WEN00003-00
HYDRAULIC EXCAVATOR
a
PC128US-8 SERIAL NUMBERS
Arm crane cannot be used on this machine.
20001 and up
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
00 Index and foreword
1
PC128US-8
00-1
00 Index and foreword Table of contents
Index Table of contents
1
00 Index and foreword Index .................................................................................................................................................. Table of contents ............................................................................................................................ Foreword and general information ..................................................................................................... Safety notice................................................................................................................................... How to read the shop manual......................................................................................................... Explanation of terms for maintenance standard ............................................................................. Handling of electric equipment and hydraulic component .............................................................. Handling of connectors newly used for engines ............................................................................. How to read electric wire code ....................................................................................................... Precautions when carrying out operation ....................................................................................... Method of disassembling and connecting push-pull type coupler .................................................. Standard tightening torque table .................................................................................................... Conversion table.............................................................................................................................
00-2 00-2 00-9 00-9 00-14 00-16 00-18 00-27 00-30 00-33 00-36 00-39 00-43
01 Specification Specification and technical data......................................................................................................... 01-3 Specification dimension drawing .................................................................................................... 01-3 Working range diagram .................................................................................................................. 01-4 Specifications ................................................................................................................................. 01-5 Weight table.................................................................................................................................... 01-8 Table of fuel, coolant and lubricants............................................................................................... 01-10 10 Structure, function and maintenance standard Engine and cooling system ................................................................................................................ 10-4 Engine and cooling system............................................................................................................. 10-4 PTO ................................................................................................................................................ 10-5 Cooling system ............................................................................................................................... 10-6 Power train ......................................................................................................................................... 10-8 Power train ..................................................................................................................................... 10-8 Swing circle .................................................................................................................................... 10-9 Swing machinery ............................................................................................................................ 10-10 Undercarriage and frame ................................................................................................................... 10-12 Track frame .................................................................................................................................... 10-12 Idler cushion ................................................................................................................................... 10-13 Idler................................................................................................................................................. 10-14 Track roller...................................................................................................................................... 10-15 Carrier roller.................................................................................................................................... 10-16 Sprocket ......................................................................................................................................... 10-17 Track shoe...................................................................................................................................... 10-18 Hydraulic system................................................................................................................................ 10-24 Hydraulic equipment layout drawing............................................................................................... 10-24 Valve control................................................................................................................................... 10-26 Hydraulic tank and filter .................................................................................................................. 10-28 Hydraulic pump............................................................................................................................... 10-30 Control valve................................................................................................................................... 10-56 CLSS .............................................................................................................................................. 10-68 Functions and operation by valve................................................................................................... 10-72 PPC valve....................................................................................................................................... 10-102 Swing motor.................................................................................................................................... 10-119 Travel motor ................................................................................................................................... 10-127
00-2
PC128US-8
00 Index and foreword Table of contents
Center swivel joint .......................................................................................................................... 10-136 Solenoid valve ................................................................................................................................ 10-140 PPC accumulator ........................................................................................................................... 10-144 Holding valve.................................................................................................................................. 10-146 Work equipment................................................................................................................................. 10-152 Work equipment ............................................................................................................................. 10-152 Dimensions of components ............................................................................................................ 10-154 Hydraulic cylinder ........................................................................................................................... 10-158 Cab and its attachments .................................................................................................................... 10-160 Air conditioner ................................................................................................................................ 10-160 Electrical system ................................................................................................................................ 10-172 Electronic control system ............................................................................................................... 10-172 Monitor system ............................................................................................................................... 10-205 KOMTRAX system ......................................................................................................................... 10-219 Sensor ............................................................................................................................................ 10-221 20 Standard value table Standard service value table.............................................................................................................. Standard value table for engine related parts ................................................................................ Standard value table for chassis related parts ...............................................................................
20-3 20-3 20-4
30 Testing and adjusting Related information on testing and adjusting..................................................................................... Tools for testing, adjusting, and troubleshooting............................................................................ Sketches of special tools................................................................................................................ Engine and cooling system ................................................................................................................ Testing engine speed ..................................................................................................................... Testing exhaust temperature.......................................................................................................... Checking exhaust gas color ........................................................................................................... Adjusting valve clearance............................................................................................................... Testing compression pressure ....................................................................................................... Testing blow-by pressure ............................................................................................................... Testing engine oil pressure ............................................................................................................ Handling fuel system parts ............................................................................................................. Releasing residual pressure from fuel system ............................................................................... Testing fuel pressure...................................................................................................................... Testing fuel return rate and fuel leakage........................................................................................ Bleeding air from fuel circuit ........................................................................................................... Checking fuel circuit for leakage .................................................................................................... Testing and adjusting alternator belt tension.................................................................................. Checking and adjusting air conditioner compressor belt tension ................................................... Power train......................................................................................................................................... Testing swing circle bearing clearance .......................................................................................... Undercarriage and frame ................................................................................................................... Checking and adjusting track shoe tension.................................................................................... Hydraulic system................................................................................................................................ Testing and adjusting oil pressure in work equipment, swing, and travel circuits .......................... Testing control circuit basic pressure ............................................................................................. Testing and adjusting oil pressure in pump PC control circuit........................................................ Testing and adjusting oil pressure in pump LS control circuit ........................................................ Testing solenoid valve output pressure.......................................................................................... Testing PPC valve output pressure................................................................................................ Adjusting play of work equipment and swing PPC valves.............................................................. Checking parts which cause hydraulic drift of work equipment...................................................... Testing and adjusting travel deviation ............................................................................................
30-3 30-3 30-7 30-8 30-8 30-9 30-10 30-11 30-13 30-15 30-16 30-17 30-17 30-18 30-19 30-21 30-23 30-24 30-25 30-26 30-26 30-27 30-27 30-29 30-29 30-32 30-33 30-36 30-40 30-41 30-43 30-44 30-46
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00 Index and foreword Table of contents
Releasing residual pressure from hydraulic circuit ......................................................................... 30-48 Testing oil leakage.......................................................................................................................... 30-49 Bleeding air from each part ............................................................................................................ 30-52 Cab and its attachments .................................................................................................................... 30-54 Checking cab tipping stopper ......................................................................................................... 30-54 Adjusting mirrors............................................................................................................................. 30-54 Electrical system ................................................................................................................................ 30-56 Special functions of machine monitor............................................................................................. 30-56 Handling voltage circuit of engine controller................................................................................... 30-108 Preparation work for troubleshooting of electrical system .............................................................. 30-109 Procedure for testing diodes........................................................................................................... 30-114 Pm-Clinic............................................................................................................................................ 30-115 Pm Clinic service ............................................................................................................................ 30-115 40 Troubleshooting Related information on troubleshooting ............................................................................................. Points to remember when performing troubleshooting................................................................... How to proceed in troubleshooting ................................................................................................. Checks before troubleshooting....................................................................................................... Classification and procedures for troubleshooting.......................................................................... Information in troubleshooting table ............................................................................................... Phenomena looking like troubles and troubleshooting Nos............................................................ Connection table of connector by No. of pins................................................................................. T-box and T-adapter list ................................................................................................................. Failure code table ........................................................................................................................... Fuse locations ................................................................................................................................ Troubleshooting by failure code ......................................................................................................... Failure code [989L00] Engine controller lock caution 1.................................................................. Failure code [989M00] Engine controller lock caution 2................................................................. Failure code [989N00] Engine controller lock caution 3 ................................................................. Failure code [AB00KE] Charge voltage low ................................................................................... Failure code [B@BAZG] Eng oil press. low.................................................................................... Failure code [B@BAZK] Eng oil level low ...................................................................................... Failure code [B@BCNS] Eng coolant overheat.............................................................................. Failure code [B@HANS] Hydr oil overheat..................................................................................... Failure code [CA111] ECM critical internal failure .......................................................................... Failure code [CA115] Eng. Ne and Bkup speed sensor error ........................................................ Failure code [CA122] Charge air press sensor high error .............................................................. Failure code [CA123] Charge air press sensor low error ............................................................... Failure code [CA131] Throttle sensor high error ............................................................................ Failure code [CA132] Throttle sensor low error.............................................................................. Failure code [CA144] Coolant temp. sensor high error .................................................................. Failure code [CA145] Coolant temp. sensor low error.................................................................... Failure code [CA153] Charge air temp. sensor high error.............................................................. Failure code [CA154] Charge air temp. sensor low error ............................................................... Failure code [CA187] Sensor sup. 2 volt. low error ........................................................................ Failure code [CA221] Ambient air press. sensor high error............................................................ Failure code [CA222] Ambient air press. sensor low error ............................................................. Failure code [CA227] Sensor sup. 2 volt. high error....................................................................... Failure code [CA234] Eng. overspeed............................................................................................ Failure code [CA238] Ne speed sensor sup. volt. error.................................................................. Failure code [CA271] IMV/PCV1 short error .................................................................................. Failure code [CA272] IMV/PCV1 open error .................................................................................. Failure code [CA322] Injector #1 (L #1) system open/short error................................................... Failure code [CA324] Injector #3 (L #3) system open/short error...................................................
00-4
40-6 40-6 40-8 40-10 40-11 40-12 40-14 40-17 40-54 40-58 40-62 40-64 40-64 40-64 40-65 40-66 40-68 40-68 40-69 40-69 40-70 40-73 40-74 40-76 40-78 40-80 40-81 40-82 40-83 40-84 40-85 40-86 40-88 40-90 40-91 40-92 40-94 40-95 40-96 40-98
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00 Index and foreword Table of contents
Failure code [CA331] Injector #2 (L #2) system open/short error .................................................. 40-100 Failure code [CA332] Injector #4 (L #4) system open/short error .................................................. 40-102 Failure code [CA351] Inj. drive circuit error .................................................................................... 40-104 Failure code [CA352] Sensor sup. 1 volt. low error........................................................................ 40-107 Failure code [CA386] Sensor sup. 1 volt. high error ...................................................................... 40-108 Failure code [CA435] Abnormality in engine oil pressure switch ................................................... 40-110 Failure code [CA441] Battery voltage low error.............................................................................. 40-111 Failure code [CA442] Battery voltage high error ............................................................................ 40-111 Failure code [CA449] Rail press. very high error ........................................................................... 40-112 Failure code [CA451] Rail press. sensor high error ....................................................................... 40-114 Failure code [CA452] Rail press. sensor low error......................................................................... 40-116 Failure code [CA553] Rail press. high error ................................................................................... 40-116 Failure code [CA559] Rail press. low error..................................................................................... 40-117 Failure code [CA689] Eng. Ne speed sensor error ........................................................................ 40-120 Failure code [CA731] Eng. Bkup speed sensor phase error .......................................................... 40-122 Failure code [CA757] All persistent data lost error......................................................................... 40-122 Failure code [CA778] Eng. Bkup speed sensor error..................................................................... 40-124 Failure code [CA1633] KOMNET datalink timeout error ................................................................ 40-126 Failure code [CA2185] Throttle sens. sup. volt. high error ............................................................. 40-128 Failure code [CA2186] Throttle sens. sup. volt. low error .............................................................. 40-130 Failure code [CA2249] Rail press. very low error........................................................................... 40-130 Failure code [CA2311] Abnormality in IMV solenoid ...................................................................... 40-131 Failure code [D110KB] Battery relay drive short ............................................................................ 40-132 Failure code [D19JKZ] Personal code relay abnormality ............................................................... 40-134 Failure code [D862KA] GPS antenna discon ................................................................................. 40-136 Failure code [DA22KK] Pump solenoid power low error ................................................................ 40-138 Failure code [DA25KP] 5V sensor 1 power abnormality ................................................................ 40-140 Failure code [DA26KP] 5V sensor 2 power abnormality ................................................................ 40-143 Failure code [DA2RMC] CAN discon (Pump controller detected) .................................................. 40-144 Failure code [DAF8KB] Short circuit in camera power supply........................................................ 40-146 Failure code [DAFGMC] GPS module error ................................................................................... 40-148 Failure code [DAFRMC] CAN discon (Monitor detected) ............................................................... 40-150 Failure code [DGH2KB] Hydr oil sensor short................................................................................ 40-152 Failure code [DHPAMA] Pump press sensor abnormality.............................................................. 40-154 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality .................................. 40-156 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality ............................... 40-158 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality.................................. 40-160 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ................................ 40-162 Failure code [DHSKMA] Blade raise PPC press sensor abnormality............................................. 40-164 Failure code [DHSLMA] Blade lower PPC press sensor abnormality ............................................ 40-166 Failure code [DHX1MA] Overload sensor abnormality (Analog) .................................................... 40-168 Failure code [DV20KB] Travel alarm S/C....................................................................................... 40-169 Failure code [DW43KA] Travel speed sol discon ........................................................................... 40-170 Failure code [DW43KB] Travel speed sol short ............................................................................. 40-171 Failure code [DW45KA] Swing brake sol discon ............................................................................ 40-172 Failure code [DW45KB] Swing brake sol short .............................................................................. 40-174 Failure code [DW91KA] Travel junction sol discon ........................................................................ 40-176 Failure code [DW91KB] Travel junction sol short........................................................................... 40-177 Failure code [DWJ0KA] Merge-divider sol discon .......................................................................... 40-178 Failure code [DWJ0KB] Merge-divider sol short ............................................................................ 40-179 Failure code [DXA8KA] PC-EPC sol discon................................................................................... 40-180 Failure code [DXA8KB] PC-EPC sol short ..................................................................................... 40-182 Failure code [DXE4KA] Service current EPC discon ..................................................................... 40-184 Failure code [DXE4KB] Service current EPC short........................................................................ 40-185 Failure code [DY20KA] Wiper working abnormality ....................................................................... 40-186 Failure code [DY20MA] Wiper parking abnormality ....................................................................... 40-188 PC128US-8
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00 Index and foreword Table of contents
Failure code [DY2CKA] Washer drive discon................................................................................. 40-190 Failure code [DY2CKB] Washer drive short ................................................................................... 40-192 Failure code [DY2DKB] Wiper drive (for) short............................................................................... 40-194 Failure code [DY2EKB] Wiper drive (rev) short .............................................................................. 40-196 Troubleshooting of electrical system (E-mode).................................................................................. 40-198 Before carrying out troubleshooting of electrical system ................................................................ 40-198 Information in troubleshooting table ............................................................................................... 40-200 E-1 When starting switch turned ON, machine monitor displays nothing....................................... 40-202 E-2 When starting switch turned ON (before starting engine), basic check item lights up ............. 40-204 E-3 Engine does not start (Engine does not turn) .......................................................................... 40-205 E-4 Preheater does not operate ..................................................................................................... 40-208 E-5 Automatic warm-up system does not operate (in cold season) ............................................... 40-210 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ............. 40-212 E-7 Precaution lights up while engine is running............................................................................ 40-214 E-8 Emergency stop item lights up while engine is running ........................................................... 40-217 E-9 Engine coolant temperature gauge does not indicate normally ............................................... 40-218 E-10 Hydraulic oil temperature gauge does not indicate normally ................................................. 40-219 E-11 Fuel level gauge does not indicate normally.......................................................................... 40-221 E-12 Contents of display by machine monitor are different from applicable machine.................... 40-223 E-13 Machine monitor does not display some items ...................................................................... 40-223 E-14 Function switch does not work............................................................................................... 40-223 E-15 Auto-decelerator does not operate normally.......................................................................... 40-224 E-16 Working mode does not change ............................................................................................ 40-225 E-17 Travel speed does not change............................................................................................... 40-226 E-18 Alarm buzzer cannot be stopped ........................................................................................... 40-227 E-19 Windshield wiper and window washer do not operate ........................................................... 40-228 E-20 Swing holding brake does not operate normally .................................................................... 40-232 E-21 Travel alarm does not sound or does not stop sounding ....................................................... 40-234 E-22 Air conditioner does not operate normally (including air conditioner abnormality record) ..... 40-235 E-23 While starting switch is in OFF position, service meter is not displayed................................ 40-247 E-24 Machine monitor cannot be set in service mode.................................................................... 40-247 E-25 Monitoring function does not display lever control signal normally ........................................ 40-248 E-26 KOMTRAX system does not operate normally ...................................................................... 40-264 Troubleshooting of hydraulic and mechanical system (H-mode) ....................................................... 40-265 Information contained in troubleshooting table............................................................................... 40-265 System chart for hydraulic and mechanical systems...................................................................... 40-266 H-1 Speed or power of all work equipment, swing, and travel are low........................................... 40-268 H-2 Engine speed sharply drops or engine stalls ........................................................................... 40-269 H-3 No work equipment, travel and swing move ............................................................................ 40-270 H-4 Abnormal noise is heard from around hydraulic pump ............................................................ 40-270 H-5 Fine control mode does not function........................................................................................ 40-271 H-6 Speed or power of boom is low ............................................................................................... 40-272 H-7 Speed or power of arm is low .................................................................................................. 40-273 H-8 Speed or power of bucket is low.............................................................................................. 40-274 H-9 Work equipment does not move in its single operation ........................................................... 40-275 H-10 Hydraulic drift of work equipment is large.............................................................................. 40-276 H-11 Time lag of work equipment is large ...................................................................................... 40-277 H-12 Work equipment loaded more is slower during compound operation.................................... 40-277 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE ........................ 40-277 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel. 40-278 H-15 Machine deviates during travel .............................................................................................. 40-279 H-16 Travel speed is low ................................................................................................................ 40-280 H-17 Machine cannot be steered easily or steering power is low .................................................. 40-281 H-18 Travel speed does not change or it is kept low or high.......................................................... 40-282 H-19 Track does not move (Only either side)................................................................................. 40-282 H-20 Machine does not swing ........................................................................................................ 40-283 00-6
PC128US-8
00 Index and foreword Table of contents
H-21 Swing acceleration or swing speed is low ............................................................................. 40-284 H-22 Excessive overrun when stopping swing............................................................................... 40-285 H-23 When upper structure stops swinging, it makes large shock................................................. 40-286 H-24 When upper structure stops swinging, it makes large sound ................................................ 40-286 H-25 Hydraulic drift of swing is large.............................................................................................. 40-287 H-26 Flow rate in attachment circuit cannot be adjusted ............................................................... 40-288 Troubleshooting of engine (S-mode) ................................................................................................. 40-290 Method of using troubleshooting chart ........................................................................................... 40-290 S-1 Starting performance is poor ................................................................................................... 40-294 S-2 Engine does not start............................................................................................................... 40-295 S-3 Engine does not pick up smoothly ........................................................................................... 40-298 S-4 Engine stops during operations ............................................................................................... 40-299 S-5 Engine does not rotate smoothly ............................................................................................. 40-300 S-6 Engine lacks output (or lacks power)....................................................................................... 40-301 S-7 Exhaust smoke is black (incomplete combustion) ................................................................... 40-302 S-8 Oil consumption is excessive (or exhaust smoke is blue) ....................................................... 40-303 S-9 Oil becomes contaminated quickly .......................................................................................... 40-304 S-10 Fuel consumption is excessive .............................................................................................. 40-305 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .................................... 40-306 S-12 Oil pressure drops ................................................................................................................. 40-307 S-13 Oil level rises (Entry of coolant or fuel) .................................................................................. 40-308 S-14 Coolant temperature becomes too high (overheating) .......................................................... 40-309 S-15 Abnormal noise is made ........................................................................................................ 40-310 S-16 Vibration is excessive ............................................................................................................ 40-311 50 Disassembly and assembly General information on disassembly and assembly .......................................................................... 50-4 How to read this manual................................................................................................................. 50-4 Coating materials list ...................................................................................................................... 50-6 Special tool list ............................................................................................................................... 50-9 Sketch of special tool ..................................................................................................................... 50-13 Engine and cooling system ................................................................................................................ 50-15 Removal and installation of fuel supply pump assembly................................................................ 50-15 Removal and installation of fuel injector assembly......................................................................... 50-17 Removal and installation of front oil seal........................................................................................ 50-20 Removal and installation of rear oil seal......................................................................................... 50-22 Removal and installation of cylinder head assembly...................................................................... 50-25 Removal and installation of radiator assembly............................................................................... 50-32 Removal and installation of aftercooler assembly .......................................................................... 50-34 Removal and installation of work equipment oil cooler assembly .................................................. 50-36 Removal and installation of engine and work equipment pump assembly..................................... 50-39 Removal and installation of fuel tank assembly ............................................................................. 50-44 Power train......................................................................................................................................... 50-46 Removal and installation of travel motor and final drive assembly................................................. 50-46 Disassembly and assembly of travel motor and final drive assembly ............................................ 50-48 Removal and installation of swing motor and swing machinery assembly..................................... 50-84 Disassembly and assembly of swing motor and swing machinery assembly ................................ 50-86 Removal and installation of swing circle assembly ........................................................................ 50-92 Undercarriage and frame ................................................................................................................... 50-93 Disassembly and assembly of track roller ...................................................................................... 50-93 Disassembly and assembly of idler assembly................................................................................ 50-96 Disassembly and assembly of recoil spring ................................................................................... 50-99 Spreading and installation of track shoe assembly ........................................................................ 50-102 Removal and installation of sprocket.............................................................................................. 50-104 Removal and installation of revolving frame assembly .................................................................. 50-105 Removal and installation of counterweight assembly (Machine without add-on weight)................ 50-107 PC128US-8
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00 Index and foreword Table of contents
Removal and installation of counterweight assembly (Machine with add-on weight)..................... 50-109 Hydraulic system................................................................................................................................ 50-111 Removal and installation of center swivel joint assembly............................................................... 50-111 Disassembly and assembly of center swivel joint assembly .......................................................... 50-113 Removal and installation of hydraulic tank assembly ..................................................................... 50-114 Removal and installation of hydraulic pump assembly................................................................... 50-117 Removal and installation of control valve assembly ....................................................................... 50-121 Disassembly and assembly of control valve assembly................................................................... 50-126 Disassembly and assembly of work equipment PPC valve assembly............................................ 50-136 Disassembly and assembly of travel PPC valve assembly ............................................................ 50-139 Disassembly and assembly of hydraulic cylinder assembly ........................................................... 50-141 Work equipment ................................................................................................................................. 50-147 Removal and installation of work equipment assembly.................................................................. 50-147 Cab and its attachments .................................................................................................................... 50-150 Removal and installation of operator cab assembly ....................................................................... 50-150 Removal and Installation of operator's cab door ............................................................................ 50-152 Removal and installation of operator's cab glass (stuck glass) ...................................................... 50-155 Removal and installation of front window assembly ....................................................................... 50-164 Removal and installation of floor frame assembly .......................................................................... 50-165 Electrical system ................................................................................................................................ 50-172 Removal and installation of air compressor assembly ................................................................... 50-172 Removal and installation of air conditioner condenser ................................................................... 50-173 Removal and installation of air conditioner unit assembly.............................................................. 50-174 Removal and installation of machine monitor assembly................................................................. 50-177 Removal and installation of pump controller assembly .................................................................. 50-178 Removal and installation of engine controller assembly................................................................. 50-179 Removal and installation of KOMTRAX communications module.................................................. 50-180 90 Diagrams and drawings Hydraulic diagrams and drawings ...................................................................................................... 90-3 Symbols used in hydraulic circuit diagrams.................................................................................... 90-3 Hydraulic circuit diagram ................................................................................................................ 90-5 Electrical diagrams and drawings ...................................................................................................... 90-9 Symbols used in electric circuit diagrams....................................................................................... 90-9 Electrical circuit diagram ................................................................................................................ 90-13 Connectors table and arrangement drawing .................................................................................. 90-25 Index .....................................................................................................................................................
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PC128US-8
00 Index and foreword Safety notice
Foreword and general information Safety notice (Rev. 2008/08) Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
PC128US-8
7)
8)
9)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w eld ing wo rk , alw ay s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
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00 Index and foreword Safety notice
2.
Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3.
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
00-10
6)
When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) 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. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
PC128US-8
00 Index and foreword Safety notice
4.
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
PC128US-8
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
00-11
00 Index and foreword Safety notice
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
00-12
7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
PC128US-8
00 Index and foreword Safety notice
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)
a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
PC128US-8
00-13
00 Index and foreword How to read the shop manual
How to read the shop manual q q q
1.
1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.
Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
00-14
PC128US-8
00 Index and foreword How to read the shop manual
3.
4.
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
Special safety precautions are necessary when performing work.
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
Places that require special attention for tightening torque during assembly.
2
5.
Coat
5
Oil, coolant
6
Drain
Remarks
Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
PC128US-8
00-15
00 Index and foreword Explanation of terms for maintenance standard
Explanation of terms for maintenance standard
1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.
Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q
Example: Standard size 120
Tolerance –0.022 –0.126
a
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
00-16
Tolerance Shaft Hole –0.030 +0.046 –0.076 +0
PC128US-8
00 Index and foreword Explanation of terms for maintenance standard
2.
Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
5.
q
3.
Standard interference When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. q
4.
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q
6.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
PC128US-8
00-17
00 Index and foreword Handling of electric equipment and hydraulic component
Handling of electric equipment and hydraulic component
1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.
Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
00-18
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.
PC128US-8
00 Index and foreword Handling of electric equipment and hydraulic component
3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be 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. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
PC128US-8
00-19
00 Index and foreword Handling of electric equipment and hydraulic component
3.
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q
00-20
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
PC128US-8
00 Index and foreword Handling of electric equipment and hydraulic component
2)
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
PC128US-8
00-21
00 Index and foreword Handling of electric equipment and hydraulic component
3)
00-22
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
q
Disconnection
q
Connection (Example of incomplete setting of (a))
PC128US-8
00 Index and foreword Handling of electric equipment and hydraulic component
4)
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter from th e c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
PC128US-8
00-23
00 Index and foreword Handling of electric equipment and hydraulic component
4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
00-24
PC128US-8
00 Index and foreword Handling of electric equipment and hydraulic component
Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
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 onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
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.
PC128US-8
00-25
00 Index and foreword Handling of electric equipment and hydraulic component
5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
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.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
00-26
PC128US-8
00 Index and foreword Handling of connectors newly used for engines
Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
PC128US-8
00-27
00 Index and foreword Handling of connectors newly used for engines
3.
Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
q
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
107 engine
a
2)
00-28
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
PC128US-8
00 Index and foreword Handling of connectors newly used for engines
q
4)
95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
1)
Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
PC128US-8
00-29
00 Index and foreword How to read electric wire code
How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile
Symbol AV
AVS
Heat-resistant low-voltAEX age wire for automobile
00-30
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
PC128US-8
00 Index and foreword How to read electric wire code
2.
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
PC128US-8
00-31
00 Index and foreword How to read electric wire code
3.
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit
Others
00-32
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
–
R B R D Y G L
–
–
WG
–
–
–
–
–
–
–
–
–
– –
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– –
Gr Br – –
PC128US-8
00 Index and foreword Precautions when carrying out operation
Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
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
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30
27
07049-02734
27
PC128US-8
22.5
34
00-33
00 Index and foreword Precautions when carrying out operation
2. q q q q q q q q q q q q q
a
a 3.
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
00-34
PC128US-8
00 Index and foreword Precautions when carrying out operation
4)
5)
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
PC128US-8
00-35
00 Index and foreword Method of disassembling and connecting push-pull type coupler
Method of disassembling and connecting push-pull type coupler
1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container. Type 1 1.
Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-36
PC128US-8
00 Index and foreword Method of disassembling and connecting push-pull type coupler
Type 2 1.
2.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
q
PC128US-8
00-37
00 Index and foreword Method of disassembling and connecting push-pull type coupler
Type 3 1.
2.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
q
00-38
PC128US-8
00 Index and foreword Standard tightening torque table
Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
The following table applies to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
Width across flats mm 10 12 14 17
Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
PC128US-8
00-39
00 Index and foreword Standard tightening torque table
2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. 02 03,04 05,06 10,12 14
4.
Width across flats mm 14 17 22
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
00-40
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC128US-8
00 Index and foreword Standard tightening torque table
5.
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}
Nominal No. of hose
Width across flats
02
19 22 24 27 32 36 41 46 55
03 04 05 06 (10) (12) (14)
6.
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
PC128US-8
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
00-41
00 Index and foreword Standard tightening torque table
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
9.
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
00-42
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC128US-8
00 Index and foreword Conversion table
Conversion table
1
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.
Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
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
PC128US-8
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-43
00 Index and foreword Conversion table
Millimeters to inches
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
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
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
00-44
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
PC128US-8
00 Index and foreword Conversion table
Liters to U.K. Gallons
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
PC128US-8
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
419.5 491.8 564.2 636.5 708.8
1142.8 1215.1 1287.5 1359.8 1432.1
426.8 499.1 571.4 643.7 716.1
1150.0 1222.4 1294.7 1367.0 1439.4
00-45
00 Index and foreword Conversion table
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
00-46
PC128US-8
00 Index and 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 (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–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
177.8 179.6 181.4 183.2 185.0
–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 60
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
PC128US-8
00-47
00 Index and foreword Conversion table
00-48
PC128US-8
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
01 Specification
1
PC128US-8
01-1
01 Specification
Contents Specification and technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
01-3
Specification dimension drawing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
01-3
Working range diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
01-4
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
01-5
Weight table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
01-8
Table of fuel, coolant and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
01-10
01-2
PC128US-8
01 Specification Specification dimension drawing
Specification and technical data Specification dimension drawing
Item
1
Unit
Standard specification Machine weight
Reinforced blade specification
PC128US-8 12,950
kg
13,450
Bucket capacity
m3
0.45
Engine type
—
Komatsu SAA4D95LE-5 Diesel engine
kW{HP}/rpm
68.4{91.7}/2,200 72.1{96.6}/2,200
Standard specification
mm
7,260
Reinforced blade specification
mm
7,970
Overall height
mm
2,850
C Overall width
mm
2,490
D Shoe width
mm
500
E
Tail swing radius
mm
1,480
F
Crawler overall length
mm
3,605
G Distance between tumbler center
mm
2,880
H Cab height
mm
2,810
Ground clearance
mm
390
Traveling speed (Low/High)
km/h
2.9/5.1
Continuous swing speed
rpm
11.0
Engine rated output • Net [ISO 9249/SAE J1349] • Gross [SAE J1995] A A' B
a
Overall length
The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine.
PC128US-8
01-3
01 Specification Working range diagram
Working range diagram
Working range (mm)
1
PC128US-8
A
Maximum digging reach
8,230
B
Maximum digging depth
5,405
C
Maximum digging height
9,260
D
Maximum vertical wall digging depth
4,860
E
Maximum dumping height
6,910
F
Minimum swing radius of work equipment
1,980
G
Maximum reach at ground level
8,110
H
Maximum raising distance of blade
470
I
Maximum lowering distance of blade
530
01-4
PC128US-8
01 Specification Specifications
Specifications
1 PC128US-8
Machine model
Standard specification m3
0.45
0.45
Machine weight
kg
12,950
13,450
Max. digging depth
mm
5,405
5,405
mm
4,860
4,860
Max. digging reach
mm
8,230
8,230
Max. reach at ground level
mm
8,110
8,110
Max. digging height
mm
9,260
9,260
Max. dumping height
mm
6,910
6,910
Max. blade lifting amount
mm
—
470
Max. blade lowering amount
mm
—
530
Maximum digging force (bucket)
kN{kg}
100{10,200}
100{10,200}
Swing speed
rpm
11.0
11.0
Swing max. slope angle
Degree
19.0
19.0
Travel speed (Low/High)
km/h
2.9/5.1
2.9/5.1
Gradeability
deg.
35
35
kPa{kg/cm }
41.2{0.42}
42.2{0.43}
Overall length (for transport)
mm
7,260
7,970
Overall width
mm
2,490
2,490
Overall height (for transport)
mm
2,850
2,850
Overall height (for work)
mm
2,830
2,830
Ground clearance of counterweight
mm
895
895
Min. ground clearance
mm
390
390
Tail swing radius
mm
1,480
1,480
Min. swing radius of work equipment
mm
1,980
1,980
Height of work equipment at min. swing radius
mm
6,765
6,765
Crawler overall width
mm
2,490
2,490
Crawler overall length
mm
3,605
3,605
Length of track on ground
mm
2,880
2,880
Track gauge
mm
1,990
1,990
Overall height of machine cab
mm
2,085
2,085
Blade width x height
mm
—
2,490 x 590
Ground pressure
Dimension
20001 and up
Bucket capacity
Max. vertical wall depth Working ranges
Performance
Serial No.
Reinforced blade specification
2
The values are based on the machine with the triple grouser shoe.
PC128US-8
01-5
01 Specification Specifications
PC128US-8
Machine model
Standard specification
20001 and up
Model
SAA4D95LE-5
Type
4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and air cooled aftercooler mm
95 x 115
Piston displacement
l{cc}
3.260{3,260}
Rated horsepower • Net [ISO 9249/SAE J1349] • Gross [SAE J1995]
kW{HP}/rpm kW{HP}/rpm
68.4{91.7}/2,200 72.1{96.6}/2,200
Max. torque
Nm{kgm}/rpm
350{35.7}/1,500
Fuel consumption ratio at rated speed
g/kWh{g/HPh}
224{167}
Max. high idle speed • At installed on machine • At independent engine
rpm rpm
2,150 2,300
Min. low idle speed
rpm
Performance
No. of cylinders-bore x stroke
1,100
Starting motor
24 V, 4.5 kW
Alternator
24 V, 35 A
Battery (*1)
12 V, 72 Ah x 2
Radiator core type
4-array aluminum mesh core
Aftercooler core type
Aluminum mesh core
Carrier roller
1 on each side
Track roller
7 on each side
Track shoe (iron shoe) (road liner) Hydraulic motor Control valve Hydraulic pump
Hydraulic system
Undercarriage
Engine
Serial No.
Reinforced blade specification
Assembly-type triple grouser shoe, 43 on each side Assembly-type road liner, 43 on each side
Type x no.
Variable displacement piston type x 1
Discharge
l/min
121+121 (at 2,200 rpm)
Set pressure
MPa{kg/cm2}
34.8{355}
Type x no.
6-spool type x 1
Control method
Hydraulic type
Travel motor
Variable displacement piston type (with brake valve and parking brake) x 2
Swing motor
Fixed displacement piston type (with safety valve and holding brake) x 1
Hydraulic tank
Box-shaped, open
Hydraulic oil filter
Tank return side
Hydraulic cooler
Air cooled (CF40)
*1. Battery capacity (Ah) is based on 5-hour rate. a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the conditionessentially the same as that when it is installed on machine.
01-6
PC128US-8
01 Specification Specifications
PC128US-8
Machine model
Standard specification
Serial No.
20001 and up
Boom cylinder
Type mm
105
105
mm
70
70
Stroke
mm
1,055
1,055
Max. length between pins
mm
2,555
2,555
Min. length between pins
mm
Arm cylinder
1,500
1,500
Reciprocating piston type
Reciprocating piston type
Cylinder inner diameter
mm
110
110
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
Max. length between pins
mm
2,798
2,798
Min. length between pins
mm
1,623
1,623
Reciprocating piston type
Reciprocating piston type
Cylinder inner diameter
mm
95
95
Piston rod diameter
mm
65
65
Stroke
mm
885
885
Max. length between pins
mm
2,263
2,263
Min. length between pins
mm
1,378
1,378
—
Reciprocating piston type
Type Blade cylinder
Reciprocating piston type
Piston rod diameter
Type Bucket cylinder
Work equipment cylinder
Hydraulic system
Reciprocating piston type
Cylinder inner diameter
Type
PC128US-8
Reinforced blade specification
Cylinder inner diameter
mm
—
110
Piston rod diameter
mm
—
75
Stroke
mm
—
181
Max. length between pins
mm
—
870
Min. length between pins
mm
—
689
01-7
01 Specification Weight table
Weight table
1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg Machine model
PC128US-8 Standard specification
Serial No.
Blade specification
20001 and up
Engine assembly (excl. coolant and oil)
458
458
• Engine (excl. coolant and oil)
332
332
• Engine mount
18.1
18.1
• PTO
5.5
5.5
• Hydraulic pump
102
102
Cooling assembly (excl. coolant and oil)
82.2
82.2
• Radiator (excl. coolant)
7.9
7.9
• Oil cooler (excl. oil)
10.2
10.2
• Aftercooler
8.1
8.1
• Fuel cooler (excl. fuel)
0.7
0.7
Revolving frame
1,400
1,400
Operator cab
375
375
Operator seat
14
14
Fuel cooler (excl. fuel)
90.6
90.6
Hydraulic tank (excl. hydraulic oil)
79.5
79.5
Control valve
95
99
Counterweight
2,855
2,320
Added counterweight
500
500
Swing motor (incl. brake valve)
20
20
Swing circle
152.6
152.6
Swing machinery
71.6
71.6
Center swivel joint
28.6
43.6
Track frame assembly (excl. track shoe)
2,300
2,410
• Track frame
1,305
1,415
• Idler assembly
79 x 2
79 x 2
• Recoil spring assembly
69 x 2
69 x 2
• Carrier roller
16.5 x 2
16.5 x 2
• Track roller
22 x 14
22 x 14
• Travel motor (with final drive)
145 x 2
145 x 2
• Sprocket
33.7 x 2
33.7 x 2
• Triple grouser shoe (500 mm)
725 x 2
725 x 2
• Triple grouser shoe (600 mm)
815 x 2
815 x 2
• Triple grouser shoe (700 mm)
905 x 2
905 x 2
• Triple grouser shoe (750 mm)
—
—
Track shoe assembly
• Single grouser shoe (510 mm)
835 x 2
835 x 2
• City pad shoe (500 mm)
720 x 2
720 x 2
• Road liner (500 mm)
780 x 2
780 x 2
01-8
PC128US-8
01 Specification Weight table
Unit: kg Machine model
PC128US-8 Standard specification
Serial No.
Blade specification
20001 and up
Boom assembly
820
820
Arm assembly
356
356
Bucket link assembly
85.6
85.6
• 955 mm width (incl. side cutter)
369
369
• 980 mm width (incl. side cutter)
—
—
• Reinforced blade (BOC type, incl. BOC)
—
688
• Blade (edge-welding type)
—
668
• Reinforced wide blade (BOC type, incl. BOC)
—
702
• Wide blade (edge-welding type)
—
682
Boom cylinder assembly
101.3 x 2
101.3 x 2
Arm cylinder assembly
125.3
125.3
Bucket cylinder assembly
77.8
77.8
Blade cylinder assembly
—
59.5 x 2
Bucket assembly
Blade assembly
a
BOC: Bolt-On Cutting edge
PC128US-8
01-9
01 Specification Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants a
1
For details of the notes (Note. 1, Note. 2 …) in the table, see the Operation and Maintenance Manual.
01-10
PC128US-8
01 Specification Table of fuel, coolant and lubricants
Unit: l Reservoir
Specified capacity
Refill capacity
Engine oil pan
11.5
11.0
Swing machinery case
2.5
2.5
Final drive case (each side)
2.1
2.1
PTO case
0.75
0.75
Hydraulic system
120
69
Fuel tank
195
—
Cooling system
12.4
—
PC128US-8
01-11
01 Specification Table of fuel, coolant and lubricants
01-12
PC128US-8
HYDRAULIC EXCAVATOR PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
10 Structure, function and maintenance standard
1
PC128US-8
10-1
10 Structure, function and maintenance standard
Contents Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-4
Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-4
PTO- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-5
Cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-6
Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-8
Power train- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-8
Swing circle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-9
Swing machinery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-10
Undercarriage and frame- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-12
Track frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-12
Idler cushion- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-13
Idler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-14
Track roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-15
Carrier roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-16
Sprocket- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-17
Track shoe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-18
Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-24
Hydraulic equipment layout drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-24
Valve control- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-26
Hydraulic tank and filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-28
Hydraulic pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-30
Control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-56
CLSS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-68
Functions and operation by valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
10-72
PPC valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-102 Swing motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-119 Travel motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-127 Center swivel joint- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-136 Solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-140 PPC accumulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-144 Holding valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-146 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-152 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-152 Dimensions of components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-154 Hydraulic cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-158 Cab and its attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-160 Air conditioner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-160 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-172 Electronic control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-172 Monitor system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-205 KOMTRAX system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-219 Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-221
10-2
PC128US-8
10 Structure, function and maintenance standard
PC128US-8
10-3
10 Structure, function and maintenance standard Engine mount
Engine and cooling system Engine mount
10-4
1
PC128US-8
10 Structure, function and maintenance standard PTO
PTO a
PTO: Abbreviation for Power Take Off
1. 2. 3. 4. 5. 6.
Flywheel Coupling Hydraulic pump shaft Drain plug Oil filler plug Oil level plug
PC128US-8
1
10-5
10 Structure, function and maintenance standard Cooling system
Cooling system
10-6
1
PC128US-8
10 Structure, function and maintenance standard Cooling system
1. 2. 3. 4. 5. 6. 7. 8. 9.
Radiator cap Shroud Reservoir tank Oil cooler inlet Oil cooler Aftercooler Radiator Fuel cooler Fuel cooler outlet
10. Fuel cooler inlet 11. Radiator outlet hose 12. Radiator inlet hose 13. Aftercooler outlet hose 14. Fan guard 15. Oil cooler outlet 16. Aftercooler inlet hose 17. Drain plug
Specifications Radiator
Oil cooler
Aftercooler
Fuel cooler
4-array aluminum mesh core
CF40
Aluminum mesh core
Drawn cup
Fine pitch (mm)
3.5/2
3.5/2
4.0/2
4.0/2
Total heat dissipation surface (m²)
22.03
12.78
6.68
0.59
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
PC128US-8
10-7
10 Structure, function and maintenance standard Power train
Power train Power train
1. 2.
Idler Control valve 2a. Self pressure reducing valve 2b. Pump merge-divider valve 2c. Travel junction valve 3. PPC lock solenoid valve 4. 2nd travel speed select solenoid valve 5. Swing holding brake solenoid valve 6. Pump merge-divider solenoid valve
10-8
1
7. Travel junction solenoid valve 8. Travel motor 9. Hydraulic pump 10. Engine 11. Swing motor 12. Center swivel joint 13. Swing machinery 14. Swing circle
PC128US-8
10 Structure, function and maintenance standard Swing circle
Swing circle
1
Unit: mm No.
Item
1
Bearing clearance
2. 3. 4. 5. 6. 7.
Swing circle bearing lubrication Swing circle pinion lubrication Outer race Ball Seal Inner race (Number of teeth: 90)
PC128US-8
Criteria
Remedy
Basic clearance
Clearance limit
0.5 – 1.6
2.6
a. b.
Replace
Inner race soft zone position Outer race soft zone position
Specifications Reduction ratio
90/11=8.182
Grease
G2-LI
Grease quantity (l)
9.1
10-9
10 Structure, function and maintenance standard Swing machinery
Swing machinery
1. Level gauge 2. Oil feed pipe 3. Oil filler cap 4. Swing pinion (Number of teeth: 11) 5. Swing machinery case 6. No. 2 planetary carrier 7. No. 2 sun gear (Number of teeth: 17) 8. Ring gear (Number of teeth: 61) 9. No. 1 planetary carrier 10. No. 1 sun gear (Number of teeth: 14) 11. Swing motor 12. No. 1 planetary gear (Number of teeth: 24) 13. No. 2 planetary gear (Number of teeth: 22) 14. Drain plug
10-10
1
Specifications Reduction ratio
(14+61) / 14 × (17+61) / 17 = 24.58
Swing reduction ratio
24.58 × 8.182 = 201.11
Swing speed (rpm)
11.0
PC128US-8
10 Structure, function and maintenance standard Swing machinery
Unit: mm No.
Item
1
Backlash between swing motor shaft and No. 1 sun gear
2
Criteria
Remedy
Standard clearance
Clearance limit
0.07 – 0.18
0.4
Backlash between No. 1 sun gear and No. 1 planetary gear
0.13 – 0.31
0.6
3
Backlash between No. 1 planetary gear and ring gear
0.15 – 0.34
0.7
4
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.14 – 0.34
0.7
5
Backlash between No. 2 sun gear and No. 2 planetary gear
0.13 – 0.31
0.6
6
Backlash between No. 2 planetary gear and ring gear
0.15 – 0.34
0.7
7
Backlash between No. 2 planetary carrier and swing pinion
0.08 – 0.19
0.4
8
Back lash between swing pinion and swing circle
0.13 – 1.16
2.3
9
Outside diameter of oil seal contacting surface on swing pinion collar
PC128US-8
Replace
Standard size
Tolerance
Repair limit
145
0 -0.100
144.8
Repair by hard chrome-plating or replace
10-11
10 Structure, function and maintenance standard Track frame
Undercarriage and frame Track frame
1
Unit: mm No.
1
2
3. 4. 5. 6.
Item
Length at idler guide
Width at idler guide
Idler Track frame Carrier roller Travel motor
10-12
Criteria
Remedy
Standard size
Repair limit
Track frame
84
89
Idler support
82
77
Rebuilding or replace
Track frame
185
193
Rebuilding
Idler support
183
175
Rebuilding or replace
Rebuilding
7. Sprocket 8. Track roller 9. Idler cushion 10. Track shoe
PC128US-8
10 Structure, function and maintenance standard Idler cushion
Idler cushion
1
Unit: mm No.
Item
Criteria
Remedy
Standard size 1
Recoil spring
2. Idler 3. Support 4. Rod 5. Recoil spring 6. Cylinder 7. U-packing 8. Pilot 9. Nut 10. Valve 11. Grease fitting
PC128US-8
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
501.4
390
84.3 kN {8,600 kg}
489
75.0 kN {7,650 kg}
Replace
Specifications Grease
G2-LI
Grease quantity (cc)
118
10-13
10 Structure, function and maintenance standard Idler
Idler
1
Unit: mm No.
Item
1
Outside diameter of projection
2
Criteria
Remedy
Standard size
Repair limit
527
—
Outside diameter of tread
489
477
3
Tread depth
19
25
4
Width of projection
52
42
5
Overall width
115
107
6
Tread width
31.5
36.5
7
Clearance between idler shaft and bushing
Standard size 54
8
Interference between bushing and idler
Standard size 61
Tolerance
Rebuilding or replace
— Rebuilding or replace
Shaft
Hole
Standard clearance
Clearance limit
-0.250 -0.280
+0.074 0
0.250 – 0.354
1.5
Tolerance Shaft
Hole
Standard interference
+0.117 +0.087
+0.030 0
0.057 – 0.117
InterferReplace ence limit —
9
Side clearance of idler (each side)
Standard clearance
Clearance limit
0.18 – 0.38
1.5
10
Tread thickness (at tread center)
Basic dimension
Repair limit
15
9
— Oil capacity
10-14
90 cc (engine oil: SAE30CD)
Rebuilding or replace —
PC128US-8
10 Structure, function and maintenance standard Track roller
Track roller
1
Unit: mm No.
Item
Criteria
Remedy
Standard size
Repair limit
158
— 120
1
Outside diameter of projection
2
Outside diameter of tread
130
3
Flange width
26.5
—
4
Overall width
176
—
5
Tread width
35
—
6
Clearance between Shaft and bushing
Standard size 50
7
Interference between roller and bushing
Standard size 54
8
Side clearance of track roller (each side)
9
Tread thickness (at tread center)
— Oil capacity
PC128US-8
Tolerance
Rebuilding or replace
— Rebuilding or replace
Shaft
Hole
Standard clearance
Clearance limit
-0.220 -0.240
+0.190 +0.030
0.250 – 0.430
1.5
Tolerance Shaft
Hole
+0.190 +0.140
± 0.030
Standard interference
InterferReplace ence limit
0.110 – 0.220
—
Standard clearance
Clearance limit
0.41 – 0.90
1.5
Standard size
Repair limit
38
33
145 – 155 cc (engine oil: SAE30CD)
Rebuilding or replace —
10-15
10 Structure, function and maintenance standard Carrier roller
Carrier roller
1
Unit: mm No.
Item
1
Outside diameter of tread
2
Tread width
3
Clearance between shaft and bushing
Criteria
Standard size 40
4
Interference between collar and bushing
Standard size 47
5
Side clearance of carrier roller (each side)
6
Tread thickness (at 10 mm from roller outer edge)
— Oil capacity
10-16
Remedy
Standard size
Repair limit
116
106
123
—
Tolerance
—
Shaft
Hole
Standard clearance
Clearance limit
+0.055 +0.035
+0.261 +0.200
0.145 – 0.226
—
Tolerance Shaft
Hole
Standard interference
+0.061 +0.036
+0.025 0
0.011 – 0.061
InterferReplace ence limit —
Standard clearance
Clearance limit
0.363 – 0.537
1.5
Standard size
Repair limit
17.7
12.7
68 – 76 cc (engine oil: SAE30CD)
Rebuilding or replace
Rebuilding or replace —
PC128US-8
10 Structure, function and maintenance standard Sprocket
Sprocket
1
Unit: mm No.
Item
1
Wear on tooth bottom diameter
2
Criteria
Remedy
Standard size
Tolerance
Repair limit
547.4
+1.0 -2.0
535
Wear on tooth tip diameter
607
—
595
3
Wear on tooth tip width
27
—
22
4
Wear on tooth bottom width
42
±1.5
39
5
Thickness at tooth bottom
111.7
+0.465 -1.160
105.5
PC128US-8
Rebuilding or replace
10-17
10 Structure, function and maintenance standard Track shoe
Track shoe
1
Triple grouser shoe, road liner, city pad shoe
*1. Triple grouser shoe, city pad shoe *2. Road liner a
P portion shows the link of bushing press fitting end.
10-18
PC128US-8
10 Structure, function and maintenance standard Track shoe
Unit: mm No.
Item
1
Link pitch
2
Bushing external diameter
3
Bushing thickness
4
Link height
5
Link thickness (bushing press fit part)
6 7
Criteria Standard size
Repair limit
175.3
178.3
Standard size
Reverse
46.3
42.3
7.9
3.9
Standard size
Repair limit
86
81
24
19 102.4
Shoe bolt pitch
Repair or replace
Replace
57
9
Internal width
52.4
10 Link
Overall width
35
11
Tread width
30.1
12 Pin projection
3
13 Regular bushing projection
3.75
14 Pin overall length
168
Bushing overall length (master bushing)
16 Spacer thickness 17 18
Reverse or replace
86.4
8
15
Remedy
Press-fit force
19 (*)
Repair or replace
Adjust or replace
86.7 —
Bushing
39.2 – 137.3 kN {4 – 14 ton}
Regular pin
78.5 – 186.3 kN {8 – 19 ton}
Master pin
39.2 – 98.1 kN {4 – 10 ton}
—
*: In case of dry type track.
PC128US-8
10-19
10 Structure, function and maintenance standard Track shoe
Unit: mm No.
Item
Criteria Tightening torque (Nm {kgm})
20 Shoe bolt
• Triple grouser shoe a. Regu- • City pad shoe lar link • Single grouser shoe
b. Master link
Interference between bushing 21 and link
22
23
Interference between regular pin and link Clearance between regular pin and bushing
90 ± 10 Retighten 50 ± 5
Tightening torque (Nm {kgm})
Retightening angle (degree)
Torque lower limit (Nm {kgm})
—
—
— Standard size
Tolerance
Standard interference
Shaft
Hole
46
+0.387 +0.347
+0.062 +0.074
0.285 – 0.387
30
+0.150 +0.074
-0.198 -0.250
0.198 – 0.400
Standard size
Standard size
Standard size 30
26 Grouser height (road liner)
196 ± 20 {20 ± 2}
147 ± 10 {15 ± 1}
30
25 Clearance between master pin (*) and bushing
Retightening angle (degree)
• Road liner
30
24 Interference between master (*) pin and link
Remedy
58
Tolerance Shaft
Hole
+0.150 +0.074
+0.830 +0.330
Tolerance Shaft
Hole
+0.020 +0.020
+0.198 -0.250
Standard clearance 0.180 – 0.830 Standard interference 0.178 – 0.270
Tolerance Shaft
Hole
-0.200 -0.300
+0.830 +0.330
Adjust or replace
Standard clearance 0.530 – 1.130 21
Replace
*: In case of dry type track.
10-20
PC128US-8
10 Structure, function and maintenance standard Track shoe
Triple grouser shoe
Unit: mm No.
Item
1
Grouser overall height
2
Shoe overall height
3
Plate thickness
4 5
Grouser bottom length
6 7
Criteria
Remedy
Standard size
Repair limit
20
10
29.5
19.5 9.5 20
Rebuilding or replace
20 14
Grouser tip length
8
PC128US-8
13 15
10-21
10 Structure, function and maintenance standard Track shoe
Single shoe
Unit: mm No.
Item
Criteria Standard size
Repair limit
50
20.5
1
Grouser overall height
2
Shoe overall height
3
Plate thickness
12
4
Grouser bottom length
25
5
Grouser tip length
14
10-22
Remedy
62
32.5
Rebuilding or replace
PC128US-8
10 Structure, function and maintenance standard Track shoe
PC128US-8
10-23
10 Structure, function and maintenance standard Hydraulic equipment layout drawing
Hydraulic system Hydraulic equipment layout drawing
1
1. Bucket cylinder 2. Arm cylinder 3. Control valve 4. Solenoid valve 5. Accumulator (for PPC circuit) 6. Boom cylinder 7. Hydraulic tank 8. Swing motor 9. Hydraulic pump 10. R.H. travel motor 11. Oil cooler 12. L.H. travel motor 13. L.H. work equipment PPC valve 14. Blade PPC valve 15. R.H. work equipment PPC valve 16. Center swivel joint 17. Travel PPC valve 18. Attachment PPC valve (Machine ready for attachment) 19. Blade cylinder (blade specification)
10-24
PC128US-8
10 Structure, function and maintenance standard Hydraulic equipment layout drawing
PC128US-8
10-25
10 Structure, function and maintenance standard Valve control
Valve control
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connecting valve Solenoid valve Accumulator (for PPC circuit) Control valve Blade PPC valve (blade specification) R.H. work equipment control lever (for boom and bucket control) Blade control lever (blade specification) L.H. work equipment control lever (for arm and swing control) L.H. work equipment PPC valve
10-26
1
10. Lock lever 11. R.H. work equipment PPC valve 12. Travel lever 13. Travel pedal 14. Travel PPC valve 15. Attachment PPC valve (Machine ready for attachment) 16. Attachment control pedal (Machine ready for attachment) 17. Lock pin
PC128US-8
10 Structure, function and maintenance standard Valve control
PC128US-8
10-27
10 Structure, function and maintenance standard Hydraulic tank and filter
Hydraulic tank and filter
1. 2. 3. 4. 5. 6. 7.
