No.: 5001 7730
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
Engine assembly (excl. water, oil)
491
491
Engine (excl. water, oil)
385
385
Engine mount
21.6
21.6
PTO
4.1
4.1
Hydraulic pump
80
80
Radiator, oil cooler assembly
54
54
1,500
1,500
Operators cab
228
228
Operators seat
12.6
12.6
Fuel tank (excl. fuel)
98
98
Hydraulic tank (excl. hydraulic oil)
92
92
Control valve
80
96
Self pressure reducing valve
4.8
4.8
3,020
2,460
Swing motor (with brake valve)
26
26
Swing circle
155
155
Swing machinery
72.2
72.2
Center swivel joint
28.6
43.6
Track frame assembly
2,275
2,445
Track frame
1,280
1,438
Idler assembly
81 x 2
81 x 2
72.9 x 2
72.9 x 2
Carrier roller
11 x 2
11 x 2
Track roller
21 x 14
21 x 14
Travel motor, final drive assembly
144 x 2
144 x 2
Sprocket
33.7 x 2
33.7 x 2
Revolving frame
Counterweight
Recoil spring assembly
PC128US-2
01-11
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
Track shoe assembly

Triple grouser shoe (500mm)
740 x 2
740 x 2
830 x 2
830 x 2
Road liner (500mm)
765 x 2
765 x 2
Boom assembly
820
820
Arm assembly
356
356
Bucket link assembly
85.6
85.6
Bucket assembly
369
369
Blade assembly
641
113.3 x 2
113.3 x 2
Arm cylinder assembly
140.9
140.9
Bucket cylinder assembly
86.3
86.3
Blade cylinder assembly
67.2 x 2
Boom cylinder assembly
01-12
(15)
PC128US-2
WEIGHT TABLE
GENERAL
FOR NORTH AMERICA SPEC.

PC128US-2 Serial No.: 5001 7730
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
491
491
385
385
Engine mount
21.6
21.6
PTO
4.1
4.1
Hydraulic pump
80
80
54
54
1,500
1,500
Operators cab
228
228
Operators seat
12.6
12.6
98
98
92
92
Control valve
80
96
4.8
4.8
3,020
2,460
Swing motor
26
26
Swing circle assembly
155
155
Swing machinery
72.2
72.2
Center swivel joint
28.6
43.6
2,275
2,445
Track frame
1,280
1,438
Idler
81 x 2
81 x 2
Idler cushion
72.9 x 2
72.9 x 2
Carrier roller
11 x 2
11 x 2
Track roller
21 x 14
21 x 14
Revolving frame assembly
Counterweight
144 x 2
144 x 2
Sprocket
33.7 x 2
33.7 x 2
740 x 2
740 x 2
830 x 2
830 x 2
925 x 2
925 x 2
Road liner (rubber pad type) (500mm)
765 x 2
765 x 2
Track shoe assembly
PC128US-2
01-13
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
Boom assembly
820
820
Arm assembly
356
356
Link assembly
85.6
85.6
Bucket assembly
369
369
Blade assembly
641
113.3 x 2
113.3 x 2
140.9
140.9
86.3
86.3
67.2 x 2

01-14
(15)
PC128US-2
WEIGHT TABLE
GENERAL
FOR KUK SPEC.

Unit: kg
PC128US-2 Serial No.: 5001 7730

PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
491
491
385
385
Engine mount
21.6
21.6
PTO
4.1
4.1
Hydraulic pump
80
80
54
54
1,500
1,500
Operators cab
228
228
Operators seat
35
35
98
98
92
92
Control valve
96
106
4.8
4.8
Boom hydraulic drift prevention valve
5.1
5.1
3,020
2,460
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
Center swivel joint
28.6
43.6
2,275
2,445
Track frame
1,280
1,438
Idler
81 x 2
81 x 2
Idler cushion
72.9 x 2
72.9 x 2
Carrier roller
11 x 2
11 x 2
Track roller
21 x 14
21 x 14
Counterweight
144 x 2
144 x 2
Sprocket
33.7 x 2
33.7 x 2
740 x 2
740 x 2
830 x 2
830 x 2
925 x 2
925 x 2
765 x 2
765 x 2
Track shoe assembly
PC128US-2
01-14-1
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
5001 7730
Boom assembly
820
820
Arm assembly (long arm)
480
480
Link assembly
85.6
85.6
376
376
641
113.3 x 2
113.3 x 2
140.9
140.9
86.3
86.3
67.2 x 2
Bucket assembly (0.36 m )

Blade assembly
01-14-2
(15)
PC128US-2
WEIGHT TABLE
GENERAL
Unit: kg

PC128US-2
Machine model
Without blade
Serial No.
With blade
7731 and up
491
491
385
385
Engine mount
21.6
21.6
PTO
4.1
4.1
Hydraulic pump
80
80
54
54
1,500
1,500
Operators cab
245
245
Operators seat
35
35
98
98
92
92
Control valve
80
96
(For KUK spec.)
96
106
4.8
4.8
3,020
2,460
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
Center swivel joint
28.6
43.6
2,275
2,445
Track frame
1,280
1,438
Idler
81 x 2
81 x 2
Idler cushion
72.9 x 2
72.9 x 2
Carrier roller
11 x 2
11 x 2
Track roller
21 x 14
21 x 14
144 x 2
144 x 2
Sprocket
33.7 x 2
33.7 x 2
Counterweight
Track shoe assembly

*1
740 x 2
740 x 2
*2
*1
710 x 2
830 x 2
710 x 2
830 x 2
*2
795 x 2
795 x 2
765 x 2
765 x 2
*1. Serial No.: 7731 9000

*2. Serial No.: 9001 and up
PC128US-2
01-14-3
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC128US-2
Machine model
Without blade
Serial No.
With blade
7731 and up
Boom assembly
820
820
Arm assembly
356
356
Link assembly
85.6
85.6
Bucket assembly
369
369
Blade assembly
641
113.3 x 2
113.3 x 2
140.9
140.9
86.3
86.3
67.2 x 2

01-14-4
(15)
PC128US-2
WEIGHT TABLE
GENERAL
Unit: kg

PC138US-2
Machine model
Without blade
Serial No.
With blade
4501 and up
491
491
360
360
Engine mount
19.6
19.6
PTO
4.1
4.1
Hydraulic pump
80
80
62
62
1,425
1,425
Operators cab
245
245
Operators seat
35
35
98
98
92
92
Control valve
80
96
(For KUK spec.)
96
106
4.8
4.8
3,400
3,000
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
Center swivel joint
28.6
43.6
2,315
2,470
Track frame
1,280
1,438
Idler
78 x 2
78 x 2
Idler cushion
69 x 2
69 x 2
Carrier roller
11 x 2
11 x 2
Track roller
21 x 14
21 x 14
Counterweight
144 x 2
144 x 2
Sprocket
33.7 x 2
33.7 x 2
755 x 2
755 x 2
845 x 2
845 x 2
935 x 2
935 x 2
815 x 2
815 x 2
Track shoe assembly
PC128US-2
01-14-5
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC138US-2
Machine model
Without blade
Serial No.
With blade
4501 and up
Boom assembly
820
820
Arm assembly
356
356
Link assembly
85.6
85.6
Bucket assembly
399
399
Blade assembly
641
116.2 x 2
116.2 x 2
135
135
95
95
61.7 x 2

01-14-6
(15)
PC128US-2
WEIGHT TABLE
GENERAL
Unit: kg

PC138USLC-2
Machine model
Without blade
Serial No.
With blade
1001 1500
491
491
385
385
Engine mount
21.6
21.6
PTO
4.1
4.1
Hydraulic pump
80
80
54
54
1,500
1,500
Operators cab
245
245
Operators seat
35
35
98
98
92
92
Control valve
80
96
4.8
4.8
3,420
3,020
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
Center swivel joint
28.6
43.6

Track frame
2,610
1,544
2,750
1,680
Counterweight
Idler
Idler cushion
81 x 2
81 x 2
72.9 x 2
72.9 x 2
Carrier roller
11 x 4
11 x 4
Track roller
21 x 16
21 x 16
144 x 2
144 x 2
Sprocket
33.1 x 2
33.1 x 2
940 x 2
895 x 2
840 x 2
805 x 2
940 x 2
895 x 2
840 x 2
805 x 2
Boom assembly
820
820
Arm assembly
356
356
Link assembly
85.6
85.6
Bucket assembly
399
399
Blade assembly
641
Track shoe assembly

*1. Serial No.: 1001 1300

*2. Serial No.: 1301 and up
PC128US-2
*1
*2
*1
*2
01-14-7
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC138USLC-2
Machine model
Without blade
Serial No.
With blade
1001 1500
113.3 x 2
113.3 x 2
140.9
140.9
95.8
95.8
67.2 x 2
01-14-8
(15)
PC128US-2
WEIGHT TABLE
GENERAL
Unit: kg

PC138USLC-2
Machine model
Without blade
Serial No.
With blade
1501 and up
464
464
360
360
Engine mount
19.6
19.6
PTO
4.1
4.1
Hydraulic pump
80
80
62
62
1,425
1,425
Operators cab
245
245
Operators seat
35
35
98
98
92
92
Control valve
80
96
4.8
4.8
3,400
3,000
Swing motor
26
26
155
155
Swing machinery
72.2
72.2
Center swivel joint
28.6
43.6

Track frame
2,595
1,544
2,735
1,680
Idler
78 x 2
78 x 2
Idler cushion
69 x 2
69 x 2
Carrier roller
11 x 4
11 x 4
Track roller
21 x 16
21 x 16
144 x 2
144 x 2
Sprocket
33.1 x 2
33.1 x 2
Track shoe assembly

895 x 2
895 x 2
805 x 2
805 x 2
Boom assembly
820
820
Arm assembly
356
356
Link assembly
85.6
85.6
Bucket assembly
399
399
Blade assembly
641
Counterweight
PC128US-2
01-14-9
(15)
WEIGHT TABLE
GENERAL
Unit: kg
PC138USLC-2
Machine model
Without blade
Serial No.
With blade
1501 and up
116.2 x 2
116.2 x 2
135
135
95
95
61.7 x 2
01-14-10
(15)
PC128US-2
GENERAL
LIST OF LUBRICANTS AND WATER

PROPER SELECTION
AMBIENT TEMPERATURE
RESERVOIR
KIND OF
FLUID 22
4
20
30
14
10
32
0
50
10
68
20
86
30
104
40
122F
50C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Swing machinery case

Final drive case
PTO gear case
Engine oil
SAE 30
SAE 30
SAE 10W-30
Hydraulic system
SAE 15W-40
ASTM D975 No.2
Fuel tank
Diesel fuel
Greasing system
Grease
Cooling system
Water
*1
NLGI No.2
Add antifreeze
*1: ASTM D975 No.1
PC128US-2
Specified
capacity
Refill
capacity
Engine oil
pan
Swing
machinery
case
Final drive
case
(each)
PTO gear
case
Hydraulic
system
Fuel tank
Cooling
system
liter
17.5
2.5
2.5
0.75
120
195
18.2
US gal
4.62
0.66
0.66
0.20
31.68
51.48
4.80
16
2.5
2.5
0.75
69
4.23
0.66
0.66
0.20
18.22
liter
US gal
PC138US-2
Specified
capacity
Refill
capacity
PC128US-2
Engine oil
pan
Swing
machinery
case
Final drive
case
(each)
PTO gear
case
Hydraulic
system
Fuel tank
Cooling
system
liter
11.5
2.5
2.5
0.75
120
195
14.2
US gal
3.04
0.66
0.66
0.20
31.68
51.48
3.75
11
2.5
2.5
0.75
69
2.91
0.66
0.66
0.20
18.22
liter
US gal
01-15
(15)
GENERAL
REMARK
When fuel sulphur content is less than 0.5%,
change oil in the oil pan according to every
periodic maintenance hours described in this
manual.
Change oil according to the following table if
fuel sulphur content is above 0.5%.
When starting the engine in an atmospheric

temperature of lower than 0C(32F), be sure
to use engine oil of SAE 10W, SAE10W-30 and
SAE15W-40, even though the atmospheric
temperature goes up to 10C(50F) more or
less during the day.
Use API classification CD as engine oil and if

API classification CC, reduce the engine oil
change interval to half.
There is no problem if single grade oil is

mixed with multigrade oil (SAE10W-30, 15W40), but be sure to add single grade oil that
matches the temperature range in the table.
We recommend Komatsu genuine oil which

has been specifically formulated and approved for use in engine and hydraulic work
equipment applications.
Specified capacity: Total amount of oil including

oil for components and oil in
piping.
Refill capacity:
Amount of oil needed to refill

system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API:
American Petroleum Institute
Fuel sulphur content
Change interval of oil in

engine oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
01-16
A
PC128US-2
10 STRUCTURE AND FUNCTION

PTO .............................................................. 10- 2
Radiator and oil cooler ............................... 10- 3
Power train .................................................. 10- 5
Swing circle ................................................ 10- 6
Swing machinery ....................................... 10- 7
Track frame ................................................. 10- 8
Idler cushion ............................................... 10- 9
Hydraulic component layout ..................... 10- 10
Valve control ............................................... 10- 12
Hydraulic tank and filter ............................. 10- 14
Hydraulic pump (Piston pump) ................. 10- 15
Control valve ............................................... 10- 36
Suction safety valve ................................... 10- 46
CLSS ............................................................ 10- 47
Self pressure reducing valve ..................... 10- 84
Center swivel joint ...................................... 10- 91
Travel motor (Final drive) .......................... 10- 93
Swing motor ............................................... 10-102
Solenoid valve ............................................ 10-108
PPC accumulator ........................................ 10-110
Accumulator for breaker (If equipped) ..... 10-111
PPC valve .................................................... 10-112
Boom hydraulic drift prevention valve ... 10-122-1
Arm hydraulic drift prevention valve ...... 10-122-6
Air-conditioner piping ................................ 10-123
Electric component layout ......................... 10-124
Engine control ............................................ 10-128
Electric control system ............................... 10-136
Monitor System .......................................... 10-149
PC128US-2
10-1
(15)
PTO
PTO
1.
2.
3.
4.
Coupling
Shaft
Breather
Gauge
10-2
5. Hydraulic pump
6. Oil filler plug
7. Level plug
PC128US-2
RADIATOR AND OIL COOLER

PC128US-2
PC128US-2
10-3
(15)
STRUCTURE
AND FUNCTION
Y
9JAOl328
1. Oil cooler
2. Radiator
3. Shroud
4. Reservoir tank
5. Oil cooler outlet
6. Oil cooler inlet
7. Radiator cap
8. Radiator inlet hose
9. Radiator outlet hose
10. Drain,valve
11. Fan
1o-4
SPECIFICATION
Radiator
Core type : CF19-4
Fin pitch
: 3.5/2 mm
Total heat dissipation
surface : 34.06 m2
Pressure valve cracking pressure :
49.0 + 14.7 kPa IO.5 ? 0.15 kg/cm21
Vacuum valve cracking pressure :
-4.9 - 0 kPa GO.05 - 0 kg/cm21
Oil cooler
Core type : CF40-1
Fin pitch
: 4.512 mm
Total heat dissipation
surface : 8.79 m2
PC1 28US-2
PC138US-2
PC128US-2
10-4-1
(15)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Shroud
Reservoir tank
Oil cooler
Charge air cooler
Radiator cap
Radiator
Radiator inlet hose
Chage air cooler outlet hose

Oil cooler inlet
Oil cooler outlet
Charge air inlet hose
Radiator outlet hose
Drain valve
Specification
Radiator
Oil cooler
Aluminum wave
(4-line)
CF40
Fin pitch (min)
3.5/2
3.5/2
4.0/2
Total heat dissipation surfase (m2)
18.81
11.83
6.17
Pressure valve cracking pressure

(kPa {kg/cm2})
49.0 14.7
{0.5 0.15}
Vacuum valve cracking pressure

(kPa {kg/cm2})
-4.9 0
{-0.05 0}
Core type
10-4-2
(15)
Charge air cooler
PC128US-2
STRUCTURE
AND FUNCTION
POWER TRAIN
POWER TRAIN
9JA01329
1. Idler
2. Control valve
3. Self pressure reducing valve
4. PPC lock solenoid valve
5. 2-speed travel changeover solenoid valve
6:Swing hold brake solenoid valve
7. 2-stage relief solenoid valve
PC1 28US-2
8.
9.
10.
11.
12.
13.
14.
Travel motor
Hydraulic pump
Engine
Swing motor
Center swivel joint
Swing machinen/
Swing circle
1o-5
STRUCTURE
SWING
AND FUNCTION
CIRCLE
SWING CIRCLE
6
.\
A-A
m
B-B
m
c-c
9JA01330
1.
2.
4.
5.
6.
Greasing to swing
Greasing to swing
Seal
Ball
Inner &e
a.
b.
Inner race soft zone position

Outer race soft zone position
1O-6
circle bearing
circle pinion
Specification
Reduction ratio : 90/l 1 = 8.182
Grease : G2-LI
Amount of filled grease : 9.1 e
PC1 28US-2
SWING MACHINERY
SWING MACHINERY
PC128US-2
1. Swing pinion (number of teeth : 11)

2. Case
3. No. 2 sun gear (number of teeth : 17)
4. No. 2 planetary carrier (number of teeth : 17)
5. Ring gear (number of teeth : 61)
8. Oil filler port
9. Swing motor
10. Level gauge
11. No. 1 planetary gear (number of teeth : 24)
13. Drain plug
14. Swing circle (number of teeth : 90)
PC128US-2
Specification
Reduction ratio : (14 + 61)/14 (17 + 61)/17 = 24.58
Swing reduction ratio : 201.11
Swing speed : 12 rpm(PC128US-2 Serial No.:
5001 6456)
: 11 rpm(PC128US-2 Serial No.:
6457 and up)
: 11 rpm(PC138USLC-2 Serial No.:
1001 1500)
Lubricating oil : SAE30CD
Lubricating oil amount : 2.5
10-7
(15)
SWING MACHINERY
PC138US-2
1. Swing pinion (number of teeth : 11)

2. Case
5. Ring gear (number of teeth : 61)
8. Oil filler port
9. Swing motor
10. Level gauge
13. Drain plug
14. Swing circle (number of teeth : 90)
10-7-1
(15)
Specification
Reduction ratio : (14 + 61)/14 (17 + 61)/17 = 24.58
Swing reduction ratio : 201.11
Swing speed : 11 rpm
Lubricating oil : SAE30CD
Lubricating oil amount : 2.5
PC128US-2
TRACK FRAME
TRACK FRAME
PC128US-2
PC138US-2
1.
2.
3.
4.
Idler
Track frame
Carrier roller
Travel motor
10-8
(15)
5.
6.
7.
8.
Sprocket
Track roller
Idler cushion
Track shoe
PC128US-2
STRUCTURE
IDLER CUSHION
AND FUNCTION
IDLER CUSHION
___-__--_--__-__-_--__---~---~~~~-_____-_--__-__-__
_____-__
_____----__-_--mm
_________-__-__-__
______-__-__-__-__---
__-
____
_____
-__-
-(r_-z-r=
9JA01333
1. Idler
2. support
3. Yoke:
4. Cylinder
5. Recoil spring
G.U-packing
7. Pilot
8. Nut
9. Valve
10. Grease fitting
PC128US-2
Specification
Grease : G2-LI
Amount of filled grease : 140 cc
1o-9
HYDRAULIC COMPONENT LAYOUT
HYDRAULIC COMPONENT LAYOUT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Bucket cylinder
Arm cylinder
Boom cylinder
Hydraulic tank
Swing motor
Hydraulic pump
Oil cooler
L.H. travel motor
L. H. PPC valve
Blade PPC valve (Blade specification)
R. H. PPC valve
Center swivel joint
2-actuator attachment PPC valve
(Option for PC128US-2 KUK only)
(Option for PC138US-2 KUK only)
Travel PPC valve
1-actuator attachment PPC valve
(When with attachment)
Boom hydraulic anti-burst valve
(For PC128US-2 KUK only)
(For PC138US-2 KUK only)
Blade cylinder (Blade specification)
Control valve
4-spool solenoid valve
PPC lock
2-speed travel speed selection
Swing holding brake
2-stage relief
10-10
(15)
PC128US-2
STRUCTURE
AND FUNCTION
1. Control valve
2. R.H. work equipment PPC valve
3. Blade PPC valve
(When with blade specification)
4. 4-spool solenoid valve
5. R.H. work equipment control lever
(Boom, Bucket)
6. Blade control lever
(When with blade specification)
7. L.H. work equipment control lever
(Arm, Swing)
8. L.H. work equipment PPC valve
9. Safety lock lever
(for L.H. & R.H. work equipment)
IO. Travel speed boost pedal
(When with blade specitication)
11. L.H. travel pedal
12. 2-actuator attachment pedal
(When with 2-actuator attachment)
13. R.H. travel pedal
14. 2-actuator attachment PPC valve
(When with 2-actuator attachment)
15. Travel PPC valve
16. L.H. travel lever
17. R.H. travel lever
18. l-actuator attachment PPC valve
(When with l-actuator attachment)
19. l-actuator attachment pedal
(When with l-actuator attachment)
20. Lock pin (When with attachment)
VALVE CONTROL
l-actuator
side
@ l-actuator
@ 2-actuator
side
@ 2-actuator
side
@ Attachment
@ Attachment
@I Attachment
attachment
outlet for arm RIGHT
attachment outlet for arm LEFT side

attachment outlet for boom RIGHT
attachment
outlet for boom LEFT
pedal LOCK
pedal HALF stroke position
pedal FULL stroket position
Lever and pedal position

@ Neutral
@ Boom RAISE
@ Boom LOWER
@ Bucket CURL
@ Bucket DUMP
@ Neutral
@ Arm OUT
@ Arm IN
@ Swing LEFT
@I Swing RIGHT
@I L.H. travel FORWARD
@I L.H. travel REVERSE
@ R.H. travel FORWARD
@ R.H. travel REVERSE
@ PPC FREE
@ PPC LOCK
@ Blade RAISE (When with blade specification)
@ Blade LOWER (When with blade specification)
@ Travel Lo (When with blade specification)
@ Travel Hi (When with blade specification)
PC 128US-2
10-13
0
VALVE CONTROL
PC128US-2
PC138US-2
10-13-1
(15)
PC128US-2
VALVE CONTROL
1. Control valve
3. R.H. work equipment control lever
(for boom and bucket operation)
4. Blade control lever (Blade specification)
5. 4-spool solenoid valve
6. L.H. work equipment control lever
(for arm, swing operation)
7. Blade PPC valve (Blade specification)
9. Safety lock lever
10. L.H. travel pedal
11. R.H. travel pedal
12. L.H. travel lever
13. R.H. travel lever
15. Attachment PPC valve
(Attachment installable machine)
16. Attachment pedal
17. Lock pin (Attachment installable machine)
Lever and Pedal Positions
1 HOLD
2 Boom LOWER
3 Boom RAISE
4 Bucket CURL
5 Bucket DUMP
6 HOLD
7 Arm OUT
8 Arm IN
9 Swing LEFT
0 Swing RIGHT
A L.H. travel FORWARD
B L.H. travel REVERSE
C R.H. travel FORWARD
D R.H. travel REVERSE
E PPC FREE
F PPC LOCK
G Blade RAISE (Blade specification)
H Blade LOWER (Blade specification)
I Attachment discharge from arm RIGHT side
J Attachment discharge from arm LEFT side
K Attachment pedal LOCK
L Attachment pedal HALF stroke
M Attachment pedal FULL stroke
PC128US-2
10-13-2
A
HYDRAULIC TANK AND FILTER

PC128US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hydraulic tank
Filter element
Bypass valve
Bypass strainer
Suction strainer
Drain plug
Sight gauge
Oil filler cap
Pressure valve
Vacuum valve
10-14
(15)
Specification
Tank capacity : 99
Hydraulic oil amount in tank : 69
16.7 6.9 kPa {0.17 0.07 kg/cm2}
-0.49 0 kPa {-0.005 0 kg/cm2}
Bypass valve set pressure :
103 19.6 kPa {1.05 0.2 kg/cm2}
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic tank
Filter element
Bypass valve
Suction strainer
Drain plug
Sight gauge
Oil filler cap
Pressure valve
Vacuum valve
PC128US-2
Specification
Tank capacity : 99
Hydraulic oil amount in tank : 69
16.7 6.9 kPa {0.17 0.07 kg/cm2}
-0.49 0 kPa {-0.005 0 kg/cm2}
Bypass valve set pressure :
147 29.4 kPa {1.5 0.3 kg/cm2}
10-14-1
(15)
HYDRAULIC PUMP
PC128US-2
1.
2.
3.
4.
5.
6.
Main pump
LS valve
PC valve
Fixed choke valve
PC-EPC valve (for PC mode selection)
LS-EPC valve (for LS set selection)
10-15-1
(15)
PLS : Control valve LS pressure inlet

PA
: Main pump delivery
PB
: Main pump pressure input
PO : Main pump drain
IM
: PC mode change current
PEPC : EPC valve basic pressure inlet
PS
: Main pump absorption
PC128US-2
HYDRAULIC PUMP
PC138US-2
1.
2.
3.
4.
5.
6.
Main pump
LS valve
PC valve
Fixed choke valve
PC-EPC valve (for PC mode selection)
LS-EPC valve (for LS set selection)
PC128US-2
IM
: PC mode change current
PA
: Main pump delivery
PB
: Main pump pressure input
PS
: Main pump absorption
PD1 : Case drain
PLS : Control valve LS pressure inlet
PEPC : EPC valve basic pressure inlet
10-15-2
(15)
HYDRAULIC PUMP
PC128US-2
1.
2.
3.
4.
5.
6.
7.
Shaft
Cradle
Case
Rocker cam
Shoe
Piston
Cylinder block
10-16
(15)
8.
9.
10.
11.
12.
13.
Valve plate
End cap
Spring
Servo last chance filter
Servo piston
Slider
PC128US-2
HYDRAULIC PUMP
PC138US-2
1.
2.
3.
4.
5.
6.
7.
Shaft
Cradle
Case
Rocker cam
Shoe
Piston
Cylinder block
PC128US-2
8.
9.
10.
11.
12.
13.
Valve plate
End cap
Spring
Servo last chance filter
Servo piston
Slider
10-16-1
(15)
HYDRAULIC
PUMP
Function
This pump converts
engine rotation and
torque transmitted
to the pump shaft into
hydraulic energy and discharges pressurized
oil according to load.
This pump can change delivery when the
swash plate angle is changed.
l
f!
IO
A-A
9JUOOO77
Structure
The cylinder block (7) is supported to the shaft
(1) with the spline a, and the shaft (1) is supported with the front and rear bearings.
The shoe (5) is punched to the tip of the piston (6) with a concave ball so that the piston
(6) and the shoe (5) form a spherical bearing.
The shoe (5) is always pressed to the plane A
of the rocker cam (4) and slides in a circle.
The rocker cam (4) leads highly pressurized
oil together with the cylindrical plane B with
the cradle (2) fixed to the case, forms a static
pressure bearing and slides.
Thepiston (6) moves in the axial direction relatively in each cylinder of the cylinder block
l
(7).
The cylinder block (7) rotates relatively while
sealing pressurized oil against the valve plate
(81, and the plane is designed to balance the
oil pressure properly.
Oil in each cylinder of the cylinder block (7) is
absorbed and discharged through the valve
plate (8).
PC128U.S2
10-17
STRUCTURE
AND FUNCTION
HYDRAULIC
Operation
1. Pump Operation
The shaft (1) rotates together with the cylinder block (7), and the shoe (5) slides on the
plate A. When the rocker arm (4) moves along
the cylindrical
plane B, the inclination
ato the
centerline X of the rocker cam (4) and the axial
direction
of the cylinder
block (7) changes.
The inclination
a_.is called swash
plate
angle.
!i
B
l
SLPOOl63
When the swash plate angle of the center line

X of the rocker cam (4) is a to the axial direction of the cylinder block (7), the plane A works
like the cam against the shoe (5).
Therefore, the piston (6) slides inside the cylinder block (7), and the capacities E and F of
the cylinder block (7) come to change differently. Then, the pump absorbs and discharges
the difference E-F.
When the capacity in the E chamber contracts
as the cylinder block (7) rotates, the pump discharges oil during the process. On the other
..k#et,
_ +h
n..--n:hr :n
,hq..cl
,a,,, .yyI
&I
te b,oyabtry
II,+h
LI
$2F chamber Increases, the pump absorbs oil during the process. (The figure shows the end of the absorbing process in the Chamber F and the end of
the discharging
process in the Chamber E.
When the centerline
X of the rocker cam (4)
comes to the axial direction
of the cylinder
block (7) (when the swash plate angle is 0),
the difference between the capacities E and F
in the cylinder block (7) comes to 0. And the
pump comes to stop absorbing
or discharging oil, i.e., the pump stops. (However, the
swash plate angle never comes to 0 practically.)
In the other words, the swash plate angle a
and the pump delivery are in the proportional
relations.
lo-18
PUMP
E
SLPOO164
/
4
9JUOOOBO
PC1 28US-2
STRUCTURE
2.
l
HYDRAULIC
AND FUNCTION
PUMP
Delivery Control
When the swash plate angle a increases, the
difference between the capacities E and F becomes larger and the delivery Q increases.
The servo piston (12) changes the swash plate
angle a.
The servo piston moves in the direction of
straight
reciprocation
according
to signal
pressures
of the PC and LS valves.
This
straight motion 7s transmitted
to the rocker
arm (4) through the slider (131, and the rocker
cam (41, which is supported with the cylindrical plane to the cradle (21, slides in the direction of rotation.
The servo pistons (12) area receiving the pressure is different on the right and left sides,
and the discharge (self) pressure PP from the
main pump is always
led to the pressure
chamber of the small diameter piston.
The output pressure Pen of the LS valve is
led to the pressure chamber of the large diameter piston.
Motions of the servo piston are controlled according to the relations
between the small
diameter piston pressure PP and the large diameter piston pressure Pen and the rate of
area receiving pressure of the small diameter
piston to that of the large diameter piston.
PC128US-2
12
13
9Juoooa2
10-19
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
LS AND PC VALVES
LS Valve
PA
PLS
PLP
PPL
PD
PS IG
PA
9JUOOO84
Pl.
2.
3.
4.
5.
6.
7.
8.
Plug
Lock nut
Sleeve
Spring
Seat
Spool
Piston
Sleeve
A
PD
PLP
PLS
PPL
PSIG
: Pump discharge pressure inlet

: Drain pressure outlet
: LS valve signal pressure outlet
: Control valve LS pressure inlet
: PC valve signal pressure inlet
: EPC valve output pressure inlet of LS control
PC Valve
9JUOOO85
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Piston
Spring
Seat
t
Spring
Seat
Spool
Piston
Sleeve
Lock nut
Plug
Lock nut
1O-20
PA
PA2
PD
PN
PPL
:
:
:
:
:
Pump discharge pressure inlet

Pump discharge pressure inlet
Drain pressure outlet
PC mode switching pressure inlet
PC valvesignal pressure outlet
PC1 28US-2
STdUCTURE
AND FUNCTION
HYDRAULIC
PUMP
FIXED THROTTLE VALVE
PO,UT
P,
9JUOOO66
1.
2.
Plug
Plug
PA
: Drain pressure outlet
POUT : Control pressure outlet
PIN
: LS valve signal pressure inlet
PC1 28US-2
10-21
HYDRAULIC
STRUCTURE AND WNCTlON
PUMP
Operation
To ma in
va
Direction
to
small
diameter
1.
I ve
SVPO7604
LS Valve
1) When the control valve is at the center
value position
The LS valve is a 3-way selector valve, and
the pressure PLS (LS pressure) from the
control valve inlet is being led to the
kpring chamber B and the pump discharge pressure PP is being led to the H
port of the sleeve (8).
The spool (6) position is determined depending on the force of the LS pressure
PLS + the force of spring (4) Z and the force
ofthe pump discharge pressure (self-pressure) PP.
l
PC1 28US-2
1 O-23
STRUCTURE
1 O-24
AND FUNCTION
Before the engine starts, the servo piston

(12) is pressed to the right side. (See the
right figure.)
If the control lever is atthe center value
position when the engine starts, the LS
pressure PLS will be 0 MPa (0 kg/cm*).
(The LS valve interconnects to the drain
circuit through the control valve spool.)
At the time, the spool (6) is pressed to the
left side and the. C port is connected to
the D port. The pump discharge pressure
enters from the K port to the piston large
diameter side and from the J port to the
piston small diameter side respectively.
So, the area difference of the servo piston (12) minimizes the swash plate angle.
HYDRAULIC
A-A
PUMP
9JUOOOB9
PC1 28US-2
HYDRAULIC PUMP
PC128US-2
PC138US-2
2) Operation in direction for maximum

pump delivery
When the LS differential pressure PLS
between the pump discharge pressure PP
and the LS pressure PLS reduces (when
the control valve is large and the discharge pressure PP drops, for example),
the combined force of the LS pressure
PLS and the spring (4) pushes the spool
(6) to the right side.
When the spool (6) moves, port D is
connected to port E to bring the PC valve
in line. At the time, the PC valve is
connected to the drain port, and the circuit D K is applied with the drain pressure PT. (The operation of the PC valve
will be explained later.)
Therefore, the pressure on the piston
large diameter side of the servo piston
10-26
(15)
(12) comes to the drain pressure PT, and

since the pump discharge pressure PP is
applied to port J on the small diameter
side, the servo piston (12) is pushed to
the right side and the swash plate is
moved to the delivery increasing direction.
When port G is applied with the output
pressure of the EPC valve for the LS
valve, the piston (7) is pushed to the left
side.
This is effective to reduce the spring (4)
set force, and the differential pressure between the oil pressure PP when ports D
and E of the spool (6) are connected and
PP changes.
PC128US-2
HYDRAULIC PUMP
PC128US-2
PC138US-2
3) Operation in direction for minimum

pump delivery
The following explains move of the servo
piston (12) to the left side (in the direction for minimum pump delivery). When
the LS differential pressure PLS increases (when the control valve opening
area becomes small and the pump discharge pressure PP increases, for example), the force of the discharge pressure PP pushes the spool (6) to the left
side.
As the spool (6) moves, the pump discharge pressure PP flows from port C to
port D and comes from port K to the piston large diameter side.
10-27-1
(15)
Though the pump discharge pressure PP

comes to port J of the piston small diameter side, the servo piston (12) is pushed
to the left side due to the area difference
between the piston large diameter side
and the piston small diameter side of the
servo piston (12) and the swash plate is
moved in the delivery reducing direction.
When port G is applied with the LS selection pressure, it is effective to reduce
the spring (4) set force.
PC128US-2
HYDRAULIC PUMP
PC128US-2 Serial No.: 5001 7730
4) When the servo piston balances

Suppose that the area receiving pressure
on the piston large diameter side is A1,
the area on the piston small diameter side
is A0 and the pressure applied to the piston large diameter side is PEN.
When the pump discharge pressure PP of
the LS valve balances with the combined
force of the LS pressure PLS and the
spring (4) force Z and the relations A0 x
PP = A1 x PEN hold, the servo piston (12)
will stop at the position and the swash
plate angle will be held at the intermediate position. (The openings of the D port
to the E port and of the C port to the D
port of the spool (6) stop almost at the
same position.)
PC128US-2
At the time, the relations of the areas receiving pressure at the both ends of the
servo piston are A0 : A1 = 1 : 1.75. When
they balance with each other, the pressures applied to the both ends of the piston are related as follows: PP : PEN .=. 1.75
: 1.
The spring (4) force has been adjusted so
that the spool (6) balance stop position is
determined at the center of the standard
when PP PLS = 2.21 MPa (22.5kg/cm2).
10-27-2
0
HYDRAULIC PUMP
PC128US-2
PC138US-2
4) When the servo piston balances

The area receiving the pressure on the
piston large diameter side is supposed to
be A1, the one on the small diameter side
is supposed to be A0 and the pressure
flowing to the piston large diameter side
is supposed to be PEN.
When the pump discharge pressure PP
of the LS valve balances with the combined force of the LS pressure PLS and
the spring (4) force Z and the relations of
A0 x PP = A1 x PEN are satisfied, the
servo piston (12) stops at the position and
the swash plate is held at the intermediate position (stops where the opening
from port D to port E of the spool (6) is
almost equal to the one from port C to
port D).
10-27-3
(18)
At the time, the relations of areas receiving the pressure on the both ends of the
servo piston (12) are A0 : A1 = 1 : 1.75,
and the ones
of pressures applied on the
.
. ends at the balancing time are
piston both
PP : PEN = 1.75 : 1 approximately.
The spring (4) force has been adjusted so
that the balance stop position of the spool
(6) is determined when PP PLS = 2.21
Mpa {22.5 kg/cm2} is satisfied at the standard center.
When port G is applied with PSIG (EPC
valve output pressure for LS valve of 0
2.9 Mpa {10 30 kg/cm2}), however, the
balance stop position changes proportionally to the PSIG pressure in the range of
PP PLS from 2.1 to 0.6 Mpa {21.5 to 6.5
kg/cm2}.
PC128US-2
STRUCTURE
AND FUNCTION
HYDRAULIC
Pilot
PUMP
Pressure
To main
LS valve
:
:
.-f
Emergency
PC-EPC
Direction
to
small
diameter
oumD
valve
:
Fixed
throttle
Direction
to
large
diameter
Pump
controller
,I
SVPO7608
2.
PC Valve
1) When the pump controller is normal, the
load to the actuator is small and the pump
discharge pressure PP is low
a. Function of PC-EPC Valve Solenoid (7)
The pump controller provides a com mand current to the PC-EPC valve solenoid (1). This command current actuates the PC-EPC valve and outputs
a signal pressure. When receiving the
signal pressure, the PC valve changes
the force given to the piston (2).
The spool (3) stops where the force to
the piston (2) balances with the combined force of the spring setting force
of the springs (4) and (6) on the opposite side and the force given to the
spool (3) by the pump discharge presl
sure PP. And the pressure output from

the PC valve (the pressure at the C
port) varies with the spool position.
The value of the command current X
is determined depending on type of
work (lever control), selection of working mode, set point of engine speed
and actual speed.
lo-28
PC1 28US-2
STRUCTURE
HYDRAULIC
AND FUNCTION
Pi lot
PUMP
pressure
To main
;j
.I,,,,,,,,,,,,;;;;;,.,:
I~IIIc-Lel
c3
Emergency
DU~D
drive
switch
n c c
JIUC
Direction
to
large
diameter
n..__
SVPO7609
b.
l
PC1 28US-2
Function of Spring
The loads to the springs (4) and (6) of
the PC valve are determined depending on swash plate position.
As the servo piston (9) moves, the piston (7) connected to the slider (8)
moves to the right or the left.
When the piston (7) moves to the left,
the spring (6) will be contracted. If the
piston moves further to the left, the
spring will be brought to the seat (5)
and be fixed there. Thereafter, the
spring (4) will only move. This means
that the spring load changes as the
piston (7) extends or contracts the
springs (4) and (6).
Also, since the pressing force of the

piston (2) changes as the command
current input to the PC-EPC valve solenoid (1) changes, the load to the
springs (4) and (6) changes depending on the value of the command current.
lo-29
STRUCTURE
1O-30
AND FUNCTION
HYDRAULIC
PUMP
The C port of the PC valve is connected

to the E port of the LS valve. The self
pressure PP is provided to the A port,
the small diameter side of the servo
piston (9) and the B port.
When the pump discharge pressure
PP is small, the spool is located at a
position in the left direction.
At the
time, the C port is connected to the D
port, and the pressure to the LS valve
becomes the drain pressure PT. If the
E port of the LS valve is connected to
the G port at the time, the pressure
from the J port to the large diameter
side of the piston will become the
drain pressure PT. And the servo piston will moves to the right side. Then,
the pump delivery will come to increase.
Also, as the servo piston (9) operates,
the slider (8) moves the piston (7) to
the right side, and the spring force
becomes weak because the springs (4)
and (6) ei<pand. As the spring force
becomes weak, the spool (3) moves
to the right side to disconnect the C
port from the D port. Then, the pump
discharge pressure ports B and C are
connected.
As a result, the pressure at the C port
rises and the pressure on the large
diameter side of the piston rises as
well, and the servo piston (9) stops
moving to the right side. This means
that the stop position of the servo piston (9) (= pump delivery)
is determined where the pressing
force
caused the pressure PP to the spool
(3), the pressing force of the PC-EPC
valve solenoid and the forces of the
springs (4) and (6) balance with each
other.
PC1 28US-2
STRUCTURE
HYDRAULIC
AND FUNCTION
Pi lot
PUMP
Pressure
0 main
valve
-
outa6 andC rad
connected
Direction
to
small
diameter
PC-EPC
valve
SVPO7610
2)
When the pump controller is normal, the

load to actuator is large and the pump
discharge pressure PP is high
When the load is large and the pump discharge pressure is high, the force pushing the spool (3) to the left side increases
and the spool (3) comes to the position
shown in the above figure.
Then, the pressure flowing from the C port
to the LS valve becomes about 3/5 of the
pump discharge pressure PP because the
pressure from the A port partly flows from
the C port to the D port through the LS
valve as shown in the above figure.
PC1 28US-2
When the E port of the LS valve is connected to the G port, this pressure is led
from the J port to the large diameter side
of the servo piston (9) and the servo piston comes to stop.
When the pump discharge pressure PP increase and the spool (3) moves further to
the left side, the discharge pressure PP will
flow to the C port so as to minimize the
pump delivery.
10-31
STRUCTURE
1 O-32
HYDRAULIC
AND FUNCTION
When the servo piston (9) moves to the

left side, the piston (7) will move to the
left. Then, the springs (4) and (6) will be
compressed and will push the spool (3)
back. If the piston (7) moves further to the
left, the ports C and D will open wide.
As a result, the pressure at the port C (=
J) will drop, and the servo piston (9) will
move to the left a_ndwill stop. At the time,
the servo piston (9) is located further to
the left than where it is when the pump
discharge pressure PP is low.
PUMP
The positional
relations between the
pump discharge pressure PP and the
servo piston (9) are shown by a broken
line because the springs (4) and (6) are 2stage ones. And the relations between
the discharge pressure PP and the pump
delivery 0 are as shown in the right figure.
Also, when the command current X to the

PC-EPC valve solenoid increases, the relations between the pump discharge pressure PP and the pump delivery 0 will
move in parallel in relation to the pushing force of the PC-EPC valve solenoid.
Therefore, the force of the PC-EPC valve
solenoid (1) will be added to the leftward
pressing force of the discharge pressure
PP to the spool (3), and the relations between PP and Q will move from @ to @
as X increases.
Pump discharoe
pressure
PP
SLIP02559
Pump discharoe
orassure
PP
SDP02560
D
Z
2
5
:
L
PC1 28U.S2
3) When the pump controller is out of order

and the PC redundant switch is set to ON
a. In case of light load to main pump
When the pump controller is out of
order, set the PC redundant switch to
ON to change the circuit to the resistor side. In this case, since the current is too large when the power is directly taken from the battery, the resistor is connected to control the current to the PC-EPC valve solenoid.
At the time, the current becomes constant and the piston (2) pressing force
becomes constant as well.
When the pump discharge pressure is
low, the combined force of the force
of the PC-EPC valve solenoid (1) and
the discharge pressure PP is smaller
PC128US-2
HYDRAULIC PUMP
than the spring set force. So, the spool

(3) balances at a position in the left
side.
At the time, the C port has the same
pressure as the drain pressure at the
D port, and the drain pressure PT is
led to the large diameter side of the
servo piston (9) through the LS valve.
Then, the servo piston (9) moves in
the direction where the delivery increases because the pressure on the
small diameter side of the piston is
large.
10-33
(18)
STRUCTURE
AND FUNCTION
HYDRAULIC
Pi lot
PUMP
Pressure
To main
va I ve
31C
--*I*
~/,~1,,,,,,,,,,,,,,,,,,
+
Direction
to
small
diameter
Emergency
PUTID
drive
switch
SVPO76 12
b.
l
1o-34
In case of heavy load to main pump

When the PC redundant switch is set
to ON just like in the previous paragraph, a constant command current is
sent to the PC-EPC valve solenoid (1).
So, the piston (2) pushes the spool (3)
with a constant force.
When the pump discharge pressure
-PP rises, the spool will moves further
to the left side than when the main
pump is lightly loaded and will balante at the position shown in the
above figure.
In this case, since the pressure from
the A port is led to the C port, the servo
piston (9) will move to the left side
(small delivery) and will stop at a position further to the left than when the
pump is lightly loaded.
PC1 28US-2
STRUCTURE
HYDRAULIC
AND FUNCTION
This means that the current, which is

sent to the PC-EPC valve solenoid
through the resistor when the PC redundant
switch is set to On, determines the curve between the pump
discharge pressure PP and the delivery 0 as shown in the figure.
When the PC redundant switch is set
to ON, the curve @ is further to the
left than the curve @ drawn when the
pump controller
is normal.
0
x
.-:
Q1
-0
z
z
Pump
PC1 28US-2
PUMP
discharge
Pressure
PP
SJpO7fj13
1o-35
CONTROL VALVE
CONTROL VALVE
OUTLINE
There are the following 2 types of contral valve.
6-spool valve (without service valve)
7-spool valve (with service valve)
7-spool valve (with blade)
8-spool valve (with blade and service valve)
8-spool valve (with 2 service valve)
9-spool valve (with blade and 2 service valve)
fl Each service valve is a single add-on type, so
it is possible to add or remove the extra valve
at any time.
Extermal oppearance and cross section is given
only for the 7 spool valve.
AA : Pressure sensor port
(pressure sensor is intalled)
A1 : To swing motor MB
A2 : To L.H. travel motor A
A3 : To R.H. travel motor A
A4 : To boom cylinder bottom
A5 : To arm cylinder head
A6 : To bucket cylinder head
A7 : To attachment 1
B1 : To swing motor MA
B2 : To L.H. travel motor B
B3 : To R.H. travel motor B
B4 : To boom cylinder head
B5 : To arm cylinder bottom
B6 : To bucket cylinder bottom
B7 : To attachment 1
BP : From boom RAISE PPC/EPC valve
LS : To pump LS valve
PA1 : From swing L.H. PPC/EPC valve
PA2 : From L.H. travel forward PPC valve
PA3 : From R.H. travel reverse PPC valve
PA4 : From boom RAISE PPC/EPC valve
PA5 : From arm OUT PPC/EPC valve
PA6 : From bucket DUMP PPC/EPC valve
PA7 : From service 1 PPC valve
PB1 : From swing R.H. PPC/EPC valve
PB2 : From L.H. travel reverse PPC valve
PB3 : From R.H. travel forward PPC valve
PB4 : From boom LOWER PPC/EPC valve
PB5 : From arm IN PPC/EPC valve
PB6 : From bucket CURL PPC/EPC valve
PB7 : From service 1 PPC valve
P : From main pump
PP : To main pump
PX : From 2-stage relief solenoid valve
SA : From swing stroke contral solenoid valve
SB : From swing stroke contral solenoid valve
TS1 : To tank
TS2 : To tank
TB : To tank
TC : To oil cooler
TSW : To swing motor
10-36
(15)
1. Swing bleed valve

2. Travel junction valve
3. Arm regeneration valve
4. Boom drift prevention valve
5. Cover
6. Service valve
7. Bucket valve
8. Arm valve
9. Boom valve
10. R.H. travel valve
11. L.H. travel valve
12. Swing valve
13. PT port block
14. Safety-suction valve
PC128US-2
CONTROL VALVE
7 spool valve
(6 spool valve + service valve)
PC128US-2
PC128US-2
10-37
(15)
CONTROL VALVE
PC138US-2
10-37-1
(15)
PC128US-2
CONTROL VALVE
CROSS-SECTIONAL DRAWING
fl Cross-sectional drawing shows 7-spool valve (6-spool + service valve).
(1/8)
1.
2.
3.
4.
5.
6.
7.
Safety-suction valve
Suction valve (L.H. travel A)
Suction valve (R.H. travel A)
Suction valve (Boom bottom)
Suction valve (Arm head)
Suction valve (Bucket head)
Safety-suction valve mount (service A)
10-38
(15)
8 Safety-suction valve mount (service B)

9. Suction valve (Bucket bottom)
10. Suction valve (Arm bottom)
11. Suction valve (Boom head)
12. Suction valve (R.H. travel B)
13. Suction valve (L.H. travel B)
14. Lift check valve
PC128US-2
CONTROL VALVE
(2/8)
1.
2.
3.
4.
5.
6.
7.
8.
Main relief valve

Spool (swing)
Spool (L.H. travel)
Spool (R.H. ravel)
Spool (boom)
Spool (arm)
Spool (bucket)
Spool (service)
PC128US-2
10-39
CONTROL VALVE
(3/8)
1.
2.
3.
4.
5.
6.
7.
8.
Pressure compensation valve F (swing)

Pressure compensation valve F (L.H. travel)
Pressure compensation valve F (R.H. travel)
Pressure compensation valve F (boom)
Pressure compensation valve F (arm)
Pressure compensation valve F (bucket)
Pressure compensation valve F (service)
Unload valve
9.
10.
11.
12.
13.
14.
15.
16.
Pressure compensation valve R (service)

Variable pressure compensation valve
Pressure compensation valve R (bucket)
Pressure compensation valve R (arm)
Pressure compensation valve R (boom)
Pressure compensation valve R (R.H. travel)
Pressure compensation valve R (L.H. travel)
Pressure compensation valve R (swing)
fl The above F and R means the following valves :

F : Flow control valve
R : Pressure reducing valve
10-40
(15)
PC128US-2
CONTROL VALVE
(4/8)
1.
2.
3.
4.
5.
6.
7.
LS pressure detection plug

LS bypass plug
Pump pressure detection plug
Check valve (bucket head)
Check valve (arm head)
Check valve (boom bottom)
LS selection valve
PC128US-2
10-41
CONTROL VALVE
(5/8)
1.
2.
3.
4.
5.
6.
Main relief valve

Cooler bypass valve
Lift check valve
LS selection valve
Spool (swing)
Pressure compensation valve R
10-42
(15)

8. Pressure compensation valve F
PC128US-2
CONTROL VALVE
(6/8)
1.
2.
3.
4.
5.
6.
7.
Suction valve (A)

Suction valve (B)
Spool (L.H. travel)
Travel junction valve
Pressure compensation valve F
Suction valve (A)
PC128US-2
8.
9.
10.
11.
Suction valve (B)

Spool (R.H. travel)

10-43
(15)
CONTROL VALVE
(7/8)
1.
2.
3.
4.
5.
6.
7.
8.
Suction valve (A)

Boom drift prevention valve
Suction valve (B)
Spool
Suction valve (A)
Suction valve (B)
10-44
(15)
9.
10.
11.
12.
Spool
Arm regemeration valve

PC128US-2
CONTROL VALVE
(8/8)
1.
2.
3.
4.
5.
6.
7.
8.
Suction valve (A)

Suction valve (B)
Spool
Safty-suction valve mount (A)
Safty-suction valve mount (B)
Spool
PC128US-2
9.
10.
11.
12.
13.

Pressure relief plug
Unload valve

10-45
(15)
CONTROL VALVE
9 spool valve
(6-spool valve + Blade valve + Full-flow service valve + Half-flow service valve)
PC128US-2
10-45-2
5
CONTROL VALVE
CROSS-SECTIONAL DRAWING
Cross-sectional drawing shows 9-spool valve (6-spool + service valve).
(1/9)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Suction valve (Left travel A)
Suction valve (Right travel A)
Suction valve (Boom bottom)
Safety-suction valve (Blade bottom)
Suction valve (Arm head)
Suction valve (Bucket head)
Safety-suction valve (Service 1-A)
Safety-suction valve (Service 2-A)
10-45-3
5
10.
11.
12.
13.
14.
15.
16.
17.
Safety-suction valve (Service 2-B)

Safety-suction valve (Service 1-B)
Suction valve (Bucket bottom)
Suction valve (Arm bottom)
Suction valve (Boom head)
Suction valve (Right travel B)
Suction valve (Left travel B)
Lift check valve
PC128US-2
CONTROL VALVE
(2/9)
1.
2.
3.
4.
5.
Main relief valve

Spool (Swing)
Spool (L.H. travel)
Spool (R.H. travel)
Spool (Boom)
PC128US-2
6.
7.
8.
9.
10.
Spool (Blade)
Spool (Arm)
Spool (Bucket)
Spool (Service 1)
Spool (Service 2)
10-45-4
(15)
CONTROL VALVE
(3/9)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Pressure compensation valve F (Swing)

Pressure compensation valve F (L.H. travel)
Pressure compensation valve F (R.H. travel)
Pressure compensation valve F (Boom)
Pressure compensation valve F (Blade)
Pressure compensation valve F (Arm)
Pressure compensation valve F (Bucket)
Pressure compensation valve F (Service 1)
Pressure compensation valve F (Service 2)
Unload valve
(Service 2)
10-45-5
(15)
12.
13.
14.
15.
16.
17.
18.
19.
Pressure compensation valve (Service 1)

Pressure compensation valve R (Bucket)
Pressure compensation valve R (Arm)
Pressure compensation valve R (Blade)
Pressure compensation valve R (Boom)
Pressure compensation valve R (R.H. travel)
Pressure compensation valve R (L.H. travel)
Pressure compensation valve R (Swing)

R : Pressure control valve
PC128US-2
CONTROL VALVE
(4/9)
1.
2.
3.
4.
5.
6.
7.
LS pressure pickup plug

LS bypass plug
Pump pressure pickup plug
Check valve (Bucket head)
Check valve (Arm head)
Check valve (Boom bottom)
LS selector valve
PC128US-2
10-45-6
5
CONTROL VALVE
(5/9)
1.
2.
3.
4.
5.
6.
7.
8.
Main relief valve

Cooler bypass valve
Lift check valve
LS selection valve
Spool
Swing bleed valve
10-45-7
(15)

PC128US-2
CONTROL VALVE
(6/9)
1.
2.
3.
4.
5.
6.
7.
Suction valve (A)

Suction valve (B)
Spool
Travel junction valve
Suction valve (A)
PC128US-2
8.
9.
10.
11.
Suction valve (B)

Spool (R.H. travel)

10-45-8
(15)
CONTROL VALVE
(7/9)
1.
2.
3.
4.
5.
6.
7.
8.
Suction valve (A)

Boom drift prevention valve
Suction valve (B)
Spool
Suction valve (A)
Suction valve (B)
10-45-9
(15)
9.
10.
11.
12.
Spool
Arm regemeration valve

PC128US-2
CONTROL VALVE
(8/9)
1.
2.
3.
4.
5.
6.
7.
8.
Suction valve (A)

Suction valve (B)
Spool
Safty-suction valve (A)
Safty-suction valve mount (B)
Spool
PC128US-2
9.
10.
11.
12.

Pressure relief plug
Unload valve

10-45-10
(15)
CONTROL VALVE
(9/9)
1.
2.
3.
4.
5.
6.
Safety-suction valve (A)

Safety-suction valve (B)
Spool

10-45-11
(15)
PC128US-2
STRUCTURE
SUCTION
AND FUNCTION
SAFETY VALVE
SUCTION SAFETY VALVE

(SAFETY VALVE WITH SUCTION FOR SERVICE PORT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Suction valve
Main valve
Piston
Piston spring
Poppet
Poppet spring
Suction valve
Sleeve
Adjustment screw
Lock nut
Specification
Part No. (Reference)
Set pressure
709-70-74600
24.5 MPa (250 kg/cm21

(at the time of Wmin.)
709-70-74700
17.2 MPa (175 kg/cm21

(at the time of 5f?/min.)
lo-46
Use
For crusher
PC1 28U.S-2
CLSS
CLSS
OUTLINE OF CLSS
Features
CLSS stands for Closed Center Load Sensing System and is featured as follows :
Fine controllability
without affect of load
Controllability
that allows digging even in the fine control mode.
Ease of compound
operation in which the flow distribution
performance
depends
area duiing compound
operation.
Saving of energy-by variable pump control
l
on spool opening
Configuration
The CLSS consists of a variable displacement piston pump, a control valve and actuators.
The pump body consists of a main pump, a PC valve and an LS valve.
l
PLS
r________________-------_
I
I
I
i
I
I
I
I
I
Control
valve
I
______(
f
Servo
valve
PC128US-2
SDPD2661
1o-47
STRUCTURE
AND FUNCTION
CLSS
Basic principle
1. Control of pump swash plate angle
The pump swash plate angle (pump delivery)
is controlled so that the LS differential pressure APLS, which is the difference between
the pump discharge pressure PP and the LS
pressure PLS (actuator load pressure) at the
control valve outlet, becomes constant.
(LS differential pressure APLS = Pump pressure PP - LS pressuFe PLS)
Actuator
1
Control
valve
-_-_-- __
-----__ I
II
I II
Pump
Passage
PLSf
I
[I
L-l
, L__-------,
I_--_--_---.
I
I I
I
Main
DumD
M i n.
-
Max.
I 1
Servo
piston
SEP02562
When the LS differential pressure APLS reduces below the set pressure of the LS valve
(when the actuator load pressure is high), the
pump swash plate angle will move in the direction of maximum. When the set pressure
is raised (when the actuator load pressure is
low), the pump swash plate angle will move
in the direction of minimum.
For the detail of the operation, see the paragraph of Hydraulic Pump.
0
-a,
z
m
Max.
LS valve
set pressure
Min.
z
0
LS differential
Dressure
APLS
SOP02563
PC 128US-2
STRUCTURE
2.
.
CLSS
AND FUNCTION
Pressure compensation control

A valve (pressure compensation
valve) is mounted on the outlet side of the control valve. In case of
compound
operation of the actuator with this valve, the differential
pressure AP between the spool
upstream (inlet) and the downstream
(outlet) of each valve becomes constant irrespective
of load
(pressure). So, the flow from the pump is distributed
(compensated)
in proportion
to the opening
areas Sl and S2 of each valve being operated.
Load
I\
I lcomensationl
Actuator
II
I\
Actua
I cobwensa~
SEP02564
PC1 28US-2
1o-49
STRUCTURE
CLSS
AND FUNCTION
EACH FUNCTION
AND OPERATION OF EACH VALVE
Hydraulic circuit diagram and valve names

Pump
detect
Pressure
detect
port
Pressure
ion
port
LS
pressure
ion
PP
x
Al
E^-..:^^
II
Service
107
T-l
[=1,
CYI .inder
..
i!T----_--_-__-- 1 j+j+
; :---
. Left
travel
motor
itl
III
/
Swing
motor
9:
31.9/34.8HPa
(325/355ko/cml
Ma
in Dump
O- 250
L ___-__
__-
_____-__
I
SWPO7804
PC1 281
STRUCTURE
AND FUNCTION
CLSS
1. Unload valve
Set pressure : 3.38 MPa (34.5 kg/cm?
2. Safety-suction valve
Set pressure : 35.8 MPa (365 kg/cm21
3. Pressure compensation valve
4. Suction valve
5. Main relief valve
Set pressure : normal : 31.9 MPa (325 kg/cm*)
High pressyre : 34.8 MPa (355 kg/cm*}
6. Lift check valve
7. Cooler bypass valve
8. LS selection valve
9. Swing bleeding valve
70. Travel junction valve
11. Boom drift prevention valve
PC1 28US-2
1o-51
STRUCTURE
CLSS
AND FUNCTION
UNLOAD VALVE
1. When the control valve is neutral
Function
When the control valve is neutral, the delivery Q equivalent to the pump minimum swash plate angle
is released to the tankcircuit. At the time, the pump discharge pressure PP is set to 2.45 MPa {25.Okg/
cm21 with the spring (3) inside the vale. (The LS pressure PLS is 0 MPa {Okg/cm2).)
l
SDP03735
Operation
The pump discharge pressure PP is applied
to the left end face of the spool (4) and the LS
pressure PLS is applied to the right end face.
.
Since the LS pressure PLS is 0 when the control valve is neutral, the pump discharge pressure PP is only applied and is set with the lead
to the spring (3).
.
When the pump discharge pressure PP rises
to the spring (31 load (2.45 MPa (25.0 kg/cm2H,
the spool (4) will move toward the right side
and the pump circuit PP will interconnect to
the tank circuit T through the drill hole.
Therefore, the pump discharge pressure PP
is set to 2.45 MPa (25.0 kg/cm21.
l
1.
2.
3.
4.
Unload valve
Sleeve
Spring
Spool
PLS : LS circuit (pressure)

PP : Pump circuit (pressure)
T
: Tank circuit
1 O-52
PC1 28US-2
STRUCTURE
CLSS
AND FUNCTION
2. When the control valve is in the fine control mode

Function
When the control valve is in the fine control mode and the requested flow of the actuator is less than
the pump minimum swash plate angle, the pump discharge pressure PP is set to the LS pressure PLS
+ 2.45 MPa (25.0 kglcm2).
When the differential pressure between the discharge pressure PP and the LS pressure PLS comes to
the spring (3) load (2.45 MPa (25.0 kg/cm21), the unload valve will open and the LS differential pressure APLS will come to 2.45 MPa (25.0 kg/cm2}.
l
SOP03736
Operation
When the control valve is operated in the fine
control mode, the LS pressure PLS will occur
and will be applied to the right end face of
the spool (4). At the time the differential pressure between the LS pressure PLS and the
pump discharge pressure PP increases because the opening area of the control valve
spool is small.
When the differential pressure between the
pump discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45
.MPa (25.0 kg/cm2)), the spool (4) will move to
the right side and the pump circuit PP will interconnect to the tank circuit T.
This means that the pump discharge pressure
PP is set to the spring force (2.45 MPa (25.0
kg/cm2} + LS pressure PLS, and the LS differential pressure APLS comes to 2.45 MPa (25.0
kg/cm21.
l
1.
2.
3.
4.
Unload valve
Sleeve
Spring
Spool

T
: Tank circuit
PC1 28US-2
1o-53
STRUCTURE
CLSS
AND FUNCTION
3. When the control valve is operated

Function
If the required flow of the actuator increases over the pump minimum swash plate angle when the
control valve is operated, the flow to the tank circuit T will be interrupted and the pump delivery 0
will be completely flown to the actuator circuit..
l
SDP03737
Operation
When the control valve is operated with large
stroke, the LS pressure PLS will occur and will
be applied to the right end face of the spool
(4). At the time, the opening areas of the control valve spool is large and the difference
between the LS pressure PLS and the pump
discharge pressure PP is small.
So, the differential
pressure between the
pump discharge pressure PP and the LS pressure PLS does not reach the spring (3) load
(2.45 MPa (25.0 kg/cm2)) and the spring (3)
pushes the spool (4) to the left side.
Then, the pump circuit PP and the tank circuit
Tare interrupted, and the pump delivery Q is
completely flown to the actuator circuit.
l
1.
2.
3.
4.
Unload valve
Sleeve
Spring
Spool

T
:Tankcircuit
1o-54
PC1 28US-2
STRUCTURE
CLSS
AND FUNCTION
LEADING OF LS PRESSURE
Function
The LS pressure is load pressure to the actuator on the outlet side of the control valve.
In case of a work equipment valve, the pressure reducing valve (3) of the pressure compensation valve reduces the pump discharge
pressure PP to the same level as the actuator
circuit pressure A and leads the pressure to
l
1.
Work equipment
the LS circuit PLS. Also, the orifice C is

mounted on the piston (5) halfway from the
pump circuit PP to the pressure reducing valve
(31, and the orifice has the damper function.
The travel valves leads the actuator circuit
pressure A directly to the LS circuit PLS.
valve (boom, arm, bucket, swing)
SOP03738
Operation
When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator
circuit A through the bridge passage b from
the flow control valve (2) and the spool notch
a.
Since the pressure reducing valve (3) moves
to the right at the same time, the pump discharge pressure PP led from the orifice c is
reduced due to pressure loss at the notch d
and is led to the LS circuit PLS and to the
spring chamber PLSl.
At the time, the LS circuit PLS is connected to
the tank circuit T from the LS bypass plug (4).
l
PC128US-2
The both end face areas of the pressure reducing valve (3) are the same (SA = SLS), and
the actuator circuit pressure PA (= A) is applied to the SA side and the reduced pump
discharge pressure PP is applied to the SLS
side on the opposite side.
Therefore, the pressure reducing valve balances at the position where the actuator circuit pressure PA becomes equal to the pressure of the spring chamber PLSl. The pump
discharge pressure PP reduced at the notch d
comes to the actuator circuit pressure A and
is led to the LS circuit PLS.
1o-55
STRUCTURE
2.
AND FUNCTION
CLSS
Travel valve
Operation
When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator
circuit A through the bridge passage b from
the flow control valve (2) and the spool notch
a.
At the same time, the actuator circuit pressure PA moves the pressure reducing valve
(3) to the right side, and the notches c and d
interconnect to the travel junction circuit e and
the LS circuit PLS respectively.
So, the actuator circuit pressure PA (= A) is
led from the notch c to the LS circuit PLS
through the notch d.
J, The travel circuit is different from the work
equipment circuit, the actuator circuit pressure PA is directly led to the LS circuit PLS.
l
lo-56
PC1 28US-2
STRUCTURE
AND FUNCTION
CLSS
LS BYPASS PLUG
Function
This plug released residual pressure of the LS
pressure PLS.
- This plug slows the rising speed of the LS
pressure PLS, causes pressure losses at the
spool and the throttle of the shuttle valve by
the discarded throttled flow and reduces the
effective LS differential pressure for higher
safety.
l
PL
SDP03740
Operation
Pressurized oil in the LS circuit PLS flows from
the clearance filter a in the space between the
LS bypass plug (1) and the valve body to the
tank circuit T through the orifice b.
1.
LS bypass plug
PC128US-2

T
: Tank circuit (pressure)
1o-57
STRUCTURE
AND FUNCTION
PRESSURE COMPENSATION
CLSS
VALVE
Function
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 oper$ion
(the upper side) is higher than that of the actuator on this side (the lower side).
l
Aa
\
(Comensaed
PP
1 O-58
PC128US-2
STRUCTURE
AND FUNCTION
CLSS
Operation
When the load pressure of another actuator
side (the upper side) rises during a compound
operation, the flow in the actuator circuit A
on this side (the lower side) is apt to increase..
In this case, the LS pressure PLS of another
actuator is applied to the spring chamber PLSl
and pushes the pressure reducing valve (1)
and the flow cont;ol valve (2) to the left side.
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.
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 and PPA.
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.
l
..
PC1 28US-2
1o-59
STRUCTURE
AND FUNCTION
AREA RATIO OF PRESSURE COMPENSATION
CLSS
VALVE
Function
The pressure compensation
valve slightly adjust the ratio (S2/Sl) of the area Sl 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.
Sl : 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)
l
9JUOOl26
Area ratio (Sl:S2) and compensation characteristics

When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pres_
sure PPBI k [LS circuit pressure PLS - Actuator circuit pressure PA (= A)] can
be held, and the flow is distributed
as per the spool opening area ratio.
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.
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.
l
1 O-60
PC1 28US-2
STRUCTURE
AND FUNCTION
CLSS
BOOM HYDRAULIC DRIFT PREVENTION VALVE

Function
. This valve prevents boom bottom oil from
leading from the spool (1) and prevents the
boom from falling naturally when the boom
lever is out of operation.
1.
At boom raise
9JUOOl27
Operation
l. When the boom is raised, the main pressure
from the control valve will push the poppet
(5) upward. And the main pressurized oil from
the control valve will flow to the boom cylinder bottom through the valve inside.
PC128US-2
lo-61
STRUCTURE
2.
CLSS
AND FUNCTION
Boom lever at neutral
9JUOO128
Operation
0. When the control lever is returned to NEUTRALwhile the boom is raised, the holding
pressure on the boom cylinder bottom is confined with the poppet (5). At the same time,
the pressurized oil flown in the inside through
the orifice a is confined with the pilot spool
(3). Then, the boom is held neutral.
1O-62
PC1 28US-2
STRUCTURE
3.
CLSS
AND FUNCTION
At boom lower
9JUOOl29
Operation
When the boom is lowered, the pilot pressure
Pl from the PPC valve will push the pilot spool
(3) and drain pressurized oil from the b chamber inside the poppet.
The pressurized oil from the boom cylinder
bottom raises the oil pressure in the Ab port
but reduces the pressurized oil in the b chamber through the orifice a.
When the pressure in the b chamber drops
below the pressure in the Aa port, the poppet
(5) will open, and the pressurized oil from the
Ab port will be led to the Aa port and flow in
the control valve.
l
PC1 28US-2
1O-63
STRUCTURE
AND FUNCTION
BOOM REGENERATION
CLSS
CIRCUIT
1. At boom lower and own weight fall

Function
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:l
9JUOOl30
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.
1O-64
At the time, part of the return flow on the bottom side passes through the regeneration
passage a of the boom spool (21, pushes the
checkvalve (3) to open it and flows to the head
side.
This increases the boom lower speed.
PC1 28US-2
STRUCTURE
CLSS
AND FUNCTION
2. At boom lower load process

Function
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.
9JUOOlJI
Operation
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.
l
PC128US-2
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.
lo-65
STRUCTURE
CLSS
AND FUNCTION
ARM REGENERATION
CIRCUIT
1. At arm in and own weight fall

Function
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.
l
PLS
9JUOO132
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.
At the time, part of the return flow on the head
side passes through the regeneration passage
a of the arm spool (21, pushes the checkvalve
(3) to open it and flows to the bottom side.
This increases the arm digging speed.
l
1.
2.
3.
Arm cvlinder
Arm spool
Check valve
A : Head circuit (pressure)

B : Bottom circuit (pressure)
1O-66
PC1 28US-2
STRUCTURE
CLSS
AND FUNCTION
2. At arm in process
Function
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.
l
9JUOO133
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.
l
PC1 28US-2
1.
2.
3.
Arm cylinder
Arm spool
Check valve
A : Head circuit (pressure)

B : Bottom circuit (pressure)
1O-67
STRUCTURE
TRAVEL JUNCTION
VALVE
(L.H. and R.H. travel junction

1.
CLSS
AND FUNCTION
When traveling
circuit)
straight
SJPO7615
1O-68
PC1 28US-2
STRUCTURE
AND FUNCTION
CLSS
Function
When the L.H. and R.H. travel spool is operated to compensate flow errors in the L.H. and
R.H. travel circuits during straight travel, the
junction circuit will open.
Then, the flows to the L.H. and R.H. travel motors will become the same during the straight
travel, and travel deviation will decrease.
At the time of steering, load pressure difference brings back the pressure reducing valve.
of the travel valve inside the steering and
closes the spool notch opening of the travel
junction valve to close the junction circuit for
steering.
l
Operation
When the L.H. and R.H. travel spool (1) is operated, the pump delivery will flow from the
pump circuit PP to A through the actuator circuit PA.
When traveling straight, the actuator circuit
PA will be equalized and the L.H. and R.H.
pressure reducing valves (2) will be pressed
the same stroke to the right. Then, the notch
a and the junction circuit will open.
* The L.H. travel forward oil pressure P7 and
the R.H. travel forward oil pressure P2 are led
to the spring chamber on the both end of the
travel junction valve spool (4) through the respective shuttle valves (5). So, PI = P2, and
the spool is at the neutral position, and the
notch d is ?open?.
Then, the L.H. and R.H. travel actuator circuits
are interconnected with the junction circuit.
When any difference occurs in the flows to
the L.H and R.H. travel motors, this valve will
compensate them and will reduce occurrence
of travel deviations.
l
PC1 28US-2
lo-69
STRUCTURE
2.
AND FUNCTION
When operating
CLSS
travel steering
SJPO7616
1O-70
PC1 28US-2
STRUCTURE
AND FUNCTION
CLSS
Operation
l- When the L.H. travel spool (L.H. 1) is returned
to the neutral side from the straight traveling
state and the steering is operated, there will
occur any difference in the load pressures in
the L.H. and RH. travel actuator circuits PA
(R.H. A > L.H. A).. The LS pressure PLS will
become the same as the R.H. A on the higher
load pressure side.
Therefore, the flow control valve on the L.H..
travel side is pressed to the left side with the
LS pressure PLS, i.e., the load pressure on the
R.H. travel side, and the notch a closes to interrupt the L.H. and R.H. travel circuits.
Also,
since the pressures in the spring chambers
on the both ends of the travel junction valve
spool (4) become different and Pl becomes
higher than P2, the spool (4) moves to the Pl
side and the notch d closes. Then, the steering can be operated.
- The damper is provided to relax the transition characteristics
of the junction circuit at
the time of abrupt operation.
l
PC1 28US-2
1o-71
STRUCTURE
AND FUNCTION
CLSS
TRAVEL LS BYPASS CIRCUIT

1.
At normal operation
1 O-72
PC1 28US-2
CLSS
Function
When an actuator is operated during travel,
this circuit will increase the discarded throttled
flow of the LS circuit PLS, lessens the pressure compensation accuracy of the travel circuit and limits reduction of the travel speed
to small extent.
The bypass circuit is closed in case of independent travel or independent operation of
an actuator.
Operation
When the boom spool (1) is operated, the LS
circuit PLS will come to the same pressure as
the boom circuit pressure A1.
At the same time, the LS circuit pressure PLS
is led to the spring chamber PLS1 of the pressure reducing valve (2) of the travel valve.
Since the travel spool is not operated, the
travel actuator circuit PA is closed and the
check valve (4) inside the flow control valve
(3) is also closed.
Therefore, the travel LS bypass circuit is
closed in case of independent operation of the
boom.
PC128US-2
10-73
(18)
STRUCTURE
AND FUNCTION
2. -At operation
CLSS
of travel + other actuator
9JYOOO2
STRUCTURE
AND FUNCTION
CLSS
Operation
When the boom spool (1) is operated, the LS
circuit PLS will come to the same pressure as
the boom circuit pressure Al.
Since the actuator circuit pressure is generally higher at boom RAISE than during travel
(Al > A2), the pressure in the spring chamber
PLSl of the flow control valve (3) on the travel
side is higher than the travel circuit pressure
PA.
4.
So, the pressure reducing valve (2) moves to
the left side, and the LS pressure of the spring
chamber PLSl pushes the check valve (4) from
the orifice a to open it and flows, to the travel
circuit PA through the passages b and c.
Therefore, when the LS circuit pressure PLS,
which has been as high as the boom circuit
pressure Al, flows to the travel circuit AZ, the
pressure will drop.
PC1 28US-2
1o-75
STRUCTURE
SELF PRESSURE REDUCING
AND FUNCTION
VALVE
SELF PRESSURE REDUCING VALVE
PR
I:
I:
Pl
kla
I--
A-4
9JUOOO62
Pl : From pump
PR : Supply to solenoid valve, PPC valve and EPC
valve, .
T : To hydraulic tank
1O-84
PC1 28US-2
STRUCTURE
AND FUNCTION
A-A
9JUOOO63
1. Control valve block

2. Valve (sequence valve)
3. Spring
4. Screw
5. Poppet
6...Spring (pressure reducing valve pilot)
PC128US-2
7.
8.
9.
10.
11.
Spring (pressure reducing valve main)

Valve (pressure reducing valve)
Spring (safety valve)
Ball
Filter
1 O-85
STRUCTURE
AND FUNCTION
Function
The self pressure reducing valves reduces the
discharge
pressure of the main pump and
supplies it to the solenoid valve, the PPC valve,
etc. as the control pressure.
l
VALVE
---__-_____-_
MIN3.
PI Pork
66MPa
I-
I
I
8
I
PI Port
I
I
I
P, Port
T Port
Hydraulic
circuit
SVP07622
1. At engine stop (total low pressure)

Operation
The spring (6) pushes the poppet (5) t the seat,
and the circuit between the ports PR and T is
closed.
- The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports PI and
PR is open.
The spring (3) pushes the valve (2) to the left
side, and the circuit between the ports Pl and
P2 is closed.
l
lo-86
PC 128W2
STRUCTURE
AND FUNCTION
SVP07623
PC1 28US-2
lo-87
STRUCTURE
AND FUNCTION
2. At neutral and reduction of load pressure P2 (at own weight fall in boom LOWER and arm IN)
Note : When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.
SVP07624
Operation
The spring (3) and the PR pressure (0 MPa (0
kg/cm2} at the time of engine stop) pushes
the valve (2) in the direction to close the circuit between the ports PI and P2. When the
hydraulic oil enters the Pl port, the expression (Pl pressure + Spring (7) force + (pld area
x PR pressure)) holds, and the self pressure
reducing valve will adjust the openings of the
ports Pl and P2 so that the Pl pressure can
be maintained higher than the PR pressure.
When the PR pressure rises above the set
pressure, the poppet (5) will open and the hydraulic oil flows through the route from the
PR port, the hole a in the spool (81, the poppet (5) opening to the tank port T.
l
Therefore, there will occur a differential pressure around the hold a in the spool (8) and
the spool will move in the direction to close
the port Pl and the PR opening. Then, the PI
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and
is supplied as the PR pressure.
1O-88
FC128US-2
STRUCTURE
3.
AND FUNCTION
VALVE
At raise of load pressure P2
-Q
Servo
SVPO7626
Operation
When the load pressure P2 rises due to digging*or other operations, the pump delivery
will increase and the Pl pressure will rise.
Then, the expression (PI pressure > Spring
(7) force + ($d area x PR pressure)) will hold,
and the valve (2) will move to the right side
..till the stroke end. As a result, the opening
between the ports Pl and P2 will increase, the
passage resistance will become smaller to
reduce engine loss horsepower.
l
fC128US-2
When the PR pressure rises above the set

pressure, the poppet (5) will open and the hydraulic oil will flow through the route from
the PR port, the hole a in the spool (81, the
poppet (5) opening to the tank port T.
Therefore, there will occur a differential pressure around the hold a in the spool (8) and
the spool will move in the direction to close
the port P1 and the PR opening. Then, the Pl
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and
is supplied as the PR pressure.
lo-89
STRUCTURE
4.
AND FUNCTION
At occurrence
of abnormal
VALVE
high pressure
9
SVP07626
Operation
When the PR pressure of the self pressure reducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports PR + T so as to reduce the PR
Then, the equipment (PPC valve,
pressure.
solenoid valve, etc.), to which the oil pressure
is supplied, is protected from the abnormal
high pressure.
l
1O-90
PC1 28US-2
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

STD (WITHOUT BLADE)
1.
2.
3.
4.
5.
Cover
Body
Slipper seal
O-ring
Shaft
PC128US-2
A1 : From control valve (R.H. travel Forward)

A2 : To R.H. travel motor B
B1 : From control valve (L.H. travel Forward)
B2 : To L.H. travel motor A
C1 : From control valve (R.H. travel Reverse)
C2 : To R.H. travel motor A
D1 : From control valve (L.H. travel Reverse)
D2 : To L.H. travel motor B
E1 : 2-stage travel selection solenoid valve
E2 : To L.H./R.H. travel motor D
DR1 : To hydraulic tank
DR2 : From L.H. travel motor C1 and R.H. travel
motor C2
10-91
A
CENTER SWIVEL JOINT
OPT (WITH BLADE)
1.
2.
3.
4.
5.
A1
A2
B1
B2
C1
C2
D1
Cover
Body
Slipper seal
Dust seal
Shaft
: From control valve (R.H. travel Forward)
: To R.H. travel motor B
: From control valve (L.H. travel Forward)
: To L.H. travel motor A
: From control valve (R.H. travel Reverse)
: To R.H. travel motor A
: From control valve (L.H. travel Reverse)
10-92
A
D2 : To L.H. travel motor B

E1 : From travel 2nd speed selector solenoid
valve
E2 : To L.H./R.H. travel motor D
F1 : From control valve (Blade LOWER)
F2 : To L.H./R.H. blade cylinder bottom
G1 : From control valve (Blade RAISE)
G2 : To L.H./R.H. blade cylinder head
DR1 : To hydraulic tank
DR2 : From L.H. travel motor C1, R.H. travel motor C2
PC128US-2
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
34
B-B
9JA01339
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Plug
Check valve spring
Check valve
Return spring
Counterbalance valve
Safetyvalve
Safety valve spring
End cover
Regulator valve
Spring
Biake piston
Cylinder
Spring
Swash plate
Pivot
Crankshaft
RV gear A
1o-94
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
RV gear B
Cover
Driven gear
Drive gear
Drain plug
Hub
Regulator piston
Spindle
Piston
Floating seal
Plate
Disc
Valve plate
Spring
Piston
Plug
Check valve
PC1 28US-2
TRAVEL MOTOR
Specification
Type
PC128US-2
Serial No.
Spec.
PC138US-2
PC138USLC-2
GM18VL-J
GM20VL-J
GM20VL-P
GM20VL2-P
5001 and up
5001 6072
6073 and up
STD
OPT(traction up)
Serial No.
4501 and up
Spec.
STD
Serial No.
1001 1500
1501 and up
Spec.
STD
STD
Theoretical delivery
(cm3/rev{cc/rev})
Rated speed
(rpm)
Hi
33.2 {33.2}
Lo
52.7 {52.7}
Hi
3,267.7
3,191
3,035
3,444
Lo
2,147.3
2,028
1,929
2,025
34.0 {34.0}
Brake releasing pressure