Hydraulic tank Suction strainer Filter element Bypass valve Drain plug Sight gauge Oil filler cap combined with breather
10-28
1
Specifications Hydraulic tank capacity (l)
99
Oil level in hydraulic tank (l)
69
Bypass valve set pressure (MPa{kg/cm²})
0.15 ± 0.03 {1.53 ± 0.3}
PC128US-8
10 Structure, function and maintenance standard Hydraulic tank and filter
Breather
1. 2. 3. 4. 5.
Filter element Bottom plate Gasket Seam valve Spring
Prevention of negative pressure in tank q The hydraulic tank is enclosed and pressurized. When the oil level in the hydraulic tank drops, negative pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) is opened to draw the atmosphere to the tank. (Intake valve set pressure: 0 – 0.49 kPa {0 – 0.005 kg/cm²}) Prevention of pressure rise in tank q When the hydraulic circuit is operating, the pressure in the hydraulic tank increases as the hydraulic cylinder operates and the oil level and temperature increase in the tank. If the pressure in the tank rises above the set value, bottom plate (2) is pushed up to release the pressure in the tank. (Exhaust valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm²})
PC128US-8
10-29
10 Structure, function and maintenance standard Hydraulic pump
Hydraulic pump
1
Type: HPD56+56
10-30
PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Outline q This pump consists of a variable-displacement swash plate type piston pump, PC valve, LS valve and EPC valve. Features of double pump system The common single pump system makes much loss in the pressure compensation valve. Accordingly, the machine travel speed is reduced much when the machine is steered. q The double pump system does not make much loss in the pressure compensation valve, since the right and left travel circuits are independent from each other. Accordingly, the machine travel speed is less reduced when the machine is steered. q The double pump has simpler structure than the tandem pump. q
BMP : Breather mounting port IM : PC mode selector current OCP : Oil level check port P1T : Travel deviation control orifice P2T : Travel deviation control orifice PA1 : Pump discharge port PA1C : Pump discharge pressure pickup port PA2 : Pump discharge port PA2C : Pump discharge pressure pickup port PB : Pump pressure input port PD1 : Case drain port PD2 : Drain plug PEN : Control pressure pickup port PEPB : EPC basic pressure pickup port PEPC: EPC basic pressure input port PLS : Load pressure input port PLSC : Load pressure pickup port PM : PC mode selector pressure pickup port PS : Pump suction port 1. 2. 3. 4. 5. 6. 7.
Main pump LS valve PC valve PC-EPC valve Shuttle valve No. 1 check valve No. 2 check valve
PC128US-8
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10 Structure, function and maintenance standard Hydraulic pump
1. 2. 3. 4. 5. 6.
Shaft Cradle Case Rocker cam Shoe Piston
10-32
7. Cylinder block 8. Valve plate 9. End cap 10. Servo piston 11. PC valve
PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Function q The pump converts the engine rotation and torque transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.
q
q
q
Structure Cylinder block (7) is supported to shaft (1) by spline (10). q Shaft (1) is supported by front and rear bearings (11). q Tip of piston (6) is shaped as a concave ball and shoe (5) is caulked to it to form one unit. q Piston (6) and shoe (5) constitute the spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement. q
PC128US-8
q q
Rocker cam (4) conducts high pressure oil to the cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside the respective cylinder chambers of cylinder block (7) is suctioned and discharged through valve plate (8).
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10 Structure, function and maintenance standard Hydraulic pump
Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the ax ial di rec tio n of cy li nder b loc k (7) changes. q (a) is named the swash plate angle.
q
q
q q
q
q
q
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) suctions and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.
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PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Control of delivery q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b ec o me s l ar g er a nd pu m p d el i v e r y ( Q ) increases. q Servo piston (12) is used for changing swash plate angle (a). q Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. q This linear movement is transmitted to rocker cam (4) via slider (13). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. Main pump discharge pressure (check valve output pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
PC128US-8
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10 Structure, function and maintenance standard Hydraulic pump
LS valve
PA : Pump port PDP : Drain port PLP : LS control pressure output port PLS : LS pressure input port PP : Pump port PPL : Control pressure input port
1. 2. 3. 4. 5. 6.
Sleeve Piston Spool Spring Sheet Sleeve
7. Plug 8. Locknut
Function q The LS (load sensing) valve detects the load and controls the delivery. q This valve controls main pump delivery (Q) according to differential pressure ( PLS) [= (PP) — (PLS)], called the LS differential pressure (the difference between main pump pressure (PP) and control valve outlet port pressure (PLS)). q Main pump pressure (PP), pressure (PLS) (called the LS pressure) coming from the control valve output enters this valve.
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PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Operation
When the control valve is situated at neutral
q
q
q
q
q
The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the outlet port of the control valve brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery pressure (check valve output pressure) (PP) determine the position of spool (6). Before the engine is started, servo piston (12) is pushed to the left. (See the diagram on the right) If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool) Spool (6) is pushed to the left, and port (C) and port (D) will be connected.
PC128US-8
q q q
Pump pressure (PP) is conducted to the larger diameter end from the port (K). The same pump pressure (PP) is conducted to the smaller diameter end from the port (J). According to the difference in the areas on servo piston (12), the pressure moves in such that the swash plate angle may be minimized.
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10 Structure, function and maintenance standard Hydraulic pump
Action for the direction of maximizing the pump delivery
q
q
q
q
When the difference between the main pump pressure (PP) and LS pressure (PLS), in other words, LS differ ential press ure ( P LS) becomes smaller [for example, when the area of opening of the control valve becomes larger and pump pressure (PP) drops], spool (6) is pushed to the right by the combined force of LS pressure (PLS) and the force of spring (4). When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve. The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT). (The operation of the PC valve is explained later.) The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT), and pump pressure (PP) enters port (J) at the small diameter end, so servo piston (12) is pushed to the right side. Therefore, the swash plate is moved in the direction to make the delivery larger.
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PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Action for the direction of minimizing the pump delivery
q
q
q
When LS differential pressure ( PLS) becomes larger [for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises] because of the leftward move (it reduces delivery) of servo piston (12), pump pressure (PP) pushes spool (6) to the left. When spool (6) moves, main pump pressure (PP) flows from port (C) to port (D) and from port (K), it enters the large diameter end of the piston. Main pump pressure (PP) also enters port (J) of the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end on servo piston (12), it is pushed to the left. As the result, the servo piston (12) moves into the direction of reducing the swash plate angle.
PC128US-8
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10 Structure, function and maintenance standard Hydraulic pump
When servo piston is balanced
q
q
q
q
Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) × (PP) = (A1) × (PEN), servo piston (12) will stop in that position. The swash plate of the pump will be held at the intermediate position. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] At this point, the relationship between the pressure receiving areas across servo piston (12) is (A0) : (A1) = 1 : 2, so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 2 : 1.
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q
Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when (PP) — (PLS) = 2.2 MPa {22.5 kg/cm2} at the median of the specified value.
PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
PC valve
PA : Pump port PA2 : Pump pressure pilot port PDP : Drain port PM : Mode selector pressure pilot port PPL : PC control pressure output port PPL2: LC control pressure output port
Function q When the pump discharge pressure (PP1) (check valve output pressure) and (PP2) (shuttle valve output pressure) are high, the PC valve controls the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it may not exceed the engine hose power. q If the pump discharge pressure (PP1) increases due to increased load during operation, this valve decreases the pump delivery. q And if the pump delivery pressure goes low, it increases the pump delivery. q In this case, relation between the mean average discharge pressure of the pump [(PP1) + (PP2)]/2 and the pump delivery (Q) will becomes as shown in the diagram if the relation is represented as the parameter of the current value to be given to PC-EPC valve solenoid. q The controller continues counting the actual engine speed. q If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed. PC128US-8
1. 2. 3. 4. 5. 6. 7. 8.
Plug Servo piston assembly Pin Spool Retainer Sheet Cover Wiring
q
If the engine speed goes below the specified value because of increased load, the controller sends a command current to PC-EPC valve solenoid in order to reduce the slope angle in proportion to reduction in the engine speed.
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10 Structure, function and maintenance standard Hydraulic pump
Operation
When pump controller is normal 1)
When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) q Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller. q This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston (2). q Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4) and (6) as well as the pump pressures (PP1) (check valve output pressure) and (PP2) (shuttle valve output pressure). 10-42
q
q
The pressure [port (C) pressure] output from PC valve is changed depending on the above position. The size of command current (X) is determined by the nature of the operation (lever operation), the selected working mode, and the set value and actual value of the engine speed.
PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Action of spring q Load of springs (4) and (6) on the PC valve is determined by the swash plate position. q As servo piston (9) moves to left, spring (6) is retracted. q If the servo piston moves further, it will be contacted again seat (5) and spring (6) will be fixed. q After that, spring (4) alone will operate. q The spring load is changed by servo piston (9) as it extends or compresses springs (4) and (6). q If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2).
PC128US-8
q
q q
q
q
Spring load of springs (4) and (6) is also affected by the command current (X) to PCEPC valve solenoid. Port (C) of the PC valve is connected to port (E) of the LS valve. Check valve output pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and shuttle valve output pressure (PP2) enters port (A). When pump pressures (PP1) and (PP2) are small, spool (3) will be positioned in the right side. Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
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10 Structure, function and maintenance standard Hydraulic pump
q
q q
q
q
q
If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes drain pressure (PT), and servo piston (9) moves to the right side. The pump delivery will be set to the increasing trend. Accompanied with move of servo piston (9), springs (4) and (6) will be expanded and the spring force becomes weaker. As the spring force is weakened, spool (3) moves to the left, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are connected. As a result, the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the rightward move of servo piston (9) is stopped. Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the pressures (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve generates and the pushing force of springs (4) and (6) are balanced.
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PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
2)
When load on actuator is large and pump discharge pressure is high
Outline q When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the left becomes larger and spool (3) will be moved to the position shown in above figure. q Part of the pressure to be conducted from port (C) to LS valve flows from port (A) to port (C) and (D) through LS valve. At the end this flow, level of this pressure becomes approximately half of the main pump pressure (PP).
PC128US-8
Operation q When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of servo piston (9), stopping servo piston (9). q If main pump pressure (PP) increases further and spool (3) moves further to the left, main pump pressure (PP1) flows to port (C) and acts to make the pump delivery the minimum. q When servo piston (9) moves to the left, springs (4) and (6) are compressed and push back spool (3). q When spool (3) moves to the right, the opening of port (C) and port (D) becomes larger.
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10 Structure, function and maintenance standard Hydraulic pump
q
q
q
q
q
q
As a result, the pressure on port (C) (= J) is decreased and the rightward move of servo piston (9) is stopped. The position in which servo piston (9) stops at this time is further to the left than the position when pump pressures (PP1) and (PP2) are low. The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their positions can be represented by the broken line in the figure because springs (4) and (6) form the double springs. The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q) becomes as shown below.
If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/ 2, and pump delivery (Q) is proportional to the force of the PC-EPC valve solenoid and moves in parallel. Namely, the force of PC-EPC valve solenoid (1) is added to the pushing force to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased.
10-46
PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
As the emergency pump drive switch is turned on due to failure on the pump controller 1)
When the main pump is under light load
q
If there is a failure in the pump controller, the emergency pump drive switch is turned on to hand the control to the resistor side. In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the resistor is set in between to control the current flowing to PC-EPC valve solenoid (1). The current becomes constant, so the force pushing piston (2) is also constant.
q
q
PC128US-8
q
q
q
If the main pump pressures (PP1) and (PP2) are low, the combined force of the pump pressure and the PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the right. The port (C) is connected to the drain pressure of the port (D), and the large diameter end of the servo piston (9) also becomes the drain pressure (PT) through the LS valve. Since the pressure on the small diameter end of the piston is large, servo piston (9) moves in the direction to make the delivery larger.
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10 Structure, function and maintenance standard Hydraulic pump
2)
When the main pump is under heavy load
q
If the emergency pump drive switch is turned on in the same way as in above, the command current (X) sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. If main pump pressures (PP1) and (PP2) increase, spool (3) moves further to the left than when the main pump load is light, and is balanced at the position in the figure above. In this case, the pressure from port (A) flows to port (C), so servo piston (9) moves to the left (smaller pump delivery) and stops at a position to the further to the left then when the load on the pump is light.
q q
q
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PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
q
q
When the emergency pump drive switch is turned on, too, the pump pressure (PP) and pump delivery (Q) have a relationship as shown with the curve in the figure corresponding to the current sent to the PC-EPC valve solenoid through the resistor. The curve resulting when the emergency pump drive switch is ON is situated further to the left (B) than when the pump controller is normal (A).
PC128US-8
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10 Structure, function and maintenance standard Hydraulic pump
PC-EPC valve
C : To PC valve P : From self pressure reducing valve T : To tank 1. 2. 3. 4. 5. 6. 7.
Connector Coil Body Spring Spool Rod Plunger
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PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the PC valve.
Operation
When signal current is 0 (coil is deenergized) q
q q
q
PC128US-8
When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. Spool (5) is pushed to the left by spring (4). Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the PC valve. The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).
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10 Structure, function and maintenance standard Hydraulic pump
When signal current is very small (coil is energized) q
q q
q q q
q
When a very small signal current flows to coil (2), coil (2) is energized, and a propulsion force is generated on the right side of plunger (7). Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C). Pressure on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become larger than the propulsion force of plunger (7). Spool (5) is pushed to the left, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (5) moves up and down so that the propulsion force of plunger (7) may be balanced with pressure of port (C) + spring load of spring (4). The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the size of the signal current.
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When signal current is maximum (coil is energized) q q
q q
q
As the signal current flows to coil (2), coil (2) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (7) is also at its maximum. Spool (5) is pushed toward right side by rod (6). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and PC valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the tank.
PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
Check valve
PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP1: Output pressure of check valve
1. 2.
Poppet valve Poppet valve
Function q A set of 2 check valves is used to select and output the higher discharge pressure of the 2 main pumps.
Operation
1. When (PA1) > (PA2) q
Discharge pressures (PA1) and (PA2) of the main pumps are applied to poppet valves (1) and (2). Since (PA1) > (PA2), however, poppet valve (2) is kept closed and (PA1) is output to (PP1).
2. When (PA1) < (PA2) q
PC128US-8
Reversely to 1., poppet valve (1) is kept closed and (PA2) is output to (PP1).
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10 Structure, function and maintenance standard Hydraulic pump
Shuttle valve
PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP2: Output pressure of shuttle valve 1. 2. 3.
Poppet valve Poppet valve Pin
Function q The shuttle valve selects and outputs the lower discharge pressure of the 2 main pumps.
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Operation q The discharge pressures (PA1) and (PA2) of the 2 main pumps are applied to poppet valves (1) and (2) respectively. q Since poppet valves (1) and (2) push each other through pin (3), either one of them receiving higher pressure is closed and the other one receiving lower pressure is opened. q Accordingly, lower discharge pressure of the 2 main pumps is output.
PC128US-8
10 Structure, function and maintenance standard Hydraulic pump
PC128US-8
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10 Structure, function and maintenance standard Control valve
Control valve
1
Outline The control valves of the following types are set. q 6-spool valve (Without service valve) q 7-spool valve (6-spool valve + service valve) q 7-spool valve (Blade) q 8-spool valve (Blade + service valve) q 8-spool valve (6-spool valve + 2 service valves) q 9-spool valve (Blade + 2 service valves) The appearance and section of only the 8-spool valve (blade + service valve) are shown here. A1 : To swing motor A2 : To blade cylinder bottom A3 : To left travel motor A4 : To right travel motor A5 : To boom cylinder bottom A6 : To arm cylinder head A7 : To bucket cylinder head A8 : To attachment B1 : To swing motor B2 : To blade cylinder head B3 : To left travel motor B4 : To right travel motor B5 : To boom cylinder head B6 : To arm cylinder bottom B7 : To bucket cylinder bottom B8 : To attachment LS : To pump LS valve P1 : From main pump P2 : From main pump PP : To main pump PR : To solenoid valve, EPC valve PS : From solenoid valve of merge-divider valve TB : To tank TC : To oil cooler BP1: From boom raise PPC valve LS1: LS1 pressure pickup port LS2: LS2 pressure pickup port
LS3 : LS3 pressure pickup port PA1 : From swing left PPC valve PA2 : From blade lower PPC valve PA3 : From left travel forward PPC valve PA4 : From right travel forward PPC valve PA5 : From boom raise PPC valve PA6 : From arm dump PPC valve PA7 : From bucket dump PPC valve PA8 : From service PPC valve PB1 : From swing right PPC valve PB2 : From blade raise PPC valve PB3 : From left travel reverse PPC valve PB4 : From right travel reverse PPC valve PB5 : From boom lower PPC valve PB6 : From arm in PPC valve PB7 : From bucket curl PPC valve PB8 : From attachment PPC valve PMAX: Pressure sensor port PP1 : PP1 pressure pickup port PP2 : PP2 pressure pickup port PPI1 : Pump 1 pressure pickup port PPI2 : Pump 2 pressure pickup port PRI : PR pressure pickup port PST : From travel junction solenoid valve TS1 : To tank PS2 : To tank TSW : To swing motor
1. 2. 3. 4. 5. 6. 7. 8.
9. Swing valve 10. Block 11. Swing bleeding valve 12. LS check valve 13. Travel junction valve + LS check valve 14. Arm regeneration valve 15. Boom hydraulic drift prevention valve 16. Merge-divider valve block
Cover Service valve Bucket valve Arm valve Boom valve Right travel valve Left travel valve Blade valve
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10 Structure, function and maintenance standard Control valve
PC128US-8
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10 Structure, function and maintenance standard Control valve
Sectional view (1/5)
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10 Structure, function and maintenance standard Control valve
1. Suction safety valve (Service) 2. Suction valve (Bucket) 3. Suction valve (Arm) 4. Suction valve (Boom) 5. Lift check valve 6. Suction valve (Right travel) 7. Suction valve (Left travel) 8. Suction valve (Blade) 9. Suction safety valve (Blade) 10. Suction valve (Left travel) 11. Suction valve (Right travel) 12. Main relief valve 13. Suction valve (Boom) 14. Suction valve (Arm)
15. Suction valve (Bucket) 16. Suction safety valve (Service) 17. Suction safety valve 18. Spool (Service) 19. Spool (Bucket) 20. Spool (Arm) 21. Spool (Boom) 22. Spool (Right travel) 23. Spool (Left travel) 24. Spool (Blade) 25. Spool (Swing) 26. Unload valve 27. Unload valve
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length × Outside diameter
Installed length
Installed load
Free length
Installed load
46.8 × 7.5
40.6
5.49 N {0.56 kg}
—
4.41 N {0.45 kg}
29 Piston return spring
72.7 × 20.6
42.5
135 N {13.8 kg}
—
108 N {11.0 kg}
30 Suction valve spring
39.2 × 4.45
33.5
5.1 N {0.52 kg}
—
4.12 N {0.42 kg}
31 Spool return spring
41.8 × 19
38.5
141 N {14.4 kg}
—
113 N {11.5 kg}
32 Spool return spring
41.44 × 19.3
38.5
137 N {13.96 kg}
—
110 N {11.2 kg}
33 Spool return spring
27.14 × 25.8
25.5
55.9 N {5.7 kg}
—
44.7 N {4.56 kg}
34 Spool return spring
32.4 × 11
31.4
60.2 N {6.137 kg}
—
48.2 N {4.91 kg}
35 Spool return spring
76.78 × 20.9
70
423 N {43.1 kg}
—
338 N {34.5 kg}
36 Spool return spring
45.7 × 28
43
221 N {22.55 kg}
—
177 N {18.04 kg}
37 Spool return spring
42.4 × 28
39
222 N {22.6 kg}
—
178 N {18.1 kg}
38 Spool return spring
45.6 × 28
43
230 N {23.5 kg}
—
184 N {18.8 kg}
39 Spool return spring
45.81 × 28
43
203 N {20.7 kg}
—
163 N {16.6 kg}
28 Suction valve spring
PC128US-8
If damaged or deformed, replace spring
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10 Structure, function and maintenance standard Control valve
(2/5)
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PC128US-8
10 Structure, function and maintenance standard Control valve
1 LS selector valve 2. Cooler bypass valve 3. Pressure compensation valve R (Service) 4. Pressure compensation valve R (Bucket) 5. Pressure compensation valve R (Arm) 6. Pressure compensation valve R (Boom) 7. Pressure compensation valve R (Right travel) 8. Pressure compensation valve R (Left travel) 9. Pressure compensation valve R (Blade) 10. Pressure compensation valve R (Swing) 11. Pressure compensation valve F (Swing) 12. Pressure compensation valve F (Blade) 13. Pressure compensation valve F (Left travel) 14. Pressure compensation valve F (Right travel) 15. Merge-divider valve spool 16. Pressure compensation valve F (Boom) 17. Pressure compensation valve F (Arm) 18. Pressure compensation valve F (Bucket) 19. Pressure compensation valve F (Service) F: R:
Flow control valve Pressure reducing valve Unit: mm
No.
Check item
Criteria
Remedy
Standard size
20 Check valve spring
21 Check valve spring
PC128US-8
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
41.5 x 8.5
31.5
5.88 N {0.6 kg}
—
4.71 N {0.48 kg}
20.3 x 13.7
16
2.94 N {0.3 kg}
—
2.35 N {0.24 kg}
If damaged or deformed, replace spring
10-61
10 Structure, function and maintenance standard Control valve
(3/5)
10-62
PC128US-8
10 Structure, function and maintenance standard Control valve
1.
LS selector valve
Swing valve 2. Pressure compensation valve F 3. Spool 4. Pressure compensation valve R 5. Swing bleed valve Blade valve 6. Suction safety valve 7. Suction valve 8. Spool 9. Pressure compensation valve R 10. Pressure compensation valve F L.H. travel valve 11. Pressure compensation valve F 12. Suction valve 13. Suction valve 14. Spool 15. Pressure compensation valve R 16. LS check valve F: R:
Flow control valve Pressure reducing valve Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
23.3 × 12.5
23
3.92 N {0.4 kg}
—
3.14 N {0.32 kg}
18 Check valve spring
21.9 × 5
15.8
1.96 N {0.2 kg}
—
1.57 N {0.16 kg}
19 Retainer spring
9.1 × 4.2
7.4
0.98 N {0.1 kg}
—
0.78 N {0.08 kg}
17 Check valve spring
PC128US-8
If damaged or deformed, replace spring
10-63
10 Structure, function and maintenance standard Control valve
(4/5)
10-64
PC128US-8
10 Structure, function and maintenance standard Control valve
R.H. Travel valve 1. Pressure compensation valve F 2. Suction valve 3. Suction valve 4. Spool 5. Pressure compensation valve R 6. Travel junction valve + LS check valve 7. Unload valve 8. LS bypass valve 9. Merge-divider valve spool 10. Main relief valve 11. Cooler bypass valve 12. Lift check valve Boom valve 13. Pressure compensation valve F 14. Suction valve 15. Hydraulic drift prevention valve 16. Suction valve 17. Spool 18. Pressure compensation valve R F: R:
Flow control valve Pressure reducing valve Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
19.26 × 7.5
14
15.7 N {1.6 kg}
—
12.6 N {1.28 kg}
20 Check valve spring
21.9 × 5
15.8
1.96 N {0.2 kg}
—
1.57 N {0.16 kg}
21 Valve return spring
58.9 × 13
53
83.4 N {8.5 kg}
—
66.7 N {6.8 kg}
22 Spool return spring
49.8 × 18.8
33
98.1 N {10 kg}
—
78.5 N {8 kg}
23 Check valve spring
16.4 × 8.9
11.5
13.7 N {1.4 kg}
—
11.0 N {1.12 kg}
24 Spool return valve spring
72.7 × 20.6
42.5
135 N {13.8 kg}
—
108 N {11 kg}
19 Spool return spring
PC128US-8
If damaged or deformed, replace spring
10-65
10 Structure, function and maintenance standard Control valve
(5/5)
10-66
PC128US-8
10 Structure, function and maintenance standard Control valve
Arm valve 1. Pressure compensation valve F 2. Suction valve 3. Suction valve 4. Spool 5. Pressure compensation valve R 6. Regeneration valve Bucket valve 7. Pressure compensation valve F 8. Suction valve 9. Suction valve 10. Spool 11. Pressure compensation valve R Service valve 12. Pressure compensation valve F 13. Suction safety valve 14. Suction safety valve 15. Spool 16. Pressure compensation valve R 17. Suction safety valve 18. Pressure release plug F: R:
Flow control valve Pressure reducing valve Unit: mm
No.
Check item
Criteria
Remedy
Standard size
19 Valve spring
PC128US-8
Repair limit
Free length × Outside diameter
Installed length
Installed load
Free length
Installed load
41.5 × 8.5
31.5
5.88 N {0.6 kg}
—
4.71 N {0.48 kg}
If damaged or deformed, replace spring
10-67
10 Structure, function and maintenance standard CLSS
CLSS
1
Outline of CLSS
1
Features CLSS stands for Closed center Load Sensing System, which has the following characteristics: q q q
q
Fine control not influenced by load Controllability enabling digging even with fine control Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations Energy saving using variable pump control
10-68
Configuration q CLSS is configured with variable capacity piston pumps, control valves, and respective actuators. q The hydraulic pump is configured with pump body, PC valve and LS valve.
PC128US-8
10 Structure, function and maintenance standard CLSS
Basic principle
1
Pump swash plate angle control q
q
The pump swash plate angle (pump delivery) is controlled so that LS differential pressure ( P L S ) ( t h e d i ff e r e n c e b e t w e e n p u m p pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. [LS differential pressure ( PLS) = Pump discharge pressure (PP) — LS pressure (PLS)]
q
q
The pump swash plate angle shifts toward the maximum position if LS differential pressure ( PLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high). If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate angle shifts toward the minimum position.
LS differential pressure ( PLS) and pump swash plate angle
a
PC128US-8
For details of functions, see the "Hydraulic pump" paragraph.
10-69
10 Structure, function and maintenance standard CLSS
Pressure compensation control
q
q
q
A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When actuators are operated together, the p r e s s u r e d i ff e r e n c e ( P ) b e t w e e n t h e upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve.
10-70
PC128US-8
10 Structure, function and maintenance standard CLSS
PC128US-8
10-71
10 Structure, function and maintenance standard Functions and operation by valve
Functions and operation by valve
1
Hydraulic circuit diagram and the name of valves
1
10-72
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
1. Swing valve 2. Blade valve 3. Left travel valve 4. Right travel valve 5. Boom valve 6. Arm valve 7. Bucket valve 8. Service valve 9. Swing spool 10. Blade spool 11. Left travel spool 12. Right travel spool 13. Boom spool 14. Arm spool 15. Bucket spool 16. Service spool 17. Pressure compensation valve 18. Suction valve 19. LS service valve 20. Merge-divider valve 21. Arm regeneration valve 22. Self pressure reducing valve 23. Travel junction valve 24. Lift check valve 25. Cooler bypass valve 26. Boom hydraulic drift prevention valve 27. Swing bleeding valve 28. Suction safety valve Set pressure: 36.8 MPa {375 kg/cm²} 29. Suction safety valve Set pressure: 24.5 MPa {250 kg/cm²} 30. Suction safety valve Set pressure: 35.8 MPa {365 kg/cm²} 31. Main relief valve Set pressure: 34.8 MPa {355 kg/cm²} 32. Unload valve
PC128US-8
10-73
10 Structure, function and maintenance standard Functions and operation by valve
Unload valve When control valve is at HOLD
Function q When the control valve is at HOLD, pump delivery (Q) discharged by the minimum swash plate angle is released to the tank circuit. At this time, pump discharge pressure (P1) and (P2) is set by spring (2) in the valve. [LS pressure (LS1) and (LS2) = 0 MPa {0 kg/cm²}] q Since the pump merge-divider valve is at the merge position, pump discharge pressures (P1) and (P2) are merged. LS pressures (LS1), (LS2), and (LS3) are also merged.
10-74
Operation q Pump discharge pressures (P1) and (P2) are applied to pump pressure receiving (SA) face of unload spool (1). q LS pressures (LS1) and (LS2) are applied to LS pressure receiving (SB) face. [(P1) = (P2), (LS1) = (LS2)] q When the control valve is at HOLD, LS pressures (LS1) and (LS2) are not generated, so only pump discharge pressures (P1) and (P2) act, and (P1) and (P2) are set by only the load of spring (2). q As pump discharge pressure (P1) and (P2) rises and reaches the load of spring (2), spool (1) is moved to the left. Pump discharge pressures (P1) and (P2) are connected to tank circuit (T) through the notch of spool (1).
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
When work equipment valve is operated
Function q When any work equipment valve is operated if the demand flow for the actuator becomes greater than the pump discharge from the minimum swash plate angle, the oil flow to tank circuit (T) is cut off, and all pump delivery (Q) flows to the actuator circuit. q Since the pump merge-divider valve is at the merge position, pump discharge pressures (P1) and (P2) are merged. LS pressures (LS1), (LS2), and (LS3) are also merged.
PC128US-8
Operation q When any work equipment valve is operated for a long stroke, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of unload spool (1) [(P1) = (P2), (LS1) = (LS2)]. q For this reason, the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). q As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump delivery (Q) flows to the actuator circuit.
10-75
10 Structure, function and maintenance standard Functions and operation by valve
During fine control of both travel valves
Function q When the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) reaches the load of spring (2), unload spool (1) opens, so excessive oil (maximum pump delivery - demand flow) flows into the tank circuit. q Since the pump merge-divider valve is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve.)
10-76
Operation q When fine control is carried out on both travel valves, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of spool (1) [(P1), (P2), (LS1), and (LS2) are separated]. q When the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) reaches the load of spring (2), spool (1) moves to the left, and pump discharge pressures (P1) and (P2) are connected to tank circuit (T) and the excessive oil (maximum pump delivery - demand flow) flows. q In other words, the excessive oil (maximum pump delivery - demand flow) above the strokes of both travel valves flows into tank circuit (T).
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
When both travel valves are operated
Function q During operation of both travel valves, when the demand flow becomes maximum, the oil flow to tank circuit (T) is cut off, and all pump delivery (Q) flows to both travel circuits. q Since the pump merge-divider spool is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve .)
PC128US-8
Operation q When both travel valves are operated to the stroke ends, LS pressures (LS1) and (LS2) are generated and act on the face (SB) of unload spool (1) [(P1), (P2), (LS1), and (LS2) are separated]. q The area of the openings of both travel valve spools is large, so LS pressures (LS1) and (LS2) are not so different from pump discharge pressures (P1) and (P2). q For this reason, the difference between pump discharge pressure (P1) and (P2) and LS pressure (LS1) and (LS2) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). q As a result, pump discharge pressures (P1) and (P2) and tank circuit (T) are shut off, and all pump delivery (Q) flows to the actuator circuit.
10-77
10 Structure, function and maintenance standard Functions and operation by valve
When either travel valve is operated
Function q The demand flow decided by the valve stroke is sent to the travel circuit on the operated travel valve side and the all pump delivery is sent to the tank circuit on the non-operated travel valve side. q Since the pump merge-divider valve is at the separate position, pump discharge pressures (P1) and (P2) are separated. LS pressures (LS1) and (LS2) are also separated. q The swash plate angle of the pump becomes maximum, so the pump delivery becomes maximum. (For details, see the sections on the pump merge-divider valve.)
q
q
q
q
q
Operation When left travel valve is operated to stroke end and right one is at HOLD. q When the left travel valve is operated to the stroke end, LS pressure (LS1) is generated and acts on the face (SB) of unload spool (1). 10-78
The area of the openings of left travel valve spool is large, so LS pressures (LS1) is not so different from pump discharge pressures (P1). For this reason, the difference between pump discharge pressure (P1) and LS pressure (LS1) does not reach the load of spring (2), so spool (1) is pushed to the right by spring (2). As a result, pump discharge pressures (P1) and tank circuit (T) are shut off, and all pump delivery (QP1) on the (P1) side flows to the left travel circuit. Since the right travel valve is at HOLD, LS pressure (LS2) is not generated, so only pump discharge pressure (P2) acts. When pump discharge pressure (P2) reaches the load of spring (2), spool (1) moves to the left, and all pump delivery (QP2) on the (P2) side flows into tank circuit (T).
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
PC128US-8
10-79
10 Structure, function and maintenance standard Functions and operation by valve
Merge-divider valve When oil is merged: (PS) = 0 kg/cm2
Function q Pump discharge pressures (P1) and (P2) are merged in pump merge-divider spool (3). (LS1), (LS2), and (LS3) are also merged. q At this time, (P1) = (P2) and (LS1) = (LS2) = (LS3) and the pump swash plate is controlled by the difference between (P) and (LS).
10-80
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
When oil is divided: (PS) = 30 kg/cm2
Function q Pump discharge pressures (P1) and (P2) are divided in pump merge-divider spool (3). (LS1), (LS2), and (LS3) are also divided. q At this time, higher one of (P1) and (P2) is applied through pump merge-divider spool (3) to the output port of the LS pressure. q As a result, there is not difference between (P) and (LS) and the pump swash plate is set to the maximum position.
PC128US-8
10-81
10 Structure, function and maintenance standard Functions and operation by valve
Introduction of LS pressure Work equipment valve
Function q The LS pressure is the actuator load pressure at the outlet port end of the control valve. q Actually, pump discharge pressure (PP) is reduced by reducing valve (3) of the pressure compensation valve to the same pressure as actuator circuit pressure (A) and sent to LS circuit (PLS). q In the travel valve, actuator circuit pressure (A) is directly introduced to LS circuit (PLS). Operation When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit (A). q At the same time, reducing valve (3) also moves to the right, so pump discharge pressure (PP) is reduced by the pressure loss at notch (c). It goes to LS circuit (PLS), and then goes to spring chamber (PLSS). q
10-82
q
q
q
When this happens, LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4) (See the section on the LS bypass valve). The areas at both ends of reducing valve (3) are the same [(SA) = (SLS)], and actuator circuit pressure (PA) acts on the (SA) end. The reduced pump discharge pressure (PP) acts on (SLS) at the other end. As a result, reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of spring chamber (PLSS) are the same. Pump discharge pressure (PP) reduced at notch (c) becomes actuator pressure (A) and is introduced into LS circuit (PLS).
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
Travel valve
Operation q When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit (A). q Actuator circuit pressure (PA) (= A) is introduced through the check valve (5) into LS circuit (PLS). a
The travel circuit is different from the work equipment circuit: actuator circuit pressure (PA) is directly introduced into LS circuit (PLS).
PC128US-8
10-83
10 Structure, function and maintenance standard Functions and operation by valve
LS bypass valve When work equipment valve is operated (including compound operation of work equipment + travel)
Function q The LS bypass valve releases the remaining pressure of LS pressure (PLS). q This lowers the rising speed of LS pressure (PLS). In addition, the discarded throttled flow causes a pressure loss in the throttled flow in the reducing valve, and that lowers the effective LS differential pressure to improve the stability. 10-84
Operation q Since pump merge-divider spool (1) is at the merge position, the hydraulic oil in LS circuits (PLS1), (PLS2), and (PLS3) flows from tip filter (a) of LS bypass valve (2) through orifice (b) to tank circuit (T).
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
When either or both travel valves are operated (Including operation of only one travel valve)
Operation q Since pump merge-divider spool (1) is at the separate position, LS circuits (PLS1) and (PLS2) are separated. q The hydraulic oil (PLS1) flows from tip filter (a) of LS bypass valve (2) through orifice (b) to tank circuit (T).
PC128US-8
q
The hydraulic oil (PLS2) flows from tip filter (c) of LS bypass valve (3) through orifice (d) to tank circuit (T).
10-85
10 Structure, function and maintenance standard Functions and operation by valve
Pressure compensation valve
10-86
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
Function q When the load pressure becomes lower than another actuator and the flow is going to increase during a compound operation, this valve compensates the load pressure. [At the time, the load pressure of another actuator under compound operation (the upper side) is higher than that of the actuator on this side (the lower side)]. Operation When the load pressure (Ab) of another actuator side (the upper side) rises during a compound operation, the flow in the actuator circuit (Aa) on this side (the lower side) is apt to increase. q In this case, the LS pressure (PLS) of another actuator is applied to the spring chamber (PLS1) and pushes the pressure reducing valve (1) and the flow control valve (2) to the left side. q The flow control valve (2) throttles the opening area between the pump circuit (PP) and the spool upstream (PPA) and causes a pressure loss between (PP) and (PPA). q The flow control valve (2) and the pressure reducing valve (1) balance each other where the pressure difference between (PA) applied to the both end faces of the pressure reducing valve (1) and (PLS) becomes the same as the pressure loss between (PP) before and after the flow control valve (2) and (PPA). q So, the pressure differences between the upstream pressures (PPA) and the downstream pressures (PA) of the both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch (a). q
PC128US-8
10-87
10 Structure, function and maintenance standard Functions and operation by valve
Area ratio of pressure compensation valve
Function q The pressure compensation valve slightly adjusts the ratio (S2) and (S1) of the area (S1) on the left side of the flow control valve (2) and the area (S2) on the right side of the pressure reducing valve (1) to suite the characteristics of each actuator and determines the compensation characteristics. S1 : Area of the flow control valve (2) – area of the piston (3) S2 : Area of the pressure reducing valve (1) – area of the piston (3)
10-88
Area ratio (S1) : (S2) and compensation characteristics q When the ratio is 1.00 : The expression [Pump (discharge) pressure (PP) – Spool notch upstream pressure (PPB)] C [LS circuit pressure (PLS) – Actuator circuit pressure (PA) (= A)] can be held, and the flow is distributed as per the spool opening area ratio. q When the ratio is more than 1.00: The expression (PP) – (PPB) > (PLS) – (PA) (= A) can be held, and the flow is distributed less than the spool opening area ratio. q When the ratio is less than 1.00: The expression (PP) – (PPB) < (PLS) – (PA) (= A) can be held, and the flow is distributed more than the spool opening area ratio.
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
Boom regeneration circuit At boom lower and own weight fall
Function q When the boom is lowered and falls due to its own weight because the bottom pressure (A) in the cylinder (1) is higher than the head pressure (B), this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed.
Operation q 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). q
q
PC128US-8
At the time, part of the return flow on the bottom side passes through the regeneration passage (a) of the boom spool (2), pushes the check valve (3) to open it and flows to the head side. This increases the boom lower speed.
10-89
10 Structure, function and maintenance standard Functions and operation by valve
At boom lower load process
Function q When the head pressure (B) of the cylinder (1) is higher than the bottom pressure (A) while the boom is lowered and the boom is in the load process, the check valve (3) will be closed, and the circuits on the head side and the bottom side will be interrupted.
10-90
Operation q When the boom is lowered and is in the load process, the head side pressure (B) of the boom cylinder (1) rises above the bottom side pressure (A). q
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.
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
Arm regeneration circuit At arm in and own weight fall
A : Head circuit B : Bottom circuit PP : Pump circuit
1. 2. 3.
Function q When the arm falls due to its own weight because the head pressure (A) in the arm cylinder (1) is higher than the bottom pressure (B) during arm digging, this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed.
Operation q 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). q At the time, part of the return flow on the head side passes through the regeneration passage (a) of the arm spool (2), pushes the check valve (3) to open it and flows to the bottom side. q This increases the arm digging speed.
PC128US-8
Arm cylinder Arm spool Check valve
10-91
10 Structure, function and maintenance standard Functions and operation by valve
At arm in process
A : Head circuit B : Bottom circuit PP : Pump circuit
1. 2. 3.
Function q When the bottom pressure (B) of the cylinder (1) rises above the head pressure (A) and the arm enters the digging process, the check valve (3) will be closed and the circuits on the head side and the bottom side will be interrupted.
Operation q 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.
10-92
Arm cylinder Arm spool Check valve
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
Hydraulic drift prevention valve When boom is raised
Function q While the boom lever is not operated, the hydraulic drift prevention valve prevents pressurized oil from leaking from the boom bottom through spool (1) to prevent the boom from drifting hydraulically.
PC128US-8
Operation q If the boom is raised out, the main pressure from the control valve pushes up poppet (5). As a result, the main pressure from the control valve flows through the valve into the boom cylinder bottom.
10-93
10 Structure, function and maintenance standard Functions and operation by valve
When boom and arm are set in neutral
Operation q If the control lever is returned to the neutral position while the boom is raised out, the holding pressure in the boom cylinder bottom and arm cylinder head is blocked by poppet (5) and the pressurized oil flowing in through orifice (a) is blocked by pilot spool (3). Accordingly, the boom is held.
10-94
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
When boom is lowered
Operation q If the boom is lowered, pilot pressure (P1) from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber (b) in the poppet is drained. q The pressurized oil in port (Ab) is raised by the pressurized oil from the boom cylinder bottom, but the pressurized oil in chamber (b) is lowered by orifice (a). q If the pressure in chamber (b) is lowered below the pressure in port (Aa), poppet (5) opens and the pressurized oil from port (Ab) flows through port (Aa) into the control valve.
PC128US-8
10-95
10 Structure, function and maintenance standard Functions and operation by valve
Swing bleeding valve
Function q When the machine swings, the bleeding valve installed to the pressure reducing valve works so that the LS pressure rises gradually and the machine swings smoothly.
10-96
Operation (In fine control operation) q The pressure reducing valve moves to the right and notch (a) connects to the LS circuit. As a result, pump circuit (PP), bleed-off circuit, and LS circuit are connected through piston (2). q Bleeding spool (3) moves to the left in proportion as swing PPC pressure (PA) rises. In the fine control area, notch (b) chokes the bleedoff circuit and determines the intermediate pressure before the lowered pressure is applied to pump discharge pressure (PP) and LS pressure (PLS). q Accordingly, the intermediate pressure is set lower than pump discharge pressure (PP) and raised as bleeding spool (3) moves. As a result, LS pressure (PLS) rises gradually. q When the lever is in neutral or operated fully, the bleed-off circuit is closed.
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
LS select valve During normal operation
Function q At the time of simultaneous operation of swing + boom RAISE, this valve prevents high swing LS pressure from entering the LS circuit (PLS) and also prevents the boom RAISE speed from reducing by securing the pump flow at the time of swing drive.
PC128US-8
Operation q The pilot pressure is not generally applied to the pilot port (BP) except for boom RAISE operation. q In this state, the pump discharge pressure (PP) pushes the valve (1) to open it and is led to the pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure (PLS) suitable for the load pressure, and the pressure is led to the pump LS valve.
10-97
10 Structure, function and maintenance standard Functions and operation by valve
At simultaneous operation of swing + boom RAISE
Operation q At the simultaneous operation of swing + boom RAISE, the signal pressure of the PPC circuit is led to the pilot port (BP). q When this pilot pressure (BP) is applied to the piston (2) and reaches a pressure that is stronger than the spring (3), the piston (2) will be pushed to the left side, the valve (1) will close and the pump discharge pressure (PP) will not come to flow to the pressure reducing valve (4) of the swing valve. q Then, the swing pressure does not cause LS pressure (PLS), but the LS pressure (PLS) caused by the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. q The pilot pressure (BP) depends on the control lever stroke.
10-98
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
Travel junction valve
Function q This valve connects both travel circuits to each other so that hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. q When the machine is steered, outside pilot pressure (PST) closes the travel junction valve to secure high steering performance.
PC128US-8
Operation When pilot pressure is turned ON q If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (2), travel junction spool (1) moves to the left stroke end and the junction circuit between port (PTL) (Left travel circuit) and (PTR) (Right travel circuit) is closed.
10-99
10 Structure, function and maintenance standard Functions and operation by valve
Self pressure reducing valve
Function q The self pressure reducing valve lowers the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valves, PPC valves, etc. Operation If the (PR) pressure rises higher than the set level, poppet (1) opens and the hydraulic oil flows from port (PR) through orifice (a) in spool (4) and opening of poppet (1) into seal drain port (TS). q Accordingly, differential pressure is generated over orifice (a) in spool (4) and spool (4) moves in the direction to close the opening between ports (P) and (PR). The (P) pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio at this time and supplied as the (PR) pressure. q
10-100
When abnormally high pressure is generated q If the (PR) pressure of the self pressure reducing valve is raised abnormally, ball (6) separates from the seat against the force of spring (5). As a result, the hydraulic oil flows from output port (PR) to (TS) and the (PR) pressure lowers. q Accordingly, the devices receiving the oil pressure (PPC valves, solenoid valves, etc.) are protected from abnormally high pressure.
PC128US-8
10 Structure, function and maintenance standard Functions and operation by valve
Lift check valve and cooler bypass valve
Lift check valve
Cooler bypass valve
Function q The lift check valve generates back pressure in the drain circuit to prevent negative pressure on each actuator (motor, cylinder, etc.)
Function q The cooler bypass valve protects oil cooler (4) from breakage when the return flow rate from the control valve increases and oil cooler inlet pressure (PB) increases. q The cooler bypass valve returns the return oil to the tank directly without passing it through oil cooler (4).
Operation q Drain circuit pressure (PA) of the control valve acts on the left side of piston (2) to move the piston to the right. q The piston is so balanced that the back pressure will be as follows. q (PA) – (PB) = Force of spring (3) / Area of piston (2) at diameter (d1) [(PB) C 0 kg/cm²]
PC128US-8
Operation q Oil cooler inlet pressure (PB) acts on the underside of piston (1) to push up the piston. q Piston (1) is so balanced that oil cooler inlet pressure (PB) will be as follows. q (PB) – (PT) = Force of spring (5) / Area of piston (1) at diameter (d2) [(PT) C 0 kg/cm²]
10-101
10 Structure, function and maintenance standard PPC valve
PPC valve
1
Work equipment and swing PPC valve 1
P P1 P2 P3 P4 T
: From self pressure reducing valve : L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port : L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port : L.H. PPC valve: Swing LEFT port/R.H PPC valve: Bucket CURL port : L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port : To tank
10-102
PC128US-8
10 Structure, function and maintenance standard PPC valve
PC128US-8
10-103
10 Structure, function and maintenance standard PPC valve
1. 2. 3. 4. 5. 6. 7. 8. 9.
Spool Piston Disc Nut (for lever connection) Joint Plate Retainer Body Filter
Unit: mm No.
Check item
Criteria Standard size
Centering spring 10 (for ports P3 and P4)
11
Centering spring (for ports P1 and P2)
12 Metering spring
10-104
Remedy Repair limit
Free length Installation Installation Installation Free length × Outside length load load diameter 42.48 × 15.5
34
17.7 N {1.8 kg}
—
14.1 N {1.44 kg}
44.45 × 15.5
34
29.4 N {3 kg}
—
23.5 N {2.40 kg}
26.9 × 8
24.9
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
If damaged or deformed, replace spring.
PC128US-8
10 Structure, function and maintenance standard PPC valve
Operation
q
When in neutral q
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.
During fine control (Neutral o fine control) q
q
q
q
q
When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).
PC128US-8
10-105
10 Structure, function and maintenance standard PPC valve
During fine control (When control lever is returned) q
q
q
q
q
q
When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
10-106
At full stroke q q
q
q
Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).
PC128US-8
10 Structure, function and maintenance standard PPC valve
Travel PPC valve
P P1 P2 P3 P4 T
: From self pressure reducing valve : L.H. reverse : L.H. forward : R.H. reverse : R.H. forward : To tank
PC128US-8
10-107
10 Structure, function and maintenance standard PPC valve
10-108
PC128US-8
10 Structure, function and maintenance standard PPC valve
1. 2. 3. 4. 5. 6.
Plate Body Piston Seal Valve Damper Unit: mm
No.
Check item
Criteria Standard size
7
Centering spring
8
Metering spring
PC128US-8
Remedy Repair limit
Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 48.57 × 108 N 86.3 N replace spring. 32.5 — 15.5 {11 kg} {8.8 kg} 26.53 × 8.15
24.9
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
10-109
10 Structure, function and maintenance standard PPC valve
Operation
q
When in neutral q
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.
During fine control (Neutral o fine control) q
q
q
q
q
When piston (4) is pushed by lever (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1).
10-110
PC128US-8
10 Structure, function and maintenance standard PPC valve
During fine control (When control lever is returned) q
q
q
q
q
q
When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
PC128US-8
At full stroke q q
q
q
Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).
10-111
10 Structure, function and maintenance standard PPC valve
Blade PPC valve
a
1
For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
10-112
PC128US-8
10 Structure, function and maintenance standard PPC valve
P P1 P2 T
: From self pressure reducing valve : To blade valve : To blade valve : To tank
1. 2. 3. 4. 5. 6. 7.
Spool Piston Lever Plate Retainer Body Filter Unit: mm
No.
Check item
Criteria Standard size
8
Centering spring
9
Metering spring
PC128US-8
Remedy Repair limit
Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 42.36 × 147 N 118 N replace spring. 32.5 — 15.5 {15 kg} {12.0 kg} 22.73 × 8.1
22
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
10-113
10 Structure, function and maintenance standard PPC valve
Attachment PPC valve (with EPC valve)
a
1
For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
10-114
PC128US-8
10 Structure, function and maintenance standard PPC valve
P P1 P2 T
: From self pressure reducing valve : To service valve : To service valve : To tank
1. 2. 3. 4. 5. 6. 7. 8.
Spool Piston Lever Plate Retainer Block Body EPC valve Unit: mm
No.
Check item
Criteria Standard size
9
Centering spring
10 Metering spring
PC128US-8
Remedy Repair limit
Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 125 N 100 N replace spring. 33.9 × 15.3 28.4 — {12.7 kg} {10.2 kg} 22.7 × 8.10
22 .0
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
10-115
10 Structure, function and maintenance standard PPC valve
1. EPC valve
C: P: T:
To control valve From self pressure reducing valve To hydraulic tank
1. 2. 3. 4. 5. 6. 7.
Body Plug Spool Push pin Coil Plunger Connector Unit: mm
No.
Check item
Criteria Standard size
8
Return spring
Free length 9.0
10-116
Remedy Repair limit
If damaged or Installation Installation Installation Free length deformed, length load load replace EPC 3.1 N valve assembly. 8.4 — — {0.32 kg}
PC128US-8
10 Structure, function and maintenance standard PPC valve
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the control valve.
Operation
When signal current is 0 (coil is de-energized) q
q q q
PC128US-8
When there is no signal current flowing from the controller to coil (14), coil (14) is de-energized. Spool (11) is pushed to the right by spring (12). Port (P) closes and the pressurized oil from the front pump does not flow to the control valve. The pressurized oil from the control valve is drained to the tank via port (C) and port (T).
10-117
10 Structure, function and maintenance standard PPC valve
When signal current is very small (coil is energized) q
q q
q
q
q
When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated on the left side of plunger (6). Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port (P) to port (C). Pressures on port (C) increases and the force to act on surface (a) of spool (2) and the spring load on spring (3) become larger than the propulsion force of plunger (6). Spool (2) is pushed to the right, port (P) is shut off from port (C) and ports (C) and (T) are connected. Spool (2) moves up and down so that the propulsion force of plunger (6) may be balanced with pressure of port (C) + spring load of spring (3). The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current.
10-118
When signal current is maximum (coil is energized) q q
q q
q
As the signal current flows to coil (5), coil (5) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. Spool (2) is pushed to the left by push pin (4). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and the control valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the hydraulic tank.
PC128US-8
10 Structure, function and maintenance standard Swing motor
Swing motor
1
Type: KMF45ABE-5
B: From swing holding brake solenoid valve MA: From control valve MB: From control valve S: From control valve T: To tank 1. 2.
Specifications Type : KMF45ABE-5 Theoretical displacement : 143.8 cm³/rev Safety valve set pressure : 27.1 MPa {276 kg/cm²} Rated speed : 2,111 rpm Brake release pressure : 1.1 MPa {11 kg/cm²}
Reverse prevention valve Safety valve
PC128US-8
10-119
10 Structure, function and maintenance standard Swing motor
10-120
PC128US-8
10 Structure, function and maintenance standard Swing motor
1. Brake spring 2. Drive shaft 3. Spacer 4. Case 5. Disc 6. Plate 7. Brake ring 8. Brake piston 9. Housing 10. Piston 11. Cylinder block 12. Valve plate 13. Center shaft 14. Center spring 15. Check valve 16. Shuttle valve Unit: mm No.
Check item
Criteria Standard size
17 Check valve spring
18 Shuttle valve spring
PC128US-8
Remedy Repair limit
Free length Installation Installation Installation × Outside Free length length load load If damaged or diameter deformed, 6.96 N 5.59 N replace spring. 66.5 × 25.6 45.0 — {0.71 kg} {0.57 kg} 24.5 × 11.6
14.5
7.45 N {0.76 kg}
—
5.98 N {0.61 kg}
10-121
10 Structure, function and maintenance standard Swing motor
Swing holding brake When solenoid valve is de-energized
When solenoid valve is energized
Operation q As the swing holding brake solenoid valve is de-energized, the pressurized oil from the self pressure reducing valve is shut off. q Port (B) is connected to tank circuit (T). q Brake piston (8) is pushed down by brake spring (1). q Disc (5) and plate (6) are pushed together, and the brake is applied.