(MPa{kg/cm2})
0.68
{6.94}
Hi-Lo switching pressure

(MPa{kg/cm2})
2.94
{30}
Final drive reduction ratio
31.5 {31.5}
55.8 {55.8}
72
75.7
OUTLINE
Travel speed selection
Swash plate (14) has 2 faces (x, y) behind it,

and is supported by pivot(15).
When pressure of control chamber a rises, it
pushes regulator piston (24), then swash plate
angle becomes minimum, then travel speed
goes high.
PC128US-2
10-95
(18)
TRAVEL MOTOR
OPERATION
Operation of motor
At slow speed (the motor swash plate angle is maximized.)
Since the travel 2nd speed selector solenoid

valve is demagnetized, the pressurized oil
from the main pump does not flow to the D
port.
Therefore, the spring (10) has pressed the
regulator valve (9) to the left side.
So, the regulator valve (9) stops the main pressurized oil led from the control valve to the
end cover by pushing the check valve (34).
The pressurized oil in the control chamber
drains in the motor case through the passage
b of the regulator valve (9).
Then, the main pressurized oil from the cylinder c chamber pushes the swash plate (14) in
the direction to maximize the swash plate
angle and the motor capacity is increased to
the maximum for slow speed travel.
10-96
2
PC128US-2
TRAVEL MOTOR
At high speed (the motor swash plate angle is minimized.)
When the travel 2nd speed selector solenoid

valve is energized, the pilot pressure from the
main pump will flow in the D port and push
the regulator valve (9) in the right direction.
Therefore, the main pressurized oil from the
control valve passes through the passage b
of the regulator valve (9), flows in the control
chamber a and pushed the regulator piston
(24) in the left direction.
Then, the swash plate (14) is pressed in the
direction to minimize the swash plate angle,
and the motor capacity is minimized for high
speed travel.
PC128US-2
10-97
2
TRAVEL MOTOR
Operation of brake valve

The brake valve consists of the check valves
(3a) and (3b), the counterbalance valve (5) and
the safety valve (6), and the circuit configuration is as per the right figure.
Functions and operations of these components are as follows :
Counterbalance valve, check valve

Function
When traveling down a slope, the machine
weight falling force will make the machine
travel faster than the motor rotation. So, traveling with reduced engine speed is very dangerous because the motor idles and runs
away.
These valves let the machine travel at a speed
appropriate for the engine speed (pump delivery) to prevent this danger.
Operation at oil supply
When the travel lever is operated, the pressurized oil from the control valve will be supplied to the PA port, push and open the check
valve (3a) and flow from the MA port on the
motor inlet side to the MB port on the motor
outlet side.
Since the motor outlet circuit is closed with
the check valve (3b) and the counterbalance
valve (5), however, the supply-side pressure
will rise.
10-98
(18)
PC128US-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
The pressurized oil on the supply side flows

in the Sl chamber from the orifice El of the
counterbalance valve (5). When the pressure
in the Sl chamber rises above the switching
pressure of the counterbalance
valve, the
counterbalance valve (5) will be pressed in
the right direction.
So, the circuit between the outlet side MB port
and the PB port will open, the motor outlet
circuit will open, and the motor will start rotating.
SJP07629
Brake cperaticn at travehg

dcwnhi!!
If the machine is going to run away when traveling downhill, the motor will idle to reduce
the oil pressure on the motor inlet side and
the pressure in the Sl chamber through the
orifice El.
When the pressure in the Sl chamber drops
below the switching pressure of the counterbalance valve, the counterbalance valve (5)
will be returned in the left direction with the
return spring (4), and the outlet side MB port
will be throttled.
Then, the pressure on the outlet side will rise
and rotation resistance will occur to the motor to prevent the machine from running
away.
This.means that the counterbalance valve (5)
moves to a position where the machine own
.-weight and the inlet side pressure balance
with the pressure at the outlet side MB port,
and the outlet circuit is throttled to control
the speed to the pump delivery.
l
PC1 28US-2
El-
sr
SJPO7630
1o-99
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
Safety valve
Function
When stopping a travel (or traveling downhill), the counterbalance valve (5) will close
the inlet and outlet circuits of the motor. Since
the motor keeps rotating by inertia, however,
the pressure on the outlet side of the motor
will rise abnormally and the motor and pipes
may be damaged. Then, the safety valve leads
the abnormally high-pressure to the inlet side
of the motor to prevent the equipment from
being damaged.
l
Operation
When the pressurized oil being supplied from
the PA port is stopped flowing at the time of
travel stop, the return spring (4) will return
the counterbalance valve (5) from the right
side to the left side (the neutral position).
Though the counterbalance valve (5) closes
the a chamber on th:e outlet side circuit, the
inertia lets the motor rotate and the pressure
in the a chamber rises.
The highly pressurized oil in the a chamber
passes through the throttle b of the safety
valve (6a) and enters in the d chamber from
the c chamber.
The pressurized oil entered
in the d chamber moves the piston (32) to the
left side. Meantime, the safety valve (6a) is
pushed to open by the pressurized oil in the a
chamber, and the pressurized
oil in the a
chamber flows in the f chamber through the
e port. Therefore, the pressurized oil in the a
chamber flows in the f chamber at a comparatively slow speed to control the pressure in
the a chamber and also to prevent cavitation
in the f chamber at the same time.
When the piston (32) reaches the stroke end,
the pressures in the d and c chambers will
rise, the safety valve (6a) will be closed again
and the pressure in the a chamber will rise
further.
Then, the safety valve (6b) will open and the
pressurized oil in the a chamber will flow in
the f chamber from the g chamber. The pressure in the a chamber can be controlled in
two stage as mentioned above, and the hydraulic motor can be smoothly braked to stop.
SJPO7631
32
SJP07632
10-100
PC128US-2
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
Operation of parking brake

When operating travel
When the travel lever is operated, the pressurized oil from the pump will work on the
counterbalance valve (5), open the circuit a
to the parkingbrake and flow in the b chamber of the brake piston (11).
- The pressure in the b chamber overcomesthe
spring (31) and pushed the brake piston (1 I)
in the lefi direction.
This will eliminate the press force to the plate
(28) and the disc (29), and the plate (28) and
the disc (29) will separate, and the brake force
will be released.
l
SJPO7633
When positioning travel neutral

When the travel lever is brought to the neutral position, the counterbalance valve (5) will
return td the neutral position and the circuit a
to the parking brake will be closed.
The pressurized oil in the b chamber of the
brake piston (11) will be drained in the case,
and the spring (31) will push the brake piston
in the right direction.
Therefore, the plate (28) and the disc (19) will
be pushed to each other, and the brake will
come to work.
l
5i?
Control
valve
PC1 28US-2
SJP07634
10-101
STRUCTURE
AND FUNCTION
SWING MOTOR
SWING MOTOR
TYPE : KMF40ABE-3
9JUOOO70
B
S
T
MA
MB
: From-iswing brake solenoid valve

: From control valve
: To tank
10-102
Specification
Type : KMF40ABE-3
Theoretical delivery : 40.2 cc/rev
Safety valve set pressure : 27.5 MPa (280 kg/cm2)
Rated speed : 2,413 rpm
Brake releasing pressure :1.77 MPaIl8.0 kg/cm2}
PC1 28U.52
STRUCTURE
SWING MOTOR
AND FUNCTION
16
c-c
1. Drive shaft
2. Spacer
3. Case
4. Disc
5.,,Plate
6. Brake ring
7. Brake piston
8. Housing
9. Reverse prevention
10. Center spring
PC1 28US-2
valve
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
17
ii is
9JUOO102
Cylinder
Valve plate
Piston
Center shaft
Safety valve
Check valve
Check valve spring
Shuttle valve
Shuttle valve spring
Brake spring
10-103
SWING MOTOR
SWING BRAKE
1. When solenoid valve is demagnetized
Operation
When the solenoid valve of the swing brake
is demagnetized, the pressurized oil from the
control pump will be interrupted and the B
port will be connected to the tank circuit.
Then, thebrake piston (7) will be pressed
downward with the_.brake spring (8) and will
push the disc (4) and the plate (5) to work the
brake.
l
SJP07636
2. When solenoid valve is energized

Operation
When the solenoid valve of the swing brake
is energized, the valve will be changed over
and the pressurized oil from the control pump
will enterthe
6 port and will flow in the brake
chamber A.
The pressurized oil in the A chamber will push
the brake spring (8) and the brake piston (7)
will move upward. Then, the disc (4) and the
plate (5) will separate to release the brake.
l
SJPO7636
10-104
PC1 28US-2
SWING MOTOR
REVERSE PREVENTION
VALVE
II
0
--I_-_-
_-J
Tl
MA
MB
T2
Z
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)
MA
MB
Tl
T2
: Port
: Port
: Port
: P&t
PC128US-2
:____
9JUOOO72
10-105
STRUCTURE
SWING MOTOR
AND FUNCTION
Effect explanation
drawing
,With
reversal
rotation
Prevention
valve
_
_.
,Without
reversal
Prevention
valve
rotation
MA pr essure
ME pr essure
Motor
ro tat
ion
Time
SJPO7637
10-106
PC1 28US-2
STRUCTURE
SWING MOTOR
AND FUNCTION
Function
This function is used for reducing swjng back
generated
on a swing body that can result
from factors such as inertia of the swing body,
backlash and rigidity of the machinery
systern and compressibility
of hydraulic oil.
This function helps preventing
loose loads at
the end of swing or cutting lead time (better
positioning
performance
allows you to proceed to the next-operation
within a shorter
time).
l
Notch
SJP07777
1. When MB port pressure is generated

Operation
MB pressure is conducted to d room via the
cutout. Utilizing difference of space (Dl>D2),
the pressure compresses the spring (6) and
drives the spool (5) leftward to interconnect
MB+e.
Since MA pressure at this time is lower than
the pressure set on the spring (31, the spool
(2) is not moved and pressurized oil remains
closed. Thus, the braking force is maintained.
l
SOP02036
2. When the motor is once stopped

Operation
The motor is reverse rotated by charging pressure generated on the MB port (1st reverse
rotation).
At this time, reversing pressure is generated
on the MA port. MA pressure conducted to a
room interconnects MA + b by compressing
the spring (3) and driving the spool (2) rightward.
- The pressure is then conducted
through
drilled hole on the spool (5) to interconnect
b
+ f. Reversing pressure on the MA port is
bypassed to the T port to disable the 2nd reverse rotation.
PC1 28US-2
I-L
II/
SDP02037
10-107
STRUCTURE
SOLENOID
AND FUNCTION
VALVE
SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND 2-STAGE
RELIEF SOLENOID VALVE.
Al
A4
A3
7i2
A-A
to
B-B
9JA01353
1.
2.
3.
4.
PPC lock solenoid valve

2nd travel speed select solenoid valve
Swing hold brake solenoid valve
2-stage relief solenoid valve
Solenoid valve
5. Push spin
6. Coil
7. Gauge
8. .Spool
9. Block
10. Spring
Al
A2
A3
A4
ACC
Pl
T
: To PPC valve
: To 2-stage relief valve
: To swing hold brake
: To 2nd travel speed select valve
: To accumulator
: From self-pressure reducing valve
: To hydraulic oil tank
Check valve
11. Plug
12. Spring
13. Plunger
lo-108
PC1 28US-2
STRUCTURE
SOLENOID
AND FUNCTION
Operation
When solenoid is demagnetized
The coil (6) remains demagnetized
as long as
signal current to it is stopped..
Thus, the spool (8) is pushed leftward by the
spring (IO).
Since ports P to A are closed by this spool,
flow of. pilot.oil
pressure to the actuator is
blocked.
At the same time, oil from the actuator is lead from A port to T port, then:
drained to the hydraulic oil tank.
VALVE
#ztiva
t
SJPO7636
When solenoid is magnetized

- The coil (6) is magnetized by signal current
conducted to it.
Thus, the spool (8) is pushed rightward by the
push pin (5).
As the result, pilot oil pressure is conducted
from P port through the cage (7) and A port
up the actuator.
At the same time, T port is closed, thereby
blocking flow of oil to the hydraulic oil tank.
l
Exe it
I)
SJPO7639
PC1 28US-2
10-109
PPC ACCUMULATOR
PPiACCUMULATOR
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
SBPOO290
Specifications
Gas used : Nitrogen gas
Gas capacity : 0.3 e
Charged gas pressure :
1.18 MPa (12 kg/cm*) at 80C
Maximum operating pressure :
6.86 MPa (70 kg/cm*)
10-l10
PC1 28US-2
ACCUMULATOR FOR BREAKER (IF EQUIPPED)
ACCUMULATOR FOR BREAKER

(If equipped)
FOR LOW PRESSURE
1.
2.
3.
4.
5.
6.
Cap
Core
Guard rubber
Lid
Plug
Shell
Specification
Type of gas : Nitrogen gas
Gas valume : 0.48
Sealed gas pressure : 0.1 MPa {1 kg/cm2}(at 80 C)
Max. actuating pressure : 6.86 MPa {70 kg/cm2}
FOR HIGH PRESSURE

1.
2.
3.
4.
Cap
Gas plug
Plug
Shell
Specification
Type of gas : Nitrogen gas
Gas valume : 0.5
Sealed gas pressure :
5.88 MPa {60 kg/cm2}(at 80 C)
Max. actuating pressure : 20.6 MPa {210 kg/cm2}
PC128US-2
10-111
C
STRUCTURE
PPC VALVE
AND FUNCTION
Operation
1. In the neutral mode
Pl and P2 ports of the operation valves A and
Band the PPCvalve are connected to the drain
room D via the fine control hole on the spool
l
(1).
2.
.
In the fine control mode

(neutral + fine control)
When the piston (4) is pushed by the disk (51,
the retainer (9) is also pushed, thereby driving the metering spring (2) down via the spool
(1).
As the result, the fine control hole f is isolated
from the drain room D and, almost at the same
time, it is connected to the pump pressure PP.
Then, pilot pressurized oil for the main pump
is conducted from PI port to A port via the
fine control hole f.
As pressure on PI port is increased, the spool
(1) is pushed back thereby disconnecting the
fine control hole f from the pump pressure
room PP. The disconnected spool (1) is in no
time connected to the drain room D, resulting in relieving pressure on Pl port.
Thus, the spool (1) is moved up and down so
that force of the metering spring (2) and pressure on Pl port may be balanced. Positional
relationship between the spool (1) and body
(10) (fine control holef is situated at mid point
betwe.en the drain room D and pump pressure room PP) remains unchanged until the
retainer (9) is contacted against the spool (1).
Therefore, the metering spring (2) is compressed in proportion to strokes of the operation lever. So, pressure on PI port is also increased in proportion to strokes of the operation lever.
As the result, the operation valve spool is
moved up to the position where pressure in
A room (the same pressure level as that on
Pl port) and force of the operation valve spool
return spring is balanced.
10-l 14
(Fio
1)
SEP02569
SEP02570
PC 128US-2
STRUCTURE
3.
.
AND FUNCTION
PPC VALVE
In the fine control modetoperating

lever
shifted back to its original position)
As the disk (5) starts returning, the spool (1)
is push up by force of the centering spring (3)
and pressure of,Pl port.
Thus, passage between the fine control hole
f and drain room D becomes, thereby relieving pressurized oil of Pl port.
If Pl port pressure goes excessively low, the
spool (1) is pushed down by the metering
spring (2) and passage between the fine control hole f and the drain room D is shut down.
And, almost at the same time, the hole is connected to the pump pressure room PP and
starts supplying pump the pressure. This supply continues until the PI port pressure is recovered to the level equivalent to the lever
position.
When the operation valve returns, oil in the
drain room D flows in through the fine control hole f on the not moving side valve. Oil
is then conducted via P2 port to the room B
to fill it up.
(Fig
3)
SEP0257
4.
.
In the full stroke mode

When the disk (51 pushes down the piston (4)
and the retainer (91 pushes down the spool
(l), connection of the fine control hole f is
switched from the drain room D to the pump
pressure room PP.
Thus, pilot pressurized oil from the control
pump passes through the fine control hole f
and conducted to A room via PI port to push
the operation valve spool.
Return oil from B room is conducted from P2
port to the drain room D via the fine control
hole f.
(Fio
41
SEP02572
FC128US-2
10-115
PPC VALVE
FOR TRAVEL
P : From main pump

T : To tank
P1 : L.H reverse
P2 : L.H forward
10-116
(15)
P3 : R.H reverse
P4 : R.H forward
P5 : Travel signal
PC128US-2
PPC VALVE
PC128US-2 Serial No. 5001 6300
1.
2.
3.
4.
Plate
Body
Piston
Collar
PC128US-2
5. Metering spring
6. Centering spring
7. Valve
10-117
(15)
PPC VALVE
PC128US-2
PC138US-2
PC138USLC-2 Serial No. 1001 and up
1.
2.
3.
4.
Plate
Body
Piston
Collar
10-117-1
(15)
5.
6.
7.
8.
Metering spring
Centering spring
Valve
Pin
PC128US-2
PPC VALVE
Operation
P1 and P2 ports of the operation valves A, B
and PPC valve are connected to the drain
room D via the fine control hole f on the spool
(1).
2. In the fine control mode

(neutral fine control)
As the piston (4) is pushed by the disk (5), the
retainer (9) is pushed, too. At the same time,
the spool (1) is also pushed down via the
metering spring (2).
By this move, connection of the fine control
hole f is switched from the drain room D to
the pump pressure room PP, and pilot pressurized oil for the main pump is conducted
from P1 port to A port.
As P1 port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure room PP to the drain room D, thereby
relieving P1 port pressure.
As the result, the spool (1) moves up and
down so that force of the metering spring (2)
and P1 port pressure may be balanced.
Positional relationship between the spool (1)
and body (10) (fine control hole f is situated
at mid point between the drain room D and
pump pressure room PP) remains unchanged
until the retainer (9) is contacted against the
spool (1).
The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the P1 port pressure, too,
increases in proportion to strokes of the operation lever.
As the result, the operation valve spool moves
to the position where pressure of A room (the
same as P1 port pressure) is balanced against
force of the operation valve spool return
spring.
10-118
PC128US-2
PPC VALVE
3. In the fine control mode (when operation lever is shifted back to its original position)
As the disk (5) starts returning, the spool (1)
is pushed up by force of the centering spring
(3) and P1 port pressure.
By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of P1 port to it.
If P1 port pressure goes excessively low, the
starts supplying pump the pressure. This supply continues until the P1 port pressure is recovered to the level equivalent to the lever
position.
When the operation valve spool returns, oil
in the drain room D flows in through the fine
control hole f on the not moving side valve.
Oil is then conducted via P2 port to the room
B to fill it up.
4. In the full stroke mode

When the disk (5) pushes down the piston (4)
and the retainer (9) pushes down the spool
(1), connection of the fine control hole f is
pressure room PP.
and conducted to A room via P1 port to push
hole f.
PC128US-2
10-119
(15)
PPC VALVE
FOR BLADE, SERVICE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Spool
Metering spring
Centering spring
Piston
Lever
Plate
Retainer
Body
Filter
10-120
(15)
P :
T :
P1 :
P2 :
From self pressure reducing valve

To tank
To blade or service valve
To blade or service valve
PC128US-2
STRUCTURE
AND FUNCTION
PPC VALVE
Operation
PI and P2 ports of the operation valves A, B
and PPC valve are connected to the drain
room D via the fine control hole f on the spool
l
(1).
2.
l
In the fine control mode

(Neutral + fine control)
As the piston (4) is pushed by the disk (5), the
retainer (7) is pushed, too. At the same time,
the spool (7) is also pushed down via the
metering spring (2).
By this move, connection of the fine control
hole f is switched from the drain room D to
the pump pressure room PP, and pilot pressurized oil for the control pump is conducted
from Pl port to A port.
As PI port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure room PPto the drain room D, thereby
relieving Pl port pressure.
As the result, the spool (1) moves up and
down so that force of the metering spring (2)
and Pl port pressure may be balanced.
Positional relationship between the spool (1)
and body (8) (fine control hole f is situated at
mid point between the drain room D and
pump pressure room PP) remains unchanged
until the retainer (7) is contacted against the
spool (1).
Themetering
spring (2) is, therefore, compressed in proportion to strokes of the opera...tion lever. Thus, the Pl port pressure, too,
increases in proportion to strokes of the operation lever.
As the result, the operation valve spool moves
to the position where pressure of A room (the
same as Pl port pressure) is balanced against
force of the operation valve spool return
spring.
PC1 28US-2
SJP07646
SJP07647
10-121
STRUCTURE
3.
.
AND FUNCTION
PPC VALVE
In the fine control mode (when the operation

lever is shifted back to its original position)
As the lever (5) starts returning, the spool (1)
is pushed up by force of the centering spring
(3) and Pl port pressure. By this move, the
fine control hole f is connected to the drain
room D and relieves pressurized oil of Pl port
to it.
If PI port pressure goes excessively low, the
starts supplying pump the pressure. This supply continues until the PI port pressure is recovered to the level equivalent to the lever
position.
When the operation valve spool returns, oil
in the drain room D flows in through the fine
control hole f on the not moving side valve.
Oil is then conducted via P2 port to the room
B to fill it up.
SJPO7648
4.
l
In the full stroke mode

When the disk (5) pushes down the piston (4)
and the retainer (7) pushes down the spool
(I), connection of the fine control hole f is
pressure room PP.
and conducted to A room via Pl port to push
hole f.
SJPO7649
10-122
PC1 28US-2
BOOM HYDRAULI DRIFT PREVENTION T VALVE

(FOR KUK SPEC.)
PC128US-2 Serial No.: 5001 7730
1.
2.
3.
4.
5.
Poppet
Check valve spring
Pilot spool
Pilot spring
PC128US-2
CY : To boom cylinder bottom

PI : From PPC valve (pilot pressure)
V : From control valve
10-122-1
C

1.
2.
3.
4.
5.
Poppet
Check valve spring
Pilot spool
Pilot spring
10-122-2
(15)
CY : To boom cylinder bottom

PI : From PPC valve (pilot pressure)
V : From control valve
PC128US-2
ARM HYDRAULIC DRIFT PREVENTION VALVE

(FOR KUK SPEC.) (If equipped)
1.
2.
3.
4.
5.
6.
Pilot spool
Spring (1st stage of spool)
Spring (2nd stage of spool)
Safety valve
Check valve
Spring
10-122-6
(15)
V
T
: To hydraulic tank
CY : To hydraulic cylinder
PI : From PPC valve
PCV : From pressure pickup and equalizer circuits
PC128US-2
Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the
oil from flowing back from the work equipment
cylinder to prevent sudden fall of the work equipment.
Operation
1. When work equipment is in neutral
[When piping is normal]
Check valve (5) is closed by the work equipment cylinder holding prssure applied
through port CY to chamber b.
When the work equipment is in neutral, no
pilot pressure is applied from the PPC valve
to port Pi. Accordingly, pilot spool (1) is moved
to the left end by the force of springs (2) and
(3), then chambers a and b are shut off from
each other.
By this operation, oil does not flow between
the main valve and the work equipment cylinder, thus the work equipment cylinder is
held.
If the pressure in the work equipment cylinder rises high abnormally, work equipment
cylinder holding pressure operates safety
valve (4).
[When piping bursts]
Even if piping A between the main valve and
work equipment cylinder bursts, chamber a
is shut off from chamber b as in the case
where the piping is normal. Accordingly, the
work equipment cylinder is held.
PC128US-2
10-122-7
C
2. When oil is sent from main valve to cylinder

If pressure of the oil sent from the main valve
to chamber a is higher than the total of pressure in chamber b connected to the work
equipment cylinder and the force of spring (6),
check valve (5) opens and chambers a and b
are connected to each other and the oil flows
from the main valve to the work equipment
cylinder.
If piping A between the main valve and work
equipment cylinder bursts, the oil in chamber a flows out through the burst part and
pressure in chamber a lowers.
If pressure lowers below the total of pressure
in chamber b and the force of spring (6), check
valve (5) closes and chambers a and b are shut
off from each other. Accordingly, pressure in
the cylinder is held and the work equipment
does not fall suddenly.
10-122-8
(18)
PC128US-2
3. When oil is returned from work equipment

cylinder to main valve
The work equipment cylinder holding pressure is applied to chamber b and check valve
(5) closes.
The pilot pressure from the PPC valve is applied port Pi. If it is higher than the force of
spring (2) (area of d), spool (1) moves to the
right standby position (1st-stage stroke).
At this time, chambers a and b are not connected to each other.
If the pilot pressure rises higher than the force
of spring (3) (area of d), spool (1) moves further to the right and chambers a and b are
connected to each other (2nd-stage stroke).
Accordingly, the oil is returned from the work
equipment cylinder to the main valve.

If piping A between the main valve and work
equipment cylinder bursts, the oil in chamber a flows out through the burst part. Since
the oil supplied from chamber b to chamber
a flows through opening c of spool (1), however, the cylinder does not fall suddenly.
PC128US-2
10-122-9
C
AIR CONDITIONER PIPING
PC128US-2
A : Hot air/cold air spurting with outlet port

B : Internal air circulation port
C : External air inlet
1.
2.
3.
4.
Hot water drain piping

Air conditioner compressor
Hot water return piping
Refrigerant piping
10-123-1
(18)
5.
6.
7.
8.
Receiver tank
Condenser
Air conditioner unit
Duct
PC128US-2
AIR CONDITIONER PIPING
PC138US-2
A:
B:
C:
D:
Hot air/cold air spurting with outlet port

Internal air circulation port
External air inlet
Refrigerant checking port
1.
2.
3.
4.
Hot water drain piping

Hot water return piping
Refrigerant piping
PC128US-2
5.
6.
7.
8.
Receiver tank
Condenser
Duct
10-123-2
(18)
ELECTRIC COMPONENT LAYOUT
1. Additional light (Standard for KUK and North

America)
2. Fuel level sensor
3. L.H. working light
4. PC-EPC solenoid valve
5. Safety relay
6. Starting motor
7. Engine speed sensor
8. Coolant temperature sensor
9. Alternator
10. Electric intale heater
11. Engine oil pressure sensor
12. Air conditioner compressor
13. Heater relay
14. Engine stop solenoid valve
15. Condenser
16. Washer tank
17. Battery relay
18. Battery
19. Fusible link
20. Swing holding brake contraller
21. Deceleration controller
22. Pump controller
23. Air conditioner unit
24. Swing holding breke release switch
25. Travel speed boost pedal
26. Emergency pump drive switch
27. Travel pressure switch
28. Overload alarm pressure switch (Standard for
KUK only)
29. Horn
30. Swing RIGHT switch
31. Swing LEFT switch
32. Arm IN pressure switch
33. 2-stage relief solenoid valve
34. Swing holding solenoid valve
35. 2-stage travel speed selection solenoid vaolve
37. R.H. working light
38. Travel alarm (Standard for KUK and North
America)
65. Automatic travel speed change controller
(Serial No.: 6301 and up )
66. Pump pressure sensor
(Serial No.: 6301 and up)
PC128US-2
Serial No. : 7731 and up
PC138US-2
PC138USLC-2 Serial No. : 1001 and up
fl For the layout drawings of electrical equipment of serial numbers later than the above,
refer to the paragraph of "CONNECTOR
TYPES AND MOUNTING LOCATIONS" in the
"TROUBLESHOOTING."
PC128US-2
10-125
(15)
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
ELECTRIC COMPONENT LAYOUT
Temperature control switch

Wind volume selection switch
Air conditioner switch
Horn switch
Monitor panel
Light switch
Car heater switch (Model with heater)
One touch deceralation pilot lamp
Starting switch
Fuse box
Throttle control motor
Overload alarm buzzer reset switch (Standard
for KUK only)
Additional light switch (Standard for North
America)
Wiper switch
Wiper controller
Swing lock switch
Travel speed selection switch
PPC lock switch
One touch deceralation switch
Additional light relay
Alarm buzzer
Room light
Antenna (Standard for North America only)
Car radio (Standard for North America only)
Speaker (Standard for North America only)
Waper motor
PC128US-2
PC138US-2
fl For the layout drawings of electrical equipment of serial numbers later than the above,
refer to the paragraph of "CONNECTOR
TYPES AND MOUNTING LOCATIONS" in the
"TROUBLESHOOTING."
PC128US-2
10-127
(15)
ENGINE CONTROL
PC128US-2
1.
2.
3.
4.
5.
6.
7.
Starting switch
Fuel control dial
Safety relay
Starting motor
Engine stop solenoid
Controller
Battery relay
PC128US-2
8.
9.
10.
11.
12.
13.
Battery
Fuel control motor
Fuel control motor relay
Engine stop solenoid relay
Governor lever
Fuel injection pump
10-128-1
(15)
ENGINE CONTROL
PC138US-2
1.
2.
3.
4.
5.
6.
7.
Starting switch
Fuel control dial
Safety relay
Starting motor
Controller
Battery relay
10-128-2
(15)
8.
9.
10.
11.
12.
13.
Battery
Fuel control motor
Fuel control motor relay
Governor lever
Fuel injection pump
PC128US-2
ENGINE CONTROL
PC128US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Safety lock lever
PPC lock switch
Starting motor cut relay
PC128US-2
10.
11.
12.
13.
14.
15.
16.
17.
Safety relay
Fuel control dial
Fuel control motor
Fuel control motor relay (for driving)
Fuel control motor relay (for acceleration)
Fuel control motor relay (for deceleration)
Starting motor
10-132-1
(15)
ENGINE CONTROL
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Safety lock lever
PPC lock switch
PC128US-2
10.
11.
12.
13.
14.
15.
16.
17.
Safety relay
Fuel control dial
Fuel control motor
Starting motor
10-132-3
(15)
ENGINE CONTROL
START OF ENGINE
When the starting switch comes to the ON position, the engine stop solenoid (16) drives the
governor stop lever to the "RUN" side. A failsafe mechanism has been adopted that stops
the engine when an abnormality occurs in the
electrical system.
When the safety lock lever (7) comes to the
"LOCK" position and the starting switch (4)
comes to the START position, a start signal
flows to the starting motor and the engine
starts. When the safety lock lever is set to
the "FREE" position, the starting motor cut relay (9) interrupts the start signal to the starting motor (7) and the engine cannot start.
At the time, the fuel control dial (11) is linked
to the fuel control motor (12), and the engine
speed comes to the speed set with the fuel
control dial (11).
CONTROL OF ENGINE SPEED
The fuel control motor (12) outputs an acceleration (engine speed increases) signal or a
deceleration (engine speed drops) signal to
the controller (6) depending on the rotational
position of the fuel control dial (11).
After receiving the signal, the controller (6)
outputs a drive signal to the fuel control motor (12) through the fuel control motor relays
(13), (14) and (15).
The fuel control motor (12) shortens or extends the cable and controls the engine speed
according to the drive signal.
STOP OF ENGINE
When the starting switch (4) comes to the OFF

position, the engine stop solenoid (18) drive
the governor stop lever to the "STOP" side and
the engine stops.
FUNCTION OF PREVENTING ENGINE

STOP SOLENOID FROM BURNING
Engine stop solenoid relay (13) is installed to

prevent engine stop solenoid (16) from burning.
The time to supply the suction current is limited to 3 seconds after starting switch (4) is
turned to the ON position by replacing the 2wire engine stop solenoid (16) (which uses the
same wire for the suction and holding currents) with the 3-wire one (which uses independent wires for the suction and holding
currents) and adding a timer function and
engine stop solenoid relay (13) to controller
(6).
10-132-4
(15)
A:
B:
C:
t:
Operation of starting switch

Suction coil current
Holding coil current
3 seconds
PC128US-2
ENGINE CONTROL
AUTO-DECELERATOR
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Fuel control dial
Fuel control motor
Monitor panel
Fuel injection pump
Boom RAISE PPC oil pressure switch
Arm IN PPC oil pressure switch
Swing PPC oil pressure switch
I/O Signals
a. Controller power supply
b. Solenoid power supply
c. Monitor panel power supply
d. S-NET signal
PC128US-2
14. Travel PPC oil pressure switch

15. Work equipment control lever PPC
oil pressure switch
16. Hydraulic pump
17. Control valve
17a. Self pressure reducing valve
17b. Main relief valve
22. Blade PPC valve (Blade specification)
e.
f.
g.
h.
PPC oil pressure switch signal

Throttle signal
Fuel control motor drive signal
Potentiometer signal
10-132-5
(15)
ENGINE CONTROL
FUNCTION
When the all control levers are set to NEUTRAL for waiting for a dump track or work,
the engine speed is automatically reduced to
a medium speed, and fuel consumption and
noise are lowered.
When the control lever is operated, engine
speed returns immediately to the speed that
is set with the fuel control dial (7).
OPERATION
PC128US-2
When the control lever is set to NEUTRAL,
If the all control levers are set to NEUTRAL
while the engine is running at faster speed
than the decelerator operating speed (1,400rpm
approx.), the engine speed lowers immediately to the 1st deceleration speed, about
200rpm slower than the speed that is set with
the fuel control dial.
When 4 sec. elapses, the engine speed lowers again to the 2nd deceleration speed (about
1,400rpm) and the speed that is kept until the
control lever is operated next time.
WHEN THE CONTROL LEVER IS OPERATED,
If any control lever is operated while the engine speed is kept for the 2nd deceleration
speed, the engine speed rises immediately to
the speed that is set with the fuel dial.
A:
B:
C:
D:
E:
F :
G:
H:
J :
K:
10-132-6
(15)
All work equipment levers at "NEUTRAL"

Work equipment lever at "OPERATION"
Speed that is set with fuel control dial
1st deceleration speed
2nd deceleration speed (1,400 rpm)
200 50 rpm
0.2 sec.
4 sec.
Max. 2 sec.
Max. 1 sec.
PC128US-2
ENGINE CONTROL
PC138US-2
When the control lever is set to NEUTRAL,
If the all control levers are set to NEUTRAL
while the engine is running at faster speed
than the decelerator operating speed (1,300rpm
approx.), the engine speed lowers immediately to the 1st deceleration speed, about
100rpm slower than the speed that is set with
the fuel control dial.
When 4 sec. elapses, the engine speed lowers again to the 2nd deceleration speed (about
1,300rpm) and the speed that is kept until the
control lever is operated next time.
WHEN THE CONTROL LEVER IS OPERATED,
If any control lever is operated while the engine speed is kept for the 2nd deceleration
speed, the engine speed rises immediately to
the speed that is set with the fuel dial.
A:
B:
C:
D:
E:
F :
G:
H:
J :
K:
PC128US-2
All work equipment levers at "NEUTRAL"

Work equipment lever at "OPERATION"
Speed that is set with fuel control dial
1st deceleration speed
2nd deceleration speed (1,300 rpm)
100 50 rpm
0.2 sec.
4 sec.
Max. 2 sec.
Max. 1 sec.
10-132-7
(15)
ENGINE CONTROL
SYSTEM COMPONENTS
FUEL ADJUST DIAL
PC128US-2 Serial No.: 5001 7730
1 : PC128US-2 Serial No. 6301 and up
1.
2.
3.
4.
One-touch deceleration pilot lamp

Fuel adjust dial
Boss
Boss
PC128US-2
5.
6.
7.
8.
Shaft
Joint
Bracket
Fuel adjust motor
10-133
(14)
ENGINE CONTROL
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
Knob
Dial
Spring
Ball
Potentiometer
Connector
Function
The potentiometer (5) is installed under the
knob (1) below the monitor panel. When the
knob is turned, the shaft of the potentiometer
(5) rotates.
When the shaft rotates, the resistance value
of the variable resistor in the potentiometer
(5) changes and any throttle signal is sent to
the controller.
10-133-1
(15)
PC128US-2
ENGINE CONTROL
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
Cable
Connector
Potentiometer
Pulley
Gear unit
Motor
Input/Output signal
DEUTSCH-6P [CN-M48]
Pin No.
1
2
3
4
5
6
Signal name
Potentiometer input
Potentiometer output
Potentiometer GND
NC
Motor (+)
Motor ()
PC128US-2
I/O signal
Input
Output
Input
Input
10-134-1
(15)
ELECTRIC CONTROL SYSTEM
PC128US-2
10-136-2
(15)
PC128US-2
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.
41.
42.
43.
44.
45.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Resistor (for driving pump in an emergency)
Emergency pump drive switch
Swing holding brake release switch
Swing lock switch
Safety lock lever
PPC lock witch
Safety relay
Fuel control dial
Fuel control motor
Monitor panel
Hydraulic pump pressure sensor
Travel/swing alarm (option)
Travel speed selector solenoid valve
Swing holding brake solenoid valve
LS-EPC valve
PC-EPC valve
R.H. work equipment PPC valve
Travel PPC valve
L.H. work equipment PPC valve
Travel PPC oil pressure switch
Work equipment control lever
PPC oil pressure switch
Starting motor
Engine speed sensor
Coolant temperature sensor
Hydraulic pump
42a. Servo piston
42b. LS valve
42c. PC valve
Control valve
Travel motor
Swing motor
PC128US-2
10-136-3
A
PC138US-2
10-136-4
(15)
PC128US-2
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.
41.
42.
43.
44.
45.
46.
47.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Swing lock switch
Safety lock lever
PPC lock witch
Safety relay
Fuel control dial
Fuel control motor
Monitor panel
Hydraulic pump pressure sensor
Travel/swing alarm (option)
LS-EPC valve
PC-EPC valve
R.H. work equipment PPC valve
Travel PPC valve
Work equipment control lever
PPC oil pressure switch
Starting motor
Engine speed sensor
Hydraulic pump
42a. Servo piston
42b. LS valve
42c. PC valve
Control valve
Travel motor
Swing motor
Heater relay
Air heater
PC128US-2
10-136-5
(15)
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
PC-EPC valve
Input/Output signals
d. S-NET signal
PC128US-2
11.
12.
13.
14.
LS-EPC valve
Engine speed sensor
Control valve
15. Hydraulic pump
15a. Servo valve
15b. LS valve
15c. PC valve
e.
f.
g.
h.
PC-FPC valve drive signal

LS-FPC valve drive signal
Coolant temperature signal
Engine speed signal
10-138-1
(15)
Function
This function is for selecting any of the three
working modes "A," "B" and "E" with the working mode selector switch on the monitor
panel. The controller can select optimum
engine torques or pump absorption torques
for works to be expected.
The controller detects the engine governor

speed set with the fuel control dial depending on the pump absorption torques set in
each mode and detects actual engine speeds.
Then, the controller controls all torques at
each output point of the engine so that the
pump can absorb them.
When an engine speed was lowered, the controller prevents the engine from stopping by
throttling the pump absorption torque.
10-138-2
(18)
PC128US-2
CONTROL METHOD IN EACH MODE

Mode A
Matching point in Mode A
PC128US-2
PC138US-2
When a load to the pump increases and the
pressure rises and the engine speed lowers.
At the time, the controller reduces the pump
delivery so that the speed lowers to the speed
at the full output point or so. If the pressure
drops on the contrary, the controller increases
the pump delivery so that the speed comes
to the speed at the full output point or so.
The controller repeats these controls so that
the engine can always be used at speeds at
the full output point or so.
PC128US-2
Mode A
66.2 kW/2,200 rpm

{88.7 HP/2,200 rpm}
10-138-3
(15)
Mode E and Mode B

Matching point in Mode E :
85% partial output point in Mode A
Matching point in Mode B :
75% partial output point in Mode A
At the time, the controller lowers the engine
speed by keeping the pump absorption torque
constant along the equal horsepower curve
with the compound control both on the engine side and on the pump side.
Therefore, the engine is used in high fuel efficient ranges.
10-138-4
(15)
Model
PC128US-2
PC138USLC-2
E mode
54.4 kW/2,000 rpm

{72.9 HP/2,000 rpm}
B mode
47.8 kW/1,800 rpm

{64.1 HP/1,800 rpm}
PC128US-2
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
9.
10.
11.
12.
13.
Travel PPC valve

Engine
Hydraulic pump
Control valve
Input/Output Signals
c. Solenoid valve drive signal
d. Travel PPC oil pressure switch signal
Function
2-stage relief
The relief pressure in the normal operation is
31.9 MPa {325 kg/cm2}, and the relief pressure
rises to 34.8 MPa {355 kg/cm2} when the 2stage relief function is operated. Therefore,
the oil pressure will rise more.
10-139-1
(15)
Condition
During travel
Relief pressure
31.9 MPa {325 kg/cm2}
34.8 MPa {355 kg/cm2}
PC128US-2
FUNCTION
Swing lock, swing holding brake
Swing lock holds swing at any position, and
swing holding brake works to prevent swing
drift.
fl Be careful when using the machine in this
condition. When the swing holding brake is
released, the swing is held only by a brake
operated hydraulically by the swing safety
valve, so therre may be hydraulic drift when
the swing is stopped on a slope.
fl Release the swing holding brake also during
arm IN operations.
Swing
lock
switch
ON
OFF
PC128US-2
Swing
lock
lamp
Function
Operation
Gose out
When the swing control lever is returned

to the neutral position, the swing holding
Swing
brake is actuated after approx. 4 seconds.
holding
When the swing control lever is operated,
brake
the swing holding brake is released, and
it is possible to operate the swing freely.
Lights up
If abnormality occurs in the swing holding brake system and OFF, the swing holding brake is canceled and it becomes possible to operate the swing.
However, even when the swing control
level is returned to the nertral position, the
swing holding brake is not actuated.
Swing
lock
10-141
(18)
Swing holding brake release

When there is a problem in the controller and
swing holding brake dosn't work properly,
swing holding brake can be released and then
swing can be operated by operating swing
holding brake release switch to ON.
(1) OFF position : Release
(2) ON position : Automatic
fl When swing lock switch is turned ON, even it
swing holding brake switch is turned ON,
swing holding brake is not released.
Swing holding
ON
breake release (When abnormality)
switch
Swing lock
ON
OFF
switch
Swing brake
Swing
lock
operates
Swing
lock
released
OFF
(When controlleris
safe)
ON
OFF
Swing
lock
operates
Swing
holding
breake
operates
Input/Output Signal time chart
10-142
(18)
PC128US-2
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Swing lock switch
Monitor panel
Input/Output Signals
d. S-NET signal
PC128US-2
12.
13.
14.
15.
16.
17.
18.
Swing motor
Engine
Hydraulic pump
Control valve
19. Travel/swing alarm (option)
e.
f.
g.
h.
Solenoid valve drive signal

Swing PPC oil pressure switch signal
Arm IN PPC oil pressure switch signal
Alarm operation signal
10-142-1
(15)
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
L.H. travel motor
d. S-NET signal
10-143-1
(15)
10.
11.
12.
13.
14.
15.
R.H. travel motor

Engine speed sensor
Pump pressure sensor
Engine
Hydraulic pump
Control valve
16. Travel/swing alarm (option)
e.
f.
g.
h.
Solenoid valve drive signal

Engine speed signal
Pump pressure signal
Alarm operation signal
PC128US-2
FUNCTION
Travel Speed Selection
1. Travel Speed "Manual" Change
Standard Specification and Blade Specification (option)
PC128US-2
Standard Specification
PC128US-2
Serial No.: 5001 7730
When the travel speed selector switch
is set to LOW or HIGH, the motor capacity changes and travel speeds can be selected.
Travel speed
selector switch
Motor capacity
(cc/rev)
52.7
33.2
Travel speed
(km/h)
3.2
5.1
Maximum
Minimum
Travel motor swash plate

angle
PC128US-2
Travel speed
selector switch
Travel accelerator pedal
Step on
Release
Blade Specification (Option)

PC128US-2 Serial No. : 5001 7730
When the travel speed selector switch or
the travel accelerator pedal is operated,
the motor capacity changes and travel
speeds can be selected.
fl The travel accelerator pedal works when
the travel speed selector switch is set to
the LOW position.
When the switch is set to the HIGH position, the travel speed does not change
even if the pedal is stepped on.
LOW
HIGH
(low speed) (high speed)
LOW
HIGH
Motor capacity
(cc/rev)
52.7
33.2
Travel speed
(km/h)
3.2
5.1
Maximum
Minimum
Motor capacity
(cc/rev)
33.2
33.2
Travel speed
(km/h)
5.1
5.1
Minimum
Minimum
Travel motor swash

plate angle
Travel motor swash

plate angle
10-143-2
(15)
Standard Specification and Blade Specification (option)

PC138US-2
Travel speed
selector switch
Motor capacity
(cc/rev)
55.8
31.5
Travel speed
(km/h)
2.9
5.1
Maximum
Minimum
Travel motor swash plate

angle
10-143-3
(15)
LOW
HIGH
PC128US-2
2. "Automatic"change of travel speed

PC128US-2
1) Automatic selection corresponding to
engine speed
If engine speed drops to 1,500 rpm or
less when travel speed selector switch
is in HIGH and travel speed is HIGH,
travel speed changes to LOW automatically.
If engine speed becomes 1,700 rpm or
is in HIGH and travel speed is LOW,
travel speed changes to HIGH automatically.
fl If travel speed selector switch is in
LOW, travel speed is not changed automatically.
2) Automatic selection corresponding to discharge pressure of pump
If travel pressure of 27.5MPa {280 kg/
cm2} or higher continues for 0.02 seconds or more when travel speed selector switch is in HIGH, travel speed
changes to LOW automatically.
cm2} or lower continues for 0.20 seconds or more when travel speed selector switch is in HIGH, travel speed
changes to HIGH automatically.
PC128US-2
10-143-4
(15)
2. "Automatic"change of travel speed

PC138US-2
1) Automatic selection corresponding to
engine speed
If engine speed drops to 1,500 rpm or
is in HIGH and travel speed is HIGH,
travel speed changes to LOW automatically.
If engine speed becomes 1,700 rpm or
is in HIGH and travel speed is LOW,
travel speed changes to HIGH automatically.
2) Automatic selection corresponding to discharge pressure of pump
cm2} or higher continues for 0.02 seconds or more when travel speed selector switch is in HIGH, travel speed
changes to LOW automatically.
cm2} or lower continues for 0.20 seconds or more when travel speed selector switch is in HIGH, travel speed
changes to HIGH automatically.
10-143-5
(15)
PC128US-2
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Safety lock lever
PPC lock switch
10.
11.
12.
13.
14.
15.
16.
Left work equipment PPC valve

Right work equipment PPC valve
Traveling PPC valve
Engine
Hydraulic pump
Operation valve
16b. Man relief valve
a. Power supply of controller
b. Power supply of solenoids
c. Solenoid valve driving signals
Function
PPC lock switch works with safety lock lever.
Setting safety lock lever to "Lock", PPC lock
switch turns to "OFF".
Turning PPC lock switch to "OFF" shuts off current to PPC lock solenoid valve, making operation lever on the work equipment disabled.
PC128US-2
10-144-1
(15)
OVERLOAD ALARM FUNCTION

(For KUK spec.)
PC128US-2 Serial No.: 5001 7730

1.
2.
3.
4.
5.
6
7.
8.
9.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
Overload alarm actuation switch
Overload alarm pressure switch
c. Power supply of monitor panel
d. S-NET signal
e. Overload alarm actuation signal
f. Overload alarm pressure signal
Function
If the pressure in the boom cylinder bottom
circuit rises above the set value, the caution
lamp lights up and the buzzer sounds to notify the operator of possibility of tipping over
of the machine by an overload.
10-144-2
(15)
PC128US-2
ENGINE CONTROL FUNCTION

PC128US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
Fuel control dial
Fuel control motor
d. S-NET signal
e. EPC valve driving signal
f. Coolant-temperature signal
PC128US-2
12.
13.
14.
15.
16.

PC-EPC valve
Governor lever
Hydraulic pump
16a. Servo valve
16b. LS valve
16c. PC valve
17. Operation valve
17a. Self-pressure reduction valve
g.
h.
i.
j.
k.
Throttle signal
Fuel control motor driving signal
Acceleration signal
Deceleration signal
10-144-3
(15)
PC138US-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
Fuel control dial
Fuel control motor
PC-EPC valve
d. S-NET signal
e. EPC valve driving signal
f. Heater drive signal
g. Coolant-temperature signal
10-144-4
(15)
13.
14.
15.
16.
17.
18.
Heater relay
Air heater
Governor lever
Engine speed sensor
Hydraulic pump
18a. Servo valve
18b. LS valve
18c. PC valve
19. Operation valve
19a. Self-pressure reduction valve
h.
i.
j.
k.
l.
m.
n.
Engine speed signal

Throttle signal
Acceleration signal
Deceleration signal
Starting switch C signal
Preheating pilot signal
PC128US-2
1. Automatic engine warming-up function

Raises engine speed automatically to
warm up engine if coolant temperature
was low after start-up of engine.
PC128US-2
Operational conditions (both required)
Coolant temperature: Less than 30C

Engine speed: 1,200 rpm or less
Operation
Release conditions (either one required)
Release
Coolant temperature: 30C or higher
Automatic
Duration of automatic warming-up: 10 minutes or more
Manual
Fuel control dial: Holded in 70% or more of full for 3 seconds or more
Engine speed: Any
PC138US-2
Operational conditions (both required)

Operation
Release conditions (either one required)
Release
Coolant temperature: 30C or higher
Automatic
Duration of automatic warming-up: 10 minutes or more
Manual
Fuel control dial: Holded in 70% or more of full for 3 seconds or more
Engine speed: Any
2. Overheat prevention function

Prevents overheat to protect engine by reducing load on pump if coolant temperature rised too much.
Operational conditions
Coolant temperature:
105C or higher
102C or higher
100C or higher
PC128US-2
Operation and actions taken

Operational mode: All modes
Engine speed: Low idling
Engine coolant monitor : Turns ON
Alarm buzzer: Sounds
Release conditions
Fuel control dial: To be returned to the
low idling position

The original conditions are restored
if two requirements above were obtained (manual restoration).

Operational mode: A mode, E mode
Engine speed: To be held as it is
Engine coolant monitor: Turns ON
Delivery of pump: To be reduced

Operational mode: A mode
Engine speed: To be held as it is
Engine coolant monitor: Turns ON
Delivery of pump: To be reduced
Release conditions

if the requirement above was obtained (automatic restoration).
Release conditions

if the requirement above was obtained (automatic restoration).
10-144-5
(15)
3. Turbocharger protection function

PC138US-2
When the engine is started at low temperature, if the engine speed is increased
sharply, the turbocharger may be seized.
This trouble is prevented by controlling
the engine speed properly.
A: Start of engine
B: Turbocharger protection time (Approx. 1.1
sec)
C: Modulation time (Approx. 1.5 sec)
D: 1,200 rpm
E: 1,300 rpm
F: 2,400 rpm
Operating condition
Coolant temperature: Max. 30C
Engine speed: Min. 1,300 rpm
Operation
Protection of turbocharger
(See above figure)
4. Function of preventing production of white

smoke when engine is started at low voltage
high current tester
PC138US-2
When the engine is started at low temperature, the intake air is warmed automatically to improve the combustion efficiency and prevent production of white
smoke caused by incomplete combustion.
Operating condition
Coolant temperature: Max. 30C
Engine speed: Min. 1,000 rpm
10-144-6
(15)
Operation
Air heater: Preheating time is

selectable
(Select preheating time in service adjustment mode: 0/30/60/
100 sec)
PC128US-2
SELF DIAGNOSIS FUNCTION

PC128US-2
PC138US-2
1. Error code display/Alarm functions
Controller always watches electronic devices which constitutes the system, including controller itself, each potentiometer which issues input signals, each solenoid valve which receives output signals, and EPC valves, to check for they normal operation.
If problem occurred in any of these devices, the controller diagnoses it and display the results on display (1) of monitor
panel as a "USER CODE" or "Service
code", sounding alarm buzzer at the same
time to notify the problem to operator.
fl Refer to the "TROUBLESHOOTING" section as for the details of display and measures to be taken.
2. Error code memory function
Controller takes in memory the error code
diagnosed about problem which occurred
in advanced system.
fl Refer to the "TESTING AND ADJUSTING"
section as for the details of display and
how to reset.
PC128US-2
10-144-7
(18)
SYSTEM COMPONENTS
ENGINE SPEED SENSOR
Function
PC128US-2 Serial No.: 5001 7730
The engine speed sensor is installed on the
ring gear of the engine flywheel. It electrically counts number of gear teeth that pass
its front side and sends the counting to the
pump controller.
1.
2.
3.
4.
5.
Wire
Magnet
Terminal
Housing
Connector
PC128US-2
PC138US-2
The engine speed sensor is installed on the
ring gear of the engine flywheel. It electrically counts number of gear teeth that pass
its front side and sends the counting to the
controller.
Remarks : Number of ring gear teeth is 127.
For the count, a magnet is used which generates current every time a gear tooth passes
its front side.
PC128US-2
10-145
(15)
PPC HYDRAULIC SWITCH
Specification
Contact structre : Normally opened
Operating (ON) pressure :
490 98.1 kPa {5.0 1.0 kg/cm2}
Resetting (OFF) pressure :
294 49.0 kPa {3.0 0.5 kg/cm2}
1. Plug
2. Switch
3. Connector
Function
PC128US-2 Serial No.: 5001 7730
3 switches installed to control valve sense
operating condetion of each actuator, and
send it to swing holding brake controller.
1 switch installed to travel PPC valve sense
travel operating condition, and operates 2stage relief solenoid valve.
PC128US-2
PC138US-2
8 switches installed to control valve sense
operating condition of each actuator, and send
it to controller.
1 switch installed to travel PPC valve sense
travel operating condition, and send it to controller.
10-146
(18)
PC128US-2
OVERLOAD ALARM PRESSURE SWITCH

(For KUK spec.)
PC128US-2 Serial No.: 5001 7730
Specifications
Composition of contacts: Normally open contacts
Operating (ON) pressure:
14.7 0.98 MPa {150 10 kg/cm2}
Function
One pressure switch is installed to the boom
cylinder bottom circuit to sense the hydraulic
pressure on the boom cylinder bottom side.
PC128US-2
10-146-1
A

1. Plug
2. Sensor
3. Connector
Function
One pressure switch is installed to the boom
cylinder bottom circuit to sense the hydraulic
pressure on the boom cylinder bottom side.
10-146-2
(15)
PC128US-2
CONTROLLER
PC128US-2
Model selection table

PC128US-2
CN-CR2, 37P CN-CR2, 27P CN-CR2, 7P CN-CR2, 16P
c
c
Attachment selection table

Standard arm
Long arm
Standard arm,
X-counterweight
long arm,
X-counterweight
Slide arm
Multi changer arm
CN-CR1, 17P CN-CR1, 11P CN-CR2, 17P

c
c : GND
: OPEN
10-147-3
(15)
PC128US-2
PC138US-2
10-147-5
(15)
PC128US-2
DEUTSCH-24P [CN-CR1]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Signal name
Fuel control motor feedback potentiometer
Boom cylinder bottom pressure sensor
Boom angle
GND (signal)
Air conditioner compressor signal
PPC hydraulic pressure switch for Arm IN
Fuel control dial
Swing boom angle sensor
NC
GND (signal)
Preheating signal
PPC hydraulic pressure switch for Arm out
Pump pressure sensor
I/O signal
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Pin No.
14
15
16
17
18
Signal name
I/O signal
Off-set angle (For PC128UU)
Input
NC
NC
C-terminal signal
Input
PPC hydraulic pressure switch for boom
Input
LOWER
19
20
21
22
23
24
NC
Arm angle (For arm crame)
GND (analog)
Power supply for sensor (+5V)
ACC terminal signal
PPC hydraulic switch for boom RAISE
I/O signal
Pin No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Signal name
S-NET
CAN0-L
CAN1-L
Flash memory write permission signal
Exterior parts interference prevention reset switch
Reset 2
Alarm switch
NC
GND (pulse)
NC
GND (S-NET)
CAN0-H
CAN1-H
GND (232C)
NC
Reset 1
NC
Clear
GND (pulse)
Engine speed sensor (+)
Pin No.
Signal name
Power supply of solenoids
GND (common to all solenoids)
Key signal (ACC)
Boom-RAISE EPC valve
Input
Output
Input
Input
DEUTSCH-40P (1) [CN-CR2]

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
NC
Set
Mode selection 2
232C_RxD
NC
NC
Swing lock switch
Electric system
Data
NC
NC
CAN shield
Mode selection 1
232C_TxD
NC
Working lamp switch
Strobe
Clock
NC
Input
Input
Input
Input
Output
Output
Input
Output
Input
Input
Output
Output
I/O signal
Input/Output
Input/Output
Input/Output
Input
Input
Input
Input
Input/Output
Input/Output
Input
Input
Input
DEUTSCH-40P (2) [CN-CR3]

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Signal name
Power supply of controller
Engine stop solenoid relay drive signal
Arm IN EPC valve
LS-EPC valve
Swing/Travel alarm buzzer
Service PPC oil pressure switch
Bucket pull-in oil pressure switch
Power supply of controller
Key signal (ACC)
Left off set stop EPC valve (For PC128UU)
PC-EPC valve
Right offset stop solenoid valve
Heater relay start signal
Left offset PPC oil pressure switch
Bucket push-out oil pressure switch
GND (controller)
PC128US-2
I/O signal
Input
Input
Output
Output
Output
Output
Output
Input
Input
Input
Input
Input
Output
Output
Output
Output
Input
Input
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
I/O signal
Input
Input
Output
Output
Output
Solenoid valve for travel speed selection
Output
Input
Right offset PPC oil pressure switch
Input
Swing PPC oil pressure switch (Right and left)
GND (controller)
GND (controller)
GND (controller)
NC
Output
Output
Boom-LOWER EPC valve
Output
Arm crane relay
Output
NC
Input
(Right, left, front, and rear)
10-147-6
(15)
PUMP PRESSURE SENSOR

PC128US-2 Serial No.: 6301 7730
1. Sensor
2. Connector
Function
Mounted on the inlet circuit of control valve,
this sensor changes discharging pressure of
pump into voltage, and send it to automatic
travel speed change controller.
PC128US-2
PC138US-2
1. Plug
2. Sensor
3. Connector
Function
Mounted on the inlet circuit of control valve,
this sensor changes discharging pressure of
pump into voltage, and send it to automatic
travel speed change controller.
10-147-7
(15)
PC128US-2
Monitor panel
fl Refer to the section describing the Monitor
System.
PC valve
LS valve
PC-EPC valve
fl Refer to the section describing the Hydraulic Pump (Piston pump).
LS-EPC valve
PC128US-2
PC138US-2
fl Refer to the section describing the Hydraulic Pump (Piston pump).

2nd speed select solenoid valve
Swing hold brake solenoid valve
fl Refer to the section describing the Solenoid
Valve.
10-148
(15)
PC128US-2
MONITOR SYSTEM
PC128US-2
PC138US-2
1.
2.
3.
4.
5.
Monitor panel
Battery
Controller
Sensors and switches
Wiper motor, window washer motor
Description
The monitor system monitors conditions of
the machine with sensors mounted on its each
section, processes promptly the information
obtained, and displays it on panel to let operator know the conditions of the machine.
a. Power supply
b. Switch signal
c. Caution signal
d. Sensor/switch signal
e. Sensor/switch signal
f. Output for driving
10-149-1
(15)
PC128US-2
MONITOR SYSTEM
MONITOR PANEL
PC128US-2 Serial No.: 5001 7730
Outline
Monitor panel has monitoring function, gauge
display function, service meter function and
switching function.
CPU (Central Processing Unit) is installed in
it.
It has LCD display in gauge display position.

It has lamps in monitor display position.
Input and output signals

AMP040-16P [CN-P01]
Pin No.
Signal name
1
Power source (24V)
2
Power source (24V)
3
GND
4
GND
5
Starting signal
6
Coolant temperature
7
Fuel level
8
KES-4P(1) [CX-P02]
Pin No.
Signal name
1
2
Work light
3
Lighting
4
Power source (24V)
10-150
(18)
I/O signal
Input
Input
Input
Pin No.
9
10
11
12
13
14
15
16
Signal name
Engine oil pressure
Battery charging level
Spare caution
Swing lock
Preheating
Alarm buzzer
Lighting
I/O signal
Input
Input
Input
Input
Output
Input
I/O signal
Output
Output
KES-3P [CN-C12]
Pin No.
Signal name
1
2
Car heater Hi
3
Car heater Lo
4
Car heater Hi
I/O signal
Output
Output
PC128US-2
MONITOR SYSTEM
PC128US-2
PC138US-2
Outline
The monitor panel has the functions to display a monitor, gauge, service meter and electric system. It has also an alarm buzzer built
in.
A CPU (Central Processing Unit) mounted inside processes, displays and outputs information.
The monitor's switch section consists of three
AMP070-12P [CN-P01]
Pin No.
Signal name
1
Starting switch (battery)
2
Starting switch (battery)
3
Window washer motor output
4
Starting switch (C-terminal)
5
Wiper W-contact
6
GND
7
GND
8
VB + (24V)
9
Wiper motor (+)
10
Wiper motor ()
11
Alarm buzzer ON signal
12
Wiper P-contact
10-151-1
(15)
I/O signal
Input
Input
Output
Input
Input
Input
Output
Output
Input
Input
flat type sheet switches. Pressing any of

these switches changes the conditions of
the machine, which are shown by LEDs located above the switches turned ON.
The monitor does not give correct display if
any of the monitor panel unit, controller, or
the wiring between monitor-panel and controller is in abnormal condition.
AMP040-20P [CN-P02]
Pin No.
Signal name
1
Engine coolant temperature
2
Fuel level
3
Radiator coolant level
4
NC
5
Air cleaner clogging
6
NC
7
Engine oil pressure
8
Engine oil level
9
S-NET signal
10
S-NET signal
11
Battery charge level
12
NC
13
GND (analog signal)
14
NC
15
Pull-up window limit switch
16
Alarm buzzer cancel
17
Swing lock
18
Preheating
19
Lamp switch
20
GND (S-NET)
I/O signal
Input
Input
Input
Input
Input
Input
Input
Input
Input/Output
Input/Output
Input
Input
Input
Input
Input
Input
PC128US-2
MONITOR SYSTEM
METER DISPLAY
Display
No. category
1
[*1]
2
Display
Caution
4a
Gauge
Caution
Pilot
[*2]
7
Coolant
temperature
Display Remarks
color
Time counting while engine is in operation

(alternator is generating) (Always lit even if
starting switch is OFF)
Count time during engine operates.

Alphanumerics in Displays 2 digit alphanumerics (user code or
service code) if electric control system is in
2 digits
abnormal condition.
3b
See picture above All the segments of the corresponding level

and lower are turned ON.
Specified tempera- (Level 8 (102C or higher):Monitor lamp
blinks. Level 9: Monitor lamp blinks and
ture (102C) or
alarm buzzer sounds.)
higher
Blue
LCD
Red
LED
Blue
LCD
Red
LED
Fuel level
See picture above All the segments of the corresponding level

and lower are turned on. (Level 1 (42 or
Specified level
less): Monitor lamp blinks.)
(42 ) or lower
Preheating
Turned on for about 30 seconds after starting switch was turned to "HEAT". It blinks
During preheating (for about 10 seconds) after preheating was
over to notify it to operator, and then it is
turned off.
Swing lock
When swing-lock
is in operation
Turned on when the swing lock function is

active.
Blinks when swing holding brake release Green
switch was turn on.
Oil
maintenance
When specified
oil-maintenance
periods elapsed
Turned ON when specified oil maintenance

periods (125h, 250, and 500h) elapsed.
(Also, elapsed time and telephone No. of
your dealer are shown on service meter.)
Not turned on if no oil maintenance period has been specified.
Lamp
Battery charge Charge in fault

(charge voltage <
level
battery voltage)
Display method
0 99999.9 h
Gauge
Display area
Service meter
3a
4b
Display item
Caution
[*3]
10
Engine oil
pressure
Overload
Turned ON when starting switch was turned

on; turned off after engine started running.
In normal condition : turned OFF
Lower than the
specified pressure In abnormal condition : turned ON
49 kPa {0.5 kg/cm2} (As for engine oil pressure only, alarm buzzer
sounds if the pressure became abnormal
Lower than the
when engine was running.)
specified pressure
14.7 MPa {150 kg/ cm2}
Red
[*1] As for display and operation, refer to the "Self Diagnosis Function" section.
[*2] As for display and operation, refer to the "TROUBLESHOOTING" chapter.
[*3] For PC128US-2 & PC138US-2 KUK specification only.
PC128US-2
10-151-2
(15)
MONITOR SYSTEM
MONITOR SWITCH
No.
Function
Operation
Travel speed selector

switch
Used to select a travel speed from two of them.

"Lo" is lit : Travel in low speed.
"Hi" is lit : Travel in high speed.
<The speed is locked at Lo when arm crane is
used.>
Lo Hi
Auto-deceleration switch
Activates the function to reduce fuel consumption.

Turned ON : The function is active.
Turned OFF : The function is not active.
<The function is made inactive when arm crane
is used.>
ON OFF
(Lit)
Wiper switch
Activates wiper of front glass.

"ON" is lit : Wiper works continuously.
"INT" is lit: Wiper works intermittently.
Not lit
: Wiper is not working.
OFF INT
ON
(Not lit) (Intermittent) (Continuous)
Sprays washer fluid onto front glass.
[When wiper is not working]

ON : Washer fluid is sprayed
and wiper works continuously.
OFF : Wiper works twice and
stops after the switch was
released.
[When wiper is working intermittently]
ON : Washer fluid is sprayed
and wiper works continuously.
OFF : Wiper works twice and returns to intermittent operation after the switch
was released.
Name
Wind washer switch
* Operation mode selector

5
switch
Sets the movement and force of the working

equipment.
"A" is lit : A mode (for heavy duty work)
"E" is lit : E mode (for fuel economical operation)
"B" is lit : B mode (for breaker work)
<All "A, E, and B" are off when arm crane is used.>
A E B
* You can change the default settings which become active when starting switch is turned on. Refer to the "TROUBLE-
SHOOTING" chapter.
fl Signs written in bold fonts in the "Operation" column above represent the positions switches default to when
starting switched is turned on.
10-151-3
A
PC128US-2
MONITOR
SYSTEM
SENSORS
l
Signal from a sensor is directly entered to the

panel.
There are two types of sensors, contact type
and resistance type.
One end of a contacttype
sensor is connected
to the ground on the machine body.
Display class
Sensor type
Sensing__approach
When normal
When failed
Caution
Engine oil pressure
Contact
OFF (open)
ON (closed)
Resistance
Resistance
Coolant
temperature
Gauge
Fuel level
ENGINE OIL PRESSURE SENSOR
69 @
Structure
of
circuit
SBD01537
1.
2.
Plug
Contact
ring
3.
4.
5.
6.
Contact
Diaphragm
Spring
Terminal
COOLANT TEMPERATURE SENSOR
@=I3
Structure
7.
2.
3.
of
circuit
SBDOl538
Connector
Plug
Thermistor
10-152
PC1 28US-2
STRUCTURE
AND FUNCTION
FUEL LEVEL SENSOR
F
Structure
fL
EMPTY
E
Y
of
circuit
1.
2.
3.
4.
SEP02590
Float
Connector
Cover
Variable resistor
PC128US-2
10-153
20
STANDADRD
VALUE TABLE
Standard
value table for engine
Standard
value table for chassis . . . . . . .. . .. . .. . . . . . . 20-3
Standard
value table for electrical
TESTING
AND ADJUSTING
TROUBLESHOOTING
*
1.
2.
3.
A
A
A
. . . . .. . . . .. . . . . . . . . . 20-2
parts .._.. 20-12
. . . .. . .. . . . . .. .. . . . .. .. . . . 20-101
. . .. . . . .. . .. . .. . .. . . . . . .. . . . .. .. . . . . . 20-201
Note the following.when

making judgments using the standard value tables for testing, adjusting, or
troubleshooting.
The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of
wear after the machine has been operated,
and as a reference value when carrying out repairs.
The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting,
park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC1 28U.S2
20-l
0
STANDARD VALUE TABLE FOR ENGINE

PC128US-2
Applicable model
PC128US-2, 138USLC-2
Engine
S4D102E-1
Item
Engine speed
Measurement conditions
Unit
Standard value
for new machine
Service limit value
High idling
rpm
2,400 60
Low idling
rpm
925 + 050
Rated speed
rpm
2,200
Bosch
index
Max. 5.5
7.5
Max. 1.0
2.0
0.25
0.51
Max. 490 {50}
980 {100}
343 588 {3.5 6.0}
245 {2.5}
Min. 9.8 {1.0}
69 {0.7}
Min. 78 {0.8}
69 {0.7}
80 110
120
At sudden acceleration
Exhaust gas color
At high idling
Valve clearance
(normal temperature)
Blow-by pressure
(SAE 30 oil)
Oil pressure
(SAE 30 oil)
Intake valve
mm
Exhaust valve
(Water temperature:
Pa
Operating range)
{mm H2O}
At high idling
(Water temperature:
Operating range)
At high idling
At low idling (SAE30)
KPa
{kg/cm2}
At low idling (SAE10W)
Oil temperature
Whole speed range

(inside oil pan)
Fuel injection timing
Before top dead center
deg
14 1
Fan belt tension

(alternator)
Deflection when pressed

with finger force of
approx. 58.8 N {6 kg.}
mm
9.5 12.7
20-2
(17)
PC128US-2
PC138US-2
Applicable model
PC138US-2, 138USLC-2
Engine
SAA4D95LE-3-A
Item
Engine speed
Unit
Standard value
for new machine
Service limit value
High idling
rpm
2,400 60
Low idling
rpm
1,100 50
Rated speed
rpm
2,200
Bosch
index
Max. 4.5
5.5
Max. 1.0
2.0
0.35
0.50
Max. 490 {50}
980 {100}
343 588 {3.5 6.0}
245 {2.5}
Min. 294 {3.0}
196 {2.0}
Min. 245 {2.5}
147 {1.5}
80 115
120
At sudden acceleration
Exhaust gas color
At high idling
Valve clearance
(normal temperature)
Blow-by pressure
(SAE 30 oil)
Oil pressure
(SAE 30 oil)
Intake valve
mm
Exhaust valve
(Water temperature:
Pa
Operating range)
{mm H2O}
At high idling
(Water temperature:
Operating range)
At high idling
At low idling (SAE30)
KPa
{kg/cm2}
At low idling (SAE10W)
Oil temperature
Whole speed range

(inside oil pan)
Fuel injection timing
Before top dead center
deg
6 0.75
Fan belt tension

(alternator)
Deflection when pressed

with finger force of
approx. 58.8 N {6 kg.}
mm
6 10
PC128US-2
20-2-1
(17)
STANDARD VALUE TABLE FOR CHASSIS
Applicable model
Operating effort of
control lever
Category
PC128US-2
Item
Engine at full throttle

Oil temperature: 45 55 C
Fit push-pull scale to center of
control lever knob to measure
Fit push-pull scale to tip of control
Travel control lever
pedal to measure
Measure max. value to end of
travel
Unit
Serial No.
5001 7730
Blade control lever
7731 and up
N
{kg}
5001 7730
7731 and up
5001 7730
7731 and up
74.5 18.6
{7.6 1.9}
Max.107.6
{Max.11}
31.87 0.49
{325 5}
31.87 0.98
20
{325 + 10
}
31.87 0.49
{325 5}
31.87 0.98
20
{325 + 10
}
31.87 0.49
{325 5}
31.87 0.98
20
{325 + 10
}
5001 7730
31.38 0.98
{320 10}
31.38 2.45
15
{320 + 25
}
7731 and up
27.46 0.98
{280 10}
27.46 2.45
15
{280 + 25
}
Travel pedal
Boom
Arm
Hydraulic oil temperature: 45 55 C

Pump discharge pressure
Relieve only circuit to be measured
Standard value Service limit

for new
value
machine
Max.24.5
Max.31.4
{Max.2.5}
{Max.3.2}
25.50 6.86
Max.32.36
{2.6 0.7}
{Max.3.3}
Max.27.5
Max.36.3
{Max.2.8}
{Max.3.7}
24.52 5.88
Max.39.23
{2.5 0.6}
{Max.4.0}
5001 and up
Bucket
Swing
+ 1.96
31.87 0
{325 + 20
0 }
Hydraulic pressure
Blade RAISE
20-4
(14)
+ 1.47
+ 1.96
31.87 0.98
20
{325 + 10
}
34.81 1.96
{355 20}
3.24 0.20
{33 2}
3.24 0.49
{33 5}
3.43 0.98
{35 10}
3.43 0.98
{35 10}
At pump relief
(normal actuation)
15.98 1.47
{163 15}
15.98 2.45
{163 25}
All levers at
HOLD
2.75 0.98
{28 10}
{}
Travel rotating
under no load
Travel lever at
half-way position
2.21 0.1
{22.5 1}
{}
Control
LS differential
pressure
+ 1.47
34.81 0.98
{355 10}
Target
value
(Range)
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
flLS differential
pressure =
pump outlet
port pressure
LS pressure
+ 1.96
32.36 2.45
{330 25}
MPa
{kg/cm}
Travel
Servo piston
input pressure
+ 1.96
32.36 1.47
{330 15}
Blade LOWER
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
+ 1.96
Control levers at
HOLD
7731 and up
PC128US-2
Applicable model
Category
Item
PC128US-2
Unit
Serial No.

for new
value
machine
fl See Fig. A
Overrun when
stopping swing

Hydraulic oil temperature: 45 55C
Stop after swinging one turn and
measure distance that swing circle Deg. 5001 and up
(mm)
moves
Figure in ( ) shows movement at
outside of swing circle
Max. 60
(Max. 580)
Max. 70
(Max. 676)
5001 6462
2.8 0.3
(3.4 0.3)
Max. 3.5
(Max. 4.0)
6463 and up
3.2 0.3
(3.9 0.3)
Max. 4.0
(Max. 4.6)
5001 6462
3.3 0.4
(4.8 0.5)
Max. 5.2
(Max. 6.3)
6463 and up
3.8 0.4
(5.5 0.5)
Max. 5.9
(Max. 7.2)
5001 6462
25 2
25 4
6463 and up
28.6 2
28.6 4
0
(0)
0
(0)
Max. 3
Max. 6
fl See Fig. A
Time taken to start

swing

Hydraulic oil temperature
: 45 55C 90
Time taken to swing 90 and
180 from starting position
Figure in ( ) shows time when
bucket is at rated load
Sec.
Swing
180
fl See Fig. A
Time taken to swing Swing one turn, and measure time
taken to swing next 5 turns
Sec.
fl See Fig. B
Hydraulic drift of
swing
Engine stopped
Bucket at rated load (450 kg) or full
of soil.
Set machine on 15 slope, and set
upper structure at an uphill angle of
45.
Deg.
Make match marks on swing circle (mm) 5001 and up
outer race and track frame.
Measure distance that match marks
move apart after 15 minutes.
Figure in ( ) shows at rated load.