Operation q As the swing holding brake solenoid valve is energized, the valve is switched. q The pressurized oil from the self pressure reducing valve is conducted brake chamber (a) via port (B). q After entering chamber (a), the pressurized oil compresses brake spring (1) and pushes brake piston (8) up. q Disc (5) is separated from plate (6), releasing the brake.
10-122
PC128US-8
10 Structure, function and maintenance standard Swing motor
Relief valve portion Outline q The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function q When the machine is in the swing holding mode, control valve (6) closes the motor outlet circuit, but the motor rotation is continued by inertial force. q The motor output, therefore, is abnormally increased, resulting in damaging the motor. q In order to prevent the motor damages, the relief valve relieves the abnormally high pressure to port (S) from the motor outlet side (high-pressure side) of the motor. Operation When starting swing q When the swing control lever is operated to the right- swing, the pressurized oil from the pump is supplied to port (MA) via control valve (6). q The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. q The pressurized oil from the outlet port of the motor passes from port (MB) through the control valve (6) and returns to the tank.
PC128US-8
When swing is stopped q When the swing control lever is returned to neutral, the supply of pressurized oil from the pump to port (MA) is stopped. q The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (6). Thus, pressure on port (MB) increases. q Rotation resistance is generated on the motor and hence the brake starts working. q Shuttle valve (4) is pressed as pressure on port (MB) goes above port (MA). q The pressure on chamber (C) is increased to the se t pr es sur e of r el ief va lv e ( 1) an d becomes the same as that of port (MB). q A high braking torque works on the motor, thereby stopping the motor. q When relief valve (1) is being actuated, the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) via check valve (3). q Above prevents cavitation on port (MA).
10-123
10 Structure, function and maintenance standard Swing motor
Reverse prevention valve
10-124
PC128US-8
10 Structure, function and maintenance standard Swing motor
MA: From control valve MB: From control valve T1: To tank T2: To tank
1. 2. 3. 4. 5. 6. 7.
Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)
Explanatory drawing of effects
PC128US-8
10-125
10 Structure, function and maintenance standard Swing motor
Function q This valve reduces the swing back generation in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. q The valve contributes in preventing collapsing of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, enabling you to proceed to the next work quicker than ever). Operation When port (MB) brake pressure is generated q Pressure (MB) is conducted to chamber (d) via notch (g). q The pressure compresses spring (6) by use of the difference in areas of circles (øD1 > øD2) of spool (5) and moves spool (5) to the left side. q Port (MB) o chamber (e) will be interconnected. q Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is kept in. Thus the braking force is ensured.
10-126
When motor is stopped temporarily q The motor rotation is reversed by the closing pressure generated at port (MB). (1st time: reverse rotation) q Reversing pressure is generated on port (MA). Pressure (MA) is conducted to chamber (a). q The pressure compresses spring (3) by use of the difference in areas of circles (øD3 > øD4) of spool (2) and moves spool (2) to the right side. q Port (MA) o chamber (b) will be interconnected. q Ports (b) and (f) will be interconnected through the drilled hole (h) on spool (5). This interconnection bypasses the reversing pressure on port (MA) to port (T), thereby preventing the reverse rotation of the 2nd time.
PC128US-8
10 Structure, function and maintenance standard Travel motor
Travel motor
A:
D: P:
From center swivel joint, port B2 (L.H. travel motor) From center swivel joint, port C2 (R.H. travel motor) From center swivel joint, port D2 (L.H. travel motor) From center swivel joint, port A2 (R.H. travel motor) To center swivel joint, port DR2 From center swivel joint, port E2
1. 2. 3.
Oil filler plug Oil level plug Drain plug
B:
PC128US-8
1
10-127
10 Structure, function and maintenance standard Travel motor
1. Plug 2. Check valve 3. Counterbalance valve 4. Sleeve 5. Relief valve 6. End cover 7. Brake piston 8. Disc 9. Plate 10. Swash plate 11. Pivot 12. Bearing 13. Hub 14. Planetary pinion B 15. Planetary pinion A
10-128
16. Cover 17. Sun gear A 18. Carrier A 19. Sun gear B 20. Carrier B 21. Regulator piston 22. Shaft 23. Piston 24. Floating seal 25. Spindle 26. Cylinder 27. Timing plate 28. Regulator valve 29. Check valve 30. Piston
PC128US-8
10 Structure, function and maintenance standard Travel motor
Specifications Type
GM21VA-A
Stroke volume (cm³/rev)
Hi
44.2
Lo
79.1
Rated speed (rpm)
Hi
2,609
Lo
1,486
Brake releasing pressure (MPa{kg/cm²})
0.76 {7.71}
Hi-Lo switching pressure (MPa{kg/cm²})
2.94 {30}
Reduction ratio
54.0
Outline
1.
Final drive Consists of 2-stage planetary gear mechanism. Reduces the hydraulic motor speed from high speed to low speed high torque.
2.
Hydraulic motor Swash plate type axial piston motor mechanism. Converts oil pressure from the hydraulic pump into rotary motion.
3.
4.
2nd travel speed selector mechanism Consists of the regulator valve and regulator piston. Changes the rotation speed in 2 stages by changing the stroke volume of the hydraulic motor.
5.
Parking brake Multiple disc type brake mechanism. Forms a unit with the hydraulic motor.
Brake valve Consists of various valves. Provides the following functions: stops the hydraulic motor smoothly, prevents runway of hydraulic motor, prevents generation of abnormally high pressure when the hydraulic motor is stopped suddenly.
PC128US-8
10-129
10 Structure, function and maintenance standard Travel motor
Operation Operation of motor At low speed (the motor swash plate angle is maximized.)
1. 2nd travel speed select solenoid valve 2. Regulator valve 3. Spring 4. Check valve 5. Regulator piston 6. Swash plate 7. Parking brake piston 8. Hydraulic pump 9. Travel control valve 10. Pump merge-divider valve 11. Self pressure reducing valve 12. Brake valve
q
q q
q
q
10-130
Since 2nd travel speed select solenoid valve (1) is de-energized, the pressurized oil from self pressure reduction valve (11) is not fed to port (P). Regulator valve (2) is pushed down with spring (3) reaction force. The main pressurized oil, sent from the control valve through check valve (4), is controlled by regulator valve (2) and used to shuts off the circuit to regular piston (5). The pressurized oil in control chamber (C) is drained from port (D) through oil passage (e) of regulator valve (2). Swash plate (7) reaches its maximum tilt angle, and the machine travels at low speed with the maximum motor capacity.
PC128US-8
10 Structure, function and maintenance standard Travel motor
At high speed (the motor swash plate angle is minimized.)
1. 2nd travel speed select solenoid valve 2. Regulator valve 3. Spring 4. Check valve 5. Regulator piston 6. Swash plate 7. Parking brake piston 8. Hydraulic pump 9. Travel control valve 10. Pump merge-divider valve 11. Self pressure reducing valve 12. Brake valve
PC128US-8
q
q q
q
When 2nd travel speed select solenoid valve (1) is energized, the pressurized oil from self pressure reduction valve (11) is fed to port (P). Regulator valve (2) is pushed up with the pressurized oil that is sent to port (P). The main pressurized oil from the control valve passes through check valve (4), and passes through oil passage (F) in regulator valve (2) to control chamber (C), and is used to push to regular piston (5) to the left. Swash plate (7) reaches its minimum tilt angle, and the machine travels at high speed with the minimum motor capacity.
10-131
10 Structure, function and maintenance standard Travel motor
Brake valve Operation when pressure oil is supplied
q
q
q
When the travel lever is operated, the pressurized oil from the control valve is fed to port (A) and check valve (1) is opened. The oil is further sent from port (C) to port (D) through the motor. At the same time, when the pressure of the hydraulic oil that entered in chamber (G) through orifice (f) exceeds spring (3) reaction force, counterbalance valve (2) moves to the right, opening ports (D) and (B), and the motor becomes ready to rotate. As ports (A) and (E) also open, parking brake piston (4) is pressed down by the hydraulic pressure. This releases the parking brake and the motor starts to rotate.
10-132
Operation when pressure is shut off
q
q
q
When the travel lever is returned to its neutral position, the hydraulic oil circuit from the control valve is closed. And counterbalance valve (2) starts to return to the left by spring (3) reaction force. The hydraulic oil in chamber (G) tends to flow to port (A) through orifice (f). However, the back pressure is generated by closing of orifice (f), controlling the return speed of counterbalance valve (2) to the right. The motor tends to rotate by inertia even when the hydraulic oil from the control valve is stopped.During this time, the oil return circuit is gradually closed by controlling the movement speed of counterbalance valve (2) and by using its cutout portion. By this, the motor is smoothly stopped.
PC128US-8
10 Structure, function and maintenance standard Travel motor
Brake operation at travelling downhill
q
q
q
q
q
If the machine is going to run away when traveling downhill, the motor idles and the hydraulic pressure at port (C) drops. The pressure of hydraulic oil that is sent to chamber (G) through orifice (f) also drops. When the hydraulic oil pressure in chamber (G) goes below spring (3) reaction force, counterbalance valve (2) starts to return to the left. The hydraulic oil in chamber (J) tends to flow to port (B) through orifice (h). However, the back pressure is generated by closing of orifice (h), controlling the return speed of counterbalance valve (2) to the right. When ports (D) and (B) are closed and when the hydraulic pressure at port (D) increases, a resistance is generated in motor rotation to protect the machine from running away. Counterbalance valve (2) is moved to the position where the hydraulic pressure at port (B) is well balanced with the pressure by the weight of machine itself and the pressure at port (A). The motor speed is controlled according to the pump delivery by controlling the opening of hydraulic oil output circuit.
PC128US-8
10-133
10 Structure, function and maintenance standard Travel motor
Relief valve When starting
q
q
q
q
q
The pressurized oil from the control valve is fed from port (A) to port (C). As port (C) is connected to the motor, the pressure drives the motor to rotate. When the hydraulic pressure at port (C) exceeds the specified value, relief valve (1a) is pushed up and the hydraulic oil is fed to port (D).However, relief valve (1b) is kept closed independent from the hydraulic pressure at port (C). The hydraulic oil is fed from port (C) to chamber (E) through the oil passages of relief valve (1a) and sleeve (2a). By this pressure, piston (3) is moved to the right. When piston (3) reaches its stroke end position, the hydraulic pressure from relief valve (1a) to chamber (E) increases. Therefore, ports (C) and (D) are closed by relief valve (1a). The hydraulic pressure at port (C) at the inlet side is controlled so that the motor is smoothly started to rotate.
10-134
When stopping
q
q
q
q
q
When the hydraulic oil from the control valve is stopped, ports (A) and (C) are closed. At the same time, ports (D) and (B) are closed, but the motor continues to rotate by the inertia. When the hydraulic pressure at port (D) exceeds the specified value, relief valve (1b) is pushed up and the hydraulic oil is fed to port (C).The hydraulic pressure applied to port (D) at the outlet side is fed to port (C) at the inlet side, and it is used to prevent the oil cavitation. The hydraulic oil from port (D) passes through the oil passages of relief valve (1b) and sleeve (2b), and sent to chamber (F). By this pressure, piston (3) is moved to the left. When piston (3) reaches its stroke end position, the hydraulic pressure from relief valve (1b) to chamber (F) increases. Therefore, ports (D) and (C) are closed by relief valve (1b). The hydraulic pressure at port (D) at the outlet side is controlled so that the motor is smoothly stopped.
PC128US-8
10 Structure, function and maintenance standard Travel motor
PC128US-8
10-135
10 Structure, function and maintenance standard Center swivel joint
Center swivel joint
1
Standard specification
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
10-136
A1: From control valve Port B3 A2: To R.H. travel motor REVERSE port A B1: From control valve Port A2 B2: To L.H. travel motor FORWARD port A C1: From control valve Port A3 C2: To R.H. travel motor FORWARD port B D1: From control valve Port B2 D2: To L.H. travel motor REVERSE port B E1: From 2nd travel speed select solenoid valve E2: To L.H. and R.H. travel motor port P DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D
PC128US-8
10 Structure, function and maintenance standard Center swivel joint
Unit: mm No.
Item
1
Clearance between rotor and shaft
PC128US-8
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
80
0.056 – 0.105
0.111
Replace
10-137
10 Structure, function and maintenance standard Center swivel joint
Blade specification (if equipped)
1. 2. 3. 4. 5.
Cover Body Slipper seal Dust seal Shaft
10-138
A1: From control valve Port B4 A2: To R.H. travel motor REVERSE port A B1: From control valve Port A3 B2: To L.H. travel motor FORWARD port A C1: From control valve Port A4 C2: To R.H. travel motor FORWARD port B D1: From control valve Port B3 D2: To L.H. travel motor REVERSE port B E1: From 2nd travel speed select solenoid valve E2: To L.H. and R.H. travel motor port P F1: From control valve (blade LOWER) F2: To L.H. and R.H. blade cylinder bottom G1: From control valve (blade RAISE) G2: To L.H. and R.H. blade cylinder head DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D PC128US-8
10 Structure, function and maintenance standard Center swivel joint
Unit: mm No. 1
Item clearance between rotor and shaft
PC128US-8
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
90
0.056 – 0.105
0.111
Replace
10-139
10 Structure, function and maintenance standard Solenoid valve
Solenoid valve
10-140
1
PC128US-8
10 Structure, function and maintenance standard Solenoid valve
P1 : From self pressure reducing valve A1 : To PPC valve A2 : To center swivel joint, port E1 A3 : To swing motor, port B A4 : To control valve, port PS A5 : To control valve, port PST T : To hydraulic tank ACC : To accumulator (for PPC circuit) 1. 2. 3. 4. 5.
Operation Check valve
PPC lock solenoid valve 2nd travel speed select solenoid valve Swing holding brake solenoid valve Pump merge-divider solenoid valve Travel junction solenoid valve
Solenoid valve 6. Coil (ON/OFF type) 7. Push pin 8. Valve spool 9. Sleeve 10. Block 11. Plug Check valve 12. Plunger 13. Plug
Installed between port (P) and PPC solenoid valve. When the engine is stopped, plunger (1) is pushed back to the left with spring (2) reaction force, and ports (ACC) and (P) are closed to maintain the pressure in the accumulator. When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P), and ports (P) and (ACC) are interconnected.
PC128US-8
10-141
q
q
10 Structure, function and maintenance standard Solenoid valve
Solenoid valve When solenoid valve is “de-energized“ (circuit is closed)
q q q
Coil (1) is de-energized when no signal current is supplied to coil (1). Spool (2) is pushed back to the left with spring (3) reaction force. As ports (P) and (A) are closed, the pilot pressure is not fed to the actuator through port (A). At the same time, port (T) is opened, allowing the oil from the actuator to drain to the hydraulic tank.
10-142
When solenoid valve is “energized“ (circuit is connected)
q q q
Coil (1) is energized when signal current is supplied to coil (1). Spool (2) is pushed to the right with push pin (4). As ports (P) and (A) are opened, the pilot pressure is fed to the actuator through port (A). At the same time, port (T) is closed, shutting off the oil from the actuator to the hydraulic tank.
PC128US-8
10 Structure, function and maintenance standard Solenoid valve
PC128US-8
10-143
10 Structure, function and maintenance standard PPC accumulator
PPC accumulator
1
For PPC circuit 1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
Outline q Mounted on the solenoid valve. If the engine is stopped with the work equipment is kept at an elevated position, the pilot pressure is supplied to the control valve by the pressure of the compressed nitrogen gas in the accumulator. Therefore, the spool can be operated to lower the work equipment by its own weight. Specifications Gas to be used: Nitrogen gas Gas capacity: 300 cc Sealed gas pressure: 1.18 MPa {12 kg/cm²} (at 80°C) Maximum operating pressure: 6.86 MPa {70 kg/cm²}
10-144
PC128US-8
10 Structure, function and maintenance standard PPC accumulator
For breaker (Machine ready for attachment) For low pressure
For high pressure
1. 2. 3. 4. 5. 6.
1. 2. 3. 4. 5. 6.
Cap Core Ring Lid Bladder Shell
Outline q Connected to the attachment piping. When the breaker operates, the oil pulsation is absorbed by the pressure of compressed nitrogen gas of the accumulator, to protect the hydraulic system devices and piping. Specifications Gas to be used: Nitrogen gas Gas capacity: 480 cc Sealed gas pressure: 0.1 MPa {1 kg/cm²} (at 80°C) Maximum operating pressure: 6.86 MPa {70 kg/cm²}
PC128US-8
Cap Core Locknut Gas port Bladder Shell
Outline q Connected to the attachment piping. When the breaker operates, the oil pulsation is absorbed by the pressure of compressed nitrogen gas of the accumulator, to protect the hydraulic system devices and piping. Specifications Gas to be used: Nitrogen gas Gas capacity: 500 cc Sealed gas pressure: 5.88 MPa {60 kg/cm²} (at 80°C) Maximum operating pressure: 20.6 MPa {210 kg/cm²}
10-145
10 Structure, function and maintenance standard Holding valve
Holding valve
1
(For boom and arm)
10-146
PC128US-8
10 Structure, function and maintenance standard Holding valve
CY : To work equipment cylinder PCY: For pressure pickup port and equalizer circuit PI : From PPC valve T : To tank V : From control valve 1. 2. 3.
Pilot spool Safety valve Check valve Unit: mm
No.
Check item
Criteria Standard size
4
Check valve spring
Remedy Repair limit
Free length Installation Installation Installation × Outside Free length length load load diameter 20.8 × 12.2
13.5
12.7 N {1.3 kg}
—
10.2 N {1.04 kg}
5
Spool return spring
41.1 × 9.6
35.0
58.8 N {6.0 kg}
—
47.1 N {4.8 kg}
6
Spool return spring
41.9 × 25.8
41.0
78.5 N {8.0 kg}
—
62.8 N {6.4 kg}
PC128US-8
If damaged or deformed, replace spring.
10-147
10 Structure, function and maintenance standard Holding valve
Function q Prevents the pressurized oil from reversing from the work equipment cylinder in order to prevents sudden drift of the work equipment at breaking of the piping between the control valve and the work equipment cylinder. Operation When the work equipment lever is in neutral When the piping is free of breakage Check valve (5) is closed under the holding pressure of the cylinder led from port (CY) to chamber (b). q At the neutral, pilot pressure led to port (PI) from the PPC valve is 0 MPa {0 kg/cm²}. q Spool (1) is pressed to the left by the force of springs (2) and (3). q Chambers (a) and (b) are shut off. q No pressurized oil flows between the control valve and the work equipment cylinder. q Accordingly, the work equipment is held in position. q If the work equipment cylinder has abnomally high pressure, safety valve (4) is actuated by the holding pressure of the work equipment cylinder. q Chambers (b) of L.H. and R.H. holding valve for the boom are interconnected by port (PCY). q Chambers (b) will have the same pressure if the L.H. and R.H. holding valves have a difference in leakage. q
10-148
If the piping is bursted q If piping (A) is broken between the control valve and the work equipment cylinder, chambers (a) and (b) are shut off in the same way as the piping is free from damages. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment.
PC128US-8
10 Structure, function and maintenance standard Holding valve
When pressurized oil flows from the main valve to the cylinder When the piping is free of breakage q Pressurized oil led to chamber (a) from the control valve becomes higher than the combined force of pressure from work equipment cylinder circuit chamber (b) and spring (6). q Check valve (5) opens and chambers (a) and (b) are interconnected. q Pressurized oil flows from the control valve to the work equipment cylinder. If the piping is bursted If piping (A) between the control valve and the work equipment cylinder is broken, pressurized oil in chamber (a) flows outside from the damaged portion. q Pressure force in chamber (a) drops. q Pressure force in chamber (a) drops lower than the combined pressure force of chamber (b) and spring (6). q Check valve (5) closes and chambers (a) and (b) are cut off. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment. q
PC128US-8
10-149
10 Structure, function and maintenance standard Holding valve
When returning pressurized oil to the main valve from the work equipment cylinder When the piping is free of burst q Holding pressure of the work equipment cylinder is led to chamber (b) and check valve (5) closes. q Pilot pressure from the PPC valve is led to port (PI) and reaches [Pilot Pressure > Force of Spring (3)] (area of d). q Spool (1) moves to the right to the standby position.(1st stage stroke) q At this point, chambers (a) and (b) are not interconnected. q Pilot pressure further rises, and reaches [Pilot pressure > Force of spring (2)] (area of d). q Spool (1) moves further to the right, and chambers (a) and (b) are interconnected. (2nd stage stroke) q Pressurized oil returns to the control valve from the work equipment cylinder.
10-150
If the piping is bursted q If piping (A) bursts between the control valve and the work equipment cylinder. q Pressurized oil in chamber (a) flows out to the bursted portion but resupplied from chamber (b). q Since pressurized oil flows via opening (c) of spool (1), a sudden drop of the cylinder is prevented.
PC128US-8
10 Structure, function and maintenance standard Holding valve
PC128US-8
10-151
10 Structure, function and maintenance standard Work equipment
Work equipment Work equipment
1
Unit: mm No.
Item
1
Clearance between mounting pin and bushing of boom and revolving frame
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
70
-0.030 -0.100
+0.143 +0.063
0.093 – 0.243
0.8
2
Clearance between mounting pin and bushing of boom and arm
70
-0.030 -0.100
+0.145 +0.065
0.095 – 0.245
0.8
3
Clearance between mounting pin and bushing of arm and bucket
60
-0.030 -0.080
+0.129 +0.074
0.104 – 0.209
0.8
4
Clearance between mounting pin and bushing of arm and link
60
-0.030 -0.080
+0.133 +0.075
0.105 – 0.213
0.8
5
Clearance between mounting pin and bushing of link and link
65
-0.030 -0.080
+0.132 +0.075
0.105 – 0.212
0.8
6
Clearance between mounting pin and bushing of link and bucket
60
-0.030 -0.080
+0.130 +0.078
0.108 – 0.210
0.8
7
Clearance between mounting pin and bushing of blade and track frame
70
-0.030 -0.100
+0.190 +0.090
0.120 – 0.290
1.5
10-152
Replace pin and bushing
PC128US-8
10 Structure, function and maintenance standard Work equipment
PC128US-8
10-153
10 Structure, function and maintenance standard Dimensions of components
Dimensions of components
1
Arm
10-154
PC128US-8
10 Structure, function and maintenance standard Dimensions of components
Unit: mm PC128US-8 No.
Measurement point
1
2
—
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
3
70
-0.030 -0.100
+0.100 0
4
—
5
—
264
±2.0
6
—
213.5
±1.0
7
—
640.6
±0.5
8
—
2,491
—
9
—
2,101.9
±1.5
10
—
290.4
±0.5
11
—
487
±0.2
12
—
415
±0.5
13
—
374.9
—
14
—
1,168.7
—
15
—
60
16
259
0 -1.0
Bucket side
261
±1.0
—
60
-0.030 -0.080
+0.200 0
Arm side
226
0 -0.5
Bucket side
274
+2.0 0
Min.
1,378
—
Max.
2,263
—
18
PC128US-8
+0.200 0
Link side
17
19
-0.030 -0.080
10-155
10 Structure, function and maintenance standard Dimensions of components
Bucket
10-156
PC128US-8
10 Structure, function and maintenance standard Dimensions of components
Unit: mm No.
PC128US-8 Measurement point
Standard size
Tolerance
1
—
371.3
±0.5
2
—
51.6
±0.5
3
—
97.9°
—
4
—
374.9
—
5
—
1,153.1
—
6
—
190.5
—
7
—
5°
—
8
—
0°
—
9
—
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
+2.0 0
22
—
51
—
23
—
34
—
24
—
101.8
—
25
—
118.8
—
26
—
74
—
27
—
65
—
PC128US-8
10-157
10 Structure, function and maintenance standard Hydraulic cylinder
Hydraulic cylinder
1
Boom cylinder
Arm cylinder
Bucket cylinder
10-158
PC128US-8
10 Structure, function and maintenance standard Hydraulic cylinder
Blade cylinder
Unit: mm No.
1
2
3
Item
Clearance between piston rod and bushing
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
PC128US-8
Criteria Cylinder name
Standard size
Boom
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
70
-0.030 -0.076
+0.259 +0.063
0.093 – 0.335
0.435
Arm
75
-0.030 -0.076
+0.279 +0.065
0.095 – 0.355
0.455
Bucket
65
-0.030 -0.076
+0.250 +0.055
0.085 – 0.326
0.426
Blade
75
-0.030 -0.076
+0.279 +0.065
0.095 – 0.355
0.455
Boom
70
-0.030 -0.100
+0.190 +0.090
0.120 – 0.290
1.0
Arm
70
-0.030 -0.100
+0.190 +0.090
0.120 – 0.290
1.0
Bucket
65
-0.030 -0.080
+0.170 +0.070
0.100 – 0.250
1.0
Blade
70
-0.030 -0.100
+0.190 +0.090
0.120 – 0.290
1.0
Boom
70
-0.030 -0.100
+0.190 +0.090
0.120 – 0.290
1.0
Arm
70
-0.030 -0.100
+0.190 +0.090
0.120 – 0.290
1.0
Bucket
65
-0.030 -0.080
+0.170 +0.070
0.100 – 0.250
1.0
Blade
70
-0.030 -0.100
+0.190 +0.090
0.120 – 0.290
1.0
Replace bushing
10-159
10 Structure, function and maintenance standard Air conditioner
Cab and its attachments Air conditioner
1
Air conditioner piping diagram
10-160
PC128US-8
10 Structure, function and maintenance standard Air conditioner
A: B: C: D: E: F:
Front warm/cool air outlet Rear warm/cool air outlet Foot warm/cool air outlet Defroster warm/cool air outlet Internal air flow outlet External air flow outlet
Dual pressure switch q If abnormally low or high pressure was generated in the refrigerant circulation circuit, this switch releases the magnet clutch of the compressor to protect a series of cooler-related equipment. High-pressure OFF: 3.14 ± 0.20 MPa {32 ± 2 kg/cm²} Low-pressure OFF: 0.20 ± 0.02 MPa {2 ± 0.2 kg/cm²}
1. Sunlight sensor 2. Machine monitor 3. Refrigerant piping 4. Compressor 5. Condenser (with built-in receiver) 6. Air conditioner controller 7. Sight glass 8. External air filter 9. Air conditioner unit 10. Internal air filter 11. Dual pressure switch 12. Hot water take-out piping 13. Ambient temperature sensor 14. Hot water return piping Specifications Refrigerant to be used
R134a
Refrigerant capacity (g)
800
PC128US-8
10-161
10 Structure, function and maintenance standard Air conditioner
1. 2. 3.
Engine Compressor Condenser 3a. Receiver 4. Sight glass 5. Air conditioner unit 6. Dual pressure switch Table of tightening torque for refrigerant piping adapter Unit: Nm{kgm} No.
Item
Criteria
7
Compressor refrigerant piping lock bolt
7.85 – 11.8 {0.8 – 1.2} (Screw size: M6 × 1.0)
8
Condenser refrigerant piping lock bolt
3.92 – 6.86 {0.4 – 0.7} (Screw size: M6 × 1.0)
9
Air conditioner unit refrigerant piping connector lock bolt
7.85 – 11.8 {0.8 – 1.2} (Screw size: M6 × 1.0)
10-162
Remedy
Retighten
PC128US-8
10 Structure, function and maintenance standard Air conditioner
PC128US-8
10-163
10 Structure, function and maintenance standard Air conditioner
Air conditioner unit
10-164
PC128US-8
10 Structure, function and maintenance standard Air conditioner
A: B: C: D:
From condenser To compressor Hot water inlet Hot water outlet
1. 2. 3. 4. 5. 6. 7. 8. 9.
Evaporator Heater core Expansion valve Blower motor Air mix damper actuator Air mix damper Mode selector damper actuator Mode selector damper Internal/external air changeover damper actuator 10. Internal/external air changeover damper 11. Power transistor 12. Evaporator temperature sensor 13. Internal air temperature sensor 14. Internal air filter
PC128US-8
Outline q The horizontal air conditioner unit on which evaporator (1) and heater core (2) is arranged in parallel. Blower motor (4) is driven to to generate cool and hot air. q Selecting the temperature on the machine monitor controls air mix damper (6) to adjust the spurting out temperature. Cooler The cooler circulates refrigerant through evaporator (1) to cause heat exchange (dehumidification and cooling). q Air taken in by blower motor (4) is cooled with evaporator (1) and then blown out from the duct and grill. q
Heater q The heater circulates engine coolant in heater core (2) to cause heat exchange (heating). q Air taken in by blower motor (4) is heated with heater core (2) and then blown out through the duct and grill.
10-165
10 Structure, function and maintenance standard Air conditioner
Functions of major components Evaporator q Evaporator fin is cooled by the low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air from the blower motor is cooled and dehumidified when passing through the fin. Heater core Fin of the heater core is heated by the hot water (coolant) being sent from the engine. Air from the blower motor is heated as it passes through the fin.
q
Expansion valve q This valve converts high-pressure, high-temperature liquid refrigerant from the condenser to low-pressure, low-temperature misty refrigerant through the throttling function. It controls flow rate of refrigerant by changing level of throttling depending on the thermal load in the operator's cab. Blower motor It suctions air by rotating the fin installed on the blower motor. And it is also used for sending air to the evaporator and heater core.
q
Air mix damper actuator q It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the air mix damper through the link mechanism. q The motor rotating direction is determined as the air conditioner controller reads the position of the potentiometer being built in the actuator. This reading is done as the target temperature is set on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned “OFF“.
Internal/external air changeover damper actuator q It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the internal/external air flow selector damper through the link mechanism. q The motor rotating direction is determined by selecting internal/external air flow on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned “OFF“. Evaporator temperature sensor In order to prevent freezing of the evaporator, it senses the evaporator temperature and sends necessary signals to the air conditioner controller.The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.
q
Internal air temperature sensor q It senses the internal air temperature and sends necessary signals to the air conditioner controller.The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.
Mode selector damper actuator It starts the built-in motor upon receipt of a signal current from the air conditioner controller in order to open or close the mode selector damper through the link mechanism. q The motor rotating direction is determined as the air conditioner controller reads the position of the potentiometer being built in the actuator. This reading is done as the mode is selected on the machine monitor. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, or when signal current from the air conditioner controller is turned “OFF“. q
10-166
PC128US-8
10 Structure, function and maintenance standard Air conditioner
Air conditioner controller
Input and output signals AMP040-36P Pin No. 1 2
Signal name NC Air mix dumper actuator potentiometer signal Actuator potentiometer power supply
Input and output signals
Pin No.
—
17
CAN_H
Input
18
CAN_L
Output
19
Signal name
Input and output signals Input/ output Input/ output
4
Dual pressure switch
Input
20
5 6 7 8
NC Back-up power supply Blower feedback signal Power transistor control signal Mode selector actuator potentiometer signal NC Internal air temperature sensor Evaporator temperature sensor External air temperature sensor NC Sunlight sensor GND
— Input Input Output
21 22 23 24
Internal/external air changeover dumper actuator (A) Internal/external air changeover dumper actuator (B) Air mix dumper actuator (A) Air mix dumper actuator (B) Mode selector actuator (A) Mode selector actuator (B)
Input
25
Relay power supply
Output
— Input Input Input — Input Output
26 27 28 29 30 31 32 33 34 35 36
NC GND (sensor) NC NC Test terminal RAM monitor (for switching display) RAM monitor I/F RAM monitor output NC Compressor clutch relay Blower main relay
— Input — — — — — — — Input Input
3
9 10 11 12 13 14 15 16
PC128US-8
Output Output Output Output Output Output
10-167
10 Structure, function and maintenance standard Air conditioner
Compressor
A: B:
From air conditioner unit To condenser
Function q Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator to high-pressure, high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature. q Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure. Specifications Number of cylinders - bore x stroke (mm)
10-168
10-32 x 20.8
Piston capacity (cc/rev)
129.2
Allowable maximum speed (rpm)
6,000
Refrigerant oil to be used
Denso: ND-OIL 8
Refrigerant oil capacity (cc)
180
PC128US-8
10 Structure, function and maintenance standard Air conditioner
Condenser
A: B: 1. 2.
From compressor To air conditioner unit Core Receiver
Function q It cools and liquefies the high-pressure and high-temperature misty refrigerant from the compressor. q The receiver holds high-pressure, high-temperature liquid refrigerant.It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent. a
Specifications Fine pitch (mm)
4.0
Total heat dissipation surface (m²)
3.58
Max. pressure used (MPa{kg/cm²}) Weight of desiccating agent (g)
3.53 {36} 290
If the fin crushes or is clogged with dusts, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.
PC128US-8
10-169
10 Structure, function and maintenance standard Air conditioner
Sensor
External air temperature sensor
Sunlight sensor
Outline q The sunlight sensor is installed on top of the machine monitor of the air duct. q It senses intensity of the sun light and sends signals to the air conditioner controller. The signal sent to the air conditioner controller is used to control the blower motor and compressor. Output characteristics
10-170
Outline q The external air temperature sensor is installed in the battery room at the rear left of the machine. q It senses the external air temperature and sends signals to the air conditioner controller. The signal sent to the air conditioner controller is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator.
PC128US-8
10 Structure, function and maintenance standard Air conditioner
PC128US-8
10-171
10 Structure, function and maintenance standard Electronic control system
Electrical system Electronic control system
1
Machine control system diagram
10-172
PC128US-8
10 Structure, function and maintenance standard Electronic control system
1
PC128US-8
10-173
10 Structure, function and maintenance standard Electronic control system
Engine control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Starting switch 6. Engine controller 7. Lock lever 8. PPC lock switch 9. Starting motor cut-out relay (for PPC lock) 10. Starting motor cut-out relay (for personal code) 11. Fuel control dial 12. Safety relay 13. Starting motor 14. Fuel supply pump 15. Sensors 16. Engine controller power cut-off relay A 17. Engine controller power cut-off relay B 18. Machine monitor 19. KOMTRAX terminal
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Function 1.
The neutral safety circuit is employed to secure safety when the engine is started. q The engine does not start until the lock lever is set in the “LOCK“ position.
2.
The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX terminal receives an engine cut command issued through external operation.
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10 Structure, function and maintenance standard Electronic control system
Starting engine q When starting switch (5) is turned “ON“, engine controller (6) sends command current to fuel supply pump (14). For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an electrical failure occurs. q When starting switch (5) is turned to “START “ with lock lever (7) set in the “LOCK“ position, a starting current is supplied to starting motor (13) causing the engine to start. However, as the neutral safety mechanism is provided, the engine will not start if lock lever (7) is set in the “FREE“ position at this time; starting motor cut-out relay (9) cuts off the starting current to starting motor (13). q Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the signal to machine monitor (18). Machine monitor (18) causes starting motor cut-out relay (10) to cut off the starting current to starting motor (13), therefore the engine does not start. Engine speed control Upon receipt of a fuel control dial (11) control signal, engine controller (6) sends a command current to fuel supply pump (14) to adjust the fuel injection amount to control the engine speed.
q
Stopping engine q When starting switch (5) is turned “OFF“, the current from the ACC terminal of starting switch (5) to engine controller (6) is cut off, and consequently the command current to fuel supply pump (14) is cut off. Fuel supply pump (14) stops fuel feed, causing the engine speed to go down and the engine stops.
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Pump and engine mutual control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Fuel supply pump 12. Sensors 13. Pump oil pressure sensor 14. Oil pressure sensor 15. Oil pressure switch 16. Hydraulic pump 16a. Servo 16b. LS valve 16c. PC valve 17. Control valve 17a. Pump merge-divider valve 17b. Self pressure reducing valve 18. PC-EPC valve
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Input and output signals a. CAN signal b. PC-EPC valve drive signal c. Solenoid valve GND d. Oil pressure sensor signal e. Oil pressure switch signal f. Throttle signal g. Fuel supply pump control signal h. Sensor signals
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Function q A function that selects working mode with the working mode selector switch in the machine monitor. 5 modes (P, E, L, ATT, B) are available, allowing the operator to select appropriate engine torque (T) and pump absorption torque depending on the work. In the default setting of the service mode, only 3 modes (P, E, L) are available in which “Without“ is selected for the attachment. q According to the pump absorption torque set at each mode, based on the engine governor set speed with the fuel control dial and the actual engine speed, the controller controls so that the pump absorbs all torques at each engine output point. q When the engine speed is lowered, the controller prevents the engine from stopping by throttling the pump absorption torque.
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Control method in each mode P mode, E mode, and ATT mode q Matching point: Working mode
P, ATT
Travel Working (At arm digging)
64.4 kW/2,050 rpm {86.4 HP/2,050 rpm}
Working (Except arm digging)
66.3 kW/2,050 rpm {88.9 HP/2,050 rpm}
E q
q
Matching point 68.4 kW/2,200 rpm {91.7 HP/2,200 rpm}
60.0 kW/1,980 rpm {80.5 HP/1,980 rpm}
In P, E, or ATT mode, engine speed is always controlled so that it is kept around the matching point specified for each mode. When a load to the pump increases and the pressure rises, the engine speed (N) lowers. At the time, the controller reduces the pump delivery (Q) to increase the engine speed to the matching point. If the pressure drops, the controller increases the pump delivery to increase the engine speed to the matching point.
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Modes B and L
q
q q
q
Working mode
Partial output
B
75%
L
70%
Matching point: Working mode
Matching point
B
50.9 kW/1,870 rpm {68.2 HP/1,870 rpm}
L
47.8 kW/1,640 rpm {64.1 HP/1,640 rpm}
In B or L mode, engine output is controlled to a constant level. The controller controls the pump absorption torque to decrease the engine speed while keeping the engine torque at a constant level along the equal engine horsepower curve. The controller controls pump delivery (Q) so that the engine torque can be kept at a constant level along the equal engine horsepower curve.
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Control function during travel q Traveling the machine in P or ATT mode increases engine speed (N). q Traveling the machine in E, L or B mode does not change engine speed (N) or pump absorption torque.
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Control function with emergency pump drive switch “ON“ q If the controller gets out of order and no work is possible because the hydraulic pump does not work properly, operating emergency pump drive switch (1) temporarily enables to maintain functions of the machine with absorption torques quite similar to those in the Mode E. In this case, a constant current flows from the battery to the PC-EPC valve, and the valve detects the oil pressure only. a. Emergency b: Normal a Emergency pump drive switch (1) is of the alternative type. If the machine is operated after the switch is set to “Emergency (a)“ even though the machine is normal, the user code “E02“ will be shown on the display.
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Auto-decelerator function
1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Fuel supply pump 6. Sensors 7. Oil pressure sensor 8. Oil pressure switch 9. Hydraulic pump 10. Control valve 10a. Pump merge-divider valve 10b. Self pressure reducing valve 11. PPC lock solenoid valve
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Input and output signals a. CAN signal b. Oil pressure sensor signal c. Oil pressure switch signal d. Throttle signal e. Fuel supply pump control signal f. Sensor signals
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Function q When all the control levers are set to NEUTRAL for waiting for a dump track or work, the engine speed is automatically reduced to a control speed, and fuel consumption and noise are lowered. q When any control lever is operated, the engine speed returns immediately to the speed that is set with the fuel control dial.
Operation When control levers are set in neutral q If all the control levers are set to NEUTRAL for 4 seconds or more with the engine speed exceeding approx. 1,400 rpm, the engine speed lowers down to the control speed (approx. 1,400 rpm) and is held until the control lever is operated again. When any control lever is operated With the engine speed at the control speed (approx. 1,400 rpm), when any control lever is operated, the engine speed increases immediately to the speed that is set with the fuel control dial.
q
A : All work equipment control levers in “NATURAL“ B : All work equipment control levers “OPERATED“ C: Fuel control dial set speed D: Engine control speed (approx. 1,400 rpm) E : 4 sec. F : Max. 2 sec. G: Max. 0.2 sec.
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Engine automatic warm-up function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Fuel supply pump 12. Sensors 13. Hydraulic oil temperature sensor 14. Hydraulic pump 14a. Servo 14b. LS valve 14c. PC valve 15. Control valve 15a. Pump merge-divider valve 15b. Self pressure reducing valve 16. PC-EPC valve
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Input and output signals a. CAN signal b. PC-EPC valve drive signal c. Solenoid valve GND d. Hydraulic oil temperature signal e. Throttle signal f . Fuel supply pump control signal g. Sensor signals
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Function q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after start-up of the engine. Operational conditions (all required)
Operation o
Coolant temperature: Max. 30°C Fuel control dial: Max. 70% of full rotation
Engine speed: 1,300 rpm
O Release conditions (either one required) Automatic Manual
Release
Coolant temperature: Min. 30°C Duration of automatic warming-up: Min. 10 minutes
o
Engine speed: Any
Fuel control dial: Held at Min. 70% of full rotation for Min. 3 seconds
Overheat prevention function a
See “Engine automatic warm-up function“ for system circuit diagram.
q
Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil temperature becomes too high. Operational conditions
Working mode: P, ATT Coolant temperature: Min. 95°C Hydraulic oil temperature: Min. 95°C Traveling status check: OFF
Operational conditions Working mode: P, ATT Coolant temperature: Min. 98°C Hydraulic oil temperature: Min. 98°C Traveling status check: ON
Operational conditions Working mode: P, ATT Coolant temperature: Min. 100°C Hydraulic oil temperature: Min. 100°C Traveling status check: Any
Operational conditions Working mode: P, ATT, E, B Coolant temperature: Min. 102°C Hydraulic oil temperature: Min. 102°C Traveling status check: Any
Operational conditions
Operation and actions taken Engine speed: Remains same
o • Sends torque control signal to
Release conditions Coolant temperature: Max. 95°C
o Hydraulic oil temperature: Max. 95°C
lower the pump absorption torque and reduce the engine load.
• The original conditions are restored if above requirements are met (automatic restoration).
Operation and actions taken
Release conditions Coolant temperature: Max. 98°C
o • Engine speed: Remains same • Travel speed: Down
Operation and actions taken Engine speed: Remains same
o • Sends torque control signal to
o Hydraulic oil temperature: Max. 98°C
• The original conditions are restored if above requirements are met (automatic restoration).
Release conditions Coolant temperature: Max. 100°C o Hydraulic oil temperature: Max. 100°C
lower the pump absorption torque and reduce the engine load.
• The original conditions are restored if above requirements are met (automatic restoration).
Operation and actions taken
Release conditions
Engine speed: Remains same
Coolant temperature: Max. 102°C Alarm monitor: ON o o Hydraulic oil temperature: Max. 102°C • The original conditions are restored if • Sends torque control signal to above requirements are met (autolower the pump absorption torque matic restoration). and reduce the engine load.
Operation and actions taken
Release conditions Coolant temperature: Max. 105°C
Working mode: Any Coolant temperature: Min. 105°C Hydraulic oil temperature: Min. 105°C Traveling status check: Any
o Engine speed: Low idle Alarm monitor: ON Alarm monitor: Sounds
Hydraulic oil temperature: Max. 105°C o Fuel control dial: Returns to low idle (MIN) position. • The original conditions are restored if above requirements are met (man-
ual restoration).
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Turbocharger protection function a
See “Engine automatic warm-up function“ for system circuit diagram.
q
When the engine is started at low temperatures and the engine speed is increased sharply, the turbocharger may be seized. Controlling the engine speed prevents this problem. Duration of engine speed control depends on the coolant temperature.
q
Operational conditions Engine oil pressure: Max. 50 kPa {0.51 kg/cm2}
A: B: C: D: E: F:
Operating o
Turbocharger protection (See the following figure)
Start engine Duration of turbocharger protection (approx. 0 – 20 sec) Modulating time (approx. 1.5 sec) 500 rpm 1,100 rpm 2,300 rpm (*1)
*1. Working mode: Mode P Fuel control dial: Full rotation (MAX) position Travel lever operated
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Swing control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Swing holding brake release switch 6. Swing lock switch 7. Pump controller 8. Machine monitor 9. Oil pressure switch 10. Hydraulic pump 11. Control valve 11a. Pump merge-divider valve 11b. Self pressure reducing valve 12. Swing motor 13. Swing holding brake solenoid valve
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Input and output signals a. Swing holding brake release signal b. Swing holding brake solenoid valve drive signal c. CAN signal d. Swing lock switch signal e. Oil pressure switch signal
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Function Swing lock and swing holding brake functions q Turning swing lock switch (1) to “ON“ locks the swing lock (manual lock) at any position. q Interlocked with the swing operation, the swing holding brake (auto lock) prevents hydraulic drift from occurring after the swing stops. q Interlocked with the arm retract operation, the swing holding brake is released to reduce the load on the swing equipment during excavation work.
Swing lock switch
OFF
ON
Swing lock monitor
OFF
ON
Function
Swing holding brake
Swing lock
• When the L.H. work • The swing holding brake works to equipment control lock the swing. lever is set to NEUTRAL, the swing • Even if the L.H. holding brake works work equipment in 5 sec. control lever is operated for • When the L.H. work swing, the swing equipment control Operation holding brake lever is operated for cannot be swing or the arm released, and no lever is operated for swing is possible. retract, the swing holding brake is released allowing free swing operation.
A: B: C: D:
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L.H. work equipment control lever “SWING“ (Swing holding brake “RELEASE“) L.H. work equipment control lever “NEUTRAL“ Swing holding brake “OPERATED“ 5 sec
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Swing holding brake release function q If the controller gets out of order and no swing is possible because the swing holding brake does not work properly, operating swing holding brake release switch (2) releases the swing holding brake and allows swing operation. a: Release (Emergency) b: Normal Swing holding brake release switch
Release (when the controller is out of order)
Normal (when the controller is in order)
Swing lock switch
ON
OFF
ON
OFF
Swing brake
Swing lock works.
Swing holding brake is released. (*1)
Swing lock works.
Swing holding brake works.
*1: Hydraulic brake by the safety valve. a
a
a
Even if the swing holding brake release switch is set to “RELEASE“, the swing holding brake is not be released while the swing lock switch is set to “ON“. When the swing holding brake is released, only the hydraulic brake with the safety valve is effective for swing. So, note that, when the swing stops on a slope, a hydraulic drift may occur. Swing holding brake release switch (2) is of the alternator type. When the switch is turned to “RELEASE (a)“ position, the swing lock monitor in the machine monitor will blink.
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Travel control function
1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Fuel supply pump 6. Sensors 7. Pump oil pressure sensor 8. Oil pressure sensor 9. Travel alarm buzzer 10. Hydraulic pump 11. Control valve 11a. Pump merge-divider valve 11b. Self pressure reducing valve 11c. Travel junction valve 12. Travel motor 13. 2nd travel speed select solenoid valve 14. Travel junction solenoid valve 15. Pump merge-divider solenoid valve
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Input and output signals a. Oil pressure sensor signal b. CAN signal c. Pump merge-divider solenoid valve drive signal d. Travel junction solenoid valve drive signal e. 2nd travel speed select solenoid valve drive signal f . Oil pressure sensor signal g. Travel alarm buzzer operation signal h. Throttle signal i . Fuel supply pump control signal j . Sensor signals
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Function Travel speed select function 1.
Travel speed “Manual“ change Turning the travel speed selector switch “Hi“ and “Lo“ changes the motor capacity and allows the machine to select travel speed.
q
Travel speed selector switch
Lo (low speed)
Hi (high speed)
Motor capacity (cc/rev.)
79.1
44.2
Travel speed (km/h)
2.9
5.1
Travel motor swash plate angle
Max.
Min.
2.
Travel speed “Automatic“ change 1) Automatic selection corresponding to engine speed q When the engine speed is lowered to below 1,500 rpm with the fuel control dial, the travel speed changes to “Lo “ automatically. 2)
Automatic selection corresponding to pump discharge pressure q If the travel pressure increases on an uphill with the travel speed selector switch in “Hi“, and the travel hydraulic pressure exceeding 32.4 MPa {330 kg/cm²} continues for 0.02 seconds or more, the travel motor capacity is switched to low speed (corresponds to “Lo“) automatically (the travel speed switch position is remain “Hi“). q If the travel pressure decreases on a flat or downhill with low speed (caused by the automatic gear shifting due to high pressure), and the travel hydraulic pressure below 17.7 MPa {180 kg/cm²} continues for 0.1 seconds or more, the travel motor capacity is switched back to the set speed of “Hi“ automatically.
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A: B: C: D:
17.7 MPa {180 kg/cm²} 32.4 MPa {330 kg/cm²} Min. 0.1 sec. Min. 0.02 sec.
Pump control function during travel a See “Pump and engine mutual control function “ for details. Travel junction function q When the travel lever is operated, detects the pilot pressure and judges whether it is for straight-travel or for steering. q For straight-travel, a signal is sent to the travel junction solenoid valve, controlling the pump flow between the right and left to be equal, to prevent travel deviation and improve straight line stability. q When steering, the signal to the travel junction solenoid valve is cut-off, separating the pump flow between the right and left, to improve steering stability.
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Pump merge-divider function q When the travel lever is operated, detects the pilot pressure and judges if it is for straight-travel. q For straight-travel, a signal is sent to the pump merge-divider solenoid valve, dividing the pump delivery, to improve travel performance. Pattern
Criterion of travel operation
1
Stop or travel at very low speed (All of following conditions are satisfied) • P1 = Min. 1.6 {16} • P2 = Min. 1.6 {16} • P3 = Min. 1.6 {16} • P4 = Min. 1.6 {16}
Mergedivider valve
Criterion of work equipment and blade operation
Merge
(All of following conditions are satisfied) • Work equipment is not operated (Work equipment PPC pressure switch is Straight travel operation "OFF"). (All of following conditions • Blade is not operated (P5 = Max. 0.3 are satisfied) • P1 – P2 absolute value = {3}). Max. 0.3 {3} (One of following conditions is satisfied) • P3 – P4 absolute value = • Work equipment is operated (Work Max. 0.3 {3} equipment PPC pressure switch is "ON"). • Blade is operated (P5 = Min. 0.5 {5}).
2
3
(*1) 4
Criterion of steering operation
Travel at normal speed (One of following conditions is satisfied) • P1 = Min. 1.8 {18} • P2 = Min. 1.8 {18} • P3 = Min. 1.8 {18} • P4 = Min. 1.8 {18} Steering operation (One of following conditions is satisfied) • P1 – P2 = Min. 0.5 {5} • P3 – P4 = Min. 0.5 {5}
5
Divide
Merge
(All of following conditions are satisfied) • Work equipment is not operated (Work equipment PPC pressure switch is "OFF"). • Blade is not operated deeply (P5 = Max. 2.0 {20}). • Pivot turn is not made. Example) Right forward pivot turn (P1 = Max. 2.0 {20} or P2, P4 = Min. 0.5 {5})
Divide
(One of following conditions is satisfied) • Work equipment is operated (Work equipment PPC pressure switch is "ON"). • Blade is operated deeply (P5 = Max. 2.2 {22}) • Pivot turn is made. Example) Right forward pivot turn (P1 = Max. 2.2 {22} and P2, P4 = Max. 0.3 {3})
Merge
*1. If the work equipment etc. is operated in pattern 4, the pump merge-divider valve is set to the merge mode of pattern 5. Even if the work equipment operation is stopped after the pump merge-divider valve is set in pattern 5, the pump merge-divider valve is not returned to pattern 4. P1: Left forward PPC pressure (MPa {kg/cm2}) P2: Right forward PPC pressure (MPa {kg/cm2}) P3: P1: Left reverse PPC pressure (MPa {kg/cm2}) P4: Right reverse PPC pressure (MPa {kg/cm2}) P5: Blade PPC pressure (MPa {kg/cm2})
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PPC lock function
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery Battery relay Fusible link Fuse box Starting switch Lock lever PPC lock switch Hydraulic pump Control valve 9a. Pump merge-divider valve 9b. Self pressure reducing valve 10. PPC lock solenoid valve
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Function q Interlocked with the lock lever, the PPC lock switch is turned “OFF“ when operating the lock lever to “LOCK“ position. q When the PPC lock switch is turned “OFF“, the current to the PPC lock solenoid valve is cut-off, causing neither the work equipment nor machine moves even if levers or pedal is operated.
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Oil flow adjuster function for attachment (Machine ready for attachment)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Pump controller Engine controller Machine monitor Fuel control dial Fuel supply pump Sensors Emergency pump drive switch Oil pressure switch Hydraulic pump 9a. Servo 9b. LS valve 9c. PC valve 10. Control valve 10a. Pump merge-divider valve 10b. Self pressure reducing valve 11. PPC lock solenoid valve 12. Oil flow adjuster EPC valve for attachment 13. PC-EPC valve 14. Attachment circuit selector valve 15. Attachment
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Input and output signals a. Oil flow adjuster EPC valve drive signal for attachment b. Oil pressure switch signal c. CAN signal d. PC-EPC valve drive signal e. Solenoid valve GND f . Throttle signal g. Fuel supply pump control signal h. Sensor signals Function q Setting of the working mode and oil flow rate on the machine monitor controls the oil flow to the attachment when the attachment control pedal is depressed all the way.
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System components Engine controller
Input and output signals q The following is the list of the symbols used for signal classification in the input/output signal chart. A: Power supply B: Input C: Ground/shield/return D: Output E: Communication DTP-4P [CN-CE03] Pin No. 1 2 3 4
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Signal name GND NC Constant power supply (24 V) NC
Signal classification C — A —
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DRC-60P(1) [CN-CE01] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Signal name NC NC NC NC NC NC NC NC NC Fuel supply pump regulator (+) Boost temperature sensor NC NC Fuel supply pump regulator (–) NC NC NC NC Boost pressure sensor Ambient pressure sensor NC NC NC NC NC Crankshaft speed sensor (5 V) NC NC Common rail pressure sensor NC
Signal classification — — — — — — — — — B B — — C — — — — B B — — — — — A — — B —
Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Signal name NC Engine oil pressure switch NC NC NC Sensor power supply (5 V) Camshaft speed sensor NC NC NC NC Crankshaft speed sensor NC Crankshaft speed sensor GND Injector #2 (+) NC Coolant temperature sensor GND Sensor GND Coolant temperature sensor NC Injector #4 (–) NC Injector #1 (–) NC Injector #3 (+) Injector #4 (+) Injector #1 (+) Injector #2 (–) Injector #3 (–) NC
Signal classification — B — — — A B — — — — B — C D — C C D — C — C — D D D C C —
DRC-60P(2) [CN-CE02] Pin No.