Leakage from swing Relieve swing circuit.
/min 5001 and up
motor
PC128US-2
20-5
(14)
Applicable model
Category
Total work
fl See Fig. G
equipment
(hydraulic drift Place in above posture and measure
at tip of bucket
extension or retraction of each cylteeth)
inder and downward movement at
tip of bucket teeth.
Boom cylinder
Horizontal, flat ground
(amount of
Bucket: Rated load (450 kg)
retraction of
Levers at HOLD
cylinder)
Engine stopped
Arm cylinder
Start measuring immediately after
(amount of
setting.
extension of
Measure hydraulic drift every 5 mincylinder)
utes, and judge from results for 15
minutes.
Bucket cylinder
(amount of
retraction of
cylinder)
Blade
(hydraulic drift
at tip of blade)
mm
Serial No.
5001 and up
Engine stopped
Set blade at maximum lifting height
and measure downward movement
at edge of blade for 15 minutes.
Cylinder fully
extended
Fully extended
fl See Fig. K
Blade
Blade in contact Engine at full throttle
with ground
: 45 55C
Blade fully
raised
PC128US-2
Max. 75
Max. 40
Max. 60
Max. 31
Max. 47
3.8 0.3
Max. 4.4
IN
3.1 0.3
Max. 4.2
3.2 0.3
Max. 4.0
3.1 0.3
Max. 3.7
5001 and up
CURL
Fully extended
Max. 50
2.9 0.3
Max. 3.7
DUMP

: 45 55C
Max. 23
2.3 0.2
Max. 2.9
RAISE
Bucket
Cylinder fully
retracted
Max. 15
(Until touching (Until touching

cushion)
cushion)
Sec
fl See Fig. J
Max. 700

cushion)
cushion)
OUT

: 45 55C
Max. 500
1.3 0.3
Max. 2.5
LOWER
Work equipment speed
fl See Fig. I
Arm
Cylinder fully
retracted

for new
value
machine

cushion)
cushion)
LOWER
Boom
fl See Fig. H
Bucket teeth in
contact with
ground
: 45 55C
Work equipment
Unit
RAISE
Hydraulic drift of work equipment
Item
PC128US-2
1.3 0.3
Max. 2.5
20-7
(18)

Applicable model
Engine speed
Category
Unit
Standard value
for new machine
Service limit value
rpm
Min. 2,100
Min. 2,000
N RAISE, LOWER
85 10
Min.75 Max.95
N IN, OUT
85 10
Min.75 Max.95
Bucket control lever
N CURL, DUMP
85 10
Min.75 Max.95
Swing control lever
N LEFT, RIGHT
85 10
Min.75 Max.95
Item
At 1-pump relief
Boom control lever
Arm control lever
Travel of control levers
PC138USLC-2
Hydraulic oil temperature : 45 55 C
Engine oil pressure :
Within operating range
Engine coolant temperature :
1 pump relief: Bucket relief
Center of lever
knob
Tip of pedal
Read max. value
to end of travel
Engine stopped
mm
Blade control lever
N RAISE, LOWER
53 6
Min.47 Max.59
N FORWARD,
REVERSE
(LEFT, RIGHT)
115 12
Min.103 Max.127
Work equipment,
swing
35
58
10 3
10 5
15.7 3.9
{1.6 0.4}
Max.24.5
{Max.2.5}
15.7 3.9
{1.6 0.4}
Max.24.5
{Max.2.5}
12.7 2.9
{1.3 0.3}
Max.21.6
{Max.2.2}
12.7 2.9
{1.3 0.3}
Max.21.6
{Max.2.2}
Blade control lever
25.50 6.86
{2.6 0.7}
Max.32.32
{Max.3.3}
24.52 5.88
{2.5 0.6}
Max.39.23
{Max.4.0}
Travel pedal
74.5 18.6
{7.6 1.9}
Max.107.6
{Max.11}
Play of control lever
Operating effort of control lever
Travel
Boom control lever Engine at full throttle
Arm control lever
pedal to measure
Bucket control lever Measure max. value to end of
travel
Swing control lever
PC128US-2
N
{kg}
20-8-1
(17)
Applicable model
Category
PC138USLC-2
Item
Unit

Standard value
for new machine
+ 1.96
31.87 0.49
{325 5}
31.87 0.98
20
{325 + 10
}
Arm
31.87 0.49
{325 5}
31.87 0.98
20
{325 + 10
}
Bucket
31.87 0.49
{325 5}
31.87 0.98
+ 20
{325 10 }
Swing
27.46 0.98
{280 10}
27.46 2.45
15
{280 + 25
}
Blade RAISE
31.87 0
+ 20
{325 0 }
Boom
+ 1.96
Hydraulic pressure
Service limit value
34.81 1.96
{355 20}
3.24 0.20
{33 2}
3.24 0.49
{33 5}
Control levers at
HOLD
3.43 0.98
{35 10}
3.43 0.98
{35 10}
At pump relief
(normal actuation)
15.98 1.47
{163 15}
15.98 2.45
{163 25}
All levers at
HOLD
2.75 0.98
{28 10}
{}
Travel rotating
under no load
Travel lever at
half-way position
2.21 0.1
{22.5 1}
{}
Max. 65
(Max. 610)
Max. 75
(Max. 720)
Control
LS differential
pressure
+ 1.96
31.87 0.98
20
{325 + 10
}
34.81 0.98
{355 10}
Target
value
(Range)
Travel
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
flLS differential
pressure =
pump outlet
port pressure
LS pressure
+ 1.47
32.36 2.45
{330 25}
MPa
{kg/cm2}
Servo piston
input pressure
+ 1.96
32.36 1.47
{330 15}
Blade LOWER
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
+ 1.96
Swing
fl See Fig. A
Overrun when
stopping swing
20-8-2
(17)

measure distance that swing circle
moves
Deg.
(mm)
PC128US-2
Applicable model
Category
Item
PC138USLC-2
Standard value
for new machine
Service limit value
2.9 0.3
(3.6 0.3)
Max. 3.6
(Max. 4.2)
4.0 0.4
(5.0 0.5)
Max. 6.0
(Max. 6.5)
25 2
25 4
0
(0)
0
(0)
Max. 3
Max. 6
Max. 41.6
50.6
Hi
Max. 26.5
32.6
Lo
Max. 25.3
Max. 30.6
Max. 15.2
Max. 18.3
Unit
fl See Fig. A
Time taken to
start swing
90
: 45 55C
Sec.
180
fl See Fig. A
Swing

Time taken to swing Hydraulic oil temperature: 45 55C Sec.
Swing one turn, and measure time
fl See Fig. B
Hydraulic drift of
swing
Engine stopped
of soil.
upper structure at an uphill angle of Deg.
(mm)
45.
Make match marks on swing circle

/min
motor
fl See Fig. C
Travel
Travel speed (1)

: 45 55C
Raise track on one side at a
time, rotate one turn, then measure time taken for next 5 turns
with no load.
Lo
Sec.
fl See Fig. D
Travel speed (2)
PC128US-2

: 45 55C
Run up for at least 10 m, and
measure time taken to travel
next 20 m on flat ground.
Sec.
Hi
20-8-3
(19)
Applicable model
Category
Item
PC138USLC-2
Unit
Standard value
for new machine
Service limit value
Max. 200
220
Max. 1.1
Max. 1.65
Max. 500
Max. 700
Max. 15
Max. 23
Max. 50
Max. 75
Max. 40
Max. 60
Max. 31
Max. 47
fl See Fig. D
fl See Fig. E
Travel deviation

Run up for at least 10 m, and measure deviation when traveling next
20 m on flat ground.
fl Use a hard horizontal surface.
mm
Travel
fl See Fig. F
Hydraulic drift of
travel
Leakage from travel

motor
Work equipment
Total work
equipment
(hydraulic drift
at tip of bucket
teeth)
Boom cylinder
(amount of
retraction of
cylinder)
Arm cylinder
(amount of
extension of
cylinder)
(19)

Lock shoes and relieve travel circuit. /min
fl See Fig. G
Place in above posture and measure
extension or retraction of each cylinder and downward movement at
Levers at HOLD
Engine stopped
setting.
Measure hydraulic drift every 5 minutes, and judge from results for 15
minutes.
mm
Bucket cylinder
(amount of
retraction of
cylinder)
Blade
(hydraulic drift
at tip of blade)
20-8-4
Engine stopped
Stop machine on 12 slope with
sprocket facing straight up the
slope.
Measure the distance the machine
moves in 5 minutes.
Engine stopped
PC128US-2
Applicable model
Boom
Bucket teeth in
contact with
ground
fl See Fig. H
: 45 55C
Unit
Cylinder fully
extended
(Until touching
cushion)
3.1 0.3
fl See Fig. I
IN
3.2 0.3
(Until touching
cushion)
3.1 0.3
OUT

: 45 55C
Fully extended
(Until touching
cushion)
Service limit value
Max. 4.4
(Until touching
cushion)
Max. 4.2
Max. 4.0
(Until touching
cushion)
Max. 3.7
(Until touching
cushion)
Sec.
CURL
3.2 0.3
Fully extended
DUMP
2.6 0.2
fl See Fig. K
Blade
Blade in contact Hydraulic oil temperature
with ground
: 45 55C
RAISE
fl See Fig. J
1.3 0.3
Blade fully
raised
LOWER
Work equipment
Arm
Cylinder fully
retracted
Standard value
for new machine
3.8 0.3
RAISE
Item
LOWER
Category
PC138USLC-2
1.3 0.3
Bucket
Cylinder fully
retracted

: 45 55C
Max. 4.0
Max. 3.2
Max. 2.5
Max. 2.5
Max. 3
Max. 3
Time lag
fl See Fig. L
Boom
PC128US-2
Engine at low idling

: 45 55C
Fully retract arm and bucket
cylinders, then lower boom from
maximum height and measure
time taken from point where
bucket contacts ground to point
where chassis rises from ground
Sec.
20-8-5
(18)
Applicable model
Category
PC138USLC-2
Standard value
for new machine
Service limit value
Max. 2
Max. 2
Max. 2
Max. 2
Blade

: 45 55C
Lower blade from maximum
height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.
Max. 2
Max. 2
Eachcylinder

: 45 55 C
Engine full
Circuit to be measured is relieved.
Max. 3.5
Max. 15
Max. 10
Max. 50
Item
Unit
fl See Fig. M
Arm

: 45 55C
Set top surface of boom horizontal, retract bucket cylinder fully,
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.
Bucket
Work equipment
Time lag
fl See Fig. N
: 45 55C
Set top surface of boom horizontal, retract arm cylinder fully, then
extend bucket cylinder and
measure time taken for bucket to
at bottom.
Sec
Internal leakage level
fl See Fig. O
cc/
min
Center swivel
joint
20-8-6
(17)
PC128US-2
PC138US-2
Applicable model
Engine speed
Category
Unit
Standard value
for new machine
Service limit value
rpm
Min. 2,100
Min. 2,000
N RAISE, LOWER
100 11
100 21
N IN, OUT
100 11
100 21
Bucket control lever
N CURL, DUMP
100 11
100 21
Swing control lever
N LEFT, RIGHT
100 11
100 21
Item
At 1-pump relief
Boom control lever
Arm control lever
Travel of control levers
PC138USLC-2
Engine oil pressure :
Engine coolant temperature :
1 pump relief: Bucket relief
Center of lever
knob
Tip of pedal
Read max. value
to end of travel
Engine stopped
mm
Blade control lever
N RAISE, LOWER
53 6
Min.47 Max.59
N FORWARD,
REVERSE
(LEFT, RIGHT)
115 12
Min.103 Max.127
Work equipment,
swing
35
58
10 3
10 5
16.67 3.92
{1.7 0.4}
Max.25.5
{Max.2.6}
16.67 3.92
{1.7 0.4}
Max.25.5
{Max.2.6}
13.73 2.94
{1.4 0.3}
Max.22.56
{Max.2.3}
13.73 2.94
{1.4 0.3}
Max.22.56
{Max.2.3}
Blade control lever
25.51 6.86
{2.6 0.7}
Max.32.36
{Max.3.3}
24.52 5.88
{2.5 0.6}
Max.39.23
{Max.4.0}
Travel pedal
74.5 18.6
{7.6 1.9}
Max.107.6
{Max.11}
Play of control lever
Operating effort of control lever
Travel
Boom control lever Engine at full throttle
Arm control lever
pedal to measure
Bucket control lever Measure max. value to end of
travel
Swing control lever
PC128US-2
N
{kg}
20-8-7
(17)
Applicable model
Category
Item
PC138USLC-2
Unit

Standard value
for new machine
+ 1.96
31.87 0.49
{325 5}
31.87 0.98
20
{325 + 10
}
Arm
31.87 0.49
{325 5}
31.87 0.98
+ 20
{325 10 }
Bucket
31.87 0.49
{325 5}
31.87 0.98
+ 20
{325 10 }
Swing
27.46 0.98
{280 10}
27.46 2.45
15
{280 + 25
}
Blade RAISE
31.87 0
+ 20
{325 0 }
Boom
+ 1.96
Hydraulic pressure
Service limit value
34.81 1.96
{355 20}
3.24 0.20
{33 2}
3.24 0.49
{33 5}
Control levers at
HOLD
3.43 0.98
{35 10}
3.43 0.98
{35 10}
At pump relief
(normal actuation)
15.98 1.47
{163 15}
15.98 2.45
{163 25}
All levers at
HOLD
2.75 0.98
{28 10}
{}
Travel rotating
under no load
Travel lever at
half-way position
2.21 0.1
{22.5 1}
{}
Max. 65
(Max. 610)
Max. 75
(Max. 720)
Control
LS differential
pressure
+ 1.96
31.87 0.98
20
{325 + 10
}
34.81 0.98
{355 10}
Target
value
(Range)
Travel
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
flLS differential
pressure =
pump outlet
port pressure
LS pressure
+ 1.47
32.36 2.45
{330 25}
MPa
{kg/cm}
Servo piston
input pressure
+ 1.96
32.36 1.47
{330 15}
Blade LOWER
Hydraulic oil
temperature
: 45 55 C
Engine at full
throttle
+ 1.96
Swing
fl See Fig. A
Overrun when
stopping swing
20-8-8
(17)

measure distance that swing circle
moves
Deg.
(mm)
PC128US-2
Applicable model
Category
Item
PC138USLC-2
Standard value
for new machine
Service limit value
3.3 0.3
(4.1 0.3)
Max. 4.1
(Max. 4.8)
4.6 0.5
(5.8 0.5)
Max. 6.4
(Max. 7.5)
28.6 2
28.6 4
0
(0)
0
(0)
Max. 3
Max. 6
Max. 45
54
Hi
Max. 26.9
32.3
Lo
Max. 26.1
Max. 31.4
Max. 14.9
Max. 18
Unit
fl See Fig. A
Time taken to
start swing
90
: 45 55C
Sec.
180
fl See Fig. A
Swing

Time taken to swing Hydraulic oil temperature: 45 55C Sec.
Swing one turn, and measure time
fl See Fig. B
Hydraulic drift of
swing
Engine stopped
of soil.
upper structure at an uphill angle of Deg.
(mm)
45.
Make match marks on swing circle

/min
motor
fl See Fig. C
Travel
Travel speed (1)

: 45 55C
Raise track on one side at a
time, rotate one turn, then measure time taken for next 5 turns
with no load.
Lo
Sec.
fl See Fig. D
Travel speed (2)
PC128US-2

: 45 55C
Run up for at least 10 m, and
measure time taken to travel
next 20 m on flat ground.
Sec.
Hi
20-8-9
(19)
Applicable model
Category
Item
PC138USLC-2
Unit
Standard value
for new machine
Service limit value
Max. 200
220
Max. 1.1
Max. 1.65
Max. 500
Max. 700
Max. 15
Max. 23
Max. 50
Max. 75
Max. 40
Max. 60
Max. 31
Max. 47
fl See Fig. D
fl See Fig. E
Travel deviation

Run up for at least 10 m, and measure deviation when traveling next
20 m on flat ground.
fl Use a hard horizontal surface.
mm
Travel
fl See Fig. F
Hydraulic drift of
travel
Leakage from travel

motor
Work equipment
Total work
equipment
(hydraulic drift
at tip of bucket
teeth)
Boom cylinder
(amount of
retraction of
cylinder)
Arm cylinder
(amount of
extension of
cylinder)

Lock shoes and relieve travel circuit. /min
fl See Fig. G
Place in above posture and measure
extension or retraction of each cylinder and downward movement at
Levers at HOLD
Engine stopped
setting.
Measure hydraulic drift every 5 minutes, and judge from results for 15
minutes.
mm
Bucket cylinder
(amount of
retraction of
cylinder)
Blade
(hydraulic drift
at tip of blade)
20-8-10
(19)
Engine stopped
Stop machine on 12 slope with
sprocket facing straight up the
slope.
Measure the distance the machine
moves in 5 minutes.
Engine stopped
PC128US-2
Applicable model
Boom
Bucket teeth in
contact with
ground
fl See Fig. H
: 45 55C
Unit
RAISE
Item
LOWER
Category
PC138USLC-2
Cylinder fully
extended
Max. 4.4
(Untill touching
chshion)
IN
3.2 0.3
(Untill touching
chshion)
3.1 0.3
OUT
Fully extended
3.8 0.3
(Untill touching
chshion)
(Untill touching
chshion)
Max. 4.2
Max. 4.0
(Untill touching
chshion)
Max. 3.7
(Untill touching
chshion)
Sec.
CURL
3.2 0.3
Fully extended
DUMP
2.5 0.3
fl See Fig. K
Blade
Blade in contact Hydraulic oil temperature
with ground
: 45 55C
RAISE
fl See Fig. J
1.3 0.3
Blade fully
raised
LOWER
Work equipment

: 45 55C
Service limit value
3.1 0.3
fl See Fig. I
Arm
Cylinder fully
retracted
Standard value
for new machine
1.3 0.3
Bucket
Cylinder fully
retracted

: 45 55C
Max. 4.0
Max. 3.1
Max. 2.5
Max. 2.5
Max. 3
Max. 3
Time lag
fl See Fig. L
Boom
PC128US-2

: 45 55C
Fully retract arm and bucket
cylinders, then lower boom from
maximum height and measure
time taken from point where
bucket contacts ground to point
where chassis rises from ground
Sec.
20-8-11
(17)
Applicable model
Category
PC138USLC-2
Standard value
for new machine
Service limit value
Max. 2
Max. 2
Max. 2
Max. 2
Blade

: 45 55C
Lower blade from maximum
height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.
Max. 2
Max. 2
Eachcylinder

: 45 55 C
Engine full
Circuit to be measured is relieved.
Max. 3.5
Max. 15
Max. 10
Max. 50
Item
Unit
fl See Fig. M
Arm

: 45 55C
Set top surface of boom horizontal, retract bucket cylinder fully,
then extend arm cylinder and
measure time taken for arm to
at bottom.
Bucket
Work equipment
Time lag
fl See Fig. N
: 45 55C
Set top surface of boom horizontal, retract arm cylinder fully, then
extend bucket cylinder and
measure time taken for bucket to
at bottom.
Sec
Internal leakage level
fl See Fig. O
cc/
min
Center swivel
joint
20-8-12
(17)
PC128US-2
Pump performance curve
TVC current: 0.4 A

Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)
Check point
As desired
Test pump
discharge
pressure
(MPa {kg/cm2})
Discharge
pressure of
other pump
(MPa {kg/cm2})
P1
P2
Average
pressure
(MPa {kg/cm2})
P1 + P2
2
Standard value
Judgement
for discharge standard lower
amount
limit
Q (/min)
Q (/min)
See graph
See graph
fl As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average
pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
fl When measuring 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 measurement, and use them as a base for calculating the pump discharge
amount at the specified speed.
PC128US-2
20-11
(18)
TESTING
STANDARD
AND ADJUSTING
Name of
component
SYS
tern
Travel
boost
solenoid
Con;Ftor
t$~-
vo5
(male)
.9
8
:g
25
.$
relief
solenoid
Judgment
V06
(male)
Ecu
eg
;z!
If the condition
is as shown
below, it is normal
Between
(I) - (2)
Between
(I),
Min.
If the condition
is as shown
below, it is normal
Between
(1) - (2)
Between
(I),
(2) -chassis
Cl3
(male)
z
ti
Between
(1)
Between
(I),
1 M.Q
in the table
Min.
Min.
1 M.Q
8-15Q
(2) -chassis
1) Turn starting
switch OFF
2) Disconnec
connector.
in the table
- (2)
1) Turn starting
switch OFF.
2) Disconnect
connector.
37-6OQ
If the condition
is as shown
below, it is normal
PC-EPC solenoid
in the table
37-60.Q
(2) -chassis
PARTS
Measurement
conditions
table
method
3
r
.2-stage
VALUE TABLE FOR ELECTRICAL
1) Turn starting
switch OFF.
2) Disconnect
connector.
1 MQ
;
.-?
_s
If the condition
is as shown
below, it is normal
in the table
P
(I
(I), (2) -chassis
Measure
Engine
speed
sensor
E07
(male)
I- (2)
Between
Between
with
Between
500 - 1000 sz
Min.
1 MQ
AC range
(I) - (2)
1) Start engine.
2) Insert T-adapter.
0.5 - 3.0 Q
1) Screw in rotation
sensor until it
contacts
ring gear, then turn back
l/6 turns.
2) It must work
as above.
PC1 28US-2
normally
1) Turn starting
switch OFF.
2) Disconnect
connector.
when
1+
adjusted
20-13
0
TESTING
j
n1
STANDARD
AND ADJUSTING
Name of
component
l-
Inspec-
Cloyector
I.
tion
I method
Judament
the condition
is as shown in Table
mel is normal.
ble 1 (CHECK, CAUTION section)
Monitor
item
(input connector)
.ngin;;if6
;;pssure
Engine
Battery charge
CN6 (IO)
Engine
Sensor signal
input
Display
started
:HECK, CAUTION
ection
Measurement
conditions
table
1 and Table 2, the monitor
Measurement
conditions
ON
Max.
OFF
20-30V
1V
started
lble 2 (Gauges)
Position of gauge
display
\
Starting
switch
Iisplay
level resistance
(Monitor panel input
resistance)
Starting
ON
switch
Min.
OFF
I
1 ) Connect
adapter.
I)Turn starting
switch OFF, and
insert dummy
resistance,
or
measure
resistance of
sensor.
!)Turn starting
switch ON, and
check display.
3)Connect socket.
Max.
(kQ)
Measure
resistance
between
coolant temperature
gauge
CN6 (female) (6)
- (3)
PARTS PARTS
Right
side
T
6.36 - 10.05
Sauges
9.47 - Disconnection
Min.
Max.
(Q)
Measure
resistance
between
fuel
level gauge
Right
side
0 - 15.7
T151
CN6 (female)
(7) - (3)
20-14
0
PC1 28US-2
TESTING
STANDARD
AND ADJUSTING
sys-
Name of
component
tern
Con;Ector
$~p-
judgment
Measurement
conditions
table
method
If the condition
Engine oil pressure

sensor
is as shown
1) Disconnect
in the table
S7
(male)
Coolant
sensor
RELATED PARTS PARTS
If the condition
is as shown
in the table
If the condition
is as shown
in the table
temperature
po6
Fuel level sensor
1.1
:~~$%Zng
When engine is running

(l/2 throttle or above) + 27.5 - 29.5 V
% If the battery is old, or after starting in
cold areas, the voltage may not rise-for
some time.
1 )Start engine.
(male)
Alternator
ii
Between
alternator
terminal R chassis
z
>
E
:
f
PC1 28US-2
20-15
0
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
PC128US-2
Kerosene mode
Model selection
Chassis control
Attachment selection
PPC hydraulic lock

solenoid
Swing holding brake

solenoid
20-16
(17)
CR2
CR1
CR2
CR1
CR2
V07
(male)
V04
(male)
Measure voltage
Measure voltage
CR3
Measurement
conditions
If the condition is as shown in the table

below, it is normal
1) Turn starting
switch OFF.
3) Turn starting
switch ON.
Because normal power

supply is used between
CR3 (1), (21) and chassis,
voltage is applied even in 20 30 V
starting motor switch
OFF state.
Between CR3 (2), (12),
(22) and chassis
below, it is normal
Diesel fuel mode
Engine
Between
full
Kerosene mode
(16)
Engine chassis Diesel fuel mode
slow
Kerosene mode
05V
6 13 V

below, it is normal

below, it is normal
At standard
mode
At kerosene
mode
Between
(6)
chassis
46V
Attachment
1) Turn starting
switch ON.
01V

below, it is normal
CR2 (27) CR1 (4)
1) Turn starting
switch ON.
07V
Measure voltage Measure voltage
Controller
PC-EPC solenoid
CR3
Judgment table
Measure resistance
Power supply voltage
Connector Inspection
No.
method
Measure
resistance
Name of
component
Measure
resistance
System
Max. 1 V
STD arm Long arm
CR (17) CR1 (10) Max. 1 V Min. 7 V
1) Turn starting
switch OFF.
3) Turn starting
switch ON.
1) Turn starting
switch OFF.
3) Turn starting
switch ON.
CR (11) CR1 (10) Min. 7 V Max. 1 V

CR (17) CR1 (10) Min. 7 V Min. 7 V
below, it is normal
Between (1) (2)
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.
Between (1), (2) chassis Min. 1 M

below, it is normal
Between (1) (2)
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.
PC128US-2
PC138US-2
Name of
component
No.
method
CR3
Measure voltage
System
Judgment table
Measurement
conditions

below, it is normal
1) Turn starting
switch OFF.
3) Turn starting
switch ON.
Because normal power

supply is used between
CR3 [1], [21] and chassis,
voltage is applied even in 20 30 V
starting motor switch
OFF state.
Between CR3 [2], [12],
[22] and chassis
PC-EPC solenoid
CR3
Measure voltage
* The voltage can be checked in monitoring mode "1036".

below, it is normal
Diesel fuel mode 0 5 V
Engine
Between
full
Kerosene mode 0 7 V
[16]
Engine chassis Diesel fuel mode 6 13 V
slow
Kerosene mode
* The controller output current can be
checked in monitoring mode "1050".
CR3
Measure voltage
Controller

below, it is normal
Swing holding brake

release solenoid
1) Turn starting
switch ON.
At swing brake
cancel switch
OFF (at release)
At swing brake
cancel switch
ON (at normal
time)
Max. 1 V
Between
CR3 [7]
CR3 [3]
1) Turn starting
switch OFF.
2) Disconnect
connector.
20 30 V
Model selection
Monitoring
If the condition is as shown in the table 1) Turn starting

below, it is normal.
switch ON.
Monitoring mode: "1020", "1021"
Model selec- Model selec- UU/US selec- Tire 2 signal
tion 1 (1020, tion 2 (1020, tion (1020, (1021 bit(5))
bit (5))
bit (6))
bit (3))
Bit OFF
Bit ON
Bit ON
Bit ON
PC128US-2
Monitoring
If the condition is as shown in the table 1) Turn starting

switch ON.
Monitoring mode: "1020"
Attachment Attachment Attachment
selection 1 selection 2 selection 3
(1020, bit (2)) (1020, bit (1)) (1020, bit (4))
Standard
Bit ON
arm
Bit OFF
Bit OFF
Long arm
Bit ON
Bit OFF
Bit OFF
20-19
(17)
Name of
component
Model selection
No.
method
Monitoring
System
Measurement
conditions
Judgment table
Monitoring mode: "1001"
Model/Attachment code
Standard arm
020
Long arm
021
1) Turn starting
switch ON.
Swing pressure switch
Travel pressure switch
Other work equipment

pressure switches
Arm OUT, bucket
CURL, bucket DUMP,

blade, attachment
20-20
(17)
Monitoring
Monitoring
Monitoring
Arm IN pressure switch
Monitoring
Controller
Boom RAISE pressure

sensor
Monitoring
Select in service adjustment mode
Service
adjustment
* The model and attachment codes do not

make difference in performance.
Diesel fuel/Kerosene mode "31"
Standard mode
310
Kerosene mode
311
1) Turn starting
switch ON.
If the condition is as shown in the table 1) Start engine.

2) Reset safety
Monitoring mode: "1023", bit (6)
lock lever.
3) Operate work
Boom RAISE position
Bit ON
equipment.
Neutral position
Bit OFF
Arm IN position
Bit ON
Neutral position
Bit OFF

Swing (Right or left) position
Bit ON
Neutral position
Bit OFF

Travel (Forward, reverse,
right, or left) position
Bit ON
Neutral position
Bit OFF
1) Start engine.
2) Reset safety
lock lever.
3) Operate work
equipment.
1) Start engine.
2) Reset safety
lock lever.
3) Operate work
equipment.
1) Start engine.
2) Reset safety
lock lever.
3) Operate work
equipment.

Monitoring mode
Arm OUT "1028" (1)
Blade, attachment "1028" (2)
Bucket CURL "1028" (3)
Bucket DUMP "1028" (4)
Other work equipment operation
Bit ON
Neutral position
Bit OFF
PC128US-2
Chassis control
Travel acceleration
solenoid
2-stage relief solenoid
PC-EPC solenoid
LS-EPC solenoid
V05
(male)
V06
(male)
C13
(male)
C14
(male)
Measure
resistance
Measure
resistance
V04
(male)
Measure
resistance
Swing holding brake

solenoid
V07
(male)
Measure
resistance
PPC hydraulic lock

solenoid
No.
method
Measure
resistance
Name of
component
Measure
resistance
System
Measurement
conditions
Judgment table
below, it is normal
Between (1) (2)
37 60

below, it is normal
Between (1) (2)
37 60
PC128US-2
Measure
resistance
C05
(male)
1) Turn starting
switch OFF.
2) Disconnect
connector.
* The controller output can be checked in

monitoring mode "1060", bit (1).
below, it is normal
Between (1) (2)
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.

below, it is normal
Between (1) (2)
37 60
1) Turn starting
switch OFF.
2) Disconnect
connector.

below, it is normal
Between (1) (2)
8 15
1) Turn starting
switch OFF.
2) Disconnect
connector.

monitoring mode "1050".
below, it is normal
Between (1) (2)
8 15
1) Turn starting
switch OFF.
2) Disconnect
connector.

below, it is normal
Pressure sensor
1) Turn starting
switch OFF.
2) Disconnect
connector.
Between (A) (B)
4.5 5.5 V
Between (e) (P)
0.5 4.5 V
1) Start engine.

20-21
(17)
Name of
component
No.
method
Judgment table
below, it is normal
Between (1) (2)
Between (1), (2) chassis
500 1,000
Min. 1 M
Engine speed sensor
E07
(male)
Measure
voltage
Measurement in the AC range
Adjustment
Chassis control
Measure
resistance
System
20-22
(17)
Between (1) (2)
0.5 3.0 V
Measurement
conditions
1) Turn starting
switch OFF.
2) Disconnect
connector.
1) Start engine.

1) Thread the speed sensor until it

touches the ring gear and return it by
1 1/6 rotations.
2) Perform normal operation according
to the above adjustment.
PC128US-2

Tools for testing, adjusting and troubleshooting ................................................................................. 20-102
Measuring engine speed ........................................................................................................................ 20-103
Measuring exhaust color ........................................................................................................................ 20-105
Adjusting valve clearance ....................................................................................................................... 20-106
Measuring blow-by pressure ................................................................................................................. 20-108
Measuring engine oil pressure ........................................................................................................... 20-108-1
Testing and adjusting fuel injection timing ........................................................................................ 20-108-2
Testing and adjusting belt tension for air conditioner compressor ................................................. 20-108-7
Testing and adjusting fan belt tension ............................................................................................... 20-108-8
Adjusting engine speed sensor ........................................................................................................... 20-108-9
Adjusting fuel control cable ................................................................................................................... 20-109
Adjusting engine stop solenoid linkage ................................................................................................ 20-110
Testing clearance of swing circle bearing ............................................................................................. 20-111
Checking wear of sprocket ..................................................................................................................... 20-112
Testing and adjusting track shoe tension .............................................................................................. 20-113
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ......................... 20-114
Testing and adjusting output pressure of PC valve (servo piston input pressure) ............................ 20-117
Testing and adjusting LS valve output pressure
(servo piston input pressure)and LS differential pressure .................................................................. 20-119
Testing and adjusting control circuit oil pressure ................................................................................ 20-122
Measuring solenoid valve output pressure .......................................................................................... 20-123
Measuring PPC valve output pressure .................................................................................................. 20-124
Adjusting PPC valve ................................................................................................................................ 20-125
Testing and adjusting travel deviation .................................................................................................. 20-126
Checking location of cause of hydraulic drift of work equipment ...................................................... 20-127
Measuring oil leakage in swing motor .................................................................................................. 20-128
Measuring oil leakage in travel motor ................................................................................................... 20-128
Bleeding air .............................................................................................................................................. 20-129
Releasing remaining pressure in hydraulic circuit ............................................................................... 20-131
Releasing remaining pressure in hydraulic tank .................................................................................. 20-131
Procedure for checking diode ................................................................................................................ 20-132
Pm clinic inspection table ....................................................................................................................... 20-133
PC128US-2
20-101
(17)
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Check or measurement item Symbol
Engine speed
Coolant and oil temperatures
Part Name
799-205-1100
Tachometer kit
795-790-2500
Take-off drive
6090-02-9190
Gear box
799-101-1502
Digital temperature gauge
- 99.9 +1,299 C
799-101-5002
Hydraulic tester
Pressure gauge
: 2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204
Digital hydraulic tester
799-101-5160
Nipple
PT1/8
799-101-5220
Nipple
10 x 1.25
07002-11023
O-ring
Adapter
1.0 MPa{10kg/cm2}
790-261-1321
790-261-1331
790-261-1340
Blow-by pressure
799-401-2320
Hydraulic gauge
799-401-2701
Differential pressure gauge
795-799-1131
Gear
799-201-1504
Blow-by checker
D
1
795-790-1950
Tool
Commercially
available
Feeler gauge
790-201-9001
Handy Smoke Checker
Commercially
available
Smoke meter
79A-264-0021
2
Valve clearance
Exhaust color
Operating effort
F
G
Stroke, hydraulic drift
Measuring voltage and resistance values
Measuring wear of sprocket
20-102
(19)
Bosch index: 0 9
0 294N{0 30kg}
Push-pull scale
Troubleshooting of wiring
harnesses and sensors
Digital display :
6.0 99,999.9rpm
Male, female both 14 x 1.5

(female PT 1/8)
(female PT 1/8)
(female PT 1/8)
(female PT 1/8)
790-261-1311
3
Adjusting fuel injection timing
Remarks
Oil pressure
Part No.
0 490N{0 50kg}
79A-264-0091
Commercially
available
Commercially
available
Commercially
available
Scale
790-601-8000
T-adapter kit
799-601-7370
For 6-pin relay
799-601-7050
SW-6P
799-601-7080
Stop watch
Tester
M-1P
Adapter
799-601-7310
SW-12P
799-601-7320
SW-16P
799-601-7340
M-16P
799-601-7540
070-18P
796-127-1140
Wear gauge
PC128US-2
MEASURING ENGINE SPEED

PC128US-2 Serial No.: 5001 7730
fl Measure the engine speed under the following
conditions.
Coolant temperature: Within operating range
1. Remove air conditioner compressor top cover.
2. Remove air conditioner compressor belt.
3. Remove cover (1) at timing gear case end.
4. Install tool A2 to speed pick-up port.
5. Connect bracket of tool A1, probe and tachometer to tool A2.
6. Start the engine, and measure the engine speed
when it is set to the conditions for measuring.
1) Measuring at low idling and high idling :
Measure the engine speed with the fuel control lever set to low idling and high idling.
2) Measuring speed at pump relief :
Run the engine at full throttle and measure
the engine speed when the main pump is relieved.
3) Measuring speed at near rated speed :
Run the engine at full throttle, operate the arm
lever, and measure the engine speed when
the arm is relieved.
PC128US-2
Measurement of engine speed
The measuring method is identical with the
method described above.
The engine speed can be displayed in monitoring
mode "1010".
PC128US-2
20-103
(19)
PC138US-2
fl Measure the engine speed under the following condition.
Coolant temperature: Within operating
range
1. Remove the cover for setting the injection timing of the injection pump from the timing gear
case and install tool A3.
2. Connect bracket [1], probe [2] and tachometer

to tool A3.
3. Start the engine and measure the following revolving speeds.
1) Measure the low idling speed and high
idling speed.
2) Set the fuel control lever to the low idling
and high idling positions and measure the
revolving speeds at the respective positions.
3) Revolving speed when pump is relieved
Relieve the pump and run engine at full
throttle and measure its revolving speed.
20-104
(19)
PC128US-2
MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR
When measuring in the field when there is no air

or electric power supply, use smoker checker G1;
when recording official data, use smoke meter G2.
fl Raise the coolant temperature to the operating
range before measuring.
When removing or installing the measuring
equipment, be careful not to touch any high temperature part.
1. Measuring with handy smoke checker G1
1) Fit filter paper in tool G1.
2) Insert the exhaust gas intake port into the exhaust pipe.
3) Accelerate the engine suddenly, and at the
same time operate the handle of tool G1 to
catch the exhaust gas on the filter paper.
4) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter G2
1) Insert probe of smoke meter G2 into the outlet port of exhaust the pipe, then tighten the
clip to secure it to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to smoke meter G2.
fl The pressure of the air supply should be
less than 1.47 MPa {15 kg/cm2}.
3) Connect the power cord to the AC100V outlet.
fl When connecting the port, check first that
the power switch of the smoke meter is
OFF.
4) Loosen the cap nut of the suction pump, then
fit the filter paper.
fl Fit the filter paper securely so that the exhaust gas does not leak.
5) Turn the power switch of smoke meter G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
smoke meter G2 and catch the exhaust gas
color on the filter paper.
7) Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (10
sheets or more) inside the filter paper holder,
and read the indicated value.
PC128US-2
20-105
(17)
ADJUSTING VALVE CLEARANCE

PC128US-2
1. Remove the cylinder head cover.
2. Using cranking tool D, rotate the crankshaft in the
normal direction until timing pin (1) enters the
hole in the gear.
fl In this position, the No.1 cylinder is at compression top dead center.
3. When the No.1 cylinder is at top dead center, adjust the valves marked . Next, rotate the crankshaft one turn (360) in the normal direction and
adjust the valve clearance of the remaining valves
marked .
fl Make a counter mark on the crankshakft pulley or damper, then rotate 360.
4. To adjust the valve clearance, loosen locknut (7),

then insert feeler gauge F between rocker lever
(4) and valve stem (5), and turn adjustment screw
(6) until the clearance is a sliding fit. Then tighten
locknut (7) to hold the adjustment screw in position.
9 Locknut : 23.5 Nm {2.4 kgm}
fl After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 180 each time and adjust the valve
clearance of each cylinder according to the
firing order.
Firing order : 1 3 4 2
fl Note that there is no timing mark on the front
pulley, so set to compression top dead center
as follows.
1) If the firing order is followed, No. 3 cylinder
comes after No. 1 cylinder, so watch the movement of the valves of No. 2 cylinder when rotating.
2) When the clearance is 0 for both the intake
and exhaust valves of the No. 2 cylinder, the
No. 3 cylinder is at compression top dead center. (When setting No. 2 cylinder, watch No. 3
cylinder.)
20-106
(17)
PC128US-2
PC138US-2
Method of adjusting valve clearance
2. Turn the crankshaft forward and bring cylinder
No. 1 to the compression top dead center and
match the TOP mark line of crank pulley (1) to
pointer (2), watching the movement of the air
intake valve of cylinder No. 4 (4 cylinders).
a The air intake valve of cylinder No. 4 (4 cylinders) moves (opens) when cylinder No. 1
comes near the compression top dead center.
a Adjust the valve clearance according to the

following procedure. Loosen locknut (8) of
adjustment screw (7). Insert filler gauge of
the specified thickness between valve stem
(6) and rocker arm (5) and adjust the valve
clearance so that the filler gauge will move
lightly.
5. Tighten the locknut to secure the adjustment

screw.
Locknut: 39.2 49 Nm {4 5 kgm}
3. Adjust the clearance of the valves marked with

q in the valve arrangement.
4. Turn the crankshaft forward by 1 turn and adjust
the clearance on the valves marked with Q.
a You may adjust the valve clearances of each

cylinder in the firing order, rotating the crankshaft by 180 each time.
PC128US-2
20-107
(17)
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

fl Measure the blow-by pressure under the following conditions.
Coolant temperature : Within operating range
1. Install the nozzle of blow-by checker E to the blowby hose.
2. Connect the nozzle and gauge with the hose.
3. Run the engine at full throttle and relieve the arm
circuit.
4. Measure the blow-by pressure at the point where
the gauge indicator remains steady.
20-108
(17)
PC128US-2
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

fl Measure the engine oil pressure under the following conditions.
Coolant temperature : Within operating range
PC128US-2
1. Remove engine oil pressure switch (1).

2. Fit a nipple C3 and install oil pressure gauge C2
(0.981 MPa {10 kg/cm2}).
3. Start the engine, and measure the engine oil pressure with the engine at low idling and at high
idling.
PC138US-2
PC128US-2
20-108-1
(17)
TESTING AND ADJUSTING FUEL INJECTION TIMING

PC128US-2
Testing
1. Using cranking tool D, rotate the crankshaft in the
normal direction until timing pin (1) enters the
hole in the gear.
2. Remove plug (2), reverse timing pin (3), and check
that pin (3) is meshed with timing pointer (4) at
the fuel injection pump end.
Adjusting
fl If the timing pin does not mesh with the pointer,
adjust as follows.
1. Remove the fuel injection pump.
For details, see REMOVAL OF FUEL INJECTION
PUMP.
2. Rotate the camshaft of the fuel injection pump
and timing pin (3) with timing pointer (4).
3. Install the fuel injection pump.
For details, see INSTALLATION OF FUEL INJECTION PUMP.
20-108-2
(17)
PC128US-2
PC138US-2
Adjustment by use of match marks
a Apply this method usually.
(Then installing the fuel injection pump to the
original engine without repairing it, when checking only the injection timing, etc.)
1. Bring cylinder No. 1 to the compression top dead
center.
1) Turn the crankshaft forward and match
1.4Top line (1) on the crank pulley to pointer
(2).
2) Check that cylinder No. 1 is at the compression top dead center by the following method.
If the following condition is not obtained, turn
the crankshaft one more turn.
a If the fuel injection pump is removed:
Check that C is seen at the tooth tip of
the idler gear.
a If the fuel injection pump is installed to
the engine: Remove the head cover and
check that (both air intake valve and
exhaust valve of cylinder No. 1 have the
valve clearance).
PC128US-2
2. Remove front cover (3) of the fuel injection

pump.
3. Install the fuel injection pump holder and drive
gear as one unit to the engine.
4. Insert the timing check pin 4.0 4.5 mm in diameter and 80 mm in length on hole a of the front
gear cover and match it to the hole of the drive
gear.
a Check that the timing check pin enters
straight and the hole of the fuel injection
pump holder is aligned with the mounting
hole of the front gear cover (in which the
mounting bolt will be inserted).
a If the holes are deviated from each other,
remove the fuel injection pump and check its
engagement with the drive gear.
5. Remove the timing check pin and tighten each

bolt.
20-108-3
(17)
Adjustment by delivery valve method

(When installing a repaired or replaced fuel injection
pump, when checking after disassembling or replacing the gear train)
4. Using spring pusher O2, compress the valve

spring and remove valve cotter (5).
5. Loosen spring pusher O2 and remove spring
seat (6) and valve spring (7).

2. Bring cylinder No. 1 to the compression top dead
center.
1) Turn the crankshaft forward and match injection timing line (1) on the crank pulley to
pointer (2).
2) Check that both air intake valve and exhaust
valve of cylinder No. 1 have the valve clearance.
a If either or both of the valves do not
have the valve clearance, turn the
crankshaft one more turn.
6. Turn the stem of air intake valve (8) with the fingers while it is in contact with the top of piston
(9) to fit it securely.
3. Remove snap ring (3) from the front end of the

rocker shaft, then remove air intake rocker arm
(4) of cylinder No. 1.
20-108-4
(17)
PC128US-2
7. Apply dial gauge O3 to the valve stem end and

turn the crankshaft forward or in reverse to set
the dial gauge to 0 when its pointer starts turning
in reverse.
8. Turn the crankshaft about 45 degrees in reverse
from the compression top dead center of cylinder No. 1.
9. Turn the crankshaft forward so that the dial
gauge indicates standard dimension a.
BTDC
(Deg)
6 0.75
mm
0.42 0.08
12. Set the fuel injection lever to the FULL position.

13. Loosen the nut at the oblong hole of the injection
pump mounting flange, then loosen the injection
pump mounting bolts (14).
10. Disconnect fuel injection pipe (10) of cylinder

No. 1.
11. Remove delivery valve holder (11), and remove
delivery valve (12) and spring (13) from its
inside. Then, install delivery valve holder (11)
again.
14. Turning the injection pump outward and operating the priming pump, move the injection pump
toward the cylinder block little by little and stop
when the fuel stops flowing out of the delivery
valve holder.
a If the injection pump is slanted out, the injection timing is delayed. If the former is slanted
toward the cylinder block, the latter is
advanced.
15. Tighten injection pump mounting bolts (14) alternately.
16. Tighten the nut at the oblong hole of the injection
pump mounting flange.
PC128US-2
20-108-5
(17)
17. Turn the crankshaft forward and check that the

pointer of the dial gauge is in the standard range
shown in the following table when cylinder No. 1
is at the top dead center (when the pointer of the
dial gauge starts moving in reverse). If the
pointer of the dial gauge is out of this range,
repeat the above steps from 7.
Dimension when cylinder is at top
dead center (mm)
0 0.08
18. Remove the delivery valve holder (11) and install

delivery valve (12) and spring (13) to it, then
install delivery valve holder (14) again.
a Replace the o-ring and copper gasket of the
delivery valve.
WARNING! Tighten the delivery valve 3
times to secure it. (If it is not tightened sufficiently, the gasket may be broken.)
Delivery valve holder:
39.2 44.1 Nm {4 4.5 kgm}
19. Connect fuel injection pipe (3).
Sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}
20. Install valve spring (7) and valve seat (6).
21. Compress the valve spring with spring pusher
O2 and install valve cotter (5).
22. Install air intake rocker arm (4) of cylinder No. 1,
then install snap ring (3).
a Install the snap ring securely.
23. Install the cylinder head cover.
Sleeve nut:
7.84 9.8 Nm {0.8 1.0 kgm}
20-108-6
(17)
PC128US-2
TESTING AND ADJUSTING BELT

TENSION FOR AIR CONDITIONER
COMPRESSOR
TESTING AND ADJUSTING BELT TENSION

FOR AIR CONDITIONER COMPRESSOR
PC128US-2 Serial No.: 5001 7730
PC128US-2 Serial No.: 5001 7730

fl If the deflection of the belt when it is pressed at a
point midway between the crankshaft pulley and
the compressor pulley is not within the standard
value, or when carrying out maintenance after replacing the belt, adjust the belt tension as follows.
1. Loosen 2 mounting bolts (2) and 2 adjustment
plate bolts (3) of compressor assembly (1).
2. Move the position of compressor assembly (1) to
adjust the belt tension.
3. When the position of compressor assembly (1) is
fixed, tighten 2 adjustment plate bolts (3) and 2
mounting bolts (2) to secure in position.
4. After adjusting the belt tension, repeat the above
testing procedure to check that the belt tension is
within the standard value.
PC128US-2
PC128US-2
PC138US-2
fl If the deflection of the belt when it is pressed at a
point midway between the crankshaft pulley and
the compressor pulley is not within the standard
value, or when carrying out maintenance after
replacing the belt, adjust the belt tension as follows:
1. Loosen two mounting bolts (2) and (3) of compressor assembly (1).
2. Loosen nut (4) and thread and adjust adjustment
bolt (5) so that the deflection of the belt can be
set to 12 to 15 (about 58.8 N {about 6 kgf}).
3. When the position of compressor assembly (1) is
fixed, tighten two mounting bolts (2) and (3) to
secure them in position.
4. After tightening adjustment bolt (5) two or three
rotations, tighten nut (4) and secure adjusting bolt
(5).
5. After adjusting the belt tension, repeat the above
testing procedure to check that the belt tension is
within the standard value.
PC128US-2
PC138US-2
20-108-7
(17)
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION

PC138US-2
fl When deflection a made by pressing the intermediate point of the belt between the alternator pulley and drive pulley is out of the standard range
or when the belt was replaced, adjust the belt tension according to the following procedure.
1. Open the engine hood and remove the cover between the hydraulic tank and operator's cab.
2. Loosen mounting bolt (2) and fixing bolt (3) of
alternator assembly (1).
3. Loosen locknut (4), and then loosen tension bolt
(5) to adjust the belt tension.
Tighten fixing bolt (3) first, and then tighten alternator mounting bolt (2) and locknut (4).
fl Do not touch the double nut (6).
4. After adjusting the belt tension, check that it is in
the standard range according to the check procedure shown above.
20-108-8
(17)
PC128US-2
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

1. Screw in until the tip of sensor (1) contacts gear
(2).
2. When gear (2) contacts sensor (1), turn back 11/
6 turn.
3. Tighten locknut (3).
fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
fl Be particularly careful when securing the sensor wiring to ensure that no excessive force
is brought to bear on the wiring.
PC128US-2
PC138US-2
PC128US-2
20-108-9
(17)
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
ENGINE
STOP SOLENOID
LINKAGE
ENGINE STOP SOLENOID LINKAGE
BEP01424
Testing
1. Turn the starting switch ON, set to the operating
condition, then adjust so that the clearance between lever (I) and stopper (2) is 1 - 2 mm.
Adjusting
1. Loosen the mounting bolts of solenoid assembly
(31, move solenoid assembly (3) to adjust the clearance between
lever (I) and stopper (21, then
tighten the mounting bolts.
*
There is an oblong hole at the bracket end.
20-110
0
PC1 28US-2
TESTING
TESTING
AND ADJUSTING
CLEARANCE
OF SWING
CIRCLE BEARING
TESTING CLEARANCE OF SWING CIRCLE BEARING

Method of testing clearance of swing circle bearing
when mounted on machine
1. Fix a magnet-type
dial gauge to the outer circle
(or inner circle) of the swing circle, and put the tip
of the probe in contact with the inner circle (or
outer circle).
Set the dial gauge at the front or rear.
-Revo
01
rame
Dial gauge
2.
Extend the work equipment

to the maximum
reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
When this is done, the front of the upper structure will go down and the rear will rise.
3.
Set the dial gauge to the zero point.
TXP02404
BLP01317
4.
5.
Set the arm more or less at

ground surface, then lowerthe
dercarriage at the front of the
the ground.
When this is done, the front
ture will rise and the rear will
of the upper strucgo down.
Read the value on the dial gauge at this point.

The value on the dial gauge is the clearance of
the swing.circle bearing.
g
6.
right angles to the

boom until the unmachine comes off
When carrying out the measurement,

do not
put your hand or feet under the undercarriage.
150-200mm
BLPOl3
Return to the condition in Step 2, and check that

the dial gauge has returned to the zero point. If it
has not returned to the zero point, repeat Steps 2
to 5.
PC1 28US-2
20-111
0
CHECKING WEAR OF SPROCKET
CHECKING WEAR OF SPROCKET

Wear
limit
line
TXP02405
1.
Remove the track shoe assembly.

*
For details, see DISASSEMBLYAND ASSEMBLY, REMOVAL OF STEEL SHOE ASSEMBLY.
2.
Align wear gauge M with the sprocket.

* Align the datum line, then align the wave
shape of the sprocket with the wave shape of
the wear gauge.
3.
Judge the sprocket wear.

Sr If the wave shape of the sprocket is above the
wear limit line :
It is possible to continue to use the sprocket.
*
If the wave shape of the sprocket has reached
the wear limit line :
Replace the sprocket with a new part.
20-112
0
PC128US-2
TESTING
TESTlNG
AND ADJUSTING
AND ADJUSTING
HYDRAULIC PRESSURE IN
WORK EQUIPMENT,
SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING HYDRAULIC

PRESSURE IN WORK EQUIPMENT,
SWING, TRAVEL CIRCUIT
Measuring
Sr Oil temperature
a
when
measuring:
45 - 55 C
Lower the work equipment

to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK position.
Remove
pressure
pick-up
plug (I) (Thread
dia.=lOmm,
Pitch=l.25mm)
from the circuit to be
measured, then install oil pressure gauge Cl (58.8
MPa {SO0 kg/cm*}).
Measuring unload hydraulic pressure

l
Start the engine, run at full throttle, and measure
the hydraulic pressure when the control levers are
at HOLD.
Measuring main relief (pump relief) oil pressure

1. Run the engine at full throttle and measure the
oil pressure when each actuator is relieved.
l
The condition for each actuator is as follows:
1) For the work equipment, operate the cylinder
to the end of its stroke.
2) Forthe swing, dig a hole and lowerthe bucket.
3) For the travel, fit block (1) under the grouser
of the track shoe, or fit block (2) between the
sprocket and frame to lock the track, and measure one side at a time.
*
The set pressure of the safety valve of the
swing motor is lower than the main relief
valve set pressure, so when the swing is
relieved, the set pressure of the safety
valve is measured.
20-114
0
BLPO1284
-1
PC1 28US2
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN

WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
Adjusting
1. Adjusting main relief valve
Disconnect high pressure hose.
1) Adjusting high pressure setting
Loosen locknut (2) of main relief valve (1),
then turn holder (3) to adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTERCLOCKWISE.
fl After adjusting, use the measurement procedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
53.9 4.9 Nm {5.5 0.5 kgm}
fl When the high pressure setting is adjusted, the low pressure setting will also
change, so adjust the low pressure setting also.
2) Adjusting low pressure setting
Loosen locknut (4) of main relief valve (1),
then turn holder (5) to adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTERCLOCKWISE.
fl After adjusting, use the measurement procedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
39.2 49.0 Nm {4 5 kgm}
2. Adjusting swing motor safety valve

fl If the swing relief pressure is not normal, adjust the swing motor safety valve as follows.
1) Loosen locknut (7) of swing motor safety valve
(6), then turn adjustment screw (8) to adjust.
fl Turn the adjustment screw as follows.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCKWISE
fl Amount of adjustment for one turn of adjustment screw : 14.0 MPa {143 kg/cm2}
PC128US-2
20-115
(18)
TESTING
TESTING
2)
AND ADJUSTING
After adjusting,
m
&
tighten
AND ADJUSTING
HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
locknut (7).
Locknut
: 53.9 + 4.9 Nm (5.5 + 0.5 kgm1
.n.fer comnletinn
of adiustment.
,-------~ -, use the
r--.-..
measurement
procedure
the oil pressure again.
above to check
9JFOO253
20-116
0
PC1 28US-2
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE

(SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING OUTPUT PRESSURE

OF PC VALVE (SERVO PISTON
INPUT PRESSURE)
Measuring
fl Oil temperature when measuring : 45 55 C
1. Remove pressure measurement plugs (1) and (2)
(Thread dia.= 10 mm, Pitch=1.25 mm), and install
oil pressure gauge C1 (39.2 MPa {400 kg/cm2}).
2. Turn the swing lock switch ON.
3. Run the engine at full throttle and measure the
oil pressure when the arm IN circuit is relieved.
[Reference]
If there is any abnormality with problem in the
LS valve or servo piston, the servo piston input
pressure becomes a value close to 0 or the same
pressure as the pump discharge pressure.
PC128US-2
20-117
(18)
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
OUTPUT PRESSURE OF PC VALVE

Adjusting
If the load increases and the engine speed drops,
or if the engine speed is normal but the work
equipment speed is slow, adjust PC valve (6) as
follows if the pump discharge pressure and LS
differential pressure are normal.
1) Loosen iocknut (41, and if the work equipment
speed is slow, turn screw (5) clockwise; if the
engine speed drops, turn the screw counterclockwise.
2) Remove pressure measurement plugs (1) and
(2) (Thread dia.= IO mm, Pitch=1.25 mm), and
install oil pressure gauge Cl (39.2 MPa (400
kg/cm*}).
3) Turn the swing lock switch ON.
Run the engine at full throttle and measure the
oil pressure when the arm IN circuit is relieved.
[Reference]
If there is any abnormality in the LS valve or servo
piston, the servo piston input pressure becomes
a value close to 0 or the same pressure as the
pump discharge pressure.
BKPOIOI5
20-118
0
PC1 28US-2
TESTING

LS VALVE OUTPUT
(SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL
AND ADJUSTING
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE

AND LS DIFFERENTIAL PRESSURE
when
measuring
: 45 - 55 C
j,
Oil temperature
1.
Measuring LS valve output pressure (servo

ton input pressure)
plugs (I)
1) Remove pressure measurement
(2) (Thread dia.= 10 mm, Pitch=1.25 mm),
install oil pressure gauge Cl (39.2 MPa
pisand
and
{400
kg/cm%
2) Use the work equipment

3)
to raise the track assembly on one side.

Run the engine at full throttle,
operate under
the conditions
shown in Table 1, rotate the
track under no load, and measure the oil pressure (the oil pressure when the travel is operated on one side under no load).
Travel
lever
Pump
pressure
MPaIkg/cmZI
Servo inlet
pressure
APaIkg/cm*)
About same
pressure
Neutral
t
Full
PC1 28U.S2
Remarks
7.85f0.49
{80+20)
4.41f0.98
(45flOI
Pressure of
about 315
PRESSURE
PRESSURE
TESTING
2.
AND ADJUSTING
Measuring
LS differential

LS VALVE OUTPUT
PRESSURE
PRESSURE
pressure
1)
Measuring with.differential pressure gauge

i) Remove oil pressure measurement plugs (1)
and (2) (Thread dia.=lOmm, Pitch=l.25mm),
and install differential pressure gauge Cl.
* Connect pump discharge pressure
side (1) to the high- pressure side of
the differential gauge and LS pressure
side (2) to the low-pressure side.
ii) Use the work equipment to raise the track
on one side.
iii) Run the engine at full throttle, set to the
conditions below, and measure the LS differential pressure.
LS differential pressure when travel lever is at.Neutral :
2.75 f 0.98 MPa 128 k 10 kg/cm*)
* The LS differential pressure when the
travel lever is at Neutral is the same
as the unload pressure.
LS differential pressure when travel lever is at half-way position (track rotating under no load) :
1.57 f 0.1 MPa I16 f lkg/cm*)
2) Measuring with oil pressure gauge
*
The maximum differentialpressure is less
than 1.96 MPa (20 kg/cm*), so measure
with the same gauge.
i) Remove oil pressure measurement plugs (I)
and (2) (thread dia.=lOmm, pitch=l.25mm),
and install oil pressure gauge Cl.
ii) Install oil pressure gauge Cl (39.23 MPa
(400 kg/cm*}) to the plug for measuring
the pump discharge pressure.
*
Use a gauge with a scale in units of
0.98 MPa {IO kg/cm*).
iii) Use the work equipment to raise the track
on one side.
iv) Run the engine at high idling, set to the
conditions in Step 1) - iii), and measure
the pump discharge pressure.
*
Stand directly in front of the indicator
and be sure to read it correctly.
v) Run the engine at high idling, set to the
conditions in Step 1) - iii), and measure
the LS pressure.
* Stand directly in front of the indicator
and be sure to read it correctly.
vi) Calculate the LS differential pressure from
the pump discharge pressure and the LS
pressure.
(Differential pressure) = (Pump discharge
pressure) - (LS pressure)
l
9JFOOl20
-1
BLP01284
20-120
0
PC128US-2
TESTING
3.
AND ADJUSTING
TESTING AND ADJUSTlNG

LS VALVE OUTPUT
Adjusting LS valve
*
If the results show that the LS differential pressure is not within the standard value, adjust
the LS valve as follows.
1) Disconnect hose (8) from LS valve (7).
2) Loosen locknut (9) and turn adjustment screw
(IO) to adjust the differential pressure.
*
Turn the adjustment
screw to adjust as
follows.
l
l
*
Amount of adjustmentfor
one turn of adjustment screw: 1.30 MPa i13.3 kg/cm*}
(LS differential pressure)
3) After adjusting, tighten locknut (8).
w
*
PC1 28US-2
PRESSURE
PRESSURE
BKP01016
Locknut : 59 f IO Nm (6 f 1 kgml
After completion of adjustment, repeat the
procedure above to check the LS differential pressure again.
20-121
0
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
CONTROL
CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING CONTROL

CIRCUIT OIL PRESSURE
:
Measuring
*
Oil temperature
a
when measuring
: 45 - 55 C
Lower the work equipment to the ground and

stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK position.
1. Remove the cover at the top of the valve.

2.
Disconnect hose (I) going to the solenoid valve,

then install adapter C3 and oil pressure gauge Cl
(5.9 MPa {SO kg/cm*)).
3.
Start the engine and measure

full throttle.
with the engine at
Adjusting
If the pressure in the control circuit is not normal,

adjust the control relief valve as follows.
Loosen locknut (2) and turn adjustment.screw

(3)
to adjust.
*
Turn the adjustment screw as follows.
l
l
*
Amount of adjustment for one turn of adjustment screw : 0.98 MPa {IO kg/cm*}
2.
After adjusting,
tighten
locknut (2).
Locknut : 19.6 - 24.5 Nm (2.0 - 2.5 kgm}
After completion
of adjustment,
repeat the
procedure above to check the oil pressure
again.
20-122
0
9JFOO266
PC1 28US-2
TESTING
TESTING
AND ADJUSTING
SOLENOID
VALVE OUTPUT
PRESSURE
TESTING SOLENOID VALVE

OUTPUT PRESSURE
when measuring
: 45 - 55 C
Oil temperature
1.
Disconnect the output hose of the solenoid valve

to be measured, then install adapter C3 between
the hose and the measurement
point.
2.
Install oil pressure gauge Cl (5.9 MPa {SO kg/cm211

to adapter C3.
3.
Measure the output pressure underthe

in the table below.
lock lever: LOCK
conditions
PPC lock actuated
Swing lock switch: LOCK
PC1 28US-2
20-123
0
TESTING
MEASURING PPC VALVE

OUTPUT PRESSURE
* Oil temperature when measuring : 45
1.
MEASURING
AND ADJUSTING
PPC VALVE OUTPUT
PRESSURE
- 55 C
Measuring PPC valve output pressure

1) Disconnect PPC hose (I) of the circuit to be
measured.
2) install adapter C3 between the hose and elbow.
3) Install oil pressure gauge Cl (5.88 MPa I60
kg/cm211 to adapter C3.
4) Run the engine at full throttle, operate the control lever of the circuit to be measured, and
measure the oil pressure.
PPC
BLP01302
20-124
0
PC1 28US-2
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
TRAVEL DEVIATION

TRAVEL DEVIATION
Travel
Posture
Testing
*
Travel on flat ground.
1.
Set the machine in the travel posture.

Ir When setting the machine in the travel posture, extend the bucket and arm cylinder rods
fully, and hold the boom at an angle of 45.
2.
Travel for IOm, then measure the deviation when

traveling the next 20m .
J, Measure with the engine at full throttle.
*
Install an oil pressure gauge and measure the
pump discharge pressure at the same time.
TDP00328
20m
Make
Make
a mark
10m midway
a mark
MIyarin;,J,
at
Point
1Om
the
Make
Run
UP
for
IOm
a mark:
midwAark
Mark
Measure
distance
the
amount
A at this
of
point
TEP00329
20-126
0
PC1 28US-2
CHECKING
TESTING
AND ADJUSTING
LOCATION OF CAUSE OF HYDRAULIC

DRIFT OF WORK EQUIPMENT
CHECKING LOCATION OF CAUSE OF HYDRAULIC

DRIFT OF WORK EQUIPMENT
*
Oil temperature
1.
Work equipment
when measuring : 45 - 55 C
cylinder
If the hydraulic drift of the work equipment is

not within the standard value, measure the
internal leakage of the cylinder as follows and
judge if the cause of the hydraulic drift is in
the cylinder or the control valve.
. If the leakage is within the standard value, the
problem is in the control valve.
. If the leakage is more than the standard value,
the problem is in the cylinder.
1) Fully extend the rod of the cylinder to be measured, then stop the engine.
2) Disconnect the hose at the head end and block

the hose at the chassis end with a blind plug.
Boom cylinder: Hose (I 1
Arm cylinder: Hose (2)
Bucket cylinder: Hose (3)
Be careful not to disconnect the hose at
g
the bottom end.
3) Start the engine, run the engine at full throttle,
and apply the relief pressure to the bottom
end of the cylinder.
*
Boom cylinder: Operate to RAISE
Arm cylinder: Operate to IN
Bucket cylinder: Operate to CURL
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
l
2.
Checking_ PPC valve

If there is a difference in the hydraulic drift
when the safety lock lever is at the LOCK or
FREE position (with the engine running), the
PPC valve is defective.
End
of
stroke
~p~connect
zi
TLP00652
PC1 28US-2
ZO-127
0
TESTING
MEASURING
MEASURING
AND ADJUSTING
OIL LEAKAGE OF SWING MOTOR,

OIL LEAKAGE OF TRAVEL MOTOR
MEASURING OIL LEAKAGE OF

SWING MOTOR
*
Oil temperature
when measuring
: 45 - 55 C
1. Disconnect drain hose (I) from the swing motor,

then install a blind plug at the tank end.
2. Dig the bucket into the ground and lock the swing.
3. Start the engine and relieve the swing circuit with
the engine at full throttle.
4. Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.
f
After measuring,
swing 180 and measure
again.
MEASURING OIL LEAKAGE OF

TRAVEL MOTOR
* Oil temperature when measuring : 45 - 55 C
1.
2.
3.
4.
Disconnect drain hose (2) from the travel motor,

then fit a blind plug at the hose end.
Fit block @ under the track shoe grouser, or fit
block @ between the sprocket and frame to lock
the track.
Start the engine and relieve the travel circuit with
the engine at full throttle.
a
When measuring
the oil leakage from the
travel motor, there is a serious risk that mistaken operation of the control lever may lead
to an accident, so always use signals and
check carefully when carrying out this operation.
Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.
*
When measuring, move the motor slightly (to
change the position between the valve plate
and cylinder, and the piston and cylinder), and
measure several times.
II
20- 128
0
9JFOOO95
PC1 28US-2
BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
Air bleeding procedure
Air bleeding item
Nature of work
Change hydraulic oil
Clean strainer
Bleed air
from
pump
Start
engine
Bleed air Bleed air Bleed air Pressurize

Start
from
from
from
hydraulic operation
cylinder
swing
travel
tank
motor
motor
(Note)
(Note)
Replace, repair control valve
Replace cylinder
Remove cylinder piping
Replace, repair swing motor

Remove swing motor piping
Replace, repair travel motor, swivel

Remove travel motor, swivel piping
Replace return filter element

Replace, repair pump
Note : Bleed the air from the swing and travel motors only when the oil inside the motor case has been
drained.
1. Bleeding air from pump
1) Loosen air bleed plug (1), and bleed the air
from the plug.
fl WHen no more air comes out with the oil,
the bleeding is completed.
2) When oil oozes out, tighten plug (1).
9 Air bleed plug :
17.16 2.45 Nm {1.75 0.25 kgm}
fl Precautions when starting the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
2. Bleeding air from cylinders
1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, and raise and
lower the boom 4 5 times in succession.
fl Operate the piston rod to approx. 100 mm
before the end of its stroke. Do not relieve the circuit under any circumstances.
3) Run the engine at full throttle and repeat Step
2). After that, run the engine at low idling,
and operate the piston rod to the end of its
stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm, bucket, swing, and blade cylinders.
PC128US-2
20-129
(17)
TESTING
AND ADJUSTING
3.
Bleeding air from swing motor

1) Turn the swing lock switch ON and run at
idling for 5 minutes.
*
Use the S port pressure to bleed the air
from the swing motor.
2) Disconnect hose (1) from the swing motor,
then fit a blind plug in the hose end.
3) Run the engine at low idling and check that
oil oozes out from elbow (2).
Jr If oil does not flow out from the elbow,
repeat Step 1).
4) Connect hose (I).
4.
Bleeding
20-130
0
BLEEDING
AIR
air from travel motor
PC1 28US-2
TESTING
AND ADJUSTING
RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT,
RELEASING REMAINING
PRESSURE IN HYDRAULIC TANK
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
Jr If the piping between the hydraulic cylinder
and
the control valve is to be disconnected, release
the remaining pressure from the circuit as follows.
The travel circuit is an open circuit, so there is no
remaining pressure. In this case, it is enough just
to the oil filler cap.
1.
Loosen the oil filler cap slowly to release the pressure inside the tank.
2.
Operate the control levers.

*
When the levers are operated 2 - 3 times, the
pressure stored in the accumulator
is removed.
3. Start the engine, run at low idling for approx. 5

minutes, then stop the engine and operate the
control levers.
Jr Repeat the above operation 2 - 3 times to release all the remaining pressure.
RELEASING REMAINING
PRESSURE IN HYDRAULIC
TANK
a The hydraulic tank is sealed and pressurized.
When removing the hoses or plugs connected
to the hydraulic tank, do as follows to release
the remaining pressure in the hydraulic tank.
1.
Lower the work equipment

the engine.
2.
Loosen the oil filler cap or oil filler plug slowly to

release the pressure inside the hydraulic tank.
PC1 28US-2
to the ground and stop
20-131
0
TESTING
PROCEDURE
AND ADJUSTING
FOR CHECKING
DIODE
PROCEDURE FOR CHECKING

DIODE
l
1.
Diode
as
individual
Diode
included
Part
Use the following procedure to check the diode

as individual part and the diode included in the
wiring harness.
Use a digital tester with a range for measuring
diodes.
Put the red (+) end of the test pin in contact with
the anode (P) of the diode, and the black (-) end in
contact with the cathode (N).
* There is a mark showing the direction of continuity on the surface of the diode.
* With a normal tester, if it is switched to the
diode range, the voltage of the internal battery is displayed. The value indicates the following.
l
No change : No continuity
l
Changes:
There is continuity (normal) (Note)
0 Value is 0 or near 0:
Short circuit inside diode
Note : In the case of silicon diodes, a value beDependtween 400 and 600 is displayed.
ing on the type of tester, 0.4 - 0.6 may also
be displayed.
in
wiring
harness
I-
TLP00664
BLPO1357
20-132
0
PC128US-2
Pm CLINIC INSPECTION TABLE
PC128US-2 # 5001 and up

Machine Serial No.
Mounted engine
HOUR INSPECTION
Work instruction No.
Date of execution
Day:
Year:
Month:
S4D102E-1
Service meter
hours
Inspector
INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK

Is there abnormality before starting inspection?
What is maximum level of coolant temperature?

(During operation)
....................................................................................................................
....................................................................................................................
White Green Green Green Green Red Red

1
2
3
4
5
6
7
....................................................................................................................
Outside temperature
Max.
Min.
Height
Check of work equipment for damage

Boom foot
Lower part of boom
Arm cylinder bracket
Revolving frame
Good
Bad
Good
Bad
Good
Bad
Other parts
Check of coolant level, oil level, and monitor

Engine coolant
Engine oil
Display of self-diagnosis
Hydraulic oil
Monitor (
Monitor panel
fl If machine is cold, warm it up.

Item
Condition
Unit
Standard
MeasureService limit
value for
ment
Good
value
new machine
result
925 975
rpm
2,340 2,460
Min. 2,100
Min. 2,000
Max. 0.49
{Max. 50}
0.34 0.59
{3.5 6.0}
Min. 0.10
{Min. 1.0}
0.34 0.59
{3.5 6.0}
Min. 0.08
{Min. 0.8}
Max. 0.98
{Max. 100}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
3.5 4.1
Max. 4.4
2.8 3.4
Max. 3.7
2.9 3.5
Max. 4.0
2.6 3.2
Max. 3.7
1.0 1.6
Max. 2.5
25 2
25 4
Max. 26
Max. 32
Max. 39
Max. 48
Max. 500
Max. 700
Low idling
Engine speed
Engine
Bucket CURL relief

Blow-by pressure
kPa
{mmAq}
Arm IN relief
High idling
SAE30
Low idling
Lubricating oil
pressure
MPa
{kg/cm2}
High idling
SAE10W
Low idling
Hydraulic oil
temperature
Boom raised
(to just before cushion)
Arm out
Arm in
Bucket curled
45 55 C
No load applied and

extended to end
Boom in horizontal
position
Bad
Boom and arm in

horizontal positions
Blade raised
sec
Left
5-turn swing
Right
High speed
Engine at full
throttle
Left
Right
5-turn travel
Left
Low speed
Right
Hydraulic drift of
work equipment
PC128US-2
Rated load applied and engine stopped
mm/15min
20-133
(14)
Oil
pressure
PC128US-2 # 5001 and up

Condition
Item
Low idling
Pc All levers in neutral
Engine at full
throttle
Control oil pressure
All levers in neutral

Boom-RAISE circuit relieved
Arm-IN circuit relieved
Main relief valve and safety valve
Bucket-CURL circuit relieved

Left-swing
circuit relieved
Right-swing
circuit relieved
Right-swing
circuit relieved
Left-swing
circuit relieved
Serial No.
5001 7730
Engine at full
Serial No.
Main oil pressure
7731 and up throttle
Blade-RAISE circuit relieved

Blade-LOWER circuit
relieved
Right-travel-forward circuit
relieved
Right-travel-reverse circuit
relieved
Left-travel-forward circuit
relieved
Left-travel-reverse circuit
relieved
Servo piston input

pressure
PC
Control lever in neutral
LS 1-side track running idle

Travel speed: Hi
Travel lever in half position
20-134
(14)
Engine at full
throttle
LS differential
pressure
< >: Reference value

Standard
value for
ment
Unit
Good
value
new machine
result
<2.45 3.43> <2.45 3.43>
{<25 35>}
{<25 35>}
3.04 3.43
2.75 3.73
{31 35}
{28 38}
<2.45 3.43>
{<25 35>}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
30.4 32.4
28.9 32.9
{310 330}
{295 335}
30.4 32.4
28.9 32.9
{310 330}
{295 335}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
MPa
31.9 33.8
30.9 33.8
{kg/cm2}
{325 345}
{315 345}
30.9 33.8
29.9 34.8
{315 345}
{305 355}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
2.45 4.41
2.45 4.41
{25.0 45.0} {25.0 45.0}
14.5 17.5
13.5 18.4
{148 178}
{138 188}
1.77 3.73
{18.0 38.0}
2.11 2.30
{21.5 23.5}
Bad
PC128US-2
PC138USLC-2 # 1001 1500

Machine Serial No.
Mounted engine
HOUR INSPECTION
Date of execution
Day:
Year:
Month:
S4D102E-1
Service meter
hours
Inspector


(During operation)
....................................................................................................................
....................................................................................................................

1
2
3
4
5
6
7
....................................................................................................................
Outside temperature
Max.
Min.
Height

Boom foot
Lower part of boom
Revolving frame
Good
Bad
Good
Bad
Good
Bad
Other parts

Engine coolant
Engine oil
Hydraulic oil
Monitor (
Monitor panel

Item
Condition
Unit
Standard
value for
ment
Good
value
new machine
result
925 975
rpm
2,340 2,460
Min. 2,100
Min. 2,000
Max. 0.49
{Max. 50}
0.34 0.59
{3.5 6.0}
Min. 0.10
{Min. 1.0}
0.34 0.59
{3.5 6.0}
Min. 0.08
{Min. 0.8}
Max. 0.98
{Max. 100}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
3.5 4.1
Max. 4.4
2.8 3.4
Max. 3.7
2.9 3.5
Max. 4.0
2.9 3.5
Max. 4.0
1.0 1.6
Max. 2.5
23.0 27.0
21.0 29.0
Max. 26.5
Max. 32.6
Max. 41.6
Max. 50.6
Max. 500
Max. 700
Low idling
Engine speed
Engine
Bucket CURL relief

Blow-by pressure
kPa
{mmAq}
Arm IN relief
High idling
SAE30
Low idling
Lubricating oil
pressure
MPa
{kg/cm2}
High idling
SAE10W
Low idling
Hydraulic oil
temperature
Boom raised
Arm out
Arm in
Bucket curled
45 55 C
No load applied and

extended to end
Boom in horizontal
position
Bad
Boom and arm in

Blade raised
sec
Left
5-turn swing
Right
High speed
Engine at full
throttle
Left
Right
5-turn travel
Left
Low speed
Right
Hydraulic drift of
work equipment
PC128US-2
mm/15min
20-135
(17)
Oil
pressure
PC138USLC-2 # 1001 1500

Condition
Item
Low idling
Engine at full
throttle

Boom-RAISE circuit
relieved

Bucket-CURL circuit
relieved
Right-swing circuit
relieved
Left-swing circuit
relieved
Blade-RAISE circuit
relieved
Blade-LOWER circuit
relieved
Right-travel-forward
circuit relieved
Right-travel-reverse
circuit relieved
Left-travel-forward
circuit relieved
Left-travel-reverse
circuit relieved
Engine at full
throttle
PC
Servo piston input

pressure
Bucket-CURL circuit
relieved

Travel speed: Hi
Travel lever in half
position
20-136
(17)
Main oil pressure
Engine at full
throttle
LS differential
pressure

Standard
value for
ment
Unit
Good
value
new machine
result
<2.45 3.43> <2.45 3.43>
{<25 35>}
{<25 35>}
3.04 3.43
2.75 3.73
{31 35}
{28 38}
<2.45 3.43>
{<25 35>}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
26.5 28.4
25.0 28.9
{270 290}
{255 295}
31.9 33.8
30.9 33.8
{325 345}
{315 345}
MPa
30.9 33.8
29.9 34.8
{kg/cm2} {315 345}
{305 355}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
2.45 4.41
2.45 4.41
{25.0 45.0} {25.0 45.0}
14.5 17.5
13.5 18.4
{148 178}
{138 188}
1.77 3.73
{18.0 38.0}
2.11 2.30
{21.5 23.5}
Bad
PC128US-2
PC138US-2
# 4501 and up
PC138USLC-2 # 1501 and up
Machine Serial No.
Mounted engine
HOUR INSPECTION
Date of execution
Day:
Year:
Month:
SAA4D95LE-3-A
Service meter
hours
Inspector


(During operation)
....................................................................................................................
....................................................................................................................

1
2
3
4
5
6
7
....................................................................................................................
Outside temperature
Max.
Min.
Height

Boom foot
Lower part of boom
Revolving frame
Good
Bad
Good
Bad
Good
Bad
Other parts

Engine coolant
Engine oil
Hydraulic oil
Monitor (
Monitor panel

Item
Condition
Unit
Low idling
Engine speed
1,050 1,150
rpm
Engine
Bucket CURL relief

Blow-by pressure
kPa
{mmAq}
Arm IN relief
High idling
SAE30
Low idling
Lubricating oil
pressure
MPa
{kg/cm2}
High idling
SAE10W
Low idling
Hydraulic oil
temperature
Boom raised
Arm out
Arm in
Bucket curled
Standard
value for
ment
Good
value
new machine
result
45 55 C
No load applied and
extended to end
Boom in horizontal
position
Bad
2,340 2,460
Min. 2,100
Min. 2,000
Max. 0.49
{Max. 50}
0.34 0.59
{3.5 6.0}
Min. 0.10
{Min. 1.0}
0.34 0.59
{3.5 6.0}
Min. 0.08
{Min. 0.8}
Max. 0.98
{Max. 100}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
3.5 4.1
Max. 4.4
2.8 3.4
Max. 3.7
2.9 3.5
Max. 4.0
2.9 3.5
Max. 4.0
1.0 1.6
Max. 2.5
23.0 27.0
21.0 29.0
Boom and arm in

Blade raised
sec
Left
5-turn swing
5-turn travel
Hydraulic drift of
work equipment
PC128US-2
Right
Left/Right
#1001 2599
High
#2600 4500 Engine at Left/Right
speed
#4501 and up full throttle Left/Right
Max. 26
Max. 32
Max. 26.9
Max. 32.3
Max. 27
Max. 33
#1001 2599
Left/Right
Max. 39
Max. 48
Low
speed #2600 4500
Left/Right
Max. 43.5
Max. 52.2
#4501 and up
Left/Right
Max. 45
Max. 54
Max. 500
Max. 700
mm/15min
20-137
(17)
PC138US-2
# 4501 and up
PC138USLC-2 # 1501 and up
Bad
Oil
pressure

Standard
value for
ment
Condition
Item
Unit
Good
value
new machine
result
<2.45 3.43> <2.45 3.43>
Low idling
{<25 35>}
{<25 35>}
3.04 3.43
2.75 3.73
Engine at full
{31 35}
{28 38}
throttle
<2.45 3.43>

{<25 35>}
31.4 32.4
30.9 33.8
Boom-RAISE circuit relieved
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
31.4 32.4
30.9 33.8
{320 330}
{315 345}
26.5 28.4
25.0 28.9
Left-swing
{270 290}
{255 295}
circuit relieved
31.9 33.8
30.9 33.8
Blade-RAISE circuit relieved Engine at full
{325 345}
{315 345}
Main oil pressure
throttle
30.9 33.8
29.9 34.8
Blade-LOWER circuit
MPa
{315 345}
{305 355}
relieved
{kg/cm2}
33.8 35.8
32.9 36.8
Right-travel-forward circuit
{345 365}
{335 375}
relieved
33.8 35.8
32.9 36.8
Right-travel-reverse circuit
{345 365}
{335 375}
relieved
33.8 35.8
32.9 36.8
Left-travel-forward circuit
{345 365}
{335 375}
relieved
33.8 35.8
32.9 36.8
Left-travel-reverse circuit
{345 365}
{335 375}
relieved
2.45 4.41
2.45 4.41
{25.0 45.0} {25.0 45.0}
PC
14.5 17.5
13.5 18.4
{148 178}
{138 188}
Servo piston input
pressure
1.77 3.73

Engine at full
{18.0 38.0}
throttle
LS differential
2.11 2.30
Travel speed: Hi
{21.5 23.5}
pressure
Travel lever in half position
20-138
(17)
PC128US-2
TROUBLESHOOTING
Points to remember when trobleshooting ............................................................................................ 20-202
Sequence of events in troubleshooting ................................................................................................ 20-203
Points to rememver when carrying out maintenance .......................................................................... 20-204
Checks before troubleshooting .............................................................................................................. 20-212
Connector types and mounting locations ............................................................................................. 20-214
Connector arrangement diagram .......................................................................................................... 20-216
Connection table for connector pin numbers ....................................................................................... 20-219
Functional description of electrical system mechanism (PC128US-2
Serial No.: 7731 and up)
(PC138USLC-2 Serial No.: 1001 and up) .... 20-231
Monitor panel display and special functions (PC128US-2
(PC138USLC-2 Serial No.: 1001 and up) ................... 20-232
Method of using troubleshooting charts (PC128US-2 Serial No.: 5001 7730) ................................ 20-247
Judgment table for electricl system, hydraulic and mechanical system
(PC128US-2 Serial No.: 5001 7730) ............................... 20-250
How to read decision list (PC128US-2
(PC138USLC-2 Serial No.: 1001 and up).................................................... 20-252
Method of using troubleshooting charts (PC128US-2
(PC138USLC-2 Serial No.: 1001 and up) .......................... 20-254
Diagnostic contents and diagnostic procedure at troubleshooting
(PC128US-2
(PC138USLC-2 Serial No.: 1001 and up) .......................... 20-256
Troubleshooting of electrical system (E mode) (PC128US-2 Serial No.: 5001 7730) ..................... 20-301
Troubleshooting of hydraulic, mechanical systems (H mode) ............................................................ 20-401
Troubleshooting of machine monitor system (M mode) (PC128US-2 Serial No.: 5001 7730) ........ 20-501
Troubleshooting of machine monitor system (M mode) (PC128US-2
(PC138USLC-2 Serial No.: 1001 and up) ... 20-551
Troubleshooting of communication system (N mode) (PC128US-2
Troubleshooting of controller CR700 [deceleration control system] (E mode)
(PC128US-2
Troubleshooting of controller CR700 [pump control system] (C mode)
(PC128US-2
Troubleshooting of controller CR700 [input signal system] (F mode)
(PC128US-2
Troubleshooting of engine (S mode) ..................................................................................................... 20-951
PC128US-2
20-201
(14)
POINTS
TROUBLESHOOTING
POINTS TO REMEMBER
TO REMEMBER
WHEN
TROUBLESHOOTING
WHEN TROUBLESHOOTING
Stop: the machine

curely fitted.
in a level place, and check that the safety pin, blocks, and parking
brake are se-
When carrying out the operation with two or more workers,

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.,
keep strictly to the agreed signals, and
Be extremely
When disconnecting
careful not to touch any hot parts or to get caught in any rotating
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.
wiring,
always disconnect
the negative
(-1 terminal
parts.
of the battery first.
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.
2.
3.
When carrying out troubleshooting,

do not
hurry to disassemble the components.
If components are disassembled
immediately
any failure occurs:
.
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
.
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 through
prior investigation
and to carry out troubleshooting in accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occured apart
from the problem that had been reported?
2) Was there anything strange about the machine before tha 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) Check the oil level.
20-202
0
2)
4.
5.
6.
Checkfor any external leakage of oil from

the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve
spool.
5) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
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.
*
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 flowchart to locate the position of the
failure exactly.
Ir 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 dailure 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 occureed. Then, remove the root
cause.
PC1 28US-2
SEQUENCE
TROUBLESHOOTING
SEQUENCE
OF EVENTS
IN TROUBLESHOOTING
OF EVENTS IN TROUBLESHOOTING
TEWOO180
TEW00181
\
step 1
Examination,
1)
When
confirmation
a request
for repairs
ask the following
2)
of symptoms
Name
of customer
Type,
serial number
Details
of jobsite,
Ask questions
is received,
II
-------
first
points.
Ring 1 Ring
__-----
of machine
etc.
to gain an outline
of the prob-
lem.
.
Condition
Work being carried out at the time of the
of failure
TEWM)182
failure
jtep
Operating
Past history,
environment
details
of maintenance,
etc.
2
Determining
1)
location
of cause
Look at the troubleshooting
section
shop
probable
manual
to find
locations
TEWO0183
of the
of possible
causes.
step 3
Preparation
1)
of troubleshooting
tools
Look at the table of troubleshooting

the shop manual
and prepare
=tools in
oa
/step
the necessaw
2)
Hydraulic
7
1.
tools.
.
T-adapter
=z
pressure
gauge
kit, etc.
Look in the parts book and prepare
the nec-
essary replacement
Pinpoint
locations
of failure
(carry out
troubleshooting)
Decide
action to take
1)
Before
starting
repair simple
2)
troubleshooting,
Check before
Other check items
starting
See the Troubleshooting

manual,
that
locate
and
failures.
select
matches
items
Section
of the shop
a troubleshooting
the symptoms,
flowchart
and carry out
troubleshooting.
TEWOO187
Drive
and
operate
the condition
the
and judge
machine
to confirm
if there
is really
Step 4
(Go]
Was there
anything
chine before
strange
the failure
Did the failure

Had any repairs
about
the ma-
occurred?
occur suddenly?
been carried
out before the
TEwoo188
PC128US-2
20-203
0
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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).
1. 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.
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.
(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.
20-204
(17)
PC128US-2
TROUBLESHOOTING
(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.
TEW00194
(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.
As already said, 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 shortcircuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing electricity through it.
(5) 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.
fl When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
fl 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.
PC128US-2
TEW00195
TEW00196
20-205
(17)
TROUBLESHOOTING
2) Removing, installing, and drying connectors and

wiring harnesses
Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. 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.
fl Never pull with one hand.
(2) When removing from clips
When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.
Catches
(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.
fl If the machine is left disassembled for a
long time, it is particularly easy for improper contact to occur, so always cover
the connector.
20-206
(17)
PC128US-2
TROUBLESHOOTING
Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check that there is no deformation, defective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or breakage to the outside of the connector.
fl 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.
fl If there is any damage or breakage, replace the connector.
(2) Fix the connector securely.
Align the position of the connector correctly,
then insert it securely.
For connectors with 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.
fl If the connector cannot be corrected easily, remove the clamp and adjust the
position.
(4) If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female connector
Normal locking state (Horizontal) : a, b, d
Incomplete locking state (Diagonal) : c
PC128US-2
20-207
(17)
TROUBLESHOOTING
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.
fl 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 oil and water from the compressed air before blowing with air.
TEW00196
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
fl 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.
TEW00202
(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.
fl After completely drying the connector,
blow it with contact restorer and reassemble.
20-208
(17)
PC128US-2
TROUBLESHOOTING
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box
unless necessary.
TEW00204
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
(5) During rainy weather, do not leave the control box in a place where it is exposed to
rain.
TEW00205
(6) Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors connected to the control box. Fit an arc welding
ground close to the welding point.
TEW00206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl 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.
fl If there is any change, there is probably defective contact in that circuit.
PC128US-2
20-209
(17)
TROUBLESHOOTING
3.
POINTS
POINTS TO REMEMBER WHEN

HYDRAULIC EQUIPMENT
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
HANDLING
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,
repairing the machine in rain or high winds,
places where there is a lot of dust.
or
or
21 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 confirm the performance after repairs,
so it is desirable to use unit exchange. Disassembly and main-tenance
of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance
should be confirmed with special test equipment.
3)
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 on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEWOO208
4)
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.
20-210
0
PC I 2aus-2
TROUBLESHOOTING
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
51 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. (Do not 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.
6) 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.
oi I
TEW00710
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 ultrafine (about 3~) particles that the filter
built into the hydraulic equipment
cannot remove, so it is an extremely effective device.
TEW00211
PC 128US-2
20-211
0
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Hydraulic, mechanical equipment
Electrical
equipment
Lubricating oil, coolant
Item
Judgment value
Action
1. Check fuel level, type of fuel
Add fuel
2. Check for impurities in fuel
Clean, drain
3. Check hydraulic oil level
Add oil
4. Check hydraulic strainer
Clean, drain
5. Check swing machinery oil level
Add oil
6. Check engine oil level
Add oil
7. Check coolant level
Add coolant
8. Check dust indicator for clogging
Clean or replace
9. Check hydraulic filter
Replace
1. Check for looseness, corrosion of battery terminal, wiring
Tighten or replace
2. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
3. Check for looseness, corrosion of starting motor terminal,

wiring
Tighten or replace
1. Check for abnormal noise, smell
Repair
2. Check for oil leakage
Repair
3. Carry out air bleeding
Bleed air
24 30V
Replace
2. Check battery electrolyte level
Add or replace
3. Check for discolored, burnt, exposed wiring
Replace
4. Check for missing wiring clamps, hanging wiring
Repair
5. Check for water leaking on wiring (be particularly careful

attention to water leaking on connectors or terminals)
Disconnect
connector and dry
Electrics, electrical equipment
1. Check battery voltage (engine stopped)
6. Check for blown, corroded fuses

7. Check alternator voltage (engine running at 1/2 throttle or
above)
20-212
(17)
After running for

several minutes:
27.5 29.5 V
Replace
Replace
PC128US-2
CONNECTOR TYPES AND MOUNTING LOCATIONS
TROUBLESHOOTING
PC128US-2
fl The Address column in this table shows the address in the connector pin allocation drawing (3dimensional drawing).
Connector No.
ConnecNo. of
tor
pins
type
Place of use
Address
Connector No.
ConnecNo. of
tor
pins
type
Place of use
Address
PC-EPC valve diode
F-5
A01
Intermediate connector
A-2
D23
KES
A02
B-2
D24
KES
Pumping switch diode
F-5
R-5
A03
SWP
16
A-2
E11
Body ground
(Ribbon heater relay)
A04
SWP
16
A-2
E13
Starting motor
N-3
A05
DT
B-2
E14
Ribbon heater relay
R-6
A06
DT
A-1
E15
N-7
A07
DT
A-2
E16
Engine air heater relay
M-6
A08
SWP
B-2
E17
Alternator
O-3
A09
SWP
16
A10
DT
(Arm crane)
(Arm crane)
A20
16
D-9
F01
Travel/swing alarm (OPT)
H-2
A21
16
D-4
F02
Arm crane revolving light
K-8
A22
12
D-4
FB1
Fuse box
F-6
A23
SWP
12
H-5
H08
F-6
C09
DT
Attachment selection connector
E-8
H09
F-6
C06 SUMITOMO 16
Prolix switch
D-8
H16
Arm crane buzzer
A-6
C05
DT
Pressure sensor
G-6
K19
Pump prolix resistor
F-8
C10
Arm ground cancel selection
F-8
M02
Safety relay
O-3
C13
EPC valve solenoid for PC
I-8
M10 DEUTSCH
G-6
C14
EPC valve solenoid for LS
J-8
M11
Fusible link
L-3
CR1
DT
24
CR700 Controller
F-7
M13
DT
Boom work equipment lamp
G-7
CR2
DT
40
CR700 Controller
F-7
M13
Speaker (Right)
K-8
CR3
CT
40
CR700 Controller
F-7
M14
Fusible link
L-3
D01
KES
Window washer diode
F-5
M15
Fusible link
L-3
D05
KES
Swing holding brake diode F-5
M16
Horn
I-2
D06
KES
Travel speed diode
F-5
X
YAZAKI
M22
090
Horn switch
B-7
E07
Engine speed sensor
N-6
M26
SWP
12
A/C unit
E-9
D08
KES
Swing holding brake cancel

switch diode
E-5
M28
Window washer
L-5
D14
SWP
Battery relay diode
L-4
M30
OPT power supply
G-3
D15
Stop solenoid diode
O-7
M31
OPT power supply
D-9
D17
KES
Heater relay diode
E-4
M34
Airconditioner compressor Q-7
D20
KES
PPC hydraulic lock diode
F-5
M36F
Kerosene mode
F-8
D22
SWP
Battery relay diode
L-4
M36M
Kerosene mode
F-8
20-218-2
(17)
C-2
E20
SWP
M-5
A-1
E30
Safety relay
N-3
PC128US-2
TROUBLESHOOTING
Connector No.
M38
ConnecNo. of
tor
pins
type
Place of use
Address
Connector No.
ConnecNo. of
tor
pins
type
Address
Place of use
Light switch
C-8
S17
Engine hydraulic switch
R-4
M40 YAZAKI
Cigar lighter
A-5
S30
Right swing pressure switch
G-4
M40
Cab work equipment lamp (STD)
I-8
S31
Boom RAISE pressure switch G-5
M41
SWP
Arm crane monitor
A-7
S32
Arm dump pressure switch
G-5
M41
Cab work equipment lamp (OPT)
J-8
S33
Boom LOWER pressure switch
G-4
M47
090
20
B-7
S34
Bucket digging pressure switch G-5
M48
DT
Auto decelerator motor
L-4
S35
Bucket dump pressure switch G-5
M49
PA
Radio
F-7
S36
G-6
M50
Wiper motor
A-6
S37
L-4
M51
Fuel dial
B-7
S50
Emergency pumping switch D-9

D-9
M71
Room lamp
L-7
S51
Swing holding brake cancel

switch
M73
Speaker (Left)
L-7
T01
Battery
L-5
M80
20
Airconditioner panel
F-6
T02
Revolving ground
L-4
M81
16
Airconditioner panel
F-6
T03
Revolving ground
L-5
M83 SUMITOMO
Intake duct (Airconditioner)
F-6
V04
Swing holding brake solenoid
G-7
M84
SWP
14
E-9
V05
Travel speed solenoid
G-8
M85
SWP
16
(Airconditioner unit)
(Airconditioner unit)
E-9
V06
2-stage relief valve solenoid G-6
M87
12
A/C unit
C-4
V07
PPC hydraulic lock solenoid H-8
M88 YAZAKI
10
B-5
W03
Rear limit switch
K-8
M92
DT
Airconditioner foot spurting

servo
Boom cylinder bottom
pressure sensor
X05
Swing lock switch
D-8
P01
AMP
12
Monitor panel
A-7
P02
AMP
20
Monitor panel
A-6
P03
Buzzer cancel switch
C-8
P06
Fuel level sensor
I-8
O-7
P07
Engine water temperature

sensor
P15
AMP
Solar radiation center
F-6
R06 SINAGAWA
B-8
R07 SINAGAWA
Motor driven relay
B-3
R08 SINAGAWA
Decelerator relay
B-3
R09 SINAGAWA
Accelerator relay
B-3
R10 SINAGAWA
Revolving light driving relay
B-7
S01
B-4
S05
Arm digging pressure switch
G-5
S08
Left swing pressure switch G-4
S10
Hydraulic lock switch
PC128US-2
E-4
20-218-3
7
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
PC128US-2
20-218-4
(17)
PC128US-2
TROUBLESHOOTING
PC138US-2
fl The Address column in this table shows the address in the connector pin allocation drawing (3dimensional drawing).
Connector No.
ConnecNo. of
tor
pins
type
Address
Place of use
Connector No.
A01
L-4
A02
SWP
14
L-4
H08
A03
SWP
14
K-4
ConnecNo. of
tor
pins
type
HOLD Terminal
Address
Place of use
Q-2
F-4
H09
F-4
A-6
H16
Arm crane buzzer
A-4
A06
DT
(Arm crane)
A20
16
C-7
J1
SUMITOMO
20
Junction connector
F-7
A21
16
D-4
J2
SUMITOMO
20
Junction connector
F-6
AR
DT
Alternator
M-5
J3
SUMITOMO
20
Junction connector
F-6
C05
DT
Pressure sensor
G-8
K19
Pump prolix resistance
F-7
C06 SUMITOMO
16
Prolix switch
C-7
M02
Safety relay
H-1
C13
EPC valve solenoid (PC)
J-9
M10
DT
G-7
C14
EPC valve solenoid (LS)
I-9
M11
Fusible link
L-4
CR1
DT
24
CR 700 controller
F-6
M13
Boom working lamp
G-9
CR2
DT
40
CR 700 controller
F-6
M13
Speaker (Right)
K-9
CR3
DT
40
CR 700 controller
F-6
M14
Fusible link
L-4
M16
SWP
Horn
A-3
M22
090
Horn switch
B-5
M26
SWP
12
E-7
M28
KES
Window washer
L-6
M30
Power source (Opt)
F-4
D01
SWP

Diode Heater relay
F-3
D02
SWP
Swing holding brake

Diode release, Battery relay, F-3
Window washer
2-stage ralief, PPC

safety lock, Swing
Diode holding brake, Travel
speed selector
D03
SWP
E07
Engine speed sensor
M-5
M31
Power source (Opt)
D-7
E11 Terminal
Electrical intake air heater relay
H-1
M34
Q-8
E12 Terminal
Relay ground
H-1
M38
Light switch
B-7
E14 Terminal
G-2
M40 YAZAKI
Cigarette lighter
A-4
E17
Alternator
N-3
M40
Cab working lamp (STD)
H-9
E30 Terminal
Safety relay
H-3
M41
SWP
Arm crane monitor
A-6
E50 Terminal
Starting motor
Q-4
M41
Cab working lamp (OPT)
J-9
E51 Terminal
G-2
M47
090
20
B-6
E52 Terminal
P-9
M48
DT
Auto-decelation motor
L-5
EU1
Overload alarm switch
F-5
M49
PA
Radio
F-5
F01
DT
Travel and swing alarm (Opt)
H-9
M50
Wiper motor
A-5
F02
Arm crane beacon lamp
K-9
M51
Fuel dial
B-6
I-3
L-9
FB1
DT
H-3
GND Terminal
20-218-8
(17)
Fuse box
F-5
M52
DT
(Engine stop solenoid relay)
Q-2
M71
Room lamp
PC128US-2
TROUBLESHOOTING
Connector No.
ConnecNo. of
tor
pins
type
Place of use
Address
Connector No.
ConnecNo. of
tor
pins
type
Address
Place of use
M73
Speaker (Left)
L-8
T01 Terminal
Battery
L-6
M80
20
Air conditioner panel
F-4
T02 Terminal
Revolving ground
L-5
M81
16
Air conditioner panel
F-5
T03 Terminal
Revolving ground
L-5
Intake duct (Air conditioner)
F-6
T04
Radio ground
F-5
F-5
T05 Terminal
Floor ground
C-3
F-7
T06 Terminal
Floor frame ground
B-3
D-3
T21 Terminal
I-1
B-3
T22 Terminal
I-3
M83 SUMITOMO
M84
SWP
14
M85
SWP
16
(Air conditioner unit)
(Air conditioner unit)
M87
12
M88 YAZAKI
10
PULL Terminal
Q-2
V03 SHINAGAWA
Starting motor relay
B-6
P01
AMP
12
Monitor panel
A-5
V4
DT
G-8
P02
AMP
20
Monitor panel
A-5
V5
DT
G-9
P03
C-7
V6
DT
G-8
P06
Fuel level gauge
I-9
V7
DT
PPC hydraulic safety lock solenoid
H-9
P07
Engine coolant temperature sensor P-8
V06
E-7
Airconditioner outsideair
temperature sensor
E-3
V07
E-7
A-5
V08
E-7
P09
SWP
P15
AMP
R06 SHINAGAWA
Starting motor cutout relay
B-6
V09
E-7
R08 SHINAGAWA
Deceleration relay
J-3
W03
Rear limit switch
K-9
R09 SHINAGAWA
Accelerator relay
J-3
X05
Swing lock switch
C-7
R10 SHINAGAWA
Beacon lamp drive relay
B-6
S01
Drive pressure switch
C-3
S05
Arm IN pressure switch
G-6
S08
Left swing pressure switch
G-5
S10
PPC hydraulic lock switch
E-3
S17 Terminal
Engine oil pressure switch
N-4
S30
Right swing pressure switch
G-5
S31
Boom RAISE oil pressure switch
G-6
S32
Boom DUMP oil pressure switch
G-6
S33
Boom LOWER oil pressure switch
G-6
S34
Bucket digging pressure switch
G-6
S35
Bucket DUMP oil pressure switch
G-7
S36
G-7
S37
G-7
S50
D-7
S51
D-7
PC128US-2
20-218-9
(17)
TROUBLESHOOTING

PC138US-2
20-218-10
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-218-11
(17)
TROUBLESHOOTING
20-218-12
(17)
PC128US-2
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
a Deuscht connector has marks of pin numbers on the wiring harness side.
X Type Connector
Number of
Pins
Male (Female housing)
Female (Male housing)
T-adapter Part
Number
Part number: 08055-00181
799-601-7010
BWP04702
799-601-7020
BWP04703
BWP04704
BWP04705
799-601-7030
BWP04706
799-601-7040
Terminal part number: 79A-222-3370

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 2.0
Quantity: 20 pieces
Grommet: red

Wire size: 2.0
Quantity: 20 pieces
Grommet: red
PC128US-2
20-219
(17)
Number of
Pins
SWP Type Connector

BWP04707
BWP04708
799-601-7050
BWP04709
BWP04711
12
BWP04713
BWP04710
799-601-7060
BWP04712
BWP04714
799-601-7070
(17)
799-601-7310
14
20-220
T-adapter Part
Number
PC128US-2
SWP Type Connector
Number of
Pins
BWP04715
16
BWP04716
T-adapter Part
Number
799-601-7320
Terminal part number:

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 1.25
Quantity: 20 pieces
Grommet: red

Wire size: 1.25
Quantity: 20 pieces
Grommet: red
PC128US-2
20-221
(17)
M Type Connector
Number of
Pins
T-adapter Part
Number
799-601-7080
BWP04717
BWP04719
BWP04721
BWP04723
BWP04725
20-222
(17)
BWP04718
799-601-7090
BWP04720
799-601-7110
BWP04722
799-601-7120
BWP04724
799-601-7130
BWP04726
799-601-7340
PC128US-2
Number of
Pins
S Type Connector
BWP04727
10
(white)
BWP04729
12
(white)
BWP04731
16
(white)
BWP04733
PC128US-2
T-adapter
Part Number
BWP04728
799-601-7140
BWP04730
799-601-7150
BWP04732
799-601-7350
BWP04734
799-601-7330
20-223
(17)
Number of
Pins
10
(blue)
S Type Connector
BWP04735
12
(blue)
BWP04737
16
(blue)
BWP04739
20-224
(17)
T-adapter Part
Number
BWP04736
BWP04738
799-601-7160
BWP04740
799-601-7170
PC128US-2
Number of
Pins
MIC Type Connector

T-adapter Part
Number
Body part number: 79A-222-2640

(Quantity: 5 pieces)

11


BWP04741
BWP04742
799-601-2710

BWP04743

BWP04744
799-601-2950

BWP04745

BWP04746
13
799-601-2720

PC128US-2

20-225
(17)
Number of
Pins
MIC Type Connector

BWP04747
BWP04748
17
799-601-2730

BWP04749

BWP04750
21
20-226
(17)
T-adapter Part
Number
799-601-2740




PC128US-2
Number of
Pins
AMP040 Type Connector

BWP04751
T-adapter Part
Number
BWP04752
799-601-7180
Housing part number: 79A-222-3430

BWP04753
BWP047544
12
799-601-7190

BWP04755
BWP04756
16
799-601-7210

BWP04757
BWP04758
20
799-601-7220

a Terminal part number: 79A-222-3470 (for all numbers of pins).
PC128US-2
20-227
(17)
Number of
Pins
AMP070 Type Connector

10
799-601-7510
12
BWP04761
14
BWP04763
18
BWP04765
20
BWP04767
20-228
(19)
T-adapter Part
Number
Part number: 7821-92-7330
BWP04762
799-601-7520
BWP04764
799-601-7530
BWP04766
799-601-7540
BWP04768
799-601-7550
PC128US-2
Number of
Pins
L Type Connector
BWP04769
BWP04770
Number of
Pins
10
BWP04771
T-adapter
Part Number
BWP04772
BENDIX (MS) Type Connector
BWP04773
PC128US-2
PA Type Connector
Number of
Pins
T-adapter
Part Number
T-adapter Part
Number
BWP04774
799-601-3460
20-229
(17)
Number of
Pins
KES1 Automobile Type Connector

BWP04775
BWP04776
Part number: 08027-10210 (Natural color)

08027-10220 (Black)
BWP04777
BWP04779

08027-10270 (Black)
BWP04778
BWP04780

08027-10420 (Black)
BWP04781

08027-10470 (Black)
BWP04782

08027-10620 (Black)
(17)
20-230
T-adapter
Part Number

08027-10670 (Black)
PC128US-2
KES1 Automobile Type Connector
Number of
Pins
T-adapter
Part Number
BWP04784
BWP04783

08027-10820 (Black)
Number of
Pins

08027-10870 (Black)
Connector for relay (Socket)

BWP04785
BWP04786
799-601-7360
BWP04787
BWP04788
799-601-7370
Type
(shell
size
code)
F Type Connector
Pin (Male terminal)
Body (Female terminal)
T-adapter
Part Number
PC128US-2
T-adapter Part
Number
20-230-1
(17)
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector
Type
(shell size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part
Number
799-601-9210
18-8
(1)
Part number: 08191-11201, 08191-11202

08191-11205, 08191-11206
Part number: 08191-14101, 08191-14102

08191-14105, 08191-14106
Pin (male terminal)
799-601-9210
Part number: 08191-11201, 08191-12202

08191-11205, 08191-12206
Pin (male terminal)
Part number: 08191-13101, 08191-13102

08191-13105, 08191-13106
799-601-9220
18-14
(2)
Part number: 08191-21201, 08191-12202

08191-21205, 08191-12206
Part number: 08191-24101, 08191-24102

08191-24105, 08191-24106
Pin (male terminal)
799-601-9220
Part number: 08191-22201, 08191-22202

08191-22205, 08191-22206
20-230-2
(17)
Part number: 08191-23101, 08191-23102

08191-23105, 08191-23106
PC128US-2
Type
(shell size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter Part
Number
799-601-9230
18-20
(3)
Part number: 08191-31201, 08191-31202

Part number: 08191-34101, 08191-34102

Pin (male terminal)
799-601-9230
Part number: 08191-32201, 08191-32202

Pin (male terminal)
Part number: 08191-33101, 08191-33102

799-601-9240
18-21
(4)
Part number: 08191-41201, 08191-42202

Part number: 08191-44101, 08191-44102

Pin (male terminal)
799-601-9240
Part number: 08191-42201, 08191-42202
PC128US-2
Part number: 08191-43101, 08191-43102
20-230-3
(17)
Type
(shell size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter Part
Number
799-601-9250
24-9
(5)
Part number: 08191-51201, 08191-51202

Part number: 08191-54101, 08191-54102

Pin (male terminal)
799-601-9250
Part number: 08191-52201, 08191-52202

Pin (male terminal)
Part number: 08191-53101, 08191-53102

799-601-9260
24-16
(6)
Part number: 08191-61201, 08191-62202

08191-61205, 08191-62206
Part number: 08191-64101, 08191-64102

08191-64105, 08191-64106
Pin (male terminal)
799-601-9260
Part number: 08191-62201, 08191-62202

08191-62205, 08191-62206
20-230-4
(17)
Part number: 08191-63101, 08191-63102

08191-63105, 08191-63106
PC128US-2
Type
(shell size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter Part
Number
799-601-9270
24-21
(7)
Part number: 08191-71201, 08191-71202

08191-71205, 08191-71206
Part number: 08191-74101, 08191-74102

08191-74105, 08191-74106
Pin (male terminal)
799-601-9270
Part number: 08191-72201, 08191-72202

08191-72205, 08191-72206
Pin (male terminal)
Part number: 08191-73102, 08191-73102

08191-73105, 08191-73106
799-601-9280
24-23
(8)
Part number: 08191-81201, 08191-81202,

08191-81203, 08191-81204,
08191-81205, 08191-80206
Part number: 08191-84101, 08191-84102,

08191-84103, 18191-84104,
08191-84105, 08191-84106
Pin (male terminal)
799-601-9280
Part number: 08191-82201, 08191-82202,

08191-82203, 08191-82204,
08191-82205, 08191-82206
PC128US-2
Part number: 08191-83101, 08191-83102,

08191-83103, 18191-83104,
08191-83105, 08191-83106
20-230-5
(17)
Type
(shell size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter Part
Number
799-601-9290
24-31
(9)
Part number: 08191-91203, 08191-91204

08191-91205, 08191-91206
Part number: 08191-94103, 08191-94104

08191-94105, 08191-94106
Pin (male terminal)
799-601-9290
Part number: 08191-92203, 08191-92204

08191-92205, 08191-92206
20-230-6
(17)
Part number: 08191-93103, 08191-93104

08191-93105, 08191-93106
PC128US-2
DT Series connector
Number
of Pins
Body (plug)
Body (receptacle)
T-adapter Part
Number
799-601-9020
Part number: 08192-12200 (normal type)

08192-22200 (fine wire type)

799-601-9030


799-601-9040


799-601-9050

PC128US-2

20-230-7
(17)
DT Series connector
Number
of Pins
Body (plug)
Body (receptacle)
8GR:
799-601-9060
8B:
799-601-9070
8G:
799-601-9080
8BR:
799-601-9080
Part number: 08192-1820 T (normal type)

08192-2820 T (fine wire type)

12GR:
799-601-9110
12B:
799-601-9120
12G:
799-601-9130
12BR:
799-601-9140
12

20-230-8
(17)
T-adapter Part
Number

PC128US-2
DTM Series connector
Number
of Pins
Body (plug)
Body (receptacle)
T-adapter Part
Number
799-601-9010
DTHD Series connector
Number
of Pins
Body (plug)
Body (receptacle)
T-adapter Part
Number
Part number:08192-31200 (Contact size #12)

08192-41200 (Contact size #8)
08192-51200 (Contact size #4)
PC128US-2
Part number:08192-31100 (Contact size #12)

08192-41100 (Contact size #8)
08192-51100 (Contact size #4)
20-230-9
(17)
No. of
pins
DRC26 Series connector

Body (plug)
Body (receptacle)
24
799-601-9360
Part No.: 7821-93-3110
40
(A)
799-601-9350
Part No.: 7821-93-3120
40
(B)
799-601-9350
20-230-10
(19)
T-adapter
Part No.
Part No.: 7821-93-3130
PC128US-2
T-ADAPTER TABLE
T-ADAPTER TABLE
a The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker assemblies are shown in the lines.
Q Q
Q Q
799-601-9300
799-601-9200
799-601-9100
799-601-2600
For measuring box
Econo-21P
799-601-3100
For measuring box
MS-37P
799-601-3200
For measuring box
MS-37P
799-601-3300
For measuring box
Econo-24P
799-601-3360
Plate
For MS box
799-601-3370
Plate
For MS box
799-601-3380
Plate
For MS box
799-601-3410
BENDIX(MS)
24P
Q Q
799-601-3420
BENDIX(MS)
24P
Q Q
799-601-3430
BENDIX(MS)
17P
Q Q
799-601-3440
BENDIX(MS)
17P
799-601-3450
BENDIX(MS)
5P
799-601-3460
BENDIX(MS)
10P
799-601-3510
BENDIX(MS)
5P
Q Q
799-601-3520
BENDIX(MS)
14P
Q Q
799-601-3530
BENDIX(MS)
19P
799-601-2910
BENDIX(MS)
14P
799-601-3470
CASE
799-601-2710
MIC
5P
Q Q
799-601-2720
MIC
13P
Q Q
799-601-2730
MIC
17P
Q Q Q Q
Q Q
799-601-2740
MIC
21P
Q Q Q Q
Q Q
799-601-2950
MIC
9P
Q Q Q
799-601-2750
ECONO
2P
Q Q
799-601-2760
ECONO
3P
Q Q
799-601-2770
ECONO
4P
Q Q
799-601-2780
ECONO
8P
Q Q
799-601-2790
ECONO
12P
Q Q
799-601-2810
DLI
8P
Q Q
799-601-2820
DLI
12P
Q Q
799-601-2830
DLI
16P
Q Q
799-601-2840
Extension cable
Q Q
799-601-2850
CASE
799-601-7010
1P
799-601-7020
2P
Q Q Q
799-601-7030
3P
Q Q Q
799-601-7040
4P
Q Q Q
PC128US-2
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
Pin No.
799-601-2800
Connector type
799-601-2700
Port No.
799-601-2500
KIT No.
Q Q
Q Q
Q Q
Q Q
Q Q
Q
20-230-11
(19)
T-ADAPTER TABLE
799-601-7050
SWP
6P
Q Q Q
799-601-7060
SWP
8P
Q Q Q
799-601-7310
SWP
12P
799-601-7070
SWP
14P
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
Pin No.
799-601-2800
Connector type
799-601-2700
Port No.
799-601-2500
KIT No.
Q
Q
Q
Q
799-601-7320
SWP
16P
799-601-7080
1P
799-601-7090
2P
Q Q Q
799-601-7110
3P
Q Q Q
799-601-7120
4P
Q Q Q
799-601-7130
6P
Q Q Q
799-601-7340
8P
799-601-7140
8P
Q Q Q
799-601-7150
10P-White
Q Q Q
799-601-7160
12P-Blue
Q Q Q
799-601-7170
16P-Blue
Q Q Q
799-601-7330
16P-White
799-601-7350
12P-White
799-601-7180
AMP040
8P
799-601-7190
AMP040
12P
799-601-7210
AMP040
16P
Q Q Q
Q
Q
Q
799-601-7220
AMP040
20P
Q Q Q
799-601-7230
Short connector
X-2
Q Q Q
799-601-7240
Case
799-601-7270
Cace
799-601-7510
070
10P
799-601-7520
070
12P
799-601-7530
070
14P
799-601-7540
070
18P
799-601-7550
070
20P
799-601-7360
Relay connector
5P
799-601-7370
Relay connector
6P
799-601-7380
JFC connector
2P
799-601-9010
DTM
2P
799-601-9020
DT
2P
799-601-9030
DT
3P
799-601-9040
DT
4P
799-601-9050
DT
6P
799-601-9060
DT
8P-Gray
799-601-9070
DT
8P-Black
799-601-9080
DT
8P-Green
Q Q
Q
799-601-9090
DT
8P-Blown
799-601-9110
DT
12P-Gray
20-230-12
(19)
PC128US-2
T-ADAPTER TABLE
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
Pin No.
799-601-2800
Connector type
799-601-2700
Port No.
799-601-2500
KIT No.
799-601-9120
DT
12P-Black
799-601-9130
DT
12P-Green
799-601-9140
DT
12P-Blown
799-601-9210
HD30
18-8
Q Q
799-601-9220
HD30
18-14
Q Q
799-601-9230
HD30
18-20
Q Q
799-601-9240
HD30
18-21
Q Q
799-601-9250
HD30
24-9
Q Q
799-601-9260
HD30
2-16
Q Q
799-601-9270
HD30
24-21
Q Q
799-601-9280
HD30
24-23
Q Q
799-601-9290
HD30
24-31
Q Q
799-601-9310
Plate
For HD30
Q Q
799-601-9320
For measuring box
For DT, HD
Q Q
799-601-9330
Case
799-601-9340
Case
799-601-9350
DRC26
40P
799-601-9360
DRC26
24P
799-601-9410
For NE, G sensor
2P
799-601-9420
For boost pressure, fuel
3P
799-601-9430
PVC socket
2P
799-601-9710
AMP 2-963215-1
AMP 2-963217-1
for HST controller
16P
799-601-9720
AMP 1-963215-1
AMP 1-963217-1
for HST controller
16P
799-601-9730
AMP 2-1437285-2
AMP 2-1437285-8
for HST controller
26P
PC128US-2
Q
Q
20-230-13
(19)
TROUBLESHOOTING
FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM
FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM

MECHANISM
PC128US-2
This electrical system control mechanism consists of a monitor panel and a controller. The monitor
panel and CR700 controller input signals each requires. On the other hand, the CR700 controller outputs
necessary signals or inputs in accordance with the signals selected by the monitor panel and controls the
absorption torque of the pump and the engine output.
Network information
1) Work mode (A, E, B) information
2) Auto-decelerator (ON/OFF) signal
3) Travel Hi/Lo signal
4) Coolant temperature (coolant temperature) information
5) Service code (failure code) information
PC128US-2
(Monitor panel CR700 controller)

(CR700 controller Monitor panel)
20-231
(17)
TROUBLESHOOTING
FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM
PC138US-2
This electrical system control mechanism consists of a monitor panel and a controller. The monitor
panel and CR700 controller input signals each requires. On the other hand, the CR700 controller outputs
necessary signals or inputs in accordance with the signals selected by the monitor panel and controls the
absorption torque of the pump and the engine output.
Network information
1) Work mode (A, E, B) information
2) Auto-decelerator (ON/OFF) signal
3) Travel Hi/Lo signal
4) Coolant temperature (water temperature) information
5) Service code (failure code) information
6) Preheating signal
20-232
(17)

PC128US-2
MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS
TROUBLESHOOTING

PC128US-2
PC138US-2
1. Lamp/Gauge/Buzzer Diagnostic Function
When the starting switch is turned ON, all lamps and gauges come on for about three seconds and
the warning buzzer sounds for about one second. The diagnosis of the monitor panel itself is performed and normal display is performed subsequently (a burnt-out bulb can be seen in the lamp that
does not come on by visual check).
2. USER CODE display function
The abnormality information of the CR700 controller is all sent to the monitor panel.
For this abnormality information having high emergency, a USER CODE is automatically displayed
on the digital meter display portion (1) of the monitor panel as the USER CODE and the operator is
urged to take corrective action.
fl The portion other than the digital meter display portion (1), service meter display portion (2), and
the point where lighting is performed ( portion in the following illustration) come out.
1) User code display
(1) Digital meter display portion
(2) Service meter display portion
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-decelerator switch
(8) Buzzer cancel switch
Example) When user code [E02] is displayed:
2) User code list

User code
PC128US-2
Abnormal system
E02
PC-EPC system
E03
Swing holding brake system
E05
Decelerator motor system
20-233
(17)
TROUBLESHOOTING
3. SERVICE CODE Display Function

The abnormality information of the CR700 controller is all sent to the monitor panel.
This abnormality information is all stored in the monitor panel as a SERVICE CODE independently
of the information that needs to or does not need to display the SERVICE CODE).
When the following operation is performed, a service code is displayed on the digital display portion
of the monitor panel and E indicating that an abnormality is currently occurring and an elapsed
time (service meter time) are displayed on the service meter display portion.
1) Service code display and cancel method
(1) Use the following procedure to switch to
a service code.
i) Continue pressing Buzzer cancel
switch (8) + Auto-decelerator switch
(7) for 2.5 seconds or more.
ii) Press Buzzer cancel switch (8) +
Working mode selector (UP) switch
(3) (or Working mode selector
(DOWN) switch (4) and set them so
that 01 can be displayed on the second or third digit from the left of service meter display portion (2).
iii) Press Setting switch (5).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Digital meter display portion

Service meter display portion
Working mode selector (DOWN) switch
Setting switch
Travel speed switch
Auto decelerator switch
Example 1) When [01] is displayed on service meter display portion (2):
Example 2) When [E213] occurred six hours

before:
fl If it is also occurring currently, E is displayed on
the third digit from the left of
service meter display portion
(2). When it is normal currently, E is not displayed.
fl An elapsed time is displayed
on the third digit from the
right of service meter display
portion (2).
20-234
(17)
PC128US-2
TROUBLESHOOTING
Example 3) If a service code is not stored,

is displayed on all digits
of digital meter display portion
(1) and service meter display
portion (2).
(2) To advance the display of a service code,
press Buzzer cancel switch (8) + Working mode selector (UP) switch (3).
(3) To return the display of a service code,
press Buzzer cancel switch (8) + Working mode selector (DOWN) switch (4).
(4) To terminate the display of a service code,
press Buzzer cancel switch (8) + Autodecelerator switch (7).
(5) To erase storage of a service code, turn
OFF Starting switch once pressing
Buzzer cancel switch (8). Turn ON the
Starting switch again and continue
pressing Buzzer cancel switch (8) for
five seconds as is.
fl If service codes stored exceed 20, the
smallest one is erased sequentially.
2) Service code list

Service code
PC128US-2
Abnormality system
User code
E101
Incorrect description contents
E108
Detection of engine water temperature exceeding 105C
E112
Wiper motor driven forward rotation system short circuit
E113
Wiper drive reverse rotation system short circuit
E114
Window washer drive system short circuit
E115
Washing is disabled for 10 seconds
E116
Storage is disabled for 10 seconds
E203
Swing holding brake solenoid system short circuit
E205
2-stage relief solenoid system short circuit
E206
Travel Hi/Lo selector solenoid system short circuit
E213
Swing holding brake solenoid relay system disconnection
E215
2-stage relief solenoid system disconnection
E216
Travel Hi/Lo selector solenoid system disconnection
E218
S-NET communication error
E222
LS-EPC system short circuit
E02
E223
LS-EPC system disconnection
E02
E03
E03
20-235
(17)
TROUBLESHOOTING
Service code
20-236
(17)
Abnormality system
User code
E224
Pump pressure sensor system error
E226
Pressure sensor system power failure
E227
Engine speed sensor system error
E232
PC-EPC solenoid system short circuit
E02
E233
PC-EPC solenoid system disconnection
E02
E241
Boom angle potentiometer system error (beyond input value range)
E242
Arm angle potentiometer system error (beyond input value range)
E255
Boom angle potentiometer corrected value error

(beyond correction value range)
E256
Checksum error
E306
Feedback potentiometer system error
E308
Fuel dial input value error
E315
Battery relay output short circuit abnormality
E316
Decelerator motor out of order abnormality
E317
Decelerator motor system disconnection abnormality
E05
E318
Decelerator motor system short circuit abnormality
E05
E05
PC128US-2
TROUBLESHOOTING
4. MONITORING CODE Display Function

Input signals from sensors into each component and output signals that drive solenoids can be
checked in real time using a monitoring code.
When the following operation is performed, a 4-digit monitoring code No. is displayed on the second
to fifth digit from the left of service meter display portion (2) of the monitor panel and monitoring
information is displayed on digital meter display portion (1).
1) Monitoring code display method

a monitoring code.
switch (8) + Auto decelerator switch
(DOWN) switch (4)) and set them so
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Setting switch
Travel speed switch
Example 1) When monitoring code 1010 (engine speed: 2,050 rpm) displayed
using a numeral is displayed:
Example 2) When monitoring code 1020

(switch input state (1)) displayed
using a bit pattern is displayed:
PC128US-2
20-237
(17)
TROUBLESHOOTING
(2) To advance the display of a service code,

press Buzzer cancel switch (8) + Working mode selector (UP) switch (3).
(3) To return the display of a service code,
press Buzzer cancel switch (8) + Working mode selector (DOWN) switch (4).
continue pressing Buzzer cancel switch
(8) + Auto-decelerator switch (5) for 2.5
seconds or more.
2) Monitoring code list
fl For details of the code displayed in the unit column as (6 bits), refer to the bit pattern list.
Display code
0008
0041
0042
0043
0045
0046
0047
0048
0049
0200
1000
1001
1002
1003
1004
1016
1027
1028
1036
1061
1010
1020
1021
1022
1023
1024
1025
1026
1030
1032
1034
1035
1040
1042
1050
1054
1060
Description
S-NET connected state
Water temperature sensor voltage
Fuel sensor voltage
Charge voltage
Sensor input 1
Sensor input 2
Output state
Wiper state
Reserved
Program version (Monitor)
Software version No.
Model selection
Attachment code
(*1)
Option selection state
(*1)
Second throttle command
(*1)
ON/OFF input 5
(*1)
ON/OFF input 6
(*1)
(*1)
ON/OFF output
(*1)
Engine speed
ON/OFF input 1
ON/OFF input 2
ON/OFF input 3
ON/OFF input 4
ON/OFF input and output
Work equipment angle sensor voltage First boom
Work angle sensor voltage Arm
Fuel dial voltage
Feedback potentiometer voltage
Boom bottom voltage
Pump pressure
EPC output current PC-EPC
EPC output current LS-EPC
ON/OFF output
Unit
Component name
(6bit)
10 mV
10 mV
100 mV
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
rpm
(6bit)
(6bit)
V
(6bit)
rpm
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
(6bit)
V
V
V
V
MPa
MPa
10 mA
10 mA
(6bit)
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
CR700 controller
(*1) PC138US-2
20-238
(17)
PC128US-2
TROUBLESHOOTING
3) Bit pattern list (The bit of the corresponding

No. comes on.)
fl [1] to [6] of digital display portion (1) indicate a bit No.
fl A monitoring code No. (four digits) is displayed on the second to fifth digit from
the left of service meter display portion
(2).
Code No.
Item
0008
S-NET connected state
0045
Sensor input 1
0046
Sensor input 2
0047
Output state
0048
Wiper state
0049
Standby
PC128US-2
Bit
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
Detailed description (state when a bit comes on)

At ID2 connection
At ID3 connection
At ID4 connection
At ID5 connection
At ID6 connection
At ID7 connection
Starting switch ON
(ON)
Starting switch Start
(Start) (ON)
Starting switch Preheat
(ON)
Light switch
(ON)
Engine oil pressure

Engine oil level
(At OPEN time)

(At OPEN time)
Charge level
Buzzer output
(At decrease time)

(ON)
Washer output
Wiper output 1
Wiper output 2
Wiper output 3
Wiper output 4
Swing lock switch
Widow limit switch
W contact
P contact
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
20-239
(17)
TROUBLESHOOTING
Code No.
1004
Item
Option selection
1020
ON/OFF input 1
1021
ON/OFF input 2
1022
ON/OFF input 3
1023
ON/OFF input 4
1024
ON/OFF input and

output
1025
1026
20-240
(17)
ON/OFF input and

output
ON/OFF input and

output
Bit
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]

Arm crane mounting
(*1)
Arm ground angle warning cancel
(*1)
ATT selection 2
ATT selection 1
Model selection 1
ATT selection 3
UU/US selection
Model selection 2
(At GND connection)

(At GND connection)
(At GND connection)
(At GND connection)
(At GND connection)
(At GND connection)
Arm crane mounting
(At power supply connection)
Kerosene mode
Travel selector switch (Panel)
Working mode selector switch
Back lamp
SET/CLEAR switch
Mode selector () switch
Mode selector () switch
(At GND connection)
Another work equipment mode selector switch (ON)

(ON)
Swing pressure switch
(ON)
Arm digging pressure switch
(ON)
Boom RAISE pressure switch
(ON)
Motor-driven power supply
(*1)
Motor relay ()
Motor relay (+)
Crane mode switch [monitor]
Display selector switch [monitor]
Arm ground angle warning cancel switch (At connector connection)
Bucket dump inhibition solenoid + Patlight (At relay output)

Warning cancel
(For EU)
PC128US-2
TROUBLESHOOTING
Code No.
1027
1028
1060
1061
PC128US-2
Item
ON/OFF input 5
ON/OFF input 6
ON/OFF output
ON/OFF output
Bit
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
[1]
[2]
[3]
[4]
[5]
[6]
Preheating signal
(*1)
C-terminal signal
(*1)
Arm OUT pressure switch

Service pressure switch
Bucket digging pressure switch
Bucket DUMP pressure switch
(*1)
(*1)
(*1)
(*1)
Swing holding brake
(At brake release)
Travel 2nd speed

Travel or swing alarm
2-stage relief
(At travel 2nd speed)

(At alarm output)
(At travel pressure switch ON)
Heater relay
(*1)
20-241
(17)
TROUBLESHOOTING
5. WORKING MODE DEFAULT Setting Function

When the normal starting switch is turned ON, the WORKING MODE of the monitor panel is set so
that Mode A can come out. If the following procedures are used to use the default setting function,
the setting can be changed so that startup can be performed in the WORKING MODE in accordance with the choice of the operator.
1) Default setting operation procedures

the default setting mode.
fl d SET is displayed on service
meter display portion (2) and indicator (10) of the mode set as a
default value flashes.
(2) To change (move) the default setting
mode,
i) press Working mode selector (UP)
switch (3) (or Working mode selector
(DOWN) switch (4)).
ii) Press Setting switch (5).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Setting switch
Travel speed switch
(3) To terminate the default setting mode (default setting mode completion), continue
the Buzzer cancel switch (8) + Auto-decelerator switch (7) for 2.5 seconds or
more.
fl When the starting switch is turned
OFF in the normal mode LED flashing
state (default setting mode), the contents of the working mode default are
not changed.
20-242
(17)
PC128US-2
TROUBLESHOOTING
(4) Confirmation method after working default setting

i) Check that the LED is changed to normal lighting.
ii) Turn OFF the starting switch and turn
on the starting switch again.
iii) Check that the working mode default
is changed to the setting state.
6. Decelerator Motor Adjustment Mode

PC128US-2
This mode is used to adjust the decelerator motor and the injection pump linkage.
fl For details, refer to the TESTING AND ADJUSTING DECELERATOR MOTOR LEVER
STROKE of Testing and Adjustment Volume.
1) Decelerator motor adjustment mode display
method
the Decelerator motor adjustment mode.
ii)
fl GOV is displayed on digital display portion (1) and GSET is displayed on service meter display
portion (2).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Setting switch
Travel speed switch
Auto-decelerator switch

continue pressing Buzzer cancel switch
(8) + Auto-decelerator switch (7) for 2.5
seconds or more.
PC128US-2
20-243
(17)
TROUBLESHOOTING
7. Governor motor adjustment mode

PC138US-2
fl Use this mode to set the engine governor lever fully.
fl Set the deceleration motor cable to the engine high idling position (to the shortest position).
fl When the starting switch is turned ON, if this mode is not selected, the governor motor may not
operate.
Reference
If a short circuit or a grounding fault occurs in the circuit of the governor motor control system, the
cable may move out of the normal control range. At this time, even if the cause of the trouble is
removed, the governor motor cannot be controlled.
If this occurs, operate the panel switch in this mode to return the cable into the normal control range
to restore the governor motor control.
No.
Operation
1 1) Turn the starting switch ON and set the fuel control dial to the
FULL position.
At this time, turn the automatic decelerator (one-touch decelerator) OFF (reset it).
Display
2) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds.
3) Set the code in the service meter section to "03".
(8) + (3): Next code
(8) + (4): Previous code
[GOV] is displayed on display portion (1),

[GSET] is displayed on service meter portion
(2).
4) Press switch (5).

* Under this condition, the deceleration motor cable is at the
engine high idling position (It becomes shortest).
2 <Function of restoring governor control>
Use this function for only above purpose (2).
(Do not use this function usually.)
Be sure to remove the cause of the trouble before using this
function.
5)-1 When engine speed does not rise from low idling
Press switch (3) several times and operate the fuel control
dial to check that the governor control is restored.
5)-2 When engine speed does not lower from high idling
Press switch (4) several times and operate the fuel control
dial to check that the governor control is restored.
3 To finish the governor motor adjustment mode, perform the operation in 1-2), and the monitor panel displays normally.
20-244
(17)
PC128US-2
TROUBLESHOOTING
8. Boom Angle Potentiometer Correction Mode

(Only at Arm Crane)
This mode is used to adjust the boom angle potentiometer.
1) Boom Angle Potentiometer Correction Mode
display method
the boom angle potentiometer correction
mode.
switch (8) + Auto decelerator switch
fl Check that 1 SET is displayed
on service meter display portion
(1) (the central three segments of
digital display portion (1) flash).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Setting switch
Travel speed switch
(2) Use the following procedure to adjust the

boom angle potentiometer correction
mode.
i) After switching to the mode of item
i), start the engine and operate
Boom to the RAISE side stroke end.
fl -- (correctable range) or ---
(uncorrectable range) flashes on
the digital display portion.
fl For the correctable range, because
incorrect mounting of the boom
angle potentiometer is assumed,
check it.
ii) Press setting switch (5) for three seconds or more.
fl The same item as item i) flashes
on digital meter display portion
(1).
PC128US-2
20-245
(17)
TROUBLESHOOTING
iii) When normal adjustment can be

made (when the boom angle belongs
to a theoretical value,
is displayed on digital meter display portion (2) for five seconds and processing returns to item i) (boom angle potentiometer correction mode).
fl When correction was disabled,
--- flashes (buzzer sounds five
times) on digital portion (2) and
processing returns to item i).
fl If correction is impossible, because incorrect mounting of the
boom angle potentiometer is assumed, check it.
20-246
(19)
PC128US-2
TROUBLESHOOTING
9. Display and Setting of OIL MAINTENANCE FUNCTION

In an oil maintenance function setting machine, the LED of Oil maintenance lamp (9) of the monitor portion and an elapsed time is displayed on the service meter display portion (2) from 10 hours
before of the oil replacement setting time to the time when it is reset. (The elapsed time is displayed
for 20 seconds after the starting switch is turned ON and returns to the display of the service time
later.)
fl Digital meter display portion (1) is not displayed (does not come ON).
The oil maintenance function can perform the setting, change, or release of the display.
1) Display of oil maintenance function

(1) The oil maintenance display mode is automatically displayed when the setting
time exceeds minus 10 hours as described above.
(2) To terminate the oil maintenance function
(within 20 seconds after the starting
switch is turned ON), pressing setting
switch (5) short returns to the normal display mode.
Example) When the oil replacement interval
setting of 250 hours and the
elapsed time of 245 hours after oil
is replaced are displayed:
PC128US-2
20-246-1
(19)
TROUBLESHOOTING
2) Setting of interval time and resetting of

elapsed time
(1) Interval time setting
iii) Press Setting switch (5) (every time
it is pressed, it is switched) to select
an interval time.Example) When the
interval time of 250h is selected (not
displayed on digital meter display
portion (1))
fl Display of an interval time (sequentially displayed repetitively)
0 : Default mode (Oil maintenance
function is not set)
125h : Sets an interval time every 125
hours.
hours.
hours.
d : Sets the demonstration mode.
(For details, refer to item iv.)
fl Select an interval time according
to the INSTRUCTION MANUAL.
iv) When Buzzer cancel switch (8) +
Auto decelerator switch (7) continue being pressed for 2.5 seconds
or more, the setting of an interval time
is terminated.
20-246-2
(17)
(1)
(2)
(3)
(4)
(5)
(6)

Setting switch
Travel speed switch
Auto-decelerator switch
PC128US-2
TROUBLESHOOTING
(2) Confirmation of elapsed time

fl If an elapsed time does not reach ten
hours before of a replacement interval, nothing is displayed.
(If the elapsed time must be watched
in this state, turn ON the starting
switch continuing pressing Setting
switch (5) and continue pressing setting switch (5).
(3) Elapsed time resetting after oil replacement
While an elapsed time and a telephone
number are displayed on the monitor
panel (within 20 seconds), if setting switch
(5) starts being pressed and is held for
about three seconds as is, the elapsed
time is reset and the elapsed time of 0h is
displayed for one second.
(4) Demonstration mode
If the demonstration mode is used, the
demonstration of the oil maintenance
function can be performed at delivery.
fl The elapsed time is fixed to 240 hours and
the same function as the oil maintenance
function is performed.
fl After the demonstration is set, if the starting switch is set to OFF ON again, the
demonstration starts.
However, if the starting switch OFF
ON is performed four times or more, the
demonstration mode is reset (demonstration display is performed up to the third
time) and is automatically switched to the
default mode.
(If demonstration must be continued, the
demonstration mode need be set again.)
PC128US-2
20-246-3
(17)
TROUBLESHOOTING
10. Setting model and attachment

Set the specification of machine model and attachment.
(PC128US with standard arm does not need this setting)
No.
Operation
1 1) Hold buzzer cancel switch (8) and switch (7) for 2.5 seconds.
2) Set the code in the service meter section to "19".
Display
Display section displays "10" and service
meter section displays "19SET".
(If 19SET has been set, current set value is
displayed in display section.)
Display
Service
meter
2 1) Set the value in the display section to a desired value.

Set value
Model
ATT
Remarks
10
PC128US
Standard arm
Controller default
11
PC128US
Long arm
20
PC138US
Standard arm
21
PC138US
Long arm

When PC138US long arm is selected
Display
After switch (5) is pressed, display section

displays "000", and then "---"

Display
3 1) To finish selection of model and attachment

Perform the operation in 1-(1), and the monitor panel displays
normally.
<Caution>
After setting 18SET and 19SET, be sure to turn the starting
switch OFF once.
This setting becomes effective only after the starting switch
is turned OFF once.
B: The buzzer cancel switch is installed on the right console.
20-246-4
(19)
PC128US-2
TROUBLESHOOTING
11. Service adjustment

This service adjustment is set for adjustment of dispersion of components and parts and for replay to
requests of each user. Perform this adjustment for the following phenomena and users' requests.
fl Basically, the following items do not need to be adjusted, since they are adjusted when delivered.
fl This service adjustment is not effective when a component or a part is broken.
1) Service adjustment items table
The phenomena of the machine which need service adjustment, procedure for changing the set
values, and precautions are listed.
fl Usually, each adjustment value is set to the initial value.
Adjustment Phenomenon of machine/ Procedure for changing
Precautions
code/set value
Users' request
set value
Engine speed lowers
Change set value to
204
Adjust to degree that work
largely during work.
decrease pump absorp- equipment cycle time is not
tion torque.
lengthened.
Service adjustment item

Adjustment of
PC-EPC valve
current

is low.
Change set value to

increase pump absorption torque.
Adjust to degree that engine

speed is not lowered largely.
Alarm sounds when machine
travels or swings.
Travel/Swing
alarm output
(If travel alarm is
installed)
210
Set for each user who

wants to sound alarm
during swinging.
Set to 211.
Adjustment of
LS-EPC valve
current
264
Engine speed lowers

largely during work.
Change set value to

Adjust to degree that work
decrease pump absorp- equipment cycle time is not
tion torque.
lengthened.
fl Perform this when adjustment with PC-EPC valve
current is insufficient.
fl Even if LS-EPC valve
current is not increased
even if adjusted toward
positive (+) side.
310
Change fuel.
When kerosene is
used, engine speed
lower largely.
310: Diesel fuel
Low idling speed is

remarkably high.
Set to () side.
Low idling speed is

remarkably low.
Set to (+) side.
Type of fuel
Adjustment of
low idling speed
*
324
Adjustment of
arm crane mode
speed
*
334
Adjustment of Emode speed

*
344
Adjustment of Bmode speed

*
White smoke
prevention logic
(Air heater relay
output)
Initialization of
set values
(Only contents of
service adjustment)
311: Kerosene
* Since the low idling speed
is set by the governor
stopper, it does not change
under normal condition.
Arm crane idling speed Set to () side.

is remarkably high.
Arm crane idling speed
Set to (+) side.
is remarkably low.
354
810
400
E-idling speed is
remarkably high.
Set to () side.
E-idling speed is
remarkably low.
Set to (+) side.
B-idling speed is
remarkably high.
Set to () side.
B-idling speed is
remarkably low.
Set to (+) side.
Set for each user who

cares white smoke
when engine is started
at low temperature.
Change set value so

that air heater will
operate automatically
after engine is started.
* If the B-mode speed is

heightened, it is set near
the high idling speed and
the auto-decelerator may
not operate normally.
fl Since air heater consumes
much current, battery can
be dead. Teach user to so
operate machine that
battery will be charged
sufficiently.
If 401 is selected, all service adjustment items are set to initial values.
* The engine speed adjustment is an auxiliary adjustment method.

(1) Check the installation condition of the governor cable.
(2) Check the condition of the governor cable motor.
PC128US-2
20-246-5
(19)
TROUBLESHOOTING
HOW TO READ DECISION LIST

PC128US-2
PC138US-2
This decision list is a tool (decision table) for selecting whether a nature of trouble of a chassis is caused
by an electrical system failure or a hydraulic or mechanical failure and advancing to troubleshooting
codes (N, E, S, C, F, H, M) that match each event.
The decision table identifies that processing should advance to which troubleshooting codes according
to the presence of the display of user and service codes.
fl The abnormality display (warning) using the monitor panel directly advances to machine monitor
troubleshooting code (M). (Refer to the machine monitor system troubleshooting.)
1. CR700 Controller (Decelerator Control System) or Engine Related Decision List
When a service code is displayed on the monitor panel, advance to troubleshooting code (E)
of the lowermost step of the decision table.
(A is marked to the point where a failure mode and a service code match.)
If a service code is not displayed and a nature of trouble appears in the monitor panel, advance to
diagnostic code (Eor S) at the right end which matches the failure mode of the decision
list.
<Example> Failure mode Engine does not start
[Procedure] Test that a service code is displayed on the monitor panel.
Controller (Decelerator Control System) or Engine-Related Decision List
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700
controller (decelerator control) system E3:
.
2) When a service code is not displayed on the monitor panel and ENGINE DOES NOT START:
When the starting motor rotates:
Check the rotation
.... Advance to MECHANICAL SYSTEM TROUBLESHOOTING S-2.
of a starting motor.
When the starting motor does not rotate:
.... Advance to ELECTRICAL SYSTEM TROUBLESHOOTING E-8.
20-252
(17)
PC128US-2
TROUBLESHOOTING
2. CR700 Controller (Pump Control System) or Oil Pressure Related Decision Table
When a service code is displayed on the monitor panel, advance to the troubleshooting
code (C) of the lowermost step of the decision table.
(A is marked to the point where a failure mode and a service code match.)
If a service code is not displayed and a nature of trouble appears in the monitor panel, check the
display of an input signal that matches the failure mode of the decision table (display the location
marked with a circle ( )) and
When an input signal is displayed normally, advance to the diagnostic code (H) at the
right of the decision list.
When an input signal is not displayed, advance to the diagnostic code (F) at the lowermost step of the decision list.
<Example> Failure mode Swing is not performed
[Procedure] Test that a service code is displayed on the monitor panel.
CR700 Controller (Pump Control System) or Oil Pressure-Related Decision Table
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the CR700
controller (decelerator control) system E2:
.
2) When a service code is not displayed on the monitor panel and SWING IS NOT PERFORMED:
When the signal is provided:
Check a CR700 controller
.... Advance to MECHANICAL SYSTEM TROUBLESHOOTING
input signal.
H-25.
(Check it in the monitorWhen the signal is not provided:
ing mode.)
.... Advance to the CR700 CONTROLLER INPUT SIGNAL SYSTEM TROUBLESHOOTING F.
PC128US-2
20-253
7
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS

PC128US-2
PC138US-2
1. Classification of Diagnostic Code No.
Diagnostic code No.
Troubleshooting device
Service code
N-cc
Communication system troubleshooting
E-cc
CR700 controller (decelerator control system) troubleshooting
C-cc
CR700 controller (pump control system) electrical system troubleshooting E2-cc system
F-cc
CR700 controller (input signal system) troubleshooting
H-cc
Hydraulic, mechanical system troubleshooting
M-cc
Machine monitor system troubleshooting
E3-cc system
E1-cc system
2. How to Read Troubleshooting (Method) Every Failure Mode

1) Title column
The title column of troubleshooting describes a troubleshooting code, service code, and
failuremode (nature of trouble).
2) Itemization
Even for the same nature of trouble, if the method of this diagnosis depends on a model, device,
or event, the contents of the nature of trouble is subdivided into a) to ?. ([2] of the example).
(This is called itemization.) Select and execute the corresponding troubleshooting. If no itemization is performed, advance troubleshooting from the beginning of the nature of trouble.
3) How to advance troubleshooting
YES
As a result of testing or measuring YES NO of

, advance to the next step
by
NO
advancing one branch of either YES or NO. (Note: The No. described in the upper right-hand
is a serial number, but not a No. showing a procedure.)
corners of
If the branch of YES or NO as the result of testing or measurement is directly coupled with a
cause, the cause is referred to and the corrective action at the right is executed. ([3] of the
example)
When the testing or measuring method and decision value in the lower column of
matches the decision value and questionnaires in the lower column of
described, NO is
applied if they deviate from the YES decision value and are not matched.
Regarding the preparatory work and decision value necessary for testing or measurement in
the lower column of the nature of trouble, because the preparatory work may be ignored and
the operation or handling method be mistaken or equipment be damaged, read them well
before testing or measurement starts and advance the work.
4) General precautions
To advance the failure mode (nature of trouble), all common precautions ([4] of the example) are
marked with a fl next to the title.Because the precautions marked with a fl are omitted in
,
be sure to execute them at the testing of
.
5) Diagnostic tools
To advance this diagnosis, prepare the necessary diagnostic tools referring to the TESTING OR
ADJUSTING AND TROUBLESHOOTING EQUIPMENT LIST and advance the work.
20-254
(17)
PC128US-2
TROUBLESHOOTING
6) Device locations and pin numbers

For the testing or measuring locations of wiring connector CN cc and connector pin numbers
shown in the flow of this diagnosis, advance the work referring to the connector type, mounting
locations, and connector pin No. table.
<Example>
[1] M-12 When the starting switch is set to ON (the engine stopped), precautions and emergency stop items flash.
(But Battery and Engine oil pressure do not come on.)
[4] fl Inspect both the alternator system and the engine hydraulic system.
[2] a) Alternator system
Itemization of a) and b)
b) Oil pressure sensor system
[3]
Cause
Remedy
1
Disconnect the terminal R.
Set the starting switch to ON.
1V max.
Is the voltage between the alternator R and the machine

body normal?
NO
Defective alternator
Replace
Hot short-circuit of harness between

P02 (female) (11) and alternator R
Repair or
replace
Defective monitor panel
Replace
YES
2
Disconnect P02.
1V max.
Is the voltage between P02 (11)

and the machine body normal?
NO
YES
PC128US-2
20-255
(17)
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT

TROUBLESHOOTING
TROUBLESHOOTING

TROUBLESHOOTING
PC128US-2
PC138US-2
When an abnormality occurred diagnosis advances in accordance with the decision table CR700 controller (decelerator control system) or CR700 controller (pump control system) that correspond to the contents of a failure. However, refer to this flow for the detailed diagnostic contents or procedure.
Further, for the diagnosis, ask the operator of detailed questions as much as possible and check the
following items previously. [1] connected state of the controller (check using monitoring codes 0200,
1000, 1001, 1002, 1003*, 1004*), [2] fuse blown, [3] power generation (charge input) voltage (monitoring
*: PC138US-2
code 0043).
Besides, the confirmation procedures of the testing items No. 3 and 4 in the following flow are described
on the next page and later pages.
YES
E02 (PC-EPC system)

E03 (Swing holding brake system)
E05 (Governor motor system)
To item 2
1
Is service code of
monitor panel
displayed?
YES
E2: Troubleshooting (C mode) of CR700 controller (pump control

system) at the number level of cc
E3: Troubleshooting (E mode) of CR700 controller (decelerator
control system) at the number level of cc
5 YES
Is engine electrical
YES system without
display of failure
4
code normal?
2
Is service code of
monitor panel
NO displayed?
Engine system or
YES hydraulic
(mechanical)
system?
Check service code

by performing
operation
Is input and output

signal of governor
NO pump
controller normal?
Check it by
monitoring
Diagnose in the
corresponding mode
Diagnose engine
main unit (S mode)
Diagnose engine
electrical system (E
mode) (flow without
Flow of part without
NO display)
decision table
abnormality display
Diagnose by hydraulic (mechanical) system

Decide system from
engine speed after NO (H mode)
hydraulic adjustment
Is all working
equipment slow and
does engine speed
decrease at heavy
load?
Diagnose by input signal system (F mode)
NO
fl Decide the details in accordance with the CR700 controller (decelerator control system) (pump
control system) decision table.
20-256
(17)
PC128US-2

TROUBLESHOOTING
TROUBLESHOOTING
For an output signal of the monitor panel, if there is no abnormality display of a communication system
sent by S-NET, it may be decided that the output signal is sent. When there is no abnormality display,
perform testing directly, such as an incorrect operation, according to the following points.Besides, whenan
abnormality occurred in the S-NET system, note diagnosis because the default mode is automatically
switched as shown below.
Default Mode When Communication Between Monitor Panel and

Governor Pump Controller is Disabled
Setting mode
Pump control side
Governor control side
Working mode
E mode
E mode
Throttle signal
E mode or equivalent
E mode or equivalent
Auto decelerator
ON (Decelerator mode)
ON (Decelerator mode)
Immersion signal
Recognized to be below 30C
Recognized to be below 30C
Travel speed
Lo
Automatic warm-up
ON (Automatic warm-up mode)
1. Confirmation Points of Monitor Panel Output Signal

fl For the monitoring mode operation method, refer to Monitor Panel Display and Special Function
1) Component connected state
(1) Set the monitoring mode and display monitoring code 08.
(2) The state indicates that the connected component comes on in the clock display portion (bit).
fl [1], [2], and [3] come on.
2) Confirmation of working mode signal
(2) Switch the working mode as shown in Table 1 and check the change of the engine speed.
Table 1
Working mode
A
Arm crane
PC128US-2
Operation
Engine speed (no load maximum speed) (rpm)
Work equipment
About 2,400
Travel
About 2,400
Work equipment
About 2,200
Travel
About 2,200
Work equipment
About 2,000
Travel
About 2,000
Work equipment
About 1,500
Travel
About 1,500
20-257
(17)

TROUBLESHOOTING
TROUBLESHOOTING
3) Confirmation of Travel Speed Selector Signal

(2) Check that the travel speed selector switch Hi, engine of 1,500 rpm or more, travel Hi travel
bit [4] comes on (or comes out).
(): The bit is ON (bit (4) comes on) above 27.46 MPa {280 kg/cm2} when the oil pressure rises
and is OFF (bit [4] comes out) below 15.69 MPa {160 kg/cm2} when the oil pressure falls.
2. Confirmation of CR700 Controller Input Signal
fl Check the input signal of each controller according to the following procedure.
Pump control system
1) Confirmation of input signal
(1) Testing of hydraulic switch
i) Set the monitoring mode and display monitoring code 1023.
ii) Operate each work equipment lever and check the lighting state of a bit pattern.
fl For the bit pattern list, refer to the monitor panel display and special functions.
(2) Testing of speed center (test it with an engine speed)
ii) Change the speed by the fuel dial and measure the engine speed at that time.
(3) Testing of pump discharge pressure sensor
fl When the display is 24.0, it indicates that the pressure is 24 MPa.
ii) Measure the oil pressure of the pump.
(4) Testing of kerosene mode input signal
ii) Ground the CR700 controller connector CR2 [6] to the GND and check that the bit [6]
comes on.
2) Confirmation of output signal
(1) Testing of LS-EPC solenoid output current
ii) When all levers are neutral and set in the A mode, measure the engine full current value.
fl When all levers are neutral: 900 100 mA Refer to the monitor display example.
At engine full and lever operation (other than travel): 0 A
(2) Confirmation of the ON OFF solenoid state
ii) Referring to Table 3, check that the corresponding bit comes on.
Table 3 Solenoid Type and Operating Condition
Solenoid name
Operating condition
Bit that comes ON
Swing holding brake
Either swing or operating equipment

lever operation
Monitor code 1060 [1]
Travel Hi/Lo
Fuel dial above 1,500 rpm and travel

speed switch
Hi and travel switch ON and travel Hi
rotation
2-stage relief
At travel lever operation
Note 1: Perform the lever operation slightly in such degree that the machine cannot move.
20-258
(17)
PC128US-2
TROUBLESHOOTING

TROUBLESHOOTING
Engine throttle Control System

1) Confirmation of Input Signal
(1) Testing of fuel dial input voltage
ii) Measure the voltage when the fuel dial is rotated from low idle to high idle.
fl The voltage is 0.3 to 4.3 V.
(2) Testing of decelerator potentiometer voltage
ii) Measure the potentiometer voltage when the fuel dial is rotated from low idle to high
idle.
fl The voltage at auto decelerator OFF.
: 2.15 4.55 V
PC128US-2
: 2.67 4.55 V
PC138US-2
2) Confirmation of Output Signal
(1) Confirmation of decelerator motor driving signal
ii) Check that bit [3] comes on when the fuel dial is rotated to the directions of the engine
speed Acceleration and Deceleration.
PC128US-2
20-259
(17)
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E MODE)
PC128US-2
PC138US-2
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM ....... 20-301-1
RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM ......................................... 20-302
E-1 Abnormality in PC-EPC system ...................................................................................................... 20-310
a) Speeds of all work equipment, travel, swing are slow or lack power .................................... 20-311
b) There is excessive drop in engine speed, or engine stalls ...................................................... 20-312
E-2 Abnormality in PPC lock solenoid system ..................................................................................... 20-318
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move .......... 20-318
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move .............. 20-318
E-3 Abnormality in swing lock solenoid system ................................................................................. 20-322
a) Even when swing lock switch is turned OFF, upper structure does not swing ...................... 20-322
b) Even when swing lock switch is turned to LOCK, upper structure swings ............................ 20-323
E-4 Abnormality in travel speed solenoid system ............................................................................... 20-326
a) Even when travel speed selector switch is turned to Hi, travel speed
does not change to high speed .................................................................................................. 20-326
b) Even when travel speed selector switch is turned to Lo, travel speed
does not change to low speed ................................................................................................... 20-326
E-5 Trouble in automatic travel speed control system ........................................................................ 20-329
a) Main pump pressure sensor system ......................................................................................... 20-329
b) Engine speed sensor system ...................................................................................................... 20-329
E-6 Abnormality in engine starting system ......................................................................................... 20-334
PC128US-2
20-301
(17)
TROUBLESHOOTING
RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM
RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL

SYSTEM
PC-EPC SYSTEM
PC128US-2
PPC LOCK SOLENOID SYSTEM

PC128US-2
20-302
(17)
PC128US-2
TROUBLESHOOTING
SWING LOCK SOLENOID SYSTEM

PC128US-2
TRAVEL SPEED SOLENOID SYSTEM

PC128US-2
PC128US-2
20-303
(17)
TROUBLESHOOTING
AUTOMATIC TRAVEL SPEED CONTROL SYSTEM

PC128US-2
20-304
(17)
PC128US-2
TROUBLESHOOTING
ENGINE STARTING SYSTEM

PC128US-2
PC128US-2
20-305
(17)
TROUBLESHOOTING
PC-EPC SYSTEM
PC138US-2
PPC LOCK SOLENOID SYSTEM

PC138US-2
20-306
(17)
PC128US-2
TROUBLESHOOTING
TRAVEL SPEED SOLENOID SYSTEM

PC138US-2
SWING LOCK SOLENOID SYSTEM

PC138US-2
PC128US-2
20-307
(17)
TROUBLESHOOTING
RELATED ELECTRICAL CIRCUIT DIAGRAM

PC138US-2
20-308
(17)
PC128US-2
TROUBLESHOOTING
ENGINE STARTING SYSTEM

PC138US-2
PC128US-2
20-309
(17)
TROUBLESHOOTING
E-1
E-1 Abnormality in PC-EPC system

PC128US-2
Items to check on LED display of pump controller when this failure mode occurs
For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the operators compartment, and use a mirror to check.
1. Content of display
1) When normal
LED lights up.
2) When there is abnormality in power supply voltage
Output stops, LED goes out.
3) When PC-EPC solenoid output is short circuited [when C01 (13) - PC-EPC solenoid C13 (1) is short
circuited]
Output stops, LED flashes. (See display pattern a).
4) When there is abnormality in machine model selection
LED flashes. (See display pattern c).
Note : When kerosene mode selector switch (terminal) is connected, ignore the flashing and carry
out troubleshooting.
5) When there is disconnection in speed sensor [when there is abnormal voltage at C01 (2), (3)]
. Output is made same as when engine speed is minimum, LED flashes. (See display pattern
d).
Note : When engine speed becomes abnormally low, LED does not flash.
6) When there is disconnection in PC-EPC solenoid output [when there is disconnection between
C01 (13) - PC-EPC solenoid C13 (1)]
LED flashes. (See display pattern b).
2. Display ( : ON, : OFF)
1) Display pattern a (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, then OFF for 2.0 seconds)
2) Display pattern b (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
3) Display pattern c (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5
seconds, then OFF for 2.0 seconds)
4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)
seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
5) If more than one of the above failures occurs at the same time, the above patterns a to d are
repeated.
Note : indicates ON for 0.1 second, indicates OFF for 0.1 second.
20-310
(17)
PC128US-2
E-1
TROUBLESHOOTING
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
a) Speeds of all work equipment, travel, swing are slow or lack power
Cause
Is resistance
YES between C05
(female) (4) and
3
chassis ground
normal?
Is resistance
between C13
YES (female) (1) - (2),
between (1)(2) chassis ground
normal?
Between C13
2
(female) (1) - (2) :
NO
Is resistance
500 - 1000
between C01
Between C13
YES (female) (3) - (4),
(female) (1)(2) - chassis ground :
between (3)(4) Min. 1 M
chassis ground
Turn starting switch OFF.
normal?
Disconnect C01.
Between C01
5 YES
(female) (3) - (4) :
Is resistance
500 - 1000
between E07
Between C01
(female) (1) - (2),
(female) (3)(4) chassis ground : NO between (1)(2) chassis ground
Min. 1 M
normal?
1 Turn starting
switch OFF.
Between C01
NO
Disconnect C01.
(female) (3) - (4) :
Does LED of pump
500 - 1000
controller flash?
Between C01 (female)
(3)(4) - chassis ground :
Min. 1 M
Start engine.
Disconnect E07.
7 YES
Is there continuity
YES between C01
(female) (5) - (10),
6
between (6) - (10)?
Does model
selector connector
NO match machine
model?
Between C01
NO
(female) (5) - (10) :Continuity
Between C01 (female)
(6) - (10) : No continuity
Disconnect C01.
NO
8 YES
A
Is resistance
between C05
(male) (2),(4) chassis ground
normal?
Min. 1 M
NO
Disconnect C05.
PC128US-2
Remedy
4 YES
To A
Short circuit with chassis

ground in wiring harness
NO between C05 (female) (4)
and C03 (female) (2)
Repair or replace
Defective PC-EPC solenoid
Replace
Defective contact,
disconnection, or short
circuit with chassis ground
in wiring harness between
C01 (female) (3) - E07
(female) (1) or C01 (4) - E07
(2)
Repair or replace
Defective engine speed

sensor
Replace
Defective pump controller
Replace
Defective contact,
C01 (male) (5) - C09 (male)
(1), C05 (female) (6) - C09
(female) (2) or C01 (female)
(10) - C09 (male) (3)
Repair or replace
Defective machine model

selection connector
Replace

between C01 (female) (13)
Repair or replace
Defective emergency pump

drive switch
Replace
20-311
(17)
TROUBLESHOOTING
E-1
b) There is excessive drop in engine speed, or engine stalls

fl When fuse 2 is normal. (If fuse 2 is blown, check for a short circuit with the ground in the circuit
related to fuse 2.)
Cause
2 YES
Is voltage between
YES C01 (1) and chassis
ground normal?
5 YES
Is pump controller
LED off?
Is resistance
(female) (1) and (2)

normal?
7 14
Turn starting
switch OFF.
Disconnect C13.
Does pump
controller LED
NO flash?
Go to A
Is resistance
YES between C05
4
normal?
YES between C13

Turn starting
switch ON.
Replace
Defective contact or
disconnection in wiring
Repair or replace
harness between fuse 2 and
C01 (female) (1)
NO
20 30 V
Turn starting switch
ON.
1
Remedy
Defective contact,
disconnection, or short circuit
with chassis ground in wiring
harness between C05 (female)
Repair or replace
(3) and C13 (female) (1), or
7 14
NO defective contact or
OFF.
(4) and C13 (female) (2)
Disconnect C05.
Replace
Replace
NO
7 YES
Is there continuity
YES between C01
(female) (5) - (10),
between (6) - (10)?
Start engine.
Does model
selection
NO connector match
machine model?
Repair or replace
harness between C01
Between C01
NO (female) (5) and C09 (male)
(female) (5) - (10) :
(1), or between C01 (female)
Continuity
(6) and C09 (male) (2)
Between C01
(female) (6) - (10) :
No continuity
OFF.
Disconnect C01.
Replace
selection connector
NO
8
A
YES
Is there continuity
between C05
(female) (1) - (3)
and (2) - (4)?
Turn starting
switch OFF.
Disconnect C05.
20-312
(17)
NO
Defective contact,
harness between C01
(female) (7) and C05 (female) Repair or replace
(1), or defective contact or
harness between C01
(female) (13) and C05
(female) (2)
Replace
drive switch
PC128US-2
TROUBLESHOOTING
E-1
E-1 Related electric circuit diagram
PC128US-2
20-313
(17)
TROUBLESHOOTING
E-1
PC138US-2
Items to check on LED display of pump controller when this failure mode occurs
For some items on the pump controller LED display, self- diagnosis is carried out by flashing lamps.
However, remove the protective cover of the pump controller at the rear of the operators compartment, and use a mirror to check.
1. Content of display
1) When normal
LED lights up.
2) When there is abnormality in power supply voltage
Output stops, LED goes out.
3) When PC-EPC solenoid output is short circuited [when CR3 (16) - PC-EPC solenoid C13 (1) is short
circuited]
Output stops, LED flashes. (See display pattern a).
4) When there is disconnection in speed sensor [when there is abnormal voltage at CR2 (39), (40)]
Output is made same as when engine speed is minimum, LED flashes. (See display pattern
d).
Note : When engine speed becomes abnormally low, LED does not flash.
5) When there is disconnection in PC-EPC solenoid output [when there is disconnection between
CR3 (16) - PC-EPC solenoid C13 (1)]
LED flashes. (See display pattern b).
2. Display ( : ON, : OFF)
1) Display pattern a (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, then OFF for 2.0 seconds)
2) Display pattern b (method of re-enaction: pattern below is repeated when starting switch is ON)
(ON for 0.5 seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
3) Display pattern c (method of re-enaction: pattern below is repeated when starting switch is ON)
seconds, then OFF for 2.0 seconds)
4) Display pattern d (method of re-enaction: pattern below is repeated when starting switch is ON)
seconds, OFF for 0.5 seconds, ON for 0.5 seconds, then OFF for 2.0 seconds)
5) If more than one of the above failures occurs at the same time, the above patterns a to d are
repeated.
Note : indicates ON for 0.1 second, indicates OFF for 0.1 second.
20-314
(17)
PC128US-2
E-1
TROUBLESHOOTING
a) Speeds of all work equipment, travel, swing are slow or lack power
PC138US-2
Cause
Remedy
4 YES
Go to A
resistance
YES Is
between C06
3
(female) (2) - (5)
normal?
Is resistance
between C13
YES (female) (1) - (2),
NO
Between C06
between (1)(2) (female) (2) - (5): 8 - 15
chassis ground
Turn starting switch OFF
normal?
Disconnect C06
Between C13
2
(male) (1) - (2) :
NO
Is resistance
8 - 15
between CR2
Between C13
YES (female) (39) - (40),
(male) (1)(2) - chassis ground :
between (39)(40) Min. 1 M
chassis ground
normal?
Disconnect CR3.
Between CR2
5 YES
(female) (39) - (40) :
Is resistance
500 - 1000
between E07
Between CR2
(female) (2) - (1),
(female) (39) - (40)
1
chassis ground : NO between (2)(1) chassis ground
Min. 1 M
normal?
Turn starting
Does LED of pump
switch OFF.
Between CR2
NO
Disconnect CR2.
controller flash?
(female) (39) - (40) :
500 - 1000
Between CR2 (female)
Start engine.
(39)(40) - chassis ground : Min. 1 M
Disconnect E07.
6 YES
Is machine model
and attachment set
NO up or arm crane 6
set up correct?
NO
7 YES
A
Is resistance
between C05
(male) (2),(6) chassis ground
normal?
Min. 1 M
NO
Disconnect C05.
PC128US-2
Disconnection or
(5) and C03 (female) (1) (2)
Repair or replace
Replace
Defective contact,
CR2 (female) (39) - E07
(female) (2) or CR2 (40) E07 (2)
Repair or replace

sensor
Replace
Replace

set up or arm crane set up
Reset up

between CR3 (female) (16)
Repair or replace

Replace
drive switch
20-315
(17)
TROUBLESHOOTING
E-1
b) There is excessive drop in engine speed, or engine stalls

related to fuse 2.)
Cause
2 YES
Is voltage between
YES CR3 (2) (12) (22)
and chassis
ground normal?
5 YES To A
Is pump controller
LED off?
Is resistance
Is resistance
YES between C06
4
normal?
Defective contact,
harness between C06
(female) (5) and C13 (female) Repair or replace
8 15
NO (1), or defective contact or
harness between C06
OFF.
(female) (23) and C13 (female)
Disconnect C06.
(6)
YES between C13
Turn starting
switch ON.
(male) (1) and (2)

normal?
3
Does pump
controller LED
NO flash?
8 15
Turn starting
switch OFF.
Disconnect C13.
Is machine model
and attachment set
NO up or arm crane
set up correct?
NO
7 YES
Is there continuity
between C06
(female) (2) - (3)
and (5) - (6)?
20-316
(17)
NO
Replace
Replace

set up or arm crane set up
Reset up
NO
6 YES
Start engine.
Turn starting
switch OFF.
Disconnect C06.
Replace
Repair or replace
CR3 (female) (2) (12) (22)
NO
20 30 V
ON.
Remedy
Defective contact,
harness between CR3 (female)
Repair or replace
(16) and C06 (female) (3), or
defective contact or
(23) and C06 (female) (6)
Replace
drive switch
PC128US-2
TROUBLESHOOTING
E-1

PC138US-2
PC128US-2
20-317
(17)
TROUBLESHOOTING
E-2
E-2 Abnormality in PPC lock solenoid system

PC128US-2
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move
Cause
Remedy
4 YES disconnection in wiring
Is resistance
YES between S12 and
S13 (wiring
harness end)
2
normal?
Is resistance
YES between V07 (male)

1
Is voltage between
V07 (female) (1)
and chassis
ground normal?
(1) - (2), between

(1)(2) - chassis
ground normal?
Is resistance
YES between S13
(wiring harness
end) and chassis
3
ground normal?
NO harness between S13 and
Max. 1
Turn starting switch OFF. chassis ground
Disconnect S13.
Max. 1
Turn starting
NO
switch OFF.
Remove S12 and S13.
Safety lock lever: FREE
Between V07 (male)

(1) - (2) :
500 - 1000 NO
Between V07 (male) (1)(2) chassis ground : Min. 1 M
Disconnect V07.
20 30 V
ON.
NO
harness between V07

(female) (2) and S12
Repair or replace
Repair or replace
Defective PPC lock switch
Replace
Defective PPC lock solenoid
Replace
V07 (female) (1)
Repair or replace
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move
Cause
YES
1
Is voltage between
V07 (1) and (2)
normal?
2 YES
Is resistance
Safety lock lever
between S12 and
[LOCK] (solenoid NO S13 (switch end)
OFF) : Max. 1 V
normal?
Safety lock lever
NO
Min. 1 M
[FREE] (solenoid
ON) : 20 30 V
Turn starting switch Disconnect S12 and S13.
Safety lock lever: [LOCK]
ON.
20-318
(17)
Remedy
Replace
harness between S13 and
chassis ground
Repair or replace
Replace
PC128US-2
TROUBLESHOOTING
E-2
E-2 Related electrical circuit diagram
PC128US-2
20-319
(17)
TROUBLESHOOTING
E-2
PC138US-2
a) Even when safety lock lever is set to FREE, no work equipment, travel, swing move
Cause
4 YES Defective contact or

Is resistance
YES between S10
(female) (1) - fuse
3
(14)normal?
Is resistance
YES between S10
(female) (2) chassis ground
2
normal?
Is resistance

1
(2) - (1), between

(2)(1) - chassis
ground normal?
NO harness between S10
Max. 1
Turn starting switch OFF. (female) (1) - fuse (14)
Disconnect S13.
37 - 60
Turn starting
NO
switch OFF.
Remove S10.
Between V7 (male)
(2) - (1) :37 - 60
Between V7
NO
(male) (2) - chassis ground :
Min. 1 M
Disconnect V7.
Is voltage between
V7 (female) (2) and
chassis ground
normal?
20 30 V
ON.
NO
harness between V7 (female)
(1) and chassis ground
Remedy
Repair or replace
Repair or replace
Replace
Replace
harness between fuse V7
(female) (2) S10 (female) (2)
Repair or replace
b) Even when safety lock lever is set to LOCK, work equipment, travel, swing move
Cause
YES
1
Is voltage between
V7 (1) and (2)
normal?
2 YES
Is resistance
between S10
Safety lock lever
[LOCK] (solenoid NO (male) (1) - (2)
normal?
OFF) : Max. 1 V
Safety lock lever
NO
Min. 1 M
[FREE] (solenoid
ON) : 20 30 V
Turn starting switch Disconnect S10.
Safety lock lever: [LOCK]
ON.
20-320
(17)
Remedy
Replace
Defective contact in wiring

harness between S10
(female) (2) - V7 (female) (2)
Repair or replace
Replace
PC128US-2
TROUBLESHOOTING
E-2
PC128US-2
20-321
(17)
TROUBLESHOOTING
E-3
E-3 Abnormality in swing lock solenoid system

PC128US-2
a) Even when swing lock switch is turned OFF, upper structure does not swing
Cause
4 YES
resistance
YES Is
between S08
3
(female) (2), S30
When C03 (female)

(female) (2) - chassis
is grounded to
ground normal?
chassis, is
Min. 1
YES resistance between
NO
S08 (female) (1),
2
S30 (female) (1),
OFF.
S05 (female) (1) Is resistance
Disconnect C03, S08,
chassis ground
between S08
and S30.
normal?
YES (male) (1) - (2), S30
(male) (1) - (2) or
Min. 1
NO
S05 (male) (1) - (2)
1
normal?
Is resistance
Disconnect C03, S08, and
Min. 1
between V04
S30.
Disconnect
S08,
(male) (1) and (2)
NO
S30, and S05.
normal?
Start engine.
Operate swing or arm control
20 60
lever slightly (but do not move
work equipment).
OFF.
NO
Disconnect V04.
Go to A
harness between S08
(female) (2), S30 (female)
(2) - chassis ground
harness between C03
(female) (3) - S08 (female)
(1), S30 (female) (1)
Is resistance
YES between C03

5
Is voltage between
A C03 (female) (1)
and chassis
ground normal?
20 30 V
ON.
(female) (2) and

chassis ground
normal?
Min. 1
NO
OFF.
Disconnect C03 and V04.
Min. 1
NO
OFF.
Disconnect C03.
NO
Is resistance
YES between X05
(female) (4) and
9
V04 (female) (2)
normal?
NO
Max. 1
Disconnect X05 and V04.
Min. 1
Turn starting switch NO
OFF.
Disconnect X05.
20-322
(17)
Repair or replace
Repair or replace
Replace
Defective swing holding

brake solenoid valve
Replace
harness between X05
(female) (3) and chassis
ground
Repair or replace
harness between V04
(female) (4)
Repair or replace
Repair or replace
Repair or replace
C03 (female) (1)
10 YES
Is resistance
B between X05
(male) (3) and (4)
normal?
Defective swing or arm IN

pressure switch (S08, S30
or S05)
8 YES Go to B
Is resistance
YES between X05
(female) (3) and
7
chassis ground
When V04 (female)
normal?
is grounded to
Min. 1
YES chassis, is
NO
resistance between
C03 (female) (4) and
6
OFF.
chassis ground
Disconnect X05.
normal?
Remedy

auto brake controller
Replace
harness between X05
(female) (3)
Repair or replace
Defective swing lock switch
Repair or replace
PC128US-2
TROUBLESHOOTING
E-3
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause
YES
1
Is voltage between
V04 (1) and (2)
normal?
2 YES
Is resistance
between X05 (male)
Swing lock switch
(3) and (4), between
[LOCK] (solenoid NO (4) and chassis
ground normal?
OFF) : Max. 1 V
Swing lock switch
NO
Min. 1 M
[FREE] (solenoid
ON) : 20 30 V
Turn starting switch Disconnect X05.
Swing lock switch: [LOCK]
ON.
Remedy

brake solenoid
Replace
harness between V04
(female) (2) and X05
(female) (4)
Repair or replace
Defective swing lock switch Replace
PC128US-2
20-323
(17)
TROUBLESHOOTING
E-3
PC138US-2
a) Even when swing lock switch is turned OFF, upper structure does not swing
Cause
4 YES
resistance
YES Is
between S08
3
(female) (2), S30
When CR 1(female)
(female) (2) - chassis
(12) is grounded to
ground normal?
chassis, is
Min. 1
YES resistance between
NO
S08 (female) (1),
2
S30 (female) (1),
OFF.
CR3 (female) (30) Is resistance
Disconnect C03, S08,
chassis ground
between S08
and S30.
normal?
YES (male) (1) - (2), S30
(male) (1) - (2) or
Min. 1
NO
S05 (male) (1) - (2)
1
normal?
Disconnect C03, S08, and
Min. 1
Is resistance
S30.
Disconnect S08,
between V4 (male)
NO
S30, and S05.
(1) and (2) normal?
Start engine.
Operate swing or arm control
37 60
lever slightly (but do not move
work equipment).
OFF.
NO
Disconnect V4.
Go to A
Is resistance
YES between CR3

5
Is voltage between
A CR3 (female) (2)
(12) (22) and
chassis ground
normal?
20 30 V
ON.
Min. 1
NO
OFF.
Disconnect C03 and V4.
(female) (7) - X05

(female) (3)
normal?
Min. 1
NO
OFF.
Disconnect C03.
Repair or replace
harness between CR3
(female) (30) - S08 (female)
(1), S30 (female) (1)
Repair or replace
Defective swing or arm IN

pressure switch (S08, S30
or S05)
Replace

brake solenoid valve
Replace
NO
Is resistance
YES between X05
(female) (4) and V4
9
(female) (2)
normal?
NO
Max. 1
Disconnect X05 and V4.
Min. 1
OFF.
Disconnect X05.
20-324
(17)
harness between X05
ground
Repair or replace
harness between V4
(female) (1) and CR3
(female) (3)
Repair or replace
Repair or replace
(7) - X05 (female) (3)
Repair or replace
CR3 (female) (2) (12) (22)
10 YES
Is resistance
B between X05
(male) (3) and (4)
normal?
harness between S08
(female) (2), S30 (female)
(2) - chassis ground
8 YES Go to B
Is resistance
YES between X05
(female) (2) and
7
chassis ground
When V4 (female) is
normal?
grounded to
Min. 1
YES chassis, is
NO
resistance between
CR3 (female) (3)
6
OFF.
and chassis ground
Disconnect X05.
normal?
Remedy

auto brake controller
Replace
harness between X05
(female) (4) and V4 (female)
(2)
Repair or replace
Repair or replace
PC128US-2
E-3
TROUBLESHOOTING
b) Even when swing lock switch is turned to LOCK, upper structure swings
Cause
YES
1
Is voltage between
V4 (1) and (2)
normal?
2 YES
Is resistance
between X05 (male)
Swing lock switch
(4) and (2), between
[LOCK] (solenoid NO (4) and chassis
ground normal?
OFF) : Max. 1 V
Swing lock switch
NO
Min. 1 M
[FREE] (solenoid
ON) : 20 30 V
Turn starting switch Disconnect X05.
Swing lock switch: [LOCK]
ON.
Remedy

brake solenoid
Replace
harness between V4
(female) (2) and X05
(female) (4)
Repair or replace
Defective swing lock switch Replace
PC128US-2
20-325
(17)
TROUBLESHOOTING
E-4
E-4 Abnormalty travel speed solenoid system

PC128US-2
a) Even when travel speed selector switch is turned to Hi, travel speed does not change to high speed
related to fuse 2.)
Cause
Remedy
4 YES disconnection in wiring

Is resistance
M39
YES between
(female) (1) and
chassis ground
3
normal?
Is resistance
YES between M39

2
Is resistance
V05 (male)
YES between
(1) - (2), between
1
Is voltage between
V05 (female) (1)
and chassis
ground normal?
(1)(2) - chassis
ground normal?
(male) (1) and (2)

normal?
harness between M39
Max. 1 . Turn
NO (female) (1) and chassis
Starting switch OFF.
ground
Disconnect S13.