Signal name
Signal classification E
Pin No.
Signal name
31
NC Engine controller power cut-off relay GND NC NC Fuel control dial (+) NC NC NC NC NC NC NC NC NC Starting switch ACC signal NC NC NC NC NC NC NC NC NC Engine controller power cut-off relay NC NC NC NC NC
1
CAN(+)
2
NC
—
32
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
NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC NC CAN (–) NC NC NC NC NC Fuel control dial (5 V) Fuel control dial (–) NC NC
— — — — — — — — — — — — — — — — — — E — — — — — A C — —
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
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Signal classification — C — — B — — — — — — — — — B — — — — — — — — — D — — — — —
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Pump controller
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Input and output signals AMP-81P [CN-C01] Pin No.
Signal name
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
Constant power supply (24 V) GND Window washer Constant power supply (24 V) GND NC NC Potentiometer power supply (5 V) Potentiometer power supply (5 V) NC Arm angle sensor NC L.H. travel REVERSE oil pressure sensor Boom LOWER oil pressure switch Arm OUT pressure switch Swing oil pressure switch Arm IN pressure switch GND (analog signal) Swing lock switch NC Model select 2 NC NC Starting switch ACC signal NC NC NC NC Hydraulic oil temperature sensor NC Boom cylinder bottom oil pressure sensor Blade RAISE oil pressure sensor NC Bucket DUMP oil pressure switch NC R.H. travel REVERSE oil pressure sensor GND (digital signal) Swing holding brake cancel switch Model select 5 Model select 1
Input/output signal Input Input Output Input Input — — Output Output — Input — Input Input Input Input Input Input Input — Input — — Input — — — — Input — Input Input — Input — Input Input Input Input Input
Pin No. 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
Input/output signal NC — NC — Starting switch ACC signal Input GND (pulse signal) Input CAN_H Input/output GND (analog signal) Input GND (analog signal) Input NC — Pump oil pressure sensor Input NC — Blade LOWER oil pressure sensor Input Attachment oil pressure switch Input Boom RAISE oil pressure switch Input NC — R.H. travel FORWARD oil pressure sensor Input Wiper motor reverse (W) Input Cab front window open limit switch Input Model select 4 Input NC — Starting switch C signal Input NC — External start signal Input NC — CAN_L Input/output NC — NC — Boom angle sensor Input NC — L.H. travel FORWARD oil pressure sensor Input GND (analog signal) Input NC — NC — Bucket CURL oil pressure switch Input NC — Wiper motor stop (P) Input Blade specification signal Input Model select 3 Input Overload alarm enable signal Input Starting switch ACC signal Input NC — GND (digital signal) Input Signal name
AMP-40P [CN-C02] Pin No. 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101
Input/output signal NC — NC — NC — NC — NC — 2nd travel speed select solenoid Output NC — NC — NC — NC — NC — NC Output Bucket DUMP operation lock solenoid Output NC — PC-EPC Output Oil flow adjuster EPC for attachment Output NC — NC — NC — Swing holding brake solenoid Output
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Signal name
Pin No. 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121
Signal name NC NC NC NC NC Travel and swing alarm buzzer Battery relay drive NC Travel junction solenoid NC Pump merge-divider solenoid NC Wiper motor (–) GND (solenoid) Solenoid power supply GND (solenoid) Solenoid power supply Wiper motor (+) GND (solenoid) Solenoid power supply
Input/output signal — — — — — Output Output — Output — Output — Output Input Input Input Input Output Input Input
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Fuel control dial
1. 2. 3. 4. 5. 6.
Knob Dial Spring Ball Potentiometer Connector
Function q Installed in the right console box. Potentiometer (5) is installed inside knob (1). Turning knob (1) causes potentiometer (5) shaft to rotate. q This rotation changes the resistance of the variable resistor within potentiometer (5), and a throttle signal is sent to the controller. q The hatched areas in the graph are error detection areas. If the throttle voltage is within the area, the engine drops down to low idle.
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Resistor
1. 2.
Resistance Connector
Specifications For PC-EPC valve: 30 z Function q Sends an electric current to each EPC valve that is appropriate for each condition, when the emergency pump drive switch is turned to “ON“. a No electric current flows in the normal condition.
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Engine oil pressure switch
1. 2. 3.
Connector Sensor O-ring
Specifications Contact type: Normal close Function q Installed in the cylinder block. Detects engine oil pressure, and turns the switch “ON“ when the pressure goes below the specified value.
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PPC oil pressure switch
1. 2. 3.
Plug Switch Connector
Specifications Contact type: Normal open Operating pressure to make contact point ON: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2} Operating pressure to break contact point OFF: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2} Function q Installed (8 places) in the connecting valve. Detects the PPC oil pressure when each actuator is operated, and turns the switch “ON“ when the pressure exceeds the specified value.
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10 Structure, function and maintenance standard Electronic control system
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PC128US-8
10 Structure, function and maintenance standard Monitor system
Monitor system
1. 2. 3. 4. 5. 6. 7. 8.
Machine monitor Battery Pump controller Engine controller Air conditioner controller KOMTRAX terminal Sensors, switches Wiper motor, window washer motor
Input and output signals a. Power supply b. CAN signal c. Sensor and switch signals d. Drive signal
PC128US-8
1
Outline q The monitor system keeps the operator informed of all machine functions, by monitoring the machine conditions using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor. The information displayed on the machine monitor falls into the following types: 1. Alarm when an error occurs 2. Machine status display (coolant temperature, hydraulic oil temperature and fuel level) q The switches on the machine monitor controls the machine.
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10 Structure, function and maintenance standard Monitor system
Machine monitor
Outline q The machine monitor provides monitor display function, mode selection function and switch function of the electrical equipment etc. Also it provides an alarm buzzer. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The machine monitor consists of display and switches: the display is of LCD type, and the switches are of flat sheet switch. q If an error occurs in the machine monitor itself, controller or wiring circuit between monitor and controller, the monitor does not display properly.
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Precautions on the machine monitor display q The LCD panel may have black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, it does not indicate a failure or a defect. q When the engine is started, the battery voltage may drop suddenly depending on ambient temperatures and battery conditions. In this case, the machine monitor may go off for a moment. However, this phenomenon is not a failure. q After the machine monitor is used continuously, blue points (points which do not go off) may be seen on the black background. This phenomenon does not indicate a failure or a defect. Blue points can never be a problem as the screen has usually blue or white background. (White in the LCD is made up of red, green and blue.)
PC128US-8
10 Structure, function and maintenance standard Monitor system
Input and output signals 070-18P(1) [CN-CM01] Pin No.
Signal name
1 2 3 4 5
Constant power supply (24 V) Constant power supply (24 V) GND (constant power supply) GND (constant power supply) Wake-up Starting motor cut-out relay (for personal code) GND (machine signal) Hydraulic oil temperature Fuel level
6 7 8 9
Input/output signal Input Input — — Input/output
Pin No.
Signal name
Input/output signal Input Input — Input Input
10 11 12 13 14
Engine coolant temperature Battery level GND (machine analog signal) Lamp switch Starting switch ACC signal
Output
15
Starting switch C signal
Input
— Input Input
16 17 18
Preheat USB power supply (5 V) GND (USB power supply)
Input Output —
070-12P(1) [CN-CM02] Pin No. 1 2 3 4 5 6
Signal name Engine oil pressure sensor Engine oil level sensor Radiator coolant level sensor Air cleaner clogging sensor Swing lock switch Spare
Input/output signal Input Input Input Input Input Input
Pin No. 7 8 9 10 11 12
Signal name GND (machine signal) CAN terminal signal CAN_H CAN_L USB data (–) USB data (+)
Input/output signal — — Input/output Input/output Input/output Input/output
070-18P(2) [CN-CM03] Pin No. 1 2 3 4 5 6 7 8 9
Signal name For communication terminal, RS232C CD For communication terminal, RS232C RXD For communication terminal, RS232C SG GND (communication terminal control signal) Communication terminal selection signal For communication terminal, RS232C RTS For communication terminal, RS232C TXD For communication terminal, RS232C DTR For communication terminal, RS232C DSR
Input/output signal
Pin No.
Input
10
Input
11
—
12
—
13
Input
14
Output
15
Output
16
Output
17
Input
18
Input/output signal
Pin No.
—
7
Reserved
—
Output
8
Reserved
—
—
9
Reserved
—
Output
10
Reserved
—
Input
11
Reserved
—
—
12
Peripheral equipment power supply (12 V)
Pin No.
Signal name
Signal name
Input/output signal
For communication terminal, RS232C CTS For communication terminal, RS232C RI GND (communication terminal power supply) Communication terminal status signal CH1 Communication terminal power supply control signal Communication terminal control signal CH1 Communication terminal control signal CH2 Communication terminal status signal CH2 Communication terminal power supply (12 V)
Output
Signal name
Input/output signal
Input Input — Input
Output Output Input Output
070-12P(2) [CN-CM04] Pin No. 1 2 3 4 5 6
Signal name GND (peripheral equipment power supply) Peripheral equipment control signal GND (for peripheral equipment, RS232C) For peripheral equipment, RS232C TXD For peripheral equipment, RS232C RXD Reserved
Output
B60-8P [CN-CM05] Pin No. 1 2 3 4
Signal name Camera power supply (8 V) Camera NTSC signal 1 Camera NTSC signal 2 Camera NTSC signal 3
PC128US-8
Input/output signal Output Input Input Input
5 6 7 8
GND (Camera power supply) GND (Camera signal 1) GND (Camera signal 2) GND (Camera signal 3)
Input/output signal — — — —
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10 Structure, function and maintenance standard Monitor system
Display
A: B:
C:
Normal operation screen All indicators light-up screen q When monitor items (14) to (16) are faulty after starting the engine, monitor items are displayed on the screen in chronological order from the upper left. q If the hydraulic oil temperature goes High or Low while the hydraulic oil temperature gauge is displayed at the center of the screen, the screen displays only hydraulic oil temperature monitor (2b). Screen with maintenance interval reminder
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10 Structure, function and maintenance standard Monitor system
No. Classification
1a
Gauge
1b
Caution
2a
Gauge
2b
Caution
3a
Gauge
3b
Caution
4
Display item
(*1) Coolant temperature
(*1) Hydraulic oil temperature
(*1) Fuel level
ECO gauge
Description Display Tempera- Background location ture (°C) color • W1 105 Red W2 102 Red • W3 100 Blue W4 85 Blue • W5 60 Blue W6 30 White See the column “Gauge“. Display Tempera- Background location ture (°C) color • H1 105 Red H2 102 Red • H3 100 Blue H4 85 Blue • H5 40 Blue H6 20 White See the column “Gauge“. Display Background Quantity (l) location color F1 139 Blue F2 116 Blue F3 96 Blue • F4 66 Blue F5 52 Blue F6 33 Red See the column “Gauge“. Segment Load level • Light to Green 1–8 medium Orange
Service meter
9,10
Heavy
6
Message
7
Air conditioner
8
Wiper Pilot
9
PC128US-8
Swing lock
Indicates corresponding temperature range. Alarm buzzer sounds when the temperature exceeds 105°C. If the monitor background appears white, warm-up the engine.
Indicates corresponding temperature range. Alarm buzzer sounds when the temperature exceeds 105°C. If the monitor background appears white, warm-up the hydraulic components.
Indicates corresponding fuel level.
Indicates average load per minute on a scale of 1 to 10. (Indicates when “Default (ECO display setting)“ of the service mode is “ON“.)
• Indicates accumulated engine operating hours (the alternator is generating). (F4 switch changes for clock display.)
00000 h – 99999 h
5 Clock
Remarks
• 12-hour display (AM/PM) • Displays time. (F4 switch changes for service meter.) • 24-hour display Background Status (If KOMTRAX is equipped.) color • Displays message status. Green There is unread message. (OFF when no message is available.) Blue There is unsent message. Light ON: ON Light OFF: OFF INT: Intermittent ON: Continuous Light OFF: Stop Swing lock Swing holding brake switch release switch OFF OFF ON OFF OFF ON ON ON
• Indicates air conditioner and air blower operating status. • Indicates front glass wiper operating status. Monitor display OFF ON Blink Blink
• Indicates swing lock operating status.
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10 Structure, function and maintenance standard Monitor system
No. Classification
Display item
Description
Remarks
*1: If the gauge signal is not available due to disconnection of CAN communication line, the gauge pointer goes off.
10
11
Preheat
Pilot
Elapsed time after turning Monitor disthe starting switch to play “HEAT (preheat)“. • Indicates preheat operating status. 0 – 30 sec. ON 30 – 40 sec. Blink 40 sec. or more OFF
Auto-decelera- Light ON: ON tor Light OFF: OFF
• Indicates auto-decelerator operating status.
P: Heavy-duty operation E: Low-fuel consumption operation Working mode L: Fine operation B: Breaker operation ATT: Compound attachment operation Lo: Low speed Travel speed Hi: High speed
12
13
• Displays working mode.
• Displays travel speed setting.
14
(*2) Engine oil level
Light ON: Abnormal range (below the specified value) Light OFF: Normal range
• When an error is detected with the engine running, the monitor lights up on the screen and the alarm buzzer sounds at the same time.
15
(*2) Engine oil pressure
Light ON: Abnormal range (below the specified value) Light OFF: Normal range
• When an error is detected with the engine stopped, the monitor lights up on the screen.
(*2) Battery level
Light ON: Defective battery charge (Charge voltage < Battery voltage) Light OFF: Normal range
• When an error is detected with the engine running, the monitor lights up on the screen.
16
Caution
Background color 17
Maintenance interval
Yellow
Red
Status
• The display changes depending on the time to/after the maintenance. There is a maintenance item which is 30 hours or • After the starting switch is turned “ON less left before next main“, the monitor turns ON if the monitor tenance. light-up conditions are met, and then There is a maintenance turns OFF in 30 seconds. overdue item.
*2: Included in the star-up check. After the staring switch is turned “ON“, the monitor turns ON for 2 seconds, and changes to a normal operation screen if no error is found.
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10 Structure, function and maintenance standard Monitor system
PC128US-8
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10 Structure, function and maintenance standard Monitor system
Switches
No.
Name
1
Auto-decelerator switch [Numeric keypad: 1]
Function Turns the auto-decelerator function ON/ OFF. Light ON: ON Light OFF: OFF
2
(*1) Working mode selector switch [Numeric keypad: 2]
Displays the working mode selector screen.
3
Travel speed selector switch [Numeric keypad: 3]
Changes the travel speed. Lo light ON: Low speed Hi light ON: High speed
4
Stops the alarm buzzer. Buzzer cancel switch (Some alarm buzzer does not stop even if [Numeric keypad: 4] the switch is pressed.)
5
Wiper switch [Numeric keypad: 5]
6
Window washer switch [Numeric keypad: 6]
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Operates the front glass wiper. INT: Intermittent ON: Continuous Light OFF: Stop
Sprays washer fluid onto the front glass.
Operation • When the working mode is in “L“, the auto-decelerator does not work. OFF io ON P: Heavy-duty operation E: Low-fuel consumption operation L: Fine operation B: Breaker operation ATT: Compound attachment operation Lo (low speed) io Hi (high speed) • Stops the alarm buzzer. • The alarm buzzer resumes when another error is detected. o INT o ON o OFF o I (Intermittent) (Continuous) (Stop) O i i i ON: Washer fluid is sprayed and wiper works continuously. [When wiper is not working] OFF: Wiper works twice and stops after the switch is released. [When wiper is working intermittently] OFF: Wiper works twice continuously and returns to intermittent operation after the switch is released.
PC128US-8
10 Structure, function and maintenance standard Monitor system
No.
Name
7
Fan switch (Up) [Numeric keypad: 7]
7a
Fan switch (Down)
8
Temperature control switch (Up) [Numeric keypad: 8]
8a
Temperature control switch (Down) [Numeric keypad: 0]
Function Controls the fan speed of the air conditioner in 6 levels. (Low, Medium 1, Medium 2, Medium 3, Medium 4, High)
Controls the temperature inside the cab. (18.0°C – 32.0°C: Aailable at every 0.5°C)
9
(*2) Auto switch [Numeric keypad: 9]
Auto-runs the air conditioner and air blower. AUTO light ON: Auto run
10
(*3) Air conditioner switch
Turns the air conditioner ON/OFF. A/C ON lights-up: Manual operation Light OFF: Stop
11
FRESH/RECIRC selector switch
Changes the FRESH/RECIRC.
Operation • The air flow increases immediately after the air conditioner adjustment screen appears. • The air flow decreases immediately after the air conditioner adjustment screen appears. • The temperature control increases immediately after the air conditioner adjustment screen appears. • The temperature control decreases immediately after the air conditioner adjustment screen appears. • Automatically controls the fan speed, air outlet port, internal/external air flow according to the temperature setting, immediately after the air conditioner adjustment screen appears. • Switches to the air conditioner adjustment screen, and pressing it again switches ON/ OFF. OFF io ON • Switches to the air conditioner adjustment screen, and pressing it again switches internal/external air flow. RECIRC io FRESH
12
13
Vent selector switch
OFF switch
14a Guidance icon 14b Function switch
Selects the air vent mode from 5 modes. 1. Front and rear 2. Front and rear-foot 3. Foot 4. Foot and defroster 5. Defroster Turns the fan and air conditioner OFF. Light OFF: OFF
• Switches to the air conditioner adjustment screen, and pressing it again switches air outlet mode. • Mode 1, 4 and 5 are not available with auto mode. o 1 o 2 o 3 o 4 o 5o I O i i i i i i • Turns the fan and air conditioner OFF.
a See “Guidance icon and function switch.“
*1: When the working mode is changed, the auto-decelerator function turns “ON“. *2: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at “High“. Even if the set temperature is reached, the fan speed remains the same. *3: When the fan is set at Stop, the air conditioner does not start even if the switch is pressed.
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10 Structure, function and maintenance standard Monitor system
Guidance icon and function switch q Functions available with the function switch depend on the guidance icon displayed above the switch. q No function is available if no guidance icon appears above the function switch. q The following is the list of guidance icons and the functions displayed above the function switches.
Function switch
Guidance icon
Item
1
Clear
Clears selected/displayed item.
2
Move selection
Moves selection down one page. (To the top page from the bottom page.)
3
Set
Sets function.
4
Start
Starts function. (Used for starting measurement of spilt fuel consumption.)
5
Stop
Stops function. (Used for stopping measurement of spilt fuel consumption.)
1
Default
Sets selected item back to default. (Used for screen adjustment.)
2
Move selection
Moves selection up one page. (To the bottom page from the top page.)
3
Clear
Clears selected/displayed item.
1
Camera image
Switches to camera image.
2
Move selection
Moves selection down one item. (To the top item from the bottom item.) Releases holding of the monitor.
3
Move selection
Moves selection to the left. (To the rightmost item from the leftmost item.)
1
Switching clock/service meter
Switches clock/service meter display.
2
Move selection
Moves selection up one item. (To the bottom item from the top item.) Holds the monitor.
3
Move selection
Moves selection to the right. (To the leftmost item from the rightmost item.)
F1
F2
F3
F4
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Function
PC128US-8
10 Structure, function and maintenance standard Monitor system
Function switch F5
F6
PC128US-8
Guidance icon
Item
1
Selecting maintenance screen
Selects maintenance screen.
2
Return
Returns to the previous screen or condition.
1
Selecting user mode screen
Selects user mode screen.
2
Fix
Fixes selected/displayed item.
Function
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10 Structure, function and maintenance standard Monitor system
Operator mode function q
q
The functions in this mode are displayed in normal operation. Display and setting of these functions are available from the operator's switch operations. Display and setting of some functions require special operation of the switch. Items available in the operator mode are as follows:
Category (*1)
A
B
C
D
Item Display of KOMATSU logo Display of inputting password Display of start-up check Display of warning after start-up check Display of overdue maintenance Display of check of working mode and travel speed Display of normal operation screen Display of end screen Selection of auto-decelerator Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Operation to display clock/service meter Check of maintenance information Setting and display of user mode • Breaker/attachment setting • Display of message (including KOMTRAX messages for user) • Screen adjustment • Clock adjustment • Language setting • Economy mode adjustment Display of energy-saving guidance Display of caution monitor Display of user code and failure code Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing attachment/maintenance password
Display order (*2) W X Y Z 1 1 1 1 2 — — — 3 2 2 2 — — 3 — — — — 3 4 3 4 4 5 4 5 5
*1: The items available in the operator mode fall into the following categories. A: Display from the time starting switch is turned “ON“ until the ordinary screen appears. Display after the starting switch is turned “OFF“. B: Display when the switch of machine monitor is operated. C: Display when a certain condition is satisfied D: Display when special switch operation is necessary. *2: For the category A, the order in which items are displayed varies depending on the setting and conditions of the machine as follows: W: When the engine start lock is set on X: When the engine start lock is set off Y: When an error is detected during start-up check. Z: When a maintenance overdue is detected. a a
For how to operate the operator mode functions, see the Operation and Maintenance Manual or “Special functions of machine monitor“ in Testing and adjusting. For how to set the engine start lock on/off, see “Password setting/cancel manual“.
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10 Structure, function and maintenance standard Monitor system
Oil flow setting for breaker
q
q
Oil flow setting for attachment
Oil flow for the breaker can be changed in the “Breaker/attachment setting“ of the user mode. Oil flow level can be set as follows: Oil flow level
Quantity (l/min)
1
q
q
Remarks
Oil flow for the compound attachment can be changed in the “Breaker/attachment setting“ of the user mode. Oil flow level can be set as follows: Oil flow level
Quantity (l/min)
60
1
30
2
70
2
85
3
80
3
105
4
90
4
130
5
100
5
155
6
110
6
175
7
120
7
200
8
130
8
225
9
140
10
150
11
160
12
170
13
180
14
190
15
200
Default
Default
Language setting
q
q
PC128US-8
Remarks
The language used in the machine monitor can be changed in the “Language setting“ of the user mode. The available languages are as follows: English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian and Thai
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10 Structure, function and maintenance standard Monitor system
Service mode function q
q
The functions in this mode are not accessible from the normal operation screen. Display and setting of these functions are available by the serviceman's special operations of the switch. This mode is used for special setting, testing, adjusting or troubleshooting. Items available in the service mode are as follows:
Monitoring Mechanical systems Abnormality record
Electrical systems Air conditioner system
Maintenance record Change of maintenance mode Setting of telephone No. Working mode with key ON Selection of units of measure Default
With/Without attachment Setting of attachment/maintenance password Setting of camera Setting of ECO display
Adjustment
Pump absorption torque Compound attachment flow adjustment
Cylinder cut-out operation No injection cranking Display of fuel consumption Setting condition of KOMTRAX terminal Display of KOMTRAX setting
Condition of positioning and communication Modem IP address (Model TH201) Modem S/N (Model TH300)
Display of KOMTRAX message
a
For how to operate the service mode functions, see “Special functions of machine monitor“ in Testing and adjusting.
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PC128US-8
10 Structure, function and maintenance standard KOMTRAX system
KOMTRAX system
q
q
q
a
1
The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, machine monitor and GPS antenna. This system sends various information of the machine via wireless communication. It allows operators of the KOMTRAX to obtain the machine information from the office and to provide various services with the customers. The information available from the KOMTRAX system are as follows: 1. Operation map 2. Service meter 3. Machine location 4. Error record To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
PC128US-8
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10 Structure, function and maintenance standard KOMTRAX system
KOMTRAX terminal Model: TH300 q Satellite wave is used.
1. 2. 3.
Communication antenna connection Machine harness connection (AMP-14P) Machine harness connection (AMP-10P)
Input and output signals AMP-14P [CN-CK01] Pin Signal name No. A1 Power supply (12 V) A2 NC (*) A3 NC (*) A4 Selection of power supply voltage A5 NC (*) A6 NC (*) A7 GND A8 GND A9 NC (*) A10 NC (*) A11 NC (*) A12 NC (*) A13 NC (*) A14 NC (*)
Input/output signal Input — — Output — — — — — — — — — —
AMP-10P [CN-CK02] Pin Signal name No. B1 RS232C DCD B2 RS232C RXD B3 RS232C TXD B4 RS232C DTR B5 RS232C SGND B6 RS232C DSR B7 NC (*) B8 NC (*) B9 NC (*) B10 NC (*)
Input/output signal Output Output Input Input Input Output — — — —
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Outline q This terminal sends various machine information based on the network signals and input signals obtained through the machine monitor, as well as GPS position data, via wireless communication. This terminal can send information via communication antenna. q Conditions of this terminal can be checked with the "KOMTRAX Settings" in the service mode of the machine monitor. q This terminal cannot be used in the countries or territories where it is not authorized by the law. a
a
When starting to use the KOMTRAX system or changing the country where it is used, you are required to notify the country where it will be used in advance. When using the KOMTRAX system in Japan, the terminal special to Japan must be mounted.
PC128US-8
10 Structure, function and maintenance standard Sensor
Sensor
1
Atmospheric pressure sensor
1. 2.
Connector Pressure inlet port
Function q Installed in the bracket on the side face of the cylinder block. Detects the ambient pressure and outputs variable voltage. Boost pressure, temperature sensor
1. 2. 3.
Connector Sensor O-ring
Function Installed in the intake manifold. Detects the boost pressure and boost temperature, and outputs signal as a variable voltage for pressure, and a resistance change for temperature.
q
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10 Structure, function and maintenance standard Sensor
Coolant temperature sensor
1. 2. 3.
Connector Sensor O-ring
Function q Installed in the water pump. Detects the temperature change and outputs signal as a resistance change. Crankshaft speed sensor Camshaft speed sensor
1. 2. 3.
Connector Sensor O-ring
Function The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is installed in the gear of the camshaft. Each of the sensors outputs a pulse voltage according to the gear rotation.
q
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10 Structure, function and maintenance standard Sensor
Common rail pressure sensor
1. 2. 3.
Common rail Sensor Connector
Function q Installed in the common rail. Detects the fuel pressure and outputs variable voltage.
Engine oil level sensor
1. 2.
Connector Bracket
3. 4.
Float Switch
Function The engine oil level sensor is installed to the side of the oil pan. If the oil level lowers below the specified level, the float lowers and the switch is turned “OFF“.
q
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10 Structure, function and maintenance standard Sensor
Fuel level sensor
1. 2. 3. 4.
Connector Float Arm Body
5. 6. 7.
Spring Contact Spacer
Function q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the fuel level. The float moves the variable resistor through the arm. The resistance changes according to the operating angle and signal voltage is generated from the source voltage according to the change of the resistance.
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10 Structure, function and maintenance standard Sensor
Hydraulic oil temperature sensor
1. 2. 3.
Connector Plug Thermistor
Function q Installed in the suction pipe of the hydraulic pump. Detects the temperature change and outputs signal as a resistance change of the thermistor.
Pump oil pressure sensor
1. 2. 3.
O-ring Sensor Connector
Output characteristics
Function The pump oil pressure sensor is installed in the control valve. Detects the pump discharge pressure and outputs variable voltage.
q
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10 Structure, function and maintenance standard Sensor
PPC oil pressure sensor (For travel and blade operation)
1. 2. 3.
O-ring Sensor Connector
Output characteristics
Function q The PPC oil pressure sensor is installed in the control valve connecting part of the pilot circuit for travel and blade operation. Detects the pilot pressure and outputs variable voltage.
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PC128US-8
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
20 Standard value table
1
PC128US-8
20-1
20 Standard value table
Contents Standard service value table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
20-3
Standard value table for engine related parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
20-3
Standard value table for chassis related parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
20-4
20-2
PC128US-8
20 Standard value table Standard value table for engine related parts
Standard service value table 1 Standard value table for engine related parts
Category
Item
Engine speed (*)
Exhaust gas color
Engine
Valve clearance
1
Applicable model
PC128US-8
Engine
SAA4D95LE-5 Unit
Standard value for new machine
Service limit value
Max. speed
rpm
2,150 ± 60
—
Min. speed
rpm
1,100 ± 50
—
Rated speed
rpm
2,050
—
At sudden acceleration
%
Max. 30
30
At max. speed
%
Max. 10
20
Intake valve
mm
0.35
—
Exhaust valve
mm
0.50
—
Test conditions
• Coolant temperature: operating range
• Coolant temperature: operating range
• Normal temperature
Compression pressure
• Oil temperature: 40 – 60°C • Engine speed: 320 – 360 rpm • SAE0W30E0S
MPa {kg/cm2}
Min. 2.9 {Min. 30}
2.0 {20}
Blow-by pressure
• Coolant temperature: operating range • Arm IN relief
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.47 {150}
0.34 – 0.59 {3.5 – 6.0}
0.25 {2.5}
0.29 – 0.49 {3.0 – 5.0}
0.2 {2.1}
Min. 0.18 {Min. 1.8}
0.15 {1.5}
Min. 0.15 {Min. 1.5}
0.13 {1.3}
Oil pressure (Hydraulic oil temperature: Min. 80°C)
• At sudden acceleration
SAE30 Oil SAE10W Oil SAE30 Oil
MPa {kg/cm2}
• At min. speed SAE10W Oil Oil temperature
• Whole speed range (inside oil pan)
°C
80 – 115
120
Fan belt tension
• Between fan pulley and alternator pulley • Deflection when pressed with finger force of approx. 60 N {6.1 kg}
mm
6 – 10
—
Air conditioner compressor belt tension
• Between fan pulley and compressor pulley • Deflection when pressed with finger force of approx. 60 N {6.1 kg}
mm
12 – 15
12 – 15
(*): The value of maximum speed and rated speed are the engine speed when operating digging work. Reference: when traveling Max. speed: 2,300 rpm Rated speed: 2,200 rpm
PC128US-8
20-3
20 Standard value table Standard value table for chassis related parts
Standard value table for chassis related parts
1
Applicable model
Engine speed
Category
Item
At 1-pump relief
Boom control lever
Travel of control levers
Arm control lever Bucket control lever Swing control lever
Operating effort of control lever
Unit
Standard value for new machine
Service limit value
• Hydraulic oil temperature: 45 – 55°C • Engine oil pressure: Within operating range • Engine water temperature: Within operating range
rpm
2,050 ± 100
2,050 ± 100
No RAISE, LOWER
100 ± 11
100 ± 21
N o IN, OUT
100 ± 11
100 ± 21
No CURL, DUMP
100 ± 11
100 ± 21
No LEFT, RIGHT
100 ± 11
100 ± 21
53 ± 6
Min. 47, Max. 59
• Center of lever knob • Tip of pedal • Read max. value to end of travel • Engine stopped
No RAISE, LOWER
Travel control lever
N o FORWARD, REVERSE (LEFT, RIGHT)
115 ± 12
Min. 103, Max. 127
Work equipment, swing
3–5
5–8
Travel
10 ± 3
10 ± 5
16.7 ± 3.3 {1.7 ± 0.3}
Max. 25.5 {Max. 2.6}
16.7 ± 3.3 {1.7 ± 0.3}
Max. 25.5 {Max. 2.6}
13.7 ± 2.7 {1.4 ± 0.3}
Max. 22.6 {Max. 2.3}
13.7 ± 2.7 {1.4 ± 0.3}
Max. 22.6 {Max. 2.3}
Blade control lever
25.5 ± 6.9 {2.6 ± 0.7}
Max. 32.4 {Max. 3.3}
Travel control lever
24.5 ± 5.9 {2.5 ± 0.6}
Max. 39.2 {Max. 4.0}
Travel pedal
74.5 ± 18.6 {7.6 ± 1.9}
Max. 107.6 {Max. 11}
1.8 – 3.8 {18 – 38}
1.8 – 3.8 {18 – 38}
34.8 ± 1.0 {355 ± 10}
34.8 –1.0 {355 +20 –10 }
34.8 ± 1.0 {355 ± 10}
34.8 –1.0 {355 +20 –10 }
34.8 ± 1.0 {355 ± 10}
34.8 –1.0 {355 +20 –10 }
Boom control lever
Hydraulic pressure
Test conditions
Blade control lever
Play of control lever
Arm control lever Bucket control lever Swing control lever
Unload pressure
Boom relief Arm relief Bucket relief
20-4
PC128US-8
mm
• Engine at high idle • Oil temperature: 45 – 55°C • Fit push-pull scale to center of control lever knob to test • Fit push-pull scale to tip of control pedal to test • Test max. value to end of travel N {kg}
• Hydraulic oil temperature: 45 – 55°C • Engine at high idle MPa • Working mode: P mode {kg/cm2} • Hydraulic pump output pressure with all control levers in NEUTRAL position • Hydraulic oil temperature: MPa 45 – 55°C {kg/cm2} • Engine at high idle • Pump discharge pressure Target • Relieve only circuit to be tested value (Range)
+2.0
+2.0
+2.0
PC128US-8
20 Standard value table Standard value table for chassis related parts
Applicable model Category
Item Swing relief
Hydraulic pressure
Unit
• Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Pump discharge pressure • Relieve only circuit to be tested
Standard value for new machine
Service limit value
27.1 ± 1.0 {276 ± 10}
27.1 –2.5 {276 +15 –25 }
+2.0
+1.5
+2.0
34.8 +0 {355 +20 +0 }
34.8 –1.0 {355 +20 –10 }
Blade LOWER
34.8 ± 1.5 {355 ± 15}
34.8 ± 2.5 {355 ± 25}
Travel relief
34.8 ± 1.0 {355 ± 10}
34.8 ± 2.0 {355 ± 20}
3.2 ± 0.2 {33 ± 2}
3.2 ± 0.5 {33 ± 5}
3.4 ± 1.0 {35 ± 10}
3.4 ± 1.0 {35 ± 10}
16.0 ± 1.5 {163 ± 15}
16.0 ± 2.5 {163 ± 25}
2.8 ± 1.0 {28 ± 10}
— {—}
2.2 ± 0.1 {22.5 ± 1}
— {—}
Max. 60 (Max. 580)
Max. 70 (Max. 676)
2.8 ± 0.3 {3.4 ± 0.3}
Max. 3.5 (Max. 4.0)
4.0 ± 0.4 {4.9 ± 0.5}
Max. 6.2 (Max. 6.4)
27.3 ± 2
27.3 ± 4
Blade RAISE
Control circuit source pressure
Servo piston input pressure
LS differential pressure
Swing
Test conditions
PC128US-8
MPa 2 • Hydraulic oil Control levers at {kg/cm } temperature: HOLD Target 45 – 55°C At pump relief value • Engine at (normal actuation) (Range) high idle • Hydraulic oil temperature: All levers at 45 – 55°C HOLD • Engine at high idle a LS differential Travel rotating pressure = under no load pump outlet port pressure Travel lever at – LS pressure half-way position
Overrun when stopping swing
• For testing posture, see Swing 1 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Stop after swinging one turn and test distance that swing circle moves • Figure in ( ) shows movement at outside of swing circle
Time taken to start swing
• For testing posture, see Swing 1 • Engine at high idle 90° • Hydraulic oil temperature: 45 – 55°C • Time taken to swing 90° and 180° from starting position 180° • Figure in ( ) shows time when bucket is at rated load
sec.
• For testing posture, see Swing 1 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Swing one turn, and test time taken to swing next 5 turns
sec.
Time taken to swing
PC128US-8
Deg. (mm)
20-5
20 Standard value table Standard value table for chassis related parts
Applicable model Test conditions
Unit
Standard value for new machine
Service limit value
Hydraulic drift of swing
• For testing posture, see Swing 2 • Engine stopped • Hydraulic oil temperature: 45 – 55°C • Bucket at rated load (450 kg) • Set machine on 15° slope, and set upper structure at an uphill angle of 45°. • Make match marks on swing circle outer race and track frame. • Test distance that match marks move apart after 15 minutes.
Deg. (mm)
0 (0)
0 (0)
Leakage from travel motor
• Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Relieve swing circuit.
l/min
Max. 3
Max. 6
Max. 39.6
Max. 45
Travel speed (without load)
• For testing posture, see Travel 1 Lo • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Raise track on one side at a time, rotate one turn, then Hi test time taken for next 5 turns with no load.
Max. 22.0
Max. 25
Max. 31.0
Max. 35
Max. 14.5
Max. 17
Item
Swing
Category
Travel
Travel speed (actual run)
20-6
PC128US-8
• For testing posture, see Travel 2 Lo • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Run up for at least 10 m, and test time taken to travel Hi next 20 m on flat ground.
sec.
sec.
Travel deviation
• For testing posture, see Travel 2 and 3 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Run up for at least 10 m, and test deviation when traveling next 20 m on flat ground. a Use a hard horizontal surface.
mm
Max. 200
220
Hydraulic drift of travel
• For testing posture, see Travel 4 • Engine stopped • Hydraulic oil temperature: 45 – 55°C • Stop machine on 12° slope with sprocket facing straight up the slope. • Test the distance the machine moves in 5 minutes.
mm
0
0
PC128US-8
20 Standard value table Standard value table for chassis related parts
Item
Test conditions
Unit
Standard value for new machine
Service limit value
Leakage from travel motor
• Engine at high idle • Hydraulic oil temperature: 45 – 55°C • Lock shoes and relieve travel circuit.
l/min
Max. 1.1
Max. 1.7
Max. 460
Max. 700
Max. 10
Max. 12
Max. 80
Max. 90
Max. 22
Max. 40
Max. 31
Max. 47
RAISE
3.8 ± 0.3 (Until touching cushion)
Max. 4.4 (Until touching cushion)
LOWER
3.1 ± 0.3
Max. 4.2
IN
3.2 ± 0.3 (Until touching cushion)
Max. 4.0 (Until touching cushion)
OUT
2.7 ± 0.3 (Until touching cushion)
Max. 3.7 (Until touching cushion)
CURL
2.9 ± 0.3
Max. 3.7
2.3 ± 0.2
Max. 2.9
1.2 ± 0.3
Max. 2.5
1.3 ± 0.3
Max. 2.5
Category
Work equipment
Hydraulic drift of 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) Bucket cylinder (amount of retraction of cylinder)
• •
mm
• Engine stopped • Hydraulic oil temperature: Blade (hydraulic 45 – 55°C drift at tip of • Set blade at maximum lifting blade) height and test downward movement at edge of blade for 15 minutes. Boom Bucket teeth in contact with ground I O Cylinder fully extended
Work equipment speed
• • • • •
For testing posture, see Work equipment 1 Place in above posture and test extension or retraction of each cylinder and downward movement at tip of bucket teeth. Horizontal, flat ground Bucket: Rated load (450 kg) Levers at HOLD Engine stopped Hydraulic oil temperature: 45 – 55°C Start testing immediately after setting. Test hydraulic drift every 5 minutes, and judge from results for 15 minutes.
Arm Cylinder fully retracted I O Fully extended Bucket Cylinder fully retracted I O Fully extended
• For testing posture, see Work equipment 2 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C
• For testing posture, see Work equipment 3 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C • For testing posture, see Work equipment 4 • Engine at high idle • Hydraulic oil temperature: 45 – 55°C
Blade • For testing posture, see Blade in contact Work equipment 5 with ground • Engine at high idle I • Hydraulic oil temperature: O 45 – 55°C Blade fully raised
PC128US-8
LOWER RAISE
Travel
PC128US-8
DUMP
Applicable model
sec.
20-7
20 Standard value table Standard value table for chassis related parts
Applicable model
20-8
Standard value for new machine
Service limit value
Boom
• For testing posture, see Work equipment 6 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Fully retract arm and bucket cylinders, then lower boom from maximum height and test time taken from point where bucket contacts ground to point where chassis rises from ground.
Max. 3
Max. 3
Arm
• For testing posture, see Work equipment 7 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Set top surface of boom horizontal, retract bucket cylinder fully, then extend arm cylinder and test time taken for arm to start moving again after stopping at bottom.
Max. 2
Max. 2
Bucket
• For testing posture, see Work equipment 8 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Set top surface of boom horizontal, retract arm cylinder fully, then extend bucket cylinder and test time taken for bucket to start moving again after stopping at bottom.
Max. 2
Max. 2
Blade
• For testing posture, see Work equipment 9 • Engine at low idle • Hydraulic oil temperature: 45 – 55°C • Lower blade from maximum height and test time taken from point where blade contacts ground to point where chassis rises from ground.
Max. 2
Max. 2
Each cylinder
• Hydraulic oil temperature: 45 – 55°C • Engine at high idle • Circuit to be tested is relieved.
Max. 3.5
Max. 15
Max. 10
Max. 50
Time lag
Item
Internal leakage level
Work equipment
Category
PC128US-8
Center swivel joint
Test conditions
Unit
sec.
cc/min
PC128US-8
20 Standard value table Standard value table for chassis related parts
Pump performance curve
q q
a a a
TVC current: 0.4 A Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm) Check point
Test pump discharge pressure (MPa {kg/cm2})
Discharge pressure of other pump (MPa {kg/cm2})
Average pressure (MPa {kg/cm2})
Standard value for discharge amount Q (l/min)
Judgement standard lower limit Q (l/min)
As desired
P1
P2
P1 + P2 2
See graph
See graph
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when testing. The error is large near the point where the graph curves, so avoid testing at this point. When testing with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of test, and use them as a base for calculating the pump discharge amount at the specified speed. Pump delivery Q in the graph is the delivery from 1 side of the pump.
PC128US-8
20-9
20 Standard value table Standard value table for chassis related parts
Posture of machine for testing performance and test procedure Swing 1: Swing brake angle, time taken to start swing, time taken to swing
Travel 2: Travel speed (actual run), travel deviation
Travel 3: Travel deviation
Swing 2: Hydraulic drift of swing
Travel 4: Hydraulic drift of travel
Travel 1: Travel speed (without load)
20-10
PC128US-8
20 Standard value table Standard value table for chassis related parts
Work equipment 1: Hydraulic drift of work equipment
Work equipment 4: Bucket speed
Work equipment 5: Blade speed Work equipment 2: Boom speed
Work equipment 6: Boom time lag Work equipment 3: Arm speed
PC128US-8
20-11
20 Standard value table Standard value table for chassis related parts
Work equipment 7: Arm time lag
Work equipment 8: Bucket time lag
Work equipment 9: Blade time lag
20-12
PC128US-8
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
30 Testing and adjusting
1
PC128US-8
30-1
30 Testing and adjusting
Contents Related information on testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-3
Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-3
Sketches of special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-7
Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-8
Testing engine speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-8
Testing exhaust temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-9
Checking exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-10
Adjusting valve clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-11
Testing compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-13
Testing blow-by pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-15
Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-16
Handling fuel system parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-17
Releasing residual pressure from fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-17
Testing fuel pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-18
Testing fuel return rate and fuel leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-19
Bleeding air from fuel circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-21
Checking fuel circuit for leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-23
Testing and adjusting alternator belt tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-24
Checking and adjusting air conditioner compressor belt tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-25
Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-26
Testing swing circle bearing clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-26
Undercarriage and frame- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-27
Checking and adjusting track shoe tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-27
Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-29
Testing and adjusting oil pressure in work equipment, swing, and travel circuits - - - - - - - - - - - - - - - - - - - - - -
30-29
Testing control circuit basic pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-32
Testing and adjusting oil pressure in pump PC control circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-33
Testing and adjusting oil pressure in pump LS control circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-36
Testing solenoid valve output pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-40
Testing PPC valve output pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-41
Adjusting play of work equipment and swing PPC valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-43
Checking parts which cause hydraulic drift of work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-44
Testing and adjusting travel deviation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-46
Releasing residual pressure from hydraulic circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-48
Testing oil leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-49
Bleeding air from each part - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-52
Cab and its attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-54
Checking cab tipping stopper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-54
Adjusting mirrors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-54
Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-56
Special functions of machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30-56
Handling voltage circuit of engine controller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-108 Preparation work for troubleshooting of electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-109 Procedure for testing diodes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-114 Pm-Clinic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-115 Pm Clinic service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-115
30-2
PC128US-8
30 Testing and adjusting Tools for testing, adjusting, and troubleshooting
1
Tools for testing, adjusting, and troubleshooting
1
Testing/Adjusting item
Symbol
Exhaust temperatures
R
Checking exhaust gas color
A
Adjusting valve clearance
B
Part No.
Part name
Q'ty
Related information on testing and adjusting
Remarks
799-101-1502 Digital thermometer
1 -99.9 – 1,299°C
1 799-201-9001 Handy smoke checker
1 Bosch index: 0 – 9
2
Commercially Smoke meter available
1
1
795-799-1131 Gear
1
2
Commercially Thickness gauge available
1
Intake: 0.35 mm Exhaust: 0.57 mm
1 795-502-1590 Compression gauge Testing compression presC 795-502-1370 Adapter sure 2 6271-11-3880 Gasket
1 0 – 7 MPa {0 – 70 kg/cm2}
Testing blow-by pressure
1 0 – 5 kPa {0 – 500 mmH2O}
D 1 799-201-1504 Blow-by checker
1 1
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
799-261-1204 Digital hydraulic tester
1
Pressure gauge:60 MPa {600 kg/cm2}
799-401-2320 Gauge
1
Pressure gauge:1 MPa {10 kg/cm2}
6732-81-3170 Adapter
1
07002-11023 O-ring
2
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge:60 MPa {600 kg/cm2}
1 Testing engine oil pressure
E
2
1 Testing fuel pressure
F 795-471-1450 Adapter
1 Size: 8 x 1.25 mm
07005-00812 Washer
1
3 799-401-2320 Gauge
1
1 6151-51-8490 Spacer
1 ø14
2
Testing fuel return rate and leakage
Testing swing circle bearing clearance
PC128US-8
Pressure gauge:1 MPa {10 kg/cm2}
2 6164-81-5750 Joint
1 ø14
3
07042-20108 Plug
1
4
Commercially Hose available
1 Internal dimensions: Approx. 6 mm
5
Commercially Hose available
1 Internal dimensions: Approx. 12 mm
6
Commercially Measuring cylinder available
1
7
Commercially Stopwatch available
1
Commercially Dial gauge available
1
G
H
For 95E-5 engine
30-3
Testing/Adjusting item
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Symbol
Q'ty
30 Testing and adjusting Tools for testing, adjusting, and troubleshooting
Remarks
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
Part No.
Part name
1 J
2
799-101-5220 Nipple
2 Size: 10 x 1.25 mm
07002-11023 O-ring
2
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
1 Testing basic pressure of control circuit
K
2
799-101-5220 Nipple
2 Size: 10 x 1.25 mm
07002-11023 O-ring
2
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600 kg/cm2}
1 Testing and adjusting oil pressure in pump PC con- L 790-261-1204 Digital hydraulic tester trol circuit 2
799-101-5220 Nipple
2 Size: 10 x 1.25 mm
07002-11023 O-ring
2
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
1 Testing and adjusting oil pressure in pump LS con- M trol circuit
2 799-401-2701 3
1 Testing solenoid valve outN put pressure
Differential pressure gauge
799-101-5220 Nipple
2 Size: 10 x 1.25 mm
07002-11023 O-ring
2
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-3100 Adapter
Testing PPC valve output pressure
P
30-4
Q
1 Size: 02
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
1
Pressure gauge: 60 MPa {600 kg/cm2}
1
2 799-401-3100 Adapter Testing oil leakage
1 49 MPa {500 kg/cm2}
Commercially Measuring cylinder available
1 Size: 02 1
PC128US-8
Testing/Adjusting item
Troubleshooting for engine controller/sensors/ actuators
Troubleshooting for chassis sensors/wiring harnesses
Symbol
S
T
Testing coolant temperature and oil temperature Testing operating effort and depressing force
—
Part name
Q'ty
30 Testing and adjusting Tools for testing, adjusting, and troubleshooting
799-601-4100 or T-adapter assembly 799-601-4200
1
799-601-4130 • T-adapter
1 CAM
799-601-4160 • T-adapter
1 Ne sensor
799-601-4220 • T-adapter
1 Engine controller
799-601-4240 • Socket
1 For ambient pressure sensor
Part No.
799-601-4190 • Socket
1 Common rall pressure sensor
799-601-4340 • Socket
1 Injector
795-799-5530 • Socket
1 Engine water temprature sensor
799-601-4380 Socket
1 Boost pressure sensor
799-601-4390 Socket
1 Engine controller
799-601-4100 or 799-601-4200 or T-adapter assembly 799-601-9000 or 799-601-9200
1
799-601-9020 • Adapter for DT
1 For DT2P
799-601-9030 • Adapter for DT
1
For DT3P (Does not include 799-6014100 and 799-601-4200)
799-601-9050 • Adapter for DT
1
For DT6P (Does not include 799-6014100 and 799-601-4200)
799-601-9110 • Adapter for DT
1
For DT12P (Does not include 799601-4100 and 799-601-4200)
799-601-9220 • Adapter for HD30
1
For HD30P (Does not include 799601-4100 and 799-601-4200)
799-601-7000 or 799-601-7100 T-adapter kit or 799-601-7400 or 799-601-8000
1
799-601-7050 • Adapter for SWP
1
799-601-7090 • Adapter for M
1 For M2P
799-601-7110 • Adapter for M
1 For M3P
799-101-1502 Digital thermometer
1 -99.9 – 1,299°C
79A-264-0021 Push-pull scale
1
79A-264-0091 Push-pull scale
1
Testing stroke and hydraulic drift
—
Commercially Ruler available
1
Testing work equipment speed
—
Commercially Stopwatch available
1
Testing voltage and resistance
—
Commercially Circuit tester available
1
PC128US-8
Remarks
For SW6P (Does not include 799601-8000)
30-5
Testing/Adjusting item
Removal and installation of engine coolant temperature sensor
a
Symbol
Part No.
Part name
Q'ty
30 Testing and adjusting Tools for testing, adjusting, and troubleshooting
Remarks
Commercially Socket available
21 mm deep socket (MITOLOY 4ML-21 or equivalent) 1 Applicable engine serial No.: 500001-502653
795T-981-1010 Socket
19 mm deep socket (MITOLOY 4ML-19 or equivalent) 1 Applicable engine serial No.: 502654 and up
—
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Troubleshooting (General information on troubleshooting), List of T-boxes and T-adapters".
30-6
PC128US-8
30 Testing and adjusting Sketches of special tools
Sketches of special tools
1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Socket
PC128US-8
30-7
30 Testing and adjusting Testing engine speed
Engine and cooling system Testing engine speed a a
1 1
4.
Testing pump relief speed 1) Start the engine and operate the arm cylinder to the IN stroke end. 2) Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P). 3) Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and test the engine speed.
5.
Testing auto-deceleration speed 1) Start the engine, set the fuel control dial in the high idle position (MAX), and turn the auto-decelerator ON. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed when the auto-decelerator operates. a The engine speed lowers to a certain level about 5 seconds after all the levers and pedals are set in neutral. This level is the auto-deceleration speed.
Test the engine speed with the monitoring function of the machine monitor. Test the engine speed under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range
1.
Preparation work Operate the machine monitor so that the engine speed can be monitored. a For the operating method of the machine monitor, see Special functions of machine monitor. a Monitoring code: 01002 Engine speed
2.
Testing low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed.
3.
Testing high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the working mode in the power mode (P) and turn the auto-decelerator OFF. 3) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and test the engine speed.
30-8
PC128US-8
30 Testing and adjusting Testing exhaust temperature
Testing exhaust temperature a
1
4.
Run the engine and test the exhaust temperature over the speed range.
5.
After finishing test, remove the testing instrument and return the removed parts.
Testing tools for exhaust temperature
Symbol
Part No.
R
799-101-1502
Part name Digital thermometer
k Install
or remove the testing instrument after the exhaust manifold temperature has lowered.
1.
Remove the engine compartment side cover and exhaust manifold cover.
2.
Remove exhaust temperature pickup plug (1) from the side of the center of the exhaust manifold.
3.
Install sensor [1] of digital thermometer R and connect it to thermometer [2].
PC128US-8
30-9
30 Testing and adjusting Checking exhaust gas color
Checking exhaust gas color a
Checking tools for exhaust gas color
Symbol A
1
Part No.
Part name
1
799-210-9001
Handy smoke checker
2
Commercially available
Smoke meter
k Stop
the machine on a level ground and lower the work equipment to the ground. k Be careful not to touch any hot part when removing or installing the checking tools. a Check the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range a If an air source and an electric power source are not available in the field, use handy smoke checker A1. When recording official data, use smoke meter A2. 1.
Testing with handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Start the engine and accelerate it suddenly or run it at high idle and operate the handle of smoke checker A1 so that the filter paper will absorb the exhaust gas. a Absorbing time: 1.4 ± 0.2 sec
2)
3)
4)
5)
6) 4) 5)
2.
Remove the filter paper and compare it with the attached scale. After finishing checking, remove the testing tools and return the removed parts.
Checking with smoke meter A2 1) Insert probe [1] of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip.
30-10
7)
8)
Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter A2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. Connect the power cable to an AC receptacle. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of smoke meter A2.
Start the engine and accelerate it suddenly or run it at high idle and depress the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing checking, remove the checking tools and return the removed parts.
PC128US-8
30 Testing and adjusting Adjusting valve clearance
Adjusting valve clearance a
3.
Remove plate (5) on the starting motor and insert gear B1.
4.
Remove compression top dead center TDC check plug (6) from the flywheel housing. Rotate the crankshaft forward with gear B1 and set it so that you can see the white mark of the flywheel.
Adjusting tools for valve clearance
Symbol B
1
Part No.