OFF.
Disconnect S12 and NO
S13.
Between V05 (male)

(1) - (2): 20 - 60
Between V06 (male) NO
(1)(2) - chassis ground :
Min. 1 M
Disconnect V05.
20 - 30 V
ON.
NO
harness between V05

(female) (2) and M39
(female) (2)
Repair or replace
Repair or replace
Defective travel speed

selector switch
Replace

solenoid
Replace
Repair or replace
V05 (female) (1)
b) Even when travel speed selector switch is turned to Lo, travel speed does not change to low speed
Cause
YES
1
Is voltage between
V05 (1) and (2)
normal?
2 YES
Is resistance
between M39
Travel speed
(male) (1) - (2),
selector switch
NO between (1)(2) [Lo] (solenoid OFF) :
chassis ground
Max. 1V
normal?
Travel speed
selector switch [Hi]
Min. 1 M
NO
(solenoid ON) :
20 30 V Disconnect M39.
Travel speed selector
ON.
switch : [Lo]
20-326
(17)
Remedy

solenoid
Replace

between V05 (female) (2)
and M39 (female) (2)
Repair or replace

selector switch
Replace
PC128US-2
TROUBLESHOOTING
E-4
PC128US-2
20-327
(17)
TROUBLESHOOTING
E-4
PC138US-2
related to fuse 1.)
fl Befor carrying out troubleshooting check that main pump pressure sensor system is normal.
Cause
YES
Remedy
Defective controller
Replace
Defective contact,
disconnect, or short circuit
with chassis ground in
wiring harness between
CR3 (female) (27) (3) - V5
(female) (2) (1)
Repair or replace

solenoid
Replace
CR3 (female) (2) (12) (22)
Repair or replace
Is resistance
YES between CR3

(female) (27) and
2
3
(3) normal?
Is resistance
V5 (male)
YES between
(2) - (1), between (2)
- chassis ground
normal?
1
Is voltage between
CR3 (female)
(2),(12),(22) and
chassis ground
normal?

OFF.
Disconnect CR3.
Between V5 (male)
(2) - (1): 37 - 60
Between V5 (male) NO
(1)(2) - chassis ground : Min. 1 M
Disconnect V5.
20 - 30 V
NO
ON.
20-328
(17)
PC128US-2
TROUBLESHOOTING
E-5
E-5 Trouble in automatic travel speed control system

PC128US-2
fl Always connect any disconnected connectors before going on to the next step.
fl If this failure mode is detected, the travel speed does not change automatically.
a) Main pump pressure sensor system
Cause
2 YES
YES Is voltage between
C05 (5) and (10)
normal?
Is voltage between
C05 (2) and (1)
normal?
Defective governor pump

controller
Replace
Disconnection, defective
contact, or short circuit
with power source or chassis ground in wiring harness between C02 (female)
(5) C05 (female) (3)
Repair or
replace
with chassis ground in wiring harness between C02
(female) (10) C05 (female)
(1)
Repair or
replace
with chassis ground in wiring harness between C02
(2)
Repair or
replace
Run engine at full NO

throttle
Relieve travel system and set
lever in neutral repeatedly
Remedy
Lever Neutral return

0.5 4.5V

ON.
18 28V
YES
3
Is voltage between
C05 (2) and chassis
NO ground normal?
Disconnect C05
ON.
18 28V
b) Engine speed sensor system

Cause
2 YES
Is resistance beYES tween C02 (female) (6) and (11)
normal?
1
Is resistance between E07 (male)
(1) and (2) normal?

OFF.
Disconnect C02.
500 1,000

OFF
Disconnect E07
NO
500 1,000
PC128US-2
Defective automatic Lo/Hi

travel speed controller
Remedy
Replace
contact, or short circuit with
power source or chassis
Repair or
replace
E07 (female) (1) or between
C02 (female) (10) E07 (female) (2)
sensor (Internal disconnection, defective contact,
short circuit with chassis
ground)
Replace
20-329
(17)
TROUBLESHOOTING
E-5
20-330
(17)
PC128US-2
E-5
TROUBLESHOOTING
PC138US-2
fl Always connect any disconnected connectors before going on to the next step.
fl If this failure mode is detected, the travel speed does not change automatically.
a) Main pump pressure sensor system
Cause
2 YES
CR1 (13) and (21)
normal?
Is voltage between
C05 (B) and (A)
normal?
Defective governor pump

controller
Replace
with power source or chassis ground in wiring harness between CR1 (female)
(13) C05 (female) (C)
Repair or
replace
with chassis ground in wiring harness between CR1
(A)
Repair or
replace
with chassis ground in wiring harness between CR1
(B)
Repair or
replace
Run engine at full NO

throttle
Relieve travel system and set
lever in neutral repeatedly
Remedy
Lever Neutral return

0.5 4.5V

ON.
4.5 5.5V
YES
3
Is voltage between
C05 (B) and
NO chassis ground
normal?
Disconnect C05
ON.
4.5 5.5V
b) Engine speed sensor system

Cause
2 YES
Is resistance beYES tween CR3 (female) (39) and (40)
normal?
1
Is resistance between E07 (male)
(1) and (2) normal?

OFF.
Disconnect CR3.
500 1,000

OFF
Disconnect E07
NO
500 1,000
PC128US-2
Defective automatic Lo/Hi

travel speed controller
Remedy
Replace
contact, or short circuit with
power source or chassis
Repair or
between CR3 (female) (39) replace
E07 (female) (2) or between
CR3 (female) (40) E07 (female) (1)
sensor (Internal disconnection, defective contact,
short circuit with chassis
ground)
Replace
20-331
(17)
TROUBLESHOOTING
E-5
20-332
(17)
PC128US-2
TROUBLESHOOTING
E-6
E-6 Abnormality in engine starting system

PC128US-2
fl Always connect any disconnected connectors before going
YES
on the next step.
4
fl When fuse 1 is normal. (If fuse 1 is blown,
Is voltage between
check for a short circuit with the ground
YES starting motor
YES
terminal B and
in the circuit related to fuse 1.)
chassis ground
normal?
5
Is voltage between
battery relay
terminal M and
NO chassis ground
normal?
20 30 V
Turn starting
switch ON.
20 30 V
Turn starting
switch ON.
3
Is there sound of
YES starting motor
pinion engaging?
6 YES
Is voltage between
battery relay
terminal B and
NO chassis ground
normal?
NO
20 30 V
ON.
YES

ON START.
7
Is voltage between
safety relay
terminal C and
NO chassis ground
normal?
YES
9
Is voltage between
YES M02 (1) and
chassis ground
normal?
20 30 V
8
ON.
Is voltage between
safety relay
terminal B and
NO
NO chassis ground
normal?
20 30 V
ON.
2
YES Is sound heard
from battery relay?
Turn starting
switch ON OFF.
20 30 V
ON.
NO
14 YES
Is there continuity
YES between battery
relay terminal E and
chassis ground?
1
Is specific gravity
of battery normal?
Min. 1.24
13
Is voltage between
battery relay
terminal BR and
NO chassis ground
normal?
20 30 V
ON.

OFF.
YES
15
Is voltage
between starting
switch terminal BR
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.
YES
16
Is voltage
between starting
switch terminal B
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.
17 YES
Is voltage between
fuse 1 inlet and
NO chassis ground
normal?
NO
20 30 V
ON.
20-334
(17)
PC128US-2
E-6
TROUBLESHOOTING
Cause
YES
Remedy
Defective starting motor
Replace
harness between battery
relay terminal M and
starting motor terminal B
Repair or replace
Defective battery relay
Replace
harness between battery (+)
terminal and battery relay
terminal B
Repair or replace
harness between safety
relay terminal C and
starting motor terminal S
Repair or replace
Defective safety relay
Replace
Defective contact,
circuit with power source in
alternator terminal R and
M02 (female) (2)
Repair or replace
10
Is voltage between
M02 (2) and
chassis ground
normal?
Max. 13 V
Turn starting
switch ON.
11 YES
Is voltage between
alternator terminal
NO R and chassis
ground normal?
NO
Max. 13 V
Disconnect terminal R.
Turn starting switch ON.
12 YES
Is voltage between
starting switch
terminal C (T09)
and chassis
ground normal?
20 - 30 V
NO
ON.
harness between starting
switch terminal C (T9) and
M02 (female) (1)
Repair or replace
Defective starting switch

(circuit C)
Replace
Repair or replace
motor terminal B and safety
relay terminal B
Replace
relay E and chassis ground
Repair or replace
switch terminal BR (T7) and
battery relay terminal BR
Repair or replace

(circuit BR)
Replace
harness between fuse 1
outlet and starting switch
terminal B (T6)
Repair or replace
harness between battery (+)
terminal - M11 (1), (2) - fuse
1 inlet
Lack of battery capacity
PC128US-2
Replace
Repair or replace
Charge or replace
20-335
(17)
TROUBLESHOOTING
E-6
20-336
(17)
PC128US-2
TROUBLESHOOTING
E-6
PC138US-2
YES
fl Before carrying out troubleshooting, check that all the

4
related connectors are properly inserted.
Is voltage between
fl Always connect any disconnected
YES starting motor
connectors before going on the
terminal B and
chassis ground
next step.
normal?
fl When fuse 1 is normal. (If fuse 1 is blown,
20 30 V
check for a short circuit with the ground
Turn starting
NO
switch ON.
in the circuit related to fuse 1.)
YES
5
Is voltage between
battery relay
terminal M and
chassis ground
normal?
20 30 V
Turn starting
switch ON.
3
Is there sound of
YES starting motor
pinion engaging?
ON START.
6 YES
Is voltage between
battery relay
terminal B and
NO chassis ground
normal?
NO
20 30 V
ON.
YES
YES
7
Is voltage between
safety relay
terminal S and
NO chassis ground
normal?
20 30 V
Turn starting
switch ON.
8
Is voltage between
safety relay
terminal C and
NO chassis ground
normal?
20 30 V
Turn starting
switch ON.
YES Is sound heard

from battery relay?
YES
Turn starting
switch ON OFF.
Is voltage between
safety relay
terminal B and
NO chassis ground
normal?
20 30 V
Turn starting
switch ON.
NO
24 YES
1
Is specific gravity
of battery normal?
Min. 1.26
Is there continuity
YES between battery
relay terminal E and
chassis ground?
23
Is voltage between
battery relay
terminal BR and
NO chassis ground
normal?
20 30 V
ON.

OFF.
YES
25
Is voltage
between starting
switch terminal BR
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.
26
Is voltage
between starting
switch terminal B
NO and chassis
ground normal?
20 30 V
Turn starting
switch ON.
YES
27 YES
Is voltage between
fuse 20 inlet and
NO chassis ground
normal?
NO
20 30 V
ON.
20-338
(17)
PC128US-2
E-6
TROUBLESHOOTING
Cause
Remedy
Replace
relay terminal M and
starting motor terminal B
Repair or replace
Replace
harness between battery (+) Repair or replace
terminal and battery relay
terminal B
YES
Replace
relay terminal C and
starting motor terminal S
Repair or replace
Defective safety relay
Replace
11
Is voltage between
YES M02 (2) and
chassis ground
normal?
10
Is voltage between
M02 (1) and
chassis ground
normal?
20 30 V
Turn starting
switch ON.
PPC lock switch:
LOCK
Max. 13 V
Turn starting
switch ON.
12 YES
Is voltage between
alternator terminal
NO R and chassis
ground normal?
NO
Max. 13 V
Disconnect terminal R.
Defective contact,
circuit with power source in
alternator terminal R and
M02 (female) (2)
Replace
Repair or replace
Go to A
NO
relay terminal B and heater
relay terminal B
Replace
Replace
relay E and chassis ground
Repair or replace
switch terminal BR (T7) and
battery relay terminal BR
(circuit BR)
Repair or replace
Replace
Repair or replace
harness between fuse 1
outlet and starting switch
terminal B (T6)
harness between battery (+) Repair or replace
terminal - M11 (1), (2) - fuse
1 inlet
Lack of battery capacity
PC128US-2
Charge or replace
20-339
(17)
TROUBLESHOOTING
E-6
Cause
13 YES
A
Is voltage between
V03 (6) and chassis
ground normal?
20 30 V
Starting switch:
START
PPC lock switch:
LOCK
YES
14
Is voltage between
V03 (3) and chassis
NO ground normal?
YES
15
Is voltage between
R06 (3) and chassis
NO ground normal?
20 30 V
Starting switch:
START
PPC lock switch:
LOCK
16 YES
NO
20 30 V
Starting switch:
START
PPC lock switch:LOCK
Is resistance
YES between R06
(female) (2) chassis ground
normal?
17
NO
Max. 1
Starting switch: OFF
Is voltage between
Disconnect R06.
R06 (1) and chassis
YES
ground normal?
Is voltage between
S10 (3) and chassis
NO ground normal?
20 30 V
Starting switch:
ON
YES
Defective V3 relay or
malfunction of KOMTRAX
Replace relay
Disconnection or defective
contact in wiring harness
between R06 (female) (3) V3 (female) (3)
Repair or replace
Go to B
Go to C
Defective R06 relay
20
Is voltage between
S10 (1) and chassis
Is voltage between
starting switch T12
NO and chassis
ground normal?
Repair or replace
Replace
(female) (1) (including fuse

14)
NO (between B - ACC)
Is voltage between
starting switch T9
and chassis
ground normal?
20 30 V
Starting switch:
START
PPC lock switch:
LOCK
Replace
22 YES contact in wiring harness
(17)
Repair or replace
20 30 V
Starting switch:
ON
20-340
Replace
21 YES between T12 - fuse 14 - S10

Repair or replace
NO ground normal?
20 30 V
Starting switch:
ON
Repair or replace
between R06 (female) (2) chassis ground
between S10 (female) (3) R06 (female) (1)
19
20 30 V
Starting switch: ON
between V03 (female) (6) M02 (female) (1)
Is voltage between
R06 (5) and chassis
NO ground normal?
20 30 V
Starting switch:
START
PPC lock switch:
LOCK
18 YES
Remedy
between T9 - R06 (female)

(5)
NO (Between B - C)
Repair or replace
Replace
PC128US-2
TROUBLESHOOTING
E-6
E-6 ENGINE STARTING SYSTEM

PC138US-2
PC128US-2
20-341
(17)
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING
l. 017tr
\ IVI
-
G
2
T-
Swing motor
T-
l-
Travel motor
a,
2
P
-ii
L
-s
5
-
s
J
4
z
.P
2
.a
.s
t
8
:
-
P
-
s
ST
;5
5
G
s
iz
s
-
PC128US-2
L
b
E
-
rrs-
l
0
l
0
cG
-
Ts
-
i00
s-
l
DO
8
b
t;
v
I
7
8
E
.-
5
7
.-E
i;
e
-
1
?
$
>
$
E
SOIC aid
5
.?
s 6 1
27T 2& s
is 2 z %
E 2
J
i-
al
2 u2 6
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i -
E
F
- - -6
6
- - F
- - - - - - - - - - - - - - - - - - -
2
a
6
-
5
-
E
uL
0
B
ij
A
H-6
H-7
H-8
H-9
H-10
H-l 1
H-12
H-13
H-14
H-15
H-16
s
-
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
20-403
0
H-l
TROUBLESHOOTING
H-l
Jr
Speeds of all work equipment,
travel, swing are slow or lack power
Check that there is no abnormal noise from the pump before starting troubleshooting.
abnormal noise, carry out troubleshooting
for H-4.)
(If there is any
Cause
4 YES
Remedy
main pump
epair or replace
Defective PC valve or
PC-EPC valve
epair or replace
Defective
valve
main relief
epair or replace
Defective
unload valve
,epair or replace
Defective self pressure

reducing valve
lepair or replace
(Pressure reducing
valve, LS circuit)
Defective operation
main valve
tepair or replace
Defective
YES
3r
pressure) normal?
-See TESTING AND NO
ADJUSTING.
YEIS Is main pump

relief pressure
normal?
GotoA
. See TESTING AND

ADJUSTING.
NO
pressure reducing
. Arm relief
pressure) normal?
* 2.7: i,, MPa

NO
(28 ? i., kglcms)
* Engine at full throttle
* 3.24 f 0.49 MPa

(33 + 5 kg/cm?)
*Engine at full
throttle
6
A
YES
Is LS differential
pressure normal?
Defective
valve
- 2.2 * 0.1 MPa

NO
(22.5 * 1 kg/ems)
- Engine at full throttle
f Operate travel on
one side under no
load.
Note :Check the control circuit equipment.

adjusting control circuit oil pressure.
20-404
0
For details,
see, TESTING
AND
of
pump LS
ADJUSTING,
Ieplace
Testing and
PC1 28US-2
H-3
TROUBLESHOOTING
H-3 No work equipment,
travel, swing move

Cause
3 YES
YE
NO
IO
YES
fiiisz?p
Al
NO
NO
20-406
0

valve
Replace
Defective chassis wiring

harness
Repair or replace
Go to Troubleshooting of
Electric System E-3b)
Repair or replace
Defective self pressure

reducing valve
Repair or replace
Defective main pump
Repair or replace
Defective PTO
Repair or replace
p5jiiiJHP
- 3.24 f 0.49 MPa

(33 f 5 kg/cm9
- Engine at full
throttle
Remedy
PC1 28US-2
H-4, H-5
TROUBLESHOOTING
H-4 Abnormal
noise generated
(around pump)
Cause
3 YES
YE
Go to Item 4
pi+JHImproper hydraulic oil
NO
YE
Remedy
Are there bubbles

in hydraulic tank?
:hange
lydraulic oil
Suction strainer blocked by

external object (cloth, etc.)
Is suction strainer
blocked by
external object?
n
Is hydraulic tank
oil level normal?
Defect inside main pump
Repair or replace
Operate for a short time

and watch for any change
in symptoms
Check again
[according to
change in
symptoms)
Improper hydraulic oil
Add hydraulic oi
Fine control
ability is poor or
response is poor
% External object:
cloth, etc.
N0
H-5 Fain control ability is poor or response is poor
Cause
YES
1
Is pump servo
orifice clogged?
2 YES
Does condition
_ become normal
NO when LS valve is
replaced?
Remedy
Clogged orifice for servo

pump
Jean
Defective LS valve
Replace
Defective servo piston
Replace
NO
PC1 28US-2
20-407
0
TROUBLESHOOTING
H-6
H-6 Boom is slow or lacks power
5 YES
YES
-
Is leakage from
hydraulic cylinder
normal?
4
YES
-
Is main pump
relief pressure
normal?
3
Does pressure
* 31237: JJ:;;
compensation
MPa 1325 T:z kg/cm?)
valve (pressure
-Engine at full
NO
YES reducing valve
throttle
piston, flow control
valve + pressure
reducing valve)
2
_
move smoothly?
YES Does control valve
P* It is also possible to
- spool move
interchange with
smoothly?
$;w.compensation NO
1
Is PPC valve
output pressure
normal?
* 3.24 * 0.49 MPa
133 t 5 kg/cm4
. Engine at full
throttle
- Operate lever fully.
20-408
0
Note
* 15 cclmin
*Engine at full
throttle
NO
6 YES
Is pressure
reducing valve
piston throttle free
of clogging?
NO
: In this case, always
be sure to
return the valves to their original
positions after checking.
NO
NO
PC128US-2
ELECTRICAL
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM

Monitor
panel
CIRCUIT DIAGRAM
FOR MONITOR
Starting
FOR MONITOR
SYSTEM
SYSTEM
Alarm
buzzer
switch
B BRACC C R, Rz
OFF 0
HEAT 0 0 o--o
ON
000
START 0 0 0 O--o
Q
Fuse
Bat terv
308
308
tterv
lay
,301;
h
0
Fuel level
sensor
20-502
0
Alternator
Engine
level
water
sensor
Engine
oil
pressure
switch
Fusible
I ink
TXP0.2417
PC128US-2
TROUBLESHOOTING
M-l
*
*
*
M-l
No display appears when starting switch is turned ON
Before carrying out troubleshooting,

check that all the related connectors are properly
Alwavs connect any disconnected connectors before going on the next step.
Check fuse 2 before starting troubleshooting.
YES
, I
Is voltage between
PO1 (female) (1)
and (3) normal?
*20-30V
*Turn starting
switch ON.
YES
Is fuse 2 normal?
NO
M-l
Related electrical
inserted.
Replace
harness between PO1
(female) (1) and fuse 2, or
between PO1 (female) (3)
and chassis ground
Repair or replace
wiring harness
Blown fuse 2
Check cause of
blown fuse, then
repair, and
replace fuse
circuit diagram
Fusible
I ink
Monitor
Panel
nA4
l-v I
I I GND
Ml4
.
.
I
IAAA~C
\vLtv
I u
\
CNll
($WP,l 6)
i%
PC1 28US-2
TXP02418
20-503
0
M-2, M-3
TROUBLESHOOTING
M-Z
*
Display does not go out after completion of self check (all lamps light
up for 3 seconds) when starting switch is turned ON

Always connect any disconnected connectors before going on the next step.
Cause
M-3
*
*
a)
Remedy
Replace
Some items do not light up during self check (all lamps light up for 3
seconds) when starting switch is turned ON

No gauges
Preheating
(fuel level, engine water temperature)

pilot lamp does not light up
Caution
lamps (engine oil pressure, battery
YES
I
Is there
disconnection in
* Check visually for

blown bulb.
20-504
0
1 Remedy
Replace
charge) do not light up
Cause
inserted.
light up
Cause
b)
inserted.
Llown bulb
Remedy
FXeplace
l-l
NO
;o to M-4
PC1 28US-2
M-4
TROUBLESHOOTING
M-4
*
*
Charge caution lamp does not light up when starting switch is turned
ON (before starting engine)
:
Before carrying
Always connect
out troubleshooting,
any disconnected
check that allthe related connectors

are properly
connectors
before going on the next step.
inserted.
Cause
YES
1
Is voltage between
PO1 (female) (10)
2 YES
and (3) normal?
_
Is voltage between
alternator terminal
- Start engine.
NO R and chassis
-27.5- 29.5 V
ground normal?
* Start engine.
-27.5 - 29.5 V
M-4
Related electrical
Monitor
Remedy
harness between PO1
(female) (10) and alternator
terminal R
NO
Replace
Repair or replace
wrng harness
Replace
circuit diagram
Panel
I
PO1 (04016)
:CN-2
(SWP12)
Alternator
El7 (X2)
3
--oR
0
TXP02419
PC1 28US-2
20-505
0
M-5
TROUBLESHOOTING
M-5
Engine oil pressure caution lamp does not light up when starting
switch is turned ON (before starting engine)
Before carrying
out troubleshooting,
Ir
Always
any disconnected
connect
check that all the related connectors

are properly
connectors
P=2 YES

Is continl
*Turn stalrting switch NO
chassis E
normal?
- Disconnect POl.
-Turn starting switch
OFF.
NO
* Max. 0.5 R
-Disconnect sensor
(+) terminal 617).
M-5 Related electrical
Monitor
inserted.
Remedy
Replace
harness between PO1
(female) (9) and S17 Wiring
harness end)
Repair or replace
wiring harness
Defective engine oil

pressuresensor
Replace
circuit diagram
Panel
I
PO1 (04016)
w-2
(SWP12)
$iJ
Engine oil
Pressure switch
a
s17
TXP02420
20-506
0
PC128US-2
M-6
TROUBLESHOOTING
M-6
*
*
Preheating
HEAT
pilot lamp does not light up when starting switch is at

check that all the related connectors are properly inserted.
Cause
YES
Remedy
Replace
Disconnection in wiring
harness between PO1
(female) (13) and starting
switch Rl, or defective
starting switch
Repair or replace
Is voltage between
PO1 (13) and (3)
normal?
*Turn starting switch NO

to HEAT position.
.20-30V
Monitor
circuit diagram
Panel
TXP0242
PC1 28US-2
20-507
0
M-7
TROUBLESHOOTING
M-7
*
Ir
*
Engine oil pressure caution lamp lights up when engine is running

are properly
Wheri engine oil pressure is normal.
Remedy
Cause
Defective engine oil

pressure sensor
YES
1
-Disconnect S13.
* Start engine.
2 YES
Is circuit between
_ PO1 (female) (9)
_
NO and chassis
ground insulated?
Contact of chassis ground

with wiring harness
and P13
NO
- Min. 1 MR
* Disconnect PO1 and P13.
-Turn starting switch OFF.
M-7 Related
Monitor
electrical
Replace
Does engine oil

pressure caution
lamp go out?
inserted.
Replace
Repair or replace
wiring harness
circuit diagram
Panel
PO1 (04016)
w-2
(SWP12)
D
E20
(SWP8)
Engine oil
Pressure switch
TXP02.420
20-508
0
PC1 28US-2
M-8
TROUBLESHOOTING
M-8
*
*
*
Charge caution lamp lights up when engine is running

When charging is being carried out normally.
inserted.
Cause
2 YES
Is continuiW
YES_ between POI
1
(female) (10) and
(3) normal?
Is voltage of
alternator terminal R normal?
ti
NO
* Stan engine.
* 27.5 - 29.5 v
. Start engine.
* Measure voltage
between alternator
No
terminal R and chassis
ground.
-27.5 - 29.5 V
Monitor
Remedy
Replace

with wiring harness
and alternator terminal R
Repair or replace
Defective generation of
electricity by alternator
Replace
circuit diagram
Panel
I
Alternator
PO 1 (040 16)
TXP02419
PC1 28US-2
20-509
0
M-9
TROUBLESHOOTING
M-9
*
Abnormality
in engine water temperature
gauge
*
*
Before carrying
out troubl&hooting,
are properly
Always connect any disconnected
connectors
When engine water temperature
is normal.
a)
After engine is started,
temperature
remains
at bottom
inserted.
level and does not move
RemedY
YES
1
Does level go up
one at a time and
finally go out?
YES
~
p
Does level go up
*Turn starting switch _ one at a time and ON.
NO finally go out?
* Connect short
connector to P07.
. Turn starting switch NO
-See Note 1.
ON.
- Short circuit PO6 (6)
and (3).
* See Note 1.
b)
Defective coolant
temperature sensor
Fil?plaCe
harness between PO1
(female) (6) - PO7
(female) (i),
or defective contact or
harness between P2 (female)
Repair or replace
wiring harness
Replace
Note 1) If the condition is normal, the

display goes up one level
approx. every 2 sec.
After engine is started, temperature
immediately
goes up (there is no overheating
but gauge enters
red range)
Cause
2 YES
Is resistance
YES between PO7
1
(male) (1) and (2)
normal?
Is voltage between
p
PO1 (3) and chassis - * Start engine
* Min. 4 kQ
ground normal?
* Disconnect P07.
*Start engine.
* Max. 0.1 V
Monitor
NO
NO
Remedy
Defective coolant
temperature sensor
Replace
harness between PO1
ground
Repair or replace
wiring harness
circuit diagram
Panel
PO1 (04016)
w-2
(SWP12)
@
Alternator
El7 (X2)
3
o
*R
0
TXP02419
20-510
0
PC1 28US-2
M-10
TROUBLESHOOTING
M-10 Abnormality
*
*
Jr
in fuel gauge

When fuel level is normal.
a) No segments
on fuel gauge light up

Cause
Defective fuel level sensor

(internal disconnection)
YES
harness between PO1
(female) (7) and PO6
(female) (I), or defective
contact or disconnection in
fuel level sensor f-end) and
chassis ground
segments light
Does fuel gauge
* Ground PO6 (female) - give full tank
(1) to chassis.
No display?
*Turn startina switch
ON.
* ;;;:3;.ircuit PO1 (7) NO
*Wait for approx. 1
minute.
. Turn starting switch ON.
*Wait for approx. 1 minute.
-1
YES
2
--out?
Is resistance of
. fuel level SenSOr
3 YES
normal?
1
PO1 (3) and chassis
-Start engine.
. Max. 0.1 V
PC128US-2
II
Do all segments
on fuel gauge go
-1
* Disconnect P06.
NO
-Turnstarting switch
ON.
*Wait for approx. 1 minute.
p
. Remove sensor.
* Move float by hand NO
and measure resistance
behveen PO6 (male) (1)
and chassis ground.
* F position: Max. 10 L2
* E position: Min. 85 Q
* Disconnect P4.
seplace
Iepair or replace
viring harness
teplace
at full tank display
Cause
Remedy
b) Fuel level has gone down but fuel gauge remains
YE
inserted.
Remedy
?eplace

and PO6 (female) (1)
Repair or replace
wiring harness
i(eplace
harness between PO1
ground
Repair or replace
wiring harness
20-511
0
TROUBLESHOOTING
c)
M-10
Even when tank is filled, fuel gauge does not give full tank display
2 YES
Is resistance of
fuel level sensor

1 - PO1 (3) and chassis ground normal?
-
normal?
- Remove sensor.
.zdv;;;;;rV
hand
* start engie.
- Max. 0.1 V
k
NO
NO
Cause
1 Remedy
Replace
harness between PO1
ground
Repair or replace
wiring harness
Replace
resistance between PO6 (male)

(1) and chassis ground.
* F position: Max. 10 Q
* Disconnect P06.
M-10 Related
Monitor
electrical
circuit diagram
Panel
I
PO 1 (040 16)
Fuel
level
sensor
TXP02425
20-512
a
PC1 28lJ.S2
M-II
TROUBLESHOOTING
M-l 1 Defective operation