Part name
1
795-799-1131
Gear
2
Commercially available
Thickness gauge
k Stop
a
the machine on a level ground and lower the work equipment to the ground. Adjust the valve clearance under the following condition. q Engine coolant temperature: Normal temperature
1.
Open the engine hood and remove air intake hose (1), air conditioner compressor hose clamp (2) and heater hose clamp (3).
2.
Remove cylinder head cover (4). a
PC128US-8
When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn.
30-11
30 Testing and adjusting Adjusting valve clearance
5.
Adjust the valve clearances marked with q in the valve arrangement drawing according to the following procedure.
1) 2)
3)
6.
7.
After finishing adjustment, remove the adjusting tools and return the removed parts. k Take care not to forget remove gear B1. 3 Cylinder head cover mounting nut: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
While fixing adjustment screw (1), loosen locknut (2). Insert thickness gauge B2 in the clearance between rocker arm (3) and valve stem (4) and adjust the valve clearance with adjustment screw (1). a With the thickness gauge inserted, turn the adjustment screw to a degree that you can move the thickness gauge lightly. While fixing adjustment screw (1), tighten locknut (2). 3 Locknut: 39.2 – 49 Nm {4 – 5 kgm} a After tightening the locknut, check the valve clearance again.
Rotate the crankshaft forward 1 turn according to step 4 to set the No. 4 cylinder to the compression top dead center and adjust the valve c l ea r a nc e s m a r k ed wi th Q i n t he va l v e arrangement drawing similarly to those marked with q.
30-12
PC128US-8
30 Testing and adjusting Testing compression pressure
Testing compression pressure a
Testing tools for compression pressure
Symbol 1 C
1
2
Part No.
Part name
795-502-1590
Compression gauge
795-502-1370
Adapter
6271-11-3880
Gasket
k When
a
1.
testing the compression pressure, take care n ot to burn you rself on t he exhaust manifold or muffler or get caught in a rotating part. Test the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60°C) Remove the injector of the cylinder to be tested according to the following procedure. a Test of the No. 1 cylinder is explained below as an example. 1) Remove wiring harness connector (2) from injector (1). 2) Move fuel scatter prevention cover (3) from the joint. 3) Remove clamp (4) and high-pressure pipe (5). 4) Pull spill hose connector (6) out of injector (1).
5)
2.
Install adapter C2 to the injector mounting part with holder (7) and connect compression gauge C1. a Fit the gasket to the adapter end without fail. 3 Holder mounting bolt:
a
27 – 30 Nm {2.8 – 3.1 kgm} Tighten the mounting bolt after the fulcrum of the holder is seated perfectly.
Remove holder (7) and injector (1). a If the injector is stuck and is not removed easily, pass a wire under the fuel inlet and pull it up to remove the injector. a Do not apply an external force to the terminal at the injector top.
PC128US-8
30-13
30 Testing and adjusting Testing compression pressure
3.
Disconnect CE03 connector (5) of the engine controller. k If the connector is not disconnected, the engine may starts during test and that is dangerous. Accordingly, be sure to disconnect the connector. k Since the CE03 connector is the power supply circuit of the engine controller, cover the connector on the machine side with a vinyl sheet etc. to prevent leak and ground fault.
4.
Rotate the engine with the starting motor and test the compression pressure. a Test the compression pressure when the gauge pointer is stabilized.
5.
After finishing test, remove the testing instruments and return the removed parts. a Install the injector and spill hose connector according to the following procedure. 1) Fit O-ring (8) and gasket (9) to injector (1). a Do not fit O-ring (8) to groove (a).
30-14
PC128US-8
30 Testing and adjusting Testing blow-by pressure
Testing blow-by pressure a
Testing tools for blow-by pressure
Symbol D
1
1
Part No. 799-201-1504
Part name Blow-by checker
k Stop
a
the machine on a level ground and lower the work equipment to the ground. Test the blow-by pressure under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range 5.
1.
Remove the undercover of the hydraulic pump.
2.
Install tool and adapter [1] of blow-by checker D1 to breather hose (1) and connect gauge [2].
3.
Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON. a If the swing lock switch is turned ON, the main relief valve is set for high-pressure relief.
4.
While running the engine at high idle, relieve the arm circuit and test the blow-by pressure. a Read the gauge when the pointer is stabilized.
PC128US-8
After finishing test, remove the testing tools and return the removed parts.
30-15
30 Testing and adjusting Testing engine oil pressure
Testing engine oil pressure a
1
Testing tools for engine oil pressure
Symbol 1 E 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Gauge
6732-81-3170
Adapter
07002-11023
O-ring
k Stop
a
the machine on a level ground and lower the work equipment to the ground. Test the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range
1.
Remove the engine compartment side cover and oil pressure pickup plug (1) from the engine block.
2.
Install nipple [1] of hydraulic tester E1 and connect hydraulic tester E2.
3.
Start the engine and turn the auto-decelerator OFF.
4.
Run the engine and test the engine oil pressure at high idle and low idle.
30-16
5.
After finishing test, remove the testing tools and return the removed parts. 3 Oil pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm}
PC128US-8
30 Testing and adjusting Handling fuel system parts
Handling fuel system parts a
a
1
Precautions for checking and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When checking and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
PC128US-8
Releasing residual pressure from fuel system 1 a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel main filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is checked and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. k Before checking the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
30-17
30 Testing and adjusting Testing fuel pressure
Testing fuel pressure a
Testing tools for fuel pressure
Symbol
Part No.
1 F
1
2 3
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
795-471-1450
Adapter (8 x 1.25 mm)
07005-00812
O-ring
799-401-2320
Gauge
k Stop
the machine on a level ground and lower the work equipment to the ground. a Test only the fuel pressure in the low-pressure circuit from the priming pump through the fuel main filter to the supply pump and the return circuit from the supply pump/common rail/ injector to fuel tank. k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be tested. 1.
Testing pressure in fuel low-pressure circuit 1) Open the engine hood and remove fuel pressure pickup plug (1) from the fuel main filter.
2)
30-18
3)
Run the engine at high idle and test the pressure in the fuel low-pressure circuit. a If the pressure in the fuel low-pressure circuit is in the following range, it is normal. Engine speed At high idle
4)
Fuel pressure -49 – 0 kPa {-0.5 – 0 kg/cm2}
After finishing test, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
Install adapter F2 and nipple [1] of hydraulic tester F1 and connect them to oil pressure gauge [2] a Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.
PC128US-8
30 Testing and adjusting Testing fuel return rate and fuel leakage
a
Testing fuel return rate and fuel leakage 1 a
Lay test hose G4 so that it will not slacken and put its end in the oil pan.
Testing tools for fuel return rate and fuel leakage
Symbol
Part No.
Part name
1
6151-51-8490
2
6164-81-5750
Joint
3
07042-20108
Plug
4
Commercially available
Hose
5
Commercially available
Hose
6
Commercially available
Measuring cylinder
7
Commercially available
Stopwatch
G
Spacer
6)
a
Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.
1.
Preparation work 1) Remove tube (3) and spill hose (4) between common rail (1) and return block (2).
Remove spill hose connector joint (5) and install plug G3.
a
2)
3)
4) 5)
The above is the preparation work for test of the leakage from the pressure limiter and return rate from the injector.
Insert spacer G1 on return block (2) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the spacer. Insert joint G2 on common rail (1) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose G4 to the end of joint G2. Connect test hose G5 to connector (6) side of spill hose (4). a Bind the connecting part of the test hose with a wire etc. to prevent it from coming off.
PC128US-8
30-19
30 Testing and adjusting Testing fuel return rate and fuel leakage
2.
Testing leakage from pressure limiter 1) Lay test hose G4 so that it will not slacken and put its end in the oil pan. 2) Start the engine and keep its speed at 1,600 rpm with no load. 3) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder G6. a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following standard range, it is normal.
4)
Engine speed (rpm)
Leakage (cc/min)
At rated output
Max. 20
3.
Testing return rate from injector a While testing the return rate from the injector, keep the test hose on the pressure limiter side connected and keep its end in the oil pan. 1) Run the engine at the rated output. 2) After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder G6. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump pressure is low, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following standard range, it is normal. Limit of return rate (spill) (cc/min)
1,600
190
1,700
200
1,800
210
1,900
220
2,000
230
After finishing test, stop the engine.
3) 4.
30-20
Rated output speed (rpm)
After finishing test, stop the engine.
After finishing test, remove the testing tools and return the removed parts. 3 Joint bolt: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
PC128US-8
30 Testing and adjusting Bleeding air from fuel circuit
Bleeding air from fuel circuit
1
a
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. k Stop the machine on a level ground and lower the work equipment to the ground.
1.
Fill the fuel tank with fuel. a Add fuel until the float of the sight gauge reaches the maximum position.
2.
Open the side cover of the pump room.
3.
Loosen knob (1) of the feed pump and pull it out, and then operate it forward and backward. a Move the knob until it becomes heavy. a The plug at the top of the fuel main filter does not need to be removed.
4.
After bleeding air, push in and tighten knob (1).
PC128US-8
30-21
30 Testing and adjusting Bleeding air from fuel circuit
a
Air bleeding route of fuel circuit Fuel tank o Pre-filter o Main filter o Feed pump o Metering unit o Fuel tank
1. Fuel tank 2. Pre-filter with water separator 3. Priming pump 4. Main filter 5. Feed pump 6. IMV (Inlet Metering Valve) 7. Overflow valve 8. Rail 9. Injector 10. Safety valve 11. High pressure pump
30-22
PC128US-8
30 Testing and adjusting Checking fuel circuit for leakage
Checking fuel circuit for leakage 1
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After checking the fuel system or removing its parts, check it for fuel leakage according to the following procedure. k Stop the machine on a level ground and lower the work equipment to the ground. a Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage. 1.
Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.
4.
Run the engine at low idle.
5.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.
6.
Run the engine at high idle.
7.
Check the fuel piping and devices for fuel leakage. a Check around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.
8.
Run the engine at high idle and load it. a Relieve the arm circuit at the IN stroke end.
PC128US-8
9.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2. a If no fuel leakage is detected, check is completed.
30-23
30 Testing and adjusting Testing and adjusting alternator belt tension
Testing and adjusting alternator belt tension 1 Testing 1. Remove the engine compartment side cover and air intake pipe (1).
Press the intermediate point of the belt between the alternator pulley and fan pulley with a finger and test deflection (a) of the belt. a Pressing force: Approx. 60 Nm {Approx. 6.1 kg} a Deflection (a): 6 – 10 mm
30-24
Adjusting a If the deflection is out of the standard range, adjust the belt tension according to the following procedure. 1.
Loosen alternator fixing bolts (1) and (2). a Loosen fixing bolt (2) from the rear side of the engine.
2.
Adjust the tension of alternator belt (4) by turning adjustment bolt (3). a Do not loosen double nut (5) at the adjustment bolt end. (If you have loosened it, apply LOCTITE (LT-2) to it when tightening.) Reference: If adjustment bolt (3) is tightened (turned to the right), the alternator belt (4) is loosened. If the former is turned to the left, the latter is tightened.
3.
After adjusting the belt tension, tighten alternator fixing bolts (1) and (2).
4.
Check again that the tension of alternator belt (4) is in the standard range.
PC128US-8
30 Testing and adjusting Checking and adjusting air conditioner compressor belt tension
Checking and adjusting air conditioner compressor belt tension k Stop
1
the machine on a level ground and lower the work equipment to the ground.
Checking 1. Open the engine hood, press the intermediate point of the belt between the fan pulley and compressor pulley with a finger, and test deflection (a) of the belt. q Belt pressing force: 60 N {6.1 kg}
PC128US-8
Adjusting a If the belt deflection is abnormal, adjust it according to the following procedure. 1.
Loosen bolts (1) and (2) and locknut (6).
2.
Move compressor (3) and bracket (4) as a set with adjustment bolt (5) to adjust the belt tension.
3.
After positioning compressor (3), tighten bolts (1) and (2) and locknut (6). a Check each pulley for breakage, wear of the V-groove, and contact of the V-belt and V-groove. a If the V-belt is so lengthened that the adjustment allowance is eliminated or it has a cut or a crack, replace it. a If the belt is replaced, adjust their tension again after operating the machine for 1 hour. a After tightening the bolts, check the belt tension again according the above procedure.
4.
After finishing test, return the removed parts.
30-25
30 Testing and adjusting Testing swing circle bearing clearance
Power train
1
Testing swing circle bearing clearance
1
a
4.
Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats. a At this time the front of the upper structure rises and the rear lowers.
5.
Under this condition, read dial gauge H. a The value indicated by dial gauge H is the clearance of the bearing. a For the standard value, see Structure, function and maintenance standard, "Swing circle".
6.
Return the machine to the condition of step 2 and check that dial gauge H indicates 0. a If the dial gauge does not indicate 0, repeat steps 2 through 5.
Testing tools for swing circle bearing clearance
Symbol
Part No.
H
Commercially available
Part name Dial gauge
a
When testing the swing circle bearing clearance installed to the machine, perform the following procedure. k Stop the machine on a level ground and lower the work equipment to the ground. k Do not put your hands or feet under the undercarriage during test.
1.
Fix dial gauge H to the track frame and apply the probe to the lower end of the outer race.
2.
Set the work equipment to the maximum reach position and set the bucket tip to the height of the under side of the revolving frame. a At this time the front of the upper structure lowers and the rear rises.
3.
Set dial gauge H to the 0 point.
30-26
PC128US-8
30 Testing and adjusting Checking and adjusting track shoe tension
Undercarriage and frame
1
Checking and adjusting track shoe tension
1
Checking 1. Run the engine at low idle and drive the machine forward by the length of track on ground, and then stop slowly. 2.
Place square bar [3] longer than the distance between idler (1) and carrier roller (2) on the track shoe. a As the steel bar, use an angle steel, etc. which will be deflected less.
3.
Test maximum clearance (a) between steel bar [3] and track shoe. q Standard maximum clearance (a): 10 – 30 mm
Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1.
Increasing tension 1) Add grease through grease fitting (2) with a grease gun. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track shoe tension again according to the above procedure.
a
PC128US-8
You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. If the tension is still low, the pins and bushings are worn much. In this case, reverse or replace the pins and bushings.
30-27
30 Testing and adjusting Checking and adjusting track shoe tension
2.
Decreasing tension 1) Loosen valve (1) to discharge grease, and then tighten it. k Do not loosen the valve more than 1 turn. If it is loosened more, it may jump out because of the highpressure grease in it. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track shoe tension again according to the above procedure.
30-28
PC128US-8
30 Testing and adjusting Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Hydraulic system
1
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 1 a
Testing and adjusting tools for oil pressure in work equipment, swing, and travel circuits
Symbol 1 J 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
2)
k Stop
the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit".
Testing a The oil pressure in the work equipment, swing, and travel circuits (pump discharge pressure) can be checked with monitoring function of the machine monitor, too (For details, see "Special functions of machine monitor"). q Monitoring code: 01100 pump pressure a Test the oil pressure in the work equipment, swing, and travel circuits under the following condition. q Hydraulic oil temperature: Within operating range 1.
Preparation work 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure port (1) check plug q (2): Pump discharge pressure port (2) check plug
PC128US-8
2.
Install nipples J2 and connect oil pressure gauges [1] of hydraulic tester J1. a Use the oil pressure gauges of 60 MPa {600 kg/cm2}.
Testing unload pressure 1) Start the engine, set the working mode in the power mode (P), and turn the autodecelerator OFF. 2) Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure. a The pressure tested when the unload valve is unloaded is indicated.
30-29
30 Testing and adjusting Testing and adjusting oil pressure in work equipment, swing, and travel circuits
3.
Testing work equipment relief pressure 1) Start the engine and move the cylinder to be tested to the stroke end. 2) Set the working mode in the power mode (P). 3) Run the engine at high idle, operate the right and left work equipment control levers to relieve the cylinder, and test the oil pressure. a The pressure tested when the main relief valve is relieved is indicated (If t he boo m is l owe r ed si ng ly, t he safety-suction valve of the control valve for lowering the boom is relieved).
4.
Testing swing relief pressure 1) Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON. 2) Run the engine at high idle, operate the left work equipment control lever to relieve the swing motor, and test the oil pressure. a The pressure tested when the swing motor relief valve is relieved is indicated. a The swing relief pressure is lower than the main relief pressure.
5.
Testing travel relief pressure 1) Run the engine and lock the travel mechanism. k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely.
30-30
2) 3)
6.
Set the working mode in the power mode (P). Run the engine at high idle, operate the travel lever and pedal to relieve the travel motor, and test the oil pressure. k Before operating the travel lever and pedal, check the position and locking direction of the locked sprocket again. a The pressure tested when the main relief valve of the control valve is relieved is indicated. The travel circuit is always relieved at high pressure.
Work after finishing test After finishing test, remove the testing tools and return the removed parts. 3 Oil pressure pickup plug: 20 – 27 Nm {2.0 – 2.8 kgm}
PC128US-8
30 Testing and adjusting Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Adjusting a The unload valve and safety-suction valve for lowering the boom cannot be adjusted. 1.
2.
Adjusting swing relief pressure a If the swing relief pressure is abnormal, adjust safety valve (6) of the swing motor according to the following procedure.
Adjusting work equipment and travel relief pressure a If the relief pressure of the work equipment circuit and travel circuit is abnormal, adjust main relief valves (3) according to the following procedure. q (3): Main relief valve a When adjusting the main relief valves, remove the side cover of the control valve.
1) 2)
1) 2) 3)
4)
Remove the control valve left side cover. While fixing holder (4), loosen locknut (5). Turn holder (4) to adjust the set pressure. a If the holder is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} While fixing holder (4), tighten locknut (5). 3 Locknut: 49 – 58.8 Nm {5 – 6 kgm}
3)
4)
5)
While fixing adjustment screw (7), loosen locknut (8). Turn adjustment screw (7) to adjust the pressure. a If the adjustment screw is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of adjustment screw: Approx. 6.7 MPa {Approx. 68.4 kg/cm2} While fixing adjustment screw (7), tighten locknut (8). 3 Locknut: 78 – 103 Nm {8 – 10.5 kgm}
After finishing adjustment, check again that the oil pressure is normal according to the above described test procedure.
After finishing adjustment, check again that the oil pressure is normal according to the above described test procedure.
PC128US-8
30-31
30 Testing and adjusting Testing control circuit basic pressure
Testing control circuit basic pressure a
3.
Start the engine, set the working mode in the power mode (P), and turn the auto-decelerator OFF.
4.
Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure.
5.
After finishing test, remove the testing tools and return the removed parts.
a
The control circuit basic pressure may be tested with oil pressure pickup plug (2) on the hydraulic pump side.
a
Do not adjust the relief valve for control circuit basic pressure.
1
Testing tools for control circuit basic pressure
Symbol 1 K 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
k Stop
a
1.
2.
the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Test the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range
Remove the control valve cover and oil pressure pickup plug (1).
Install nipple K2 and connect oil pressure gauge [1] of hydraulic tester K1. a Use the oil pressure gauge of 6 MPa {60 kg/ cm2}.
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PC128US-8
30 Testing and adjusting Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump PC control circuit 1 a
Testing and adjusting tools for oil pressure in pump PC control circuit
Symbol 1 L 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
k Stop
the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit".
2)
Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1.
Testing a Before testing the oil pressure in the PC control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure of the control circuit are normal. a Test the oil pressure in the pump PC control circuit under the following condition. q Hydraulic oil temperature: Within operating range 1.
a
Testing PC valve output pressure (servo piston inlet pressure) a Test the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): PC valve output pressure pickup plug
a
3) 4)
PC128US-8
Install nipple L2 to the inspection part of plug (2) and connect it to oil pressure gauge [1] by hose [2] of hydraulic tester L1. Use the oil pressure gauges of 60 MPa {600 kg/cm2}.
Start the engine and move the arm cylinder to the IN stroke end. Set the working mode in the power mode (P).
30-33
30 Testing and adjusting Testing and adjusting oil pressure in pump PC control circuit
5)
Run the engine at high idle, operate the left work equipment control lever to relieve the arm circuit at the IN stroke end, and test the oil pressure.
2)
Install nipples L2 and connect them to oil pressure gauges [1]. a Use the oil pressure gauges of 6 MPa {60 kg/cm2}.
a
3)
Start the engine and set the working mode in the power mode (P). Run the engine at high idle and low idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed.
Testing condition and method of judgment: If the pressures are in the following ratio, the PC valve is normal. Tested oil pressure
Pump discharge pressure PC valve output pressure
Operation of lever
4)
Ratio of oil pressures 1
Arm IN relief
Approx. 0.6 (Approx. 3/5)
a
6)
2.
If the PC valve or the servo piston is abnormal, the PC valve output pressure (servo piston inlet pressure) is "the same as the pump discharge pressure" or "almost 0". After finishing test, remove the testing tools and return the removed parts.
Testing PC-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup plugs (3). (3): PC-EPC valve output pressure pickup plug
a
Testing condition and method of judgment: If the output pressures are in the following ratio, the PC-EPC valve is normal.
Engine Low idle High idle
5)
30-34
Operation of lever All control levers and pedals in neutral
Output pressure Approx. 2.9 MPa {Approx. 30 kg/cm2} Approx. 3.4 MPa {Approx. 35 kg/cm2}
After finishing test, remove the testing tools and return the removed parts.
PC128US-8
30 Testing and adjusting Testing and adjusting oil pressure in pump PC control circuit
Adjusting Adjusting pump PC valve a If the following phenomenon occurs and PC valve (4) seems to be defective, adjust PC valve (4) according to the following procedure. q As the working load increases, the engine speed lowers remarkably. q The engine speed is normal but the work equipment speed is low. a The width across flats of the PC valve locknut is 13 mm and that of the adjustment screw (inside width) is 4 mm. Do not turn any other locknuts or adjustment screws since they affects the hydraulic pump performance.
1.
Loosen locknut (5). a Before loosening the locknut, make counter mark at the adjustment screw end so that you can see the position of the locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse).
2.
Turn adjustment screw (6) clockwise or counterclockwise to adjust. a Turn the adjustment screw q Clockwise when the work equipment s pee d i s low ( to i nc re ase pu mp absorption torque) and q Counterclockwise when the engine speed lowers (to decrease pump absorption torque).
3.
Tighten locknut (5). 3 Locknut: 27 – 34 Nm {2.8 – 3.5 kgm}
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4.
After finishing adjustment, check again that the PC valve output pressure (servo piston inlet pressure) is normal according to the above described test procedure.
30-35
30 Testing and adjusting Testing and adjusting oil pressure in pump LS control circuit
Testing and adjusting oil pressure in pump LS control circuit 1 a
Testing and adjusting tools for oil pressure in pump LS control circuit
Symbol 1 M
2 3
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2701
Differential pressure gauge
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
k Stop
the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit".
2)
Install nipple M3 and connect it to oil pressure gauge [1] of hydraulic tester M1.
Testing a Before testing the oil pressure in the LS control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure of the control circuit are normal. a Test the oil pressure in the pump LS control circuit under the following condition. q Hydraulic oil temperature: Within operating range a 1.
Testing LS valve output pressure (servo piston inlet pressure) a Test the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): LS valve output pressure pickup plug
a
3)
30-36
Install nipple M3 to the inspection part of plug (2) and connect it to oil pressure gauge [1] by hose [2] of hydraulic tester M1. Use the oil pressure gauges of 60 MPa {600 kg/cm2}.
Start the engine and push up the track shoe on the side to be tested with the work equipment and prepare for running the track shoe idle. k Since the raised track shoe will be run idle during test, secure a sufficient working area.
PC128US-8
30 Testing and adjusting Testing and adjusting oil pressure in pump LS control circuit
4)
5)
Set the working mode in the power mode (P) and set the travel speed in the High position. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed. Then, operate the travel lever to run the track shoe idle and test the oil pressure. k While checking the safety around the machine extremely, run the track shoe pushed up idle. a Do not operate the travel lever to the stroke end (but stop it halfway).
a
Testing condition and method of judgment: If the pressures are in the following ratio, the LS valve is normal. Position of levers and pedals All levers and pedals are at neutral Pump discharge pressure
Hydraulic pressure to be measured LS valve output pressure
6)
2.
Travel lever moved halfway (Travel at idle) 1. (Actual valve is set as 1)
Almost same
Approx. 3/5 of pressure above
2)
Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Pump discharge pressure pickup plug q (2): LS pressure pickup plug
3)
Install nipples M3 and connect it to differential pressure gauge M2 or the oil pressure gauge [1] of hydraulic tester M1. a When using differential pressure gauge M2: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12V power source, connect it to a battery. a When using oil pressure gauge (in M1): Use the oil pressure gauge of 60 MPa {600 kg/cm 2 } having the unit of 1.0 MPa {10 kg/cm2}. Since the differential pressure is approximately 3.9 MPa {40 kg/cm2} at maximum, test it by installing the same gauge to the pickup plugs alternately. q The figure shows the pump discharge pressure side.
After finishing test, remove the testing tools and return the removed parts.
Testing LS differential pressure a Test the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the difference between them. 1) Remove connector V5 (Port A4) of the solenoid valve. Purpose: Remove the connector to set the merge-divider valve in the constant merge state and stabilize the LS differential pressure.
PC128US-8
30-37
30 Testing and adjusting Testing and adjusting oil pressure in pump LS control circuit
q
a
The figure shows the LS pressure side.
7)
4)
5)
6)
30-38
Testing condition and method of judgment: If the pressures are in the following ratio, the LS valve is normal. Operation of levers
LS differential pressure
All control levers and pedals in neutral
2.8 ± 1.0 MPa {28 ± 10 kg/cm2}
Travel lever moved halfway (No-load travel operation of one side)
2.2 ± 0.1 MPa {22.5 ± 1 kg/cm2}
After finishing test, remove the testing tools and return the removed parts. Insert the removed connector V5 of the solenoid valve in its original position.
Run the engine, push up the track shoe on the side to be tested with the work equipment, and prepare for running track shoe idle. q When testing P1 circuit: Right track shoe q When testing P2 circuit: Left track shoe k Since the raised track shoe will be run idle during test, secure a sufficient working area. Set the working mode in the power mode (P) and set the travel speed in the High position. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and test the oil pressure at each speed. Then, operate the travel lever to run the track shoe idle and test the oil pressure. k While checking the safety around the machine extremely, run the track shoe pushed up idle. a Do not operate the travel lever to the stroke end (but stop it halfway).
PC128US-8
30 Testing and adjusting Testing and adjusting oil pressure in pump LS control circuit
Adjusting Adjusting LS valve a If the LS differential pressure is abnormal, adjust the LS valve according to the following procedure. q (3): Pump LS valve
1.
While fixing adjustment screw (4), loosen locknut (5).
2.
Turn adjustment screw (4) to adjust the differential pressure. a If the adjustment screw is q Turned to the right, the differential pressure is increased. q Turned to the left, the differential pressure is decreased. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. 1.1 MPa {Approx. 10.8 kg/cm2}
3.
While fixing adjustment screw (4), tighten locknut (5). 3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
4.
After finishing adjustment, check again that the LS differential pressure is normal according to the above described test procedure.
PC128US-8
30-39
30 Testing and adjusting Testing solenoid valve output pressure
Testing solenoid valve output pressure a
Part No. 799-101-5002
1
N
2
Install adapter N2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester N1 and connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 6 MPa {60 kg/ cm2}. a The figure shows the testing tools connected to outlet hose (1) of the PPC lock solenoid valve.
4.
Start the engine.
5.
Run the engine at high idle, operate the control levers and switches to turn the solenoid valve ON or OFF, and test the oil pressure. a For the conditions for turning the solenoid valve ON and OFF, see the operation table of each solenoid valve. a The operating condition of the solenoid valve can be checked with the monitoring function of the machine monitor (For details, see "Special functions of machine monitor"). q Monitoring code: 02300 Solenoid 1 a If the output pressure is as follows, the solenoid valve is normal.
1
Testing tools for solenoid valve output pressure
Symbol
2.
Part name Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3100
Adapter (Size: 02)
k Stop
a a
1.
the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Before testing the solenoid valve output pressure, check that the basic pressure of the control circuit is normal. Test the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range
Remove the control valve left side cover and disconnect outlet hoses (1) – (5) of the solenoid valve to be checked. No.
Solenoid valve to be tested
1
PPC lock solenoid valve
2
Travel speed shifting solenoid valve
3
Swing holding brake solenoid valve
4
Merge-divider valve
5
Travel junction solenoid valve
a
When testing with hose (1), remove the undercover (rear side) of the operator's cab.
6.
30-40
Solenoid valve
Output pressure
OFF (Demagnetization)
0 MPa {0 kg/cm2}
ON (Excitation)
2.9 MPa {30 kg/cm2}
After finishing test, remove the testing tools and return the removed parts.
PC128US-8
30 Testing and adjusting Testing PPC valve output pressure
Testing PPC valve output pressure
a
1
Testing tools for PPC valve output pressure
Symbol
Connecting points of PPC piping P
1 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3100
Adapter (Size: 02)
k Stop
a a a
a
The above figure shows the connecting points of the PPC piping on the control valve of 1 attachment installation specification. The colors in ( ) are the colors of the bands installed for distinction of the pipes. The figure at right shows the check points of the steering signal voltage of the travel PPC valve. When testing the steering signal voltage, remove the undercover of the operator's cab (front side).
PC128US-8
the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit". Before testing the PPC valve output pressure, check that the basic pressure of the control circuit is normal. Test the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range
1.
Disconnect the hose of the PPC circuit to be tested. a For the hose to be disconnected, see "Connecting points of PPC piping".
2.
Install adapter P2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester P1 and connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 6 MPa {60 kg/ cm2}. a The figure shows the testing tools connected to the hose of the bucket dump PPC circuit.
30-41
30 Testing and adjusting Testing PPC valve output pressure
4.
Start the engine and set the working mode in the power mode (P).
5.
Run the engine at high idle and test the oil pressure with the control lever in neutral and moved to the stroke end.
a
6.
If the output pressure is as follows, the PPC valve is normal. Operation of lever
Output pressure
Neutral
0 MPa {0 kg/cm2}
Stroke end
Almost same as control circuit basic pressure (See standard values table)
After finishing test, remove the testing tools and return the removed parts.
30-42
PC128US-8
30 Testing and adjusting Adjusting play of work equipment and swing PPC valves
Adjusting play of work equipment and swing PPC valves 1 a
If the right and left work equipment levers have large play, adjust them according to the following procedure.
1.
Remove the work equipment and swing PPC valve assembly.
2.
Remove bellows (1).
3.
Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4).
4.
Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 98 – 127 Nm {10 – 13 kgm}
5.
Install bellows (1).
6.
Install the work equipment and swing PPC valve assembly.
PC128US-8
30-43
30 Testing and adjusting Checking parts which cause hydraulic drift of work equipment
Checking parts which cause hydraulic drift of work equipment1 a
If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylind e r pa c k i n g s i d e o r c o n t r o l v a l v e s i d e according to the following procedure.
1.
Checking boom cylinder and bucket cylinder 1) Set the machine in the position for testing hydraulic drift and stop the engine. a Fill the bucket with a rated load or with dirt and sand.
2.
Checking arm cylinder 1) Stop the arm cylinder approximately 100 mm before the IN stroke end and stop the engine.
2)
2)
30-44
When checking the boom cylinder, set the boom control lever in the RAISE position. When checking the bucket cylinder, set the bucket control lever in the CURL position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for approximately 5 seconds to heighten the pressure in the accumulator.
Operate the arm control lever in the IN position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator. [Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2) As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then the lowering speed is lowered. 3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.
PC128US-8
30 Testing and adjusting Checking parts which cause hydraulic drift of work equipment
3.
Checking PPC valve While the pressure in the accumulator is high, set the lock lever in the LOCK/FREE position and test the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator. a If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).
PC128US-8
30-45
30 Testing and adjusting Testing and adjusting travel deviation
Testing and adjusting travel deviation
1
Inspection 1. Run the engine and heighten the hydraulic oil temperature to the operating range and set the machine in the travel posture. a To set the machine in the travel posture, extract the bucket cylinder and arm cylinder fully and set the boom angle to 45°. 2.
Set the working mode to P and travel speed to Lo.
3.
Run up for 10 m with the engine speed at high idle and continue travel under the same condition for 20 m and measure the deviation (a). a Install an oil pressure gauge and check that the P1 and P2 discharge pressures of the hydraulic pump are even.
30-46
PC128US-8
30 Testing and adjusting Testing and adjusting travel deviation
Adjustment a If the machine deviates, it can be corrected by partially draining the oil discharged more from the pump through the travel deviation adjusting plug. (If the travel deviation is corrected by this method, however, the pump discharge is reduced. As a result, the travel speed, work equipment speed in compound operation, and relief pressure may lower.) a If the machine deviates in the same direction regardless of the travel direction, correct it according to the following procedure. (If the deviating direction of the machine depends on the travel direction, the cause of deviation may not be in the hydraulic pump. In this case, carry out troubleshooting.) a Only when the travel deviation is 200 mm or less, it can be corrected by the following method. k If the adjusting plug is loosened more than the adjustment limit, high-pressure oil will spout out. Take care extremely. k Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the residual pressure from the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 1.
Check the deviating direction and the locations of travel deviation adjusting plugs (1) and (2). q (1): Right deviation adjusting plug (P1 pump) q (2): Left deviation adjusting plug (P2 pump) a Loosen only the plug on either side for adjustment. Do not loosen the plugs on both sides.
PC128US-8
2.
Fixing plug (3) with a hexagonal wrench (Width across flats: 4 mm), loosen locknut (4). a If the locknut is sealed with a vinyl tape, remove that tape. a Before loosening the locknut, make match marks on it and pump case. q Loosening angle of locknut: Approx. 90 – 180°
3.
Loosen plug (3) to adjust the travel deviation. q Quantity of adjustment of deviation per turn of plug: 150 mm (Reference) a The plug is fully tightened when shipped. Adjust the deviation by the loosening angle of the plug from the fully tightened position. a If the plug is turned together with the locknut, tighten it fully again, then start adjustment. a The plug can be loosened by 2 turns (720°) from the fully tightened position.
4.
Fixing plug (3) with a hexagonal wrench, tighten locknut (4). 3 Locknut: 2.9 – 4.9 Nm {0.3 – 0.5 kgm} a After tightening the locknut, seal its hole with a vinyl tape.
5.
After finishing adjustment, check travel deviation again according to the procedure for inspection described above.
30-47
30 Testing and adjusting Releasing residual pressure from hydraulic circuit
Releasing residual pressure from hydraulic circuit 1 1.
2.
Releasing residual pressure from hydraulic tank k Since the hydraulic tank is enclosed and pressurized, release the residual pressure from it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable position and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank.
4)
Repeat steps 2) and 3) above 2 – 3 times, and the residual pressure in the piping is released completely.
3.
Releasing residual pressure from swing motor circuit The residual pressure in the swing motor circuit can be released by performing the operation for "Releasing residual pressure from hydraulic cylinder circuit" (Operate the lever in the swing direction only, however).
4.
Releasing residual pressure from travel motor circuit Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by performing "Releasing residual pressure from hydraulic tank".
Releasing residual pressure from hydraulic cylinder circuit k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the residual pressure from the piping according to the following procedure. 1) Lower the work equipment and release the residual pressure from the hydraulic tank. For details, see "Releasing residual pressure from hydraulic tank". a Keep the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch ON and set the lock lever in the FREE position, and then operate the right and left work equipment control levers forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up, however, after the control valve is operated 2 – 3 times. 3) Run the engine at low idle for 5 seconds to heighten the pressure in the accumulator. a The engine does not start until the lock lever is set in the LOCK position once.
30-48
PC128US-8
30 Testing and adjusting Testing oil leakage
Testing oil leakage a
1
Testing tools for oil leakage
Symbol
Part No.
Q
Commercially available
Part name Measuring cylinder
a
Test the oil leakage under the following condition. q Hydraulic oil temperature: Within operating range
1.
Testing oil leakage from boom cylinder 1) Move the boom cylinder to the RAISE stroke end and stop the engine. k Release the residual pressure from the piping on the boom cylinder head side. For details, see "Releasing residual pressure from hydraulic circuit" (Operate the lever in the boom RAISE direction only, however). 2) Disconnect hose (1) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70422 (Plug #04)
2.
Testing oil leakage from arm cylinder 1) Move the arm cylinder to the IN stroke end and stop the engine. k Release the residual pressure from the piping on the arm cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the arm IN direction only, however). 2) Disconnect hose (2) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70522 (Plug #05)
3)
4)
5)
3)
4)
5)
Run the engine at high idle and relieve the arm circuit by moving the arm IN. k Take care not to "move the arm OUT". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.
Run the engine at high idle and relieve the boom circuit by raising the boom. k Take care not to "lower the boom". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.
PC128US-8
30-49
30 Testing and adjusting Testing oil leakage
3.
Testing oil leakage from bucket cylinder 1) Move the bucket cylinder to the CURL stroke end and stop the engine. k Release the residual pressure from the piping on the bucket cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the bucket CURL direction only, however). 2) Disconnect hose (3) on the cylinder head side and block it with a plug. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-70422 (Plug #04)
4.
Testing oil leakage from swing motor 1) Disconnect 2 drain hoses (4) and block the hose side with plugs. a Use the following parts to block the hose side. 07376-70315 (Plug #03)
2) 3)
4)
3)
4)
5)
30-50
Turn the swing lock switch ON. Run the engine at high idle and relieve the swing circuit by swinging. a Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. a After testing 1 time, swing 180°, and then test again. After finishing test, return the removed parts.
Run the engine at high idle and relieve the bucket circuit by curling the bucket. k Take care not to "dump the bucket". Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. After finishing test, return the removed parts.
PC128US-8
30 Testing and adjusting Testing oil leakage
5.
Testing oil leakage from travel motor 1) Remove the travel motor cover. 2) Run the engine, lock the travel mechanism, and stop the engine. k Put pin [1] between the sprocket and track frame to lock the travel mechanism securely.
3)
Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Use the following part to block the hose side. 07376-70422 (Plug #04)
4)
Run the engine at high idle, relieve the travel circuit, and test the oil leakage. k Before operating the travel lever, check the position and locking direction of the locked sprocket again. k Wrong operation of the lever can cause an accident. Accordingly, make signs and checks securely. a Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute. a Test several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time.
PC128US-8
5)
After finishing test, return the removed parts.
30-51
30 Testing and adjusting Bleeding air from each part
Bleeding air from each part
1 Air bleeding procedure
Air bleeding item 1
2
3
Bleeding air from hydraulic pump
Starting engine
q
q
4
5
6
Bleeding air Bleeding air Bleeding air from swing from travel from cylinder motor motor
Checking oil level and starting operation
q
q (See note)
q (See note)
q
q
o
o
o
q
q
q
o
o
q
• Replacing and repairing control valve • Removing control valve piping
q
q
o
o
q
• Replacing and repairing cylinder • Removing cylinder piping
q
q
o
o
q
• Replacing and repairing swing motor • Removing swing motor piping
q
o
q
o
q
• Replacing and repairing travel motor • Removing travel motor piping
q
o
o
q
q
• Replacing and repairing swivel joint • Removing swivel joint piping
q
o
o
o
q
Contents of work • Replacing hydraulic oil • Cleaning strainer • Replacing return filter element • Replacing and repairing hydraulic pump • Removing suction piping
q
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1.
Bleeding air from hydraulic pump 1) Loosen air bleeder (1) and check that oil oozes out through the air bleeder. 2) After the oil oozes out, tighten air bleeder (1). 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} a Do not use an impact wrench to tighten the air bleeder.
30-52
2.
Starting engine When running the engine after performing step 1, keep its speed at low idle for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).
3.
Bleeding air from cylinder a If a cylinder is replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idle for about 5 minutes. 2) While running the engine at low idle, raise and lower the boom 4 – 5 times. a Stop the piston rod approximately 100 mm before each stroke end. Do not relieve the oil.
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30 Testing and adjusting Bleeding air from each part
3) 4)
5)
4.
While running the engine at high idle, perform step 2). While running the engine at low idle, move the piston rod to the stroke end and relieve the oil. Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4).
6.
Checking oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.
Bleeding air from swing motor 1) Turn the swing lock switch "ON" and run the engine at low idle for 5 minutes. a Bleed air from the swing motor by applying the S-port pressure. 2) Remove the swing motor top cover, disconnect hose (1) from the swing motor, and block the hose with a plug. a Use the following plug to block the hose. 07379-70628 (Plug #06) 2)
3)
4)
5.
Check the oil level by sight gauge (3) on the rear side of the hydraulic tank. a If the oil level is below line L, it is insufficient. Add oil. a The oil level changes according to the oil temperature. Add oil when the oil level is out of the following standard ranges. q When oil temperature is 10 – 30°C: Between line H and line L q When oil temperature is 50 – 80°C: Near line H
Run the engine at low idle and check that oil flows out of elbow (2). a If no oil flows out of the elbow, perform step 1) again. Connect hose (1) under its normal condition.
Bleeding air from travel motor 1) Remove the travel motor cover and disconnect motor drain hose (2). 2) Run the engine at low idle and check that oil flows out of nipple (3).
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30-53
30 Testing and adjusting Checking cab tipping stopper
Cab and its attachments Checking cab tipping stopper
1 1
Adjusting mirrors
1
Adjusting mirrors (a1) and (b1) Loosen bolts (1) and (2) of the mirrors and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator's seat. a Adjust the mirrors so that the operator can see persons (or things 1 m high and approximately 30 cm in diameter) at the right and left rear of the machine.
a
Check the cab tipping stopper according to the following procedure.
1.
Remove the side lower cover of the operator's cab. a Perform this step only when the additional undercover is installed.
2.
Check the tightening torque of the mounting bolt (2) of the lock plate (1). 3 Bolt (2): 98 – 123 Nm {10 – 12.5 kgm}
[Reference] The tightening torque of mounting bolt (4) of cab tipping stopper (3) is different from that of a common bolt 30 mm in diameter. Take care. 3 Bolt (4): 245 – 309 Nm {25 – 31.5 kgm}
q
30-54
Adjusting mirrors (c1) and (d1) Adjust the mirrors so that the operator can see the ground at 1 m around the machine from the operator's seat. a If the mirror is hard to move for adjustment, loosen bolts (3) and (4).
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30 Testing and adjusting Adjusting mirrors
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30 Testing and adjusting Special functions of machine monitor
Electrical system
1
Special functions of machine monitor
1
Air conditioner specification
30-56
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30 Testing and adjusting Special functions of machine monitor
Upper section of machine monitor (Display section) (a): Multi-display a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Auto-decelerator switch [2]: Numeral 2 input switch/Working mode selector switch [3]: Numeral 3 input switch/Travel speed shifting switch [4]: Numeral 4 input switch/Alarm buzzer cancel switch [5]: Numeral 5 input switch/Wiper switch [6]: Numeral 6 input switch/Windshield washer switch [7]: Numeral 7 input switch/Air conditioner or heater switch [8]: Numeral 8 input switch/Air conditioner or heater switch [9]: Numeral 9 input switch/Air conditioner or heater switch [0]: Numeral 0 input switch/Air conditioner or heater switch Switch having no numerals: Air conditioner or heater switch a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multidisplay.
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30 Testing and adjusting Special functions of machine monitor
t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
t Operator mode (Outline)
Page
Page Service mode
30-60p
30-73p
A Display of KOMATSU logo
30-60p
Monitoring
30-74p
A Display of inputting password
30-61p
30-79p
A Display of check before starting
30-61p
A Display of warning after check before starting
30-61p
Mechanical Systems Abnormality Electrical Systems Record Air-conditioning System
30-86p
A Display of ending of maintenance interval
30-61p
Maintenance Record
30-87p
Maintenance Mode Change
30-88p
Phone Number Entry
30-90p
Display of check of working mode and travel speed
30-62p
A Display of ordinary screen
30-62p
A Display of end screen
30-62p
B Selection of auto-deceleration
30-62p
B Selection of working mode
30-63p
B Selection of travel speed
30-64p
B Operation to stop alarm buzzer
30-64p
B Operation of windshield wiper
30-64p
B Operation of window washer
30-64p
B Operation of air conditioner/heater
30-65p
B Operation to display camera mode
30-65p
B Operation to display clock and service meter
30-66p
B Check of maintenance information
30-66p
O (Special operation)
A
Key-on Mode
30-91p
Unit
30-92p
With/Without Attachment
30-93p
Attachment/Maintenance Password
30-94p
Camera
30-95p
ECO Display
30-97p
Pump Absorption Torque
30-98p
Attachment Flow Adjustment
30-99p
Default
Adjustment Cylinder Cut-Out
30-100p
No Injection
30-101p
Fuel Consumption
30-103p 30-104p
30-107p
C Display of energy-saving guidance
30-68p
Terminal Status KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300)
C Display of caution monitor
30-68p
Display of KOMTRAX message
C Display of user code and failure code
30-68p
B
Setting and display of user mode (Including KOMTRAX messages for user)
30-67p
30-80p
30-105p 30-106p
O (Special operation) Function of checking display of LCD (Liquid Crystal Display)
30-70p
D Function of checking service meter
30-70p
D
D
Function of changing attachment/maintenance password
30-58
30-71p
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30 Testing and adjusting Special functions of machine monitor
a
Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch
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30 Testing and adjusting Special functions of machine monitor
t
Operator mode (Outline)
a
Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see the Structure, function and maintenance standard, or Operation and Maintenance Manual. The following are the displays or functions of the operator mode explained in this section (including some items which need special operations).
a
a
Display pattern A B C D E Display of KOMATSU logo
1 1 1 1 1
Display of inputting password
2 — — — —
Display of check before starting
3 2 3 2 2
Display of warning after check before starting
— — — 3 —
Display of ending of maintenance interval
— — — — 3
Display of check of working mode and travel speed
4 3 4 4 4
Display of ordinary screen
5 4 5 5 5
Display pattern of operator mode The contents of display from the time when starting switch is turned ON to time when screen changes to ordinary screen depends on the setting and condition of the machine. A : When engine start lock is set effective B : When engine start lock is set ineffective C : When working mode at start is set to breaker mode (B) D : When there is abnormal item in checkbefore-starting items E : When there is maintenance item which is not maintained after specified interval
Display of KOMATSU logo When the s tarting switch is turned ON, the KOMATSU logo is displayed for 2 seconds. a After the KOMATSU logo is displayed for 2 seconds, the screen changes to "Display of inputting password", or "Display of check before starting".
Display of end screen Selection of auto-deceleration Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user)
a
Display of energy-saving guidance Display of caution monitor Display of user code and failure code O (Special operation)
a
The following screen may be displayed instead of the above Display of inputting password screen. If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.
Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing attachment/maintenance password
30-60
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30 Testing and adjusting Special functions of machine monitor
Display of inputting password After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective. a If the password is input normally, the screen changes to "Display of check before starting". a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.
Display of check before starting When the screen changes to the check-beforestarting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of ending of maintenance interval". a If no abnormality is detected by the check before starting, the screen changes to "Display of check of working mode and travel speed". a The monitors (3 pieces) displayed on the screen are the items under the check before starting.
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Display of warning after check before starting If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the engine oil level monitor (a) is warning of low of engine oil level.
Display of ending of maintenance interval When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode. a After display of this screen is finished, the screen changes to "Display of check of working mode and travel speed".
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30 Testing and adjusting Special functions of machine monitor
Display of check of working mode and travel speed If the check before starting is finished normally, the screen to check the working mode and travel speed is displayed for 2 seconds. a After display of check of the working mode and travel speed is finished, the screen changes to "Display of ordinary screen".
Display of ordinary screen If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a ECO gauge (b) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).
30-62
Display of end screen When the starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.
Selection of auto-deceleration While the ordinary screen is displayed, if the autodeceleration switch is pressed, large auto-deceleration monitor (a) is displayed for 2 seconds and the setting of the auto-deceleration is changed. a Each time the auto-deceleration switch is pressed, the auto-deceleration is turned ON and OFF alternately. a If the auto-deceleration is turned ON, large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously. a If the auto-deceleration is turned OFF, autodeceleration monitor (b) goes off.
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30 Testing and adjusting Special functions of machine monitor
Selection of working mode Select a working mode according to the following procedure. 1. While the ordinary screen is displayed, press the working mode selector switch, and the working mode selection screen is displayed. a The following figure is the working mode selection screen displayed when "With attachment" is set (If "With attachment" is not set in the service mode, the attachment mode [ATT] is not displayed).
2.
Operate the function switches or working mode selector switch to select and confirm the working mode which you will use. Function switches q [F3]: Move to lower working mode q [F4]: Move to upper working mode q [F5]: Cancel selection and return to ordinary screen q [F6]: Confirm selection and return to ordinary screen Working mode selector switch q Press: Move to lower working mode q Hold down:Confirm selection and return to ordinary screen a If you do not touch any of the function switches and working mode selector switch for 5 seconds, the selection is confirmed and the screen changes to the ordinary screen.
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3.
When the ordinary screen is displayed again, large working mode monitor (a) is displayed for 2 seconds, and then the setting of the working mode is changed. a When large monitor (a) is displayed, the display of working mode monitor (b) is changed, too.
<Precautions for selecting breaker mode [B]> q If breaker mode [B] is selected, both of the control of the hydraulic pump and the setting of the hydraulic circuit are changed. q If an attachment other than the breaker is used, the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged.
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30 Testing and adjusting Special functions of machine monitor
Selection of travel speed While the ordinary screen is displayed, if the travel speed shifting switch is pressed, large travel speed monitor (a) is displayed for 2 seconds and the setting of the travel speed is changed. a Each time the travel speed shifting switch is pressed, the travel speed is changed to Lo, Hi, and Lo again in order. a When large monitor (a) is displayed, the display of travel speed monitor (b) is changed, too.
Operation to stop alarm buzzer While the alarm buzzer is sounding, if the alarm buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the alarm buzzer cancel switch is pressed, the screen does not change.
30-64
Operation of windshield wiper While the ordinary screen is displayed, if the wiper switch is pressed, large wiper monitor (a) is displayed for 2 seconds and the windshield wiper starts or stops. a Each time the wiper switch is pressed, the windshield wiper setting is changed to INT, ON, OFF, and INT again in order. a When large monitor (a) is displayed, the display of wiper monitor (b) is changed or turned OFF, too. a If the windshield wiper is turned OFF, large monitor (a) is not displayed.
Operation of window washer While the ordinary screen is displayed, if the window washer switch is pressed, the washing liquid is splashed only while the switch is held down. a Even if the window washer switch is pressed, the screen does not change.
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30 Testing and adjusting Special functions of machine monitor
Operation of air conditioner/heater While the ordinary screen is displayed, press the air conditioner switch and the air conditioner adjustment screen is displayed. a While the air conditioner adjustment screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the ordinary screen. a Air conditioner specification
Operation to display camera mode When [F3] is pressed, the multi-display changes to the camera image (Set the connection of the camera in the service mode).
a
a
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If a caution is generated in the camera mode, the caution monitor is displayed at the left upper of the screen (The low hydraulic oil temperature caution is not displayed there, however). When an error that there is a user code occurs in the camera mode, if you do not touch any control lever for 10 seconds, the screen changes to the ordinary screen and displays the error information.
30-65
30 Testing and adjusting Special functions of machine monitor
Operation to display clock and service meter While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function.
Check of maintenance information While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.
a
30-66
To reset the time left after finishing maintenance, more operations are necessary.
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30 Testing and adjusting Special functions of machine monitor
Setting and display of user mode (Including KOMTRAX messages for user) While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.
a
[KOMTRAX message] q There are 2 types of KOMTRAX message; 1 is for the user and the other is for the service. q For user: A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is displayed on the ordinary screen. To see the contents of the message, operate "User Message" in the above user menu. q For service: A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed on the ordinary screen. To see the contents of the message, operate "KOMTRAX message" display in the service menu.
There are following items in the user menu. Breaker/Attachment Settings User Message Screen Adjustment Clock Adjustment Language Economy Mode Adjustment
a
The breaker/attachment setting menu is displayed only when "With attachment" is set in the service mode.
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30 Testing and adjusting Special functions of machine monitor
Display of energy-saving guidance When the machine is set in a certain operating condition, the energy-saving guidance screen is displayed automatically to urge the operator to the energy-saving operation. a The energy-saving guidance is displayed when the following condition is satisfied while the display setting is set effective in the service mode. a Condition for display: Engine is running + All levers have been in neutral for 5 minutes + Caution (Note) or user code is not generated (Note) Note: Excluding hydraulic oil low temperature caution a If any lever or pedal is operated, or [F5] is pressed, the screen returns to the ordinary screen.
Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor flashes at the left upper of the screen when the caution is generated.
30-68
Display of user code and failure code If an abnormality which displays a user code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a): User code (3 digits) (b): Failure code (5 or 6 digits) (c): Telephone mark (d): Telephone No. a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the abnormality record in the service mode, check the details in the service mode.
a
When the caution monitor is also displayed, the telephone mark is not displayed.
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30 Testing and adjusting Special functions of machine monitor
a
Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual)
User code
Failure mode
Action
E02
Pump control system error
When emergency pump drive switch is at the up (emergency) position, normal operations become possible, but have inspection carried out immediately.
E03
Swing brake system error
Have inspection carried out immediately.
E10
Engine controller power source error Engine controller drive system circuit error Have inspection carried out immediately. (engine stopped)
E11
Engine controller system error Output reduced to protect engine
Operate machine to a safe posture and have inspection carried out immediately.
E14
Abnormality in throttle system
Operate machine to a safe posture and have inspection carried out immediately.
E15
Engine sensor (coolant temperature, fuel pressure, oil pressure) system error
Operations are possible, but have inspection carried out immediately.
E20
Abnormality in travel system
Operations are possible, but have inspection carried out immediately.
E0E
Network error
Operate machine to a safe posture and have inspection carried out immediately.
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30-69
30 Testing and adjusting Special functions of machine monitor
Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.
30-70
Function of checking service meter To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.
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30 Testing and adjusting Special functions of machine monitor
Function of changing attachment/maintenance password When changing the attachment/maintenance password used for the attachment setting function and maintenance setting function, follow these procedures. 1. While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [5] o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.
2.
After the Attachment/Maintenance PASSWORD screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.
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3.
After the New password input screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. a Set a new password of 4 – 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral
4.
After the New password input screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.
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30 Testing and adjusting Special functions of machine monitor
5.
If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully.
30-72
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30 Testing and adjusting Special functions of machine monitor
t
Service mode
To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1.
Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a This operation of the switches is accepted only while the ordinary screen is displayed.
a
The items which can be selected in the service menu are as follows (including some items which need special operations).
01 Monitoring Mechanical Systems 02 Abnormality Electrical Systems Record Air-conditioning System 03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Unit With/Without Attachment 06 Default
Attachment/Maintenance Password Camera ECO Display
07 Adjustment
Pump Absorption Torque Attachment Flow Adjustment
08 Cylinder Cut-Out 09 No Injection 10 Fuel Consumption Terminal Status
2.
Selection of service menu When the Service menu screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].
PC128US-8
11 KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300) MODEM IP Address (TH200/201)
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30 Testing and adjusting Special functions of machine monitor
Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1.
Selecting menu Select "Monitoring" on the service menu screen.
3.
2.
Selecting monitoring items After the "Monitoring selection menu screen" is displayed, select items to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Reset input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.
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Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
4.
Executing monitoring After the "Executing monitoring screen" is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be set to SI unit, metric unit, or inch unit with the Initialization function in the service mode.
5.
Holding monitoring information The monitoring information can be held and reset with the function switches. q [F3]: Reset holding q [F4]: Hold information (displayed data) q [F5]: Return to monitoring selection menu screen
PC128US-8
6.
Changing machine setting mode To change the setting of the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished.
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30 Testing and adjusting Special functions of machine monitor
Monitoring items table Unit (Initial setting: ISO) Code No.
Monitoring item (Display on screen)
ISO
meter
inch
rpm rpm psi psi psi psi psi psi psi °F °F mA mA V V V psi psi °F
Component in charge PUMP ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP ENG PUMP PUMP PUMP PUMP ENG MON ENG ENG ENG
psi
ENG
% % kgm lbft V V V V V V V V V V V V V V V V — % % % % % % mg/st mg/st mg/st MPa kg/cm2 psi CA CA CA l/h l/h gal/h % % % Nm kgm lbft MPa kg/cm2 psi ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF
ENG ENG ENG MON ENG PUMP ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP
00200 00201 01002 01601 01100 07102 07103 07104 07105 07106 07107 04107 04401 01300 01700 03200 03203 04300 36400 37400 18500
Controller model select Machine ID Engine speed 2nd eng. speed command Pump pressure Travel FW L PPC pressure Travel FW R PPC pressure Travel BW L PPC pressure Travel BW R PPC pressure Blade raise PPC pressure Blade lower PPC pressure Coolant temperature Hyd oil temperature PC-EPC sol current Attachment sol current Battery voltage Battery power supply Battery charge vol. Rail pressure Ambient pressure Charge temperature
r/min r/min MPa MPa MPa MPa MPa MPa MPa °C °C mA mA V V V MPa kPa °C
— — rpm rpm kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 °C °C mA mA V V V kg/cm2 kg/cm2 °C
36500
Charge pressure-abs
kPa
kg/cm2
36700 18700 03000 04200 04105 04402 37401 18501 36501 36401 17500 31701 31706 18600 36200 36300 37300 01602 13113 15900
Engine torque ratio Engine output torque Fuel dial pos sens volt Fuel level sensor volt Coolant temp sens volt Hyd temp sens volt Ambient press sens volt Charge temp sens volt Charge press sens volt Rail pressure sens volt Engine power mode Throttle position Final throttle position Inject fueling command Rail press command Injection timing command Fuel rate 2nd eng. speed command Main pump absorb torque Boom bottom pressure Swing Boom lower Pressure switch 1 Boom raise Arm curl Arm dump
% Nm V V V V V V V V
01900
30-76
Remarks
All items (including the ambient pressure) are indicated by absolute values.
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30 Testing and adjusting Special functions of machine monitor
Unit (Initial setting: ISO) Code No.
01901
02300
02200 02201 02202 02204 03701
04500
04501 04502
04503
04504
04505
04506 20216 20217 18900 20400 20227 20402
Monitoring item (Display on screen) Bucket curl Pressure switch 2 Bucket dump Attachment Travel junction Swing brake Solenoid valve 1 Merge-divide Travel speed Swing release sw Switch input 1 Swing brake sw Blade spec Switch input 2 Overload alarm Switch input 3 Key switch Window limit sw. Switch input 5 P limit sw. W limit sw. Controller output 2 Travel alarm Key switch Start Monitor input 1 Preheat Light Eng. oil level Monitor input 2 Battery charge Monitor input 3 Swing brake sw. F1 F2 F3 Monitor function switches F4 F5 F6 SW1 SW2 Monitor 1st & 2nd SW3 row switches SW4 SW5 SW6 SW7 SW8 Monitor 3rd & 4th SW9 row switches SW10 SW11 SW12 SW13 Monitor 5th row SW14 switches SW15 ECM build version ECM calibration data ver ECM internal temp ECM serial No Monitor ass'y P/N Monitor serial No
PC128US-8
ISO
°C
meter ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF — — °C — — —
inch
°F
Component in charge PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON ENG ENG ENG ENG MON MON
Remarks
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30 Testing and adjusting Special functions of machine monitor
Unit (Initial setting: ISO) Code No. 20228 20229 20403 20230
Monitoring item (Display on screen) Monitor prog. P/N Pump con ass'y P/N Pump con serial No Pump con. prog P/N
ISO
meter
inch
— — — —
Component in charge MON PUMP PUMP PUMP
Remarks
a
Monitoring code "00200" "00201" is not applied following serial number. q PC128US-8 : 25996 and up
a
Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen. Unit The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in Initialization of the service menu). "CA" in the display unit is an abbreviation for crankshaft angle. "mg/st" in the display unit is an abbreviation for milligram/stroke. Component in charge MON: The machine monitor is in charge of detection of monitoring information. ENG: The engine controller is in charge of detection of monitoring information. PUMP: The pump controller is in charge of detection of monitoring information.
a
a
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PC128US-8
30 Testing and adjusting Special functions of machine monitor
Abnormality Record (Mechanical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning system or heater system. To check the mechanical system abnormality record, perform the following procedures. 1.
Selecting menu Select "Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "Mechanical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heaterless specification.
PC128US-8
3.
Information displayed on "abnormality record" screen On the "Mechanical Systems" screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to abnormality record screen a If no abnormality record is recorded, "No abnormality record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table in "Abnormality Record (Electrical Systems)".
4.
Resetting abnormality record The contents of the mechanical system abnormality record cannot be reset.
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30 Testing and adjusting Special functions of machine monitor
Abnormality Record (Electrical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning system. To check the electrical system abnormality record, perform the following procedures. 1.
Selecting menu Select "Abnormality Record" on the "Service Menu" Screen. 3.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System", which may not be displayed in the heaterless specification.
30-80
Information displayed on "abnormality record" screen On the "Electrical Systems" screen, the following information is displayed. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65,535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "abnormality record" screen a If no abnormality record is recorded, "No abnormality record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the failure codes table.
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30 Testing and adjusting Special functions of machine monitor
4.
Resetting abnormality record 1) While the "Electrical Systems" screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3]
2)
Check that the screen is set in the reset mode, and then reset the items one by one or together with the function switches. a If the screen is set in the reset mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Reset all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to abnormality record screen q [F6]: Reset selected item a To reset items one by one: Select the item to be reset with [F3] or [F4] and press [F6]. a To reset all items together: Press [F2], and all the items are reset, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the resetting operation is accepted but the information is not reset.
PC128US-8
3)
After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to "Electrical systems" screen (Reset mode) q [F6]: Execute reset a The following figure shows the screen displayed when the items are reset one by one (which is a little different from the screen displayed when all the items are reset together).
4)
If the screen to notify completion of reset is displayed and then the "Electrical Systems" (reset mode) screen is displayed, the reset of the abnormality record is completed. a After a while, the screen returns to the "Electrical Systems" screen.
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30 Testing and adjusting Special functions of machine monitor
Failure codes table User code
Failure code
Trouble (Displayed on screen)
Alarm buzzer
989L00
Engine controller lock caution 1
989M00
Engine controller lock caution 2
989N00
Engine controller lock caution 3
AB00KE
Charge voltage low
B@BAZG
Eng oil press. low
B@BAZK
Eng oil level low
B@BCNS
Eng coolant overheat
e
B@HANS
Hydr oil overheat
e
e
E10
CA111
ECM critical internal failure
q
E10
CA115
Eng. Ne and Bkup speed sensor error
q
E11
CA122
Charge air press sensor high error
q
E11
CA123
Charge air press sensor low error
q
E14
CA131
Throttle sensor high error
q
E14
CA132
Throttle sensor low error
q
E15
CA144
Coolant temp. sensor high error
q
E15
CA145
Coolant temp. sensor low error
q
E15
CA153
Charge air temp. sensor high error
q
E15
CA154
Charge air temp. sensor low error
q
E15
CA187
Sensor sup. 2 volt. low error
q
E11
CA221
Ambient air press. sensor high error
q
E11
CA222
Ambient air press. sensor low error
q
E15
CA227
Sensor sup. 2 volt. high error
q
CA234
Eng. overspeed
E15
CA238
Ne speed sensor sup. volt. error
q
E10
CA271
IMV/PCV1 short error
q
E10
CA272
IMV/PCV1 open error
q
E11
CA322
Injector #1 (L #1) system open/short error
q
E11
CA324
Injector #3 (L #3) system open/short error
q
E11
CA331
Injector #2 (L #2) system open/short error
q
E11
CA332
Injector #4 (L #4) system open/short error
q
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Component Category of in charge record Electrical MON system Electrical MON system Electrical MON system Mechanical MON system Mechanical ENG system Mechanical MON system Mechanical ENG system Mechanical PUMP system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Mechanical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Alarm buzzer
User code
Failure code
E10
CA351
Inj. drive circuit error
q
E15
CA352
Sensor sup. 1 volt. low error
q
E15
CA386
Sensor sup. 1 volt. high error
q
E15
CA435
Abnormality in engine oil pressure switch
q
E10
CA441
Battery voltage low error
q
E10
CA442
Battery voltage high error
q
E11
CA449
Rail press. very high error
q
E11
CA451
Rail press. sensor high error
q
E11
CA452
Rail press. sensor low error
q
E15
CA553
Rail press. high error
q
E15
CA559
Rail press. low error
q
E15
CA689
Eng. Ne speed sensor error
q
E15
CA731
Eng. Bkup speed sensor phase error
q
E10
CA757
All persistent data lost error
q
E15
CA778
Eng. Bkup speed sensor error
q
E0E
CA1633
KOMNET datalink timeout error
q
E14
CA2185
Throttle sens. sup. volt. high error
q
E14
CA2186
Throttle sens. sup. volt. low error
q
E11
CA2249
Rail press. very low error
q
E11
CA2311
Abnormality in IMV solenoid
q
D110KB
Battery relay drive short
D19JKZ
Personal code relay abnormality
D862KA
GPS antenna discon
DA22KK
Pump solenoid power low error
DA25KP
5V sensor 1 power abnormality
DA26KP
5V sensor 2 power abnormality
DA2RMC
CAN discon (Pump con detected)
DAF8KB
Short circuit in camera power supply
DAFGMC
GPS module error
DAFRMC
CAN discon (Monitor detected)
E01
E0E
E0E
E0E
PC128US-8
Trouble (Displayed on screen)
q
q
q
q
Component Category of in charge record Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical PUMP system Electrical MON2 system Electrical MON2 system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical MON system Electrical MON2 system Electrical MON system
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30 Testing and adjusting Special functions of machine monitor
User code
Failure code
Trouble (Displayed on screen)
Alarm buzzer
DGH2KB
Hydr oil sensor short
DHPAMA
Pump press sensor abnormality
E20
DHSFMA
Travel left forward PPC press sensor abnormality
q
E20
DHSGMA
Travel right forward PPC press sensor abnormality
q
E20
DHSHMA
Travel left reverse PPC press sensor abnormality
q
E20
DHSJMA
Travel right reverse PPC press sensor abnormality
q
DHSKMA
Blade raise PPC press sensor abnormality
DHSLMA
Blade lower PPC press sensor abnormality
DHX1MA
Overload sensor abnormality (Analog)
DV20KB
Travel alarm S/C
DW43KA
Travel speed sol discon
DW43KB
Travel speed sol short
E03
DW45KA
Swing brake sol discon
q
E03
DW45KB
Swing brake sol short
q
DW91KA
Travel junction sol discon
DW91KB
Travel junction sol short
DWJ0KA
Merge-divider sol discon
DWJ0KB
Merge-divider sol short
E02
DXA8KA
PC-EPC sol discon
q
E02
DXA8KB
PC-EPC sol short
q
DXE4KA
Service current EPC discon
DXE4KB
Service current EPC short
DY20KA
Wiper working abnormality
DY20MA
Wiper parking abnormality
DY2CKA
Washer drive discon
DY2CKB
Washer drive short
DY2DKB
Wiper drive (for) short
DY2EKB
Wiper drive (rev) short
30-84
Component Category of in charge record Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system
PC128US-8
30 Testing and adjusting Special functions of machine monitor
a a
a
a
a
Entry order of items in table The items are entered in the order of their failure codes (incremental order). User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the abnormality. Alarm buzzer q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). e: Since the caution monitor is also turned ON, its function sounds the buzzer. Component in charge MON: The machine monitor is in charge of detection of abnormality. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. ENG: The engine controller is in charge of detection of abnormality. PUMP: The pump controller is in charge of detection of abnormality. Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record.
PC128US-8
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30 Testing and adjusting Special functions of machine monitor
Abnormality Record (Air-conditioning System) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems, electrical systems, and air-conditioning abnormalities. To check the air-conditioning abnormality record or heater abnormality record, perform the following procedures. 1.
Selecting menu Select "Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "Air-conditioning System" or "Heater System" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].
30-86
3.
Information displayed on "abnormality record" screen On the "Air-conditioning System" screen, the following information is displayed. (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) q [F2]: Reset abnormality record q [F5]: Return to abnormality record screen If [E] is displayed on the left of a condition, the abnormality is still occurring or resetting of it has not been confirmed. If CAN disconnection is displayed in Communication condition, communication cannot be carried out normally. Accordingly, the conditions of other items are turned OFF.
4.
Resetting abnormality record While the "abnormality record" screen is displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
a
Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section.
1.
01 Engine oil change 02 Engine oil filter change 03 Fuel main filter change 41 Fuel pre-filter change 04 Hydraulic oil filter change 05 Hydraulic tank breather change 06 Corrosion resistor change 07 Damper case service 08 Final drive case oil change 09 Machinery case oil change 10 Hydraulic oil change
Selecting menu Select "Maintenance Record" on the "Service Menu" screen.
3.
2.
The following items can be selected in the maintenance record.
Items displayed on maintenance record screen The following items are displayed. (a) : Maintenance items (b) : Number of times of replacement up to now (c) : Service meter reading (SMR) at previous replacement
Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.
PC128US-8
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30 Testing and adjusting Special functions of machine monitor
a
Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set replacement interval (by items) q Initialize all set replacement intervals 1.
00 Maintenance mode on/off 01 Engine oil change int. 02 Engine oil filter change int. 03 Fuel main filter change int. 41 Fuel pre filter change int. 04 Hyd oil filter change int. 05 Hyd tank breather change int. 06 Corrosion resistor change int. 07 Damper case service int. 08 Final drive case oil change int. 09 Machinery case change int. 10 Hydraulic oil change int. 99 Initialize all items
Selecting menu Select of "Maintenance Mode Change" on the "Service Menu" screen.
3.
2.
Selecting sub menu After the "Maintenance Mode Change" screen is displayed, select an item to change the setting with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].
30-88
The following items can be selected on the Change of maintenance mode screen.
Contents of setting of Maintenance mode on/ off After selecting "Maintenance Mode On/Off", if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode change screen q [F6]: Confirm selection and return to Maintenance mode change screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
4.
Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches. q Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). q Set value: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 50 hours). q ON: Maintenance function of this item is set effective in operator mode. q OFF: Maintenance function of this item is set ineffective in operator mode. q [F3]: Select Reduce set value (Upper) or OFF (Lower). q [F4]: Select Increase set value (Upper) or ON (Lower). q [F5]: Cancel setting before confirmation and return to Maintenance mode change screen. q [F6]: Confirm setting of upper or lower line. a After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode change screen with [F5], the setting is effective. a If the set value of an item set to "ON" is changed after 1 or more operating hours since the start of setting, the change is recognized as a resetting operation.
PC128US-8
5.
Function of initializing all items After selecting "All Default Value", if the screen is displayed, set with the function switches. q If this operation is executed, the set values of all the maintenance items are initialized. q [F5]: Return to Maintenance mode change screen q [F6]: Execute initialization a A while after [F6] is pressed, the initialization completion screen is displayed. Then, if the "Maintenance Mode Change" screen is displayed, initialization is completed.
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30 Testing and adjusting Special functions of machine monitor
Phone Number Entry The telephone No. displayed when the user code/ failure code is displayed in the operator mode can be input and changed according to the following procedure. If a telephone No. is not input with this function, no telephone No. is displayed in the operator mode. 1.
Selecting menu Select "Phone Number Entry" on the "Service Menu" screen.
2.
Registering and changing telephone No. After the "Phone Number Entry" screen is displayed, register or change the telephone No. q [F2]: Reset all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Reset input digit/Return to service menu q [F6]: Confirm input
a a
30-90
a
If [F6] is pressed without inputting a digit, there is not information of telephone No. Accordingly, no telephone No. is displayed in the operator mode.
Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (orange background) and overwrite it with the correct digit.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Default (Key-on Mode) Check or change various settings related to the machine monitor and machine by "Default". The function of working mode with key ON is used to set the working mode displayed on the machine monitor when the starting switch is turned ON.
q
1.
q
Selecting menu Select "Default" on the "Service Menu" screen.
q q q
a a a
a
2.
Selecting sub menu After the "Default" screen is displayed, select "Key-on Mode" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set with the function switches. q Power Mode: [P] is displayed when key is ON q Economy Mode: [E] is displayed when key is ON q Lifting Mode: [L] is displayed when key is ON q Breaker Mode: [B] is displayed when key is ON q Attachment Mode: [ATT] is displayed when key is ON
PC128US-8
Mode at Previous Key-off: Final mode in previous operation is displayed when key is ON [F3]: Move to lower item [F4]: Move to upper item [F5]: Cancel selection and return to "Default" screen [F6]: Confirm selection and return to "Default" screen When the machine is delivered, Mode at previous key-OFF is set. If "With attachment" is not set, the attachment mode cannot be selected. While Attachment mode [ATT] is selected, if "Without attachment" is set, Power mode [P] is displayed when the key is turned ON. If the engine is stopped while breaker mode [B] is selected in the operator mode, Breaker mode [B] is always displayed, regardless of the above setting.
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30 Testing and adjusting Special functions of machine monitor
Default (Unit) Check or change various settings related to the machine monitor and machine by "Default". The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1.
Selecting menu Select "Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "Unit" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting unit After the "Unit" screen is displayed, select the unit to be set with the function switches. q [F3]: Move to lower unit q [F4]: Move to upper unit q [F5]: Cancel selection and return to "Default" screen q [F6]: Confirm selection and return to "Default" screen
30-92
a
When the machine is delivered, the SI unit system is set.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Default (With/Without Attachment) Check or change various settings related to the machine monitor and machine by "Default". The "With/Without attachment" function is used to set an installed or a remove attachment. 1.
Selecting menu Select "Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "With/Without Attachment" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting With/Without After the "With/Without Attachment" screen is displayed, select the setting with the function switches. q Without Attachment: When attachment is not installed q With Attachment: When attachment is installed q [F3] : Move to lower item q [F4] : Move to upper item q [F5] : Cancel selection and return to Default screen q [F6] : Confirm selection and return to Default screen
PC128US-8
a
When an attachment is installed, if this setting is not carried out normally, the attachment cannot be set in the operator mode. As a result, the attachment may not work normally or the hydraulic components may have trouble.
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30 Testing and adjusting Special functions of machine monitor
Default (Attachment/Maintenance Password) Check or change various settings related to the machine monitor and machine by "Default". The function of setting attachment/maintenance password is used to set the display of the password screen when the functions related to the attachment and maintenance are used in the operator mode. 1.
Selecting menu Select "Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "Attachment/Maintenance Password" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
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3.
Selecting Disable/Enable After the Attachment/Maintenance Password screen is displayed, select the setting with the function switches. q Disable : Password screen is not displayed q Enable : Password screen is displayed q [F3] : Move to lower item q [F4] : Move to upper item q [F5] : Cancel selection and return to "Default" screen q [F6] : Confirm selection and return to "Default" screen
4.
Displaying attachment/maintenance password screen When the following operation is performed, the password screen is displayed in the operator mode. q Maintenance mode: The Maintenance table screen is changed to the Maintenance interval reset screen. q User mode: On the User menu screen, the Breaker/Attachment setting menu is selected and the screen is changed to the Attachment setting menu screen.
5.
Changing attachment/maintenance password The password can be changed by operating the switches specially in the operator mode. a See Attachment/Maintenance password changing function in the operator mode. a Default password: [000000] a If the password setting is changed from Enable to Disable, the password is reset to the default. When Enable is set again, be sure to set a new password. a The attachment/maintenance password is different from the engine start lock password.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Default (Camera) a Serial number: 20001 - 26415 Check or change various settings related to the machine monitor and machine by "Default". The camera setting function is used to set installation and removal of a camera. 1.
Selecting menu Select "Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "Ca mer a" with the fu ncti on s witc hes or numeral input switches. a Select this item similarly to an item on the "Service Menu" Screen.
PC128US-8
3.
Selecting camera setting After the "Camera" setting screen is displayed, select the setting with the function switches. q OFF: Camera is not used q Original Image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse Image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to "Default" screen q [F6]: Confirm selection in each line a After "Camera" screen is displayed, camera 1 can be always set. a After confirming the setting of each line with [F6], return to the "Default" screen with [F5], and the setting is effective. a If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a When a camera is installed, check that the displayed image is not inverted horizontally.
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30 Testing and adjusting Special functions of machine monitor
a Serial number: 26416 and up Check or change various settings related to the machine monitor and machine by "Default". The camera setting function is used to set installation and removal of a camera. 1.
Selecting menu Select "Default" on the "Service Menu" screen.
4.
2.
Selecting sub menu After the "Default" screen is displayed, select "Ca mer a" with the fu ncti on switc hes or numeral input switches. a Select this item similarly to an item on the "Service Menu" Screen.
3.
Selecting no camera or aspect ratio After "Camera setting" screen is displayed, select a setting with the corresponding function switch. q Without Camera : Return to initialization screen q Aspect Ratio 4:3 : Go to next screen q Aspect Ratio 16:9 : Go to next screen
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Selecting camera setting After the "Camera" setting screen is displayed, select the setting with the function switches. q OFF: Camera is not used q Original Image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse Image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to "Default" screen q [F6]: Confirm selection in each line a After "Camera" screen is displayed, camera 1 can be always set. a After confirming the setting of each line with [F6], return to the "Default" screen with [F5], and the setting is effective. a If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a When a camera is installed, check that the displayed image is not inverted horizontally.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Default (ECO Display) Check or change various settings related to the machine monitor and machine by "Default". The ECO display setting function is used to set the display of the ECO gauge and energy saving guidance. 1.
2.
3.
a
If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen. Even if the energy saving guidance is turned ON, however, it is not displayed if the condition for display is not satisfied on the ordinary screen.
a
Display of ECO gauge (a)
a
Display of energy saving guidance
Selecting menu Select "Default" on the "Service Menu" screen.
Selecting sub menu After the "Default" screen is displayed, select "ECO Display" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
Selecting display setting After the "ECO Display" screen is displayed, select the setting with the function switches. q ON : Display ECO q OFF: Do not display ECO q [F3] : Move to left item q [F4] : Move to right item q [F5] : Cancel setting before confirmation and return to "Default" screen q [F6] : Confirm selection in each line a After confirming the setting of the upper and lower lines with [F6], return to the "Default" screen with [F5], and the setting is effective.
PC128US-8
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30 Testing and adjusting Special functions of machine monitor
Adjustment (Pump Absorption Torque) The operator can adjust various items related to the machine with the machine monitor. The pump absorption torque function is used to finely adjust the absorption torque on the hydraulic pump. 1.
Selecting menu Select "Adjustment" on the "Service Menu" screen.
2.
Selecting sub menu After the "Adjustment" screen is displayed, select "Pump Absorption Torque" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting absorption torque After the "Pump Absorption Torque" screen is displayed, select a set value on the right side with the function switches. q Set value: For actual torque adjustment value, see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.
a
Relationship between set value torque adjustment value Code
022
30-98
Set value 000 001 002 003 004 005 006 007 008
and
Torque adjustment value +39.2 Nm {+4 kgm} +29.4 Nm {+3 kgm} +19.6 Nm {+2 kgm} +9.8 Nm {+1 kgm} 0 Nm {0 kgm} –9.8 Nm {–1 kgm} –19.6 Nm {–2 kgm} –29.4 Nm {–3 kgm} –39.2 Nm {–4 kgm}
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Adjustment (Attachment Flow Adjustment) The operator can adjust various items related to the machine with the machine monitor. The function of "Attachment Flow Adjustment" is used to finely adjust the oil flow to the attachment in compound operation. 1. Selecting menu Select "Adjustment" on the "Service Menu" screen.
2.
Selecting sub menu After the "Adjustment" screen is displayed, select "Attachment Flow Adjustment" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3.
Selecting distribution of oil flow After the screen of "Attachment Flow Adjustment" is displayed, select a set value on the right side with the function switches. q Set value: For actual distribution of flow, see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.
a
Relationship between set value and distribution of flow to attachment Code
037
PC128US-8
Set value 000 001 002 003
Distribution of flow to attachment 50 % 70 % 100 % 40 %
30-99
30 Testing and adjusting Special functions of machine monitor
Cylinder Cut-Out The operator can perform "Cylinder Cut-Out" operation with the machine monitor. "Cylinder Cut-Out" operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1.
2.
Selecting menu Select "Cylinder Cut-Out" on the "Service Menu" screen.
Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be Cut-Out with the function switches. q [F1]: Move selection mark (R) to left q [F2]: Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to service menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is Cut-Out. a If the machine monitor Cut-Out a cylinder but the engine controller cannot Cut-Out that cylinder, the background (a) of the cylinder No. becomes yellow. a One or more cylinders can be Cut-Out. a In the cylinder Cut-Out operation, the auto-deceleration function can be selected. If the auto-deceleration is turned ON, auto-deceleration monitor (b) is displayed.
30-100
3.
Resetting Cut-Out cylinder When changing a cylinder to be Cut-Out or when Cylinder Cut-Out operation is finished, select a Cut-Out cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset. a If the machine monitor resets a Cut-Out cylinder but the engine controller cannot reset that Cut-Out cylinder, the background (a) of the cylinder No. becomes red. a The Cut-Out operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the cylinder cut-out operation is finished.
4.
Function of holding displayed information If [F4] is pressed during the cylinder Cut-Out operation, the displayed information is newly held (c) (The real-time information is kept displayed on the left side). While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the reduced cylinder mode operation.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
[Reference] q If a normally operating cylinder is Cut-Out, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.
PC128US-8
No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the no-injection cranking while the engine is stopped. 1.
Selecting menu Select "No Injection" on the "Service Menu" screen.
2.
Displaying check screen If the "No injection" screen is displayed, the machine monitor asks the operator if no injection cranking should be performed. Answer with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform a While the screen is changing to the following screen, the screen of "Communication between controllers is being checked" is displayed.
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30 Testing and adjusting Special functions of machine monitor
3.
Starting no injection cranking If no injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of "Setting is being prepared" is displayed. a Limit the cranking time to 20 seconds to protect the starting motor.
4.
Finishing no injection cranking After completing the no injection cranking operation, press [F6], and finish of no injection cranking is displayed and the screen returns to the "Service Menu" screen automatically.
30-102
5.
Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running, the message that the engine is running is displayed and the no injection cranking is not set effective. a This function can be selected even while the engine is running. If the no injection cranking is performed, however, the message of "Engine is running" is displayed on the screen.
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Fuel Consumption This function calculates the hourly fuel consumption from the actual fuel consumption in a testing period and indicates it. 1. Selecting menu Select "Fuel Consumption" on the "Service Menu" screen.
2.
Starting test After the screen of "Fuel Consumption" is displayed, start test with the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to Service menu screen a When the screen of Fuel consumption is displayed, if a data is indicated, it is the data of the previous test. This data is not an obstacle to new test and can be reset by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and test starts.
a
3.
Display and function during test Clock mark (a) flashes during test. a While the fuel consumption is being tested, the operator can work with the operator mode and other functions. Test is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is tested only while the engine is running).
4.
Finishing test Press [F1], and test is finished and the data are displayed on the finishing date and time side.
5.
Displaying fuel consumption If the test is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.
The display unit of the fuel changes according to the unit set with the default (unit setting) function. SI and meter: l/h inch: gal/h
PC128US-8
30-103
30 Testing and adjusting Special functions of machine monitor
KOMTRAX Settings (Terminal Status) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX setting. Setting condition of terminal is used to check the setting condition of the KOMTRAX terminal. 1.
Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Terminal Status" with the function switches or numeral input switches. a Select this item similarly to an item on the Service menu screen. a The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is displayed.
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3.
Contents of display of terminal status On the "Terminal Status" screen, the following items are displayed. q Terminal type: Model name of KOMTRAX communication MODEM q KOMTRAX communication: Executing condition of station opening inspection q GMT time: Greenwich Meant Time q [F5]: Return to KOMTRAX settings screen
PC128US-8
30 Testing and adjusting Special functions of machine monitor
KOMTRAX Settings (GPS & Communication Status) The setting condition and operating condition of KOMTRAX can be checked with "KOMTRAX Settings". GPS & communication status is used to check the condition of positioning and communication of the KOMTRAX terminal. 1.
Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select GPS & communication status with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen. a The following figure shows the display when Model TH300 KOMTRAX is installed. When TH200 is installed, "03 IP Adress" is displayed.
PC128US-8
3.
Contents of display of GPS & communication status On the screen of "GPS & Communication Status", the following items are displayed. q Positioning: Positioning condition of GPS q Communication: Communication environment of communication MODEM and connecting condi tion of c ommunication MODEM q Number of message not yet sent: Number of mails which are saved in machine monitor and not transmitted yet q [F5]: Return to KOMTRAX settings screen
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30 Testing and adjusting Special functions of machine monitor
KOMTRAX Setting (MODEM S/N: TH300) The setting condition and operating condition of K O MTRA X c an be c hec k ed wi th Di sp lay of KOMTRAX setting. MODEM S/N is used to check the serial No. of the KOMTRAX communication MODEM. 1.
Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
30-106
3.
Contents of display of Modem S/N The serial No. of TH300 Modem is displayed. q [F5]: Return to KOMTRAX settings screen
PC128US-8
30 Testing and adjusting Special functions of machine monitor
Display of KOMTRAX message Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this function. If there is setting in a message, a return mail can be sent by using numeral input switches. 1.
Operation to display menu Select "Service message" on the service menu screen.
2.
Display of message (Read-only) If there is a message, its contents are displayed. If there is not a message, "No message" is displayed. q [F5]: Return to service menu screen a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
PC128US-8
3.
Display of message (with return mail function) If a box to enter a value with the numeral keys is displayed under the message, enter a proper number with the numeral input switches and function switches and confirm it, and the information is returned to the KOMTRAX base station. q [F5]: Return to service menu screen q [F6]: Confirm and return input value a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
30-107
30 Testing and adjusting Handling voltage circuit of engine controller
Handling voltage circuit of engine controller 1 1.
Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF.
2.
If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
30-108
PC128US-8
30 Testing and adjusting Preparation work for troubleshooting of electrical system
Preparation work for troubleshooting of electrical system a
a
1.
3)
1
When carrying out troubleshooting of an electric circuit related to the machine monitor, e n g i n e c o n t r o l l e r, p u m p c o n t r o l l e r, o r KOMTRAX communication MODEM, expose the related connectors according to the following procedure. Disconnect and connect the connectors having special locking mechanisms according to the procedure shown below. Machine monitor 1) Remove 2 mounting bolts and cover (1). a One of the mounting bolts is installed in the cover on the right of the daylight sensor. a While removing the mounting bolts, disconnect connector P31 of the daylight sensor. a The following figure shows the model of the arm crane specification equipped with a level.
2)
2.
Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM03 of machine monitor (4). a Connectors CM02 and CM03 are of the same type. When returning them, check the mark plates of the mounting brackets and take care not to make a wrong connection.
Engine controller 1) Open the engine hood. a The engine controller is mounted on the cooling frame (on the counterweight side). 2) Insert or connect troubleshooting T-adapters in or to connectors CE01, CE02, and CE03 of engine controller (5). a Connectors CE01 and CE02 are fixed with screws. When disconnecting them, loosen the screws. a When returning connectors CE01 and CE02, tighten the screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
Remove 1 mounting bolt and duct (3).
PC128US-8
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30 Testing and adjusting Preparation work for troubleshooting of electrical system
3.
Pump controller 1) Slide the operator's seat and seat stand to the forward end.
2)
Connect the troubleshooting adapters to connectors C01 and C02 of pump controller (12). a Install the adapters to only the wiring harness side.
a
30-110
The pump controller connector has a special locking mechanism. Disconnect it according to procedures (a) – ( c ) s ho wn be lo w a nd c on ne ct i t according to procedures (d) – (f). Disconnection: (a) Unlock – (b) Slide lever – (c) Disconnect connector. Connection: (d) Position connector – (e) Slide lever – (f) Lock.
PC128US-8
30 Testing and adjusting Preparation work for troubleshooting of electrical system
4.
KOMTRAX communication module 1) Slide the operator's seat and seat stand to the forward end.
2)
5.
Engine Ne speed sensor (Crank sensor) Engine Bkup speed sensor (Cam sensor) Engine oil pressure switch (Oil pressure switch) a Disconnection and connection of connectors The connectors of the engine Ne speed s ens or, eng ine Bku p sp eed s ens or, engine oil pressure switch have a special locking mechanism. Disconnect them according to steps (a) – (c) and connect them according to steps (d) – (f) as shown below. Disconnection: (a) Slide lever – (b) Unlock – (c) Disconnect connector. Connection: (d) Connect connector – (e) Lock – (f) Slide lever.
a
PC128US-8
Connect troubleshooting T-adapters to connectors CK01 and CK02 of KOMTRAX communication module (13). a Cable (14) is for the communication antenna.
Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. See "Tools for testing, adjusting, and troubleshooting".
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30 Testing and adjusting Preparation work for troubleshooting of electrical system
6.
Boost pressure and temperature sensor (Boost press & IMT) a Disconnection and connection of connector The connector of the boost pressure and temperature sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
7.
Supply pump IMV solenoid (Fuel regulator) a Disconnection and connection of connector The connector of the supply pump IMV solenoid has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
a a
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Removal and installation of sensor A torque wrench is necessary for removal and installation of the boost pressure and temperature sensor. See "Tools for testing, adjusting, and troubleshooting".
Precautions for disconnecting connector The direction of the lock of the connector varies with the tightened position of the sensor and the lock may be in a direction in which it is difficult to reset (on the underside or engine side). In this case, pinch the lock in direction (a) with bent-nose nippers [1] (commercially available), and the lock is reset. Since the lock clicks when it is reset, disconnect the connector after a click is heard.
PC128US-8
30 Testing and adjusting Preparation work for troubleshooting of electrical system
a
8.
Precautions for connecting connector Take care not to connect the connector reversely. Engage lock (e) on the wiring harness side with triangular notch (f) on the sensor side (Do not engage lock (e) with square guide (g) on the opposite side of triangular notch (f)).
Common rail pressure sensor (Fuel rail press) a Disconnection and connection of connector The connector of the common rail pressure sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
PC128US-8
9.
Engine coolant temperature sensor (Coolant temp) a Disconnection and connection of connector The connector of the engine coolant temperature sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
a
Removal and installation of sensor A deep socket is necessary for removal and installation of the engine coolant temperature sensor. See "Tools for testing, adjusting, and troubleshooting".
30-113
30 Testing and adjusting Procedure for testing diodes
Procedure for testing diodes a a
1
Test the assembled-type diode (8-pin) and the single diode (2-pin) according to the following procedure. The conductive directions of the assembledtype diode are as follows.
2.
a
The conductive direction of the single diode is indicated on the surface of the diode.
1.
When using digital circuit tester 1) Set the tester in the diode range and check the indicated value. a When an ordinary circuit tester is used, the voltage of the internal battery is indicated. 2) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode (N) side and check the indicated value. 3) Judge the condition of the diode by the indicated value. q The indicated value does not change: The diode does not have conductivity (Defective). q The indicated value changes: The diode has conductivity (Normal). Note: In the case of a silicon diode, a value in the range from 460 to 600 is indicated.
30-114
When using analog circuit tester 1) Set the tester in the resistance range. 2) Apply the leads of the tester as explained below and check the movement of the pointer. i) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode (N) side. ii) Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (–) lead to the anode (P) side. 3) Judge the condition of the diode by the movement of the pointer. q The pointer does not move in i) but moves in ii): The diode is normal (The moving range (resistance) depends on the type and selected range of the tester, however). q The pointer moves in both i) and ii): The diode is defective (Internal short circuit). q The pointer moves in neither of i) and ii): The diode is defective (Internal disconnection).
PC128US-8
30 Testing and adjusting Pm Clinic service
Pm-Clinic
1
Pm Clinic service
1
Model name
Serial No.
Service meter
T PC128US-8
h
User's name
Date of execution /
Inspector
/
Specifications Main components Boom Arm Bucket
T Standard T ( T Standard T ( T Standard T (
Attachments ) ) )
Shoe width
T Breaker T( T(
) )
T 500 mm T 600 mm T 700 mm
T(
)
Check of oil/coolant level T Radiator coolant T Engine oil T Hydraulic oil
When necessary T Damper case oil T Final drive case oil
T Machinery case oil T(
Ambient temperature
)
Altitude
°C
m Operator's opinion
Result of visual inspection
Mechanical equipment system fault history 989EKX
times/1st time
h/last
Electrical equipment system fault history h
times/1st time
h/last
h
AB00KE
times/1st time
h/last
h
times/1st time
h/last
h
B@BAZG
times/1st time
h/last
h
times/1st time
h/last
h
B@BAZK
times/1st time
h/last
h
times/1st time
h/last
h
B@BCNS
times/1st time
h/last
h
times/1st time
h/last
h
B@HANS
times/1st time
h/last
h
times/1st time
h/last
h
CA234
times/1st time
h/last
h
times/1st time
h/last
h
Max. range of engine coolant temperature gauge
PC128US-8
Max. range of hydraulic oil temperature gauge
30-115
30 Testing and adjusting Pm Clinic service
Check sheet Model
Serial No.
Service meter
User's name
Date of execution /
Check item
1
Engine speed
2
Engine oil pressure
3
Engine speed
Work- Autoing decelmode eration
Operation of work equipment
MAX
All levers in neutral P
OFF
Unit
Standard value for new machine
rpm
2,090 – 2,210 2,090 – 2,210
MPa {kg/cm2} rpm
MIN
All levers in neutral
Min. 0.10 {Min. 1.0}
0.07 {0.7}
Boom RAISE
2
Arm IN
3
Arm OUT
4
Bucket CURL
Working mode
Unit
Standard value for new machine
Service limit value
sec
3.5 – 4.1
Max. 4.4
sec
2.9 – 3.5
Max. 4.0
sec
2.4 – 3.0
Max. 3.7
Boom top horizontal Arm cylinder retracted fully
sec
2.6 – 3.2
Max. 3.7
sec
25.3 – 29.3
23.3 – 31.3
LO STD
sec
Max. 39.5
Max. 49
HI STD
sec
Max. 22.3
Max. 27
Unit
Standard value for new machine
Service limit value
mm/ 15 min
Max. 310
Max. 460
Checking posture, etc. Work equipment extended fully Boom top horizontal
MAX
P
5
Swing (5 turns)
Work equipment extended fully Swing right and left
6
Travel (5 idle turns)
One side of track pushed up and turned forward and backward
Measured value
Bad
1
Fuel control dial
Measured value
Bad
Check item
Hydraulic drift of work equipment Checking condition
1
1,050 – 1,150 1,050 – 1,150
Work equipment speed
No.
No.
Measured value
0.25 {2.5}
MPa {kg/cm2}
Checking condition
3.
0.34 – 0.59 {3.47 – 6.02}
Service limit value
Good
2.
Engine oil pressure
Fuel control dial
Bad
No.
Good
Engine Checking condition
4
/
Good
1.
Inspector
Check item
Fuel control dial
Working mode
Hydraulic drift of Engine stopped bucket tip
30-116
Checking posture, etc. Boom top horizontal Arm cylinder retracted fully Bucket loaded
PC128US-8
30 Testing and adjusting Pm Clinic service
[3]
[4]
[5]
No.
Checked part
Fuel control dial
Working mode
600K
600K
600K
600K
60K
Operation of work equipment
Pump main 1
Pump main 2
Pump LS 1
Pump LS 2
Control
—
—
—
—
—
—
1
Self pressure reducing valve
All lever in neutral
2
Main relief valve
Arm out relief
3
Unload valve
4
5
6
All levers in neutral Right track driven idle Lever moved halfway
LS valve
Swing motor safety valve
B
C1
C1
D1
Left track driven idle Lever moved halfway MAX
Main relief valve Travel motor Safety valve Travel junction valve
E
Swing lock Left swing relief
E
E
Right travel lock Right forward relief
F
Right travel lock Right reverse relief
F
Left travel lock Left forward relief
—
Left travel lock Left reverse relief
—
— D2
— —
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
F F
Service limit value
3.0 – 3.4 {31 – 35}
2.7 – 3.7 {28 – 35}
33.8 – 35.8 {345 – 365}
33.8 – 36.8 {345 – 375}
1.8 – 3.8 {18 – 38}
1.8 – 3.8 {18 – 38}
B (Work equipment relief pressure) MPa {kg/cm2}
D (LS differential pressure)
— —
D2
—
A
Standard value for new machine
A (Control circuit basic pressure)
C (Unload pressure)
C2
D1
— E
Unit
C2
—
Swing lock Right swing relief
P
Checked oil pressure Standard value
B
Bad
[2]
Good
[1]
Checking condition
Bad
Hydraulic circuit
Good
4.
2.1 – 2.3 {21.5 – 23.5}
2.1 – 2.3 {21.5 – 23.5}
E (Swing relief pressure)
28.2 – 30.2 {288 – 308}
26.7 – 30.7 {273 – 313}
F (Travel relief pressure)
33.8 – 35.8 {345 – 365}
32.8 – 36.8 {335 – 375}
* Gauge changing work: Change hoses of gauges [3] and [4]. Checking condition No.
Standard value
7
Check item
Servo piston
Fuel control dial
Working mode
Operation of work equipment
MAX
P
Arm out relief
Checked oil pressure
Unit
H (Servo control pressure)
—
PC128US-8
[1]
[2]
[3a]
[4a]
[5]
600K
600K
600K
600K
60K
F pump main
R pump main
F pump servo
R pump servo
Control
H1
H1
H2
H2
Standard value for new machine
—
Service limit value
H1 : H2 = 1 : 0.6 (Oil pressure ratio)
30-117
30 Testing and adjusting Pm Clinic service
[2]
[3b]
[4b]
[5a]
No.
Check item
Fuel control dial
600K
600K
60K
60K
60K
F pump main
R pump main
F pump (F)
R pump (R)
LS-EPC
—
—
J1
J1
—
—
J2
J2
—
—
J3
J3
L
—
—
J4
J4
B
—
—
J5
J5
Working mode
Operation of work equipment
MIN P
8
PC-EPC valve
E
All levers in neutral
MAX
Standard value
Checked oil pressure
Unit
J1 (PC-EPC valve output pressure 1)
— — — —
Service limit value
Approx. 0.3 {Approx. 3} MPa {kg/cm2}
Approx. 0.5 {Approx. 5}
J4 (PC-EPC valve output pressure 4)
Approx. 0.4 {Approx. 5}
J5 (PC-EPC valve output pressure 5)
Approx. 0.4 {Approx. 5}
30-118
—
Approx. 1.7 {Approx. 18}
J2 (PC-EPC valve output pressure 2) J3 (PC-EPC valve output pressure 3)
Standard value for new machine
Bad
[1]
Checking condition
Good
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
PC128US-8
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
40 Troubleshooting
1
PC128US-8
40-1
40 Troubleshooting
Contents Related information on troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-6
Points to remember when performing troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-6
How to proceed in troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-8
Checks before troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-10
Classification and procedures for troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-11
Information in troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-12
Phenomena looking like troubles and troubleshooting Nos.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-14
Connection table of connector by No. of pins - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-17
T-box and T-adapter list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-54
Failure code table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-58
Fuse locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-62
Troubleshooting by failure code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-64
Failure code [989L00] Engine controller lock caution 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-64
Failure code [989M00] Engine controller lock caution 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-64
Failure code [989N00] Engine controller lock caution 3- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-65
Failure code [AB00KE] Charge voltage low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-66
Failure code [B@BAZG] Eng oil press. low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-68
Failure code [B@BAZK] Eng oil level low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-68
Failure code [B@BCNS] Eng coolant overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-69
Failure code [B@HANS] Hydr oil overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-69
Failure code [CA111] ECM critical internal failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-70
Failure code [CA115] Eng. Ne and Bkup speed sensor error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-73
Failure code [CA122] Charge air press sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-74
Failure code [CA123] Charge air press sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-76
Failure code [CA131] Throttle sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-78
Failure code [CA132] Throttle sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-80
Failure code [CA144] Coolant temp. sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-81
Failure code [CA145] Coolant temp. sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-82
Failure code [CA153] Charge air temp. sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-83
Failure code [CA154] Charge air temp. sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-84
Failure code [CA187] Sensor sup. 2 volt. low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-85
Failure code [CA221] Ambient air press. sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-86
Failure code [CA222] Ambient air press. sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-88
Failure code [CA227] Sensor sup. 2 volt. high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-90
Failure code [CA234] Eng. overspeed- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-91
Failure code [CA238] Ne speed sensor sup. volt. error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-92
Failure code [CA271] IMV/PCV1 short error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-94
Failure code [CA272] IMV/PCV1 open error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-95
Failure code [CA322] Injector #1 (L #1) system open/short error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-96
Failure code [CA324] Injector #3 (L #3) system open/short error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
40-98
Failure code [CA331] Injector #2 (L #2) system open/short error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-100 Failure code [CA332] Injector #4 (L #4) system open/short error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-102 Failure code [CA351] Inj. drive circuit error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-104 Failure code [CA352] Sensor sup. 1 volt. low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-107 Failure code [CA386] Sensor sup. 1 volt. high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-108 Failure code [CA435] Abnormality in engine oil pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-110 Failure code [CA441] Battery voltage low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-111 Failure code [CA442] Battery voltage high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-111
40-2
PC128US-8
40 Troubleshooting
Failure code [CA449] Rail press. very high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-112 Failure code [CA451] Rail press. sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-114 Failure code [CA452] Rail press. sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-116 Failure code [CA553] Rail press. high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-116 Failure code [CA559] Rail press. low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-117 Failure code [CA689] Eng. Ne speed sensor error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-120 Failure code [CA731] Eng. Bkup speed sensor phase error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-122 Failure code [CA757] All persistent data lost error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-122 Failure code [CA778] Eng. Bkup speed sensor error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-124 Failure code [CA1633] KOMNET datalink timeout error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-126 Failure code [CA2185] Throttle sens. sup. volt. high error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-128 Failure code [CA2186] Throttle sens. sup. volt. low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-130 Failure code [CA2249] Rail press. very low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-130 Failure code [CA2311] Abnormality in IMV solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-131 Failure code [D110KB] Battery relay drive short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-132 Failure code [D19JKZ] Personal code relay abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-134 Failure code [D862KA] GPS antenna discon - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-136 Failure code [DA22KK] Pump solenoid power low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-138 Failure code [DA25KP] 5V sensor 1 power abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-140 Failure code [DA26KP] 5V sensor 2 power abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-143 Failure code [DA2RMC] CAN discon (Pump controller detected) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-144 Failure code [DAF8KB] Short circuit in camera power supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-146 Failure code [DAFGMC] GPS module error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-148 Failure code [DAFRMC] CAN discon (Monitor detected)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-150 Failure code [DGH2KB] Hydr oil sensor short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-152 Failure code [DHPAMA] Pump press sensor abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-154 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality - - - - - - - - - - - - - - - - - - - - - - - - - 40-156 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality - - - - - - - - - - - - - - - - - - - - - - - - 40-158 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality - - - - - - - - - - - - - - - - - - - - - - - - - 40-160 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality- - - - - - - - - - - - - - - - - - - - - - - - - 40-162 Failure code [DHSKMA] Blade raise PPC press sensor abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-164 Failure code [DHSLMA] Blade lower PPC press sensor abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-166 Failure code [DHX1MA] Overload sensor abnormality (Analog)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-168 Failure code [DV20KB] Travel alarm S/C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-169 Failure code [DW43KA] Travel speed sol discon - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-170 Failure code [DW43KB] Travel speed sol short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-171 Failure code [DW45KA] Swing brake sol discon - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-172 Failure code [DW45KB] Swing brake sol short- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-174 Failure code [DW91KA] Travel junction sol discon - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-176 Failure code [DW91KB] Travel junction sol short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-177 Failure code [DWJ0KA] Merge-divider sol discon- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-178 Failure code [DWJ0KB] Merge-divider sol short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-179 Failure code [DXA8KA] PC-EPC sol discon- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-180 Failure code [DXA8KB] PC-EPC sol short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-182 Failure code [DXE4KA] Service current EPC discon - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-184 Failure code [DXE4KB] Service current EPC short- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-185 Failure code [DY20KA] Wiper working abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-186 Failure code [DY20MA] Wiper parking abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-188 Failure code [DY2CKA] Washer drive discon- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-190 Failure code [DY2CKB] Washer drive short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-192
PC128US-8
40-3
40 Troubleshooting
Failure code [DY2DKB] Wiper drive (for) short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-194 Failure code [DY2EKB] Wiper drive (rev) short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-196 Troubleshooting of electrical system (E-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-198 Before carrying out troubleshooting of electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-198 Information in troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-200 E-1 When starting switch turned ON, machine monitor displays nothing- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-202 E-2 When starting switch turned ON (before starting engine), basic check item lights up - - - - - - - - - - - - - - - - 40-204 E-3 Engine does not start (Engine does not turn) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-205 E-4 Preheater does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-208 E-5 Automatic warm-up system does not operate (in cold season) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-210 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked - - - - - - - - - - - - - - - - 40-212 E-7 Precaution lights up while engine is running - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-214 E-8 Emergency stop item lights up while engine is running - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-217 E-9 Engine coolant temperature gauge does not indicate normally - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-218 E-10 Hydraulic oil temperature gauge does not indicate normally - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-219 E-11 Fuel level gauge does not indicate normally- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-221 E-12 Contents of display by machine monitor are different from applicable machine - - - - - - - - - - - - - - - - - - - 40-223 E-13 Machine monitor does not display some items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-223 E-14 Function switch does not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-223 E-15 Auto-decelerator does not operate normally- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-224 E-16 Working mode does not change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-225 E-17 Travel speed does not change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-226 E-18 Alarm buzzer cannot be stopped - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-227 E-19 Windshield wiper and window washer do not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-228 E-20 Swing holding brake does not operate normally - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-232 E-21 Travel alarm does not sound or does not stop sounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-234 E-22 Air conditioner does not operate normally (including air conditioner abnormality record) - - - - - - - - - - - - 40-235 E-23 While starting switch is in OFF position, service meter is not displayed - - - - - - - - - - - - - - - - - - - - - - - - 40-247 E-24 Machine monitor cannot be set in service mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-247 E-25 Monitoring function does not display lever control signal normally - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-248 E-26 KOMTRAX system does not operate normally - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-264 Troubleshooting of hydraulic and mechanical system (H-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-265 Information contained in troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-265 System chart for hydraulic and mechanical systems- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-266 H-1 Speed or power of all work equipment, swing, and travel are low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-268 H-2 Engine speed sharply drops or engine stalls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-269 H-3 No work equipment, travel and swing move- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-270 H-4 Abnormal noise is heard from around hydraulic pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-270 H-5 Fine control mode does not function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-271 H-6 Speed or power of boom is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-272 H-7 Speed or power of arm is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-273 H-8 Speed or power of bucket is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-274 H-9 Work equipment does not move in its single operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-275 H-10 Hydraulic drift of work equipment is large - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-276 H-11 Time lag of work equipment is large - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-277 H-12 Work equipment loaded more is slower during compound operation - - - - - - - - - - - - - - - - - - - - - - - - - - 40-277 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE - - - - - - - - - - - - - - - - - - - - - 40-277 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel - - - - - - - - - - 40-278 H-15 Machine deviates during travel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-279 H-16 Travel speed is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-280
40-4
PC128US-8
40 Troubleshooting
H-17 Machine cannot be steered easily or steering power is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-281 H-18 Travel speed does not change or it is kept low or high - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-282 H-19 Track does not move (Only either side)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-282 H-20 Machine does not swing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-283 H-21 Swing acceleration or swing speed is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-284 H-22 Excessive overrun when stopping swing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-285 H-23 When upper structure stops swinging, it makes large shock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-286 H-24 When upper structure stops swinging, it makes large sound - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-286 H-25 Hydraulic drift of swing is large- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-287 H-26 Flow rate in attachment circuit cannot be adjusted - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-288 Troubleshooting of engine (S-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-290 Method of using troubleshooting chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-290 S-1 Starting performance is poor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-294 S-2 Engine does not start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-295 S-3 Engine does not pick up smoothly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-298 S-4 Engine stops during operations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-299 S-5 Engine does not rotate smoothly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-300 S-6 Engine lacks output (or lacks power) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-301 S-7 Exhaust smoke is black (incomplete combustion) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-302 S-8 Oil consumption is excessive (or exhaust smoke is blue) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-303 S-9 Oil becomes contaminated quickly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-304 S-10 Fuel consumption is excessive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-305 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-306 S-12 Oil pressure drops- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-307 S-13 Oil level rises (Entry of coolant or fuel) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-308 S-14 Coolant temperature becomes too high (overheating) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-309 S-15 Abnormal noise is made - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-310 S-16 Vibration is excessive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-311
PC128US-8
40-5
40 Troubleshooting Points to remember when performing troubleshooting
Related information on troubleshooting Points to remember when performing troubleshooting
1 (Rev. 2012/11)
k Stop the machine on a level place and make sure that the frame lock pin, chocks, parking brake,
etc. are applied normally.
k When performing the operation with 2 or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k 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.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, etc., be sure to remove the starting switch key and set the battery
disconnect switch to OFF position.
k 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. k Before starting inspection or replacement of the coolant temperature sensor, be sure to drain about 10 l of coolant because the coolant can spout out through the temperature sensor mounting port even if the radiator cap has been removed. k When inspecting or replacing the engine oil pressure sensor (switch), open the engine oil filler port and make sure the engine oil temperature has dropped enough to avoid burning. k When checking or replacing an oil temperature sensor or oil pressure sensor, loosen the oil filler cap of hydraulic tank to release the pressure inside the hydraulic tank and release the remaining pressure in the hydraulic circuit. For details, see "Releasing remaining pressure in hydraulic circuit" in Testing and adjusting. Use the monitoring function to display the hydraulic oil temperature on the machine monitor and check that it is 40°C or below to prevent burn injury. The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to prevent reoccurrence of the failure. Despite the importance of understanding the structure and operation of the target system in troubleshooting, you should be aware how identifying rough causes of the given undesirable symptom through the interview with the operator concerned can facilitate the troubleshooting. 1. When performing troubleshooting, do not hurry to disassemble the machine. If the machine is disassembled immediately after any failure occurs, q Parts that have no connection with the failure or other unnecessary parts are disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of staff-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation and to perform troubleshooting corresponding to the fixed procedure. 2. Points to ask the user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything unusual about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been performed before the failure? When were these repairs performed? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Does the machine have abnormal symptoms? 2) Check "Check before starting" items. 3) Check other check items. 4) Check other maintenance matters which can be checked externally and are considered to be necessary. 4. Checking failure Check the extent of the failure yourself, and judge whether it is a real failure or a problem of the method of operation, etc. a When operating the machine to reproduce the failure symptom, do not perform any investigation or measurement that may make the problem worse. 40-6
PC128US-8
40 Troubleshooting Points to remember when performing troubleshooting
5.