*
Ir
a)
of alarm buzzer
Before carrvino out troubleshooting,

Buzzer does not sound
inserted.
Remedy
YES
leplace
harness between PO4
(female) (15). or defective
buzzer
tepair or replace
viring harness
1
Does buzzer sound
when PO1 (female) _
VE --A =I --^
- YES
~~~
*Turn starting switch

ON.
b)
Buzzer continues
relay terminal M - Ml4 (1).
(2)-CN-4(l)-fuse2-PO4
(female) (2). or blown fuse !5
NO
Iepair or replace
wiring harness
to sound and does not stop

Remedy
Replace
when PO1 is
disconnected?

with wiring harness
and PO4 (female) (1)
-Disconnect POl.
NO
ON.
M-l 1 Related
electrical
circuit diagram
1 (KESl
PO4 (M2)
2)
@.
Panel
=
-
a
Monitor
Repair or replace
wiring harness
Al arm
buzzer
Fusible
I ink
3
ry
TXP02426
PC1 28U.52
20-513
0
M-12
TROUBLESHOOTING
M-12 Service meter does not advance when engine is running

*
Ir

a)
When battery
charge caution
inserted.
lamp does not light up

Remedy
YES
1
Is voltage between
PO1 (female) (10)
and (3) normal?
NO
*Start engine.
.20-30V
b)
When battery
charge caution
Jc Carry out Troubleshooting
Replace

with wiring harness
and CN-2 (female) (5)
Repair or replace
wiring harness
lamp lights up
Remedy
No. M-9.
YES
Is continuity
between PO1
?) (10) and
NO
ngine.
29.5 v
* Start engine.
- Measure voltage
between alternator
terminal R and
chassis ground.
-27.5 - 29.5 V
Defective generation of
electricity by alternator
qepair or replacf
3eolace
No
Monitor

with wiring harness
and tilternator terminal R
Replace
circuit diagram
Panel
I
PO1 (04016)
CN-2
(SWP12)
@
Alternator
El7 (X2) -o
--OR
0
TXP02419
20-5 14
0
PC1 28US-2
M-13
TROUBLESHOOTING
M-13 Night lighting does not light up

J, -Before carrying out troubleshooting,
-k .Always connect any disconnected connectors before going on the next step.
a)
Gauge lighting
inserted.
does not light up

Remedy
Cause
1
Is voltage between
PO1 (female) (16)
and (3) normal?
Blown lamp (mslde monitor

panel) for night lighting
YES
harness between PO1
(female) (3)
11
* Disconnect POl.
NO
. Turn starting switch
ON.
. Turn light switch ON.
.20-30V
b)
Service mefer
lighting
Remedy
Replace
circuit diagram
Lighting
switch
,...
PC1 28US-2
does not light up
electrical
Repair or replace
wiring harness
Cause
M-13 Related
Rep,ace
Fusible
I ink
Battery
relay
TXP02428
20-515
0
M-14
TROUBLESHOOTING
M-14 Heater does not work

*
*

a)
Neither
Hi nor Lo work
Remedy
2 YES
Isthere continuity
:Es
Is continuity
(between MO6
male terminals) of _
heater switch as
shown in table
below?
between MO6
(female) (4) and
chassis ground?
NO
* Turn starting
switch OFF.
* Turn starting switch

OFF.
NO
-Disconnect M06.
b)
inserted.
F
Go to troubleshooting of
heater
harness between MO6
ground
Repair or replace
Defective heater switch
Replace
Only Lo does not work

Cause
2 YES
Is there continuity
YES between Ml 2
(female) (2) and
1
chassis ground?
~
Is there continuity
_ - DisconnectM12.
between MO6
(male) (3) and (4)?
NO
OFF.
to Lo.
- Disconnect M06.
- 2;; starting switch NO
1 Remedy
heater
harness between MO6
(female) (3) and Ml2
(female) (2)
Repair or replace
Replace
*Turn heater switch to

Lo.
c)
Only Hi does not work

Cause
Remedy
heater
I
I
*Disconnect M12.
NO
-Turn starting switch OFF.
-Turn starting switch to Hi
between MO6
(male) (2) and (4)?
4
-Disconnect M06.
-2;;
starting switch NO
harness between MO6
(female) (3) and Ml2
(female) (2)
3epair or replace
Ieplace
-Turn heater switch to

Hi.
20-5 16
0
PC1 28US-2
TROU~~LESHOOTING
M-14
M-14 Related electrical circuit diagram
Preheating
switch
~06 (KES~
~12 (KES~
4)
PC1 28US-2
3)
Preheating
switch
,____
TXP0.2429
20-517
0
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
PC128US-2
PC138US-2
Actions to be taken on monitor panel and phenomena on machine body
at the time of abnormality occurrence ....................................................................................................... 20-554
Electrical circuit diagram of mode M System .............................................................................................. 20-556
M-1
[E101] (An error history data abnormality) is displayed .................................................................. 20-560
M-2
[E108] (Detection of engine water temperature 105 ) is displayed................................................ 20-562
M-3
[E112] (Short circuit of wiper normal rotation output) is displayed .................................................. 20-562
M-4
[E113] (Short circuit of wiper reverse rotation output) is displayed ................................................. 20-562
M-5
[E114] (Contact of washer output with 24V) is displayed................................................................ 20-562
M-6
[E115] (Impossibility in 10 sec. at the time of wiping away) is displayed ........................................ 20-562
M-7
[E116] (Impossibility in 10 sec. of storage) is displayed.................................................................. 20-562
M-8
When the starting switch is set to ON, the whole monitor panel does not come ON for 3 sec ....... 20-563
a) When the whole monitor panel does not come ON .................................................................... 20-563
b) When part of the monitor panel does not come ON ................................................................... 20-563
M-9
The starting switch is set to ON, and the whole monitor panel remains lighted.............................. 20-566
M-10 (The engine pre-heating monitor) comes ON even without pre-heating arrangement ................... 20-567
M-11 When the starting switch is set to ON, the engine is started, the basic check items flash.............. 20-569
a) Alternator system........................................................................................................................ 20-569
b) Engine oil pressure system ........................................................................................................ 20-570
M-12 When the starting switch is set to ON (the engine stopped), precautions and
emergency stop items flash. (But "Battery" and "Engine oil pressure" do not come ON)............... 20-571
a) Alternator system........................................................................................................................ 20-571
b) Oil pressure sensor system ........................................................................................................ 20-572
M-13 When the starting switch is set to ON and the engine is started, precautions and emergency
stop items flash. (But when inspection items before diagnosis and engine are normal) ................ 20-573
a) (Engine oil pressure) flashes ...................................................................................................... 20-573
b) (Battery charge level) flashes ..................................................................................................... 20-573
c) (Coolant temperature) flashes .................................................................................................... 20-574
d) (Fuel level) flashes ..................................................................................................................... 20-575
M-14 When the starting switch is set to ON (the engine stops), the buzzer does not sound for 1 sec
Though caution items flash, the buzzer does not sound ................................................................ 20-576
M-15 Monitor panel night lighting does not come ON. (The liquid crystal display is normal)................... 20-577
M-16 The coolant temperature gauge does not rise ................................................................................ 20-578
M-17 The coolant temperature gauge does not indicate
(During operation, the gauge does not indicate any stage) ............................................................ 20-578
PC128US-2
20-551
(17)
M-18
M-19
M-20
M-21
M-22
M-23
M-24
M-25
The fuel level gauge indicates FULL all the time ............................................................................ 20-580
The fuel level gauge indicates nothing............................................................................................ 20-580
Though the swing lock switch is set to ON (lock), (the swing lock monitor) does not come ON..... 20-582
While the engine is rotating, the service meter does not advance.................................................. 20-582
The fuel level sensor system is defective ....................................................................................... 20-583
The coolant temperature sensor system is defective...................................................................... 20-584
The windshield wiper does not work, or works though the wiper is not switched ON..................... 20-585
a) The windshield wiper does not work........................................................................................... 20-585
b) The windshield wiper works though it is not switched ON .......................................................... 20-585
The washer motor does not work, or works though the washer is not switched ON ...................... 20-588
a) The washer motor does not work ............................................................................................... 20-588
b) The washer motor works though the washer is not switched ON............................................... 20-588
! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were
inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and
connectors were returned to the original positions, the machine has restored.
! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the
service code "E" is displayed. (When the service code is not displayed, the machine has restored.)
! Before diagnosis, check if related connectors are engaged properly.
! Be sure to return disconnected connectors to the original positions before proceeding to the next step.
20-552
(17)
PC128US-2
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM

PC128US-2
20-556
(17)
PC128US-2
TROUBLESHOOTING
PC138US-2
20-558
(17)
PC128US-2
TROUBLESHOOTING
PC128US-2
20-559
(17)
TROUBLESHOOTING
M-1
M-1 [E101] (An error history data abnormality) is displayed.

PC128US-2
" This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13
connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the battery terminals are disconnected and connected for troubleshooting. This is not an abnormality.
(When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF)
" When the service code is displayed again after the resetting arrangement is made, follow the procedures
below for diagnosis:
Cause
Remedy
1
After making the "Resetting arrangement," check the situations for a while in the normal
operation. (See Note 1.)
Is the service code displayed NO

again after the "Resetting arrangement" is taken?
Normal
YES
2
Set the starting switch to
OFF.
20 30V
Is the voltage between P01 (8) NO

Disconnection, defective contact or

ground fault of harness among the bat- Repair or
tery, M13 (1), (2) and P01 (female) (8) replace
YES
Replace
Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)
M-1 Related Electrical Circuit Diagram
20-560
(17)
PC128US-2
TROUBLESHOOTING
M-1
PC138US-2
" This display will appear when P01 connector, A20 connector, Fuse 18, A04 connector, A02 connector, M13
connector or battery relay B terminal of the monitor panel power supply system is disconnected, or the battery terminals are disconnected and connected for troubleshooting. This is not an abnormality.
(When the starting switch is set to OFF and the monitor panel power supply circuit is cut OFF)
" When the service code is displayed again after the resetting arrangement is made, follow the procedures
below for diagnosis:
Cause
Remedy
1
After making the "Resetting arrangement," check the situations for a while in the normal
operation. (See Note 1.)
Is the service code displayed NO

again after the "Resetting arrangement" is taken?
Normal
YES
2
OFF.
20 30V


ground fault of harness among the bat- Repair or
tery, M13 (1), (2) and P01 (female) (8) replace
YES
Replace
Note : Resetting arrangement : Set the starting switch to OFF once, hold down the buzzer cancel switch and set
the starting switch to ON again. Then, keep pressing the switch for 5 sec. or more as it is.
(This deletes all service codes stored in the internal memory.)
PC128US-2
20-561
(17)
TROUBLESHOOTING
M-2, M-3, M-4, M-5, M-6, M-7
M-2 [E108] (Detection of engine water temperature 105) is displayed.
Cause
Remedy
1
Does the coolant temperature gauge NO
on the monitor indicate a red range
and is the caution lamp flashing?
YES
See M-13-c).
Failure of engine body system

(See Note 1.)
2
Is "E" shown in front of the serv- NO

ice code?
YES
Replace
Note 1 : The monitor panel has returned to normal as far as the display is concerned. Since the coolant temperature sensor detected water temperatures of over 105C so far, remove the factors in the troubleshooting of the engine body.
M-3 [E112] (Short circuit of wiper normal rotation output) is displayed.

" See M-24.
M-4 [E113] (Short circuit of wiper reverse rotation output) is displayed.

" See M-24.
M-5 [E114] (Contact of washer output with 24V) is displayed.

" See M-25.
M-6 [E115] (Impossibility in 10 sec. at the time of wiping away) is

displayed.
" See M-24.
M-7 [E116] (Impossibility in 10 sec. of storage) is displayed.

" See M-24.
20-562
(17)
PC128US-2
TROUBLESHOOTING
M-8
M-8 When the starting switch is set to ON, the whole monitor panel does
not come ON for 3 sec.
PC128US-2
" Make sure that Fuses 6, 13 and 18 are not blown.
a) When the whole monitor panel does not come ON
Cause
Remedy
1
20 30V
Are the voltages among P01 (8) NO

(6), (7), P02 (1), (2) (6) and (7)
normal?
YES
Defective monitor panel.
Replace
2
20 30V
Is the voltage between Fuse 13 NO

YES
Disconnection, defective contact or Repair or

ground fault of harness between Fuse
replace
13 and battery relay RM.
ground fault of harness between P01
(female) (1) (2) and Fuse 13
Repair or
replace
3
20 30V

YES

replace
18 and Battery B.
(female) (19) and Fuse 6
Repair or
replace
b) When part of the monitor panel does not come ON
Cause
PC128US-2
Remedy
Replace
20-563
(17)
TROUBLESHOOTING
M-8
M-8 a) Related Electrical Circuit Diagram
20-564
(17)
PC128US-2
M-8
TROUBLESHOOTING
PC138US-2
a Make sure that Fuses 6, 12 and 18 are not blown.
a) When the whole monitor panel does not come ON
Cause
Remedy
1
20 30V
Are the voltages among P01 (8) NO

(6), (7), P02 (1), (2) (6) and (7)
normal?
YES
Replace
2
20 30V

YES

replace
12 and battery relay RM.
(female) (1) (2) and Fuse 12
Repair or
replace
3
20 30V

YES

replace
18 and Battery B.
(female) (19) and Fuse 6
Repair or
replace
b) When part of the monitor panel does not come ON
Cause
PC128US-2
Remedy
Replace
20-565
(17)
TROUBLESHOOTING
M-8, M-9
M-9 The starting switch is set to ON, and the whole monitor panel
remains lighted.
Cause
20-566
(17)
Remedy
Replace
PC128US-2
TROUBLESHOOTING
M-10
M-10
(The engine pre-heating monitor) comes ON even without

pre-heating arrangement.
PC128US-2
Cause
Remedy
1
Disconnect the terminal R1.
Max. 1V
Is the voltage between the starting NO

switch R1 and the machine body
normal?
Replace
YES
2
ON.
Max. 1V

Hot short circuit of harness between Repair or

starting switch R1 and P02 (female) replace
(18)
YES
Replace
PC128US-2
20-567
(17)
TROUBLESHOOTING
M-10
PC138US-2
a Make sure that S-NET is normal
Cause
Remedy
1
Disconnect the terminal R1.
Max. 1V
Is the voltage between the starting NO

switch R1 and the machine body
normal?
Replace
YES
2
ON.
Max. 1V
Is the voltage between CR1 (11) NO

Hot short circuit of harness between Repair or

starting switch R1 and CR1 (female) replace
(11)
YES
3
Are the monitoring code [0045] NO
(3) and [1027] (3) ON?
Replace
Replace
Replace
YES
4
Is the monitoring code [1061] NO
(2) ON?
YES
20-568
(17)
PC128US-2
TROUBLESHOOTING
M-11
M-11 When the starting switch is set to ON, the engine is started, the
basic check items flash.
a Inspect both the alternator system and the engine oil pressure system.
a) Alternator system
a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is
defective.
Cause
Remedy
1
Engine start, Medium speed
min.
20 30V
Is the voltage between the alter- NO

nator R and the machine body
normal?
Replace
YES
2
Engine start, Medium speed
min.
20 30V
Is the voltage between P02 (fe- NO

male) (11) and the machine body
normal?
Disconnection or defective contact of Repair or

harness between alternator R and P02 replace
(female) (11)
YES
Replace

PC128US-2
PC138US-2
PC128US-2
20-569
(17)
TROUBLESHOOTING
M-11
b) Engine oil pressure system

a When the engine oil pressure is normal
a Check Bit (3) of Monitoring Code [0046] When it is ON, the monitor panel is defective.
Cause
Remedy
1
Engine slow
Does the display disappear when NO

the oil pressure sensor terminal S17
is disconnected at engine slow?
YES
The oil pressure sensor is defective

(at low pressure).
Replace
Replace
2
Set the starting switch to OFF.
Disconnect the sensor harness
and P02.
Is there continuity between P02

NO
(female) (7) and the machine
body?
YES
Ground fault of harness between P02 Repair or

(female) (7) and sensor terminal S17
replace
M-11 b) Related Electrical Circuit Diagram

PC128US-2
PC138US-2
20-570
(17)
PC128US-2
TROUBLESHOOTING
M-12
M-12 When the starting switch is set to ON (the engine stopped),

precautions and emergency stop items flash.
(But "Battery" and "Engine oil pressure" do not come ON.)
a
Inspect both the alternator system and the engine hydraulic system.
a) Alternator system
a Check Engine Medium speed Min. 100 of Monitoring Code [0043] When it is ON, the monitor panel is
defective.
Cause
Remedy
1
Disconnect the terminal R.
Max. 1V
Is the voltage between the alter- NO

nator R and the machine body
normal?
Replace
YES
2
Disconnect P02.
Max. 1V

Hot short-circuit of harness between Repair or

P02 (female) (11) and alternator R
replace
YES
Replace

PC128US-2
PC138US-2
PC128US-2
20-571
(17)
TROUBLESHOOTING
M-12
b) Oil pressure sensor system

a When the engine oil pressure is normal
a Check Bit (3) of Monitoring Code [0046] When it is ON, the monitor panel is defective.
Cause
Remedy
1
Disconnect the sensor terminal
S17.
Is there continuity between the NO

sensor terminal S17 and the machine body?
Defective oil pressure sensor
Replace
YES
2
Disconnect P02 and sensor
terminal S17.
Is there continuity between P02 NO

(female) (11) and the sensor terminal S17?
Disconnection or defective contact of

harness between P02 (female) (7) and Repair or
replace
sensor terminal S17
YES
Replace
M-12 b) Related Electrical Circuit Diagram

PC128US-2
PC138US-2
20-572
(17)
PC128US-2
TROUBLESHOOTING
M-13
M-13 When the starting switch is set to ON and the engine is started, precautions and emergency stop items flash. (but when inspection
items before diagnosis and engine are normal)
a)
(Engine oil pressure) flashes.

! Before diagnosis, make sure that the engine oil pressure is normal.
Cause
See M-12-b).
b)
(Battery charge level) flashes.
Cause
See M-12-a).
PC128US-2
Remedy
Remedy
20-573
(17)
TROUBLESHOOTING
c)
M-13
(Coolant temperature) flashes.

!
Before diagnosis, make sure that the engine oil pressure is normal.
Cause
Remedy
1
Engine start
Medium speed min.
Is the coolant temperature gauge NO

in the red range?
Replace
YES
2
Engine start
Is only Level 1 (the lowest level)

of the gauge displayed after P07 NO
is disconnected?
YES
The coolant temperature sensor

system is defective. (See M-25.)
3
Disconnect P02 and P07.
Max. 1
Is the resistance value between

NO
P02 (female) (1) and P07 (female) (1) normal?

harness between P02 (female) (1) and
replace
P07 (female) (1)
YES

replace
P07 (female) (2)
M-13 c) Related Electrical Circuit Diagram

PC128US-2
PC138US-2
20-574
(17)
PC128US-2
TROUBLESHOOTING
d)
M-13
(Fuel level) flashes.

! Before diagnosis, make sure that fuel is not empty.
Cause
Remedy
1
Engine start
Is the fuel gauge in the red range?
NO
Replace
The fuel level sensor system is

defective. (See M-22.)
YES
Engine start
Wait for 2 minutes approx.
(The display of fuel level is
arranged to be slightly delayed because the fuel level
fluctuates.)
Connect P06 (female) (1) to

the machine body ground.
ON.
Max. 0.3V
2
Does the gauge indication come
on up to Level 9 (the right end) NO
when P06 (female) (1) is connected to the machine body ground?
YES
3
YES

replace
P06 (female) (1)
Replace
M-13 d) Related Electrical Circuit Diagram

PC128US-2
PC138US-2
PC128US-2
20-575
(17)
TROUBLESHOOTING
M-14
M-14 When the starting switch is set to ON (the engine stops), the buzzer
does not sound for 1 sec.
Though caution items flash, the buzzer does not sound.
! Even when "BATTERY CHARGE LEVEL" or "FUEL" of the caution items becomes abnormal, the buzzer
does not sound.
! The buzzer is controlled inside the monitor panel. When a buzzer sound is requested or when the voltage
of P01 (11) comes to the range from 20 to 30V, the buzzer will sound.
Cause
OFF.
Disconnect P03.
Set the buzzer cancel switch
to ON : Max. 1
Set the buzzer cancel switch
to OFF : Min. 1 M
Remedy
1
Is the resistance value between NO
P03 (female) (1) a d (2) normal?
Defective buzzer cancel switch
Replace
YES
2
Disconnect P03.
20 30V


(female) (16) and P03 (female) (2)
replace
YES
Replace

PC128US-2
PC138US-2
20-576
(17)
PC128US-2
TROUBLESHOOTING
M-15
M-15 Monitor panel night lighting does not come ON.

(The liquid crystal display is normal.)
! When the headlamp and the working lamp come ON normally,
Cause
Remedy
1
Set to Monitoring Code
[0045].
NO
Is Bit (4) of Monitoring Code

[0045] OFF?
YES
Replace
2
Set the lighting switch to ON.
20 30V


Repair or
harness between P02 (female) (19)
replace
and M47 (male) (14)
YES
Replace
PC128US-2
20-577
(17)
TROUBLESHOOTING
M-16, M-17
M-16 The coolant temperature gauge does not rise.

!
When engine water temperature does not rise practically, flashes the engine system.
Cause
Remedy
1
Disconnect P07.
When a short connector is connected to P07 (female), does the gauge NO

level rise step by step and does the
gauge go out finally?
YES


P07 (female) (1)
Repair or
replace

(20) and machine body P02 (female)
(2) machine body
Repair or
replace
Replace
2

(female) (1) and P07 (female)
(1)?
YES
3
Is there continuity between P02

(female) (13) (20) and P07
(female) (2)?
NO
YES
M-17 The coolant temperature gauge does not indicate.

(During operation, the gauge does not indicate any stage.)
! When the starting switch is set to ON, the gauge level will rise step by step and the gauge will go out finally
or during operation the gauge does not indicate any satage.
Cause
Remedy
1
Disconnect P07.
Does the gauge indication appear NO

when P07 is disconnected?
YES

2

(female) (1) and the machine
body?
YES
20-578
(17)
Replace
Ground fault of harness between P02

Repair or
replace
PC128US-2
TROUBLESHOOTING
M-16, M-17
M-16, M-17 Related Electrical Circuit Diagram

PC128US-2
PC138US-2
PC128US-2
20-579
(17)
TROUBLESHOOTING
M-18, M-19
M-18 The fuel level gauge indicates FULL all the time.
! Before the diagnosis, make sure that the fuel tank is really filled with fuel.
Cause
Wait for 2 minutes approx.
(The display of fuel level is
arranged to be slightly delayed because the fuel level
fluctuates.)
Remedy
1
When P06 is disconnected, does the NO
gauge level fall step by step and does
the gauge indication go out finally?
YES

Replace
2
OFF.
Is there continuity between P02 (fe- NO

male) (2) and the machine body?
YES

replace
M-19 The fuel level gauge indicates nothing.

! Before the diagnosis, make sure that fuel remains in the fuel tank.
Cause
Remedy
1
Disconnect P06.
Does the gauge indicate anything NO

after P06 (female) (1) is connected to the machine body ground?
YES

2
Is there continuity between P02 (female) (2) and the machine body after NO
P06 (female) (1) is connected to the
machine body ground?
YES
20-580
(17)

replace
P06 (female) (1)
Replace
PC128US-2
TROUBLESHOOTING
M-18, M-19
M-18, M-19 Related Electrical Circuit Diagram

PC128US-2
PC138US-2
PC128US-2
20-581
(17)
TROUBLESHOOTING
M-20, M-21
M-20 Though the swing lock switch is set to ON (lock),

(the swing lock monitor) does not come ON.
! Execute this troubleshooting only when the swing lock is in operation practically.
Cause
Remedy
1
and the machine body as per the
table?

Repair or
replace
and X05 (male) (1)
YES
Table
Swing lock switch ON
Swing lock switch OFF
Replace
Max. 1V
20 30V

PC128US-2
PC138US-2
M-21 While the engine is rotating, the service meter does not advance.
Cause
Remedy
1
Start the engine.
Medium speed min.
Is the battery charge level caution NO

lamp ON?
Replace
See M-12 a).
YES
20-582
(17)
PC128US-2
TROUBLESHOOTING
M-22
M-22 The fuel level sensor system is defective.

! Before the diagnosis, remove the fuel level sensor.
Cause
Remedy
1
Check by raising and lowering
the float if the resistance valve NO
between the connector (1) and
the flange is as per the table.
YES
2
NO
Defective sensor (See Note 2.)
Replace
Does the float have large crack, NO

chip or flaw?
Defective contact of connector
Clean or
replace the
connector.
Interference of sensor in tank
Replace the
sensor.
(See Note 2.)
Defective sensor
Replace
Does the arm move smoothly?
YES
YES
4
Is it found in visual check that the NO
harness is cut?
Disconnection of harness (See Note 3.)

(Defective clamp)
(Apply of external force)
YES
Table
Upper stopper position
(Full)
About Max. 12
Lower stopper position

(Empty)
About 85 110
Note 1 : Difference between Fuel Level and Gauge Indication

When the gauge indication is FULL, the fuel level is indicated as 78~100%, and when the indication is
at the lowest position, the fuel level is indicated as 14.5% max. When the machine body is inclined, the
actual indication is different from them. Check the gauge 2 or more minutes later than parking the
machine body on a level ground. (The gauge is arranged to indicate fuel level slowly because the fuel
level fluctuates.)
Note 2 : Install the sensor carefully so that it does not interfere inside the tank or that it may be installed improperly.
Note 3 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.
PC128US-2
20-583
(17)
TROUBLESHOOTING
M-23
M-23 The coolant temperature sensor system is defective.

Cause
Remedy
1
Is the resistance value between the NO
temperature sensor connectors
(male) (1) and (2) as per the table?
YES
Defective contact of connector

(See Note 1.)
Clean the
connector or
replace the
sensor.
Defective sensor
Replace
2
Is it found in visual check that the NO
harness is cut?
YES
Disconnection of harness (See Note 2.)

Replace the
(Defective clamp)
sensor.
(Apply of external force)
Table
Normal temperature (25C)
About 37 50k
100C
About 3.5 4.0k
Note 1 : In case of recurrence, the machine side connector (female side) is supposed to be defective. So, check
the machine side connector and harness.
Note 2 : Check if connector installed positions vibrate. If they vibrate largely, take proper measures.
20-584
(17)
PC128US-2
TROUBLESHOOTING
M-24
M-24 The windshield wiper does not work, or works though the wiper is
not switched ON.
a) The windshield wiper does not work.
! Make sure that the fuse 18 is normal.
! Execute this diagnosis when the service code [E112] [E113], [E115] or [E116] is displayed.
Cause
Front window : Close position
Set the monitoring code to
[0049].
Remedy
1
NO
Does Bit (3) of the monitoring

code [0049] come on?
YES
Set the wiper switch to "ON"
or "INT."
[0049].
2
When the wiper switch is set to
"ON" or "INT," do Bits (4) and (5) NO
of the monitoring code [0049] go
out?
Replace
Defective wiper motor
Replace
YES
3
NO
Are the voltages between pins of

M50 as per Table 1?
YES
4
Disconnect P02 and M50.
Are the resistance values between pins from P01 (female) and NO
M50 (male) as per Table 2?
YES

Disconnect Terminals (1)
and (2) of W03.
Max. 1
Disconnection, defective contact, short- Repair or

circuit of ground fault of harness of im- replace
proper resistance value
5
Terminals (1) and (2) of the rear
limit switch W03 normal?
Replace
Check the
front window,
The rear limit switch is defective, or the or replace the
front window is opened.
rear limit
switch.
YES
6
. Set the starting switch to OFF.
Disconnect P02 and Terminals (1) and (2) of W03.
Max. 1
Are the resistance values between

the rear limit switch W03 terminal NO
(1) and P02 (female) (15) and between W03 Terminal (2) and the
machine body normal?

harness of improper resistance value
replace
YES
Replace
b) The windshield wiper works though it is not switched ON.

Cause
Remedy
1
Front window : Closed position
[0049]
NO
Does Bit (3) of the monitoring

code [0049] come ON?
Replace
Replace
YES
Set the wiper switch to "ON"
or "INT."
[0049].
PC128US-2
2
When the wiper switch is set to NO
"ON" or "INT," do Bits (4) and (5) of
the monitoring code [0049] go out?
YES
Hot short circuit of harness between

P01 (female) (9) and M50 (female) (3) Repair or
or between P01 (female) (10) and M50 replace
(female) (1)
20-585
(17)
TROUBLESHOOTING
M-24
Table 1
Timing Chart when the windshield wiper is set to ON
Symbol
Set time
Temporary stop
time to the next
operation
Item
Tia
0.13 sec
Safety circuit during

wiper operation
(Safety function 1)
Tsa
10 sec
Temporary halt time

at wiper blade storage
Tip
1.5 sec
Safety circuit at
wiper storage
(Safety function 2)
Tsp
10 sec
When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in the range
of 20 30V.
Timing Chart when the windshield wiper is set to INT.

Item
Symbol Set time
Temporary stop time to

the next operation
Tia
4 sec
Safety circuit during

wiper operation (Safety
function 1)
Tsa
10 sec
Temporary halt time at

wiper blade storage
Tip
1.5 sec
Safety circuit at wiper

storage
(Safety function 2)
Tsp
10 sec
When the wiper is switched OFF, the voltage is Max. 3V, and when it is switched ON, the voltage is in
the range from 20 30V.
Table 2
Diagnosis 1
Resistance value
Between P01 (female) (10) and M50 (male) (1)

Max. 1
Between P01 (female) (6), (7) and M50 (male) (5)

Between M50 (female) (1), (3), (4), (5), (6) and GND
20-586
(17)
Min. 1M
PC128US-2
TROUBLESHOOTING
M-24

PC128US-2
PC138US-2
PC128US-2
20-587
(17)
TROUBLESHOOTING
M25
M-25 The washer motor does not work, or works though the washer is not
switched ON.
a) The washer motor does not work.
! Make sure that Fuse 4 is normal.
a-1) When [E114] is displayed.
Cause
Remedy
1
Max. 1V
Is the voltage among P01 (fe- NO

male) (3), M28 (female) (2) and
the machine body normal?
YES
Hot short circuit of harness between

Replace
P01 (female) (3) and M28 (female) (1).
Defective diode
Repair or
replace
a-2) When [E114] is not displayed.
Cause
Remedy
1
Disconnect M28.
Max. 20 30V
Is the voltage among Fuse 4, NO

M28 (female) (2) and the machine body normal?

harness between Fuse 4 and M28 (fereplace
male) (2).
YES
2
Max. 1

P01 (female) (3), M28 (female)
(1) normal?

M28 (female) (1).
Repair or
replace
Defective washer motor
Replace
Replace
YES
3
Set the washer switch to ON.
Max. 1V
Is the voltage between P01 (fe- NO

male) (3) and the machine body
normal?
YES
b) The washer motor works though the washer is not switched ON.
Cause
Remedy
1
Min. 1M

M28 (female) (1) and the machine body normal?

(female) (3) and M28 (female) (1).
replace
YES
20-588
(17)
Replace
PC128US-2
TROUBLESHOOTING
M-25

PC128US-2
PC138US-2
PC128US-2
20-589
(17)
TROUBLESHOOTING OF COMMUNICATION
SYSTEM (N MODE)
PC128US-2
PC138US-2
N-1 [E218] Communication abnormality ................................................................................................... 20-602
! When the service code "E" is no longer displayed after connectors were disconnected and T-adapters were
inserted for troubleshooting against any abnormality occurred or after T-adapters were disconnected and
connectors were returned to the original positions, the machine has restored.
! When any abnormality occurred, set the starting switch to OFF once and set it to ON to make sure that the
service code "E" is displayed. (When the service code is not displayed, the machine has restored.)
! Before diagnosis, check if related connectors are engaged properly.
! Be sure to return disconnected connectors to the original positions before proceeding to the next step.
PC128US-2
20-601
(17)
TROUBLESHOOTING
N-1
N-1
[E218] Communication abnormality
PC128US-2
1
Cause
Remedy
Are [128] and "US" intermittently NO

displayed in the monitoring code
1002?
YES

7.5V min.
Disconnect CR2 and measure
the voltage on the harness
side.
The machine has restored.
Defective controller CR700
Replace
2
YES
3
Is the resistance value among NO
P02 (9), (10) and CR2 (21)
normal?
YES
Disconnection of harness among P02

Replace
(9), (10) and CR2 (21)
Replace
When each controller is not connected to the network, "---" is displayed. When a correct alphanumeric
character is not displayed (when another model is displayed), the model of each controller has not been
selected properly.
N-1 Related Electrical Circuit Diagram
20-602
(17)
PC128US-2
TROUBLESHOOTING
N-1
PC138US-2
1
Cause
Remedy
Are model code and attachment NO

code displayed according to
setting in monitoring code 1001?
YES

7.5V min.
Disconnect CR2 and measure
the voltage on the harness
side.
The machine has restored.
Replace
2
YES
3
Is the resistance value among NO
P02 (9), (10) and CR2 (21)
normal?
YES
Disconnection of harness among P02

Replace
(9), (10) and CR2 (21)
Replace
N-1 Related Electrical Circuit Diagram
PC128US-2
20-603
(17)
TROUBLESHOOTING OF CONTROLLER CR700

[DECELERATION CONTROL SYSTEM]
(E MODE)
PC128US-2
PC138US-2
Cautions when troubleshooting controller CR700 [Deceleration control system] ....................................... 20-702
Response of controller and phenomena on machine body when abnormality has occurred...................... 20-704
Table for determining controller (Engine throttle control system) or engine related .................................... 20-706
Electric circuit diagram of E mode system ................................................................................................. 20-708
E-1
Abnormality in power supply of controller CR700 (LED on controller is OFF) ................................ 20-712
E-2
[E321] [E322] "Short circuit/disconnection in motor drive relay system" is displayed .................... 20-714
E-3
[E323] [E324] "Short circuit/disconnection in accelerator relay system" is displayed ..................... 20-715
E-4
[E325] [E326] "Short circuit/disconnection in decelerator relay system" is displayed..................... 20-717
E-5
[E328] "Abnormality in motor stall system" is displayed ................................................................. 20-719
E-6
[E308] "Abnormality in fuel dial input value" is displayed ............................................................... 20-721
E-7
[E227] "Abnormality in engine speed sensor system" is displayed ................................................ 20-722
E-8
[E306] "Abnormality in motor feedback potentiometer input value" is displayed ............................ 20-723
E-9
[E258] "Short circuit in potentiometer power supply" is displayed .................................................. 20-725
E-10 [E304] [E314] "Short circuit/disconnection in engine stop solenoid relay system" is displayed...... 20-727
E-11 Auto-decelerator does not operate ................................................................................................. 20-728
! During troubleshooting after an abnormality occurred, if service code "E" is not displayed when you inserted
a T-adapter after detaching a connector, or when you connected the connector after detaching the Tadapter, the normal condition has been restored already.
! If you have turned off starting-switch after an abnormality occurred, turn it on and check to see if service
code "E" is displayed. (If it is not displayed, the normal condition has been restored).
! Before starting troubleshooting, check for any faulty engagement of related connectors.
! Before going to next step in the troubleshooting procedure, be sure to connect any connector you have
detached.
PC128US-2
20-701
(17)
CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700

TROUBLESHOOTING
CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700

1. The machine has the control function as shown below for starting cold engine to prevent seizure of turbocharger because of cold engine coolant (lower than 30C).
Deceleration-motor
potentiometer
(Controls the process.)
Engine is forced to be fixed at the rpm for

warming-up. (Any throttle direction is ignored.)
Any rpm
(Follows the throttle
direction.)
2 seconds
Starting switch
turned "ON"
A: Turbocharger protection time

C: Modulation range
Starting switch
turned to "START"
B: Modulation time
D: When engine speed does not reach 1,200 rpm
The machine does not allow engine to start when coolant is cold (lower than 30 C) when the deceleration
motor was found normal by the check of whether or not the deceleration motor linkage worked.
! To release this control of cold engine start, connect a short-circuit connector to engine-coolant-temperature sensor (CN-P07) connected to CN-P02 ((1)) on monitor panel and cause short circuit between it
and GND {or between CN-P07 (female) (1) and GND}, or check operation in the deceleration-adjustment mode.
2. Cautions when an abnormality occurred with no user code displayed
The engine is under the control of controller CR700.
Problems which may occur in this system include:
1) Higher (lower) idling speed
2) Lower rpm in high idle
3) Higher (lower) rpm in auto-deceleration
4) Higher (lower) engine speed during auto-matic warming-up
5) Hunting
6) Engine does not stop.
If an abnormality occurred, and it was alarmed in the clock-display section on monitor panel, look up to the
corresponding diagnosis flow of E1 through E10 according to the quick-reference table for troubleshooting.
If no abnormality was alarmed on the display though it existed in the machine body, you have to determine
whether it occurred in "mechanical system or electric system". The problems listed in 1) - 6) above may
also occur due to faulty adjustment of the linkage between deceleration motor and injection pump. If any of
1) - 6) above occurred without no alarm on the display, diagnose it according to the following procedure:
20-702
(17)
PC128US-2
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

PC128US-2
(1/2)
20-708
(17)
PC128US-2
TROUBLESHOOTING
(2/2)
PC128US-2
20-709
(17)
TROUBLESHOOTING
PC138US-2
(1/2)
20-710
(17)
PC128US-2
TROUBLESHOOTING
(2/2)
PC128US-2
20-711
(17)
TROUBLESHOOTING
E-1
E-1
Abnormality in power supply of controller CR700

(LED on controller is OFF)
! Check that fuse 11 is not blown.

! If starting motor runs normally, follow the procedure below. (Otherwise, refer to E-8.)
Cause
Remedy
1
Turn starting switch ON
20 30V
Is voltage normal between CR3 NO

(1),(11) (21), (31), (32), (33)?
YES
Replace
2
Starting switch ON
20 30V
Is voltage between fuse 18 and NO

body normal?
YES

harness between fuse 18 and battery.
replace
harnesses between fuse 18 and CR3 Repair or
replace
(female) (1),(11).

PC128US-2
20-712
(17)
PC128US-2
TROUBLESHOOTING
E-1
PC138US-2
PC128US-2
20-713
(17)
TROUBLESHOOTING
E-2
E-2
[E321] [E322] "Short circuit/Disconnection in motor drive relay

system" is displayed
Cause
Turn starting switch ON;

operate fuel dial.
1.2A or less
Temperature of engine
coolant: 30C or higher
Remedy
1
Is current value normal between NO
CR3 (female) (18) and (23)?
YES
Replace
2
Detach R07 and CR3.
Min. 1 M
Is resistance value normal between NO

CR3 (female) (18) and body?
Defective harness; defective connector Repair or

CN-A09
replace
YES
Defective relay
Replace
20-714
(17)
PC128US-2
TROUBLESHOOTING
E-3
E-3
[E323] [E324] "Short circuit/Disconnection in accelerator relay system" is displayed
Cause
Remedy
1
operate dial (up).
1.2A or less

YES
Replace
2
Detach R09 and CR3.
Min. 1 M

Defective harness; defective connector Repair or

CN-A09
replace
YES
Defective relay
Replace

PC128US-2
PC128US-2
20-715
(17)
TROUBLESHOOTING
E-3
PC138US-2
20-716
(17)
PC128US-2
TROUBLESHOOTING
E-4
E-4
[E325] [E326] "Short circuit/Disconnection in decelerator relay system" is displayed

Cause
Remedy
1
operate dial (down).
1.2A or less.

YES
Replace
Defective harness
Repair or
replace
Defective relay
Replace
2
Detach R08 and CR3.
Min. 1 M

YES

PC128US-2
PC128US-2
20-717
(17)
TROUBLESHOOTING
E-4
PC138US-2
20-718
(17)
PC128US-2
TROUBLESHOOTING
E-5
E-5
[E328] "Abnormality in motor stall system" is displayed
! Abnormality in motor stall is alarmed if motor did not follow the operation of dial for 10 seconds after the
operation. Check by monitoring whether input signal and relay output are normal while the alarm issued
remains on the display.
PC128US-2
Cause
4A or less if normal
When dialed up:
(+) on (5) side, () on (6) side
When dialed down:
() on (5) side, (+) on (6) side
Resistance value between

(1) and (2) of eachrelay:
290 10%
Operation of each relay
(when starting switch is ON)
When neutral:
(3) and (6) continue.
When dialed up:
R07, and R09 (3) and (5)
continue.
When dialed down:
R07, and R08 (3) and (5)
continue.
Remedy
1
M48 (female) (5) (motor (+)) and
(6)(motor ())?
YES
Defective motor (drive system)
Replace
motor
Defective relay
Replace
Defective harness; fuse (9) blown
Repair or
replace
2
Do relays of R07, R08 and R09 NO
operate normally?
YES
PC128US-2
20-719
(17)
TROUBLESHOOTING
E-5
PC138US-2
20-720
(17)
PC128US-2
E-6
TROUBLESHOOTING
E-6
[E308] "Abnormality in fuel dial input value" is displayed
! Check that the input value is normal in the monitoring mode.

Cause
Remedy
Fuel control dial voltage:

Fuel control dial FULL: 0.7 V
Is fuel control dial voltage of NO

monitoring 1034 normal?
Fuel control dial SLOW: 4.3 V

Disconnect M51.
M51 (male)
Between (1) (2):
0.25 5 k
Between (2) (3):
0.25 5 k
Between (1) (3): 4 6 k
Between M51 (male) (1), (2),
(3) chassis ground:
Min. 1 M
YES
Replace
Defective fuel control dial
Replace
Defective wiring harness
Repair or
replace
2
Is resistance between M51 (male) NO
(1), (2), and (3) normal?
YES
PC128US-2
20-721
(17)
TROUBLESHOOTING
E-7
E-7
[E227] "Abnormality in engine speed sensor system" Is displayed

Cause
Turn starting switch OFF: 0

Engine slow:
93 +50 (930 rpm) (*1)
110 5 (1,100 rpm) (*2)
Engine full:
240 5 (2,400 rpm)
Remedy
1
NO
Is engine speed (monitoring code

1010) normal?
YES
Replace
Defective engine speed sensor
Replace
Defective harness
Replace
motor
Faulty installation of engine-speed

sensor
Testing and
adjusting
2
Detach E07
500 1,000
Is resistance value normal between E07 (male) (1) and (2)?
NO
YES
3
Detach CR2
500 1,000
Is resistance value normal between CR2 (female) (39) and

(40)?
YES
(*1) PC128US-2
PC138USLC-2
(*2) PC138US-2
PC138USLC-2
NO

Serial No.: 1001 1500

PC128US-2
PC138US-2
20-722
(17)
PC128US-2
E-8
TROUBLESHOOTING
E-8
[E306] "Abnormality in motor feedback potentiometer input value" is

displayed
! Check that the input value is normal in the monitoring mode.
Cause
Reset auto-decelerator.
Feedback potentiometer
voltage:
Fuel control dial FULL:
4.2 V (*1)
4.6 V (*2)
Fuel control dial SLOW:
2.1 V (*1)
2.7 V (*2)
Disconnect M48.
M48 (male)
Between (1) (2):
0.36 3.9 k
Between (2) (3):
1.4 5.5 k
Between (1) (3): 5 1 k
Between M48 (male) (1), (2),
(3) chassis ground:
Min. 1 M
(*1) PC128US-2
PC138USLC-2
(*2) PC138US-2
PC138USLC-2
Remedy
1
Is feedback potentiometer voltage NO
of monitoring 1035 normal?
YES
Replace
Defective decelerator motor
Replace
Repair or
replace
2
Is resistance between M48 (male) NO
(1), (2), and (3) normal?
YES

Serial No.: 1001 1500

PC128US-2
PC128US-2
20-723
(17)
TROUBLESHOOTING
E-8
PC138US-2
20-724
(17)
PC128US-2
E-9
TROUBLESHOOTING
E-9
[E258] "Short circuit in potentiometer power supply" is displayed
Disconnect CR1.
Resistance between CR1
(female) (22) chassis
ground: Min. 1 M
Cause
Remedy
Is resistance between CR1 (female) NO

(22) and chassis ground normal?
YES
Disconnect M48.
ground: Min. 1 M
Replace
Defective deceleration motor
Replace

(Short circuit in 5-V line)
Repair or
replace
Defective fuel control dial
Replace
2
YES
Disconnect M51.
ground: Min. 1 M
3
YES

PC128US-2
PC128US-2
20-725
(17)
TROUBLESHOOTING
E-9
PC138US-2
20-726
(17)
PC128US-2
E-10
TROUBLESHOOTING
E-10 [E304] [E314] "Short circuit/Disconnection in engine stop solenoid

relay system" is displayed
PC138US-2
Cause
Disconnect CR3.
ground: 68 10%
Remedy
1
Is resistance between CR3 (female)
NO
YES
Replace
Defective stop solenoid relay
Replace

(Grounding fault)
Repair or
replace
Defective diode (D03)
Replace
Disconnect M52.
Resistance between M52
(male) (1) (2): 68 10%
Resistance between M52
(male) (1), (2) chassis
ground: Min. 1 M
Are resistance between stop solenoid

relay M52 (male) (1) and (2) and
resistance between each pin and
chassis ground normal?
Disconnect D32
(with M52 disconnected).
ground: Min. 1 M
Is resistance between CR3 (female)

NO
YES
3
NO
YES
PC128US-2
20-727
(17)
TROUBLESHOOTING
E-11
E-11 Auto-decelerator does not operate

PC138US-2
! Check the auto-decelerator reset input signal and each pressure switch input signal in the monitoring mode.
Cause
When auto-decelerator reset
switch is pressed;
Bit (2): ON (Auto-decelerator
reset)
Remedy
1
Is auto-decelerator reset switch NO
of monitoring 1022 normal?
Defective monitor panel or controller
Replace
Replace
Defective pressure switch

(Internal seizure)
Replace

(Grounding fault in signal line)
Repair or
replace
YES
Monitoring code [1023]
Bit (1): OFF (Boom LOWER
pressure switch)
Bit (3): OFF (Travel pressure
switch)
Bit (4): OFF (Swing pressure
switch)
Bit (5): OFF (Arm IN
pressure switch)
Bit (6): OFF (Boom RAISE
pressure switch)
Monitoring code [1028]
Bit (1): OFF (Arm OUT
pressure switch)
Bit (2): OFF (Att, blade
RAISE/LOWER pressure
switch)
Bit (3): OFF (Bucket CURL
pressure switch)
Bit (4): OFF (Bucket DUMP
pressure switch)
2
Is each pressure switch signal of
monitoring 1023 and 1028 nor- NO
mal?
YES
3
When pressure switch connector of
NO
abnormal part is disconnected,
does bit keep lighting?
YES
! The pressure switches for the blade and attachments are not shown in this figure.
20-728
(17)
PC128US-2

[PUMP CONTROL SYSTEM]
(C MODE)
PC128US-2
PC138US-2
Cautions when troubleshooting controller CR700 [Pump control system] .................................................. 20-802
Response of controller and phenomena on machine body when abnormality has occurred...................... 20-804
Table for determining controller CR700 [Pump control system] or oil pressure in ralated .......................... 20-808
Electric circuit diagram of C mode system ................................................................................................. 20-812
Troubleshooting flow chart for each failure mode
C-1
Abnormality in power supply of controller (LED on controller is OFF) ............................................ 20-816
C-2
[E232] "Short circuit in PC-EPC solenoid system" is displayed ...................................................... 20-818
C-3
[E233] "Disconnection in PC-EPC solenoid system" is displayed .................................................. 20-820
C-4
[E203] "Short circuit in swing holding brake solenoid system" is displayed.................................... 20-822
C-5
[E213] "Disconnection in swing holding brake solenoid system" is displayed ................................ 20-826
C-6
[E206] "Short circuit in travel Hi/Lo selection solenoid system" is displayed .................................. 20-830
C-7
[E216] "Disconnection in travel Hi/Lo selection solenoid system" is displayed............................... 20-832
C-8
[E205] "Short circuit in 2-stage relief solenoid system" is displayed............................................... 20-834
C-9
[E215] "Disconnection in 2-stage relief solenoid system" is displayed ........................................... 20-836
C-10 [E222] "Short circuit in LS-EPC solenoid system" is displayed ...................................................... 20-838
C-11 [E223] "Disconnection in LS-EPC solenoid system" is displayed ................................................... 20-839
C-12 [E224] "Abnormality in pump pressure sensor system" is displayed .............................................. 20-840
C-13 [E227] "Abnormality in engine speed sensor system" is displayed ................................................ 20-841
! During troubleshooting after an abnormality occurred, if no service code "E" is displayed when you inserted
a T-adapter after detaching a connector, or when you connected the connector after detaching the Tadapter, the normal condition has been restored already.
! Before starting troubleshooting, check for any faulty engagement of related connectors.
! Before going to next step in the troubleshooting procedure, be sure to connect the connector you have
detached.
PC128US-2
20-801
(17)
TABLE FOR DETERMINING CONTROLLER

CR700 (PUMP CONTROL SYSTEM) OR OIL PRESSURE IN RELATED
TROUBLESHOOTING
TABLE FOR DETERMINING CONTROLLER CR700 (PUMP CONTROL

SYSTEM) OR OIL PRESSURE IN RELATED
PC128US-2
Controller CR700 (E2: XX type)
Abnormality in power supply of
controller
Short circuit in PC-EPC
solenoid system
Disconnection in PC-EPC
solenoid system
Short circuit in swing holding
brake solenoid system
Disconnection in swing holding brake solenoid system
Short circuit in travel speed
selection solenoid system
Disconnection in travel speed
Short circuit in 2-Stage relief
solenoid system
Disconnection in 2-Stage
relief solenoid system
Short circuit in LS-EPC
solenoid system
Disconnection in LS-EPC
solenoid system
Results of self-diagnosis displayed
User codes
Traveling system
Compound
operation
Work-equipment
Entire work-equipment, traveling, and

swinging
Failure mode
Service codes
Slower speed or reduced power of entire work equipment, traveling,
and swinging
Substantial drop of engine speed, or engine stop
Entire work equipment, traveling, and swinging are inoperable.
Abnormal noise (from around pump)
Auto-deceleration inoperable
Poor fine control performance, or poor response
Slower or less powerful movement of boom
Slower or less powerful movement of arm
Slower or less powerful movement of bucket
Boom inoperable
Arm inoperable
Bucket inoperable
Greater hydraulic drift
Greater time lag (engine slow)
Independent relief causes other work equipment's movement.
Full power cannot be attained when pressure is increased.
Worsened or weaker stroke-end cushion of boom RAISE
In the case of compound operation, the greater the load, the longer
the time of operation.
Boom moves slower in the case of the swing + boom (RAISE) operation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Travel deviation
Deviation is great at the start of traveling
Slower traveling speed
Steering is hard or not powerful.
Traveling speed is unchangeable, or faster than the set speed.
Inoperable (only on one side)
Does not swing.
Swinging system
E02
E03
LED
off 232 233 203 213 206 216 205 215 222 223
Worsened acceleration
performance or speed
of swinging
Both R.H. and L.H.

One side only
Both R.H. and L.H.
One side only
Both R.H. and L.H.

One side only
Greater shock when swinging is stopped (only on one side)
Greater abnormal noise when swinging is stopped
Greater hydraulic drift When swing holding brake is released
during swinging
When swing holding brake is operating
Diagnosis codes when service codes are displayed
Diagnosis codes when abnormality was found by checking monitoring
codes
Greater drift when
swinging is stopped
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
Items checked only by monitoring
20-808
(17)
PC128US-2

TROUBLESHOOTING
! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.
LS-EPC current output
PC-EPC current output
Monitoring codes
1023
1021
1060
1002 1010 1042 1050 1054
Diagnosis codes when no service code is

displayed
Bit patterns
227
Engine speed input
Model code
Traveling
2-stage relief (6)
PPC initial pressure (2)
Swing holding brake (1)
Kerosene mode (6)
Service pressure switch (2)
Bucket DUMP (2)
Bucket CURL (2)
Arm OUT (2)
Arm IN (5)
Boom RAISE (6)
Boom LOWER (2)
Traveling (3)
224
Status of solenoid in
operation
Oil-pressure switch
Pump discharge pressure input
Items to be checked in the monitoring mode
Swinging (4)
Abnormality in pump
pressure sensor system
Abnormality in engine speed

sensor system
Controller CR700
(E2: XX type)
Results of self diagnosis displayed
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
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
H-26
H-27
H-28
C-12
C-13
F-1
F-2
F-3
F-4
F-5
PC128US-2
F-6
F-7
F-8
F-9 F-10
20-809
(17)

TROUBLESHOOTING
PC138US-2
Controller CR700 (E2: XX type)
Abnormality in power supply of
controller
Short circuit in PC-EPC
solenoid system
Disconnection in PC-EPC
solenoid system
Short circuit in swing holding
brake solenoid system
Disconnection in swing holding brake solenoid system
Short circuit in travel speed
Disconnection in travel speed
Short circuit in 2-Stage relief
solenoid system
Disconnection in 2-Stage
relief solenoid system
Short circuit in LS-EPC
solenoid system
Disconnection in LS-EPC
solenoid system
Results of self-diagnosis displayed
User codes
Traveling system
Compound
operation
Work-equipment
Entire work-equipment, traveling, and

swinging
Failure mode
Service codes
Slower speed or reduced power of entire work equipment, traveling,
and swinging
Substantial drop of engine speed, or engine stop
Entire work equipment, traveling, and swinging are inoperable.
Abnormal noise (from around pump)
Auto-deceleration inoperable
Poor fine control performance, or poor response
Slower or less powerful movement of boom
Slower or less powerful movement of arm
Slower or less powerful movement of bucket
Boom inoperable
Arm inoperable
Bucket inoperable
Greater hydraulic drift
Greater time lag (engine slow)
Independent relief causes other work equipment's movement.
Full power cannot be attained when pressure is increased.
Worsened or weaker stroke-end cushion of boom RAISE
In the case of compound operation, the greater the load, the longer
the time of operation.
Boom moves slower in the case of the swing + boom (RAISE) operation.
Travel speed decreases greatly in the case of the swing + travel
operation.
Deviation is great during constant traveling
Travel deviation
Deviation is great at the start of traveling
Slower traveling speed
Steering is hard or not powerful.
Traveling speed is unchangeable, or faster than the set speed.
Inoperable (only on one side)
Does not swing.
Swinging system
E02
E03
LED
off 232 233 203 213 206 216 205 215 222 223
Worsened acceleration
performance or speed
of swinging
Both R.H. and L.H.

One side only
Both R.H. and L.H.
One side only
Both R.H. and L.H.

One side only
Greater shock when swinging is stopped (only on one side)
Greater abnormal noise when swinging is stopped
Greater hydraulic drift When swing holding brake is released
during swinging
When swing holding brake is operating
Diagnosis codes when service codes are displayed
Diagnosis codes when abnormality was found by checking monitoring
codes
Greater drift when
swinging is stopped
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11
Items checked only by monitoring
20-810
(17)
PC128US-2

TROUBLESHOOTING
! If service code E218 (abnormality in network) was shown, go to troubleshooting in N mode.
1023
LS-EPC current output
PC-EPC current output
Monitoring codes
1028
1021
1060
1002 1010 1042 1050 1054
Diagnosis codes when no service code is

displayed
Bit patterns
227
Engine speed input
Model code
Traveling
2-stage relief (6)
PPC initial pressure (2)
Swing holding brake (1)
Kerosene mode (6)
Service pressure switch (2)
Bucket DUMP (4)
Bucket CURL (3)
Arm OUT (1)
Arm IN (5)
Boom RAISE (6)
Boom LOWER (1)
Traveling (3)
224
Status of solenoid in
operation
Oil-pressure switch
Pump discharge pressure input
Items to be checked in the monitoring mode
Swinging (4)
Abnormality in pump
pressure sensor system
Abnormality in engine speed

sensor system
Controller CR700
(E2: XX type)
Results of self diagnosis displayed
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
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
H-26
H-27
H-28
C-12
C-13
F-1
F-2
F-3
F-4
F-5
PC128US-2
F-6
F-7
F-8
F-9 F-10
20-811
(17)
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM

PC128US-2
(1/2)
20-812
(17)
PC128US-2
TROUBLESHOOTING
(2/2)
PC128US-2
20-813
(17)
TROUBLESHOOTING
PC138US-2
(1/2)
20-814
(17)
PC128US-2
TROUBLESHOOTING
(2/2)
PC128US-2
20-815
(17)
TROUBLESHOOTING
C-1
C-1
Abnormality in power supply of controller (LED on controller is OFF)
! Check that fuses (1) and (18) are not blown.
Cause
2 YES
Remedy
Replace
Is voltage normal
YES between CR3 (14),

(24) (21), (31),
1
(32), (33)?
Is voltage normal
between CR3 (1),
(11) and each (21),
ON
(31), (32) and
20 30 V
(33)?
Attach T-adapter
OFF: 20 30 V
Disconnection or defective con- Repair or

tact of harnesses between CR3 replace
(14), (24) and CNM47 (3)
contact between fuse (18) and
CR3 (1),(11); Disconnection or Replace
defectivecontact between CR3 motor
(21),(31),(32),(33) and CN-A04
(12),(14)
C-1 Related electric circuit diagram

PC128US-2
20-816
(17)
PC128US-2
TROUBLESHOOTING
C-1
PC138US-2
PC128US-2
20-817
(17)
TROUBLESHOOTING
C-2
!
C-2
[E232] "Short circuit in PC-EPC solenoid system" is displayed
Be sure to turn emergency pump drive switch to DOWN (normal).
Cause
YES
4 YES
Do resistance values
Do resistance valbetween CR3 (feYES male)(16) and (23),
ues between C06
(male) (2) and (3),
and between (16)
YES
between (5) and (6),
and body match with
and between C06
Table 1?
(male) (2), (3), (5),
3
(6) and body match
Do
resistance
valOFF.
with Table 2?
1
ues between C06
Disconnect CR3.
(female) (2) and (5),
NO
Turn starting
Attach directcoupled
switch OFF.
between C13 (male)
connector to
NO and between (2) and
body match with Ta Disconnect C06.
(1) and (2), and beCN-D23 and D24.
ble 1?
Turn emergency
tween (1) and body
pump drive switch to
match with Table 1?
DOWN (normal).
OFF.
Disconnect C06.
OFF.
NO
Disconnect C13.
Replace
Ground fault or hot-short-circuit

of harness between CR3 (fe- Repair or
male)(16) and C06 (female)(3);
or hot short circuit of harness replace
between CR3 (female)(23) and
C06 (female)(6).
Defective emergency pumpdrive switch (inner ground Replace

fault or hot short circuit)
Ground fault or hot-short-circuit of harness between C06
(female)(2) and C13 (female); Repair or
or hot short circuit of harness
between C06 (female)(5) and replace
C13 (female)(2).
(internal short-circuit or
ground fault)
Defective diode
NO
Remedy
Replace
Table 1
Diagnosis No.2
Diagnosis No.3
Diagnosis No.4
C13 (male) (1) (2)
CR3 (female) (16) (23)
C06 (female) (2) (5)
C13 (male) (1) body
CR3 (female) (16) body
C06 (female) (2) 2body
Resistance
8 15
Min. 1 M
Table 2
Diagnosis No.5
C06 (male) (2) (3), (5) (6)
C06 (female) (2), (3), (5), (6) body
20-818
(17)
Resistance
Max. 1
Min. 1 M
PC128US-2
TROUBLESHOOTING
C-2

PC128US-2
PC138US-2
PC128US-2
20-819
(17)
TROUBLESHOOTING
C-3
C-3
[E233] "Disconnection in PC-EPC solenoid system" Is displayed
! If a solenoid or its harness was disconnected, current does not flow through the solenoid. If ground fault
occurs on the 2-pin side of the solenoid, current (about 1 A) remains to flow.
! Be sure to turn emergency-pump drive switch to DOWN (normal).
Cause
YES
Disconnection or defective contact of harness between CR3

(female)(16) and C06 (fe4
YES
male)(3); or disconnection, deDo resistance valbetween CR3 (fefective contact or ground fault of
YES male) (16) and (23),
ues between C06
harness between CR3 (fe(male) (2) and (3),
male)(23) and C06 (female)(6).
and between (23)
YES
between (5) and (6)
and body match with
and between C06
Table 1?
3 (male) (2), (3), (5),
(6) and body match
Defective emergency pumpDo resistance valOFF.
with Table 2?
1
drive switch (inner disconnecues between C06
Disconnect CR3.
(female) (2) and (5),
NO tion, defective contact or
Turn starting
Attach directcoupled
ground fault).
switch OFF.
between C13 (male)
connector to
NO and between (2) and
body
match
with
Ta
Disconnect
C06.
(1) and (2), and beCN-D23 and D24.
Disconnection of defective conble 1?
Turn emergency
tween (2) and body
tact of harness between C06 (fepump drive switch to
match with Table 1?
male)(2) and C13 (female); or
DOWN (normal).
OFF.
disconnection, defective contact
Disconnect C06.
or ground fault of harness beOFF.
NO
tween C06 (female)(5) and C06
Disconnect C13.
(female)(2).

(internal short circuit or
ground fault)
Defective diode
NO
Remedy
Replace
Repair or
replace
Replace
Repair or
replace
Replace
Table 1
Diagnosis No.2
Diagnosis No.3
Diagnosis No.4
C13 (male) (1) (2)
CR3 (female) (16) (23)
C06 (female) (2) (5)
C13 (male) (1) body
C06 (female) (2) 2body
Resistance
8 15
Min. 1 M
Table 2
Diagnosis No.5
C06 (male) (2) (3), (5) (6)
C06 (female) (2), (3), (5), (6) body
20-820
(17)
Resistance
Max.1
Min. 1 M
PC128US-2
TROUBLESHOOTING
C-3

PC128US-2
PC138US-2
PC128US-2
20-821
(17)
TROUBLESHOOTING
C-4
C-4
[E203] "Short circuit in swing holding brake solenoid system" is displayed
PC128US-2
! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that
service code "E" is displayed. (If it is not displayed, the normal condition has been restored.)
! Be sure to turn OFF (normal) both swing holding brake release switch and swing lock switch before starting
check.
Cause
3 YES
Is resistance norYES mal between CR3
(female)(7) and
body?
2
(1) and (2), and between (2) and body

match with Table 1?
Turn starting
switch OFF.
Disconnect V04.
Is [E203] displayed
after replacing the
solenoid and connector with other
ones?
Turn starting
switch OFF.
NO
Replace V04 with
another one.
Start engine.
Operate swing-lever or a lever of
work-equipment
(for just a moment).

OFF.
Disconnect CR3.
Turn swing lock switch OFF.
Attach a direct coupled connector to CN-D08.
37 60
NO
YES Is resistance normal
Is resistance normal between X05

(female) (3), (4)
and body?
between X05 (male)

(4) and body?

OFF.
Disconnect X05.
37 60

OFF.
NO
Disconnect X05.
Min. 1 M
Replace
to A
Defective swing-holding-brake
solenoid (inner short-circuit or Replace
ground fault)
5 YES
4
Remedy
Ground fault of either harness

connecting CR3 (female) (7) Repair or
D08 (2), (1) to M47 (19), or (1) replace
to X05 (male)(3).
Ground fault of harness connecting X05 (male)(4) M47 Repair or
(3) and then to V04 (female) replace
(2).
Defective swing-lock switch
Replace
(inner short circuit)
Table 1
V04 (male)(1) (2)
37 60
V04 (male)(2) body
Min. 1 M
20-822
(17)
PC128US-2
TROUBLESHOOTING
C-4
PC128US-2
20-823
(17)
TROUBLESHOOTING
C-4
PC138US-2
! If you have turned off starting switch after an abnormality occurred, turn on starting switch and check that
service code "E" is displayed. (If it is not displayed, the normal condition has been restored.)
check.
Cause
3 YES
(female)(7) and
body?
2
(1) and (2), and between (2) and body

match with Table 1?
Turn starting
switch OFF.
Disconnect V4.
Is [E203] displayed
after replacing the
solenoid and connector with other
ones?
Turn starting
switch OFF.
NO
Replace V4 with
another one.
Start engine.
Operate swing-lever or a lever of
work-equipment
(for just a moment).

OFF.
Disconnect CR3.
Attach a direct coupled between D02 (4) (8).
37 60
NO
YES Is resistance normal
Is resistance normal between X05

(female) (3), (4)
and body?
between X05 (male)

(4) and body?

OFF.
Disconnect X05.
37 60

OFF.
NO
Disconnect X05.
Min. 1 M
Replace
to A
Defective swing-holding-brake
solenoid (inner short-circuit or Replace
ground fault)
5 YES
4
Remedy
Ground fault of either harness

connecting CR3 (female) (7) Repair or
D02 (8), (4) to M47 (19) to replace
X05 (male)(3).
Ground fault of harness connecting X05 (male)(4) M47 Repair or
(3) and then to V4 (female) replace
(2).
Defective swing-lock switch
Replace
(inner short circuit)
Table 1
V4 (male)(1) (2)
37 60
V4 (male)(2) body
Min. 1 M
20-824
(17)
PC128US-2
TROUBLESHOOTING
C-4
PC128US-2
20-825
(17)
TROUBLESHOOTING
C-5
C-5
[E213] "Disconnection in swing holding brake solenoid system" is

displayed
PC128US-2
check.
NOTE: [Note] An error [E213] is detected if swing holding brake release switch was turned OFF (swinging
enabled); this is not a failure.
NOTE: [Note] If an error [E213] was detected when swing lock switch was turned ON (swinging locked), do
troubleshooting (F-9) of the swing lock signal input system.
Cause
3 YES
Does resistance
YES between CR3 (fe2
male) (7) and body
match with Table 1?
YES Is resistance nor
mal between V04
ON.
1 (male)(1) and (2)?
Disconnect D08.
Is [E213] displayed
Turn
starting
after replacing the
switch OFF.
solenoid and conNO
Disconnect V04.
nector with other
37
60
ones?
OFF.
Replace V04 with NO
another one.
Remedy
Replace
to A
Defective swing holding brake

solenoid (inner disconnection Replace
or hot short circuit)
Disconnection or defective con-
6 YES tact of either harness connect- Repair or

Is resistance nor-
YES mal between CR3
Is resistance norYES mal between X05

(male) (4) and
4
body?
Is resistance nor Turn starting
mal between X05
switch OFF.
(female) (3) and
Disconnect X05.
(4)?
37 60 ohm
Turn starting
switch OFF.
Disconnect X05. NO
Max.1
ing D08 (female)(1) M47 (19) replace

or (1) X05 (male)(3).
(female) (7) and

D08 (female) (2)?
contact of harness between Repair or
Turn starting
NO CR3 (female)(7) and D08 (fereplace
male)(2).
switch OFF.
Disconnect D08, CR3.
Disconnection, defective con Max. 1
tact or hot short circuit of ei- Repair or
ther harness connecting X05
NO
(male)(4) M47 (20) or M47 replace
(20) V04 (female)(2).
(inner disconnection or hot Replace
short circuit)
Table 1
Diagnosis No. 3
D08(1) body
20-826
(17)
Voltage
Measuring conditions
0 10 V
4 5 seconds after putting all levers to Neutral.
20 30 V
When swing-lever or a lever of work equipment is operated (just for a moment)
PC128US-2
TROUBLESHOOTING
C-5
PC128US-2
20-827
(17)
TROUBLESHOOTING
C-5
PC138US-2
check.
NOTE: [Note] An error [E213] is detected if swing holding brake release switch was turned OFF (swinging
enabled); this is not a failure.
NOTE: [Note] If an error [E213] was detected when swing lock switch was turned ON (swinging locked), do
troubleshooting (F-9) of the swing lock signal input system.
Cause
3 YES
Does resistance
YES between CR3 (fe2
male) (7) and body
match with Table 1?
YES Is resistance nor
mal between V4
ON.
1 (male)(1) and (2)?
Disconnect D02.
Is [E213] displayed
Turn
starting
after replacing the
switch OFF.
solenoid and conNO
Disconnect V4.
nector with other
37
60
ones?
OFF.
Replace V4 with
NO
another one.
Remedy
Replace
to A
Defective swing holding brake

solenoid (inner disconnection Replace
or hot short circuit)
Disconnection or defective con-
6 YES tact of either harness connect- Repair or

Is resistance nor-
YES mal between CR3
Is resistance norYES mal between X05

(male) (4) and
4
body?
Is resistance nor Turn starting
mal between X05
switch OFF.
(female) (3) and
Disconnect X05.
(4)?
37 60 ohm
Turn starting
switch OFF.
Disconnect X05. NO
Max.1
ing D02 (female)(8) M47 (19) replace

X05 (male)(3).
(female) (7) and

D02 (female) (8)?
contact of harness between Repair or
Turn starting
NO CR3 (female)(7) and D02 (fereplace
male)(8).
switch OFF.
Disconnect D02, CR3.
Disconnection, defective con Max. 1
tact or hot short circuit of ei- Repair or
ther harness connecting X05
NO
(male)(4) M47 (20) or M47 replace
(20) V4 (female)(2).
(inner disconnection or hot Replace
short circuit)
Table 1
Diagnosis No. 3
D02(8) body
20-828
(17)
Voltage
Measuring conditions
0 10 V
4 5 seconds after putting all levers to Neutral.
20 30 V
When swing-lever or a lever of work equipment is operated (just for a moment)
PC128US-2
TROUBLESHOOTING
C-5
PC128US-2
20-829
(17)
TROUBLESHOOTING
C-6
C-6
[E206] "Short circuit in travel Hi/Lo selection solenoid system" is

displayed
PC128US-2
Cause
3 YES
YES Is resistance normal between CR3
2
(female)(27) and
Do resistance valbody?
ues between V05
YES (male)(1) and (2),
Turn starting
and between (2)
switch OFF.
1
and body, match
Disconnect CR3.
with Table 1?
Is [E206] displayed
37 60
Turn starting
after replacing the
switch OFF.
solenoid and conNO
nector with other
Disconnect V05.
ones?
OFF.
Replace V05 with NO
another one.
Start engine.
Turn travel-speed
switch to "Mi" or
"Hi".
Operate travel lever
just for a moment.
NO
Remedy
Defective engine throttle and

Replace
pump controller
Ground fault of harness connecting CR3 (female)(27) Repair or
A08 (1) and then to V05 (fereplace
male)(2); or continuing diode
D07.
Defective travel-Hi/Lo selection solenoid (inner short cir- Replace

cuit or ground fault)
Table 1
V05 (male)(1) (2)
37 60
V05 (male)(2) body
Min. 1 M
20-830
(17)
PC128US-2
C-6
TROUBLESHOOTING
PC138US-2
Cause
3 YES
YES Is resistance normal between CR3
2
(female)(27) and
Do resistance valbody?
ues between V5
YES (male)(1) and (2),
Turn starting
and between (2)
switch OFF.
1
and body, match
Disconnect CR3.
with Table 1?
Is [E206] displayed
37 60
Turn starting
after replacing the
switch OFF.
solenoid and conNO
nector with other
Disconnect V5.
ones?
OFF.
Replace V5 with
NO
another one.
Start engine.
Turn travel-speed
switch to "Mi" or
"Hi".
Operate travel lever
just for a moment.
NO
Remedy

Replace
pump controller
Ground fault of harness connecting CR3 (female)(27) V5 Repair or
(female)(2); or continuing di- replace
ode D01(1) (5).
Defective travel-Hi/Lo selection solenoid (inner short cir- Replace

cuit or ground fault)
Table 1
V5 (male)(1) (2)
37 60
V5 (male)(2) body
Min. 1 M
PC128US-2
20-831
(17)
TROUBLESHOOTING
C-7
C-7
[E216] "Disconnection in travel Hi/Lo selection solenoid system" is

displayed
PC128US-2
Cause
3 YES
2
(female) (27) and
body?
YES Is resistance be
Turn starting
tween V05 (male)
switch OFF.
(1)
and
(2)
normal?
1
Disconnect CR3.
Is [E216] displayed
37 60
Turn
starting
after replacing the
switch
OFF.
solenoid and conNO
Disconnect V05.
nector with other
37
60
ones?
OFF.
Replace V03 with NO
another one.
ON.
NO
Remedy

Replace
pump-controller
contact of harness connecting Repair or
CR3 (female) (27) A08 (1)
and then V05 (female) (2), replace
or V05 (female) (1) to body.
Defective travel-speed solenoid (inner disconnection or Replace

hot short circuit)
20-832
(17)
PC128US-2
C-7
TROUBLESHOOTING
PC138US-2
Cause
3 YES
2
(female) (27) and
body?
YES Is resistance be
Turn starting
tween V5 (male)
switch OFF.
1 (1) and (2) normal?
Disconnect CR3.
Is [E216] displayed
37 60
Turn
starting
after replacing the
switch
OFF.
solenoid and conNO
Disconnect V5.
nector with other
37
60
ones?
OFF.
Replace V5 with
NO
another one.
ON.
NO
Remedy

Replace
pump-controller
contact of harness connecting Repair or
CR3 (female) (27) A08 (1)
and then V5 (female) (2), or replace
V5 (female) (1) to body.
Defective travel-speed solenoid (inner disconnection or Replace

hot short circuit)
PC128US-2
20-833
(17)
TROUBLESHOOTING
C-8
C-8
[E205] "Short circuit in 2-stage relief solenoid system" is displayed
PC128US-2
Cause
3 YES
Remedy
Replace
Is resistance nor-
YES mal between CR3
2
(female) (28) and
body?
between
V06
(male)
YES
Turn starting
(1) and (2) and beswitch OFF.
1 tween (2) and body Disconnect CR3.
match with Table 1?
Is [E205] displayed
Turn starting switch 37 60
after replacing the
OFF.
solenoid and conNO
Disconnect V06.
nector with other
ones?
OFF.
Replace V06 with NO
another one.
Start engine.
Turn on swing lock
switch.
NO
Ground fault of harness between CR3 (female) (28) and Repair or

replace
V06 (female) (2)
Defective 2-stage relief solenoid (inner short-circuit or Replace

ground fault)
Table 1
V06 (male)(1) (2)
37 60
V06 (male)(2) body
Min. 1 M
20-834
(17)
PC128US-2
C-8
TROUBLESHOOTING
PC138US-2
Cause
3 YES
2
(female) (28) and
body?
Turn starting
(1) and (2) and beswitch OFF.
tween
(2)
and
body
1
Disconnect CR3.
match with Table 1?
Is [E205] displayed
Turn starting switch 37 60
after replacing the
OFF.
solenoid and conNO
Disconnect V6.
nector with other
ones?
OFF.
Replace V6 with
NO
another one.
Start engine.
Turn on swing lock
switch.
NO
Remedy
Replace
Ground fault of harness between CR3 (female) (28) and Repair or

replace
V6 (female) (2)
Defective 2-stage relief solenoid (inner short-circuit or Replace

ground fault)
Table 1
V6 (male)(1) (2)
37 60
V6 (male)(2) body
Min. 1 M
PC128US-2
20-835
(17)
TROUBLESHOOTING
C-9
C-9
[E215] "Disconnection in 2-stage relief solenoid system" is

displayed
PC128US-2
Cause
3 YES
2
(female) (28) and
body?
YES Is resistance bet Turn starting switch NO
ween V06 (male) (1)
OFF.
and (2) normal?
1
Disconnect CR3.
Is [E215] displayed
37 60
after replacing the
OFF.
solenoid and conNO
Disconnect V06.
nector with other
37 60
ones?
OFF.
NO
Replace V06 with
another one.
ON.
Remedy
Replace
Disconnection, defective contact or hot short circuit of harness between CR3 (female) Repair or
(28) and V06 (female) (2), or replace
between V06 (female) (1) and
body.
Defective 2-stage relief solenoid (inner disconnection or Replace

hot short circuit)
20-836
(17)
PC128US-2
C-9
TROUBLESHOOTING
PC138US-2
Cause
3 YES
2
(female) (28) and
body?
YES Is resistance bet Turn starting switch NO
ween V6 (male) (1)
OFF.
and (2) normal?
1
Disconnect CR3.
Is [E215] displayed
37 60
after replacing the
OFF.
solenoid and conNO
Disconnect V6.
nector with other
37 60
ones?
OFF.
NO
Replace V6 with
another one.
ON.
Remedy
Replace
Disconnection, defective contact or hot short circuit of harness between CR3 (female) Repair or
(28) and V6 (female) (2), or be- replace
tween V6 (female) (1) and body.
Defective 2-stage relief solenoid (inner disconnection or Replace

hot short circuit)
PC128US-2
20-837
(17)
TROUBLESHOOTING
C-10
C-10 [E222] "Short circuit in LS-EPC solenoid system" is displayed
Cause
2 YES
Do resistance values between CR3

YES (female) (6) and (13)
and between (6) and
1
body match with Table 1?
between C14 (male)
(1) and (2) and beOFF.
tween (1) and body
Disconnect CR3.
match with Table 1?
Remedy
Replace
Ground fault or hot short circuit of harnessbetween CR3

(female) (6) and C14 (female) Repair or
(1), or hot short circuit of har- replace
ness between CR3 (female)
(13) and C14 (female)(2).
Defective LS-EPC solenoid
(inner ground fault or hot short
circuit)

OFF.
NO
Disconnect C14.
Replace
Table 1
Diagnosis No.1
Diagnosis No.2
Resistance
C14 (male) (1) (2)
CR3 (female) (6) (13)
8 15
C14 (male) (1) body
Min. 1 M

PC128US-2
PC138US-2
20-838
(17)
PC128US-2
TROUBLESHOOTING
C-11
C-11 [E223] "Disconnection in LS-EPC solenoid system" is displayed

! If a solenoid or its harness was disconnected, current does not flow through the solenoid.
If ground fault occurs on the 2-pin side of the solenoid, current (about 1A) remains to flow.
! Be sure to turn emergency-pump drive switch to DOWN (normal).
Cause
2 YES
Do resistance values between CR3

YES (female) (6) and (13)
and between (13)
1
and body match with
Do resistance valTable 1?
ues between C14
(male) (1) and (2)
OFF.
and between (2) and
body match with Ta Disconnect CR3.
ble 1?
OFF.
NO
Disconnect C14.
Remedy
Replace
Disconnection or defective contact of harness between CR3

(female)(6) and C14 (female) Repair or
(1); or disconnection, defective replace
contact, or ground fault of harness between CR3 (female)
(13) and C14 (female) (2).
Defective LS-EPC solenoid
(inner ground fault or hot short
circuit)
Replace
Table 1
Diagnosis No.1
Diagnosis No.2
C14 (male) (1) (2)
CR3 (female) (6) (13)
C14 (male) (1) body
Resistance
8 15
Min. 1 M

PC128US-2
PC138US-2
PC128US-2
20-839
(17)
TROUBLESHOOTING
C-12
C-12 [E224] "Abnormality in pump pressure sensor system" is displayed

Cause
3 YES
YES
2
YES
1
T-adapter (B) (C)
to C05 of pump
pressure sensor?
C05
(C) (A)
Remedy
Replace
CR1
(13) (21)
OFF.
Attach T-adapter.
Run engine at full speed.
Repeat operations:
arm excavation relief
Run engine at full

Neutral lever.
speed.
0.5 4.5 V
Repeat operations:
arm-excavation relief NO
Neutral lever.
0.5 4.5 V
OFF.
Attach T-adapter.
NO
Run engine at full
speed.
5V
Disconnection, ground fault or

Repair or
hot short circuit between C05
replace
(C) and CR1 (13).
Defective pump pressure senReplace

sor)
Disconnection, ground fault or
hot short circuit between CR3 Repair or
CR3 (22) and C05 (B)
replace
Disconnection between CR3
(21) and C05 (C)

PC128US-2
PC138US-2
20-840
(17)
PC128US-2
TROUBLESHOOTING
C-13
C-13 [E227] "Abnormality in engine speed sensor system" Is displayed

Cause
2 YES
Is resistance beYES tween CR2 (female)
(40) and (39) nor1
mal?
Is resistance be
tween E07 (male)
OFF.
(1) and (2) normal?
Disconnect CR2.
500 1000
OFF.
NO
Disconnect E07.
500 1000
Remedy
Replace
Disconnection, defective contact or ground fault of harness

between CR2(female)(40) and Repair or
E07 (female) (1), or between replace
CR2 (female)(39) and E07 (female)(2).
Defective engine speed sensor
(inner disconnection, defective Replace
contact or ground fault).

PC128US-2
PC138US-2
PC128US-2
20-841
(17)

[INPUT SIGNAL SYSTEM]
(F MODE)
PC128US-2
Electric circuit diagram for f mode............................................................................................................... 20-902
F-1
Bit-pattern 1023-(4) Swing pressure switch is not turned ON........................................................ 20-904
F-2
Bit-pattern 1023-(3) Travel pressure switch is not turned ON........................................................ 20-906
F-3
Bit-pattern 1023-(2) Boom LOWER pressure switch is not turned ON .......................................... 20-908
F-4
Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON ............................................ 20-910
F-5
Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON ...................................................... 20-912
F-6
Bit-pattern 1023-(2) Arm OUT pressure switch is not turned ON .................................................. 20-914
F-7
Bit-pattern 1023-(2) Bucket CURL pressure switch is not turned ON............................................ 20-916
F-8
Bit-pattern 1023-(2) Bucket DUMP pressure switch is not turned ON ........................................... 20-918
F-9
Bit-pattern 1023-(2) Service pressure switch is not turned ON...................................................... 20-920
F-10 Bit-pattern 1021-(6) Kerosene mode connection is not turned ON................................................ 20-922
PC128US-2
PC138US-2
Electric circuit diagram for f mode............................................................................................................... 20-903
F-1
Bit-pattern 1023-(4) Swing pressure switch is not turned ON........................................................ 20-905
F-2
Bit-pattern 1023-(3) Travel pressure switch is not turned ON........................................................ 20-907
F-3
Bit-pattern 1023-(1) Boom LOWER pressure switch is not turned ON .......................................... 20-909
F-4
Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON .............................................20-911
F-5
Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON ...................................................... 20-913
F-6
Bit-pattern 1028-(1) Arm OUT pressure switch is not turned ON .................................................. 20-915
F-7
Bit-pattern 1028-(3) Bucket CURL pressure switch is not turned ON............................................ 20-917
F-8
Bit-pattern 1028-(4) Bucket DUMP pressure switch is not turned ON ........................................... 20-919
F-9
Bit-pattern 1028-(2) Service pressure switch is not turned ON...................................................... 20-921
In troubleshooting after an abnormality occurred, if the display in the Monitoring mode is normal after you
attached a T-adapter instead of a connector detached, or after you connected the connector instead of the
T-adapter detached, the normal condition has been restored.
Before starting troubleshooting, check for any faulty engagement in related connectors.
Before going to next step in troubleshooting process, be sure to connect the connector you have detached.
PC128US-2
20-901
(17)
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM

PC128US-2
20-902
(17)
PC128US-2
TROUBLESHOOTING
PC138US-2
PC128US-2
20-903
(17)
TROUBLESHOOTING
F-1
F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON

PC128US-2
Turn on swing-lock switch before operating swing lever (even if just for a moment).
If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.
Cause
Detach S08.
Start engine.
Put swing lever in Neutral:
Min. 1 M
Operate swing lever for L.H.
swinging: Max. 1
Refer to Note.
Is resistance between S08 (male)

NO
(1) and (2) normal?
Is the connection insulated from
body?
Detach S30.
Start engine.
Min. 1 M
Operate swing lever for
R.H. swinging: Max.1
Refer to Note.

NO
(1) and (2) normal?
body?

Detach S08 and S30 from
CR1.
CR1 S08/S30: Max.1
Harness body: Min. 1 M
Are resistance values between

CR1 (female) (24) and each of NO
S08 and S30 (female) (2) normal?
Are the connections insulated
from body?
Remedy
1
Defective L.H. swing pressure switch
Replace
Defective R.H. swing pressure switch
Replace
YES
YES

ground fault of harness between CR1 Repair or
(female)(24) and S08 (female)(2) or replace
S30 (female)(2).
YES
Start engine.
Put swing-lever in Neutral:
20 30 V
Operate swing lever:
Max. 1 V
4
Is voltage between CR1(24) and NO
body normal?
Replace
YES
5
Start engine.
Max.1 V

body normal?

harness between S08 (female)(1) or Repair or
replace
S30 (female)(1) and body GND.
YES
Replace
[Note] You may diagnose with a short-circuit connector attached.In step 2 of diagnosis,
if the voltage between CR1(24) and body is 20 30 V, go to YES;
if it is 1 V or less, go to NO.
F-1 Related electric circuit diagram
20-904
(17)
PC128US-2
TROUBLESHOOTING
F-1
F-1 Bit-pattern 1023-(4) Swing pressure switch is not turned ON

PC138US-2
Turn on swing-lock switch before operating swing lever (even if just for a moment).
Cause
Detach S08.
Start engine.
Min. 1 M
Operate swing lever for L.H.
swinging: Max. 1
Refer to Note.

NO
(1) and (2) normal?
body?
Detach S30.
Start engine.
Min. 1 M
Operate swing lever for
R.H. swinging: Max.1
Refer to Note.

NO
(1) and (2) normal?
body?

Detach S08 and S30 from
CR3.
CR3 S08/S30: Max.1
Are resistance values between

CR3 (female) (30) and each of NO
S08 and S30 (female) (2) normal?
Are the connections insulated
from body?
Remedy
1
Defective L.H. swing pressure switch
Replace
Defective R.H. swing pressure switch
Replace
YES
YES

(female)(30) and S08 (female)(2) or replace
S30 (female)(2).
YES
Start engine.
Put swing-lever in Neutral:
20 30 V
Max. 1 V
4
body normal?
Replace
YES
5
Start engine.
Max.1 V

body normal?

harness between S08 (female)(1) or Repair or
replace
S30 (female)(1) and body GND.
YES
Replace
PC128US-2
20-905
(17)
TROUBLESHOOTING
F-2
F-2
Bit-pattern 1023-(3) Travel pressure switch is not turned ON
PC128US-2
Look around to be sure of safety before operating travel lever (even if just for a moment).
Cause
Detach S01.
Start engine.
Put travel lever in Neutral:
Min. 1 M
Operate travel lever:
Max. 1
Refer to Note.
Remedy
1
Is resistance between S01 (male) NO
(1) and (2) normal? Is the connection insulated from body?
Defective travel pressure switch
Replace
YES
2
Detach S01 from CR1.
Between CR1 and S01:
Max. 1
Between harness and body:
Min. 1 M
Is resistance between CR1 (female)(18) and S01 (female)(2) NO

normal? Is the connection insulated from body?

replace
(female) (18) and S01 (female) (2)
YES
3
Start engine.
20 30 V

body normal?
Replace
YES
4
Start engine.
Max. 1 V

body normal?

harness between S01 (female) (1) and Repair or
replace
body GND.
YES
Replace
20-906
(17)
PC128US-2
TROUBLESHOOTING
F-2
F-2
Bit-pattern 1023-(3) Travel pressure switch is not turned ON
PC138US-2
Look around to be sure of safety before operating travel lever (even if just for a moment).
Cause
Detach S01.
Start engine.
Put travel lever in Neutral:
Min. 1 M
Max. 1
Refer to Note.
Remedy
1
Defective travel pressure switch
Replace
YES
2
Detach S01 from CR3.
Max. 1
Min. 1 M
Is resistance between CR3 (female)(40) and S01 (female)(2) NO


replace
(female) (40) and S01 (female) (2)
YES
3
Start engine.
20 30 V

body normal?
Replace
YES
4
Start engine.
Max. 1 V

body normal?

replace
body GND.
YES
Replace
PC128US-2
20-907
(17)
TROUBLESHOOTING
F-3
F-3
Bit-pattern 1023-(2) Boom LOWER pressure switch is not turned ON
PC128US-2
If you take some measurement with engine started, operate a lever to such an extent that no movement of
work equipment is caused.
(If you take some measurement with engine stopped, accumulate pressure in accumulator beforehand.)
Cause
Remedy
1
Start engine.
Put boom lever in Neutral:
20 30 V
Is resistance between CR1 (5) NO

and body normal?
Replace
Replace
YES
2
Start engine.
Put boom lever in LOWER:
Max. 1 V

and body normal?
YES
Disconnect S33.
Start engine.
Min. 1 M
Max. 1
Refer to Note.


Disconnect S33 from CR1.
Max. 1
Min. 1 M
Is resistance between CR1 (female) (5) and S33 (female) (2) NO

Defective boom LOWER pressure

Replace
switch
YES
YES

replace
(female)(5) and S33 (female)(2).
Repair or
harness between S33 (female)(1) and
replace
body GND.
if it is Max. 1 V, go to NO.
20-908
(17)
PC128US-2
F-3
TROUBLESHOOTING
F-3
Bit-pattern 1023-(1) Boom LOWER pressure switch is not turned ON
PC138US-2
Cause
Remedy
1
Start engine.
20 30 V

and body normal?
Replace
Replace
YES
2
Start engine.
Max. 1 V

and body normal?
YES
Disconnect S33.
Start engine.
Min. 1 M
Max. 1
Refer to Note.


Max. 1
Min. 1 M

Defective boom LOWER pressure

Replace
switch
YES
YES

replace
(female)(18 ) and S33 (female)(2).
Repair or
replace
body GND.
PC128US-2
20-909
(17)
TROUBLESHOOTING
F-4
F-4
Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON
PC128US-2
Cause
Remedy
1
Start engine.
20 30 V

and body normal?
Replace
Replace
Defective boom RAISE pressure

switch
Replace
YES
2
Start engine.
Put boom lever in RAISE:
Max. 1 V

and body normal?
YES
Disconnect S31.
Start engine.
Min. 1 M
Max. 1
Refer to Note.
Max. 1
Min. 1 M
3
YES
4
YES

replace
replace
body GND.
if it is Max.1 V, go to NO.
20-910
(17)
PC128US-2
TROUBLESHOOTING
F-4
F-4
Bit-pattern 1023-(6) Boom RAISE pressure switch is not turned ON
PC138US-2
Cause
Remedy
1
Start engine.
20 30 V

and body normal?
Replace
Replace
Defective boom RAISE pressure

switch
Replace
YES
2
Start engine.
Max. 1 V

and body normal?
YES
Disconnect S31.
Start engine.
Min. 1 M
Max. 1
Refer to Note.
Max. 1
Min. 1 M
3
YES
4
YES

replace
replace
body GND.
if it is Max.1 V, go to NO.
PC128US-2
20-911
(17)
TROUBLESHOOTING
F-5
F-5
Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON
PC128US-2
Cause
Remedy
1
Start engine.
Put arm lever in Neutral:
20 30 V

and body normal?
Replace
Replace
Defective arm IN pressure switch
Replace
YES
2
Start engine.
Put arm lever in IN:
Max. 1 V

and body normal?
YES
Disconnect S05.
Start engine.
Min. 1 M
Max. 1
Refer to Note.


Max. 1
Min. 1 M

YES
YES

replace
(female) (6) and S05 (female) (2).
harness between S05 (female)(1) and Repair or
replace
body GND.
20-912
(17)
PC128US-2
TROUBLESHOOTING
F-5
F-5
Bit-pattern 1023-(5) Arm IN pressure switch is not turned ON
PC138US-2
Cause
Remedy
1
Start engine.
20 30 V

and body normal?
Replace
Replace
Defective arm IN pressure switch
Replace
YES
2
Start engine.
Max. 1 V

and body normal?
YES
Disconnect S05.
Start engine.
Min. 1 M
Max. 1
Refer to Note.


Max. 1
Min. 1 M

YES
YES

replace
replace
body GND.
PC128US-2
20-913
(17)
F-6
TROUBLESHOOTING
F-6 Bit-pattern 1023-(2) Arm OUT pressure switch is not turned ON

PC128US-2
Cause
Remedy
1
Start engine.
Put arm-lever in Neutral:
20 30 V
Is resistance between CR1 (5)

and body normal?
NO
Replace
Replace
Defective arm OUT pressure switch
Replace
YES
2
Start engine.
Put arm lever in OUT:
Max. 1 V

and body normal?
YES
Disconnect S32.
Start engine.
Min. 1 M
Max. 1
Refer to Note.


DisconnectS32 from CR1.
Max. 1
Min. 1 M

YES
YES

ground fault of harness between CR1 replace
Repair or
replace
body GND.
20-914
(17)
PC128US-2
F-6
TROUBLESHOOTING
F-6 Bit-pattern 1028-(1) Arm OUT pressure switch is not turned ON

PC138US-2
Cause
Remedy
1
Start engine.
Put arm-lever in Neutral:
20 30 V
Is resistance between CR1 (6)

and body normal?
NO
Replace
Replace
Defective arm OUT pressure switch
Replace
YES
2
Start engine.
Max. 1 V

and body normal?
YES
Disconnect S32.
Start engine.
Min. 1 M
Max. 1
Refer to Note.


DisconnectS32 from CR1.
Max. 1
Min. 1 M

YES
YES

Repair or
replace
body GND.
PC128US-2
20-915
(17)
TROUBLESHOOTING
F-7
F-7
Bit-pattern 1023-(2) Bucket CURL pressure switch is not turned ON
PC128US-2
Cause
Remedy
1
Start engine.
Put bucket lever in Neutral:
20 30 V
Is voltage between CR1 (5) and NO

body normal?
Replace
Replace
YES
2
Start engine.
Put bucket lever in CURL:
Max. 1 V

body normal?
YES
Disconnect S34.
Start engine.
Min.1 Mz
Max. 1 z
Refer to Note.

(1) and (2) normal?
NO
body?

Max. 1 z
Min. 1 Mz

normal?
body?
Defective
switch
bucket
CURL
pressure
Replace