6.
Troubleshooting Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure, then use the troubleshooting flowchart or troubleshooting flow (matrix) to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, you must locate and eliminate the primary cause behind the given failure.
PC128US-8
40-7
40 Troubleshooting How to proceed in troubleshooting
How to proceed in troubleshooting
1 (Rev. 2011/09)
40-8
PC128US-8
40 Troubleshooting How to proceed in troubleshooting
PC128US-8
40-9
40 Troubleshooting Checks before troubleshooting
Checks before troubleshooting Item
Lubricating oil/Coolant
Electrical equipment
Hydraulic/ Mechanical equipment
40-10
Criterion
Remedy
1. Check of level and type of fuel
—
Add fuel
2. Check of fuel for foreign matter
—
Clean and drain
3. Check of fuel filter
—
Replace
4. Check of hydraulic oil level
—
Add oil
5. Check of hydraulic oil strainer
—
Clean and drain
6. Check of swing machinery oil level
—
Add oil
7. Check of level and type of engine oil (in oil pan)
—
Add oil
8. Check of coolant level
—
Add coolant
9. Check of dust indicator for clogging
—
Clean or replace
10. Check of hydraulic oil filter
—
Replace
1. Check of battery terminals and wiring for looseness and corrosion
—
Retighten or replace
2. Check of alternator terminals and wiring for looseness and corrosion
—
Retighten or replace
3. Check of starting motor terminals and wiring for looseness and corrosion
—
Retighten or replace
1. Check for abnormal noise and smell
—
Repair
2. Check for oil leakage
—
Repair
3. Bleeding air
—
Bleed air
20 – 30 V
Replace
1. Check of battery voltage (with engine stopped)
Electric, electrical equipment
1
2. Check of electrolyte level
—
Add or replace
3. Check of wires for discoloration, burn, and removal of cover
—
Replace
4. Check for released wire clamp and drooping wire
—
Repair
5. Check of wires for wetness (Check connectors and terminals for wetness, in particular)
—
Disconnect the connectors and dry
6. Check of fuse for disconnection and corrosion
—
Replace
7. Check of alternator voltage (while engine speed is at middle or higher)
After operating for several minutes: 27.5 – 29.5 V
Replace
8. Check of battery relay for operating sound (when starting switch is turned ON or OFF)
—
Replace
PC128US-8
40 Troubleshooting Classification and procedures for troubleshooting
Classification and procedures for troubleshooting
1
Classification for troubleshooting Mode Display of code
Contents Troubleshooting by failure code
E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1.
Procedure for troubleshooting to be taken when user code and failure code are displayed on machine monitor: If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for the corresponding "Display of code" according to the displayed failure code.
2.
When electrical system error code or mechanical system error code is recorded in abnormality record: If a user code and a failure code are not displayed on the machine monitor, check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according to the recorded code. a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is still detected. a An error code of the mechanical system cannot be deleted. a If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the abnormality record function, carry out the corresponding troubleshooting in E-mode.
3.
When user code and failure code is not displayed and no failure code is recorded in abnormality record: If a user code and failure code are not displayed on the machine monitor and no failure code is recorded in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode".
PC128US-8
40-11
40 Troubleshooting Information in troubleshooting table
Information in troubleshooting table a
1
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. User code
Failure code
Display on Display on machine machine monimonitor tor Contents of trouble
Trouble
Trouble name displayed in abnormality record machine monitor
Contents of trouble detected by machine monitor or controller
Action of Action taken by machine monitor or controller to protect system or devices when engine conmachine monitroller detects trouble tor or controller Problem that appears on machine
Problem that appears on machine as result of action taken by machine monitor or controller (shown above)
Related information
Information related to detected trouble or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting <Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment
1
2
Possible causes and standard value in normal state
40-12
<Troubles in wiring harness> • Disconnection Connector is connected imperfectly or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.
Possible causes of trouble 3 (Given numbers are reference numbers, which do not <Precautions for troubleshooting> (1) Method of indicating connector No. and handling of Tindicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of “male” and “female” , disconnect connector and insert T-adapters in both 4 male side and female side. • If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 5 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.
PC128US-8
40 Troubleshooting Information in troubleshooting table
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting. q q
q
PC128US-8
Connector No.: Indicates (Model – Number of pins) and (Color). “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. Arrow ( ): Roughly shows the location on the machine.
40-13
40 Troubleshooting Phenomena looking like troubles and troubleshooting Nos.
Phenomena looking like troubles and troubleshooting Nos.
1
Troubleshooting No.
Phenomena looking like troubles
Display of code
E-mode
H-mode
S-mode
Phenomena related to user code/failure code 1
User code and failure code are displayed on ordinary screen of machine monitor Accord-
2
When abnormality record is checked, failure code is displayed in mechanical system abnormality record
3
When abnormality record is checked, failure code is displayed in electrical system abnormality record
4
When abnormality record is checked, failure code is displayed in air conditioner or heater abnormality record
ing to displayed code
E-22
Phenomena related to engine 5 Starting performance is poor
S-1
6 Engine does not start (Engine does not turn)
E-3
S-2
7 Engine does not pick up smoothly
S-3
8 Engine stops during operations
S-4
9 Engine does not rotate smoothly
S-5
10 Engine lacks output (or lacks power)
S-6
11 Exhaust smoke is black (incomplete combustion)
S-7
12 Oil consumption is excessive (or exhaust smoke is blue)
S-8
13 Oil becomes contaminated quickly
S-9
14 Fuel consumption is excessive
S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
16 Oil pressure drops
S-12
17 Oil level rises (Entry of coolant or fuel)
S-13
18 Coolant temperature becomes too high (overheating)
S-14
19 Abnormal noise is made
S-15
20 Vibration is excessive
S-16
21 Preheater does not operate
E-4
22 Automatic warm-up system does not operate (in cold season)
E-5
23 Auto-decelerator does not operate normally
E-15
Phenomena related to work equipment/swing/travel 24
All work equipment, swing, and travel mechanism do not move or cannot be locked
E-6
H-3
25 Speed or power of all work equipment, swing, and travel are low
H-1
26 Engine speed sharply drops or engine stalls
H-2
27 Working mode does not change
S-6
E-16
28 Abnormal noise is heard from around hydraulic pump
H-4
29 Fine control mode does not function
H-5
Phenomena related to work equipment 30 Speed or power of boom is low
H-6
31 Speed or power of arm is low
H-7
32 Speed or power of bucket is low
H-8
33 Work equipment does not move in its single operation
H-9
40-14
PC128US-8
40 Troubleshooting Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting No.
Phenomena looking like troubles
Display of code
E-mode
H-mode
34 Hydraulic drift of work equipment is large
H-10
35 Time lag of work equipment is large
H-11
36
Flow rate in attachment circuit cannot be adjusted (when attachment is installed)
S-mode
H-26
Phenomena related to compound operation 37 Work equipment loaded more is slower during compound operation
H-12
38
Boom RAISE speed is low in compound operation of swing + boom RAISE
H-13
39
Travel speed lowers largely during compound operation of work equipment/swing + travel
H-14
Phenomena related to travel 40 Machine deviates during travel
H-15
41 Travel speed is low
H-16
42 Machine cannot be steered easily or steering power is low
H-17
43 Travel speed does not change or it is kept low or high
E-17
44 Track does not move (Only either side)
H-18 H-19
45 Travel alarm does not sound or does not stop sounding
E-21
Phenomena related to swing 46 Machine does not swing
H-20
47 Swing acceleration or swing speed is low
H-21
48 Excessive overrun when stopping swing
H-22
49 When upper structure stops swinging, it makes large shock
H-23
50 When upper structure stops swinging, it makes large sound
H-24
51
Swing holding brake does not operate normally Hydraulic drift of swing is large
E-20
H-25
Phenomena related to machine monitor 52 When starting switch turned ON, machine monitor displays nothing 53
When starting switch turned ON (before starting engine), basic check item lights up
E-1 E-2
54 Precaution lights up while engine is running
E-7
55 Emergency stop item lights up while engine is running
E-8
56 Engine coolant temperature gauge does not indicate normally
E-9
57 Hydraulic oil temperature gauge does not indicate normally
E-10
58 Fuel level gauge does not indicate normally
E-11
59
Contents of display by machine monitor are different from applicable machine
E-12
60 Machine monitor does not display some items
E-13
61 Function switch does not work
E-14
62 Alarm buzzer cannot be stopped
E-18
63 Windshield wiper and window washer do not operate
E-19
Air conditioner does not operate normally (including air conditioner abnormality record)
E-22
65 While starting switch is in OFF position, service meter is not displayed
E-23
66 Machine monitor cannot be set in service mode
E-24
67 Monitoring function does not display lever control signal normally
E-25
64
PC128US-8
40-15
40 Troubleshooting Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting No.
Phenomena looking like troubles
Display of code
E-mode
H-mode
S-mode
Other phenomena 68 KOMTRAX system does not operate normally
40-16
E-26
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
Connection table of connector by No. of pins
1
(Rev. 2012. 09) a Terms "Male connector" and "Female connector" that indicate connector type relate to their pin type and terms "Male housing" and "Female housing" relate to the convex or concave shapes of their fitting (housing).
PC128US-8
40-17
40 Troubleshooting Connection table of connector by No. of pins
40-18
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-19
40 Troubleshooting Connection table of connector by No. of pins
40-20
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-21
40 Troubleshooting Connection table of connector by No. of pins
40-22
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-23
40 Troubleshooting Connection table of connector by No. of pins
40-24
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-25
40 Troubleshooting Connection table of connector by No. of pins
40-26
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-27
40 Troubleshooting Connection table of connector by No. of pins
40-28
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-29
40 Troubleshooting Connection table of connector by No. of pins
40-30
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-31
40 Troubleshooting Connection table of connector by No. of pins
40-32
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-33
40 Troubleshooting Connection table of connector by No. of pins
40-34
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-35
40 Troubleshooting Connection table of connector by No. of pins
40-36
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-37
40 Troubleshooting Connection table of connector by No. of pins
40-38
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-39
40 Troubleshooting Connection table of connector by No. of pins
40-40
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-41
40 Troubleshooting Connection table of connector by No. of pins
40-42
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-43
40 Troubleshooting Connection table of connector by No. of pins
40-44
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-45
40 Troubleshooting Connection table of connector by No. of pins
40-46
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-47
40 Troubleshooting Connection table of connector by No. of pins
40-48
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-49
40 Troubleshooting Connection table of connector by No. of pins
40-50
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-51
40 Troubleshooting Connection table of connector by No. of pins
40-52
PC128US-8
40 Troubleshooting Connection table of connector by No. of pins
PC128US-8
40-53
40 Troubleshooting T-box and T-adapter list
T-box and T-adapter list
1
(Rev. 2012. 09) a Part numbers of separate T-boxes and T-adapters are listed in the vertical column, and part numbers of harness checker assemblies are listed in the horizontal line.
799-601-2840 799-601-2850 799-601-4350 799-601-4360 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320
40-54
q
21 37 37 24 24 17 17 5 10 5 17 19 14
q
q q
Not included in kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
T-box (for ECONO) T-box (for MS) T-box (for MS) Plate for MS (14 pins) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Case Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for DLI Adapter for DLI Adapter for DLI Extension cable (ECONO type) Case T-box (for DRC60 and ECONO) Case Adapter for X (T-adapter) Adapter for X Adapter for X Adapter for X Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP
Identifying symbol
799-601-7000
799-601-2600 799-601-3100 799-601-3200 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830
No. of pins
799-601-2800
Part Name
799-601-2700
Part No.
799-601-2500
T-adapter and adapter kit
q q q q q q q q q q q q q q
MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P
5 13 17 21 9 2 3 4 8 12 8 12 16
MIC-5P q MIC-13P q MIC-17P q MIC-21P q MIC-9P ECONO-2P q ECONO-3P q ECONO-4P q ECONO-8P q ECONO-12P q DLI-8P q DLI-12P q DLI-16P q
q q q q q q
12
ECONO-12P q q
q q q q q q q q q
q q q
q q q q q q q q q
q q
60
q 1 2 3 4 6 8 12 14 16
X2P X3P X4P SW6P SW8P SW12P SW14P SW16P
q q q q q
q q q q q
q q q q q q
q q q q
q q
q q
PC128US-8
40 Troubleshooting T-box and T-adapter list
PC128US-8
10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21
M2P M3P M4P M6P M8P S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P
07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21
q q
799-601-4201
Not included in kit
799-601-4101
799-601-9300
q q q q
799-601-9200
q q q q
799-601-9100
q q q q
q q q q q
799-601-9000
q q q q
799-601-8000
q q q q
q q q q q
799-601-7500
799-601-7400
1 2 3 4 6 8 8 10 12 16 16 12 8 12 16 20 2
799-601-7100
Adapter for M (T-adapter) Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M Adapter for S Adapter for S (white) Adapter for S (blue) Adapter for S (blue) Adapter for S (white) Adapter for S (white) Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Short connector for X Case Case Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for relay Adapter for relay Adapter for JFC Adapter for DTM Adapter for DT Adapter for DT Adapter for DT Adapter for DT Adapter for DT (gray) Adapter for DT (black) Adapter for DT (green) Adapter for DT (brown) Adapter for DT (gray) Adapter for DT (black) Adapter for DT (green) Adapter for DT (brown) Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24
Identifying symbol
799-601-7000
799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340 799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270
No. of pins
799-601-2800
Part Name
799-601-2700
Part No.
799-601-2500
T-adapter and adapter kit
q
q q
q q q q q q q q q q q q q q
q
q q q q
q q q q q q q q q q q q q q q q q q q q q q q q q q q q
q q q q q q q q q q q q q
q q q q
q q q q q q q
40-55
40 Troubleshooting T-box and T-adapter list
799-601-9420
799-601-9430* 799-601-9440* 795-799-5520* 795-799-5530*
795-799-5540* 795-799-5460 795-799-5470 795-799-5480 799-601-4110 799-601-4130 799-601-4140 799-601-4150 799-601-4160 799-601-4180 799-601-4190* 799-601-4230* 799-601-4240* 799-601-4250* 799-601-4330*
40-56
Not included in kit
799-601-4201
799-601-4101
q q q q
799-601-9300
q q q q q
799-601-9200
799-601-9100
799-601-8000
799-601-9000
24
799-601-7500
D24-23 D24-31
799-601-7400
23 31
799-601-7100
Adapter for HD30-24 Adapter for HD30-24 Plate for HD30 (24 pins) T-box (for ECONO) Case Case Adapter for DRC Adapter for DRC Socket for engine (CRI-T2) Adapter for engine (CRI-T2) Adapter for engine (CRI-T3) PFUEL Oil pressure sensor Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV Socket for engine (CRI-T2) Socket for engine (HPI-T2) Socket for engine (HPI-T2) Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM Cable for engine (HPI-T2) Cable for engine (HPI-T2) Cable for engine (HPI-T2) Adapter for engine (140-T3) PIM Adapter for engine (CRI-T3) NE, CAM Adapter for engine (CRI-T3) Ambient pressure Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) Oil pressure switch Adapter for engine (CRI-T3) PEVA Socket for engine (CRI-T3) Common rail pressure Socket for engine (CRI-T3) Boost pressure/ temperature Socket for engine (CRI-T3) PAMB Socket for engine (CRI-T3) PIM Socket for engine (CRI-T3)
Identifying symbol
799-601-7000
799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410*
No. of pins
799-601-2800
Part Name
799-601-2700
Part No.
799-601-2500
T-adapter and adapter kit
q q
q q q
40 24 2
DRC-40 DRC-24 G
3
A3
q q
2
P
q q
3 2
1,2,3 S
2
C
q q
2
A
q q
q
q q
q q q
3 3 3 4
ITT3N
q q
3
FCIN
q q
3
FCIG
q q
3
FCIB
q q
2
4160
q q
3
4180
q q
3
1,2,3L
q q
4
1,2,3,4C
q q
3
1,2,3A
q q
3
1,2,3B
q q
3
1,2,3,G
q q
PC128US-8
40 Troubleshooting T-box and T-adapter list
Socket for engine (CRI-T3) 2 Pump actuator Socket for engine (CRI-T3) (95) 799-601-4380* 4 Boost pressure/ temperature Adapter for controller 799-601-4260 4 (ENG) Adapter for controller 799-601-4211 50 (ENG) Adapter for controller 799-601-4220 60 (ENG) Socket for controller 799-601-4390* 60 (95ENG) 799-601-4280* Box for controller (PUMP) 121 Adapter for controller 799-601-9720 16 (HST) Adapter for controller 799-601-9710 16 (HST) Adapter for controller 799-601-9730 26 (HST) Multiple adapter for DT2 to 799-601-9890 2, 3, 4 DT4 pins and DTM2 pin
799-601-4340*
799-601-4201
Not included in kit
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
Identifying symbol
799-601-7000
No. of pins
799-601-2800
Part Name
799-601-2700
Part No.
799-601-2500
T-adapter and adapter kit
q q
2,PA
q
1,2,3,4T
DTP4
q q
DRC50
q
DRC60
q q q
HST16A
q
HST16B
q
HST26A
q q
Part No.
799-601-4620 799-601-4630 799-601-4640 799-601-4651 799-601-4660
Part Name
Adapter for controller (ENG-T4) Adapter for controller (ENG-T4) Adapter for controller (ENG-T4) Adapter for controller (ENG-T4) Adapter for controller (ENG-T4) KDPF differential pressure sensor short 799T-601-4611 connector KDPF outlet pressure sensor short 799T-601-4670 connector 799T-601-4680 KDPF dummy temperature sensor
PC128US-8
799-A65-4600
T-adapter and adapter kit No. of pins
Identifying symbol
4 2 2 24 3
799-601-4620 799-601-4630 799-601-4640 799-601-4651 799-601-4660
q q q q q
4
799T-601-4611
q
4
799-601-4620
q
4
799-601-4630
q
Not included in kit
*: Indicates that it is not a T-adapter but a socket.
40-57
40 Troubleshooting Failure code table
Failure code table User code
Failure code
1 Trouble (Displayed on screen)
Alarm buzzer
Component Category of in charge record
989L00
Engine controller lock caution 1
MON
989M00
Engine controller lock caution 2
MON
989N00
Engine controller lock caution 3
MON
AB00KE
Charge voltage low
MON
B@BAZG Eng oil press. low
e
B@BAZK Eng oil level low
ENG MON
B@BCNS Eng coolant overheat
e
ENG
B@HANS Hydr oil overheat
e
PUMP
E10
CA111
ECM critical internal failure
q
ENG
E10
CA115
Eng. Ne and Bkup speed sensor error
q
ENG
E11
CA122
Charge air press sensor high error
q
ENG
E11
CA123
Charge air press sensor low error
q
ENG
E14
CA131
Throttle sensor high error
q
ENG
E14
CA132
Throttle sensor low error
q
ENG
E15
CA144
Coolant temp. sensor high error
q
ENG
E15
CA145
Coolant temp. sensor low error
q
ENG
E15
CA153
Charge air temp. sensor high error
q
ENG
E15
CA154
Charge air temp. sensor low error
q
ENG
E15
CA187
Sensor sup. 2 volt. low error
q
ENG
E11
CA221
Ambient air press. sensor high error
q
ENG
E11
CA222
Ambient air press. sensor low error
q
ENG
E15
CA227
Sensor sup. 2 volt. high error
q
ENG
CA234
Eng. overspeed
E15
CA238
Ne speed sensor sup. volt. error
q
ENG
E10
CA271
IMV/PCV1 short error
q
ENG
E10
CA272
IMV/PCV1 open error
q
ENG
E11
CA322
Injector #1 (L #1) system open/short error
q
ENG
E11
CA324
Injector #3 (L #3) system open/short error
q
ENG
40-58
ENG
Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system
PC128US-8
40 Troubleshooting Failure code table
Alarm buzzer
User code
Failure code
E11
CA331
Injector #2 (L #2) system open/short error
q
E11
CA332
Injector #4 (L #4) system open/short error
q
E10
CA351
Inj. drive circuit error
q
E15
CA352
Sensor sup. 1 volt. low error
q
E15
CA386
Sensor sup. 1 volt. high error
q
E15
CA435
Abnormality in engine oil pressure switch
q
E10
CA441
Battery voltage low error
q
E10
CA442
Battery voltage high error
q
E11
CA449
Rail press. very high error
q
E11
CA451
Rail press. sensor high error
q
E11
CA452
Rail press. sensor low error
q
E15
CA553
Rail press. high error
q
E15
CA559
Rail press. low error
q
E15
CA689
Eng. Ne speed sensor error
q
E15
CA731
Eng. Bkup speed sensor phase error
q
E10
CA757
All persistent data lost error
q
E15
CA778
Eng. Bkup speed sensor error
q
E0E
CA1633
KOMNET datalink timeout error
q
E14
CA2185
Throttle sens. sup. volt. high error
q
E14
CA2186
Throttle sens. sup. volt. low error
q
E11
CA2249
Rail press. very low error
q
E11
CA2311
Abnormality in IMV solenoid
q
D110KB
Battery relay drive short
D19JKZ
Personal code relay abnormality
D862KA
GPS antenna discon
DA22KK
Pump solenoid power low error
DA25KP
5V sensor 1 power abnormality
DA26KP
5V sensor 2 power abnormality
DA2RMC
CAN discon (Pump controller detected)
DAF8KB
Short circuit in camera power supply
E01
E0E
E0E
PC128US-8
Trouble (Displayed on screen)
q
q
q
Component Category of in charge record Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical PUMP system Electrical MON2 system Electrical MON2 system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical MON system
40-59
40 Troubleshooting Failure code table
User code
Failure code
Trouble (Displayed on screen)
Alarm buzzer
DAFGMC
GPS module error
DAFRMC
CAN discon (Monitor detected)
DGH2KB
Hydr oil sensor short
DHPAMA
Pump press sensor abnormality
E20
DHSFMA
Travel left forward PPC press sensor abnormality
q
E20
DHSGMA
Travel right forward PPC press sensor abnormality
q
E20
DHSHMA
Travel left reverse PPC press sensor abnormality
q
E20
DHSJMA
Travel right reverse PPC press sensor abnormality
q
DHSKMA
Blade raise PPC press sensor abnormality
DHSLMA
Blade lower PPC press sensor abnormality
DHX1MA
Overload sensor abnormality (Analog)
DV20KB
Travel alarm S/C
DW43KA
Travel speed sol discon
DW43KB
Travel speed sol short
E03
DW45KA
Swing brake sol discon
q
E03
DW45KB
Swing brake sol short
q
DW91KA
Travel junction sol discon
DW91KB
Travel junction sol short
DWJ0KA
Merge-divider sol discon
DWJ0KB
Merge-divider sol short
E02
DXA8KA
PC-EPC sol discon
q
E02
DXA8KB
PC-EPC sol short
q
DXE4KA
Service current EPC discon
DXE4KB
Service current EPC short
DY20KA
Wiper working abnormality
DY20MA
Wiper parking abnormality
DY2CKA
Washer drive discon
DY2CKB
Washer drive short
DY2DKB
Wiper drive (for) short
DY2EKB
Wiper drive (rev) short
E0E
40-60
q
Component Category of in charge record Electrical MON2 system Electrical MON system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system
PC128US-8
40 Troubleshooting Failure code table
a a
a
a
a
Entry order of items in table The items are entered in the order of their failure codes (incremental order). User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the abnormality. Alarm buzzer q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). e: Since the caution monitor is also turned ON, its function sounds the buzzer. Component in charge MON: The machine monitor is in charge of detection of abnormality. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. ENG: The engine controller is in charge of detection of abnormality. PUMP: The pump controller is in charge of detection of abnormality. Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. Electrical system: Abnormality information is recorded in the electrical system abnormality record.
PC128US-8
40-61
40 Troubleshooting Fuse locations
Fuse locations
1
Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally. Type of power supply
Switch power supply
Switch power supply
Switch power supply
Constant power supply
Switch power supply
40-62
Fusible link
F02 (45A)
F02 (45A)
F02 (45A)
F03 (45A)
Starting switch ACC
Fuse No.
Fuse capacity
1
10A
Emergency operating circuit
2
30A
Solenoid valve
3
15A
Cigarette lighter
4
10A
Windshield washer
Destination of power
5
10A
Horn
6
5A
Working lamp relay, horn relay
7
10A
Revolving lamp (If equipped)
8
20A
Working lamp
9
10A
Radio, speaker
10
5A
Air conditioner
11
20A
Air conditioner unit
12
10A
Optional power supply (1)
13
10A
Optional power supply (2), power supply of 12 volt
14
10A
Spare
15
5A
Air conditioner
16
10A
Radio backup, room lamp
17
20A
Machine monitor, pump controller, starting switch
18
30A
Engine controller
19
5A
Engine controller
20
5A
PPC oil pressure lock solenoid
PC128US-8
40 Troubleshooting Fuse locations
Locations of fusible links
Location of fuse box and fuse Nos.
PC128US-8
40-63
40 Troubleshooting Failure code [989L00] Engine controller lock caution 1
Troubleshooting by failure code Failure code [989L00] Engine controller lock caution 1 User code
Failure code
—
989L00
Contents of trouble
Trouble
1
Engine controller lock caution 1 (Machine monitor system)
• Engine controller lock is detected (Factor 1).
Action of • None in particular. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine
• Engine cannot be started.
Related information
• If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. • Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
1
Cause
Standard value in normal state/Remarks on troubleshooting
Replacement of machine monitor
This trouble may be caused by replacement of machine monitor.
Failure code [989M00] Engine controller lock caution 2 User code
Failure code
—
989M00
Contents of trouble
Trouble
1
Engine controller lock caution 2 (Machine monitor system)
• Engine controller lock is detected (Factor 2).
Action of • None in particular. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine
• Engine cannot be started.
Related information
• If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. • Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-64
Cause
Standard value in normal state/Remarks on troubleshooting
Replacement of machine monitor
This trouble may be caused by replacement of machine monitor.
2 Defective machine monitor
If this failure code is displayed while machine monitor is not replaced, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
1
PC128US-8
40 Troubleshooting Failure code [989N00] Engine controller lock caution 3
Failure code [989N00] Engine controller lock caution 3 User code
Failure code
—
989N00
Contents of trouble
Trouble
1
Engine controller lock caution 3 (Machine monitor system)
• Engine controller lock is detected (Factor 3).
Action of • Tries automatic resetting. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine Related information
Possible causes and standard value in normal state
PC128US-8
• Method of reproducing failure code: Failure code is not reproduced since system is reset automatically. Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective engine controller
If this failure code is displayed repeatedly, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-65
40 Troubleshooting Failure code [AB00KE] Charge voltage low
Failure code [AB00KE] Charge voltage low User code
Failure code
—
AB00KE
Contents of trouble
Trouble
1
Charge voltage low (Machine monitor system)
• While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
Action of • Displays charge level monitor on machine monitor. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine
• If machine is operated as it is, battery may not be charged.
Related information
• Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage) • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Possible causes and standard value in normal state
1
2
40-66
Defective charge of alternator (when system is normal)
E12 (male)
Engine speed
Voltage
Between (1) – chassis ground
Min. medium speed
27.5 – 29.5 V
If cause 1 is not detected, charge level monitor system may be Defective charge level monidefective. Carry out troubleshooting for "E-7 Caution item flashes tor while engine is running" in E-mode.
PC128US-8
40 Troubleshooting Failure code [AB00KE] Charge voltage low
Related circuit diagram
PC128US-8
40-67
40 Troubleshooting Failure code [B@BAZG] Eng oil press. low
Failure code [B@BAZG] Eng oil press. low User code
Failure code
—
B@BAZG
Trouble
1
Engine oil pressure low (Engine controller system)
Contents of trouble
• While engine was running, signal circuit of engine oil pressure switch detected low engine oil pressure (sensor contact opened).
Action of controller
• Displays engine oil pressure monitor on machine monitor. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• If machine is operated as it is, engine may be damaged.
Related information
• Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor. • Method of reproducing failure code: Start engine.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Lowering of engine oil pres1 sure (when system is normal)
Engine oil pressure may be low. Check it and remove cause if it is low.
2
Defective engine oil pressure If cause 1 is not detected, engine oil pressure switch system may switch system be defective. Carry out troubleshooting for failure code [CA435].
Failure code [B@BAZK] Eng oil level low User code
Failure code
—
B@BAZK
Contents of trouble
Trouble
1
Engine oil level low (Machine monitor system)
• When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch detected low engine oil level (sensor contact opened).
Action of • Displays engine oil level monitor on machine monitor. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine
• If machine is operated as it is, engine may be damaged.
Related information
• Engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2) • Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-68
1
Cause
Standard value in normal state/Remarks on troubleshooting
Lowering of engine oil level (when system is normal)
Engine oil level may be low. Check it and add new oil if it is low.
Defective engine oil level 2 monitor system
If cause 1 is not detected, engine oil level monitor system may be defective. Carry out troubleshooting for "E-2 Basic check item lights up when starting switch is turned ON (but engine is not started)" in E-mode.
PC128US-8
40 Troubleshooting Failure code [B@BCNS] Eng coolant overheat
Failure code [B@BCNS] Eng coolant overheat User code
Failure code
—
B@BCNS
Trouble
1
Engine coolant overheat (Engine controller system)
Contents of trouble
• While engine was running, signal circuit of engine coolant temperature sensor detected overheating of engine coolant (above about 102°C).
Action of controller
• Displays engine coolant temperature monitor with red on machine monitor. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• If machine is operated as it is, engine may be seized.
Related information
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor. • Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature) • Method of reproducing failure code: Start engine. Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
Overheating of engine Engine coolant may be overheating. Check it and remove cause if 1 coolant (when system is norit is overheating. mal) 2
Defective engine coolant temperature sensor system
If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].
Failure code [B@HANS] Hydr oil overheat User code
Failure code
—
B@HANS
Trouble
1
Hydraulic oil overheat (Pump controller system)
Contents of trouble
• While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of hydraulic oil (above about 102°C).
Action of controller
• Displays hydraulic oil temperature monitor with red on machine monitor. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• If machine is operated as it is, engine may be seized.
Related information
• Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine monitor. • Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature) • Method of reproducing failure code: Start engine.
Possible causes and standard value in normal state
PC128US-8
Cause
Standard value in normal state/Remarks on troubleshooting
Overheating of hydraulic oil 1 (when system is normal)
Hydraulic oil may be overheating. Check it and remove cause if it is overheating.
Defective hydraulic oil temperature gauge system
If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for "E-10 Hydraulic oil temperature gauge does not work normally" in E-mode.
2
40-69
40 Troubleshooting Failure code [CA111] ECM critical internal failure
Failure code [CA111] ECM critical internal failure User code
Failure code
E10
CA111
Trouble
ECM critical internal failure (Engine controller system)
Contents of trouble
• Abnormality occurred in controller.
Action of controller
• None in particular.
Problem that appears on machine
1
• Engine runs normally but it may stop during operation or may not be able to start.
Related information Cause 1 Defective fuse
Defective power supply cut2 out relay
Standard value in normal state/Remarks on troubleshooting Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) – (32)
Resistance
185 – 265 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
40-70
Wiring harness between CE02 (female) (55) – R23 (1)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (55) – R24 (1)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (32) – R23 (2)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (32) – R24 (2)
Resistance
Max. 1 z
Wiring harness between CE03 (female) (1) – T12
Resistance
Max. 1 z
Wiring harness between CE03 (female) (3) – R23 (5)
Resistance
Max. 1 z
Wiring harness between CE03 (female) (3) – R24 (5)
Resistance
Max. 1 z
Wiring harness between R23 (female) (3) – battery (+)
Resistance
Max. 1 z
Wiring harness between R24 (female) (3) – battery (+)
Resistance
Max. 1 z
PC128US-8
40 Troubleshooting Failure code [CA111] ECM critical internal failure
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between CE02 (female) (55) – R23 (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE02 (female) (55) – R24 (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE02 (female) (32) – R23 (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between CE03 (female) (3) – R24 (5) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between R23 (female) (3) – battery (+) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between R24 (female) (3) – battery (+) and chassis ground
Resistance
Min. 1 Mz
Ground fault in wiring harWiring harness between CE02 (female) (32) 4 ness (Short circuit with GND – R24 (2) and chassis ground circuit) Wiring harness between CE03 (female) (3) – R23 (5) and chassis ground
a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
PC128US-8
CE03
Voltage
Between (3) – (1)
20 – 30 V
40-71
40 Troubleshooting Failure code [CA111] ECM critical internal failure
Related circuit diagram
40-72
PC128US-8
40 Troubleshooting Failure code [CA115] Eng. Ne and Bkup speed sensor error
Failure code [CA115] Eng. Ne and Bkup speed sensor error User code
Failure code
E10
CA115
Trouble
1
Eng. Ne and Bkup speed sensor error (Engine controller system)
Contents of trouble
• Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
Action of controller
• None in particular.
Problem that appears on machine
• Engine cannot be started (if engine has been stopped). • Engine stops (if engine has been running).
Related information Causes
Possible causes and standard value in normal state
1
Defective Ne speed sensor system
Carry out troubleshooting for failure code [CA689].
2
Defective Bkup speed sensor system
Carry out troubleshooting for failure code [CA778].
3
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, indicator-ring of crankshaft, etc.)
4
Defective mount of Bkup speed sensor
5
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defecconnection) tive connection (wrong connection).
6 Defective engine controller
PC128US-8
Standard value in normal state/Remarks on troubleshooting
Check mount of Bkup speed sensor directly for defect (defective installation of sensor, indicator-ring of crankshaft, etc.)
If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-73
40 Troubleshooting Failure code [CA122] Charge air press sensor high error
Failure code [CA122] Charge air press sensor high error User code
Failure code
E11
CA122
Trouble
1
Charge air press sensor high error (Engine controller system)
Contents of trouble
• High voltage was detected in charge pressure sensor circuit.
Action of controller
• Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears on machine
• Acceleration performance of engine drops.
Related information
• Signal voltage of charge pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage). • Method of reproducing failure code: Turn starting switch ON. Causes
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble1 ply system shooting for it first. Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective charge pressure 2 sensor (Internal trouble)
Possible causes and standard value in normal state
PTIM Between (2) – (4)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between CE01 (female) (19) – PTIM (female) (1)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (36) – PTIM (female) (2)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (48) – PTIM (female) (4)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-74
Wiring harness between CE01 (female) (19) – PTIM (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (36) – PTIM (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (48) – PTIM (female) (4) and chassis ground
Resistance
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [CA122] Charge air press sensor high error
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Short circuit in wiring harness 5 (With another wiring harness)
Wiring harness between CE01 (female) (19) – PTIM (female) (1) and wiring harness between CE01 (female) (36) – PTIM (female) (2)
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (19) – PTIM (female) (1) and wiring harness between CE01 (female) (48) – PTIM (female) (4)
Resistance
Min. 1 Mz
Chassis ground between CE01 (female) (36) – PTIM (female) (2) and chassis ground between CE01 (female) (48) – PTIM (female) (4)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 6 Defective engine controller
CE01 Between (36) – (48)
Voltage Power supply
4.75 – 5.25 V
Related circuit diagram
PC128US-8
40-75
40 Troubleshooting Failure code [CA123] Charge air press sensor low error
Failure code [CA123] Charge air press sensor low error User code
Failure code
E11
CA123
Trouble
Charge air press sensor low error (Engine controller system)
Contents of trouble
• Low voltage was detected in charge pressure sensor circuit.
Action of controller
• Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears on machine
• Acceleration performance of engine drops.
Related information
• Signal voltage of charge pressure sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage). • Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-76
Cause
1
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA122].
PC128US-8
40 Troubleshooting Failure code [CA123] Charge air press sensor low error
PC128US-8
40-77
40 Troubleshooting Failure code [CA131] Throttle sensor high error
Failure code [CA131] Throttle sensor high error User code
Failure code
E14
CA131
Trouble
1
Throttle sensor high error (Engine controller system)
Contents of trouble
• High voltage was detected in fuel control dial circuit.
Action of controller
• Sets throttle angle with signal other than fuel control dial signal and continues operation (depending on each model)
Problem that appears on machine
• Engine speed cannot be controlled with fuel control dial.
Related information
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) • Method of reproducing failure code: Turn starting switch ON. Causes
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA2185] or [CA2186] is indicated, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
Defective fuel control dial (Internal trouble)
P20 (male)
Resistance
Between (1) – (3)
4.0 – 6.0 kz
Between (2) – (1)
0.25 – 5.0 kz
Between (2) – (3)
0.25 – 5.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between CE02 (female) (27) – P20 (female) (1)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (35) – P20 (female) (2)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (28) – P20 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
Wiring harness between CE02 (female) (27) – P20 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE02 (female) (35) – P20 (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE02 (female) (28) – P20 (female) (3) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
40-78
CE02
Voltage
Between (27) – (28)
Power supply
4.75 – 5.25 V
Between (35) – (28)
Signal
0.5 – 4.5 V
PC128US-8
40 Troubleshooting Failure code [CA131] Throttle sensor high error
Related circuit diagram
PC128US-8
40-79
40 Troubleshooting Failure code [CA132] Throttle sensor low error
Failure code [CA132] Throttle sensor low error User code
Failure code
E14
CA132
Trouble
1
Throttle sensor low error (Engine controller system)
Contents of trouble
• Low voltage was detected in fuel control dial circuit.
Action of controller
• Sets throttle angle with signal other than fuel control dial signal and continues operation (depending on each model)
Problem that appears on machine
• Engine speed cannot be controlled with fuel control dial.
Related information
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) • Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-80
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA131].
PC128US-8
40 Troubleshooting Failure code [CA144] Coolant temp. sensor high error
Failure code [CA144] Coolant temp. sensor high error User code
Failure code
E15
CA144
Trouble
1
Coolant temp. sensor high error (Engine controller system)
Contents of trouble
• High voltage was detected in coolant temperature sensor circuit.
Action of controller
• Fixes coolant temperature (90°C) and continues operation.
Problem that appears on machine Related information
• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Engine coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause
1
Defective coolant temperature sensor (Internal trouble)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male)
Coolant temperature
Resistance
Between (1) – (2)
10 – 100°C
0.6 – 20 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (47) 2 or defective contact in con- – TWTR (female) (1) nector) Wiring harness between CE01 (female) (49) – TWTR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (49) Resiscircuit) Min. 1 Mz – TWTR (female) (2) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
CE01 (female)
Coolant temperature
Resistance
Between (47) – (49)
10 – 100°C
0.6 – 20 kz
Related circuit diagram
PC128US-8
40-81
40 Troubleshooting Failure code [CA145] Coolant temp. sensor low error
Failure code [CA145] Coolant temp. sensor low error User code
Failure code
E15
CA145
Trouble
1
Coolant temp. sensor low error (Engine controller system)
Contents of trouble
• Low voltage was detected in coolant temperature sensor circuit.
Action of controller
• Fixes coolant temperature (90°C) and continues operation.
Problem that appears on machine Related information
Possible causes and standard value in normal state
40-82
• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Engine coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA144].
PC128US-8
40 Troubleshooting Failure code [CA153] Charge air temp. sensor high error
Failure code [CA153] Charge air temp. sensor high error User code
Failure code
E15
CA153
Trouble
1
Charge air temp. sensor high error (Engine controller system)
Contents of trouble
• High voltage was detected in charge temperature sensor circuit.
Action of controller
• Fixes charge temperature (intake air temperature) (70°C) and continues operation.
Problem that appears on machine Related information
• Signal voltage of charge temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective charge temperature sensor (Internal trouble)
PTIM (male)
Intake air temperature
Resistance
Between (3) – (4)
10 – 100°C
0.5 – 20 kz
Between (3) – chassis ground
All range
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring ing without turning starting switch ON. harness Wiring harness between CE01 (female) (11) Resis2 (Disconnection in wiring or Max. 1 z – PTIM (female) (3) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z – PTIM (female) (4) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (11) Resiscircuit) Min. 1 Mz – PTIM (female) (3) and chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
CE01 (female)
Intake air temperature
Resistance
Between (11) – (48)
10 – 100°C
0.5 – 20 kz
Related circuit diagram
PC128US-8
40-83
40 Troubleshooting Failure code [CA154] Charge air temp. sensor low error
Failure code [CA154] Charge air temp. sensor low error User code
Failure code
E15
CA154
Trouble
1
Charge air temp. sensor low error (Engine controller system)
Contents of trouble
• Low voltage was detected in charge temperature sensor circuit.
Action of controller
• Fixes charge temperature (intake air temperature) (70°C) and continues operation.
Problem that appears on machine Related information
Possible causes and standard value in normal state
40-84
• Signal voltage of charge temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting failure code [CA153].
PC128US-8
40 Troubleshooting Failure code [CA187] Sensor sup. 2 volt. low error
Failure code [CA187] Sensor sup. 2 volt. low error User code
Failure code
E15
CA187
Trouble
1
Sensor sup. 2 volt. low error (Engine controller system)
Contents of trouble
• Low voltage was detected in sensor power supply 2 (5 V) circuit.
Action of controller
• Operates Bkup speed sensor with signals of Ne speed sensor. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that appears on machine
• Output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
PC128US-8
Causes
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA227].
40-85
40 Troubleshooting Failure code [CA221] Ambient air press. sensor high error
Failure code [CA221] Ambient air press. sensor high error User code
Failure code
E11
CA221
Trouble
1
Ambient air press. sensor high error (Engine controller system)
Contents of trouble
• High voltage was detected in ambient pressure sensor circuit.
Action of controller
• Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears on machine
• Output drops.
Related information
• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Causes
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PAMB Defective atmospheric pres2 sure sensor (Internal trouble)
Voltage
Between (1) – (3)
Power supply
4.75 – 5.25 V
Between (2) – (3)
Signal
0.3 – 4.7 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between CE01 (female) (36) – PAMB (female) (1)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (20) – PAMB (female) (2)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (48) – PAMB (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-86
Wiring harness between CE01 (female) (36) – PAMB (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (20) – PAMB (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (48) – PAMB (female) (3) and chassis ground
Resistance
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [CA221] Ambient air press. sensor high error
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Short circuit in wiring harness 5 (With another wiring harness)
Wiring harness between CE01 (female) (36) – PAMB (female) (1) and wiring harness between CE01 (female) (20) – PAMB (female) (2)
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (36) – PAMB (female) (1) and wiring harness between CE01 (female) (48) – PAMB (female) (3)
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (20) – PAMB (female) (2) and wiring harness between CE01 (female) (48) – PAMB (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
CE01
Voltage
Between (36) – (48)
4.75 – 5.25 V
Between (20) – (48)
0.3 – 4.7 V
Related circuit diagram
PC128US-8
40-87
40 Troubleshooting Failure code [CA222] Ambient air press. sensor low error
Failure code [CA222] Ambient air press. sensor low error User code
Failure code
E11
CA222
Trouble
Ambient air press. sensor low error (Engine controller system)
Contents of trouble
• Low voltage was detected in ambient pressure sensor circuit.
Action of controller
• Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that appears on machine
• Output drops.
Related information
• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-88
Causes
1
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA221].
PC128US-8
40 Troubleshooting Failure code [CA222] Ambient air press. sensor low error
PC128US-8
40-89
40 Troubleshooting Failure code [CA227] Sensor sup. 2 volt. high error
Failure code [CA227] Sensor sup. 2 volt. high error User code
Failure code
E15
CA227
Contents of trouble
Trouble
1
Sensor sup. 2 volt. high error (Engine controller system)
• High voltage was detected in sensor power supply 2 (5 V) circuit.
Action of controller Problem that appears on machine Related information
• Method of reproducing failure code: Turn starting switch ON.
Causes Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Defective engine controller
CE02
Voltage
Between (26) – (22)
4.75 – 5.25V
Related circuit diagram
40-90
PC128US-8
40 Troubleshooting Failure code [CA234] Eng. overspeed
Failure code [CA234] Eng. overspeed User code
Failure code
—
CA234
Trouble
Eng. overspeed (Engine controller system)
Contents of trouble
• Engine speed is above operating range.
Action of controller
• Limits fuel injection rate until engine speed lowers to operating range.
Problem that appears on machine
• Engine speed fluctuates.
Related information
• Engine speed can be checked with monitoring function. (Code: 01002 Engine speed) • Method of reproducing failure code: Run engine at high idle. Cause
Possible causes and standard value in normal state
PC128US-8
1
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code is indicated, carry out troubleshooting for it.
2 Improper way of use
Way of use may be improper. Teach proper way of use to operator.
3 Defective engine controller
If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-91
40 Troubleshooting Failure code [CA238] Ne speed sensor sup. volt. error
Failure code [CA238] Ne speed sensor sup. volt. error User code
Failure code
E15
CA238
Trouble
1
Ne speed sensor sup. volt. error (Engine controller system)
Contents of trouble
• Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Action of controller
• Controls Ne speed sensor with signals of Bkup speed sensor.
Problem that appears on machine
• Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective Ne speed sensor (Internal trouble)
Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.
Ne speed sensor
NE connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (26) 2 or defective contact in con- – NE (female) (1) nector) Wiring harness between CE01 (female) (44) – NE (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between CE01 (female) (26) 3 ness (Short circuit with GND – NE (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (44) – NE (female) (2) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (26) – NE (female) (1) and between CE01 (female) (44) – NE (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
40-92
CE01
Voltage
Between (26) – (44)
4.75 – 5.25 V
PC128US-8
40 Troubleshooting Failure code [CA238] Ne speed sensor sup. volt. error
Related circuit diagram
PC128US-8
40-93
40 Troubleshooting Failure code [CA271] IMV/PCV1 short error
Failure code [CA271] IMV/PCV1 short error User code
Failure code
E10
CA271
Trouble
1
IMV/PCV1 short error (Engine controller system)
Contents of trouble
• There is short circuit in IMV circuit of supply pump.
Action of controller
• None in particular.
Problem that appears on machine Related information
• Method of reproducing failure code: Turn starting switch ON.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective supply pump IMV (Internal trouble)
Ground fault in wiring harness 2 (Short circuit with GND circuit)
PREG (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (10) – PREG (female) (2)
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (14) – PREG (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Hot short (Short circuit with Wiring harness between CE01 (female) (10) 24V circuit) in wiring harness – PREG (female) (2) and chassis ground
Voltage
Max. 1V
Wiring harness between CE01 (female) (14) – PREG (female) (1) and chassis ground
Voltage
Max. 1V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
CE01 (female)
Resistance
Between (10) – (14)
2.3 – 5.3 z
Between (10), (14) – chassis ground
Min. 1 Mz
Related circuit diagram
40-94
PC128US-8
40 Troubleshooting Failure code [CA272] IMV/PCV1 open error
Failure code [CA272] IMV/PCV1 open error User code
Failure code
E10
CA272
Trouble
1
IMV/PCV1 open error (Engine controller system)
Contents of trouble
• There is disconnection in IMV circuit of supply pump.
Action of controller
• None in particular.
Problem that appears on machine Related information
• Method of reproducing failure code: Turn starting switch ON.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective supply pump IMV (Internal disconnection)
PREG (male)
Resistance
Between (1) – (2)
2.3 – 5.3 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between CE01 (female) (10) Resis2 (Disconnection in wiring or Max. 1 z – PREG (female) (2) tance defective contact in connecWiring harness between CE01 (female) (14) Resistor) Max. 1 z – PREG (female) (1) tance Ground fault in wiring harness 3 (Short circuit with GND circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (10) – PREG (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (14) – PREG (female) (1) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
CE01 (female)
Resistance
Between (10) – (14)
2.3 – 5.3 z
Between (10) (14) – chassis ground
Min. 1 Mz
Related circuit diagram
PC128US-8
40-95
40 Troubleshooting Failure code [CA322] Injector #1 (L #1) system open/short error
Failure code [CA322] Injector #1 (L #1) system open/short error User code
Failure code
E11
CA322
Trouble
Injector #1 (L #1) system open/short error (Engine controller system)
Contents of trouble
• There is disconnection or short circuit in injector #1 circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
• Method of reproducing failure code: Start engine.
Causes
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective injector #1 (Internal trouble)
CN1 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between CE01 (female) (57) Resis2 (Disconnection in wiring or Max. 1 z – CN1 (female) (1) tance defective contact in connecWiring harness between CE01 (female) (53) Resistor) Max. 1 z – CN1 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit)
4
Defective injector or wiring harness of another cylinder
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (57) – CN1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (53) – CN1 (female) (2) and chassis ground
Resistance
Min. 1 Mz
If another failure code for injector abnormality is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
40-96
CE01 (female)
Resistance
Between (57) – (53)
0.4 – 1.1 z
Between (57), (53) – chassis ground
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [CA322] Injector #1 (L #1) system open/short error
Related circuit diagram
PC128US-8
40-97
40 Troubleshooting Failure code [CA324] Injector #3 (L #3) system open/short error
Failure code [CA324] Injector #3 (L #3) system open/short error User code
Failure code
E11
CA324
Trouble
Injector #3 (L #3) system open/short error (Engine controller system)
Contents of trouble
• There is disconnection or short circuit in injector #3 circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
• Method of reproducing failure code: Start engine.
Cause
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #3 (Internal trouble)
CN3 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (55) 2 or defective contact in con- – CN3 (female) (1) nector) Wiring harness between CE01 (female) (59) – CN3 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between CE01 (female) (55) 3 ness (Short circuit with GND – CN3 (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (59) – CN3 (female) (2) and chassis ground 4
Defective injector or wiring harness of another cylinder
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If another failure code for injector abnormality is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
40-98
CE01 (female)
Resistance
Between (55) – (59)
0.4 – 1.1 z
Between (55), (59) – chassis ground
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [CA324] Injector #3 (L #3) system open/short error
Related circuit diagram
PC128US-8
40-99
40 Troubleshooting Failure code [CA331] Injector #2 (L #2) system open/short error
Failure code [CA331] Injector #2 (L #2) system open/short error User code
Failure code
E11
CA331
Trouble
Injector #2 (L #2) system open/short error (Engine controller system)
Contents of trouble
• There is disconnection or short circuit in injector #2 circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
• Method of reproducing failure code: Start engine.