YES
YES

replace
body GND.
20-916
(17)
PC128US-2
F-7
TROUBLESHOOTING
F-7
Bit-pattern 1028-(3) Bucket CURL pressure switch is not turned ON
PC138US-2
Cause
Remedy
1
Start engine.
20 30 V

body normal?
Replace
Replace
YES
2
Start engine.
Max. 1 V

body normal?
YES
Disconnect S34.
Start engine.
Min.1 Mz
Max. 1 z
Refer to Note.

(1) and (2) normal?
NO
body?

Max. 1 z
Min. 1 Mz

normal?
body?
Defective
switch
bucket
CURL
pressure
Replace
YES
YES

replace
body GND.
PC128US-2
20-917
(17)
TROUBLESHOOTING
F-8
F-8
Bit-pattern 1023-(2) Bucket DUMP pressure switch is not turned ON
PC128US-2
Cause
Remedy
1
Start engine.
20 30 V

body?
Replace
Replace
Defective bucket Dump pressure

switch
Replace
YES
2
Start engine.
Put bucket lever in Dump:
Max. 1 V

body normal?
YES
Disconnect S35.
Start engine.
Min.1 Mz
Max. 1 z
Refer to Note.

(1) and (2) normal?
NO
body?

Max. 1 z
Min. 1 Mz

normal?
body?
YES
YES

ground fault of harness between CR1 Replace
motor
replace
body GND.
20-918
(17)
PC128US-2
F-8
TROUBLESHOOTING
F-8
Bit-pattern 1028-(4) Bucket DUMP pressure switch is not turned ON
PC138US-2
Cause
Remedy
1
Start engine.
20 30 V

body?
Replace
Replace
Defective bucket Dump pressure

switch
Replace
YES
2
Start engine.
Max. 1 V

body normal?
YES
Disconnect S35.
Start engine.
Min.1 Mz
Max. 1 z
Refer to Note.

(1) and (2) normal?
NO
body?

Max. 1 z
Min. 1 Mz

normal?
body?
YES
YES

ground fault of harness between CR3 Replace
motor
replace
body GND.
PC128US-2
20-919
(17)
TROUBLESHOOTING
F-9
F-9
Bit-pattern 1023-(2) Service pressure switch is not turned ON
PC128US-2
ATT is caused.
Cause
Remedy
1
Start engine.
20 30 V
Operate swing lever: Max. 1 V
Disconnect S40.
Start engine.
Put ATT-pedal in Neutral:
Min.1 M
Operate ATT pedal service
(front) pressure switch:
Max. 1
Refer to Note.
Disconnect S41.
Start engine.
Put ATT-pedal in Neutral:
Max.1 M
Operate ATT pedal service
(front) pressure switch:
Max. 1
Refer to Note.

Disconnect S40 and S41
from CR1.
Between CR1 and S40, S41:
Max. 1

body?
YES
Replace
Defective service (front) pressure switch
Replace
Defective service (rear) pressure switch
Replace
2
(1) and (2) normal?
NO
body?
YES
3
(1) and (2) normal?
NO
body?
YES
Are resistance values between CR1

(female) (5) and each of S40 and NO
S41 (female) (2) normal?
Are the connections insulated from
body?
YES
Disconnection, defective contact or Replace

ground fault of harness between CR1 motor
(female) (5) and S40(female)(2) or S41
(female)(2).
Repair or
harness between S40 (female) (1) or
replace
S41 (female) (1) and body GND.
[Note] You may diagnose with a short-circuit connector attached.In this case,
f it is Max. 1 V, go to NO.
20-920
(17)
PC128US-2
F-9
TROUBLESHOOTING
F-9
Bit-pattern 1028-(2) Service pressure switch is not turned ON
PC138US-2
blade is caused.
Cause
Remedy
1
Start engine.
20 30 V
Operate swing lever: Max. 1 V

body?
YES
Disconnect S38.
Start engine.
Put blade lever in Neutral:
Min.1 M
Operate blade LOWER
pressure switch:
Max. 1
Refer to Note.
Disconnect S39.
Start engine.
Put blade lever in Neutral:
Max.1 M
Operate blade RAISE (front)
pressure switch:
Max. 1
Refer to Note.

Disconnect S38 and S39
from CR3.
Between CR3 and S40, S41:
Max. 1
Replace
2
(1) and (2) normal?
NO
body?
Defective blade LOWER pressure switch Replace
YES
3
(1) and (2) normal?
NO
body?
Defective blade RAISE pressure switch
Replace
YES
Are resistance values between CR3

(female) (9) and each of S38 and NO
S39 (female) (2) normal?
Are the connections insulated from
body?
YES
Disconnection, defective contact or Replace

ground fault of harness between CR3 motor
(female) (9) and S38(female)(2) or S39
(female)(2).
Repair or
harness between S38 (female) (1) or
replace
S39 (female) (1) and body GND.
[Note] You may diagnose with a short-circuit connector attached.In this case,
f it is Max. 1 V, go to NO.
PC128US-2
20-921
(17)
TROUBLESHOOTING
F-10
F-10 Bit-pattern 1021-(6) Kerosene mode connection is not turned ON

Shown below is the case where a harness for Kerosene mode is connected (M36M(1) and M36F(1) are
connected).
Cause
S Harness for Kerosene mode:
Connected: 20 30 V
Open: Max. 1 V
Max. 1
Remedy

harness between CR2 (female) (6) and Repair or
IIs voltage between CR2 (6) and NO
body normal?
(Max. 1V ) fuse (1) in the harness for kerosene replace
mode.
YES (20 30 V)
Replace
20-922
(17)
PC128US-2
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts ............................................................................................. 20-952

S- 1 Starting performance is poor (Starting always takes time) ...................................................... 20-956
S- 2 Engine does not start ................................................................................................................... 20-958
(1) Engine does not turn ............................................................................................................. 20-958
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .................... 20-959
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ................. 20-960
S- 3 Engine does not pick-up smoothly (Follow-up is poor) ............................................................ 20-961
S- 4 Engine stops during operations .................................................................................................. 20-962
S- 5 Engine does not rotate smoothly (Hunting) ............................................................................... 20-963
S- 6 Engine lacks output (or lacks power) .......................................................................................... 20-964
S- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-965
S- 8 Oil consumption is excessive (or exhaust gas is blue).............................................................. 20-966
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-967
S-10 Fuel consumption is excessive .................................................................................................... 20-968
S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-969
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ....................................................... 20-970
S-13 Oil level rises (Water, fuel in oil) ................................................................................................. 20-971
S-14 Water temperature becomes too high (Overheating) ............................................................... 20-972
S-15 Abnormal noise is made .............................................................................................................. 20-973
S-16 Vibration is excessive ................................................................................................................... 20-974
PC128US-2
20-951
(14)
TROUBLESHOOTING

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items
that can be obtained from the user, depending
on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
Causes
Questions
(b) (2) (3)
(a)
w
w
(b)
w
(c)
(d)
c
c
Troubleshooting
Check items
(e)
20-952
(14)
i
ii
iii
b
b
b
PC128US-2
inje
ctio
n)
Causes
Seiz
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with !, and of these, causes that have a high probability are marked with T.
Check each of the [Questions] and [Check items] in
turn, and marked the ! or T in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with # to use as reference
for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes.
2. Use the # in the Cause column as reference
for [Degree of use (Operated for long period)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
ed t
urbo
cha
Clog
rger
ged
, int
air c
erfe
lean
Wor
renc
er e
n pi
e
lem
ston
e
n
ring
Clog
t
, cyl
ged
inde
, sei
r
zed
Imp
inje
rope
ctio
r inj
n no
e
ctio
Defe
zzle
n tim
ctiv
e in
ing
ject
ion
pum
p (e
xces
sive
TROUBLESHOOTING
Confirm recent repair history
Degree of use
Operatred for long period
PC128US-2
20-953
(14)
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel
Causes
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Seiz
ed t
Clog urboch
arge
ged
r, in
air
Wor
terfe
n pis cleaner
elem rence
ton
Clog
ring
ent
ged
, cyli
, se
nde
Imp
r
rope ized inje
r
c
tion
inje
Defe
ctio
ctiv
n tim nozzle
e
in
ing
Imp
rope jection
pum
r va
Cru
lve
p (e
she
c
xces
le
d, c
aran
sive
logg
Lea
ce
inje
kag
e
d
ctio
muf
e of
n)
fler
Defe
air b
ctiv
etw
e
e
e
con
n tu
Deff
t
a
r
ectiv
boc
ct o
harg
f va
e in
lve,
er a
ject
valv
ion
nd h
e se
pum
ead
at
p (ra
ck, p
lung
er s
eize
d

Degree of use
Operated for long period
Questions
Suddenly became black

Color of exhaust gas
Gradually became black

Blue under light load
Engine oil must be added more frequently

Power was lost
Suddenly
Gradually
Non-specified fuel has been used

Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low

Speed of some cylinders does not change when operating
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
20-954
(14)
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does

not return
PC128US-2
TROUBLESHOOTING
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
PC128US-2
20-955
(14)
TROUBLESHOOTING
S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but
engine takes time to start
Defective electrical system
Insufficient supply of fuel
Improper selection of fuel
(At ambient temperature of -10C or below,
ASTM D975 No. 2 diesel fuel is used)
Causes
n pi
ston
Defe
ring
, cyl
ctive
inde
cont
Clog
r
act o
ged
f val
a
i
r
ve, v
clea
Clog
ner
ged
elem alve sea
fuel
t
Clog
ent
filte
ged
r, st
rain
feed
e
Elec
r
p
ump
trica
gau
l int
ze fi
ake
lter
air h
eate
r
fl Battery charging rate

Ambient
temperature
Charging rate
20C
0C
10C
90 %
80 %
75 %
70 %
1.28
1.29
1.30
1.26
1.27
1.28
1.24
1.25
1.26
1.23
1.24
1.25
1.22
1.23
1.24
The specific gravity should exceed the value for the

charging rate of 70% in the above table.
In cold areas the specific gravity must exceed the
value for the charging rate of 75% in the above table.
Wor
100 %
Questions

Degree of use of machine
Operated for long period
Ease of starting
Gradually became worse

Starts when warm
Indicator lamp does not light up

Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Check items
Engine does not pick up smoothly, and combustion is irregular

Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When air cleaner element is inspected directly, it is found to be clogged
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Heater mount does not become warm
Is voltage 2630V between alternator terminal B and terminal E
with engine at low idling?
Yes
No
Either specific gravity of electrolyte or voltage of battery is low

Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
20-956
(14)
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
Use a test stand
PC128US-2
PC128US-2
Replace
Replace
Clean
Correct
Replace
Adjust
Replace
Replace
Replace
Replace
Defe
ctive
regu
Defe
lato
ctive
r
a
ltern
Defe
ator
ctive
or d
Defe
eter
ctive
iora
ted
injec
Defe
batt
tion
tive
ery
nozz
injec
le
Defe
tion
tive
timi
injec
ng
Leak
tion
age,
p
ump
clog
(rac
Clog
ging
k , pl
ged
, air
ung
a
i
i
n
r
er st
brea
fuel
Defe
uc k )
ther
pipi
ctive
ng
h
o
f
e
l
e in
ed p
Defe
fuel
ump
ctive
tank
boo
st co
mpe
nsat
or c
ance
l
TROUBLESHOOTING
S-1
Causes
20-957
(14)
TROUBLESHOOTING
S-2
S-2 Engine does not start

(1) Engine does not turn
Causes
General causes why engine does not turn
fl If internal parts of the engine are seized, carry

out troubleshooting for "Engine stops during
operations".
Defective electrical system
Failure in power train

Degree of use of machine Operated for long period
Condition of horn when
Horn sounds
starting switch is turned
Horn volume is low
ON
Speed of rotation is low
When starting switch is
Makes grating noise
turned to START, pinion
Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
move out
When starting switch is turned to ON, there is no clicking
sound
20-958
(14)
Replace
Replace
Remedy
Replace
For the following conditions 1) - 5), turn the starting switch

OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are
3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and
terminal E
When ring gear is inspected directly, tooth surface is found to
be chipped
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Troubleshooting
Specific gravity of electrolyte, voltage of battery is low
Replace
When battery is checked, battery electrolyte is found to be low
Replace
When starting switch is turned ON, linkage is not actuated
Replace
Battery terminal is loose
Replace
Check items
Questions
Defe
ctiv
ew
iring
Defe
ctiv
of s
e or
tarti
Defe
dete
ng c
ctiv
rior
ircu
e st
ated
it
artin
Bro
batt
ken
gm
ery
r
o
i
n
t
or
g ge
Defe
ar
ctiv
e sa
fety
Defe
rela
ctiv
y or
e ba
Defe
ttery
safe
ctiv
ty s
r
e
lay
e ba
witc
Defe
ttery
h
ctiv
t
e
rmin
e fu
el cu
al co
Defe
t so
nne
ctiv
leno
e st
ctio
artin
n
id
g sw
itch
Internal parts of engine seized
Troubleshooting of defective wiring in starting circuit
PC128US-2
S-2
TROUBLESHOOTING
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust smoke
comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Standards for use of fuel

AMBIENT TEMPRATURE
KIND
OF FLUID
-4
-20
14
-10
32
0
50
10
68F
20C
ASTM D975 No.2
Diesel fuel
Bro
ASTM D975 No.1
ken
inje
ctio
Defe
n pu
ctiv
mp
e in
driv
ject
Seiz
ion
e sh
ed,
pum
aft,
brok
key
p (ra
en f
Clog
ck, p
eed
ged
p
lung
fuel
ump
Clog
er s
filte
pist
ged
eize
r, st
on
d)
feed
rain
Insu
e
p
r
u
ffici
mp
ent
stra
fuel
Clog
iner
in ta
ged
, lea
nk
Clog
king
ged
fuel
air b
pipi
Defe
reat
ng
ctiv
her
e
hole
fuel
Imp
in fu
cut
rope
sole
el ta
r fue
noid
nk
l us
ed
Causes
Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Check items
When starting switch is turned ON, linkage is not actuated

When fuel filter is drained, fuel does not come out
1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Troubleshooting
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
PC128US-2
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
Cannot be moved by hand even when linkage of fuel cut

solenoid is disconnected
20-959
(14)
TROUBLESHOOTING
S-2
General causes why exhaust smoke comes out but

engine not start
Lack of rotating force due to defective electrical system

Improper selection of fuel and oil
Defe
Causes
ctive
, bro
Defe
ke n
v a lv
ctiv
e sy s
e in
ject
tem
Wor
ion
(valv
n pi
pum
e , ro
ston
p (ra
cke r
Clog
ring
le v e
ck, p
ged
, cyl
r, etc
lung
inde
fuel
Clog
.)
e
r
f
r
i
l
l
stuc
i
t
ner
ged
er, s
k)
f
t
e
r
a
e
iner
d pu
Clog
mp
ged
stra
air c
Defe
iner
l
e
ane
ctiv
r ele
e el
men
ectr
Defe
ical
t
ctiv
inta
e or
ke a
Lea
dete
i
kag
r he
rior
e, cl
ater
ated
ogg
Clog
b
a
i
n
ttery
ged
g, a
ir in
inje
Clog
ctio
fuel
n no
ged
syst
zzle
a
em
i
r br
Imp
,
defe
eat h
rope
ctiv
er h
r fue
e
ole
spra
l us
in fu
y
ed
el t a
nk c
ap
(3) Exhaust smoke comes out but

engine does not start (Fuel is
being injected)

Questions
Suddenly failed to start

When engine is cranked, abnormal noise is heard from
around cylinder head
Non-specified fuel is being used
Operation Manual
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items

1) Little fuel comes out even when injection pump piping
sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
Troubleshooting
When exhaust manifold is touched immediately after starting

engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly
When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
20-960
(14)
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
PC128US-2
TROUBLESHOOTING
S-3
S-3 Engine does not pick-up smoothly

(Follow-up is poor)
Causes
General causes why engine does not pick up smoothly

Improper condition of fuel injction
Improper fuel used
Clog
ged
air c
Clog
lean
ged
er e
lem
f
uel
Clog
ent
filte
ged
r, st
feed
rain
Clog
er
pum
ged
p st
inje
rain
Seiz
ctio
er
ed i
n no
njec
zzle
tion
, de
Wor
fect
pum
n pi
ive
p pl
ston
spra
Seiz
ung
ring
y
er
ed t
,
cylin
urbo
d
Imp
e
c
harg
r lin
rope
er
er, i
r va
nter
Clog
lve
fere
clea
ged
nce
ranc
air b
e
Clog
reat
her
ged
hole
, lea
Defe
king
in fu
ctiv
fuel
el t a
e co
nk c
pipi
ntac
ng
ap
t of
valv
e an
d va
lve
seat
Questions

Operation Manual
Engine pick-up suddenly became poor

Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
Troubleshooting

When air cleaner element is inspected directly, it is found to
be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
PC128US-2
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
20-961
(14)
S-4
TROUBLESHOOTING
S-4 Engine stops during operations

General causes why engine stops during operations
Seized parts inside engine
Overheating
Causes
ken
, sei
zed
Bro
pist
ken
on,
, sei
co n
zed
Brok
nec
cran
en d
ting
ksha
ynam
ro d
ft be
Bro
i
c va
ken
a
ring
lve s
, sei
yste
Bro
zed
m (
ken
gea
valv
pum
r tra
e, ro
in
p au
Bro
cker
ken
x
leve
i
l
i
ary
fuel
r, et
equ
Insu
pum
c.)
ipm
ffici
p
driv
ent
ent
e sh
fuel
Clog
aft,
in ta
ged
key
nk
fuel
Clog
filte
ged
r, st
rain
feed
Bro
er
pum
ken
p st
, sei
rain
z
Clog
ed f
er
eed
ged
, lea
pum
king
Clog
p pi
ston
fuel
ged
pipi
air b
Defe
ng
r
e
a
ther
ctiv
e in
hole
ject
Fail
in fu
ion
ure
el ta
pum
in p
nk
owe
p (r a
r tra
c
k
,
in
plun
ger
stuc
k)
fl If there is overheating and the engine stops,

carry out troubleshooting for overheating.
Failure in power train
Bro
fl If the engine stops because of a failure in

the power train, carry out troubleshooting
for the chassis.
Questions

Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Engine stopped slowly
There was hunting and engine stopped
Replacement of filters has not been carried out according
to Operation Manual
Fuel level lamp lights up
Check items

Engine rotates, but stops when power train is operated
Does not turn at all
When it is attempted to
turn by hand using
barring tool
Turns in opposite direction

Moves amount of backlash
Shaft does not turn
Troubleshooting of chassis

Metal particles are found when oil is drained
Remove oil pan and inspect directly
Troubleshooting
Remove head cover and inspect directly

When gear train is inspected, it does not turn
Rotates when pump auxiliary equipment is removed
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
20-962
(14)
Replace
Clean
Correct
Replace
Replace
Clean
Clean
Add
Replace
Replace
Replace
Replace
Remedy
Replace

does not return
PC128US-2
S-5
TROUBLESHOOTING
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly
Air in fuel system
Defective governor mechanism
Defective electric governor mechanism
(engine with electric governor)
Causes
Defe
ctiv
e op
Defe
erat
ctiv
ion
e ad
of g
Defe
ove
just
rn o r
men
ctiv
e op
t of
gov
Low
erat
erno
ion
idlin
of c
r
g sp
Insu
ontr
eed
ffici
o
l rac
is to
ent
k
o
fuel
Clog
in ta low
ged
nk
feed
Clog
pum
ged
p st
fuel
rain
Clog
f
ilter
er
ged,
,
stra
air in
iner
Clog
c
i
rcuit
ged,
betw
air in
een
Clog
circu
fuel
ged
it be
tank
air b
t
w
and
een
reat
feed
feed
her
pum
pum
hole
p
p an
in fu
d no
el t a
zzle
nk
fl If hunting stops when electric governor rod is

disconnected, carry out troubleshooting for the
chassis.
Questions

Occurs at a certain speed range
Condition of hunting
Occurs at low idling

Occurs even when speed is raised
Occurs on slopes

to Operation Manual
Rust, water are found when fuel tank is drained
Check items

When feed pump is operated,
1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Troubleshooting
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
PC128US-2
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust

found to be clogged
20-963
(14)
TROUBLESHOOTING
S-6
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output
Clog
fl If there is overheating and lack of output,

carry out troubleshooting for overheating.
Seiz

Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overtaking
ged
air c
lean
ed t
er e
urbo
lem
Wor
cha
ent
rger
n pi
, int
ston
erfe
Clog
ring
renc
ged
, cyl
e
inde
fuel
Clog
r
filte
ged
r
,
s
f
t
e
r
a
ed p
Clog
ump iner
ged
stra
inje
Seiz
iner
c
tion
ed i
noz
njec
zle,
Imp
tion
defe
rope
pum
ctiv
r va
p pl
e sp
Defe
lve
u
ray
nge
clea
ctiv
r
ranc
e co
e
ntac
Ben
t fue
t of
valv
l lev
Clog
e an
er li
ged
nka
d va
ge,
, lea
lve
d
k
seat
Clog
efec
ing
fuel
tive
ged
adju
pipi
a
i
r
brea
Defe
ng
stm
ther
ent
ctiv
e bo
hole
Defe
o
s
in fu
t co
ctiv
el ta
mpe
ew
estg
nk
nsa
t
ate
diap or diap
hrag
hrag
m
m
Causes

Questions
Power was lost
Suddenly
Gradually

to Operation Manual
Black

Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
High idling speed of engine is low
When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

found to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
20-964
(14)
Replace
Replace
Clean
Correct
Adjust
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
PC128US-2
S-7
TROUBLESHOOTING
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black
Causes
Seiz
ed t
urbo
Clog
cha
rger
ged
, int
air c
Wor
erfe
lean
renc
n pi
er e
ston
e
lem
Clog
ent
ring
ged
, cyl
i
i
nde
njec
Imp
r
tion
rope
noz
r inj
zle,
Defe
ecti
o
ctiv
n tim defecti
e in
ve s
ing
Imp
ject
pray
i
rope
on p
r
u
v
m
a
Cru
p
l
v
(
e
e
she
xces
clea
d, c
ranc
sive
logg
Lea
e
inje
ed m
kag
ctio
e of
u
n)
f
fler
air b
Defe
e
ctiv
t we
e
en t
con
Defe
urbo
tact
ctiv
cha
of v
e in
rger
alve
ject
and
and
ion
hea
pum
valv
d
e se
p (ra
at
ck, p
lung
er s
eize
d)

Questions
Suddenly became black

Gradually became black


Power was lost
Suddenly
Gradually

Check items

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Timing lock on fuel injection pump does not match
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
PC128US-2
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace

does not return
20-965
(14)
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
General causes why oil consumption is excessive

Abnormal combustion of oil
External leakage of oil
Wear of lubrication system
Bro
Causes
ken
pist
on r
Wor
ing
n pi
ston
Clog
ring
ged
, cyl
inde
brea
Lea
r (lin
ther
kag
er le
or b
e fro
ss e
reat
Lea
mo
ngin
her
kag
il fil
h
e)
e fro
ose
ter o
mo
Lea
r
o
il co
il pi
kag
ping
e fro
oler
mo
Lea
kag
il dr
e fro
ain
plug
mo
Bro
ken
il pa
oil c
n or
oole
Wor
cylin
r
n se
der
al a
hea
t tur
Wor
d
bine
n se
a
e
l
n
at b
d
Wor
low
n, b
er e
roke
nd
n re
Dus
Turb
ar s
t su
eal,
cked
och
seal
arge
Wor
in fr
surf
r
n va
om
ace
inta
lve
(ste
ke s
m, g
yste
uide
m
), br
oke
n se
al
fl Do not run the engine at idling for more than 20

minutes continuously. (Both low and high idling)

Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Amount of blow-by gas
Excessive
None
Area around engine is dirty with oil

Check items
There is oil in engine cooling water

When exhaust pipe is removed, inside is found to be dirty with oil
When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose
Troubleshooting

When breather element is inspected, it is found to be
clogged with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
20-966
(14)
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be

dirty with oil
PC128US-2
S-9
TROUBLESHOOTING
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
Improper oil used
Operation under excessive load
Causes
Wor
n pi
ston
Clog
ring
, cyl
ged
inde
brea
Clog
r lin
ther
ged
er
, b re
o
athe
i
l filt
Wor
r ho
er
n va
se
lve,
Clog
valv
ged
e gu
oil c
ide
Clog
oole
ged
r
turb
Defe
och
ctiv
arge
e se
r oil
Exh
al a
drai
aus
t tur
n tu
t sm
boc
be
harg
oke
is b
e
r
turb
lack
ine
end
Questions

Non-specified oil is being used

Black
Carry out troubleshooting for Exhaust smoke is black.
Check items
Excessive
Amount of blow-by gas
None
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly
When breather element is inspected directly, hose is

broken or is found to be clogged with dirty oil
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger oil drain tube is clogged
PC128US-2
Replace
Clean
Clean
Replace
Replace
Remedy
Clean
Excessive play of turbocharger shaft

When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Troubleshooting
20-967
(14)
S-10
TROUBLESHOOTING
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Leakage of fuel
Defe
ctive
injec
tion
Defe
pum
ctive
p (ex
nozz
Defe
cess
le ho
ive i
ctive
lder
njec
spra
i
n
j
e
tion
Defe
ction
y
)
ctive
pum
fuel
p plu
Exte
injec
n
ger
rnal
tion
leak
timi
age
ng
Leak
from
age
fuel
of fu
pipin
el in
Defe
side
g, fu
ctive
el fil
h
oil s
ead
ter
Defe
e
c
a
o
l
v
insid
ctive
er
e fee
adju
d pu
stme
mp
nt o
(pist
f fue
on)
l con
trol
linka
ge
Causes
Questions

Condition of fuel
consumption
More than for other machines of same

model
Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
Check items
There is irregular combustion

When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive
Troubleshooting

When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found
to be incorrect
Remove feed pump and inspect directly
20-968
(14)
Adjust
Correct
Correct
Correct
Adjust
Replace
Replace
Remedy
Adjust
When engine speed is measured, low idling and high idling speeds
are found to be high
PC128US-2
S-11
TROUBLESHOOTING
S-11 Oil is in cooling water, or water

spurts back, or water level goes
down
Causes
General causes why oil is in cooling water

Internal leakage in lubrication system
Internal leakage in cooling system
Brok
en o
il co
oler
Brok
core
en c
, O-r
ylind
ing
er h
Brok
e
en p
ad, h
owe
e
a
d
r tra
Hole
gask
in oi
s ca
et
l coo
used
ler
by p
Inter
ittin
nal c
g
rack
s in
cylin
der
bloc
k
Questions

Oil level
Suddenly increased
Gradually increased
Hard water is being used as cooling water
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
Pressure-tightness test of cylinder head shows there is leakage
PC128US-2
Replace
Replace
Replace
Remedy
Replace
Replace
Troubleshooting
Check items
Engine oil level has risen, oil is cloudy white
20-969
(14)
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights

up (Drop in oil pressure)
General causes why oil pressure lamp lights up
Leakage, clogging, wear of lubricating system

Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating
fl Standards for engine oil selection
Type of oil
Selection of SAE No. according to

ambient temperature
30 20
10
10
20
30
Causes
40C
SAE10WCD
SAE10W-30CD
Clog
SAE15W-40CD
Wor
Engine oil
ged
oil f
ilter
n be
arin
Clog
g, jo
urna
ged
stra
l
Clog
iner
ged
insi
d
o
e oi
i
l pip
Bro
l pa
ken
e in
n
suct
side
ion
Defe
o
i
l
pipe
pan
ctiv
e oi
braz
Lack
l pu
ing
mp
of o
i
l in
Defe
oil p
ctiv
an
e re
gula
Defe
tor v
ctiv
e re
alve
lief
Lea
valv
king
e
, cru
Defe
she
d hy
ctiv
e oi
drau
l pre
Defe
lic p
ssur
ctiv
ipin
e oi
e se
g
l
n
leve
sor
Wat
l sen
er, f
sor
uel
in o
il
SAE30CD
Questions

Operation Manual
Caution lamp lights up
Lights up at low idling
Condition when oil
pressure lamp lights up
Lights up at low, high idling

Lights up on slopes
Check items
Sometimes lights up
There is crushing, leakage from hydraulic piping (external)
Oil level sensor lamp lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are stuck to oil filter element
Carry out troubleshooting

for Oil level rises.
Oil is cloudy white or smells of diesel oil

Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
20-970
(14)
Replace
Replace
Correct
Adjust
Adjust
Add
Replace
Correct
Clean
Clean
Remedy
Clean
When oil pressure is measured, it is found to be within

standard value
Clean
Troubleshooting
When oil filter is inspected, it is found to be clogged
PC128US-2
S-13
TROUBLESHOOTING
S-13 Oil level rises (Water, fuel in oil)

fl If there is oil in the cooling water, carry out troubleshooting for Oil is in cooling water.
Water in oil (milky white)

Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component
Bro
ken
oil c
oole
Defe
r co
ctiv
re, O
e no
Bro
-ring
zzle
ken
hold
cylin
er s
Wor
der
leev
n, d
hea
e
ama
d, h
ead
Defe
ged
gas
rear
ctiv
ket
e pu
seal
Lea
mp
surf
kag
aux
ace
e of
i
l
iary
fuel
Defe
equ
from
ctiv
ipm
e pa
pipi
ent
Defe
rt in
n
seal
g in
ctiv
s
i
d
side
e
e th
i
n
hea
j
erm
ecti
Hole
d co
on p
osta
sm
ver
ump
t
ade
Crac
by p
ks in
ittin
g
side
cylin
der
bloc
k
General causes why oil level rises
Causes
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
Check items
Exhaust smoke is white

When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Oil level goes down in clutch, TORQFLOW transmission,
or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
PC128US-2
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Remedy
Replace
Remove oil pan and check directly
20-971
(14)
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes too
high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature in power train
fl Carry out troubleshooting for chassis.
Bro
ken
wat
er p
Clog
ump
ged
, cru
Clog
she
d ra
ged
diat
radi
or fi
Defe
ator
ns
ctiv
core
e
ther
Defe
mos
ctiv
tat (
ew
doe
ater
Lack
s no
tem
of c
t op
pera
ooli
en)
Fan
ture
n
g
w
belt
g
a
aug
t
e
s
r
l
e
i
p
Clog
ping
ged
, wo
, bro
rn fa
Defe
ken
n pu
ctiv
oil c
lley
e pr
oole
essu
Bro
r
ken
r
e va
cylin
lve
Hole
der
sm
h
ead
ade
,
hea
Rise
by p
d ga
ittin
in to
sket
g
rque
con
vert
er o
il te
mpe
ratu
re
Causes

Questions

Condition of overheating
Suddenly overheated
Always tends to overheat
Water temperature
gauge
Rises quickly
Does not go down from red range
Radiator water level sensor lights up

Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Check items
Excessive air bubbles inside radiator, water spurts back

Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator tanks

is excessive
Temperature difference between top and bottom radiator tanks
is slight
When water filler port is inspected, core is found to be clogged
When function test is carried out on thermostat, it does not
open even at cracking temperature
Carry out troubleshooting for chassis.
Troubleshooting
Power train oil temperature enters red range faster than

engine water temperature
When water temperature is measured, it is found to be normal

When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
20-972
(14)
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
PC128US-2
S-15
TROUBLESHOOTING
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an external
noise.
Abnormality due to defective parts

Abnormal combustion
Air sucked in from intake system
Exce
ssive
wea
Seiz
r of
ed t
pisto
urbo
n rin
Mis
c
g, cy
harg
sing
linde
er, i
, sei
r (lin
n
t
e
z
Clog
rfer
ed b
er le
enc
ged
ss en
ush
e
,
i
n
gine
s
g
e
Defe
ized
)
ctiv
i
n
ject
e in
i
on n
ject
Defe
ion
ctiv
pum ozzle
e in
p (ra
Defo
ject
ion
ck, p
rme
pum
d fa
lung
Defe
p (e
n, fa
er s
x
ctiv
n be
cess
eize
e ad
d)
lt in
ive
Brok
just
i
t
n
e
ject
r
fere
men
en d
ion)
nce
ynam
t of
valv
Imp
ic va
rope
e cle
lve s
r ge
aran
yste
Leak
a
m (v
ce
r
train
age
alve
of ai
b
,
ackl
rock
r bet
Defe
er le
ash
wee
ct in
ver,
n tu r
side
etc.)
b o ch
muf
arg e
fler (
r an d
divid
ing b
cylin
oard
d er h
out o
ead
f pos
ition
)
General causes why abnormal noise is made
Causes
Questions

Condition of abnormal
noise
Gradually occurred
Suddenly occurred


Black
Metal particles are found in oil filter

Check items

Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler
Troubleshooting
Remove gear cover and inspect directly

Speed does not change when operation of certain cylinders is
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
PC128US-2
Replace
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
When muffler is removed, abnormal noise disappears
20-973
(14)
S-16
TROUBLESHOOTING
S-16 Vibration is excessive
General causes why vibration is excessive
Defective parts (abnormal wear, breakage)

Improper alignment
Abnormal combustion
Causes
Wor
n co
nne
ctin
Wor
g ro
n ca
d, m
m
bus
Loo
ain
hing
bea
se e
ring
ngin
Bro
e
mou
ken
ntin
part
g bo
Cen
insi
lts,
de o
ter o
brok
utpu
f en
en c
Imp
gine
t
s
h
ush
rope
a
a
f
t
nd p
ion
(dam
r ge
owe
Defe
a
per)
r
train
r tra
ctive
i
n
d
b
y
ackl
mis
nam
Defe
alig
ic va
ash
ctiv
ned
lve s
e in
ystem
ject
(valv
ion
e, ro
pum
cker
p (e
lever
xces
, etc.
sive
stuck
fuel
)
inje
ctio
n)
fl If there is abnormal noise together with the vibration, carry out troubleshooting also for Abnormal noise is made.
Questions

Condition of vibration
Suddenly increased
Gradually increased

Metal particles are found in oil filter
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black
Troubleshooting
Remove side cover and inspect directly

Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
20-974
(14)
Adjust
Replace
Correct
Correct
Replace
Replace
Replace
Remedy
Replace
PC128US-2
30 DISASSEMBLY AND ASSEMBLY

Method of using manual.................................. 30- 2
Precautions when carrying out operation........ 30- 3
Special tool list ................................................ 30- 5
Sketch of special tool .................................... 30- 9
CYLINDER HEAD ASSEMBLY
Removal and Installation ........................... 30-11
INJECTION PUMP ASSEMBLY
ENGINE AND MAIN PUMP ASSEMBLY
RADIATOR, HYDRAULIC OIL COOLER
RADIATOR ASSEMBLY
HYDRAULIC OIL COOLER ASSEMBLY
AFTER COOLER ASSEMBLY
FUEL TANK
CENTER SWIVEL JOINT
Disassembly and Assembly ...................... 30-40
SWING MOTOR, SWING MACHINERY
SWING MACHINERY
REVOLVING FRAME
SWING CIRCLE
TRAVEL MOTOR AND FINAL DRIVE
RECOIL SPRING
IDLER
TRACK ROLLER
TRACK SHOE
HYDRAULIC TANK
PC128US-2
MAIN PUMP
Removal and Installation..........................30- 73
CONTROL VALVE
Removal and Installation..........................30- 76
Disassembly and Assembly .....................30- 78
LS SELECTION VALVE
PRESSURE COMPENSATION VALVE
MAIN RELIEF VALVE
WORK EQUIPMENT PPC VALVE
(FOR BOOM, BUCKET, ARM, SWING CONTROL)
Disassembly and Assembly .................... 30-100
TRAVEL PPC VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
Removal and Installation..........................30-114
OPERATOR'S CAB
Removal and Installation..........................30-116
OPERATOR'S CAB GLASS (STUCK GLASS)
Removal and Installation......................... 30-123
FRONT WINDOW ASSEMBLY
FLOOR FRAME
AIR CONDITIONER COMPRESSOR
AIR CONDITIONER Condenser
AIR CONDITIONER UNIT
COUNTERWEIGHT
MONITOR PANEL ASSEMBLY
CONTROLLER ASSEMBLY
30-1
(16)
METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
[1] When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
[2] Any special techniques applying only to the installation procedure are marked [*1], and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
(Example)
REMOVAL OF QQQQ ASSEMBLY ........... Title of operation
k ................................................................ Precautions related to safety when carrying out the operation

1.
(1) ............................................ Step in operation

a ............................................................ Technique or important point to remember when removing
(1).
2. EEEE (2)............................................ [*1] ..........Indicates that a technique is listed for use
during installation
3. T T T T assembly (3)
6............................................................. See Lubricant and Coolant Table
INSTALLATION OF QQQQ ASSEMBLY ... Title of operation

Carry out installation in the reverse order to removal.
[*1] ................................................................ Technique used during installation
a ............................................................ Technique or important point to remember when installing
EEEE (2).
Adding water, oil ..................................... Step in operation
a ............................................................ Point to remember when adding water or oil
5 ......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools
[1] For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-2
(16)
PC128US-2
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. Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind 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.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Nominal
number
02
03
04
05
06
10
12
Plug
Sleeve nut (elbow end) Use the two items below as a set
07376-50210
07376-50315
07376-50422
07376-50522
07376-50628
07376-51034
07376-51234
07221-20210(Nut),
07221-20315(Nut),
07221-20422(Nut),
07221-20522(Nut),
07221-20628(Nut),
07221-21034(Nut),
07221-21234(Nut),
07222-00210(Plug)
07222-00312(Plug)
07222-00414(Plug)
07222-00515(Plug)
07222-00616(Plug)
07222-01018(Plug)
07222-01219(Plug)
1) Hoses and tubes using sleeve nuts

Nominal
number
04
05
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
2) Split flange type hoses and tubes

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
27
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
07049-02734
PC128US-2
D
6
8
10
12
14
16
18
20
22
24
27
Dimensions
d
L
5
8
6.5
11
8.5
12
10
15
11.5
18
13.5
20
15
22
17
25
18.5
28
20
30
22.5
34
30-3
(16)
2.
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.
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.
a 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 idling.
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.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
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.
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.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-4
(16)
PC128US-2
SPECIAL TOOL LIST
SPECIAL TOOL LIST
790-331-1110
Wrench
790-101-2501
Push puller KIT
790-101-2510
Block
790-101-2550
Leg
790-101-2560
Nut
790-101-2570
Plate
790-101-3101
Bearing puller
790-101-4200
Puller
(294 kN {30 ton})
790-101-1102
Hydraulic oil pump
1 796T-426-1140
Push tool
2 790-201-2680
Plate
1 790-201-2850
Spacer
2 790-201-2750
Spacer
790-101-5401
Push tool KIT (C)
Press fit of bearing outer

race
790-101-5461
Plate
For main bearing
790-101-5441
Plate
For sub-bearing
790-101-5421
Grip
01010-51240
Bolt
790-201-2750
Spacer
796T-226-1210
Wrench assembly
790-101-5401
Push tool kit (C)
790-101-5461
Plate
790-101-5421
Grip
01010-51240
Bolt
790-101-5401
Push tool kit (C)
790-101-5471
Plate
790-101-5421
Grip
01010-51240
Bolt
790-201-2850
Push tool
Symbol
A
Disassembly, assembly of
swing machinery
PC128US-2
Part No.
Part Name
Sketch
Qty
Disassembl, assembly of
cylinder head
Necessity
Component
New/
remodel
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t : Cannot be substituted, should always be prepared (used)
q : Extremely useful if available, 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, used without any modification
a Tools marked Q in the Sketch column are tools introduced in special sketches.
Nature of work, remarks
Tightening of cylinder head
Removal of bearing
Press fit of oil seal
Press fit of bearing inner

race
Removal separate caler

Q
Removal, installation of nut
Press fitting of main bearing

outer race
Press fitting of sub bearing

outer race
Press fitting of main bearing

inner race
30-5
(16)
SPECIAL TOOL LIST
10
797T-423-1360
Push tool
11
795-630-1803
Torque wrench
Press fitting of sub bearing

inner race
Measurement of running
torque of shaft
791-675-1510
Installer
Application of floating seal
791-600-2001
or
791-685-8006
Compressor (A)
791-635-3160
Extension
790-201-2770
Spacer
790-101-1600
Cylinder
(686 kN {70 ton})
790-101-1102
Pump
790-201-1500
Push tool KIT
790-201-1590
Plate (Periphery 74)
790-201-1610
Plate (Periphery 79)
790-101-5021
Grip
01010-50816
Bolt
790-434-1650
Installer
791-601-1000
Oil pump
791-616-1040
Remover & installer
790-105-1100
Cylinder
(297 kN {30 ton})
791-101-1102
Pump
791-616-1110
Frame
791-616-1121
Plate
791-616-1131
Plate
791-616-1150
Guide
791-616-1160
Adapter
791T-616-1280
Adapter
791-620-3530
Push
791-620-3260
Push
791-620-3270
Guide
01011-62260
Bolt
01643-62260
Washer
01011-61455
Bolt
01643-31445
Washer
790-105-1100
Cylinder
(297 kN {30 ton})
790-101-1102
Pump
790-101-2501
Push puller
790-101-2510
Block
Symbol
idler recoil spring
track roller
Expansion, installation of
track shoe
Disassembly of center
swivel joint
30-6
(16)
Part No.
Part Name
Compressor (B)
Sketch
Qty
swing machinery
Necessity
Component
New/
remodel
1
1
Compression of spring
Press fit of piston dust seal
Application of floating seal

88
Sealing of oil and checking of
air leak
PC128US-2
Removal,
pressfit of
master pin
Q
Removal,
PC138USLCpressfit of
2
master pin
Disconnection of rotor from

shaft
PC128US-2
SPECIAL TOOL LIST
Disassembly of center
swivel joint
hydraulic cylinder
PC128US-2
Part Name
790-101-2520
Screw
790-101-2540
Washer
791-112-1180
Nut
790-101-2630
Leg
790-101-2570
Washer
790-101-2560
Nut
791-112-2650
Adapter
790-502-1003
Repair stand
790-101-1102
Pump
790-102-4300
Wrench assy
790-201-4310
Pin
790-201-1702
Push tool KIT
790-201-1791
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1702
Push tool KIT
790-201-1811
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1702
Push tool KIT
790-201-1821
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
Push tool KIT
790-201-1610
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
Push tool KIT
790-201-1620
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
Push tool KIT
790-201-1630
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-720-1000
Expander
Sketch
Part No.
Qty
Symbol
New/
remodel
Nature of work
Necessity
Disconnection of rotor from

shaft
cylinder
Removal, installation of
piston
Press fit of bucket cylinder

roll bushings
1
Press fit of boom cylinder roll
bushings
1
Press fit of arm and blade
cylinder roll bushings
1
Press fit of bucket cylinder
dust seal
1
Application of boom cylinder
dust seal
Application of arm and blade

cylinder dust seal
Extension of piston ring
30-7
(16)
SPECIAL TOOL LIST
Removal, installation, of
work equipment and boom
Floor frame assembly

airconditioner compressor X
assembly
airconditioner condenser
assembly
airconditioner unit
assembly
(19)
Ring
07281-01029
Clamp
796-720-1660
Ring
07281-01159
Clamp
792-785-1100
Remover
796-270-1110
Adapter
790-101-4000
Puller
(490 kN {50 ton})
790-101-1102
Pump
793-498-1210
Lifter (Suction cup)
20Y-54-13180
Adapter
799-703-1200
Service tool KIT
799-703-1100
Vacuum pump(100V)
For Japan
799-703-1110
Vacuum pump(220V)
For overseas
790-703-1120
Vacuum pump(240V)
For overseas
799-703-1401
Gas leak detector
Part No.
Part Name
Sketch
796-720-1650
Symbol
Operators cab glass

(stuck glass)
30-8
Qty
hydraulic cylinder
Necessity
Nature of work
New/
remodel

Bucket
cylinder
(PC128UU-2)
Bucket cylinder
(PC138US-2)
(PC138USLC-2)
Arm, boom, blade
cylinder
Removal,
installation
of piston
ring
Removal,
installation
of piston
ring
Removal of boom foot pin
Removal and installation operatiors cab glass (stuck glass)
Charging of
air-conditioning gas
PC128US-2
SKETCH OF SPECIAL TOOL

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
F2-1 Push tool
a Unless otherwise specified, there shall be on burrs or flushes at the corner.

F6 Wrench
PC128US-2
30-9
(16)
F-10 Push tool
R Adapter
30-10
(16)
PC128US-2
CYLINDER HEAD
CYLINDER HEAD ASSEMBLY

PC138US-2
REMOVAL
k Disconnect the cable from the negative () terminal of the battery.

1. Remove the counter weight. For details, See
REMOVAL OF COUNTERWEIGHT.
2. Drain the coolant.
6 Coolant: 13.2 l
3. Remove frame (1) and (2).

4. Remove cover (3)
5. Remove connector (M34) (4) and cover (5).
6. Loosen air conditioner compressor (6) mounting
bolt (7) and adjustment bolt and remove air conditioner compressor belt (8).
7. Remove air conditioner compressor (6).
a Put the air conditioner compressor in front of
the turbocharger.
8. Disconnect heater hoses (9).
9. Disconnect air hose (10) and remove aftercooler
hose (11).
[*1]
10. Disconnect radiator hose (12).
[*2]
11. Remove cover (13).

12. Remove muffler drain tube (14).
13. Remove clamp (15).
[*3]
14. Remove mufler (16) and bracket (17) together.

15. Disconnect water temperature sensor connector
(P07) (18).
PC128US-2
30-11
(16)
CYLINDER HEAD
16. Disconnect spill tube (19).

17. Remove the bracket mounting bolts of fuel filter
(20).
18. Disconnect clip (21) and boost compensator
hose (22).
19. Remove the 4 fuel injection tube (23).
[*4]
20. Remove air conditioner compressor bracket (24).

21. Disconnect blow-by hose (25).
22. Remove nut (26) and bracket (27) and disconnect engine stop solenoid (28).
23. Disconnect heater terminal E52 (29) and clip
(30).
24. Disconnect air tube (32) from turbocharger (31).
25. Disconnect turbocharger lubrication tubes (33)

and (34) on the engine side.
26. Disconnect clip (35).
a There are 2 spacers.
27. Lift off turbocharger, exhaust manifold, and lubrication tube assembly (36).
[*5]
28. Loosen mounting bolts (38) and (39) of alternator

(37) and adjustment bolt (40) and remove alternator belt (41).
30-12
(16)
PC128US-2
CYLINDER HEAD

30. Disconnect heater hoses (43) and radiator hose
(44).
[*2]
31. Remove fan guard (45).
32. Remove the 6 mounting bolts (46) of, fan (47),
and pully (48).
33. Remove water pump assembly (49).
34. Remove cylinder head cover (50).
[*6]
35. Loosen locknut (51), and then loosen adjustment

screw (52) by 2 3 turns.
a Perform this work for all of the 8 places. [*7]
36. Remove 5 mounting bolts (53), 3 mounting nuts
(54), and rocker arm and shaft assembly (55).
[*8]
37. Remove the 8 push rods (56).
38. Remove the 17 mounting bolts and lift off
exhaust manifold assembly (57).
[*9]
4 Clinder head, intake manifold Assembly:

40 kg
PC128US-2
30-13
(16)
CYLINDER HEAD
INSTALLATION
Carry out installation in the reverse order to

removal.
[*1]
3 Air hose clamp

After cooler hose clamp:
10.8 0.5 Nm {1.1 0.05 kgm}
[*2]
[*3]
2 Apply gasket sealant (ThreeBond

TB1208E) to the range of 30 mm from
each end of radiator hose adapters (of
the radiator and water pump) and connect the radiator hose.
3 Radiator hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
3 Mounting bolt of clamp between turbocharger and muffler:
1st time: 39.2 49 Nm {4 5 kgm}
2nd time:
68.6 122.5 Nm {7 12.5 kgm}
[*4]
3 Fuel injection pipe sleeve nut:

19.6 24.5 Nm {2 2.5 kgm}
[*5]
3 Mounting bolt of exhaust manihold and

turbocharger:
34.3 53.9 Nm {3.5 5.5 kgm}
[*6]
a Insert the cylinder head cover O-ring in the

O-ring groove, taking care not to expand or
contact it, and fit it to the cylinder head.
Apply adhesive, if necessary.
3 Head cover mounting bolt:
7.84 9.8 Nm {0.8 1.0 kgm}
[*7]
3 Rock nut: 39.2 49 Nm {4 5 kgm}
[*8]
3 Rocker arm shaft mounting bolt and nut:

19.6 29.4 Nm {2 3 kgm}
[*9]
1. Tighten the cylinder head mounting bolts in the
following order.
1) Apply molybdenum disulphide LM-P all over
the threads and seating face of each bolt and
the seats of the cylinder head holes.
2) Turn the bolts with the fingers until they are
screwed in the threaded holes of the cylinder
head by 2 3 threads in the order of [1]
[17] shown in the figure.
3) Tighten the bolts to 68.6 9.8 Nm {7 1
kgm} in the order of [1] [17] shown in the
figure.
4) Tighten the bolts to 107.8 4.9 Nm {11 0.5
kgm} in the order of [1] [17] shown in the
figure.
a (1): Exhaust side, (2): Air intake side, (3):
Front, (4): Rear
30-14
(16)
PC128US-2
CYLINDER HEAD
5) Use the tool A1 or make marks f with paint

on the Y bolt heads and their seats on the
cylinder head, and then tighten the bolts in
the order of [1] [17] so that the mark of
each bolt will be at 90 +30
from the mark of
0
the cylinder head.
a After tightening the bolts, make 1 punch
mark (g) on each bolt head.
a If there are 5 or more punch marks on a
bolt head, do not use that bolt again but
replace it.
Reference
3 U-clamp nut:
7.8 9.8 Nm {0.8 1.0 kgm}
3 Mounting bolt of nozzle holder:

39.2 49 Nm {4 5 kgm}
3 Turbocharger unit mounting bolt:
27 34 Nm {2.8 3.5 kgm}
a If the exhaust manifold is removed, apply
gasket sealant LG-7 in the form of a string 1
mm in diameter as shown below.
Supplying coolant
Supply coolant from the cooloant filter port to the
specified level, start the engine to circulate coolant and recheck the level.
5 Coolant: 13.2 l
Bleeding air
Bleed air from the fuel system. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC128US-2
30-15
(16)
INJECTION PUMP
INJECTION PUMP ASSEMBLY

PC138US-2
REMOVAL
k Disconnect the wiring harness from the negative terminal of the battery.
1. Remove the counterweight. (See REMOVAL OF
COUNTERWEIGHT.)
2. Remove frame (1).
3. Remove oil gauge guide (2).
4. Remove nut (3), and then remove engine stop
solenoid (4) and bracket together.
5. Remove cover (6), loosen the mounting bolts
and adjustment bolt of air conditioner compressor (5), and then remove air conditioner compressor belt (7).
6. Remove blow-by tube (8).
7. Disconnect clamp (9).

8. Remove nut (10) and disconnect fuel control
cable (12) and bracket (11) together.
9. Disconnect spill hose (13) and fuel feed hoses
(14) and (15).
10. Remove fuel filter (16).
11. Disconnect fuel feed hose (17) and fuel return
hose (18).
12. Remove 4 fuel injection tubes (19).
[*1]
13. Remove lubrication tube (20).

14. Disconnect boost compensator hose (21).
15. Remove clamp (22) and separate wiring harness
(23) from fuel injection pump (24).
16. Remove bracket (25).
30-16
(16)
PC128US-2
INJECTION PUMP
17. Remove cover (26) and set the No. 1 cylinder to

the compression top dead center.
1) Rotate bolt B forward to match the stamped
line of 1.4TOP to pointer C under pulley A.
a If there is not valve clearance in the No. 1
cylinder, the No. 4 is at the compression
top dead center. In this case, rotate bolt
B forward further to match the stamped
line of 1.4TOP to pointer C again.
2) Check that bolt hole D on this side is
matched to the hole of the pump gear (that
the No. 1 cylinder is at the compression top
dead center) by inserting a pin about 8 cm
long (a round rod) [2].
18. Remove 6 mounting bolts (27) on the pulley side,
mounting bolts (28) and (29) on the pump side,
and fuel injection pump (24).
a Do not remove the bolt at part E, since it is
used as a plug. (Remove it to fix the pump
gear when installing.)
a Fuel injection pump (24) is disconnected
from F.
PC128US-2
30-17
(16)
INJECTION PUMP
INSTALLATION
1. Before installing fuel injection pump (24), remove
the bolt from part E and secure the gear with M6
bolt [3] 35 mm or longer.

removal.
[*1]
3 Fuel injection pipe sleeve nut:

19.6 24.5 Nm {2 3.5 kgm}
Bleed air from the fuel system. For details, see

each part.
30-18
(16)
PC128US-2
ENGINE AND MAIN PUMP

ASSEMBLY
PC128US-2
Serial No. : 5001 8100
PC138US-2
Serial No. : 1001 3200
PC138USLC-2 Serial No. : 1001 1500
REMOVAL
k Completely ground the work equipment.
k Disconnect the negative (-) terminal of the battery.

1. Remove the radiator, hydraulic oil cooler assembly by referring to "REMOVAL OF RADIATOR,
HYDRAULIC OIL COOLER ASSEMBLY".
2. Disconnect hose (1) between the radiator upper
tanks.
3. Remove bracket (2) from the fuel tank together
with the reserve tank.
4. Disconnect bracket (3) from the main pump.
a The EPC valve connector is attached to it.
5. Disconnect PPC main pressure hose (4).
6. Disconnect earth cable (5).
7. Disconnect LS pressure input hose (6).
8. Disconnect EPC valve connector (7) (C13).
9. Disconnect suction tube (8) from the main pump.
10. Disconnect main pump output hose (9).
11. Disconnect main pump pressure input hose (10).
12. Disconnect case drain hose (11).
13. Disconnect engine oil filter (12) from the hydraulic oil tank and put it near the main pump.
14. Remove stays (13), (14) and (15).
15. Remove adiabatic cover (16).
17. Remove muffler (18).
a Loosen the turbo charger clamp beforehand.
18. Disconnect heater outlet hose (19).
19. Disconnect airconditioner hose (20).
a Fit blind plugs into the hoses to prevent the
entry of moisture, dust or dirt.
20. Disconnect accelerator cable (21).

[*1]
21. Disconnect fuel inlet hose (22) and return hose
(23).
22. Disconnect airconditioner hose clamp (24) at two
positions.
23. Disconnect engine connectors (25) (E15), (26)
(E20), (27) (E16) and (28) (E07) to remove
clamp (29).
24. Disconnect fuel spill hose (30).
a Apply the blind plug to the hose.
PC128US-2
30-19
(16)
25. Disconnect clamp (31) to remove hose (32).

26. Remove engine side cover (33).
27. Disconnect engine connectors (34) (M02) and
(35) (E17).
28. Disconnect starter wire (36) (E13) and safety
relay wire (37) (E30).
29. Disconnect heater return hose (38).
30. Remove three of four engine mounts (39).
31. Temporarily lift engine main pump assembly
(40), remove the remaining mounting bolt and
carefully lift the assembly to remove it.
[*2]
4 Engine main pump assembly : 270 kg
INSTALLATION
Installation is performed in the opposite way to

removal.
[*1]
[*2]
a Adjust the cable length by referring to

"ADJUSTMENT OF FUEL CONTROL
CABLE".
a Install the engine main pump assembly by
placing the engine mounting rubber as
shown in the figure below.
3 Engine mounting tightening bolt :

277.0 31.9 Nm {28.25 3.25 kgm}
Supplying coolant
a Supply coolant from the water filler port to
the specified level, start the engine to circulate coolant and recheck the level.
Supplying oil (hydraulic oil tank)

a 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
a Bleed air from the main pump. For details, see
each part.
30-20
(16)
PC128US-2

ASSEMBLY
PC128US-2 Serial No. : 8101 and up
PC138US-2 Serial No. : 3201 4500
REMOVAL
k Lower the work equipment to the ground and

stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.

1. Remove the counterweight (See REMOVAL OF
COUNTERWEIGHT).
2. Drain hydraulic oil and coolant.
6 Hydraulic oil: 69 l
(Oil level in hydraulic tank)
6 Coolant: 17.2 l
3. Collect air conditioner gas from air conditioner

circuit.
4. Remove battery (1).
5. Disconnect air hose (2), aftercooler inlet hose
(3), and radiator inlet hose (4).
[*1]
6. Disconnect aftercooler outlet hose (5) and radiator outlet hose (6).
[*2]
7. Disconnect reservoir tank hose (7) and remove

reservoir tank (8).
8. Disconnect wiring connector (9) (M28) and window washer hose (10) and remove washer tank
(11).
9. Remove bracket (12) from the main pump.
10. Disconnect wiring connectors (13) (C13) and
(14) (C14).
11. Disconnect suction tube (15)
PC128US-2
30-21
(19)

13. Disconnect main pump output hose (17).
14. Disconnect main pump pressure input hose (18).
16. Remove engine oil filter (20) from the hydraulic
tank and move it toward the main pump.
17. Disconnect engine wiring connectors (21) (E15),

(22) (E20), (23) (E16), and (24) (E07) and
remove clamp (25).
18. Remove stays (26), (27), and (28).

19. Remove heat insulation cover (29).
21. Remove muffler (31).
a Loosen the turbocharger clamp.
22. Disconnect heater hose (32).

23. Disconnect 2 air conditioner hoses (33).
a Take measures to prevent dirt, water, etc.
from entering the piping.
30-22
(16)
PC128US-2
24. Disconnect fuel control cable (34).

[*3]
a Before disconnecting the fuel control cable,
measure its installed length.
25. Disconnect fuel inlet hose (35) and outlet hose
(36).
a Plug the hoses to stop the fuel.
26. Disconnect fuel spill hose (37).
a Plug the hose to stop the fuel.
27. Disconnect 2 air conditioner hose clamps (38).

28. Disconnect clamp (39) and hose (40).
29. Remove engine side cover (41).
30. Disconnect alternator wiring connector (42)

(M02).
31. Disconnect starting motor wire (43) (E13), and
safety relay wires (44) (E30) and (45) (E17).
33. Remove 4 mounting bolts (47) of the radiator,
aftercooler, and hydraulic oil cooler assembly.
34. Move radiator, aftercooler, and hydraulic oil

cooler assembly (48) toward the battery about 50
mm.
35. Sling engine and main pump assembly (49) temporarily, remove 4 engine mounting bolts (50),
and lift off the engine and main pump assembly.
[*4]
a Check that all the wires and pipes are disconnected.
a Take care particularly not to damage the
radiator, aftercooler, and hydraulic oil cooler
assembly.
PC128US-2
30-23
(16)
INSTALLATION

removal.
[*1] [*2]

3 Air hose clamp:
9.8 0.5 Nm {1.0 0.05 kgm}

8.8 0.5 Nm {0.9 0.05 kgm}
3 Aftercooler hose clamp:

10.8 0.5 Nm {1.1 0.05 kgm}
[*3]
Adjust the cable length. For details, see TESTING AND ADJUSTING, Adjustment of fuel control cable.
[*4]
a Install the engine main pump assembly by

placing the engine mounting rubber as
shown in the figure below.
3 Engine mounting tightening bolt:

277.0 31.9 Nm {28.25 3.25 kgm}

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.
5 Hydraulic tank: 69 l
Supplying coolant
Supply coolant from the coolant filler port to the
5 Coolant: 17.2 l
Bleeding air
Bleed air from the pump. For details, see TESTING AND ADJUSTING, Bleeding air from each
part.
Charging air conditioner with refrigerant gas

Using tool X3, charge the air conditioner circuit
with refrigerant gas (R134a).
30-24
(16)
PC128US-2

ASSEMBLY
PC138US-2
REMOVAL

k Disconnect the cable from the negative (-) terminal of the battery.
1. Remove the counterweight.
(See REMOVAL OF COUNTERWEIGHT).
2. Drain the hydraulic oil and the coolant.
6 Coolant: 13.2 l
3. Remove frames (1) and (2).

5. Disconnect connector (M34) (4) and remove
cover (5).
6. Loosen mounting bolts (7) and the adjustment
bolt of air conditioner compressor (6), and then
remove air conditioner compressor belt (8).
7. Remove airconditioner compressor (6).
a Put the air conditioner compressor in front of
the turbocharger.
9. Disconnect air hose (10) and remove after cooler
hose (11).
[*1]
10. Disconnect radiator hose (12).
[*2]
11. Disconnect coolant temperature sensor connector (P07) (13).

12. Disconnect heater terminal (E52) (14).
PC128US-2
30-25
(16)
13. Disconnect PULL, GND, and HOLD from the top

of engine stop solenoid terminals (15).
a If the terminal cover falls from the wiring harness, the signal label of the wiring harness
falls, too. Accordingly, take a measure to
hold the terminal cover.
a Terminal name seal is stuck to the engine
stop solenoid.
14. Disconnect clip (16) and (17).
15. Remove nut (19), loosen locknut (20), and disconnect fuel control cable (18).
[*3]
16. Disconnect fuel hoses (61) and (62).
17. Disconnect starting motor terminals E13 (21) and

E54 (22).
[*4]
18. Disconnect clip (23) and separate wiring harnesses (24) and (25) from the engine.
19. Disconnect ground terminal (26).
21. Disconnect heater hose (28) and radiator hose
(29).
[*2]
22. Remove fan guard (30).
23. Remove the 6 mounting bolts (31) and fan (32).
24. Disconnect air tube (34) from turbocharger (33).
30-26
(16)
PC128US-2
25. Disconnect terminal S17 (35) and connectors

E17 (36) and E07 (37) from the bottom of the turbocharger.
26. Remove clip (38).
27. Remove cap (40), and then remove reservoir

tank (42) and bracket (41) together.
28. Disconnect connectors C14 (43), C13 (44), and
clip (45).
29. Disconnect drain hose (46) and pump pressure

input hose (47).
30. Disconnect pump spout tube (48) and suction
tube (49).
31. Disconnect LS pressure input hose (50) from A.
32. Remove corrosion resistor (51), oil filter (52), and
their brackets together.
33. Remove frame (53).

34. Remove the mounting bolt (54).
PC128US-2
[*5]
30-27
(16)
35. Lift off engine assembly (55).

a Use bolt hole B of the exhaust manifold to
sling the engine by 3 points stably.
4 Engine assy : 480 kg
30-28
(16)
PC128US-2
INSTALLATION

removal.
[*1]
3 Air hose clamp and aftercooler hose

clamp: 10.8 0.5 Nm {1.1 0.5 kgm}
[*2]

8.8 0.5 Nm {0.9 0.05 kgm}
[*3]
Adjustment to fuel control cable. For details, see
TESTING AND ADJUSTING, testing and adjusting of an accelerator pedal.
[*4]
3 Starting motor terminal E13 (21) (M10):

15.7 19.6 Nm {1.6 2 kgm}
3 Starting motor terminal E54 (22) (M5):
2.5 3 Nm {0.25 0.31 kgm}
[*5]
Note that washer B on the inside of the chassis
(INSIDE) and that on the outside of the chassis
(OUTSIDE) to support bottom rubber A of the
engine mount on the chassis are different from
each other.
3 Engine mount mounting bolt:
245 309 Nm {25 31.5 kgm}
PC128US-2
30-29
(16)

5 Hydraulic tank: 69 l (Oil level)
100 l (Capacity)
Supply coolant
Supply coolant from the coolant filler port to the
5 Coolant: 13.2 l
Bleeding air
Bleed air from the pump and fuel system. For
details, see TESTING AND ADJUSTING, Bleeding air from each part.
30-30
(16)
PC128US-2
RADIATOR, HYDRAULIC OIL

COOLER
PC128US-2
Serial No. : 5001 8100
PC138US-2
Serial No. : 1001 3200
REMOVAL
kGradually loosen the hydraulic oil tank cap to

bleed the internal air after completely grounding
the work equipment and stopping the engine.
1. Remove the counterweight assembly by referring to "REMOVAL OF COUNTERWEIGHT
ASSEMBLY".
2. Drain hydraulic oil and coolant.
6 Hydraulic oil : 69 l
6 Cooling : 18.2 l

circuit.
4. Remove stay (1).
5. Remove stay (2).
a Disconnect the accelerator cable clamped to
stay (2).
6. Remove bracket (3) together with the washer
tank.
a Disconnect the washer motor connector
(M28) from the hose.
7. Remove two batteries (4).
8. Remove battery relay (5).
9. Remove silencer (6) and tube (7) to remove air
cleaner assembly (8).
11. Disconnect airconditioner capacitor pipings (10)
and (11).
[*1]
a Make sure to double-engage the wrench
before disconnection.
12. Remove the mounting bolt to remove air conditioner capacitor assembly (12).
13. Remove clamp (13) to remove bracket (14).
14. Disconnect oil cooler outlet hose (15) and inlet
hose (16).
15. Disconnect radiator outlet hose (17) and inlet
hose (18) as well as reserve tank hose (19).
PC128US-2
30-31
(19)
16. Temporarily lift radiator, hydraulic oil cooler

assembly (20) to remove the four mounting bolts
on the bottom.
a Carefully lift and remove the assembly after
slightly lifting it and pulling it to the opposite
side from the engine to make sure that it
does not come in contact with the fan.
4 Radiator/hydraulic oil cooler assembly :
55 kg
INSTALLATION

removal.
[*1]
a Check that the O-ring is not damaged or

deteriorated, then connect the hoses.
Using tool X3, charge air conditioner gas

(R134a) to air conditioner circuit.
Refilling with coolant

Add coolant through the coolant filler to the specified level. Run the engine to circulate the water
through the system. Then check the coolant
level again.
Refilling with oil (hydraulic tank)

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.
5 Coolant: 18.2 l
30-32
(19)
PC128US-2
RADIATOR
RADIATOR ASSEMBLY
PC128US-2
PC138US-2

REMOVAL
1. Drain cooling water.
6 Coolant : 17.2 l
[*3]
2. Remove the aftercoolar assembly by referring to

"REMOVAL OF AFTER COOLER ASSEMBLY".
3. Remove engine hood stay (1) from radiator
assembly.
4. Disconnect radiator inlet hose (2).
[*1]
5. Disconnect radiator outlet hose (3).
[*2]
6. Removethe 2 mounting bolts (4) of radiator.

7. Pull up radiator assembly (5) to remove it.
a Raise radiator assembly (5) a little, and then
slide it toward the oil cooler.
a Take care not to damage the radiator core.
INSTALLATION

removal.
[*1] [*2]

8.8 0.5 Nm {0.9 0.05 kgm}
Refilling with coolant

Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant
level again.
5 Coolant: 17.2 l
[*3]
[*3]
PC138US-2
Coolant : 13.2 l
PC128US-2
30-33
(16)
HYDRAULIC OIL COOLER

ASSEMBLY
PC128US-2
PC138US-2
REMOVAL
k Gradually loosen the hydraulic oil tank cap to

1. Drain hydraulic oil
6 Hydraulic oil :
69 l (Oil level in hydraulic tank)
100 l (Capacity)
2. Remove the after cooler assembly by referring to

"REMOVAL OF AFTER COOLER ASSEMBLY".
3. Remove the engine hood cover assembly (1).
4. Disconnect clamp (2), and then disconnect air
intake hose (3) from the air cleaner.
a Move the air intake hose toward the engine.
5. Remove the oil cooler undercover and disconnect oil cooler outlet tube (4).
a Prepare an oil receiving can to receive the
leaking hydraulic oil before disconnecting the
tube.
6. Remove 2 mounting bolts of oil cooler inlet tube

(5).
7. Loosen U-clamp (6) and disconnect oil cooler
inlet tube (5) from the hydraulic oil cooler.
a Loosen the U-clamp but do not remove it.
8. Remove 2 oil cooler mounting bolts (7).
30-34
(16)
PC128US-2
9. Raise oil cooler assembly (8) a little, and then

slide it toward the radiator.
11. Pull up oil cooler assembly (8) to remove it.

a Take care not to damage the oil cooler core.
INSTALLATION

removal.

5 Hydraulic oil :
69 l (Oil level in hydraulic tank)
100 l (Capacity)
PC128US-2
30-35
(16)
AFTER COOLER

PC128US-2
PC138US-2
Serial No. : 3201 4500
REMOVAL
k Completely grounding the work equipment.

1. Open 2 engine hoods (1) and remove cover (2).
2. Remove reservoir tank hose (3).
3. Remove aftercooler inlet hose (4).
[*1]
4. Disconnect aftercooler outlet hose (5).
[*2]
5. Remove 2 aftercooler assembly mounting bolts

(6).
6. Pull up aftercooler assembly (7) to remove it.
a Take care not to damage the aftercooler
core.
INSTALLATION

removal.
[*1] [*2]
3 After cooler hose clamp:

10.8 0.5 Nm {1.1 0.05 kgm}
30-36
(16)
PC128US-2
AFTER COOLER

PC138US-2
REMOVAL

1. Remove mirror (1).
2. Open engine hood (2) and remove cover (3).
3. Remove the undercover and disconnect aftercooler lower hose (4).
[*1]
a "A" is the radiator hose.
5. Disconnect reservoir tank hose (6).
6. Disconnect aftercooler upper hose (7).
[*1]

8. Remove mounting bolt (9) and aftercooler (10).
INSTALLATION

removal.
[*1]
3 After cooler hose clamp:

10.8 0.5 Nm {1.1 0.05 kgm}
PC128US-2
30-37
(16)
FUEL TANK
FUEL TANK
REMOVAL

1. Drain the fuel.
6 Fuel tank : 195 l
2. Remove two hand rails (1) to remove side covers

(2) and (3), and upper covers (4), (5), (6) and (7).
3. Disconnect hose (8) from the radiator, the
mounting bolt and bracket (9) together with the
reserve tank.
4. Disconnect engine fuel return hoses (10) and
(11).
5. Disconnect fuel sensor connector (12) (P06) to
remove clamp (13).
6. Remove brackets (14) and (15) on the left side of
the fuel tank.
7. Disconnect mounting bolt (16) on the right side.
8. Disconnect hoses (17) (to the fuel pump) and
(18) (for draining) from the bottom of the fuel
tank.
a Lift the fuel tank before disconnection.
9. Temporarily lift fuel tank (19), remove the mounting bolt and then carefully lift the tank to remove
it.
[*1]
4 Fuel tank assembly : 100 kg
INSTALLATION

removal.
[*1]
2 Fuel tank mounting bolt screw :

Liquefied adhesive (LT-2)
3 Fuel tank mounting bolt :

277.0 31.9 Nm {28.25 3.25 kgm}
Supplying oil (fuel tank)

Supply fuel.
30-38
(16)
PC128US-2
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

REMOVAL


1. Remove cover at rear of boom. For details, see
"REMOVAL OF SWING MOTOR AND SWING
MACHINERY ASSEMBLY".
2. Disconnect hoses (1) (6) between travel motor
and swivel joint.
3. Remove elbow (7).
4. Disconnect drain hose (8).
5. Disconnect hoses (9) (12) between control
valve and swivel joint.
6. Disconnect hose (13) from solenoid valve.
7. Remove plate (14).
8. Disconnect hoses (for changing the speed) (15)
and (16) between both travel motors and swivel
joint.
9. Remove mounting bolts and lift off center swivel
joint assembly (17).
[*1]
a Sling the joint assembly temporarily, then
remove the bolts.
4 Center swivel joint assembly
: 30 kg (Standard specification)
: 45 kg (Blade specification)
INSTALLATION

removal.
[*1]
2 Mounting bolt screw :

3 Mounting bolt :
98.1 123.0 Nm {10.0 12.5 kgm}
Bleeding air
Bleed air from the swing motor. For details, see
each part.
PC128US-2
30-39
(16)
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

DISASSEMBLY
2. Remove snap ring (2).
3. Using tool T, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
4. Remove O-rings (6) and slipper seals (7) from
swivel shaft (5).
ASSEMBLY
1. Fit slipper seals (7) and O-rings (6) to swivel
rotor.
2. 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.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).
3 Swivel joint mounting bolt :

31.3 2.9 Nm {3.2 0.3 kgm}
30-40
(16)
PC128US-2
SWING MOTOR, SWING MACHINERY
SWING MOTOR,
SWING MACHINERY
REMOVAL


1. Remove boom rear covers (1) and (2).
2. Disconnect MB and MA port hoses (3) and (4), S
port hose (5), and B and T port hoses (6) and
(7).
3. Remove the mounting bolt and tighten forcing
screw [1] to disconnect swing motor, swing
machinery (8) from the revolving frame.
[*1]
a Temporarily lift the swing motor/swing
machinery assembly and gradually lift it
upward according to the amount disconnected by the forcing screw.
4. Lift and remove swing motor/swing machinery
assembly (8).
4 Swing motor, swing machinery assembly

: 100 kg
INSTALLATION

removal.
[*1]
2 Swing machinery fitting surface :

Gasket sealant (LG-4 or LG-6)
3 Mounting bolt :
277.0 31.9 Nm {28.25 3.25 kgm}
Bleeding air
Bleed air from the swing motor. For details , see
each part.
PC128US-2
30-41
(16)
SWING MACHINERY
SWING MACHINERY
PC128US-2
PC138US-2
Serial No. : 1001 4500
DISASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery.
6 Swing machinery case : Approx. 2.5 l
2. Swing motor
Remove swing motor assembly (1).
4 Swing motor assembly : 30 kg
3. No. 1 carrier, No. 2 sun gear assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 1 carrier and No. 2 sun gear
assembly (3).
3) Disassemble No. 1 carrier and No. 2 sun

gear assembly (3) as follows.
i) Remove snap ring (4), then remove
thrust washer (5), gear (6), bearing (7),
and thrust washer (8).
ii) Knock in pin (9) and knock out shaft (10).

a After removing the shaft, remove pin
(9).
iii) Remove snap ring (11), then remove No.
2 sun gear (12) from carrier (13).
30-42
(16)
PC128US-2
SWING MACHINERY
4. Ring gear
Remove ring gear (14).
5. No. 2 carrier assembly
1) Remove spacer (15).
2) Remove No. 2 carrier assembly (16).
3) Disassemble No. 2 carrier assembly as follows.

i) Push in pin (17), and knock out shaft (18)
from carrier (19).
a After removing the shaft, remove pin
(17).
ii) Remove thrust washer (20), gear (21),
bearing (22), and thrust washer (23).
6. Retainer, collar
1) Remove retainer (24).
2) Set shaft and case assembly to press, push
split collar (25) with push tool F5, and press
fit bearing (26).
a Operate the press gradually and press fit
the bearing to a point where the split collar can be removed.
3) Remove split collar (25).
7. Shaft assembly
1) Set shaft and case assembly (27) to block
[2], then using push tool [3], remove shaft
assembly (28) with press.
2) Remove bearing (26).
PC128US-2
30-43
(16)
SWING MACHINERY
3) Using push tool F1, remove bearing (29) and

collar (30) from shaft (31).
8. Oil seal, bearing outer race

1) Remove oil seal (32) from case (33).
2) Using puller [5], remove bearing outer races

(34) and (35) from case (33).
30-44
(16)
PC128US-2
SWING MACHINERY
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing outer races
Using push tool F4, press fit outer races (34) and
(35) to case (33).
2. Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
shaft (31).
2) Using push tool F3-1, press fit bearing (29)
with press.
3) Set case assembly (36) to shaft assembly

(28).
4) Using push tool F3-2, press fit bearing (26)
with a press to a point where split collar (25)
enters.
a Press-fitting force : 11.760 N {1,200 kg}
a Press fit the bearing slowly while rotating
the case.
5) Install split collars (25).

6) Screw bolt (12mm, P=1.75mm) into case,
then using push- pull scale [8], measure tangential force in direction of rotation.
a Tangential force : Max. 176.4 N {18 kg}
a The tangential force is the maximum
force at the start of rotation.
PC128US-2
30-45
(16)
SWING MACHINERY
3. Oil seal
Using push tool F2, press fit oil seal (32).
a Replace the oil seal with a new part.
2 Periphery of oil seal: LG-6
a Do not stick LG-6 to the lip and shaft.
2 Lip of oil seal : Grease (G2-LI)
4. Retainer
Install retainer (24).

1) Assemble No. 2 carrier assembly as follows.
i) Assemble bearing (22) to gear (21).
ii) Fit top and bottom thrust washers (20)
and (23), then set gear assembly to carrier (19).
iii) Align position of pin holes of shaft and

carrier, then tap with plastic hammer and
install shaft (18).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washers.
iv) Insert pin (17).
a After inserting the pin, caulk the carrier pin portion.
30-46
(16)
PC128US-2
SWING MACHINERY
2) Install No. 2 carrier assembly (16) to shaft

and case assembly.
3) Install spacer (15).
6. Ring gear
Assemble O-ring (37) to shaft and case assembly, and install ring gear (14).
7. No. 1 carrier, No. 2 sun gear assembly

1) Assemble No. 1 carrier and No. 2 sun gear
assembly as follows.
i) Assemble No. 1 carrier (13) to No. 2 sun
gear (12), and install snap ring (11).
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer to
install shaft (10).
iii) Insert pin (9).
a After inserting the pin, caulk the carrier pin portion.
a Check that the stepped difference a
between the shaft and carrier is less
than 0.2 mm.
iv) Assemble thrust washer (8), bearing (7),
gear (6), and thrust washer (5), then
install snap ring (4).
PC128US-2
30-47
(16)
SWING MACHINERY
2) Install No. 1 carrier and No. 2 sun gear

assembly (3).
3) Install No. 1 sun gear (2).
8. Swing motor assembly

Install swing motor assembly (1).
3 Mounting bolt :
110.3 12.3 Nm {11.25 1.25 kgm}
9. Refilling with oil (swing machinery case)

Tighten the drain plug and add engine oil EO30CD through the oil filler.
5 Swing machinery case : Approx. 2.5 l
30-48
(16)
PC128US-2
SWING MACHINERY
SWING MACHINERY
PC138US-2
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
6 Swing machinery case: 2.5 l

Lift off the swing motor assembly (1).
4 Swing motor assembly: 30 kg
3. No. 1 sun gear and No. 1 carrier assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 1 carrier assembly (3).
4) Disassemble No. 1 carrier assembly (3)

according to the following procedure.
i) Remove snap ring (5), thrust washer (6),
gear (7), bearing (8), spacer (11) and
thrust washer (9).
ii) Remove snap ring (4).
iii) Remove No. 2 sun gear (13).
4. Ring gear
Remove ring gear (14).
PC128US-2
30-49
(16)
SWING MACHINERY

1) Disassemble No. 2 carrier assembly according to the following procedure.
i) Remove snap ring (16), thrust washer
(17), gear (18), bearing (19), spacer (23)
and thrust washer (20).
ii) Using tool F6, remove nut (21).
iii) Set shaft and case assembly (27) to
block [2]. Using push tool [3] and the
press, remove shaft assembly (28) and
carrier (22).
a Set a wood board, etc. under the
press so that the shaft assembly will
not be damaged when it comes out
and falls.
iv) Remove sub bearing (25) from carrier
(22).
6. Shaft assembly
Using push tool F1, remove bearing (29) and collar (30) from shaft (31).
7. Oil seal, bearing outer race

1) Remove oil seal (32) from case (33).
30-50
(16)
PC128US-2
SWING MACHINERY
2) Using puller [4], remove bearing outer races

(34) and (35) from case (33).
PC128US-2
30-51
(16)
SWING MACHINERY
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing outer races
Using push tool F7 and F8, press fit outer races
(34) and (35) to case (33).
2. Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
shaft (31).
2) Using push tool F9, press fit bearing (29)
with press.
a Press-fitting force:
11.8 31.4 kN {1.2 3.2 ton}
3) Using tool F10 [5], press fit sub bearing (25)

to the No. 2 carrier (22).
4) Using tool [5] and the press, press fit No. 2
carrier (22) to the shaft spline.
2 Splined : Grease (G2-LI)

a Press-fitting force:
7.25 31.8 kN {0.74 3.24 ton}
a Turning the case, press fit the bearing
slowly.
5) Using tool F6 and install nut (21).

Tighten nut (21) to the specified torque and
give the bearing 3 turns clockwise and counterclockwise respectively, and then tighten
the nut to the specified torque again.
2 Nut (21) : Thread tightener (LT-2)
(Min. 0.5 cc, 10 drops)
3 Nut (21) :
784 833 Nm {80 85 kgm)
6) Using tool F6 and F11, measure the running
torque of the shaft.
a Running torque: Max. 19.6 Nm {Max. 2.0
kgm}
30-52
(16)
PC128US-2
SWING MACHINERY
3. Oil seal
Using push tool F2, press fit oil seal (32).
a Replace the oil seal with a new part.
2 Periphery of oil seal: LG-6
a Do not stick LG-6 to the lip and shaft.
2 Lip of oil seal : Grease (G2-LI)

1) Assemble No. 2 carrier assembly according
to the following procedure.
Install thrust washer (20), spacer (23),
bearing (19), gear (18), thrust washer
(17), and snap ring (16) to carrier (22).
5. Ring gear
Install ring gear (14).
6. No. 1 carrier assy

1) Install No. 2 sun gear (13) to carrier (10), and
then install snap ring (4).
2) Install thrust washer (9), bearing (8), gear
(7), thrust washer (6), and snap ring (5).
PC128US-2
30-53
(16)
SWING MACHINERY
3) Install No. 1 carrier assembly (3).

4) Install No. 1 sun gear (2).

Install swing motor assembly (1).
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
Supplying oil and grease

Tighten the drain plug and supply engine oil
EO30-CD through the oil filler.
5 Swing machinery case: Approx. 2.5 l
a Apply LG-5 to the fitting part of the drain

tube.
3 Drain plug:
44.1 93.1 Nm {4.5 9.5 kgm}
a When mounting the assembly on the
machine, apply gasket sealant LG-6 to the
fitting face of the revolving frame.
30-54
(16)
PC128US-2
REVOLVING FRAME
REVOLVING FRAME
REMOVAL

1. Remove the work equipment assembly by referring to "REMOVAL OF WORK EQUIPMENT
ASSEMBLY".
2. Disconnect boom cylinder hoses (1) (right) and
(2) (left).
a Be sure to apply the blind plug to the disconnected hose.
3. Remove covers (3) and (4).
4. Temporarily lift the boom cylinder to remove pins
(5) on the bottom.
a Check the number and position of the shims
mounted.
[*1]
5. Lift boom cylinder assembly (6) to remove it.
4 Boom cylinder assembly : 120 kg
6. Remove operator cab assembly (7) by referring

to "REMOVAL OF OPERATOR CAB ASSEMBLY".
7. Disconnect drain hose (8) and hoses (9) and
(10) between control valve and left travel motor
from center swivel joint.
8. Disconnect hoses (11) and (12) between control
valve and right travel motor.
9. Disconnect hoses (13) between solenoid valve
(Boost) and both travel motors.
10. Disconnect plate (14) from revolving frame.
11. Remove mounting bolts (15), leaving one each at

front and rear.
[*2]
PC128US-2
30-55
(16)
REVOLVING FRAME
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

removal.
[*1]
2 Surface inside bushing during pin

assembly : Hyper white grease (G2-T)
2 Greasing after pin assembly :

Hyper white grease (G2-T)
kNever put your finger in the pin hole when

adjusting the position.
a Adjust the clearance between the mount on
the boom cylinder bottom and the frame
using the shims so that it becomes 1mm or
less.
[*2]
2 Swing circle contacting face :

Liquefied gasket (LG-1)
2 Revolving frame mounting bolt screw :
3 Revolving frame mounting bolt :

277.5 32.4 Nm {28.3 3.3 kgm}

Bleeding air
Bleed the air. For details , see TESTING AND
ADJUSTING, Bleeding air from each part.
30-56
(16)
PC128US-2
SWING CIRCLE
SWING CIRCLE
REMOVAL

bleed the air from the tank after grounding the
work equipment and stopping the engine and
lock the safety lock lever.
1. Remove the revolving frame assembly by referring to "REMOVAL OF REVOLVING FRAME
ASSEMBLY".
2. Temporarily lift swing circle assembly (1) to
remove the 38 mounting bolts.
[*1]
3. Remove swing circle assembly (1).
4 Swing circle assembly : 155 kg
[*2]
INSTALLATION

removal.
[*1]
2 Swing circle mounting bolt :

3 Swing circle mounting bolt :

245 308.9 Nm {25 31.5 kgm}
[*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 (G2-LI grease)
PC128US-2
30-57
(16)
TRAVEL MOTOR AND FINAL DRIVE
TRAVEL MOTOR AND FINAL

DRIVE ASSEMBLY
REMOVAL
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
k 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.
2. Swing work equipment 90, then push up chasis
with work equipment and set block [1] between
track frame and track shoe.
3. Lift off sprocket (1).
4 Sprocket : 40 kg
[*1]
4. Remove travel motor cover.

5. Disconnect 4 travel motor hoses (2).
6. 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
INSTALLATION

removal.
[*1]
2 Thread of travel motor mounting bolt :

Thread tightener (LT-2)
3 Sprocket mounting bolt :

323.6 362.8 Nm {33 37 kgm}
[*2]
2 Thread of travel motor and final drive

assembly mounting bolt :
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.
Bleeding air from travel motor.

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.
30-58
(16)
PC128US-2
RECOIL SPRING
RECOIL SPRING
PC128US-2
PC138US-2
Serial No. : 1001 4500
DISASSEMBLY
1. Remove lock plate (1), then remove seat (2) and

valve (3).
2. Remove yoke piston assembly (5) from recoil
spring assembly (4).
3. Disassembly of recoil spring assembly (4)
1) Set recoil spring assembly (4) to tool L2.
kThe 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
: 78,500 N {8,000 kg} (PC128US-2)
: 93,200 N {9,500 kg} (PC138USLC-2)
2) 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.
3) Remove pilot (8), spring (7), cylinder (9), and
dust seal (10).
4. Disassembly of yoke piston assembly (5)

1) Remove snap ring (12), then remove Upacking (13).
2) Remove wear ring (14) from yoke piston (11).
PC128US-2
30-59
(16)
RECOIL SPRING
ASSEMBLY
1. Assembly of yoke piston assembly
1) Assemble wear ring (14) to yoke piston (11).
2) Assemble U-packing (13) and secure with
snap ring (14).
2. Assembly of recoil spring assembly
1) Using tool L3, press fit dust seal (10) to cylinder (9).
2) Assemble cylinder (9) and pilot (8) to spring
(7), and set to tool L2.
spring, and tighten nut (6) so that installed
length of spring is dimension "a".
a Installed length "a" of spring : 390 mm
4) Remove recoil spring assembly (4) from tool
L2.
3. Assemble yoke piston assembly (5) to recoil
2 Yoke piston sliding portion wear ring :
Grease (G2-LI)
4. Fit valve (3) and seat (2), and secure with lock
plate (1).
a Install the valve so that the direction of the fitting (15) is to the outside.
5. Fill inside of cylinder with a minimum of 120 cc of
grease.
2 Inside cylinder : Grease (G2-LI)
30-60
(16)
PC128US-2
RECOIL SPRING
RECOIL SPRING
PC138US-2
DISASSEMBLY
1. Remove lock plate (1), then remove seat (2) and

valve (3).
2. Remove yoke piston assembly (5) from recoil
3. Disassembly of recoil spring assembly (4)
1) Set recoil spring assembly (4) to tool L2.
kThe 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}
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.
3) Remove pilot (8), and spring (7).
4) Remove snap ring (10), dust seal (11) and
bush (12) from cylinder (9).
4. Disassembly of yoke piston (5) assembly

1) Remove snap ring (14), then remove Upacking (15).
2) Remove wear ring (16) from yoke piston
(13).
PC128US-2
30-61
(16)
RECOIL SPRING
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).
2. 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).
3) Assemble cylinder (9) and pilot (8) to spring
(7), and set to tool L2.
spring, and tighten nut (6) so that installed
length of spring is dimension "a".
a Installed length "a" of spring : 390 mm
5) Remove recoil spring assembly (4) from tool
L2.
3. Assemble yoke piston assembly (5) to recoil
2 Yoke piston sliding portion wear ring :
Grease (G2-LI)
4. 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.
5. Fill inside of cylinder with a approximately 120 cc
of grease.
2 Inside cylinder : Grease (G2-LI)
30-62
(16)
PC128US-2
IDLER
IDLER
DISASSEMBLY
1. Remove dowel pin (1), then remove support (2).
2. Remove floating seal (3) from support (2) and
idler (4).
3. 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.
4. Remove floating seal (6) (on opposite side) from
idler (4) and shaft (5) and support assembly (7).
5. Remove dowel pin (8), then remove support (7)
from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
PC128US-2
30-63
(16)
IDLER
ASSEMBLY
1. Press fit bushings (9) and (10) to idler (4).
2. Fit O-ring and install support (7) to shaft (5) with

dowel pin (8).
3. 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.
4. Assemble shaft (5) and support assembly (7) to

idler (4).
30-64
(16)
PC128US-2
IDLER
5. Add oil between shaft (5) and idler (4).

5 Oil : 90 105 cc (EO30-CD)
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.
PC128US-2
30-65
(16)
IDLER
7. Install O-ring, then install support (2) with dowel

pin (1).
30-66
(16)
PC128US-2
TRACK ROLLER
TRACK ROLLER
DISASSEMBLY
1. Remove pin (1), then remove collar (2).
5
6
10
4
9
3
1
2
11
CLP00790
2. Remove floating seal (3) from collar (2) and roller

(4).
3. 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.
4. Remove floating seal (6) (on opposite side) from
roller (4) and shaft (5).
PC128US-2
30-67
(16)
TRACK ROLLER
5. Remove collar (8) from shaft (5).

6. Remove bushings (9) and (10) from roller (4).
5
6
8
CLP00791
ASSEMBLY
1. Using push tool [1], press fit bushings (9) and
(10) to roller (4).
2. Assemble collar (8) to shaft (5).
3. 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.
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.
5. Assemble shaft (5) to roller (4).
CLP00793
6. Turn over roller (4) and shaft (5) assembly.

7. 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.
CLP00866
30-68
(16)
PC128US-2
TRACK ROLLER
8. Assemble collar (2) to shaft (5), and install pin

(1).
CLP00867
9. 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.
10. Using tool M2, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil : 75 85 cc (EO30-CD)
PC128US-2
30-69
(16)
TRACK SHOE
TRACK SHOE
REMOVAL
1. Lower work equipment to ground, then loosen
lubricator (1), and relieve track tension.
[*1]
kThe 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.
2. Move machine forward so that position of master

pin is at front of idler, and set block [1] in position.
3. Using tool R, pull out master pin.
[*2]
4. Remove tool R, pull out temporary pin, and

remove dust seal, then drive machine in reverse
to lay out track (2).
[*3]
INSTALLATION
[*1]
[*2]
[*3]
a Adjust the track tension.

Testing and adjusting track tension.
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
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.
30-70
(16)
PC128US-2
HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL
k Gradually loosen the hydraulic tank cap to


1. Drain the hydraulic oil.
6 Hydraulic oil : 100 l (Capacity)

69 l (Oil level)
2. Remove the fuel tank assembly by referring to

"REMOVAL OF FUEL TANK ASSEMBLY".
3. Disconnect the clamp from the swing machinery
oil level gauge pipe.
4. Disconnect inter-oil cooler hose (2) and intercontrol valve hose (3) to disconnect hose clamp
(4).
5.
6.
7.
8.
Disconnect main pump suction hose (5).

Disconnect PPC valve drain hose (6).
Disconnect harness clamp (7).
Disconnect engine oil filter bracket (8).
a Move the filter assembly close to the engine.
a Put the reserve tank on the main pump.
9. Disconnect self pressure reducing valve drain

hose (9), swing motor drain hose (10), boom lock
valve drain hose (11), solenoid valve drain hose
(12), main pump drain hose (13) and travel
motor drain hose (14).
10. Temporarily lift hydraulic tank (15) and remove

the mounting bolt to slowly lift and remove it. [*1]
4 Hydraulic tank assembly : 95 kg
PC128US-2
30-71
(16)
HYDRAULIC TANK
INSTALLATION

removal.
[*1]
2 Thread of hydraulic tank mounting bolt :

3 Hydraulic tank mounting bolt :

277.0 31.9 Nm {28.25 3.25 kgm}

5 Hydraulic tank : 100 l (Capacity)
69 l (Oil level)
Bleeding air
Bleed the air.
Bleeding air from each part.
30-72
(16)
PC128US-2
MAIN PUMP
MAIN PUMP
PC128US-2
PC138US-2
Serial No. : 1001 4500
REMOVAL


69 l (Oil level)

ASSEMBLY".
3. Disconnect hose (1) from the radiator upper tank
to remove bracket (2) from the fuel tank together
with the reserve tank.
a An EPC valve connector is mounted to it.
5. Disconnect PPC main pressure hose (4).
6. Disconnect earth cable (5) from the pump side.
8. Disconnect EPC valve connector (7) (C13).
9. Disconnect suction tube (8) from the pump.
10. Disconnect pump output hose (9).
11. Disconnect pump pressure input hose (10).
13. Disconnect muffler drain tube (12).
14. Remove adiabatic cover (13).
15. Disconnect joint (14) between the turbo charger
and the muffler and remove muffler assembly
(15) by removing the mounting bolt.
16. Drain the oil from the flywheel case.
6 Flywheel case : 0.75 l
17. Temporarily lift the pump to remove the mounting

bolt and lift main pump assembly (16) to remove
it.
[*1]
a Carefully remove it to prevent it from coming
in contact with the engine oil filter.
a It can be removed easier by lifting it at two
points to make it parallel using a lever block.
4 Main pump assembly : 95 kg
PC128US-2
30-73
(16)
MAIN PUMP
MAIN PUMP
PC138US-2
REMOVAL

ASSEMBLY".

69 l (Oil level)
3. Remove cap (40), and then remove reservoir

tank (42) and bracket (41) together.
4. Disconnect connectors C14 (43), C13 (44), and
clip (45).
5. Disconnect drain hose (46) and pump pressure

input hose (47).
6. Disconnect pump spout tube (48) and suction
tube (49).
7. Disconnect LS pressure input hose (50) from A.
8. Remove the mounting bolts and lift off the main

pump (51).
[*1]
4 Main pump assembly : 90 kg
30-74
(16)
PC128US-2
MAIN PUMP
PC128US-2
PC138US-2
INSTALLATION

removal.
[*1]
2 Mating surface of pump case :

Gasket sealant (LG-6)
Refilling with oil (PTO gear case)

a Add engine oil E010-CD through the oil filler
to the specified level.

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.
5 Hydraulic tank : 100 l (Capacity)
69 l (Oil level)
Bleeding air
a Bleed the air from main pump.
PC128US-2
30-75
(16)
CONTROL VALVE
CONTROL VALVE
REMOVAL

stop the engine. Turn on the main switch and
operate the work equipment control levers on
both sides freely to release the PPC pressure,
then turn off the main switch.
1. Drain hydraulic oil.
2. Remove handrail (1), then remove covers (2),

(3), and (4).
3. Disconnect solenoid valve outlet hoses (5) (PPC
main pressure), (6) (2nd travel speed), (7)
(Swing holding brake), and (8) (2nd relief).
4. Disconnect hoses (9) connected to bucket cylinder.

5. Disconnect hoses (10) connected to arm cylinder.
6. Disconnect hoses (11) and (12) connected to
boom cylinder.
7. Disconnect boom lock valve drain hose (13).

8. Disconnect hoses (14) connected to right travel
motor and hoses (15) connected to left travel
motor.
9. Disconnect 2 hoses (16) connected to both
swing motors.
30-76
(16)
PC128US-2
CONTROL VALVE
10. Disconnect hose (17) connected to main pump.

11. Disconnect hose (18) connected to PC-EPC
valve.
12. Disconnect drain hoses (19) and (20).
13. Disconnect hose (21) between main relief valve
and solenoid valve (A2).
14. Disconnect hoses (22) and (23) connected to
main pump (LS valve).
15. Disconnect right PPC hoses (24) (Bucket), (25)
(Arm), (26) (Boom), (27) and (28) (Right and left
travel), and (29) (Swing).
16. Disconnect left PPC hoses (30) (Bucket), (31)
(Arm), (32) (Boom), (33) (Right and left travel),
and (35) (Swing).
17. Disconnect drain hose (36).
18. Sling control valve assembly (38) temporarily
and remove mounting bolts (37).
19. Lift off control valve assembly (38).
4 Control valve assembly

: 85 kg (Standard specification)
:100 kg (Blade specification)
INSTALLATION

removal.

Bleeding air.
Bleed the air from the circuit between the valve
and the hydraulic cylinder.
PC128US-2
30-77
(16)
CONTROL VALVE
CONTROL VALVE
PC128US-2
PC138US-2
Serial No. : 1001 4500
DISASSEMBLY
30-78
(16)
PC128US-2
PC128US-2
CONTROL VALVE
30-79
(16)
30-80
(16)
CONTROL VALVE
PC128US-2
a Pressure is still applied to the safety-suction

valve circuit for a while after the machine is
stopped. Accordingly, loosen pressure releasing
plug (1) gradually to release the internal pressure.
a Do not disassemble the safety-suction valve,
since its pressure cannot be set while it is
installed to the machine.
a The spools and pressure compensation valves
(flow control valve, pressure reducing valve, and
piston) of the valves are not interchangeable with
each other and they must be assembled in their
own directions. Accordingly, be sure to mark
them before removing them.
1. Valve assembly
1) Remove main relief valve assembly (2).
2) Remove safety-suction valve assembly (3).
3) Remove LS select valve assembly (4).
4) Remove 10 suction valve assemblies (5).
5) Remove unload valve assembly (6).
2. Lift check valve and cooler bypass valve
1) Remove case (7), then remove spring (8),
piston (9), and sleeve (10).
2) Remove case (11), then remove spring (12),
piston (13), and sleeve (14).
3. Swing control valve
1) Remove 2 cases (15), then remove 2 springs
(16) and 2 retainers (17).
2) Remove spool assembly (18).
a Do not disassemble the spool assembly.
1) Remove flange (19).
2) Remove plug (20), then remove spring (21)
and spool (22).
3) Remove plug (23), then remove ball (24).
5. Left travel control valve and right travel control valve
CONTROL VALVE
7. Boom control valve

8. Boom hydraulic drift prevention valve
a When disassembling the boom hydraulic drift
prevention valve after removing it from the
valve unit, remove 4 bolts (39) and 2 bolts
(40).
Bolt (41) is used to install plate (42).
a When disassembling the boom hydraulic drift
prevention valve without removing it from the
valve unit, remove 4 bolts (39) and 1 bolt
(41).
1) Remove plate (42), then remove spring (43),
piston (44), spring (45), and valve (46).
2) Remove spring (47), then piston (48).
3) Remove plug (49), then remove sleeve (50).
9. Arm control valve
Remove plug (55), then remove spring (56) and
valve (57).
11. Bucket control valve
12. Service control valve
13. Swing pressure compensation valve
1) Remove plug (66), then remove valve (67)
and spring (68).
2) Remove plug (69), then remove spring (70),
piston (71), and valve (72).
6. Travel interconnection valve

1) Remove 2 plugs (29), then remove 2 springs
(30), 2 retainers (31), and 2 spools (32).
2) Remove 2 plugs (33), then remove 2 balls
(34).
PC128US-2
30-81
(16)
CONTROL VALVE
14. Left travel pressure compensation valve and

right travel pressure compensation valve
1) Loosen plug (73) and remove it together with
valve (74).
2) Loosen plug (75), then remove spring (76)
and valve (77).
15. Boom pressure compensation valve
and spring (80).
2) Remove plug (81), then spring (82), piston
(83), and valve (84).
16. Arm pressure compensation valve
and spring (87).
(90), and valve (91).
17. Bucket pressure compensation valve
and spring (94).
(97), and valve (98).
18. Service pressure compensation valve
and spring (101).
2) Remove valve (102), then spring (103), and
valve (104).
19. Studs for combination (Addition of service
valve)
a When adding a service valve, disassemble
1) Remove 4 nuts (105), then remove 4 studs.
a Remove the studs with a flat-head
screwdriver.
2) Remove cover (106).
30-82
(16)
PC128US-2
CONTROL VALVE
ASSEMBLY
PC128US-2
30-83
(16)
30-84
(16)
CONTROL VALVE
PC128US-2
PC128US-2
CONTROL VALVE
30-85
(16)
a Before assembling the parts, apply engine oil to

their sliding surfaces.
1. Studs for combination (Addition of service
valve)
a When adding a service valve, assemble
1) Tighten 4 studs temporarily.
2) Install service valve assembly.
3) Install cover (106).
4) Install 4 washers and tighten nuts (105).
a Tighten the nuts in the diagonal order
3 Nut :
1st time : 64 4.9 Nm
{6.5 0.5 kgm}
At this time, check that the
height of the stud top is
0.5 3 mm above the nut
top. If it is out of this
range, loosen the nut and
adjust the height of the
stud with a flat-head
screwdriver.
2nd time : 83.36 4.9 Nm
{8.5 0.5 kgm}
3rd time : 105.42 7.4 Nm
{10.75 0.75 kgm}
Check again that the
height of the stud top is
0.5 3 mm above the nut
top.
2. Service pressure compensation valve

1) Install valve (104) and spring (103), then
install valve (102).
3 Valve : 215.6 19.6 Nm {22 2 kgm}
2) Install spring (101) and valve (100), then

install plug (99).
3 Plug : 215.6 19.6 Nm {22 2 kgm}
3. Bucket pressure compensation valve

1) Install valve (98), piston (97), and spring
(96), then install plug (95).
3 Plug : 166.6 19.6Nm {17 2 kgm}
2) Install spring (94) and valve (93), then install

plug (92).
3 Plug : 215.6 19.6 Nm {22 2 kgm}
CONTROL VALVE

plug (85).
3 Plug : 215.6 19.6 Nm {22 2 kgm}
5. Boom pressure compensation valve

3 Plug : 166.6 19.6 Nm {17 2 kgm}

plug (78).
3 Plug : 215.6 19.6 Nm {22 2 kgm}
6. Right travel pressure compensation valve

and left travel pressure compensation valve
1) Install valve (77) and spring (76), then install
plug (75).
3 Plug : 166.6 19.6 Nm {17 2 kgm}
2) Install valve (74) and plug (73) as one unit.
3 Plug : 107.8 9.8 Nm {11 1 kgm}
7. Swing pressure compensation valve

3 Plug : 166.6 19.6 Nm {17 2 kgm}

plug (66).
3 Plug : 215.6 19.6 Nm {22 2 kgm}
8. Service control valve

1) Install spool assembly (65).
2) Install 2 retainers (64) and 2 springs (63),
then install 2 cases (62).
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
9. Bucket control valve

3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}

Install valve (57) and spring (56), then install plug
(55).
4. Arm pressure compensation valve

3 Plug : 166.6 19.6 Nm {17 2 kgm}
30-86
(16)
PC128US-2
CONTROL VALVE
11. Arm control valve

17. Swing control valve

12. Boom hydraulic drift prevention valve

1) Install sleeve (50), then install plug (49).
2) Install piston (48), then install spring (47).
3) Install valve (46), spring (45), piston (44),
and spring (43), then install plate (42).
18. Cooler bypass valve and lift check valve

1) Install sleeve (14), piston (13), and spring
(12), then install case (11).
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
3 Mounting bolts (39), (40) :

30.9 3.4 Nm {3.15 0.35 kgm}
Mounting bolt (41) :
13.2 1.5 Nm {1.35 0.15 kgm}
13. Boom control valve

3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
14. Travel interconnection valve

1) Install 2 balls (34), then install 2 plugs (33).
3 Plug : 7.4 1.5 Nm {0.75 0.15 kgm}
2) Install 2 spools (32), 2 retainers (31), and 2

springs (30), then install 2 plugs (29).
3 Plug : 55.9 6.9 Nm {5.7 0.7 kgm}
15. Right travel control valve and left travel control valve
1) Install spool (28).
2) Install 2 retainers (27), 2 springs (26), then
install 2 cases (25).
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
3 Mounting bolt :
30.9 3.4 Nm {3.15 0.35 kgm}
2) Install sleeve (10), piston (9), and spring (8),

then install case (7).
3 Mounting bolt :
30.9 3.4 Nm {3.15 0.35 kgm}
19. Valve assembly

1) Install unload valve assembly (6).
3 Unload valve assembly :

166.6 19.6 Nm {17 2 kgm}
2) Install 10 suction valve assemblies (5).
3 Suction valve assembly :

147 9.8 Nm {15 1 kgm}
3) Install LS select valve assembly (4).
3 LS select valve assembly:

127.4 19.6 Nm {13 2 kgm}
4) Install safety-suction valve assembly (3).
3 Safety-suction valve assembly :

186.2 9.8 Nm {19 1 kgm}
5) Install main relief valve assembly (2).
3 Main relief valve assembly :

98 9.8 Nm {10 1 kgm}

1) Install ball (24), then install plug (23).
3 Plug :
7.35 1.5 Nm {0.75 0.15 kgm}
2) Install spool (22) and spring (21), then install

plug (20).
3 Plug : 29.4 4.9 Nm {3 0.5 kgm}
3) Install flange (19).
3 Mounting bolt :
13.2 1.5 Nm {1.35 0.15 kgm}
PC128US-2
30-87
(16)
CONTROL VALVE
CONTROL VALVE
PC138US-2
ASSEMBLY
30-88
(16)
PC128US-2
a In this section, only the precautions for assembling the control valve assembly are described.
Before assembling the parts, apply engine oil to

2 Mating face:
Liquid sealant (Sealend 242 or equivalent)
a The tightening torque of the parts and the precautions are shown below (in random order).
T (Install cover (1)):

Tighten the nuts in the diagonal order according
to the following procedure.
1st time :
3 58.8 68.6 Nm {6 7 kgm}
CONTROL VALVE
a When loosening and tightening plug T1-5L, be

sure to keep the spool in the valve chamber.
3 T1-5L:14.7 19.6 Nm {1.5 2 kgm}
See LOCTITE shown below.
3 T1-2L: 11.8 14.7 Nm {1.2 1.5 kgm}

See LOCTITE shown below.
2 T1-2L, T1-5L:
Apply 1 drop (about 0.02 g) of
LOCTITE No. 638 to each of the
points shown below.
a Degrease and dry up the threads of the plugs
and female screws in advance. Do not apply
pressure for 2 hours after tightening them.
2nd time :
3 78.5 88.3 Nm {8 9 kgm}
3rd time :
3 98.1 113 Nm {10 11.5 kgm}
a The height of the stud top above the nut top:
0.5 3 mm
3 T1-2 : 11.8 14.7 Nm {1.2 1.5 kgm}
3 T2-8 : 27.5 34.3 Nm {2.8 3.5 kgm}
3 T2
: 19.6 27.5 Nm {2 2.8 kgm}
3 T5
: 49 63.7 Nm {5 6.5 kgm}
3 T3-5 : 34 44 Nm {3.5 4.5 kgm}
3 T6
3 T9
: 59 78 Nm {6 8 kgm}
: 88.3 107.9 Nm {9 11 kgm}
3 T10 : 98.1 123 Nm {10 12.5 kgm}
3 T11 : 108 147 Nm {11 15 kgm}
3 T14 : 137 157 Nm {14 16 kgm}
3 T15 : 147 186 Nm {15 19 kgm}
3 T18 : 176.6 196.2 Nm {18 20 kgm}
3 T20 : 196 240 Nm {20 24.5 kgm}
PC128US-2
30-89
(16)
30-90
(16)
CONTROL VALVE
PC128US-2
PC128US-2
CONTROL VALVE
30-91
(16)
LS SELECTION VALVE
LS SELECTION VALVE
DISASSEMBLY
1. Remove valve (2) from sleeve (1).

2. Remove O-rings (4) and (5), and seal (6) from
sleeve (1).
3. Remove plug (7), then remove pistons (8) and
(9), and spring (10).
4. Remove O-ring (11) from plug (7), then remove
seal (12) and O-ring (13) from piston (9).
a After disassembling, if there is any abnormality in any part except O-rings (4), (5), (11), or
seal (6), replace the whole LS select valve
assembly.
ASSEMBLY
a Before assembling coat the sliding surface with
engine oil.
1. Install O-ring (13) and seal (12) to piston (9),
then assemble piston (8) and spring (10), and
install in sleeve (1).
2. Assemble O-ring (11) to plug (7) and install to
sleeve (1).
3 Plug : 68.6 9.8 Nm {7 1 kgm}
3. Install valve (2) to sleeve (1).

4. Install O-rings (4) and (5), and seal (6) to sleeve
(1).
30-92
(16)
PC128US-2

DISASSEMBLY
Pressure compensation valve A : Bucket (Dump, Curl)
B : Arm (Out, In)
C : Boom (Raise, Lower)
D : Travel (Forward, Reverse)
E : Swing (Left, Right)
30-94
(16)
PC128US-2
Disassembly of pressure compensation valves

A, B, C, D, and E
Some parts of different part Nos. may have

shapes similar to each other. Take care when
assembling them.
1. A (Bucket)
2) Remove plug (5), then pull out valve (6) and
remove spring (7) from it.
2. B (Arm)
2) Remove plug (12), then pull out valve (13)
and remove spring (14) from it.
3. C (Boom)
4. D (Travel)
1) Remove plug (22), then remove spring (23)
and valve (24).
2) Remove plug (25), then remove bolt (26) and
washer together.
3) Remove sleeve (27), then remove spring
(28) and valve (29).
5. E (Swing)
(32), and valve (33).
PC128US-2
30-95
(16)
ASSEMBLY
Pressure compensation valve A : Bucket (Dump, Curl)
B : Arm (Out, In)
C : Boom (Raise, Lower)
D : Travel (Forward, Reverse)
E : Swing (Left, Right)
30-96
(16)
PC128US-2
Assembly of pressure compensation valves A, B,

C, D, and E
a Tightening torque of plug, bolt, and sleeve
3 Plugs 1, 8, 12, 15, 22, 30 :
147.0 186.0 Nm {15.0 19.0 kgm}
5. E (Swing)
1) Fit spring (36) to valve (35) and insert them
in valve body, then install O-ring and plug
(34).
2) Install piston (32) and spring (31) to valve (33)
and insert them in valve body, then install Oring and plug (30).
3 Plug 25 :
98.1 123.0 Nm {10.0 12.5 kgm}
3 Plugs 5, 19, 34 :
196.0 240.0 Nm {20.0 24.5 kgm}
3 Bolt 26 :
11.8 14.7 Nm {1.2 1.5 kgm}
3 Sleeve 27 :
147.0 186.0 Nm {15.0 19.0 kgm}
1. A (Bucket)
1) Fit spring (7) to valve (6) and insert them in
valve body, then install O-ring and plug (5).
2. B (Arm)
(12).
3. C (Boom)
(19).
2) Install piston (17) and spring (16) to valve
(18) and insert them in valve body, then
install O-ring and plug (15).
4. D (Travel)
1) Install spring (28) and valve (29) to sleeve
(27) and insert them in valve body and fix
them with washer and bolt (26), then install
O-ring and plug (25) to sleeve (27).
(22).
PC128US-2
30-97
(16)
MAIN RELIEF VALVE
MAIN RELIEF VALVE

DISASSEMBLY
1. Remove ring (1) to remove valve (2) and spring

(3).
2. Loosen nut (4) to remove plug (5) and remove Oring (6) from plug (5).
3. Loosen nut (7) to remove holder (8) and remove
retainer (9), O-ring (10) and nut (7) from holder
(8).
4. Remove spring (12) and puppet (13) from sleeve
(11) and remove seat (14).
5. Remove ring (15) and O-ring (16) from seat (14).
6. Remove O-ring (17), seal (18), and O-ring (19)
from sleeve (11).
a If any abnormality is detected on valve (2),
holder (8), retainer (9), seat (14), ring (15),
O-ring (16) or sleeve (11), replace the entire
main relief valve assembly.
30-98
(16)
PC128US-2
MAIN RELIEF VALVE
ASSEMBLY
1. Fit O-ring (16) and ring (15) to seat (14), then
install sleeve (11).
2. Install nut (7) and O-ring (10) to holder (8), then
assemble and install retainer (9), puppet (13),
and spring (12) to sleeves (1) and (2).
a Set contact surfaces of seat (14) and puppet
(13) securely.
3. Fit O-ring (6) to plug (5), then install them to
holder (8).
4. Install spring (3) and valve (2) to sleeve (11),
then fit ring (1).
5. Fit O-rings (19) and (17) and seal (18) to sleeve
(11).
6. Tighten nut (7) to specified torque.
3 Nut : 58.8 4.9 Nm {6 0.5 kgm}
7. Tighten nut (4) to specified torque.
3 Nut : 44.1 4.9 Nm {4.5 0.5 kgm}
a After install the main relief valve assembly to the

control valve assembly, adjust the pressure. For
details, see TESTING AND ADJUSTING, Testing
and adjusting hydraulic pressure in work equipment, swing, and travel circuits.
PC128US-2
30-99
(16)
WORK EQUIPMENT PPC

VALVE
(FOR BOOM, BUCKET, ARM,
SWING CONTROL)
PC128US-2
PC138US-2
Serial No. : 1001 4500
DISASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(4).
2. Remove bolts, then remove plate (5).
a Do not remove joint (3) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),
springs (10) and (11), and shim (12).
a Spring (10), (11) 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.
5. Pull out valve (13) from body (14).
30-100
(16)
PC128US-2
ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve
(13).
a When assembling spring (11), set the end
with the small coil diameter (inside diameter)
at shim (12) end.
3. Assemble spring (10), retainer (9), and piston
(8).
a The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Position of port
Free length of spring
P1, P2
44.4mm
P3, P4
42.4mm
a The position of each port is marked on the

bottom of the valve body.
2 Piston : Grease (G2-LI)
a When assembling the piston, coat the outside of the piston and the inside of the hole in
the body with grease.
4. Fit O-ring to collar (7) and assemble in body (14),
then install seal (6).
5. Install plate (5).
3 Mounting bolt :
13.23 1.47 Nm {1.35 0.15 kgm}
6. Install joint (3).
2 Sliding portion of joint : Grease (G2-LI)
2 Female thread of body :

a Coat two places on the female thread (A)

with one drop each of Loctite as shown in the
diagram below.
3 Joint : 44.1 4.9 Nm {4.5 0.5 kgm}
a Keep strictly to the tightening torque.
7. Assemble boot (4) and disc (2), and tighten with
nut (1).
3 Nut : 112.7 14.7 Nm {11.5 1.5 kgm}
a After assembling the disc, adjust the height of

the disc.
Adjusting PPC valve.
PC128US-2
30-101
(16)
WORK EQUIPMENT PPC

VALVE
(FOR BOOM, BUCKET, ARM,
SWING CONTROL)
PC138US-2
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.
1. 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}
2. The head of plug (3) must not be projected from

the body surface.
3 Plug (3) : 6 11 Nm {0.6 1.1 kgm}
3. When installing piston (8), apply grease (G2-LI)

to its outside and the inside of the body hole.
4. Install spring (5) with its small diameter side on
the shim (4) side.
Diameter of spring (Inside diameter)
Small diameter side: 4.9, Large diameter
side: 5.4
5. When installing springs (6) and (7), note that
they are different and they must be installed to
different hydraulic ports.
Installed height: 34 mm (Common to both
springs)
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}
30-102
(16)
PC128US-2
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}

7. Install nut (11).
2 Apply 1 drop (about 0.02 g) of LOCTITE

No. 641 to each of the points shown
below.
8. 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
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 degrees)
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}
PC128US-2
30-103
(16)
TRAVEL PPC VALVE
TRAVEL PPC VALVE

PC128US-2
PC138US-2
Serial No. : 1001 4500
DISASSEMBLY
4
1. Remove screw (1) to remove lever (2).
2. Remove mounting bolt (3) to remove case shaft

assembly (4).
3. Remove mounting bolt (5) to remove plate (6)
together with damper assembly (7).
a Check the thickness and the mounting position of washer (18).
5
18
1
4. Remove mounting bolt (8) to remove damper

assembly (7) from plate (6).
5. Remove seal (9) and collar (10).
10
6. Remove piston (11) to remove retainer (12),

springs (13) and (14) and shim (15).
a Store shim (15) after checking the thickness
and the number of shims at each mounting
position.
11
7
12
8
13
7. Remove valve (16) from body (17).
14
15
16
17
CEP00533
Details of body (17)
30-104
(16)
PC128US-2
TRAVEL PPC VALVE
ASSEMBLY
1. Engage valve (16) with body (17).
2. Engage shim (15) and spring (14) with valve

(16).
a Mount shim (15) on the position which has
been checked at the time of disassembly
with the proper thickness and number.
Standard shim thickness : 0.3mm
a Since spring (14) is not symmetric vertically ,
engage it with the smaller diameter side facing the shim.
4
2
5
18
3. Mount spring (13), retainer (12) and piston (11).
2 Piston outside perimeter and body hole :

Grease (G2-LI)
6
9
4. Place the O-ring on collar (10) to engage them

with body (17) and mount seal (9) on them.
10
5. Mount damper assembly (7) on plate (6) and

tighten mounting bolt (8).
11
2 Mounting bolt : Adhesive (LT-2)
3 Mounting bolt :
4.4 0.5 Nm {0.45 0.05 kgm}
6. Plate (6) together with damper assembly (7) and
tighten mounting bolt (5).
a Engage washer (18) with a standard washer
(1.6 mm) beforehand.
After completing assembly, measure the difference in the angles when the left and right
levers are at full strokes. If it is larger than
0.7, change the thickness of the washer
(18) to make it 0.7 or less.
Washer thickness : 1.0, 1.3 or 1.6 mm
a Reducing the washer thickness by 0.3
mm increases the full stroke angle by
0.39.
12
8
13
14
15
16
17
CEP00533
3 Mounting bolt :
31.0 3.4 Nm {3.15 0.35 kgm}
7. Mount case shaft assembly (4) and tighten

mounting bolt (3).
2 Shaft swaying part, and lever and piston

contacting part : Grease (G2-LI)
3 Mounting bolt :
28.0 3.4 Nm {2.85 0.35 kgm}
8. Mount lever (2) and tighten screw (1).
2 Lever pin and plate swaying part :

Grease (G2-LI)
3 Screw : 8.8 1.0 Nm {0.9 0.1 kgm}
PC128US-2
30-105
(16)
TRAVEL PPC VALVE
TRAVEL PPC VALVE

PC138US-2
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.
1. When installing piston (1), apply grease (G2-LI)
to its outside and the inside of the body hole.
2. Install spring (2) with its small diameter side on
the shim (3) side.
Diameter of spring (Inside diameter)
Small diameter side: 4.9, Large diameter
side: 5.55
3. Use the insertion jig to insert bushing (4). (Do
not drive in the bushing with impact loads of a
hammer, etc.)
4. Use the insertion jig to insert pin (5). (Do not drive
in the pin with impact loads of a hammer, etc.)
5. 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
6. Install plate (8) with the cut part on the outside of

the PPC assembly.
7. 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.)
Thickness of washer t: 1.0, 1.3, 1.6
8. Tighten each part to the following torque.
Plug (11): 6 11 Nm {0.6 1.1 kgm}
Bolt (12): 3.9 4.9 Nm {0.4 0.5 kgm}
(Apply LOCTITE #262.)
Screw (13): 7.8 9.8 Nm {0.8 1.0 kgm}
Plug (14): 4 9 Nm {0.4 0.9 kgm}
Bolt (15): 25 30 Nm {2.5 3.2 kgm}
Bolt (16): 27 34 Nm {2.8 3.5 kgm}
30-106
(16)
PC128US-2
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
DISASSEMBLY
a 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".
1. 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.
i) Set piston rod assembly (2) on tool U1.
ii) Remove piston assembly lock screw (3).

Screw size
M12 x 1.75 pitch : Boom, arm and blade
M10 x 1.5 pitch : Bucket
a If screw (3) is caulked too tightly to be

removed, force the screw in once and
then tap it to remove it.
PC128US-2
30-107
(16)
HYDRAULIC CYLINDER
iii) Use tool U2 to remove piston assembly

(4).
If tool U2 is not used, use the four
drill holes (diameter = 10) to loosen
the piston assembly.
iv) Remove plunger (5).
Arm cylinder and boom cylinder.
v) Remove collar (6).
vi) Remove the head assembly (7).
vii) Remove cap (8) to remove eleven balls

(9) and cushion plunger (10).
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. 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).
30-108
(16)
PC128US-2
HYDRAULIC CYLINDER
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).
PC128US-2
30-109
(16)
HYDRAULIC CYLINDER
ASSEMBLY
a Be careful not to damage the packing, the dust
seal, the O-ring or the like
a Do not forcibly insert the backup ring but make it
warm with hot water (50 to 60C) before insertion.
1. 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).
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.
3) Mount the backup ring and O-ring (14).

4) Engage wear ring (12).
5) Engage ring (11).
a Be careful not to expand the ring abutment joint too much.
2 Ring groove : Grease (G2-LI)
30-110
(16)
PC128US-2
HYDRAULIC CYLINDER
3. Piston rod assembly

1) Set piston rod assembly (2) on tool U1.
2) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (6), and
assemble.
4) Assemble plunger (5).
a Check that there is a small amount of
play at the tip of the plunger.
5) Set cushion plunger (10) on the piston rod

and engage 11 balls (9) and fix them using
cap (8).
6) Assemble piston assembly (4) in the following procedure.
When the rod and piston assembly (2)
are reused
a Completely wash them and clear
them of cut powder or dust.
i) 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.
ii) 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}
PC128US-2
30-111
(16)
HYDRAULIC CYLINDER
iii) Caulk the screw at two points through

punching.
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.
i)
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 After tightening the piston, make sure
that there is some play with plunger.
For the boom and arm cylinders only.
ii) 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).
Screw processing dimensions (mm)
Tap drill Tap drill
Tap used
diameter depth
Cylinder
Tap
depth
Boom, arm
and blade
10.3
27
121.75
20
Bucket
8.5
27
101.5
20
iii) Clear it of cut powder and dust and completely wash it after processing.
iv) 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}
v) Caulk the screw at four points through
punching.
30-112
(16)
PC128US-2
HYDRAULIC CYLINDER
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
Tightening torque
Bucket
17225 Nm {17.52.5 kgm}
Arm
27039 Nm {27.54.0 kgm}
Boom
17225 Nm {17.52.5 kgm}
Blade
27039 Nm {27.54.0 kgm}
9) Mount the piping.
PC128US-2
30-113
(16)
WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL
k Fully extend the work equipment and set a

block at the arm end and lower the bucket tip to
the ground.
1. Remove handrail (1), then remove covers (2),
(3), and (4).
2. Remove undercovers (5) and (6) from boom
mounting section.
3. Disconnect working lamp wiring connector (7)
(M10).
4. Remove guard (8).
5. 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.
6. Disconnect grease tube (13).

7. Remove lock bolt (14).
[*1]
8. 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.
9. 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.
10. Remove plug (17) from boom foot pin (19).
11. Remove mounting bolts to remove lock plate
(18).
12. Set tool V to boom foot pin (19).
30-114
(16)
PC128US-2
WORK EQUIPMENT
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
INSTALLATION
[*1]
[*2]

removal.
a When tightening the locknut, tighten so that
the clearance a between the plate and nut is
0.5 1.5 mm.
2 Inside surface of bushing when assembling pin :
Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :
Grease (LM-G)
kWhen 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
[*3]
2 Inside surface of bushing when assembling pin :

Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :

Grease (LM-G)
kWhen 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.
Bleeding air from hydraulic cylinder.

system. Then add oil to the specified level.
PC128US-2
30-115
(16)
OPERATORS CAB
OPERATORS CAB
PC128US-2
Serial No. : 5001 7299
PC138US-2
Serial No. : 1001 2599
PC138USLC-2 Serial No. :
REMOVAL

1. Remove louver (1).
2. Remove four screws to remove airconditioner
switch panel (2).
3. Remove screw (3) to slide duct (4) forward.
4. Disconnect airconditioner connectors (M12 and
M31) (5) and (6) to remove duct (4).
5. Disconnect wiper motor connector (CN-75) (7).
6. Disconnect window washer hose (8).
a Bend it to prevent detergent liquid from flowing out of the washer tank.
7. Disconnect radio connector (9)(B3).
8. Remove controller housing panel cover (10).
9. Remove 3 mounting bolts (11) and remove panel

assembly (12) from operators cab, then shift it to
rear of operators cab.
30-116
(16)
PC128US-2
OPERATORS CAB
10. Remove the mounting bolt and lift operator cab

assembly (13) to remove it.
4 Operator cab assembly : 240 kg
INSTALLATION

removal.
PC128US-2
30-117
(16)
OPERATOR'S CAB
OPERATORS CAB
PC128US-2
PC138US-2
Serial No. : 2601 4500
REMOVAL
k When removing the floor frame together, swing

to the left by 135 degrees. (See REMOVAL OF
FLOOR FRAME ASSEMBLY.).
k Remove the negative (-) terminal from the battery before setting to work.
1. Remove covers (1) (4) on the monitor panel.
a Be sure to remove in the order of (1), (2), (3),
(4). Otherwise, the covers may not be
removed.
a When removing cover (2), disconnect cigarette lighter connector (CN-M40).
2. Remove cover (5) at the lower front of the operator seat and remove ducts (6), (7), (8).
3. Remove covers (9), (10), (11) and (12) at the

rear in the operator cab.
4. Loosen four mounting bolts on the bracket

mounting CR700 controller (13) and move the
controller forward (toward the operator).
30-118
(16)
PC128US-2
OPERATOR'S CAB
5. Remove cover (14) and disconnect connectors

(CN-A20)(15), (CN-A21)(16), (CN-A22)(17), and
(CN-M87)(18) at the rear in the operator cab.
6. Remove ducts (19), (20), (21).
7. Disconnect connectors (CN-H08)(22) and (CNH09)(23) at the rear left in the operator cab.
8. Disconnect intake duct switching connector (CNM83)(25) and remove duct (26).
a Lift the duct (25) to remove.
PC128US-2
30-119
(16)
OPERATOR'S CAB
9. Remove six mounting bolts (8) (marked with )

and four nuts (7)(marked with #).
[*1]
a Tighten the nuts (7) together with the floor
frame.
10. Lift and remove the operator cab assembly (29).

4 Operator cab assembly: 280 kg
INSTALLATION
Carry out installation in reverse oder to removal.
30-120
(16)
PC128US-2
OPERATOR'S CAB
OPERATORS CAB
PC138US-2
REMOVAL
a When removing the floor frame together, swing
to the left by 135 degrees. (See REMOVAL OF
FLOOR FRAME ASSEMBLY.)
1. Remove the floor mat.
3. Loosen right console (2) and move it inward.
a There is the cigarette lighter, M40.
5. Lower duct joint A, remove connector M88 (4),
and then remove duct (5).
6. Remove covers (6), (7), (8), (9), and (10).
7. Remove ducts (11) and (12).

9. Disconnect connectors A20 (14), A21 (15), and
M87 (16).
10. Remove duct (17).
12. Remove the mounting bolts of controller (19) and
place controller (19) on the floor.
PC128US-2
30-121
(16)
OPERATOR'S CAB
13. Disconnect connector (20).

14. Remove the 2 mounting bolts and duct (21).
15. Disconnect connector R19 (22).
16. Disconnect connector H09 (23), H08 (24), and
V02 (25).
17. Disconnect antenna connector (26).
18. Remove duct hose (27).

19. Disconnect connectors V06 (28) and V09 (29)
from the clip.
20. Disconnect connector V01 (30) (secured with a
screw), (31) (press the hook to disconnect), and
(32) (turn it to disconnect) from KOMTRAX (33).
21. Disconnect wiring harness (34) from the operator's cab.
22. Take out grommet (35) from the right front of the
cab and disconnect windshield washer hose
from (36).
23. Remove 4 mounting bolts (37) and 6 mounting
bolts (38).
24. Lift off operator's cab assembly (39).
4 Operator's cab assembly: 280 kg
INSTALLATION
Carry out installation in reverse order to

removed.
30-122
(16)
PC128US-2
OPERATORS 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.
PC128US-2
(1):
(2):
(3):
(4):
(5):
(6):
Right side window glass

Left side rear window glass
Door upper window glass
Door lower window glass
Front window glass
Front window assembly
(Front window glass + Front frame)
( 7 ) : Both-sided adhesive tape
(16) : Center trim seal
30-123
(16)
1 793-498-1210
2 20Y-54-13180 Adapter
Sketch
Lifter
t
(Suction cup)
Part name
New/Removal
Qty
Part No.
Necessity
Symbol
SPECIAL TOOLS
REMOVAL
a Remove the window glass to be replaced accoring to the following procedure.
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operators cab
(metal sheet) (8).
a 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.)
a If the window glass is broken finaly, it may be
removed with knife [4] and a screwdriver.
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape with
knife [4].
loader.)
2. Remove the window glass.
30-124
(16)
PC128US-2
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 surfaces. (If the
painted surfaces are scratched, adhesion will
be lowered.)
loader.)
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.
PC128US-2
30-125
(16)
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. (Discard the
primer 24 hours after it is 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.
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 Parts to be coated with primer: Apply the

primer all over dimension (a).
Dimension to apply primer (a): 25 mm
30-126
(16)
PC128US-2
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.
Part (b)
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wring primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
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.)
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).
a Do not apply the primer to the boarder
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutues (within 8 hours) to dry.
a Never apply wring the primer. If the
glass primer is applied by mistake, wipe
it off with white gasoline.
PC128US-2
30-127
(16)
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 bothsided 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.
a 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.
1) Stick both-sided adhesive tape (7) for right
side window glass (1) as shown in the figure.
a 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
2) Stick both-sided adhesive tape (7) for left

side rear window glass (2) as shown in the
figure.
30-128
(16)
PC128US-2
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.)
(The figure shows the door lower window

glass.)
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
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).
PC128US-2
30-129
(16)
5. 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 operators cab before
installing the window glass.
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.
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.
30-130
(16)
PC128US-2
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.
Dimension (q) : 10 mm
Dimension (r) : 15 mm
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
4) Remove the release tape of the both-sided

adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of bothsided adhesive tape (7) of the operators
cab.
PC128US-2
30-131
(16)
a Apply adhesive (15) to dimensions s and

t of both-sided adhesive tape (7) of operators cab (8).
Dimension (s) : 10 mm
Dimension (t) : 15 mm
a Apply adhesive (15) higher than bothsided adhesive tape (7).
a Apply the adhesive evenly.
a As for the right side window glass, apply

the adhesive to the outside of the bothsided adhesive tape on the periphery of
the glass.
7. 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.)
30-132
(16)
PC128US-2
a After installing front window glass (5),

install the center trim seal to its bottom.
Then, apply caulking material all around
the glass to fill part 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
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.)
PC128US-2
30-133
(16)
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and bothsided adhesive tape of fit them completely.
9. 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.
30-134
(16)
PC128US-2
FRONT WINDOW
FRONT WINDOW ASSEMBLY

stop the engine.
a 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]
2. Remove left lower block (1) and right lower block
(2).
[*2]
3. Reset the lock at the rear of the cab.
4. 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).
5. 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

removal.
PC128US-2
30-135
(16)
FLOOR FRAME
FLOOR FRAME
PC128US-2
Serial No. : 5001 7300
PC138US-2
Serial No. : 1001 2600
REMOVAL

1. Remove operators cab.
(See REMOVAL OF OPERATORS CAB)
2. Remove left side cover (1).
3. Disconnect wiring connectors (2) (CN1), (3)
(CN2), (4) (CN4), and (5) (CN3).
4. Disconnect ground cable (6).
5. Remove handrail (7).

7. Disconnect PPC hoses (10) (Bucket dump, arm
out, boom raise, bucket tilt from above).
8. Disconnect PPC hoses (11) (Arm tilt, boom
lower, right swing, and left swing from above).
a If the color tapes are broken and cannot be
judged correctly, put tags, etc. for correct
judgment.
9. Disconnect PPC hoses (12) and (13) for travel

(Right).
10. Disconnect PPC hoses (14) and (15) for travel
(Left).
30-136
(19)
PC128US-2
FLOOR FRAME
11. Disconnect PPC main pressure hose (16) (A1).

12. Disconnect PPC drain hose (17).
a Drain hydraulic oil
13. Lift off floor frame assembly (18).

a Take care not to damage the PPC hoses.
4 Floor frame assembly : 65 kg
INSTALLATION

removal.
Refilling with oil

Run the engine, then check the oil level again.
PC128US-2
30-137
(19)
FLOOR FRAME
FLOOR FRAME
PC138US-2 Serial No. : 2601 4500
a Swing the upper structure to the left by 135
degrees. (For step 7)
REMOVAL
1. Drain coolant
6 Coolant: 17.2 l
2. Collect air conditioner gas (R134a) from air conditioner circuit.

3. Remove the operator cab assembly by referring
to the "OPERATORS CAB ASSEMBLY
[REMOVAL]" section.
4. Remove the side cover (1).
5. Disconnect connectors (1)A01, (2)A03, (3)A04,
(4)A07, (5)A02, (6)A05, (7)A08 , (8)A010 ,and
earth wire(9) and remove tool tray (10).
6. Remove heater hose (11).
7. Remove undercover and disconnect PPC hoses

(12) (P port) and (13) (T port), and four travel
PPC valve hoses (14).
a Four travelling PPC valve hoses may be
removed on the control valve side.
30-138
(19)
PC128US-2
FLOOR FRAME
8. Remove upper cover (15) which covers the control valves.

9. Separate eight work equipment and swing PPC
valve hoses (16).
a The PPC hoses are identified by the following markings in the order from the top:
For bucket CURL: Red
For boom LOWER: Black
For left swing: White
For arm IN: Green
For bucket DUMP: Red
For boom RAISE: Yellow
For right swing: Brown
For arm OUT: Orange
10. Remove the clamp (17) at the right front of the
revolving frame.
11. Remove the cover from under the seat and disconnect air conditioner tubes (18) and (19) from
the air conditioner unit.
[*1]
12. Lift and remove floor frame assembly (20).

4 Floor frame assembly: 270 kg
INSTALLATION
[*1]
3 Air conditioner tube nut:

11.8 14.7 Nm {1.2 1.5 kgm}
Filling air conditioning gas

Hydraulic oil
Start the engine, fill the pipings with hydraulic oil,
and refill to the specified level.
Coolant supply
Feed coolant from the filling port to the specified
level. Recheck the level after starting the engine
and circulating coolant.
PC128US-2
30-139
(19)
FLOOR FRAME
FLOOR FRAME
PC138US-2
a Swing the upper structure to the left by 135
degrees. (For step 9)
REMOVAL
1. Drain coolant
6 Coolant: 13.2 l
2. Collect air conditioner gas (134a) from air conditioner circuit.

3. Remove the operator cab assembly by referring
to the "OPERATORS CAB ASSEMBLY
[REMOVAL]" section.
4. Remove the side cover (1) and front cover (2).
5. Disconnect connectors (3)A01, (4)A02, (5)A03

and remove from a clip.
6. Disconnect hone connector (6) M18 and earth

wire (7)
7. Remove tool tray.
30-140
(19)
PC128US-2
FLOOR FRAME
8. Disconnect 2 heater hoses (11), upper and lower

ones, from under the rear part of the seat.
9. Remove undercover and disconnect PPC hoses

(12) (P port: Blue and White) and (13)(T port:
Red and Green), and four travel PPC valve
hoses (14).
(From the top: Yellow and Black, Yellow and
Green, Yellow and Orange, Yellow and Brown)
a Four travelling PPC valve hoses may be
removed on the control valve side.
10. Remove upper cover (15) which covers the control valves.
11. Separate eight work equipment and swing PPC
valve hoses (16).
a The PPC hoses are identified by the following markings in the order from the top:
For bucket CURL: Red
For boom LOWER: Black
For left swing: White
For arm IN: Green
For bucket DUMP: Red
For boom RAISE: Yellow
For right swing: Brown
For arm OUT: Orange
12. Remove the clamp (17) at the right front of the
revolving frame.
PC128US-2
30-141
(16)
FLOOR FRAME
13. Remove the cover from under the seat and disconnect air conditioner tubes (18) and (19) from
the air conditioner unit.
[*1]
14. Lift and remove floor frame assembly (20).

4 Floor frame assembly: 270 kg
INSTALLATION
Carry out installation in reverse order to removal.
[*1]

11.8 14.7 Nm {1.2 1.5 kgm}
Filling air conditioning gas

Hydraulic oil
Start the engine, fill the pipings with hydraulic oil,
and refill to the specified level.
Coolant supply
Feed coolant from the filling port to the specified
level. Recheck the level after starting the engine
and circulating coolant.
30-142
(19)
PC128US-2
AIR CONDITIONER
COMPRESSOR
PC128US-2 Serial No. : 5001 7299
PC138US-2 Serial No. : 1001 2599
REMOVAL

2. Open cover (1).
4. Disconnect hoses (3) and (4).
a Plug the hoses and compressor to prevent
dust, water, etc. from entering them.
5. Disconnect wiring connector (5) (M34).

6. Loosen belt tension adjustment bolt (6) and
mounting bolt (7) to remove drive belt (8).
7. Remove bolts (6) and (7) to remove air conditioner compressor assembly (9).
INSTALLATION

removal.
Filling air-conditioning gas

PC128US-2
30-143
(19)
AIR CONDITIONER
COMPRESSOR
PC128US-2
PC138US-2
REMOVAL
k Lower the work equipment to the ground completely.
k Remove the negative (-) terminal from the battery.

2. Open the cover (1).
3. Remove bolt (2) and Loosen bolt (4) and remove
cover (3).
4. Separate hoses (5) and (7) by loosening bolt (6).
a Put blind caps to prevent the entry of dirt or
water into hoses and compressor.
5. Disconnect wire and connector (8)(M34).
6. Loosen mounting bolt (9), lock nut (11), and bolt
(12) to remove air compressor belt .
7. Remove the bolts (4) and (9) and reomve the air
compressor assembly (13).
a PC128US-2
PC138US-2
INSTALLATION
Carry out installation in reverse oder to reomval.
Filling new chlorofluorocarbon

30-144
(19)
PC128US-2
AIR CONDITIONER CONDENSER
AIR CONDITIONER
CONDENSER
PC128US-2 Serial No. : 5001 7299
PC138US-2 Serial No. : 1001 2599
REMOVAL

1. Remove counterweight assembly. For details, see
REMOVAL OF COUNTERWEIGHT ASSEMBLY.
4. Remove air cleaner assembly (3).
5. Disconnect battery relay (4) from bracket.
a Shift the disconnected battery relay forward.
6. Disconnect hose (5) connected to air conditioner
compressor and hose (6) connected to receiver
tank.
a When disconnecting these hoses, be sure to
use two spanners.
7. Remove mounting bolts to remove air conditioner
compressor (7).
a Since the fins are soft, take care when
removing the air conditioner compressor.
INSTALLATION

removal.

PC128US-2
30-145
(19)
AIR CONDITIONER CONDENSER
AIR CONDITIONER
CONDENSER
REMOVAL
k Lower the work equipment to the ground completely.
k Remove the negative (-) terminal from the battery.

2. Loosen bolts (1) and remove cover (2).
3. Remove air cleaner cover (3) and remove the
element.
4. Loosen bolts (4) and remove the wire harness
clamp.
5. Loosen bolt (5) and remove the battery relay
assembly.
(The wire related to the battery relay must not be
removed.)
6. Loosen bolt (6) and remove the battery relay
mounting plate.
7. Remove battery cover fixing screws (7).
8. Remove hose mounting bolts (8) and (9) and disconnect the hose.
a Put blind caps to prevent the entry of dirt or
water into hoses and compressor.
9. Remove bolts (10) and remove condenser [11].
INSTALLATION
Carry out installation in reverse oder to remaval.

30-146
(19)
PC128US-2

PC128US-2 Serial No. : 5001 7299
PC138US-2 Serial No. : 1001 2599
REMOVAL

2. Remove floor mat (1).
4. Remove louver (4) and the four screws to
remove switch panel (5).
5. Remove screw (6) to slide duct (7) forward.
6. Disconnect airconditioner switch connectors (8)

and (9) to remove duct (7).
7. Remove grommet (10).
8. Remove the mounting bolt to disconnect duct
(11) from the airconditioner unit.
9. Disconnect airconditioner unit connector (12)
(M26).
a It is located on the bottom of the centralized
harness.
10. Disconnect heater hoses (13) and (14) at the
rear of the airconditioner unit.
a Since coolant flows out, bend and disconnect
the hose and apply the blind plug to it.
11. Disconnect airconditioner hoses (15) and (16).
a Make sure to double-engage the wrench
before disconnection.
12. Disconnect two relay connectors (17).
PC128US-2
30-147
(19)
13. Remove the mounting bolt to remove airconditioner unit assembly (18).
a Make sure that duct (11) is completely disconnected and remove it by sliding it forward.
INSTALLATION

removal.

30-148
(19)
PC128US-2

PC128US-2
PC138US-2
Serial No. : 2601 4500
REMOVAL
1. Drain coolant.
6 Coolant: 17.2 l

circuit.
3. Remove covers (1), (2), (3), (4) from the monitor
panel.
a Be sure to remove in the order of (1), (2), (3),
(4). Otherwise, the covers may not be
removed.
a When removing the cover (2), disconnect the
cigarette lighter connector (CN-M19).
4. Remove cover in front of the operator seat and
remove ducts (6), (7), (8).
5. Remove covers (9), (10), (11), (12) at the rear of

the operator cab.
PC128US-2
30-149
(19)
6. Remove the cover (13) and separate the connector (14)(CN-M87). (At the rear right in the
operator cab)
7. Remove ducts (15), (16), (17).
8. Disconnect connectors (CN-M26)(18), (CNM85)(19), and (CN-M84)(20) (at the rear of the
operator seat).
9. Disconnect the CR700 controller connector (CN021 023)(at three positions) and remove the
CR700 controller (21).
30-150
(16)
PC128US-2
10. Remove the heater hose (11).
11. Remove five seat stand mounting bolts and lift

the seat stand by screwing bolts [1] (M12, L =
100mm) into seat stand lifting nuts (left: 2, right:
1).
12. Disconnect two air conditioning hoses, remove
six air conditioning unit mounting bolts and
remove air conditioning unit assembly (25) by
pulling it out from the downside of the operator
seat.
INSTALLATION
a When installing the hoses of the air conditioning

circuit, care should be taken to prevent the entry
of dirt, dust, water, etc. into hose.
a Check that the pipe couplers of the air conditioning hoses have O-rings in them before installation.
a Check the O-rings for flaw, deterioration, etc.
a Filling air-conditioning gas
PC128US-2
30-151
(19)

ASSEMBLY
PC138US-2
REMOVAL
k Disconnect negative (-) terminal of the battery.

circuit.
2. Drain engine coolant.
6 Drain 13.2 l of the cooling water.
3. Remove floor mat.

5. Loosen right console (2) and move it inward.
a There is the cigarette lighter, M40.
8. Lower duct joint A, remove connector M88 (6),
and then remove duct (7).
9. Remove duct (8).
10. Disconnect 2 air conditioner tubes (9).
[*1]
11. Remove covers (10), (11), (12), and (13).
12. Remove ducts (14) and (15).
30-152
(19)
PC128US-2
13. Remove duct (16).

14. Disconnect connector (17).
15. Remove the 2 mounting bolts and duct (18).
17. Disconnect clip (20).

18. Disconnect connectors M26 (21), M85 (22), and
M84 (23) and remove them from the connector
clips.
19. Disconnect 2 heater hoses (24), upper one and
lower one.
a Do not wet controller B.
20. Remove five seat stand mounting bolts and lift

the seat stand by screwing bolts [1] (M12, L =
100mm) into seat stand lifting nuts (left: 2, right:
1).
21. Remove six air conditioning unit mounting bolts
and remove air conditioning unit assembly (25)
by pulling it out from the downside of the operator seat.
PC128US-2
30-153
(19)
INSTALLATION
Carry out installation in reverse order to removal.
a When installing the hoses of the air conditioning

circuit, care should be taken to prevent the entry
of dirt, dust, water, etc. into hose.
a Check that the pipe couplers of the air conditioning hoses have O-rings in them before installation.
a Check the O-rings for flaw, deterioration, etc.
[*1]

11.8 14.7 Nm {1.2 1.5 kgm}

Supplying coolant
Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant
level again.
5 Coolant: 13.2 l
30-154
(19)
PC128US-2
COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL

1. Remove engine upper cover (1).
2. Disconnect flywheel case oil filler hose (2).
3. Remove fuel gauge connector (3) from the
clamp.
a This is intended to prevent it from coming in
contact with the frame when the counterweight is lifted.
4. Sling counterweight assembly temporarily and
remove 3 mounting bolts (4).
[*1]
Width across flats of mounting bolt: 65 mm
5. Lift off counterweight assembly (5) carefully.
4 Counterweight assembly (PC128US-2)

: 3,050 kg (Standard specification)
: 2,500 kg (Blade specification)
4 Counterweight assembly (PC138US,
PC138USLC-2)
: 3,450 kg (Standard specification)
: 3,050 kg (Blade specification)
INSTALLATION

removal.
[*1]
3 Mounting bolt :
3,850 4,710 Nm (393 480 kgm)
PC128US-2
30-155
(16)
MONITOR PANEL
MONITOR PANEL ASSEMBLY

REMOVAL
1. Pull cover (2) of monitor panel (1) and remove
the claw stopper.
2. Remove side cover (3).
3. Remove the stopper of cover (4).
4. Remove the 3 mounting bolts of monitor panel

(1) and connectors (5) and (6) on the back side,
then remove monitor panel assembly (1).
INSTALLATION

removal.
30-156
(16)
PC128US-2
CONTROLLER
CONTROLLER ASSEMBLY
PC138US-2
REMOVAL
1. Remove cover (1) from under the rear part of the
seat.
2. Disconnect controller wiring connectors CR1 (2),

CR2 (3) and CR3 (4).
3. Remove the 4 mounting bolts and controller
assembly (5).
INSTALLATION

removal.
PC128US-2
30-157
(16)
40 MAINTENANCE STANDARD
Swing machinery ......................................... 40- 2

Swing circle .................................................. 40- 4
Track frame, idler cushion ........................... 40- 5
Idler ................................................................ 40- 6
Carrier roller .................................................. 40- 8
Track roller .................................................... 40- 9
Sprocket ........................................................ 40-12
Track shoe ..................................................... 40-13
Hydraulic pump (piston pump) ................... 40-17
Control valve ................................................. 40-18
Suction safety valve ..................................... 40-27
Self pressure reduction valve ...................... 40-28
Travel motor .................................................. 40-29
Swing motor ................................................. 40-30
Solenoid valve .............................................. 40-31
Center swivel joint ........................................ 40-32
PPC valve ...................................................... 40-34
Boom hydraulic drift prevention valve
(FOR KUK SPEC.) .......................................... 40-37
Arm hydraulic drift prevention valve
(FOR KUK SPEC.) (If equipped) ................ 40-37-2
Hydraulic cylinder ........................................ 40-38
Work equipment ........................................... 40-41
Dimension of work equipment .................... 40-44
PC128US-2
40-1
(15)
SWING MACHINERY
SWING MACHINERY
PC128US-2
40-2
(15)
PC128US-2
SWING MACHINERY
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.07 0.18
0.4
Backlash of swing motor

shaft and No. 1 sun gear
Backlash between No. 1

sun gear and No. 1 planetary gear
0.13 0.31
0.6

planetary gear and ring
gear
0.15 0.34
0.7

planetary carrier and No. 2
sun gear
0.14 0.34
0.7

gear
0.15 0.34
0.7

0.13 0.31
0.6

planetary carrier and swing
pinion
0.08 0.19
0.4
Backlash between swing

pinion and swing circle
0.13 1.16
2.3
Wear on swing pinion

collars contact surface
against oil seal
PC128US-2
Replace
Standard size
Tolerance
Repair limit
145
0
0.100
144.8
Apply
hardchrome
plating recondition, or replace
40-3
(14)
SWING MACHINERY
PC138US-2
40-3-1
(15)
PC128US-2
SWING MACHINERY
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.07 0.18
0.4
Backlash of swing motor

shaft and No. 1 sun gear

0.13 0.32
0.6

gear
0.14 0.40
0.7

planetary carrier and No. 2
sun gear
0.14 0.34
0.7

gear
0.13 0.39
0.7

0.12 0.31
0.6

planetary carrier and swing
pinion
0.009 0.117
0.2
Backlash between swing

pinion and swing circle
0.13 1.16
2.3
Wear on swing pinion

collars contact surface
against oil seal
PC128US-2
Replace
Standard size
Tolerance
Repair limit
145
0
0.100
144.8
Apply
hardchrome
plating recondition, or replace
40-3-2
(15)
SWING CIRCLE
SWING CIRCLE
Unit: mm
No.
Check item
Clearance between bearing

and circle
40-4
(14)
Criteria
Remedy
Standard size
Clearance limit
0.5 1.6
2.6
Replace
PC128US-2
TRACK FRAME, IDLER CUSHION
TRACK FRAME, IDLER CUSHION

PC128US-2
PC138US-2
Unit: mm
No.
Check item
Criteria
Standard size
Clearance limit
84
89
82
77
Track
frame
185
193
Rebuild
Idler
support
183
175
Rebuild or
replace
Rebuild
Track
Idler guide top
frame
and bottom width
Idler
support
Idler guide left

and right width
Standard size
Recoil spring
Remedy
Rebuild or
replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
507
390
78.5 kN
{8,000 kg}
494
69.8 kN
{7,120 kg}
502
390
84.3 kN
{8,600 kg}
490
75.0 kN
{7,650 kg}
Replace
1. For PC128US-2 Serial No.: 5001 5362

2. For PC128US-2 Serial No.: 5363 and up, PC138US-2 Serial No.: 4501 and up
PC128US-2
40-5
(15)
IDLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Outer diameter of
protruding portion
527
Outer diameter of tread
489
477
Depth of protruding
portion
19
25
Width of protruding
portion
52
42
Total width
115
107
Width of tread
Clearance between
idler shaft and bushing
Interference between idler

and bushing
31.5
Standard
size
54
Standard
size
61
10
Side clearance of idler

(on one side)
Tread wall thickness
(at center of tread)
Oil amount
PC128US-2
Tolerance
Shaft
Hole
+0.074
0.250
0
0.280
Tolerance
Shaft
Hole
+0.117
+0.030
+0.087
0
Rebuild or
replace
36.5
Standard
clearance
Clearance
limit
0.250 0.354
1.5
Standard in- Interference

terference
limit
0.057 0.117
Standard clearance
Clearance limit
0.18 0.38
1.5
Standard size
Repair limit
15
90 cc (Engine oil: SAE30CD Red)
Replace
Rebuild or
replace
40-6-1
A
IDLER
PC128US-2
PC138US-2
40-6-2
(15)
PC128US-2
IDLER
Unit: mm
No.
Check item
Criteria
Outer diameter of
protruding portion
Remedy
Standard size
Repair limit
527
489
477
Depth of protruding
portion
19
25
Width of protruding
portion
52
42
Total width
115
107
Width of tread
Clearance between
idler shaft and bushing
Interference between idler

and bushing
31.5
Standard
size
Standard
size
61
Side clearance of idler

(on one side)
10

(at center of tread)
Oil amount
PC128US-2
36.5
Tolerance
Shaft
Hole
0.250
0.280
54
Rebuild or
replace
+0.074
0
Standard
clearance
Clearance
limit
0.250 0.354
1.5
Tolerance
Shaft
Hole

terference
limit
+0.117
+0.087
0.057 0.117
+0.030
0
Standard clearance
Clearance limit
0.200 0.405
1.5
Standard size
Repair limit
16.5
10.5
90 105 cc (Engine oil: SAE30CD)
Replace
Rebuild or
replace
40-7
A
CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No.
Check item
Width of tread
Clearance between shaft

and bushing
Criteria
Standard size
Repair limit
116
106
123
Standard
size
40
Standard
size
Interference between collar

and bushing
47
Play on carrier roller in

axial direction
(at 10 mm away from end
face roller)
Tolerance
Rebuild or
replace
Shaft
Hole
Standard
clearance
Clearance
limit
+0.055
0.035
+0.261
+0.200
0.145
0.226
Tolerance
Shaft
Hole
+0.061
+0.036
+0.025
0
Replace
terference
limit
0.011
0.061
Standard size
Repair limit
0.363 0.537
1.5
17.7
12.7
40-8
Rebuild or
replace
72 cc (Engine oil: SAE30CD Red)
Oil amount
(15)
Remedy
68 76 cc (Engine oil: SAE30CD Red)
1. For PC128US-2 Serial No.: 5001 7138

2. For PC128US-2 Serial No.: 7139 and up
For PC138US-2 Serial No.: 4501 and up
For PC138USLC-2 Serial No.: 1001 and up
PC128US-2
TRACK ROLLER
TRACK ROLLER
PC128US-2 Serial No.: 5001 5362
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Diameter of flange
(outside)
158
130
120
Flange width
Total width
Width of tread

and bushing
Interference between roller

and bushing
Track roller side clearance

(on one side)

(at center of width)
Oil amount
PC128US-2
26.5
Rebuild or
replace
176
35
Tolerance
Rebuild or
replace
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
50
0.250
0.270
+0.187
0.025
0.225 0.457
1.5
Tolerance
Standard
size
Shaft
Hole
57
+0.190
+0.110
+0.090
+0.060

terference
limit
0.020 0.130
Standard clearance
Clearance limit
0.155 0.345
1.5
Standard size
Repair limit
36.5
31.5
Replace
Rebuild or
replace
40-9
A
TRACK ROLLER
ONE SIDE PIN TYPE

PC128US-2
PC138US-2
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Diameter of flange
(outside)
158
130
120
Flange width
Total width
Width of tread

and bushing

and bushing

(on one side)

Oil amount
40-10
(15)
26.5
Rebuild or
replace
176
35
Tolerance
Rebuild or
replace
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
48
0.250
0.350
+0.186
0.025
0.225 0.536
1.5
Tolerance
Standard
size
Shaft
Hole
55
+0.190
+0.110
+0.093
+0.063

terference
limit
0.017 0.127
Standard clearance
Clearance limit
0.160 0.345
1.5
Standard size
Repair limit
37.5
32.5
Replace
Rebuild or
replace
PC128US-2
TRACK ROLLER
BOTH SIDE PIN TYPE

PC128US-2
PC138US-2
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Diameter of flange
(outside)
158
130
120
Flange width
Total width
Width of tread

and bushing

and bushing

(on one side)

Oil amount
PC128US-2
26.5
Rebuild or
replace
176
35
Tolerance
Rebuild or
replace
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
48
0.250
0.350
+0.186
0.025
0.225 0.536
1.5
Tolerance
Standard
size
Shaft
Hole
55
+0.190
+0.110
+0.093
+0.063

terference
limit
0.017 0.127
Standard clearance
Clearance limit
0.165 0.440
1.5
Standard size
Repair limit
37.5
32.5
Replace
Rebuild or
replace
40-11
(15)
SPROCKET
SPROCKET
Unit: mm
No.
Check item
Remedy
Standard size
Tolerance
Repair limit
547.4
+1.0
2.0
535
PC138USLC-2
542.8
+1.0
2.0
530
PC128US-2
607
595
PC138USLC-2
607.5
595
Wear on
tooth bottom PC128US-2
diameter
Wear on addendum
diameter
Criteria
Wear on addendum width
27
22
Wear on tooth bottom width
42
1.5
39
111.7
+0.465
1.160
105.5
Tooth bottom PC128US-2

wall thickness
PC138USLC-2
109.4
+0.465
1.160
103
40-12
0
Rebuild or
replace
PC128US-2
TRACK SHOE
TRACK SHOE
TRIPLE SHOE, ROAD LINER, CITY PAD SHOE
1. Triple shoe , city pad shoe

2. Road liner
fl P portion shows the link of bushing press fitting end.
PC128US-2
40-13
7
TRACK SHOE
PC128US-2
(1/2)
No.
Unit: mm
Check item
Criteria
Standard size
Repair limit
175.25
178.25
Link pitch
Bushing outer diameter

46.3
Link height
Link wall thickness

(at the section where
bushing is to be press fit)
Reverse or
replace
When turned
Standard size
2
Remedy
Normal load
Impact load
42.3
Standard size
Repair limit
86
81
24
19
Reverse or
replace
102.4
Replace
Shoe bolt pitch
86.4
57
8
9
Link
10
Inner width
52.4
Total width
35
30.1
Width of tread
11
Pin protrusion volume
5.5
12
Regular brush protrusion

volume
3.75
13
Total pin length
173
14
Total bushing length

(master bushing)
15
Bushing wall thickness
16
Spacer thickness
Bushing
17
18
Press fitting
Regular pin
force
19
Master pin
Reverse or
replace
Adjust or
replace
86.7
Standard size
Repair limit
7.8
3.8
39.2 137.3 kN {4 14 ton}

78.5 186.3 kN {8 19 ton}
39.2 98.1 kN {4 10 ton}
Items with marking are applicable to the dry type shoe.
40-14
(15)
PC128US-2
TRACK SHOE
PC128US-2
(2/2)
No.
Unit: mm
Check item
Criteria
Remedy
Tightening torque (Nm {kgm}) Additional tightening angle (deg)

a. Regular link
Shoe bolt
20
Triple
City pad
196 20
{20 2}
90 10
Road liner
147 10
{15 1}
50 5
Retighten
Tightening torque
(Nm {kgm})
Additional tightening angle (deg)
Lower limit torque

(Nm {kgm})
b. Master link
Number of shoes
(on one side)
42
43
Tolerance
Standard size
21
22
Hole
46
+0.387
+0.347
+0.062
0
0.285 0.387
30
+0.150
0
0.198
0.250
0.198 0.400
Tolerance
Standard size
23
Clearance between regular

pin and bushing
30
1 Interference between
24 master pin and link
26
a. Road liner
Hole
+0.150
0
+0.830
+0.330
0.180 0.830
Shaft
Hole
Standard
interference
+0.020
0.020
0.198
0.250
0.178 0.270
Shaft
Hole
Standard
clearance
0.200
0.300
+0.630
+0.230
Tolerance
Standard size
30
Grouser
height
Standard
clearance
Shaft
Tolerance
Standard size
30
1 Clearance between master

25 pin and bushing
Standard
interference
Shaft
Interference between
bushing and link
regular pin and link
Adjust or
replace
0.430 0.930
Standard size
Repair limit
58
21
Replace
Items with 1. marking are applicable to the dry type shoe.

2. Serial No.: 7731 9000
3. Serial No.: 9001 and up
PC128US-2
40-15
(15)
TRACK SHOE
PC138US-2
(1/2)
No.
Unit: mm
Check item
Criteria
Standard size
Repair limit
175.25
178.25
Link pitch

50.6
Link height
Link wall thickness

Reverse or
replace
When turned
Standard size
2
Remedy
Normal load
Impact load
46.6
Standard size
Repair limit
90
85
24
19
Reverse or
replace
102.4
Replace
Shoe bolt pitch
86.4
57
8
9
Link
10
Inner width
52.4
Total width
35
30.1
Width of tread
11
5.5
12
Regular bushing
protrusion volume
3.75
13
Total pin length
173
14

(master bushing)
86.7
15
16
Spacer thickness
17
18
Bushing
Press fitting
Regular pin
force
19
Master pin
Reverse or
replace
Adjust or
replace
Standard size
Repair limit
9.0
58.8 176.5 kN {6 18 ton}

98.1 235.4 kN {10 24 ton}
98.1 235.4 kN {10 24 ton}
40-15-1
(15)
PC128US-2
TRACK SHOE
PC138US-2
(2/2)
No.
Unit: mm
Check item
Criteria
Remedy

a. Regular link
196 20
{20 2}
Triple
Shoe bolt
20
Lower limit torque

(Nm {kgm})
b. Master link
Tolerance
Hole
50.2
+0.387
+0.347
+0.074
0
0.273 0.387
32
+0.150
+0.050
0.188
0.250
0.238 0.400
Tolerance
Standard size
23

pin and bushing
32
24
master pin and link
Clearance between master

pin and bushing
Grouser height
Hole
+0.150
+0.050
+0.830
+0.330
0.180 0.780
Shaft
Hole
Standard
interference
+0.060
+0.020
0.188
0.250
0.208 0.310
Shaft
Hole
Standard
clearance
0.200
0.300
+0.830
+0.330
Tolerance
Standard size
32
26
Standard
clearance
Shaft
Tolerance
Standard size
32
25
Standard
interference
Shaft
bushing and link
43
Standard size
22
Retighten
Tightening torque
(Nm {kgm})
Number of shoes
(on one side)
21
90 10
Adjust or
replace
0.530 1.130
Standard size
Repair limit
Replace
PC128US-2
40-15-2
(15)
PC138USLC-2
(1/2)
No.
Unit: mm
Check item
Criteria
Standard size
Repair limit
175.25
178.25
Link pitch

50.6
Link height
Link wall thickness

Reverse or
replace
When turned
Standard size
2
Remedy
Normal load
Impact load
46.6
Standard size
Repair limit
90
85
24
19
Reverse or
replace
102.4
Replace
Shoe bolt pitch
86.4
57
8
9
Link
10
Inner width
52.4
Total width
35
30.1
Width of tread
11
5.5
12
Regular bushing
protrusion volume
3.75
13
Total pin length
173
14

(master bushing)
86.7
15
16
Spacer thickness
17
18
Bushing
Press fitting
Regular pin
force
19
Master pin
Reverse or
replace
Adjust or
replace
Standard size
Repair limit
9.0
58.8 176.5 kN {6 18 ton}

98.1 235.4 kN {10 24 ton}
98.1 235.4 kN {10 24 ton}
40-15-3
(15)
PC128US-2
TRACK SHOE
PC138USLC-2
(2/2)
No.
Unit: mm
Check item
Criteria
Remedy

a. Regular link
196 20
{20 2}
Triple
Shoe bolt
20
Lower limit torque

(Nm {kgm})
b. Master link
Tolerance
Hole
50.2
+0.387
+0.347
+0.074
0
0.273 0.387
32
+0.150
+0.050
0.188
0.250
0.238 0.400
Tolerance
Standard size
23

pin and bushing
32
24
master pin and link
Clearance between master

pin and bushing
Grouser height
Hole
+0.150
+0.050
+0.830
+0.330
0.180 0.780
Shaft
Hole
Standard
interference
+0.060
+0.020
0.188
0.250
0.208 0.310
Shaft
Hole
Standard
clearance
0.200
0.300
+0.830
+0.330
Tolerance
Standard size
32
26
Standard
clearance
Shaft
Tolerance
Standard size
32
25
Standard
interference
Shaft
bushing and link
46
Standard size
22
Retighten
Tightening torque
(Nm {kgm})
Number of shoes
(on one side)
21
90 10
Adjust or
replace
0.530 1.130
Standard size
Repair limit
Replace
PC128US-2
40-15-4
(15)
TRACK SHOE
Triple shoe and city pat shoe
Unit: mm
No.
2
3
Check item
Grouser height
Shoe height
Plate thickness
4
5
Grouser edge length
Criteria
Remedy
Standard size
Repair limit
25
15
20
10
33
23
29.5
19.5
9.5
18
14
11
13
18
15
Rebuild or
replace
1.: PC128US-2 (Serial No.: 5001 9000), PC138USLC-2 (Serial No.: 1001 1300)
2.: PC128US-2 (Serial No.: 9001 and up), PC138US-2 (Serial No.: 4501 and up),
PC138USLC-2 (Serial No.: 1301 and up)
40-16
(15)
PC128US-2
HYDRAULIC PUMP
HYDRAULIC PUMP (PISTON PUMP)

TYPE : HPV95 (for 105 cc/rev.)
PC128US-2 Serial No.: 5001 7730
PC128US-2
40-17
(15)
HYDRAULIC PUMP
PC128US-2
40-17-1
(15)
PC128US-2
HYDRAULIC PUMP
PC138US-2
PC128US-2
40-17-2
(15)
CONTROL VALVE
CONTROL VALVE
7 SPOOL (6 SPOOL + SERVICE VALVE)
PC128US-2
(1/9)
40-18
(15)
PC128US-2
CONTROL VALVE
PC138US-2
(1/9)
PC128US-2
40-18-1
(15)
CONTROL VALVE
(2/9)
Unit: mm
No.
Check item
Criteria
Standard size
Suction valve spring
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
46.8 7.50
40.6
5.500.40N
{0.560.04kg}
4.40 N
{0.45 kg}
16.0 16.0
12.0
5.70 N
{0.58 kg}
4.50 N
{0.46 kg}
Piston spring
20.0 7.0
14.0
1.20 N
{0.12 kg}
0.98 N
{0.10 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-19
(15)
MAINTENANCE
STANDARD
CONTROL VALVE
B-B
9JYOOO59
Unit: mm
No
-
Check
item
Criteria
Standard
Fryg;gth
. .
Spool return spring
lrx;Azd
Remedy
size
Repair limit
Installed
load
Free length
Installed
load
184N
0
Spool return spring
45.7
28.0
Spool return spring
42.4
26.0
40-20
43.0
222+13.7N
{22.6+1.40kg)
a.8kg)
178N
(la.1 kg}
Replace
spring if any
damages or
deformations
are found
PC1 28U.S2
CONTROL VALVE
(4/9)
Unit: mm
No.
Check item
Criteria
Standard size
Flow control valve spring
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
36.2 5.30
32.0
9.810.98N
{1.00.10kg}
7.85 N
{0.80 kg}
Pressure reduction valve

spring
27.5 14.2
18.0
17.70.98N
{1.800.10kg}
13.7 N
{1.40 kg}

spring
28.2 14.5
26.0
29.42.94N
{3.00.30kg}
23.5 N
{2.40 kg}

spring
24.1 15.0
14.5
9.810.98N
{1.00.10kg}
7.85 N
{0.80 kg}
Relief valve spring
17.1 9.0
15.5
74.5 N
{7.60 kg}
59.8 N
{6.10 kg}

spring
32.5 14.2
23
17.6 N
{1.8 kg}
14.1 N
{1.44 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-21
(15)
CONTROL VALVE
(5/9)
Unit: mm
No.
Check item
Criteria
Standard size
Check valve spring
Check valve spring
40-22
(15)
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
41.5 8.50
31.5
5.88 N
{0.60 kg}
4.71 N
{0.48 kg}
20.3 13.7
15.6
3.14 N
{0.32 kg}
2.25 N
{0.26 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
CONTROL VALVE
(6/9)
Unit: mm
No.
Check item
Criteria
Standard size
Lift check valve spring

Cooler bypass valve spring
Bleed spool return spring
PC128US-2
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
72.7 20.6
42.5
1354.90N
{13.80.50kg}
113 N
{11.5 kg}
23.3 12.5
23.0
3.920.98N
{0.400.10kg}
2.94 N
{0.30 kg}
Replace
spring if any
damages or
deformations
are found
40-23
(15)
CONTROL VALVE
(7/9)
Unit: mm
No.
Check item
Travel junction spool

return spring
Criteria
Free length
O.D.
17.7 8.20
40-24
Standard size
Installed
Installed
length
load
13.0
13.70.10N
{1.400.10kg}
Remedy
Repair limit
Installed
Free length
load
10.1 N
{1.10 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
CONTROL VALVE
(8/9)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
26.1 17.0
25.0
26.51.57N
{2.700.16kg}
21.2 N
{2.16 kg}
Piston return spring
23.7 7.70
12.0
1.94 N
{0.30 kg}
2.35 N
{0.24 kg}
Check valve spring
41.5 8.50
31.5
5.88 N
{0.60 kg}
4.71 N
{0.48 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-25
(15)
CONTROL VALVE
(9/9)
40-26
(15)
PC128US-2
CONTROL VALVE
FOR KUK SPEC.

PC128US-2
9 spool valve
(6-spool valve + Blade valve + Full-flow service valve + Half-flow service valve)
40-26-2
(15)
PC128US-2
CONTROL VALVE
(1/8)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
46.8 7.50
40.6
5.500.40N
{0.560.04kg}
4.40 N
{0.45 kg}
16.0 16.0
12.0
5.70 N
{0.58 kg}
4.50 N
{0.46 kg}
Piston spring
10.5 7.0
6.8
2N
{0.21 kg}
1.6 N
{0.17 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-26-3
(15)
CONTROL VALVE
(2/8)
Unit: mm
No.
Check item
Criteria
Standard size
Spool return spring
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
45.6 28.0
43.0
23014.7N
{23.51.50kg}
184 N
{18.8 kg}
Spool return spring
45.7 28.0
43.0
22213.7N
{22.61.40kg}
178 N
{18.1 kg}
Spool return spring
42.4 28.0
39.0
22213.7N
{22.61.40kg}
178 N
{18.1 kg}
40-26-4
(15)
Replace
spring if any
damages or
deformations
are found
PC128US-2
CONTROL VALVE
(3/8)
Unit: mm
No.
Check item
Criteria
Standard size
Repair limit
Free length Installed
Installed
Installed
Free length
O.D.
length
load
load
7.85 N
9.810.98N
36.2 5.30
32.0
{0.80 kg}
{1.00.10kg}
Flow control valve spring

spring
27.5 14.2
18.0
28.2 14.5
26.0

spring
spring
24.1 15.0
14.5
Relief valve spring
17.1 9.0
15.5
9.810.98N
{1.00.10kg}
74.5 N
{7.60 kg}

spring
32.5 14.2
23.0
33.32N
{3.40.2kg}
PC128US-2
Remedy
17.70.98N
{1.800.10kg}
29.42.94N
{3.00.30kg}
13.7 N
{1.40 kg}
23.5 N
{2.40 kg}
7.85 N
{0.80 kg}
59.8 N
{6.10 kg}
26.6 N
{2.7 kg}
Replace
spring if any
damages or
deformations
are found
40-26-5
(15)
CONTROL VALVE
(4/8)
Unit: mm
No.
Check item
Criteria
Standard size
Check valve spring
Check valve spring
40-26-6
(15)
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
41.5 8.50
31.5
5.88 N
{0.60 kg}
4.71 N
{0.48 kg}
20.3 13.7
15.6
3.14 N
{0.32 kg}
2.25 N
{0.26 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
CONTROL VALVE
(5/8)
Unit: mm
No.
Check item
Criteria
Standard size

Cooler bypass valve spring
Bleed spool return spring
PC128US-2
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
72.7 20.6
42.5
1354.90N
{13.80.50kg}
113 N
{11.5 kg}
23.3 12.5
23.0
3.920.98N
{0.400.10kg}
2.94 N
{0.30 kg}
Replace
spring if any
damages or
deformations
are found
40-26-7
(15)
CONTROL VALVE
(6/8)
Unit: mm
No.
Check item
Travel junction spool

return spring
Criteria
Free length
O.D.
17.7 8.20
40-26-8
(15)
Standard size
Installed
Installed
length
load
13.0
13.70.10N
{1.400.10kg}
Remedy
Repair limit
Installed
Free length
load
10.1 N
{1.10 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
CONTROL VALVE
(7/8)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
26.1 17.0
25.0
26.51.57N
{2.700.16kg}
21.2 N
{2.16 kg}
Piston return spring
23.7 7.70
12.0
1.94 N
{0.30 kg}
2.35 N
{0.24 kg}
Check valve spring
41.5 8.50
31.5
5.88 N
{0.60 kg}
4.71 N
{0.48 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-26-9
(15)
CONTROL VALVE
(8/8)
40-26-10
(15)
PC128US-2

FOR SERVICE VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Piston spring
PC128US-2
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
16.3 21.3
9.50
2.06 N
{0.21 kg}
1.57 N
{0.16 kg}
20.0 7.0
14.0
2.06 N
{0.21 kg}
1.57 N
{0.16 kg}
Replace
spring if any
damages or
deformations
are found
40-27
(15)
SELF PRESSURE REDUCTION VALVE
SELF PRESSURE REDUCTION VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Spring
(pressure reduction main)
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
19.2 7.20
16.1
19.6 N
{2.0 kg}
17.7 N
{1.80 kg}
Spring (pressure reduction

valve pilot)
16.5 7.20
12.7
20.6 N
{2.10 kg}
18.6 N
{1.90 kg}
Spring
71.0 18.0
59.0
200 N
{20.4 kg}
186 N
{19.0 kg}
Spring (safety valve)
16.1 7.80
13.4
61.7 N
{6.30 kg}
58.8 N
{6.0 kg}
40-28
Replace
spring if any
damages or
deformations
are found
PC128US-2
TRAVEL MOTOR
TRAVEL MOTOR
GM18VL-J : PC128US-2
GM20VL-J : PC128US-2
GM20VL-P : PC128US-2
PC138USLC-2
GM20VL2-P : PC138US-2
PC138USLC-2
PC128US-2
STD
OPT (Traction up)
OPT (Traction up)
STD
STD
STD
(Serial No. 5001 and up)

(Serial No. 5001 6072)
(Serial No. 1001 1500)
40-29
(15)
SWING MOTOR
SWING MOTOR
KMF40ABE-3
Unit: mm
No.
Check item
Criteria
Standard size
Check valve spring
Shuttle valve spring
40-30
2
Free length
O.D.
Remedy
Repair limit
Installed
length
Installed
load
Free length
Installed
load
23.0
1.28 N
{0.13 kg}
0.98 N
{0.10 kg}
33.0 13.8
16.4 8.90
11.5
13.7 N
{1.40 kg}
10.8 N
{1.10 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
MAINTENANCE
STANDARD
SOLENOID
VALVE
SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECTOR, SWING AND PARK BRAKE, AND 2STAGE RELIEF SOLENOID VALVE
21.6*2.2Nm
(2.2*0.22kPml
B-B
PC1 28US-2
40-31
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

STD (WITHOUT BLADE)
Unit: mm
No.
Check item
Criteria
Standard size
Clearance between rotor

and shaft
40-32
A
Remedy
Standard clearance
clearance limit
0.056 0.105
0.111
Replace
80
PC128US-2
CENTER SWIVEL JOINT
OPT (WITH BLADE)
Unit: mm
No.
Check item
Criteria
Standard size
Clearance between rotor

and shaft
PC128US-2
Remedy
Standard clearance
clearance limit
0.056 0.105
0.111
Replace
80
40-33
A
PPC VALVE
PPC VALVE
FOR SWING, WORK EQUIPMENT
PC128US-2 Serial No.: 5001 7730

No.
Unit: mm
Check item
Centering spring
(for P3 and P4 ports)
Criteria
Standard size
Installed
O.D.
length
load
Remedy
Repair limit
Installed
Free length
load
44.45 15.5
34.0
29.42 N
{3.0 kg}
23.5 N
{2.4 kg}
Centering spring
47.93 15.5
34.0
39.22 N
{4.0 kg}
31.4 N
{3.2 kg}
Metering spring
26.53 8.15
24.9
17.0 N
{1.70 kg}
13.3 N
{1.36 kg}
40-34
(15)
Replace
spring if any
damages or
deformations
are found
PC128US-2
PC128US-2
PC128US-2
PC138US-2
PC138USLC-2
No.
PPC VALVE

Serial No.: 5001 and up (For KUK spec.)
Check item
Centering spring
Unit: mm
Criteria
Free length
O.D.
Standard size
Installed
Installed
length
load
Remedy
Repair limit
Installed
Free length
load
42.48 15.5
34.0
17.65 N
{1.80 kg}
14.1 N
{1.44 kg}
Centering spring
47.93 15.5
34.0
39.22 N
{4.0 kg}
31.4 N
{3.2 kg}
Metering spring
26.53 8.15
24.9
17.0 N
{1.70 kg}
13.3 N
{1.36 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-34-1
(15)
PPC VALVE
FOR TRAVEL
PC128US-2 Serial No.: 5001 6300
Unit: mm
No.
Check item
Criteria
Standard size
Metering spring
Centering spring
PC128US-2
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
26.5 8.15
24.9
16.7 N
{1.70 kg}
13.7 N
{1.40 kg}
48.6 15.5
32.5
108 N
{11.0 kg}
86.3 N
{8.80 kg}
Replace
spring if any
damages or
deformations
are found
40-35
(15)
PPC VALVE
PC128US-2
PC138US-2
Unit: mm
No.
Check item
Criteria
Standard size
Metering spring
Centering spring
40-35-1
(15)
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
26.5 8.15
24.9
16.7 N
{1.70 kg}
13.7 N
{1.40 kg}
48.1 15.5
32.5
108 N
{11.0 kg}
86.3 N
{8.80 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2
PPC VALVE
FOR BLADE, FOR SERVICE
For blade
No.
Unit: mm
Check item
Centering spring
Metering spring
Criteria
Remedy
Standard size
Installed
O.D.
length
load
Repair limit
Installed
Free length
load
100 N
{10.2 kg}
13.3 N
{1.36 kg}
33.9 15.3
28.4
124.5 N
{12.7 kg}
22.7 8.10
22.0
16.7 N
{1.70 kg}
For service
No.
Unit: mm
Check item
Criteria
Standard size
Centering spring
Metering spring
40-36
(15)
Replace
spring if any
damages or
deformations
are found
Free length
O.D.
Remedy
Repair limit
Installed
length
Installed
load
Free length
Installed
load
28.4
207.8 N
{21.2 kg}
167 N
{17.0 kg}
42.4 15.5
22.7 8.10
22.0
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
Replace
spring if any
damages or
deformations
are found
PC128US-2

(FOR KUK SPEC.)
PC128US-2 Serial No.: 5001 7730
Unit: mm
No.
Check item
Pilot spool spring
Criteria
Standard size
Installed
O.D.
length
load
Remedy
Repair limit
Installed
Free length
load
31.75 8.5
25.0
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
Check valve spring
24.5 11.6
18.0
4.9 N
{0.5 kg}
3.9 N
{0.4 kg}
Spool return spring
30.9 20.6
29.0
69.6 N
{7.1 kg}
55.9 N
{5.7 kg}
PC128US-2
Replace
spring if any
damages or
deformations
are found
40-37
C

Unit: mm
No.
Check item
Criteria
Standard size
Pilot spool spring
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
31.75 8.5
25.0
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
Check valve spring
24.5 11.6
18.0
4.9 N
{0.5 kg}
3.9 N
{0.4 kg}
Spool return spring
30.9 20.6
29.0
69.6 N
{7.1 kg}
55.9 N
{5.7 kg}
40-37-1
(15)
Replace
spring if any
damages or
deformations
are found
PC128US-2

(FOR KUK SPEC.) (If equipped)
Unit: mm
No.
Check item
Check valve spring
Criteria
Standard size
Installed
O.D.
length
load
Remedy
Repair limit
Installed
Free length
load
25.4 11.6
18
4.9 N
{0.5 kg}
3.9 N
{0.4 kg}
Spool return spring
31.8 8.5
25
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
Spool return spring
30.9 20.6
29
69.6 N
{7.1 kg}
55.7 N
{5.7 kg}
PC128US-2
If damaged or
deformed,
replace spring
40-37-2
(15)
MAINTENANCE
STANDARD
HYDRAULIC
HYDRAULIC
CYLINDER
CYLINDER
BOOM CYLINDER
2
9JA01392
ARM CYLINDER
9JA01393
BUCKET CYLINDER
9JA01394
BLADE CYLINDER
9JAOl395
40-38
0
PC128US-2
HYDRAULIC CYLINDER
PC128US-2
No.
Check item
Cylinder
Boom
Clearance between piston rod Arm

and bushing
Cylinder piston
tightening torque
Cylinder piston
lock screw tightening torque
PC128US-2
70
75
Blade
75
Boom
70
70
65
Blade
70
Boom
70
Clearance beArm
tween cylinder
bottom support
shaft and bushing Bucket
Cylinder head
tightening torque
Standard
size
65
Blade
Criteria
Bucket
Clearance beArm
tween piston rod
support shaft and
Bucket
bushing
Unit: mm
70
65
70
Tolerance
Shaft
Hole
+0.259
0.030
+0.063
0.076
+0.279
0.030
+0.065
0.076
+0.250
0.030
+0.055
0.076
+0.279
0.030
+0.065
0.076
+0.198
0.030
+0.124
0.100
+0.198
0.030
+0.124
0.100
+0.174
0.030
+0.100
0.080
+0.198
0.030
+0.124
0.100
+0.198
0.030
+0.124
0.100
+0.198
0.030
+0.124
0.100
+0.174
0.030
+0.100
0.080
+0.198
0.030
+0.124
0.100
Remedy
Standard
clearance
Clearance
limit
0.093
0.335
0.095
0.355
0.085
0.326
0.095
0.355
0.154
0.298
0.154
0.298
0.130
0.254
0.154
0.298
0.154
0.298
0.154
0.298
0.130
0.254
0.154
0.298
0.435
Boom
171.6 24.5 Nm {17.5 2.5 kgm}
Arm
269.7 39.2 Nm {27.5 4.0 kgm}
Bucket
171.6 24.5 Nm {17.5 2.5 kgm}
Blade
269.7 39.2 Nm {27.5 4.0 kgm}
Boom
294.2 29.4 Nm {30.0 3.0 kgm}
Arm
294.2 29.4 Nm {30.0 3.0 kgm}
Bucket
294.2 29.4 Nm {30.0 3.0 kgm}
Blade
294.2 29.4 Nm {30.0 3.0 kgm}
Boom
66.2 7.4 Nm {6.75 0.75 kgm}
Arm
66.2 7.4 Nm {6.75 0.75 kgm}
Bucket
30.9 3.4 Nm {3.15 0.35 kgm}
Blade
66.2 7.4 Nm {6.75 0.75 kgm}
0.455
0.426
0.455
1.0
1.0
Replace
bushing
1.0
1.0
1.0
1.0
1.0
1.0
Re-tightening
40-39
(15)
HYDRAULIC CYLINDER
PC138US-2
No.
Check item
Cylinder
Boom
Clearance between piston rod Arm

and bushing
Cylinder piston
tightening torque
Cylinder piston
lock screw tightening torque
40-40
(15)
70
75
Blade
75
Boom
70
70
65
Blade
70
Boom
70
Clearance beArm
tween cylinder
bottom support
shaft and bushing Bucket
Cylinder head
tightening torque
Standard
size
65
Blade
Criteria
Bucket
Clearance beArm
tween piston rod
support shaft and
Bucket
bushing
Unit: mm
70
65
70
Tolerance
Shaft
Hole
+0.259
0.030
+0.063
0.076
+0.279
0.030
+0.065
0.076
+0.250
0.030
+0.055
0.076
+0.279
0.030
+0.065
0.076
+0.190
0.030
+0.070
0.100
+0.190
0.030
+0.070
0.100
+0.170
0.030
+0.070
0.080
+0.170
0.030
+0.070
0.100
+0.190
0.030
+0.070
0.100
+0.190
0.030
+0.070
0.100
+0.170
0.030
+0.070
0.080
+0.170
0.030
+0.070
0.100
Remedy
Standard
clearance
Clearance
limit
0.093
0.335
0.095
0.355
0.085
0.326
0.095
0.355
0.100
0.290
0.100
0.290
0.100
0.250
0.100
0.270
0.100
0.290
0.100
0.290
0.100
0.250
0.100
0.270
0.435
Boom
172 24.5 Nm {17.5 2.5 kgm}
Arm
270 39 Nm {27.5 4.0 kgm}
Bucket
172 24.5 Nm {17.5 2.5 kgm}
Blade
270 39 Nm {27.5 4.0 kgm}
Boom
294 29.4 Nm {30.0 3.0 kgm}
Arm
294 29.4 Nm {30.0 3.0 kgm}
Bucket
294 29.4 Nm {30.0 3.0 kgm}
Blade
294 29.4 Nm {30.0 3.0 kgm}
Boom
66.2 7.4 Nm {6.75 0.75 kgm}
Arm
66.2 7.4 Nm {6.75 0.75 kgm}
Bucket
30.9 3.4 Nm {3.15 0.35 kgm}
Blade
66.2 7.4 Nm {6.75 0.75 kgm}
0.455
0.426
0.455
1.0
1.0
Replace
bushing
1.0
1.0
1.0
1.0
1.0
1.0
Re-tightening
PC128US-2
MAINTENANCE
STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
9JAOI396
PC1 28US-2
40-4 1
MAINTENANCE
WORK EQUIPMENT
STANDARD
c-c
B-B
A-A
M-M
L-L
K-K
J-J
H-H
G-G
F-F
E-E
D-D
N-N
P-P
9JA01397
40-42
PC1 28US-2
WORK EQUIPMENT
Unit: mm
No.
Check item
Clearance between connecting pin and bushing of

revolving frame and boom.
2
3
4
5
6
7

boom and arm.
arm and link.
arm and bucket.
link and bucket.
link and link.
Clearance between the
blade and track frame
mounting pin and bushing
PC128US-2
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
70
0.030
0.100
+0.130
+0.065
0.095
0.230
0.8
70
0.030
0.100
+0.141
+0.074
0.104
0.241
0.8
60
0.030
0.080
+0.129
+0.074
0.104
0.209
0.8
60
0.030
0.080
+0.135
+0.074
0.104
0.215
0.8
65
0.030
0.080
+0.133
+0.074
0.104
0.213
0.8
60
0.030
0.080
+0.130
+0.074
0.104
0.210
0.8
70
0.030
0.100
+0.198
+0.124
0.154
0.298
1.5
Replace
40-43
A
DIMENSION
DIMENSION OF WORK EQUIPMENT
OF WORK EQUIPMENT
FOR STD ARM
A-A
B-B
c-c
9JA01398
40-44
0
PC128US-2
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
70
Tolerance
Shaft
Hole
0.030
0.100
+0.100
0
Arm side
81.5
+1.0
0
Cylinder head side
80
1.2
Boom side
226
+0.5
0
Arm side
226
0.2
0.7
0.030
0.100
+0.100
0
70
264
2.0
213.5
1.0
640.6
0.5
2,491
2,101.9
1.5
10
290.4
0.5
11
487
0.2
12
415
0.5
13
374.9
14
1,246.2
15
60
0.030
0.080
+0.200
0
Link side
259
0
0.1
Bucket side
261
1.0
16
17
60
0.030
0.080
+0.200
0
Arm side
226
0
0.5
Bucket side
274
+2.0
0
18
Min.
1,378
Max.
2,263
19
40-45-1
(15)
PC128US-2
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
70
Tolerance
Shaft
Hole
0.030
0.100
+0.100
0
Arm side
81.5
+1.0
0
Cylinder head side
80
1.2
Boom side
226
+0.5
0
Arm side
226
0.2
0.7
70
0.030
0.100
+0.100
0
284.3
2.0
230.3
1.0
635.8
1.0
2,991.1
2,098.9
1.5
10
289.8
0.5
11
487
0.2
12
415
0.5
13
374.9
14
1,246.2
15
60
0.030
0.080
+0.200
0
Link side
259
0
1.0
Bucket side
261
1.0
16
17
60
0.030
0.080
+0.200
0
Arm side
226
0
0.5
Bucket side
274
+2.0
0
18
Min.
1,378
Max.
2,263
19
40-45-5
(15)
PC128US-2
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
70
Tolerance
Shaft
Hole
0.030
0.100
+0.100
0
Arm side
81.5
+1.0
0
Cylinder head side
80
1.2
Boom side
226
+0.5
0
Arm side
226
0.2
0.7
70
0.030
0.100
+0.100
0
280.5
2.0
213.0
1.0
640.7
1.0
2,088.5
2,101.7
1.5
10
290.0
0.5
11
487
0.2
12
415
0.5
13
374.9
14
1,246.2
15
60
0.030
0.080
+0.200
0
Link side
259
0
1.0
Bucket side
261
1.0
16
17
60
0.030
0.080
+0.200
0
Arm side
226
0
0.5
Bucket side
274
+2.0
0
18
Min.
1,378
Max.
2,263
19
40-45-9
(15)
PC128US-2
MAINTENANCE
STANDARD
DIMENSION
OF WORK EQUIPMENT
Unit:mm
PC128US-2
No.
Measuring position
Standard size
I
-
371.3
51.6
97.9'
I
-
11
12
73
I--
14
15
~.
374.9
-
Tolerance
i 0.5
-
I
-
1,I 59.6
zk0.5
190.5
5'
0'
+0.2
0
0 60
0 64
0 80
+0.25
0
261
t 1.0
50
85
380
+l.O
0
16
018
17
0110
0130
0132
0108
19
21
22
23
274
51
34
106.7
124.3
25
26
74
27
65
PC128US-2
40-47
Unit: mm
PC138US-2
PC138USLC-2
No.
Measuring position
Standard size
Tolerance
371.3
0.5
51.6
0.5
97.9
374.9
1,231.6
190.2
60
+0.2
0
10
64
11
80
+0.25
0
12
261
1.0
13
50
14
85
15
380
+1.0
0
16
18
17
110
18
130
19
132
20
108
21
274
22
51
23
34
24
104.2
25
119.6
26
74
27
65
40-47-1
(15)
PC128US-2
90 OTHERS
Hydraulic circuit diagram (Attachment)
(Breaker : 1 service valve : 50% amount) ..................................................... 90- 3
(Crasher : 1 service valve : 100% amount) ................................................... 90- 5
(Crasher : 2 service valve : 100% amount) .................................................. 90-5-2
Electric circuit diagram (Air conditioner)
PC128US-2
(Serial No.: 5001 7730) ....................................................... 90- 7
Electric circuit diagram (Air conditioner)
PC128US-2
PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-7-2
Hydraulic circuit diagram
PC128US-2
(Serial No.: 5001 7730) ....................................................... 90- 9
PC128US-2
PC138US-2
PC138USLC-2 (Serial No.: 1001 and up) ...................................................... 90-9-2
(With 1 actuator attachment)
PC128US-2
(Serial No.: 5001 7730) ....................................................... 90- 11
PC128US-2
PC138US-2
PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-11-2
(With blade + 1 actuator attachment)
PC128US-2
(Serial No.: 5001 7730) ....................................................... 90- 13
(With blade + 1 actuator attachment)
PC128US-2
PC138US-2
PC138USLC-2 (Serial No.: 1001 and up) .................................................... 90-13-2
Hydraulic circuit diagram (For KUK spec.)
PC128US-2
(Serial No.: 5001 7730) ..................................................... 90-13-4
Hydraulic circuit diagram (For KUK spec.)
PC128US-2
PC138US-2
(Serial No.: 4501 and up) .................................................... 90-13-6
(With 2 actuator attachment) (For KUK spec.)
PC128US-2
(Serial No.: 5001 7730) ..................................................... 90-13-8
(With 2 actuator attachment) (For KUK spec.)
PC128US-2
PC138US-2
(Serial No.: 4501 and up) .................................................. 90-13-10
Electric circuit diagram (1/2)
PC128US-2 (Serial No.: 5001 6300) ........................................................ 90-15
PC128US-2
(Serial No.: 5001 6300) ........................................................ 90-17
PC128US-2
90-1
(15)

PC128US-2
(Serial No.: 6301 7730) ..................................................... 90-17-2
PC128US-2
(Serial No.: 6301 7730) ..................................................... 90-17-4
PC128US-2
(Serial No.: 7731 7874) ..................................................... 90-17-6
PC128US-2
(Serial No.: 7731 7874) ..................................................... 90-17-8
PC128US-2
PC138USLC-2 (Serial No.: 1001 1500) ................................................... 90-17-10
PC128US-2
PC138USLC-2 (Serial No.: 1001 1500) ................................................... 90-17-12
PC138US-2
PC138USLC-2 (Serial No.: 1501 and up) .................................................. 90-17-14
PC138US-2
PC138US-2
Electric circuit diagram (For KUK spec.) (1/2)
PC128US-2
(Serial No.: 5001 6300) ........................................................ 90-19
PC128US-2
(Serial No.: 5001 6300) ........................................................ 90-21
PC128US-2
(Serial No.: 6301 7730) ........................................................ 90-23
PC128US-2
(Serial No.: 6301 7730) ........................................................ 90-25
PC128US-2
(Serial No.: 7731 and up) ....................................................... 90-27
PC128US-2
(Serial No.: 7731 and up) ....................................................... 90-29
PC138US-2
(Serial No.: 4501 and up) ....................................................... 90-31
PC138US-2
(Serial No.: 4501 and up) ....................................................... 90-33
PC138US-2
(Serial No.: 4501 and up) ....................................................... 90-35
90-2
(15)
PC128US-2
HYDRAULIC
OTHERS
CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)

(BREAKER : 1 SERVICE VALVE : 50% AMOUNT)
SERVICE I
(PPC valve)
Selector valve ~2
__-__--__
Ii
IPl
P2 I
L-_-__*--__-_qL____-_XL__f\
I
A7
!__
-c---i
87
SERVICE I -
I
_!
Bl
I
-f2
-
--Al
71
Control valve
Main Puma
PC1 28US-2
SXPO7808
90-3
HYDRAULIC
OTHERS
HYDRAULIC CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
(ATTACHMENT)
(CRASHER : 1 SERVICE VALVE : 100% AMOUNT)
SERVICE I
(PPC valve)
Lock Din
(Large
amount)
--i
I
I
Ii
I-
!--C
SERVICE
A7
-
To oil
cooler
Crusher
ilOO% amount1
SXPO7809
PC1 28US-2
90-5
OTHERS
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)

(CRASHER : 2 SERVICE VALVE : 100% AMOUNT)
PC128US-2
90-5-2
A

PC128US-2
PC138US-2
*1. PC128US-2
Serial No.: 7731 and up *2. PC138US-2
PC128US-2
90-9-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACTUATOR ATTACHMENT)

PC128US-2
PC138US-2
*1. PC128US-2
PC128US-2
90-11-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT)

PC128US-2
PC138US-2
*1. PC128US-2
PC128US-2
90-13-2
(15)
HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.)

*1. PC128US-2 Serial No.: 7731 and up
PC128US-2
90-13-6
(15)
HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.)

PC128US-2
90-13-10
(15)
9JB00694
ELECTRIC CIRCUIT DIAGRAM (1/2)
PC128US-2
PC128US-2
Serial No.: 7731 7874
90-17-6
A

PC128US-2
PC128US-2
9JB00695
Serial No.: 7731 7874
90-17-8
A

PC128US-2
PC128US-2
90-17-10
(15)

PC128US-2
PC128US-2
90-17-12
(15)

PC138US-2
PC128US-2
90-17-14
(15)

PC138US-2
PC128US-2
90-17-16
(15)

PC138US-2
PC128US-2
90-17-18
(15)
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2)

PC128US-2
90-27
(15)

PC128US-2
90-29
(15)

PC128US-2
90-31
(15)

PC128US-2
90-33
(15)

PC128US-2
90-35
(15)

Pc128us-2 Sebm018419 PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Pc128us-2 Sebm018419 PDF

Uploaded by

Copyright:

Available Formats

SEBM018419

Copyright 2007 Komatsu

GENERAL ............................................................................................................ 01-1

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

MAINTENANCE STANDARD ............................................................... 40-1

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised

LIST OF REVISED PAGES

To prevent injury to workers, the symbol

Always wear safety glasses when hitting

3. If welding repairs are needed, always have a

6. Decide a place in the repair workshop to keep

PRECAUTIONS DURING WORK

19.Be sure to assemble all parts again in their original places.

STRUCTURE AND FUNCTION

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

Chassis volume: Issued for every machine model

Revised pages are shown in the LIST OF REVISED

Special safety precautions

Special technical precautions or other precautions

Weight of parts of systems. Caution necessary

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

Slinging near the edge of the hook may cause

3) Do not sling a heavy load with one rope alone,

4) Do not sling a heavy load with ropes forming a

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

1) Hold the mouthpiece of the tightening portion

1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

2) Hold in the condition in Step 1), and push

3) Hold in the condition in Steps 1) and 2), and

3) Hold in the condition in Steps 1) and 2), and

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening portion

Main applications, featuresr

Used to prevent rubber gaskets,

Used in places requiring an immediately effective, strong adhesive.

Features: Resistance to heat and

Used as adhesive or sealant for

Used as sealant for machined

Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Resistance to heat, chemicals

Used as adhesive or sealant for

Used as sealant for various

Features: Silicon based, resistance to heat, cold

Main applications, featuresr