Cause
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #2 (Internal trouble)
CN2 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (45) 2 or defective contact in con- – CN2 (female) (1) nector) Wiring harness between CE01 (female) (58) – CN2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between CE01 (female) (45) 3 ness (Short circuit with GND – CN2 (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (58) – CN2 (female) (2) and chassis ground 4
Defective injector or wiring harness of another cylinder
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If another failure code for injector abnormality is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
40-100
CE01 (female)
Resistance
Between (45) – (58)
0.4 – 1.1 z
Between (45), (58) – chassis ground
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [CA331] Injector #2 (L #2) system open/short error
Related circuit diagram
PC128US-8
40-101
40 Troubleshooting Failure code [CA332] Injector #4 (L #4) system open/short error
Failure code [CA332] Injector #4 (L #4) system open/short error User code
Failure code
E11
CA332
Trouble
Injector #4 (L #4) system open/short error (Engine controller system)
Contents of trouble
• There is disconnection or short circuit in injector #4 circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Output drops. • Rotation is unstable.
Related information
• Method of reproducing failure code: Start engine.
Cause
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective injector #4 (Internal trouble)
CN4 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (56) 2 or defective contact in con- – CN4 (female) (1) nector) Wiring harness between CE01 (female) (51) – CN4 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between CE01 (female) (56) 3 ness (Short circuit with GND – CN4 (female) (1) and chassis ground circuit) Wiring harness between CE01 (female) (51) – CN4 (female) (2) and chassis ground 4
Defective injector or wiring harness of another cylinder
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If another failure code for injector abnormality is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
40-102
CE01 (female)
Resistance
Between (56) – (51)
0.4 – 1.1 z
Between (56), (51) – chassis ground
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [CA332] Injector #4 (L #4) system open/short error
Related circuit diagram
PC128US-8
40-103
40 Troubleshooting Failure code [CA351] Inj. drive circuit error
Failure code [CA351] Inj. drive circuit error User code
Failure code
E10
CA351
Trouble
Inj. drive circuit error (Engine controller system)
Contents of trouble
• Abnormality occurred in injector drive circuit.
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears on machine
• Output drops.
Related information
• Method of reproducing failure code: Start engine.
Cause
1
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)
3
Defective power supply cutout relay
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (55) – (32)
Resistance
185 – 265 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)
40-104
Wiring harness between CE02 (female) (55) – R23 (1)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (55) – R24 (1)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (32) – R23 (2)
Resistance
Max. 1 z
Wiring harness between CE02 (female) (32) – R24 (2)
Resistance
Max. 1 z
Wiring harness between CE03 (female) (1) – T12
Resistance
Max. 1 z
Wiring harness between CE03 (female) (3) – R23 (5)
Resistance
Max. 1 z
Wiring harness between CE03 (female) (3) – R24 (5)
Resistance
Max. 1 z
Wiring harness between R23 (female) (3) – battery (+)
Resistance
Max. 1 z
Wiring harness between R24 (female) (3) – battery (+)
Resistance
Max. 1 z
PC128US-8
40 Troubleshooting Failure code [CA351] Inj. drive circuit error
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between CE02 (female) (55) – R23 (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE02 (female) (55) – R24 (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE02 (female) (32) – R23 (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between CE03 (female) (3) – R24 (5) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between R23 (female) (3) – battery (+) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between R24 (female) (3) – battery (+) and chassis ground
Resistance
Min. 1 Mz
Ground fault in wiring harWiring harness between CE02 (female) (32) 5 ness (Short circuit with GND – R24 (2) and chassis ground circuit) Wiring harness between CE03 (female) (3) – R23 (5) and chassis ground
a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 6 Defective engine controller
PC128US-8
CE03
Voltage
Between (3) – (1)
20 – 30 V
40-105
40 Troubleshooting Failure code [CA351] Inj. drive circuit error
Related circuit diagram
40-106
PC128US-8
40 Troubleshooting Failure code [CA352] Sensor sup. 1 volt. low error
Failure code [CA352] Sensor sup. 1 volt. low error User code
Failure code
E15
CA352
Trouble
1
Sensor sup. 1 volt. low error (Engine controller system)
Contents of trouble
• Low voltage was detected in sensor power supply 1 (5 V) circuit.
Action of controller
• Limits output of common rail pressure sensor and continues operation (Limits common rail pressure).
Problem that appears on machine
• Output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
PC128US-8
Causes
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA386].
40-107
40 Troubleshooting Failure code [CA386] Sensor sup. 1 volt. high error
Failure code [CA386] Sensor sup. 1 volt. high error User code
Failure code
E15
CA386
Trouble
1
Sensor sup. 1 volt. high error (Engine controller system)
Contents of trouble
• High voltage was detected in sensor power supply 1 (5 V) circuit.
Action of controller
• Operates Bkup speed sensor with signals of Ne speed sensor. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. • Limits output and continues operation (Limits common rail pressure).
Problem that appears on machine
• Output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Causes 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
2
Possible causes and standard value in normal state
Defective sensor (Internal trouble)
Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.
Bkup speed sensor
CAM connector
Atmospheric pressure sensor
PAMB connector
Charge pressure sensor
PTIM connector
Common rail pressure sensor
PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between CE01 (female) (36) Resis3 (Disconnection in wiring or Max. 1 z – PFUEL (female) (1) tance defective contact in connecWiring harness between CE01 (female) (48) Resistor) Max. 1 z – PFUEL (female) (3) tance Ground fault in wiring harness 4 (Short circuit with GND circuit)
Short circuit in wiring harness 5 (With another wiring harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE01 (female) (48) – PFUEL (female) (3) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and Wiring harness between CE01 (female) (48) – PFUEL (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6
40-108
Defective engine controller
CE01
Voltage
Between (36) – (48)
4.75 – 5.25V
PC128US-8
40 Troubleshooting Failure code [CA386] Sensor sup. 1 volt. high error
Related circuit diagram
PC128US-8
40-109
40 Troubleshooting Failure code [CA435] Abnormality in engine oil pressure switch
Failure code [CA435] Abnormality in engine oil pressure switch User code
Failure code
E15
CA435
Trouble
Abnormality in engine oil pressure switch (Engine controller system)
Contents of trouble
• Abnormality occurred in engine oil pressure switch signal circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Engine oil pressure switch-based engine protection function does not function. • Engine oil pressure monitor does not display normally.
Related information
• Method of reproducing failure code: Turn starting switch or start engine. Causes
1
Possible causes and standard value in normal state
Defective engine oil pressure switch
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. POIL (Male)
Resistance
Between (1) – chassis ground
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshootness ing without turning starting switch ON. 2 (Disconnection in wiring or Resisdefective contact in connec- Wiring harness between CE01 (female) (32) Max. 1 z – POIL (female) (1) tance tor) a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Short circuit in wiring harness Wiring harness among all pins between (With another wiring harness) CE01 (female) (32) – CE01 (female) (With all connectors of wiring harness disconnected)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
CE01 (Female)
Resistance
Between (32) – chassis ground
Max. 1 z
Related circuit diagram
40-110
PC128US-8
40 Troubleshooting Failure code [CA441] Battery voltage low error
Failure code [CA441] Battery voltage low error User code
Failure code
E10
CA441
Trouble
1
Battery voltage low error (Engine controller system)
Contents of trouble
• Low voltage was detected in controller power supply voltage circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
Failure code [CA442] Battery voltage high error User code
Failure code
E10
CA442
Trouble
1
Battery voltage high error (Engine controller system)
Contents of trouble
• High voltage was detected in controller power supply voltage circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
PC128US-8
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
40-111
40 Troubleshooting Failure code [CA449] Rail press. very high error
Failure code [CA449] Rail press. very high error User code
Failure code
E11
CA449
Trouble
Rail press. very high error (Engine controller system)
Contents of trouble
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears on machine
• Output drops.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine.
Possible causes and standard value in normal state
40-112
Causes
1
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA553].
PC128US-8
40 Troubleshooting Failure code [CA449] Rail press. very high error
PC128US-8
40-113
40 Troubleshooting Failure code [CA451] Rail press. sensor high error
Failure code [CA451] Rail press. sensor high error User code
Failure code
E11
CA451
Trouble
1
Rail press. sensor high error (Engine controller system)
Contents of trouble
• High voltage was detected in common rail pressure sensor circuit.
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears on machine
• Output drops.
Related information
• Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Causes 1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA352] or [CA386] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL
Defective common rail pres2 sure sensor (Internal trouble)
Voltage
Between (1) – (3)
Power supply
4.75 – 5.25 V
Between (2) – (3)
Signal
0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between CE01 (female) (36) – PFUEL (female) (1)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (29) – PFUEL (female) (2)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (48) – PFUEL (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-114
Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and chassis ground
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (29) – PFUEL (female) (2) and chassis ground
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (48) – PFUEL (female) (3) and chassis ground
Resistance
Min.1 Mz
PC128US-8
40 Troubleshooting Failure code [CA451] Rail press. sensor high error
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Short circuit in wiring harness 5 (With another wiring harness)
Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and wiring harness between CE01 (female) (29) – PFUEL (female) (2)
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (36) – PFUEL (female) (1) and wiring harness between CE01 (female) (48) – PFUEL (female) (3)
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (29) – PFUEL (female) (2) and wiring harness between CE01 (female) (48) – PFUEL (female) (3)
Resistance
Min.1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
CE01
Voltage
Between (36) – (48)
4.75 – 5.25 V
Between (29) – (48)
0.25 – 4.6 V
Related circuit diagram
PC128US-8
40-115
40 Troubleshooting Failure code [CA452] Rail press. sensor low error
Failure code [CA452] Rail press. sensor low error User code
Failure code
E11
CA452
Trouble
1
Rail press. sensor low error (Engine controller system)
Contents of trouble
• Low voltage was detected in common rail pressure sensor circuit.
Action of controller
• Limits output and continues operation (Limits common rail pressure).
Problem that appears on machine
• Output drops.
Related information
• Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA451].
Failure code [CA553] Rail press. high error User code
Failure code
E15
CA553
Trouble
Rail press. high error (Engine controller system)
Contents of trouble
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
Action of controller
• None in particular.
Problem that appears on machine
• Output drops.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. Causes
Possible causes and standard value in normal state
40-116
1
Standard value in normal state/Remarks on troubleshooting
1 Defective related system
If another failure code is indicated, carry out troubleshooting for it.
2 Use of improper fuel
Check fuel used directly (for high viscosity).
3
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out common rail pressure sensor troubleshooting for failure code [CA451].
Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and stuck ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
7 Defective pressure limiter
Check pressure limiter directly for mechanical defect.
PC128US-8
40 Troubleshooting Failure code [CA559] Rail press. low error
Failure code [CA559] Rail press. low error User code
Failure code
E15
CA559
Trouble
Rail press. low error (Engine controller system)
Contents of trouble
• Supply pump does not feed fuel (level 1).
Action of controller
• Limits common rail pressure.
Problem that appears on machine
• Output drops.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. Causes 1 Defective related system
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it.
2 Use of improper fuel
Check fuel used directly (for high viscosity).
3 Clogging of fuel filter
a If a fuel filter is clogged, replace it.
4
Possible causes and standard value in normal state
1
Defective low-pressure circuit device
a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel pressure". Pressure in fuel low-pressure circuit (At high idle or rated load)
-49 – 0 kPa {-0.5 – 0 kg/cm2}
5
Defective electrical system of Supply pump IMV may have electric trouble. Carry out troublesupply pump IMV shooting for following failure codes [CA271], [CA272].
6
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor ness for damage. a For testing of leakage from pressure limiter, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector".
7 Defective pressure limiter
Leakage from pressure limiter *:
Max. 20 cc/min (*)
A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)".
a For testing of return rate (spill) from injector, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector".
8 Defective injector
9 Defective supply pump
Speed at rated operation
Return (Spill) limit from injector
1,600 rpm
190 cc/min
1,700 rpm
200 cc/min
1,800 rpm
210 cc/min
1,900 rpm
220 cc/min
2,000 rpm
230 cc/min
If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet> Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed“. Note 1: Check the low-pressure circuit parts for the following items. 1) Fuel level 2) Clogging of fuel tank breather 3) Sticking and wear of feed pump and clogging of filter 4) Leakage through and clogging of low-pressure fuel piping 5) Clogging of fuel filter PC128US-8
40-117
40 Troubleshooting Failure code [CA559] Rail press. low error
Check sheet for no-pressure feed Model Machine serial No.
Work No. #
Date of check
Engine Engine serial No.
/
/
Service meter #
h
Worker's name
A. Visual check
Good NG
1
Fuel leakage to outside
2
Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3
Check of failure code
/
/
/
Good NG
/
Check of monitoring information Code
*1
*2
4
Unit
Standard value (Reference value)
Low idle
rpm
1,100 ± 50
High idle
rpm
2,300 ± 60
Equivalent to rating
rpm
2,200
Low idle
%
0
High idle
%
100 —
—
—
Displayed item
Engine speed
Throttle opening degree
Checking condition
Measured value
Good NG
*3
Fuel injection command
Equivalent to rating
mm3
*4
Common rail pressure command
Equivalent to rating
MPa
*5
Common rail fuel pressure
Equivalent to rating
MPa
Low idle
CA
—
—
—
*6
Fuel injection timing command
High idle
CA
—
—
—
Equivalent to rating
CA
—
—
—
*7
Boost pressure
Equivalent to rating
kPa
—
—
—
*8
Engine coolant temperature
Low idle
°C
—
—
—
*9
Fuel temperature
Low idle
°C
—
—
—
Unit
Standard value (Reference value)
Check of reduced cylinder mode operation (Engine speed) Function
5 *10
Reduced cylinder
Measured value
Low idle
rpm
—
—
—
No. 2 cylinder
Low idle
rpm
—
—
—
No. 3 cylinder
Low idle
rpm
—
—
—
No. 4 cylinder
Low idle
rpm
—
—
—
Unit
Standard value (Reference value)
kPa {kg/cm2}
-49 – 0 {-0.5 – 0}
Checking condition
Fuel low-pressure circuit pressure High idle or rated load
Measured value
D. Check of strainers and filters 7
9
Good NG
Good NG
Visual check of fuel filter
E.Check of leakage and return rate 8
Good NG
No. 1 cylinder
C. Check of fuel circuit pressure
6
Checking condition
Leakage through pressure limiter
Return rate from injector
40-118
Checking condition
Unit
Standard value (Reference value)
Equivalent to rating
cc/min
Max. 20 (*)
Equivalent to rating 1,600 rpm
cc/min
190
Equivalent to rating 1,700 rpm
cc/min
200
Equivalent to rating 1,800 rpm
cc/min
210
Equivalent to rating 1,900 rpm
cc/min
220
Equivalent to rating 2,000 rpm
cc/min
230
Measured value
Good NG
Speed: Return rate:
PC128US-8
40 Troubleshooting Failure code [CA559] Rail press. low error
*1 – *10: See Testing and adjusting, "Special functions of machine monitor", Monitoring items table. *: A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)". Rating or equivalent: Relieve the circuit under the following condition. 1) Engine: Full throttle 2) Mode: P 3) Boom: Raise
PC128US-8
40-119
40 Troubleshooting Failure code [CA689] Eng. Ne speed sensor error
Failure code [CA689] Eng. Ne speed sensor error User code
Failure code
E15
CA689
Trouble
Eng. Ne speed sensor error (Engine controller system)
Contents of trouble
• Abnormality occurred in engine Ne speed sensor circuit.
Action of controller
• Operates with signals of Bkup speed sensor.
Problem that appears on machine
• Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related information
• Method of reproducing failure code: Start engine.
Causes 1
1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
Wiring harness between CE01 (female) (26) – NE (female) (1)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (44) – NE (female) (2)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (42) – NE (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state
Wiring harness between CE01 (female) (26) – NE (female) (1) and chassis ground
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (44) – NE (female) (2) and chassis ground
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (42) – NE (female) (3) and chassis ground
Resistance
Min.1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring harness 4 (With another wiring harness)
Wiring harness between CE01 (female) (26) – NE (female) (1) and wiring harness between CE01 (female) (44) – NE (female) (2)
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (26) – NE (female) (1) and wiring harness between CE01 (female) (42) – NE (female) (3)
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (44) – NE (female) (2) and wiring harness between CE01 (female) (42) – NE (female) (3)
Resistance
Min.1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (crankshaft pulley) part directly for defect. 6
40-120
Defective engine Ne speed sensor
If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [CA689] Eng. Ne speed sensor error
Possible causes and standard value in normal state
Causes
Standard value in normal state/Remarks on troubleshooting
7 Defective engine controller
If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Related circuit diagram
PC128US-8
40-121
40 Troubleshooting Failure code [CA731] Eng. Bkup speed sensor phase error
Failure code [CA731] Eng. Bkup speed sensor phase error User code
Failure code
E15
CA731
Trouble
Eng. Bkup speed sensor phase error (Engine controller system)
Contents of trouble
• Engine Bkup speed sensor circuit detected abnormality in phase.
Action of controller
• Controls with signals of engine Ne speed sensor.
Problem that appears on machine
• Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information
• Method of reproducing failure code: Start engine.
Cause Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
1
Defective engine Ne speed sensor system
Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA698].
2
Defective engine Bkup speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
Failure code [CA757] All persistent data lost error User code
Failure code
E10
CA757
Trouble
1
All persistent data lost error (Engine controller system)
Contents of trouble
• All data in engine controller are lost.
Action of controller
• None in particular.
Problem that appears on machine
• Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-122
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA111].
PC128US-8
40 Troubleshooting Failure code [CA757] All persistent data lost error
PC128US-8
40-123
40 Troubleshooting Failure code [CA778] Eng. Bkup speed sensor error
Failure code [CA778] Eng. Bkup speed sensor error User code
Failure code
E15
CA778
Trouble
Eng. Bkup speed sensor error (Engine controller system)
Contents of trouble
• Abnormality occurred in engine Bkup speed sensor circuit.
Action of controller
• Operates with signals of Ne speed sensor.
Problem that appears on machine
• Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information
• Method of reproducing failure code: Start engine.
Causes 1
1
Standard value in normal state/Remarks on troubleshooting
Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
Wiring harness between CE01 (female) (36) – CAM (female) (1)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (48) – CAM (female) (2)
Resistance
Max. 1 z
Wiring harness between CE01 (female) (37) – CAM (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state
Wiring harness between CE01 (female) (36) – CAM (female) (1) and chassis ground
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (48) – CAM (female) (2) and chassis ground
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (37) – CAM (female) (3) and chassis ground
Resistance
Min.1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring harness 4 (With another wiring harness)
Wiring harness between CE01 (female) (36) – CAM (female) (1) and between CE01 (female) (48) – CAM (female) (2)
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (36) – CAM (female) (1) and between CE01 (female) (37) – CAM (female) (3)
Resistance
Min.1 Mz
Wiring harness between CE01 (female) (48) – CAM (female) (2) and between CE01 (female) (37) – CAM (female) (3)
Resistance
Min.1 Mz
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly part for defect. Defective engine Bkup speed sensor
If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7 Defective engine controller
If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
6
40-124
PC128US-8
40 Troubleshooting Failure code [CA778] Eng. Bkup speed sensor error
Related circuit diagram
PC128US-8
40-125
40 Troubleshooting Failure code [CA1633] KOMNET datalink timeout error
Failure code [CA1633] KOMNET datalink timeout error User code E0E
Failure code CA1633
Trouble
1
KOMNET datalink timeout error (Engine controller system)
Contents of trouble
• Engine controller detected communication error in KOMNET communication circuit between pump controller and machine monitor.
Action of controller
• Continues operation in default mode. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Information may not transmitted normally by KOMNET communication and machine may not operate normally. (Trouble phenomenon depends on failed section.)
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CM02 (female) (8), ness (Disconnection in wiring (9) – C01 (female) (45), – CE02 (female) 1 or defective contact in con- (1), – K02 (female) (A) nector) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between CM02 (female) (8), Ground fault in wiring har(9) – C01 (female) (45), – CE02 (female) 2 ness (Short circuit with GND (1), – K02 (female) (A), – N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) – C01 (female) (45), – CE02 (female) 3 24V circuit) in wiring harness (1), – K02 (female) (A), – N08 (male) (3)
Voltage
Max. 5.5 V
Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Voltage
Max. 5.5 V
Defective CAN terminal 4 resistance (Internal short circuit or disconnection)
5 Defective engine controller
40-126
Resistance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. K02 (male)
Resistance
Between (A) – (B)
120 ± 12 z
If causes 1 – 4 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [CA1633] KOMNET datalink timeout error
Related circuit diagram
PC128US-8
40-127
40 Troubleshooting Failure code [CA2185] Throttle sens. sup. volt. high error
Failure code [CA2185] Throttle sens. sup. volt. high error User code
Failure code
E14
CA2185
Trouble
1
Throttle Sens. sup. volt. high error (Engine controller system)
Contents of trouble
• High voltage was detected in throttle sensor power supply (5 V) circuit.
Action of controller
• Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model).
Problem that appears on machine
• Engine speed cannot be controlled with fuel control dial.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Possible causes and standard value in normal state
Defective fuel control dial (Internal trouble)
Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.
Fuel control dial
P20 connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE02 (female) (27) Resis2 Max. 1 z or defective contact in con- – P20 (female) (1) tance nector) Wiring harness between CE02 (female) (28) ResisMax. 1 z – P20 (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between CE02 (female) (27) 3 ness (Short circuit with GND – P20 (female) (1) and chassis ground circuit) Wiring harness between CE02 (female) (28) – P20 (female) (3) and chassis ground Short circuit in wiring har4 ness (with another wiring harness)
Resistance
Min.1 Mz
Resistance
Min.1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) (27) – P20 (female) (1) and between CE02 (female) (28) – P20 (female) (3)
Resistance
Min.1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
40-128
CE02
Voltage
Between (27) – (28)
4.75 – 5.25 V
PC128US-8
40 Troubleshooting Failure code [CA2185] Throttle sens. sup. volt. high error
Related circuit diagram
PC128US-8
40-129
40 Troubleshooting Failure code [CA2186] Throttle sens. sup. volt. low error
Failure code [CA2186] Throttle sens. sup. volt. low error User code
Failure code
E14
CA2186
Trouble
1
Throttle sens. sup. volt. low error (Engine controller system)
Contents of trouble
• Low voltage was detected in throttle sensor power supply (5 V) circuit.
Action of controller
• Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model).
Problem that appears on machine
• Engine speed cannot be controlled with fuel control dial.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA2185].
Failure code [CA2249] Rail press. very low error User code
Failure code
E11
CA2249
Trouble
Rail press. very low error (Engine controller system)
Contents of trouble
• Supply pump does not feed fuel (level 2).
Action of controller
• Limits common rail pressure.
Problem that appears on machine
• Output drops.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine.
Possible causes and standard value in normal state
40-130
Cause
1
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA559].
PC128US-8
40 Troubleshooting Failure code [CA2311] Abnormality in IMV solenoid
Failure code [CA2311] Abnormality in IMV solenoid User code
Failure code
E11
CA2311
Trouble
Abnormality in IMV solenoid (Engine controller system)
Contents of trouble
• Resistance in supply pump actuator is abnormally high or low.
Action of controller
• None in particular.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Start engine.
Possible causes and standard value in normal state
PC128US-8
Causes 1
1
Standard value in normal state/Remarks on troubleshooting Perform troubleshooting for failure codes [CA271] and [CA272].
40-131
40 Troubleshooting Failure code [D110KB] Battery relay drive short
Failure code [D110KB] Battery relay drive short User code
Failure code
—
D110KB
Trouble
1
Battery relay drive short (Pump controller system)
Contents of trouble
• Abnormal current flowed at output to battery relay drive circuit.
Action of controller
• Turns output to battery relay drive circuit OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Engine does not stop.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Possible causes and standard value in normal state
Defective battery relay (Internal defect)
Ground fault in wiring harness 2 (Short circuit with GND circuit)
Battery relay
Resistance
Between BR (terminal BR) – RE (terminal E)
There is continuity
Between BR (terminal BR) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (108) – D02 – J06 – BR (terminal BR) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective pump controller
40-132
C02 (female)
Turn starting switch OFF.
Voltage
Between (108) – chassis ground
ON o OFF
20 – 30 V (4 – 7 sec.)
PC128US-8
40 Troubleshooting Failure code [D110KB] Battery relay drive short
Related circuit diagram
PC128US-8
40-133
40 Troubleshooting Failure code [D19JKZ] Personal code relay abnormality
Failure code [D19JKZ] Personal code relay abnormality User code
Failure code
E01
D19JKZ
Contents of trouble
Action of controller
Trouble
1
Personal code relay abnormality (KOMTRAX system in machine monitor)
• Disconnection or short circuit was detected in personal code relay circuit. • • • •
None in particular (when disconnection is detected). Turns output to personal code relay OFF (when short circuit is detected). If cause of failure disappears, system resets itself (when disconnection is detected). Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF (when disconnection is detected).
Problem that appears on machine Related information
• This failure code is displayed only when engine lock function is effective. • Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble cannot be reproduced on machine (Short circuit). Cause 1 Defective fuse No. 20
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (Troubleshooting for relay unit) R07 (male)
Resistance
Defective personal code Between (1) – (2) (300 – 600 z) 2 relay (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON or short circuit) and carry out troubleshooting. (Troubleshooting by replacement)
Possible causes and standard value in normal state
Replace personal code relay (R07) with another relay and perform reproducing operation. If "E" of failure code goes off at this time, replaced relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (20) – R07 Resis3 Max. 1 z or defective contact in con- (female) (1) tance nector) Wiring harness between R07 (female) (2) – ResisMax. 1 z CM01 (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between F01 (20) – R07 4 ness (Short circuit with GND (female) (1) circuit) Wiring harness between R07 (female) (2) – CM01 (female) (6) 5
40-134
Defective machine monitor (KOMTRAX section)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If causes 1 – 4 are not detected, machine monitor (KOMTRAX) may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [D19JKZ] Personal code relay abnormality
Related circuit diagram
PC128US-8
40-135
40 Troubleshooting Failure code [D862KA] GPS antenna discon
Failure code [D862KA] GPS antenna discon User code
Failure code
—
D862KA
Trouble
GPS antenna disconnection (KOMTRAX system in machine monitor)
Contents of trouble
• Disconnection was detected in GPS antenna circuit.
Action of controller
• None in particular. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• GPS cannot measure position.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
1
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective GPS antenna or antenna cable
Possible causes are defective GPS antenna, disconnection or short circuit in antenna cable, and defective connection of antenna cable connector (GPS).
Configuration drawing
40-136
PC128US-8
40 Troubleshooting Failure code [D862KA] GPS antenna discon
PC128US-8
40-137
40 Troubleshooting Failure code [DA22KK] Pump solenoid power low error
Failure code [DA22KK] Pump solenoid power low error User code
Failure code
E0E
DA22KK
Trouble
1
Lowering of solenoid power supply voltage (Pump controller system)
Contents of trouble
• Solenoid power supply voltage of controller is below 20 V.
Action of controller
• While this failure code is displayed, detection of failure codes (disconnection/short circuit) of all the solenoid systems is stopped. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Since no solenoid valve is driven normally, machine does not operate normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defective fuse F01
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See Cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C02 (female) (116), ness (Disconnection in wiring (118), (121) – F01-2 2 or defective contact in con- Wiring harness between F01-1A – F02 nector) (male) (2) Wiring harness between F02 (male) (1) – RM Possible causes and standard value in normal state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (116), Ground fault in wiring har(118), (121) – F01-2 3 ness (Short circuit with GND Wiring harness between F01-1A – F02 circuit) (male) (2), – circuit branch end Wiring harness between F02 (male) (1) – RM
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective pump controller
40-138
C01 (female), C02 (female)
Voltage
Between C02 (116), (118), (121) – C01 (2), (5)
20 – 30 V
PC128US-8
40 Troubleshooting Failure code [DA22KK] Pump solenoid power low error
Related circuit diagram
PC128US-8
40-139
40 Troubleshooting Failure code [DA25KP] 5V sensor 1 power abnormality
Failure code [DA25KP] 5V sensor 1 power abnormality User code
Failure code
—
DA25KP
Trouble
1
5V sensor power supply output 1 abnormality (Pump controller system)
Contents of trouble
• Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
Action of controller
• Turns output of 5V sensor power supply output 1 OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Automatic gear shifting function does not work (pump pressure sensor system). • Auto-decelerator keeps working and is not reset or fine control performance of work equipment is lowered (PPC pressure sensor system).
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective pressure sensor 1 (Internal short circuit)
Possible causes and standard value in normal state
40-140
Disconnect sensors at right in order and carry out operation to reproduce trouble. If "E" of failure code goes off when a sensor is disconnected, that sensor is defective.
Bucket DUMP PPC pressure switch
P01
Boom RAISE PPC pressure switch
P03
Bucket CURL PPC pressure switch
P04
Arm IN PPC pressure switch
P05
Swing RIGHT PPC pressure switch
P07
Swing LEFT PPC pressure switch
P08
Pump pressure sensor
P25
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C01 (female) (34) – P01 (female) (2), P01 (female) (1) – J03 – ground (T08) [Bucket DUMP PPC pressure switch system]
Resistance
Min. 1 Mz
Wiring harness between C01 (female) (53) – P03 (female) (2), P03 (female) (1) – J03 – ground (T08) [Boom RAISE PPC pressure switch system]
Resistance
Min. 1 Mz
Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C01 (female) (73) – P04 (female) (2), P04 (female) (1) – J03 – circuit) ground (T08) [Bucket CURL PPC pressure switch system]
Resistance
Min. 1 Mz
Wiring harness between C01 (female) (17) – P05 (female) (2), P05 (female) (1) – J03 – ground (T08) [Arm IN PPC pressure switch system]
Resistance
Min. 1 Mz
Wiring harness between C01 (female) (16) – P07 (female) (2), P07 (female) (1) – J03 – ground (T08) [Swing RIGHT PPC pressure switch system]
Resistance
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [DA25KP] 5V sensor 1 power abnormality
Cause
Standard value in normal state/Remarks on troubleshooting
Wiring harness between C01 (female) (16) – P08 (female) (2), P08 (female) (1) – J03 – ground (T08) Ground fault in wiring har2 ness (Short circuit with GND [Swing LEFT PPC pressure switch system] circuit) Wiring harness between C01 (female) (9) – J07 – P25 (female) (3) [Pump pressure sensor system]
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between C01 (female) (34) – P01 (female) (2), P01 (female) (1) – J03 – ground (T08) [Bucket CURL PPC pressure sensor system]
Voltage
Max. 1 V
Wiring harness between C01 (female) (53) – P03 (female) (2), P03 (female) (1) – J03 – ground (T08) [Swing LEFT PPC pressure sensor system]
Voltage
Max. 1 V
Wiring harness between C01 (female) (73) – P04 (female) (2), P04 (female) (1) – J03 – ground (T08) [Arm IN PPC pressure sensor system]
Voltage
Max. 1 V
Hot short (Short circuit with Wiring harness between C01 (female) (17) 24V circuit) in wiring harness – P05 (female) (2), P05 (female) (1) – J03 – ground (T08) [Bucket DUMP PPC pressure sensor system]
Voltage
Max. 1 V
Wiring harness between C01 (female) (16) – P07 (female) (2), P07 (female) (1) – J03 – ground (T08) [Boom RAISE PPC pressure sensor system]
Voltage
Max. 1 V
Wiring harness between C01 (female) (16) – P08 (female) (2), P08 (female) (1) – J03 – ground (T08) [Swing RIGHT PPC pressure sensor system]
Voltage
Max. 1 V
Wiring harness between C01 (female) (9) – J07 – P25 (female) (3) [Pump pressure sensor system]
Voltage
Max. 1 V
Possible causes and standard value in normal state 3
4 Defective pump controller
PC128US-8
If causes 1 – 3 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-141
40 Troubleshooting Failure code [DA25KP] 5V sensor 1 power abnormality
Related circuit diagram
40-142
PC128US-8
40 Troubleshooting Failure code [DA26KP] 5V sensor 2 power abnormality
Failure code [DA26KP] 5V sensor 2 power abnormality User code
Failure code
—
DA26KP
Trouble
1
5V sensor power supply output 2 abnormality (Pump controller system)
Contents of trouble
• Voltage of 5V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
Action of controller
• Turns output of 5V sensor power supply output 2 OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 1 ness (Short circuit with GND Wiring harness between C01 (female) (8) – Resiscircuit) Min. 1 Mz A08 (female) (3), (6) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between C01 (female) (8) – Voltage Max. 1 V A08 (female) (3), (6) and chassis ground 3 Defective pump controller
If causes 1 – 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Related circuit diagram
PC128US-8
40-143
40 Troubleshooting Failure code [DA2RMC] CAN discon (Pump controller detected)
Failure code [DA2RMC] CAN discon (Pump controller detected) User code E0E
Failure code DA2RMC
Trouble
1
CAN disconnection (Pump controller detected) (Pump controller system)
Contents of trouble
• Pump controller detected communication error in CAN communication circuit between machine monitor and engine controller.
Action of controller
• Continues operation with information of CAN communication just before detection of error. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble phenomenon depends on failed section.)
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CM02 (female) (8), ness (Disconnection in wiring (9) – C01 (female) (45), – CE02 (female) 1 or defective contact in con- (1), – K02 (female) (A) nector) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between CM02 (female) (8), Ground fault in wiring har(9) – C01 (female) (45), – CE02 (female) 2 ness (Short circuit with GND (1), – K02 (female) (A), – N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) – C01 (female) (45), – CE02 (female) 3 24V circuit) in wiring harness (1), – K02 (female) (A), – N08 (male) (3)
Voltage
Max. 5.5 V
Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Voltage
Max. 5.5 V
Defective CAN terminal 4 resistance (Internal short circuit or disconnection) 5 Defective pump controller
40-144
Resistance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. K02 (male)
Resistance
Between (A) – (B)
120 ± 12 z
If causes 1 – 4 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DA2RMC] CAN discon (Pump controller detected)
Related circuit diagram
PC128US-8
40-145
40 Troubleshooting Failure code [DAF8KB] Short circuit in camera power supply
Failure code [DAF8KB] Short circuit in camera power supply User code
Failure code
— Contents of trouble
DAF8KB
Trouble
1
Short circuit in camera power supply (Machine monitor system)
• Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above 10 V.
Action of • Turns output power supply voltage (Rating: 8 V) to camera OFF. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine
• Camera image is not displayed on monitor screen.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Defective camera (Internal 1 short circuit)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Disconnect camera and perform failure reproduction operation. If failure code disappears at this time, camera is defective.
a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Ground fault in wiring har(Disconnect camera and check that it is not defective in 2 ness (Contact with GND ciradvance.) cuit) Between CM05 (female) (1) – CAMERA Voltage Min. 6 V (female) (F) wiring harness and ground
3
Hot short (Contact with 24V circuit) in wiring harness
a Disconnect camera with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Disconnect camera and check that it is not defective in advance.) Between CM05 (female) (1) – CAMERA (female) (F) wiring harness and ground
4 Defective machine monitor
40-146
Voltage
Max. 10 V
If causes 1 – 3 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DAF8KB] Short circuit in camera power supply
Related circuit diagram
PC128US-8
40-147
40 Troubleshooting Failure code [DAFGMC] GPS module error
Failure code [DAFGMC] GPS module error User code — Contents of trouble
Failure code DAFGMC
Trouble
1
GPS module operation error (KOMTRAX system in machine monitor)
• Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication MODEM in 50 seconds after KOMTRAX is started.
Action of • None in particular. machine monitor • If cause of failure disappears, system resets itself. Problem that appears on machine Related information Possible causes and standard value in normal state
40-148
• Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting switch is turned ON). Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective machine monitor
GPS module of machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DAFGMC] GPS module error
PC128US-8
40-149
40 Troubleshooting Failure code [DAFRMC] CAN discon (Monitor detected)
Failure code [DAFRMC] CAN discon (Monitor detected) User code E0E Contents of trouble
Failure code DAFRMC
Trouble
1
CAN disconnection (Monitor detected) (Machine monitor system)
• Machine monitor detected communication error in CAN communication circuit between pump controller and engine controller.
Action of • If cause of failure disappears, system resets itself. machine monitor Problem that appears on machine
• Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble phenomenon depends on failed section.)
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CM02 (female) (8), ness (Disconnection in wiring (9) – C01 (female) (45), – CE02 (female) 1 or defective contact in con- (1), – K02 (female) (A) nector) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between CM02 (female) (8), Ground fault in wiring har(9) – C01 (female) (45), – CE02 (female) 2 ness (Short circuit with GND (1), – K02 (female) (A), – N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between CM02 (female) (8), Hot short (Short circuit with (9) – C01 (female) (45), – CE02 (female) 3 24V circuit) in wiring harness (1), – K02 (female) (A), – N08 (male) (3)
Voltage
Max. 5.5 V
Wiring harness between CM02 (female) (10) – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Voltage
Max. 5.5 V
Defective CAN terminal 4 resistance (Internal short circuit or disconnection)
5 Defective machine monitor
40-150
Resistance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. K02 (male)
Resistance
Between (A) – (B)
120 ± 12 z
If causes 1 – 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DAFRMC] CAN discon (Monitor detected)
Related circuit diagram
PC128US-8
40-151
40 Troubleshooting Failure code [DGH2KB] Hydr oil sensor short
Failure code [DGH2KB] Hydr oil sensor short User code
Failure code
—
DGH2KB
Trouble
1
Hydraulic oil temperature sensor short (Pump controller system)
Contents of trouble
• Ground fault was detected in hydraulic oil temperature sensor circuit.
Action of controller
• Controls pump in normal mode (as when hydraulic oil temperature is 20°C to below 95°C). (Overheat prevention function does not work.)
Problem that appears on machine
• While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from top of white range (bottom of green range).
Related information
• Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function. (Code: 04402 Hydraulic oil temperature sensor voltage) • Method of reproducing failure code: Start engine. Cause
Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P22 (male)
Resistance
Between (1) – (2)
3.5 – 90 kz
Between (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C01 (female) (29) Resiscircuit) Min. 1 Mz – P22 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C01 (female)
Resistance
Between (29) – (46)
3.5 – 90 kz
Between (29) – chassis ground
Min. 1 Mz
Related circuit diagram
40-152
PC128US-8
40 Troubleshooting Failure code [DGH2KB] Hydr oil sensor short
PC128US-8
40-153
40 Troubleshooting Failure code [DHPAMA] Pump press sensor abnormality
Failure code [DHPAMA] Pump press sensor abnormality User code
Failure code
—
DHPAMA
Trouble
1
Pump pressure sensor abnormality (Pump controller system)
Contents of trouble
• Signal voltage of pump pressure sensor circuit is below 0.3 V or above 4.4 V.
Action of controller
• Fixes pump pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Automatic gear shifting function does not work. • Straight travel performance or steering performance lowers.
Related information
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Pump pressure can be checked with monitoring function. (Code: 01100 Pump pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5V sensor power 1 supply 1 system
a If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P25
Defective pump pressure 2 sensor (Internal defect)
Voltage
Between (3) – (1)
Power supply
4.5 – 5.5 V
Between (2) – (1)
Signal
0.3 – 4.5 V
If voltage is abnormal, check failure code. (If "E" of failure code goes off at this time, pump pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring har- Wiring harness between C01 (female) (18) ness (Disconnection in wiring – P25 (female) (1) 3 or defective contact in con- Wiring harness between C01 (female) (49) nector) – P25 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between C01 (female) (9) – J07 – P25 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (49) Resiscircuit) Min. 1 Mz – P25 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (49) Voltage Max. 1 V – P25 (female) (2) 6 Defective pump controller
40-154
If causes 1 – 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DHPAMA] Pump press sensor abnormality
Related circuit diagram
PC128US-8
40-155
40 Troubleshooting Failure code [DHSFMA] Travel left forward PPC press sensor abnormality
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality User code
Failure code
E20
DHSFMA
Trouble
1
Travel left forward PPC pressure sensor abnormality (Pump controller system)
Contents of trouble
• Signal voltage of travel left forward PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
• Fixes travel left forward PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Automatic decelerator cannot be reset. • Travel left forward performance lowers.
Related information
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel left forward PPC pressure can be checked with monitoring function. (Code: 07102 Travel left forward PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5V sensor power supply 1 system
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P10
Defective travel left forward 2 PPC pressure sensor (Internal defect)
Possible causes and standard value in normal state
Voltage
Between (3) – (1)
Power supply
4.5 – 5.5 V
Between (2) – (1)
Signal
0.3 – 4.5 V
If voltage is abnormal, replace travel left forward PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel left forward PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C01 (female) (18) ness (Disconnection in wiring – P10 (female) (1) 3 or defective contact in con- Wiring harness between C01 (female) (69) nector) – P10 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between C01 (female) (9) – J07 – P10 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (69) Resiscircuit) Min. 1 Mz – P10 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (69) Voltage Max. 1 V – P10 (female) (2) 6 Defective pump controller
40-156
If causes 1 – 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DHSFMA] Travel left forward PPC press sensor abnormality
Related circuit diagram
PC128US-8
40-157
40 Troubleshooting Failure code [DHSGMA] Travel right forward PPC press sensor abnormality
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality User code
Failure code
E20
DHSGMA
Trouble
1
Travel right forward PPC pressure sensor abnormality (Pump controller system)
Contents of trouble
• Signal voltage of travel right forward PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
• Fixes travel right forward PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Automatic decelerator cannot be reset. • Travel right forward performance lowers.
Related information
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel right forward PPC pressure can be checked with monitoring function. (Code: 07103 Travel right forward PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5V sensor power supply 1 system
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P09
Defective travel right forward 2 PPC pressure sensor (Internal defect)
Possible causes and standard value in normal state
Voltage
Between (3) – (1)
Power supply
4.5 – 5.5 V
Between (2) – (1)
Signal
0.3 – 4.5 V
If voltage is abnormal, replace travel right forward PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel right forward PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C01 (female) (18) ness (Disconnection in wiring – P09 (female) (1) 3 or defective contact in con- Wiring harness between C01 (female) (55) nector) – P09 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between C01 (female) (9) – J06 – P09 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (55) Resiscircuit) Min. 1 Mz – P09 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (55) Voltage Max. 1 V – P09 (female) (2) 6 Defective pump controller
40-158
If causes 1 – 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DHSGMA] Travel right forward PPC press sensor abnormality
Related circuit diagram
PC128US-8
40-159
40 Troubleshooting Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality User code
Failure code
E20
DHSHMA
Trouble
1
Travel left reverse PPC pressure sensor abnormality (Pump controller system)
Contents of trouble
• Signal voltage of travel left reverse PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
• Fixes travel left reverse PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Automatic decelerator cannot be reset. • Travel left reverse performance lowers.
Related information
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel left reverse PPC pressure can be checked with monitoring function. (Code: 07104 Travel left reverse PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5V sensor power supply 1 system
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P27
Defective travel left reverse 2 PPC pressure sensor (Internal defect)
Possible causes and standard value in normal state
Voltage
Between (3) – (1)
Power supply
4.5 – 5.5 V
Between (2) – (1)
Signal
0.3 – 4.5 V
If voltage is abnormal, replace travel left reverse PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel left reverse PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C01 (female) (18) ness (Disconnection in wiring – P27 (female) (1) 3 or defective contact in con- Wiring harness between C01 (female) (13) nector) – P27 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between C01 (female) (9) – J07 – P27 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (13) Resiscircuit) Min. 1 Mz – P27 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (13) Voltage Max. 1 V – P27 (female) (2) 6 Defective pump controller
40-160
If causes 1 – 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality
Related circuit diagram
PC128US-8
40-161
40 Troubleshooting Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality User code
Failure code
E20
DHSJMA
Trouble
1
Travel right reverse PPC pressure sensor abnormality (Pump controller system)
Contents of trouble
• Signal voltage of travel right reverse PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
• Fixes travel right reverse PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Automatic decelerator cannot be reset. • Travel right reverse performance lowers.
Related information
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Travel right reverse PPC pressure can be checked with monitoring function. (Code: 07105 Travel right reverse PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5V sensor power supply 1 system
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P26
Defective travel right reverse 2 PPC pressure sensor (Internal defect)
Possible causes and standard value in normal state
Voltage
Between (3) – (1)
Power supply
4.5 – 5.5 V
Between (2) – (1)
Signal
0.3 – 4.5 V
If voltage is abnormal, replace travel right reverse PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, travel right reverse PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C01 (female) (18) ness (Disconnection in wiring – P26 (female) (1) 3 or defective contact in con- Wiring harness between C01 (female) (36) nector) – P26 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between C01 (female) (9) – J07 – P26 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (36) Resiscircuit) Min. 1 Mz – P26 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (36) Voltage Max. 1 V – P26 (female) (2) 6 Defective pump controller
40-162
If causes 1 – 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality
Related circuit diagram
PC128US-8
40-163
40 Troubleshooting Failure code [DHSKMA] Blade raise PPC press sensor abnormality
Failure code [DHSKMA] Blade raise PPC press sensor abnormality User code
Failure code
—
DHSKMA
Trouble
1
Blade raise PPC pressure sensor abnormality (Pump controller system)
Contents of trouble
• Signal voltage of blade raise PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
• Fixes blade raise PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Automatic decelerator cannot be reset. • Blade raise performance lowers.
Related information
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Blade raise PPC pressure can be checked with monitoring function. (Code: 07106 Blade raise PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5V sensor power supply 1 system
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P28
Defective blade raise PPC 2 pressure sensor (Internal defect)
Possible causes and standard value in normal state
Voltage
Between (3) – (1)
Power supply
4.5 – 5.5 V
Between (2) – (1)
Signal
0.3 – 4.5 V
If voltage is abnormal, replace blade raise PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, blade raise PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C01 (female) (18) ness (Disconnection in wiring – P28 (female) (1) 3 or defective contact in con- Wiring harness between C01 (female) (32) nector) – P28 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between C01 (female) (9) – J07 – P28 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (32) Resiscircuit) Min. 1 Mz – P28 (female) (2) tance
5
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (32) – P28 (female) (2)
6 Defective pump controller
40-164
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage
Max. 1 V
If causes 1 – 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DHSKMA] Blade raise PPC press sensor abnormality
Related circuit diagram
PC128US-8
40-165
40 Troubleshooting Failure code [DHSLMA] Blade lower PPC press sensor abnormality
Failure code [DHSLMA] Blade lower PPC press sensor abnormality User code
Failure code
—
DHSLMA
Trouble
1
Blade lower PPC pressure sensor abnormality (Pump controller system)
Contents of trouble
• Signal voltage of blade lower PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
• Fixes blade lower PPC pressure at 0 MPa {0 kg/cm2} and continues control. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Automatic decelerator cannot be reset. • Blade lower performance lowers.
Related information
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. • Blade lower PPC pressure can be checked with monitoring function. (Code: 07107 Blade lower PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5V sensor power supply 1 system
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting in each case. P11
Defective blade lower PPC 2 pressure sensor (Internal defect)
Possible causes and standard value in normal state
Voltage
Between (3) – (1)
Power supply
4.5 – 5.5 V
Between (2) – (1)
Signal
0.3 – 4.5 V
If voltage is abnormal, replace blade lower PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time, blade lower PPC pressure sensor is defective.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C01 (female) (18) ness (Disconnection in wiring – P11 (female) (1) 3 or defective contact in con- Wiring harness between C01 (female) (51) nector) – P11 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between C01 (female) (9) – J07 – P11 (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (51) Resiscircuit) Min. 1 Mz – P11 (female) (2) tance
5
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (51) – P11 (female) (2)
6 Defective pump controller
40-166
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage
Max. 1 V
If causes 1 – 5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DHSLMA] Blade lower PPC press sensor abnormality
Related circuit diagram
PC128US-8
40-167
40 Troubleshooting Failure code [DHX1MA] Overload sensor abnormality (Analog)
Failure code [DHX1MA] Overload sensor abnormality (Analog) User code
Failure code
—
DHX1MA
Trouble
1
Overload sensor (Analog) (Pump controller system)
Contents of trouble
• Monitor which is not set to be displayed (Overload alarm monitor) is displayed.
Action of controller
• None in particular. • If cause of failure disappears, system resets itself.
Problem that appears on machine Related information Possible causes and standard value in normal state
40-168
Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective pump controller
Pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DV20KB] Travel alarm S/C
Failure code [DV20KB] Travel alarm S/C User code
Failure code
—
DV20KB
Trouble
1
Travel alarm S/C (Pump controller system)
Contents of trouble
• Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
Action of controller
• Power to the travel alarm circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Problem that appears on machine
• The travel alarm does not sound.
Related information
• Operation of the travel alarm (ON or OFF) can be checked in the monitoring function. (Code: 03701 Controller output 2) Cause
Standard value in normal state/Remarks on troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. M14 (female)
Travel alarm defective 1 (Internal defect)
Possible causes and standard value in normal state
Between (1) and (2)
Travel lever
Voltage
Neutral
Max. 1 V
Operated
20 – 30 V
If the above voltage is normal but the travel alarm does not operate, the travel alarm is defective. a Turn the engine starting switch OFF for the preparations, and Grounding fault of wiring harhold it in the OFF position during the troubleshooting. ness 2 (Contact with grounding cir- Between wiring harness between C02 Resis(female) (107) and M14 (female) (1) and Min. 1 Mz cuit) tance grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 3 Pump controller defective
C02
Travel lever
Voltage
Between (107) – chassis ground
Neutral
Max. 1 V
Operated
20 – 30 V
Related circuit diagram
PC128US-8
40-169
40 Troubleshooting Failure code [DW43KA] Travel speed sol discon
Failure code [DW43KA] Travel speed sol discon User code
Failure code
—
DW43KA
Trouble
1
Travel speed solenoid system disconnection (Pump controller system)
Contents of trouble
• When output to travel speed shifting solenoid was turned ON, disconnection was detected in circuit.
Action of controller
• None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle).
Related information
• Operating condition of travel speed shifting solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. Cause Defective travel speed shift1 ing solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V02 (male)
Resistance
Between (1) – (2)
20 – 60 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (87) 2 or defective contact in con- – V02 (female) (2) nector) Wiring harness between C02 (female) (115), (117), (120) – V02 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C01 (female)
Resistance
Between (87) – (115), (117), (120)
20 – 60 z
Related circuit diagram
40-170
PC128US-8
40 Troubleshooting Failure code [DW43KB] Travel speed sol short
Failure code [DW43KB] Travel speed sol short User code
Failure code
—
DW43KB
Trouble
1
Travel speed solenoid system short (Pump controller system)
Contents of trouble
• When output to travel speed shifting solenoid was turned ON, short circuit was detected in circuit.
Action of controller
• Turns output to travel speed shifting solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle).
Related information
• Operating condition of travel speed shifting solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. Cause
Defective travel speed shift1 ing solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V02 (male)
Resistance
Between (1) – (2)
20 – 60 z
Between (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND ResisWiring harness between C02 (female) (87) circuit) Min. 1 Mz – V02 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C02 (female)
Resistance
Between (87) – (115), (117), (120)
20 – 60 z
Between (87) – chassis ground
Min. 1 Mz
Related circuit diagram
PC128US-8
40-171
40 Troubleshooting Failure code [DW45KA] Swing brake sol discon
Failure code [DW45KA] Swing brake sol discon User code
Failure code
E03
DW45KA
Trouble
1
Swing holding brake solenoid system disconnection (Pump controller system)
Contents of trouble
• When output to swing holding brake solenoid was turned OFF, disconnection was detected in circuit.
Action of controller
• None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Machine cannot swing (Swing holding brake is not reset).
Related information
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work, however, when machine stops). • Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. • Operating condition of swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Turn starting switch ON. Cause Defective swing holding 1 brake solenoid (Internal disconnection)
Defective assembled-type 2 diode D01 (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V03 (male)
Resistance
Between (1) – (2)
20 – 60 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D01 (male)
Digital circuit tester
Continuity
Between (7) – (3)
Diode mode
There is continuity
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Defective swing lock switch (Internal disconnection)
S04 (male) Between (3) – (4)
Possible causes and standard value in normal state
Swing lock switch
Resistance
OFF
Max. 1 z
ON
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (101) – D01 (female) (7)
Resistance
Max. 1 z
Resistance
Max. 1 z
V03 (female) (2)
Resistance
Max. 1 z
Wiring harness between C02 (female) (115), (117), (120) – V03 (female) (1)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between D01 (female) (3) – 4 or defective contact in con- J04 – S04 (female) (3) nector) Wiring harness between S04 (female) (4) –
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective pump controller
C02 (female) Between (101) – (115), (117), (120)
40-172
Disconnect D01 and connect pins (3) and (7) on female side directly.
Resistance 20 – 60 z
PC128US-8
40 Troubleshooting Failure code [DW45KA] Swing brake sol discon
Related circuit diagram
PC128US-8
40-173
40 Troubleshooting Failure code [DW45KB] Swing brake sol short
Failure code [DW45KB] Swing brake sol short User code
Failure code
E03
DW45KB
Trouble
1
Swing holding brake solenoid system short (Pump controller system)
Contents of trouble
• When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit.
Action of controller
• Turns output to swing holding brake solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Machine cannot swing (Swing holding brake is not reset).
Related information
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work, however, when machine stops). • Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. • Operating condition of swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Swing with left work equipment control lever. Cause
Defective swing holding 1 brake solenoid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V03 (male)
Resistance
Between (1) – (2)
20 – 60 z
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. ness (Disconnection in wiring 2 Wiring harness between C02 (female) (101) or defective contact in conResis– D01 – J04 – S04 – V03 (female) (2), – S25 Min. 1 Mz nector) tance (female) (14) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance
C02 (female) 3 Defective pump controller
Between (101) – (115), (117), (120) Between (101) – chassis ground
40-174
Disconnect D01 and connect pins (3) and (7) on female side directly.
20 – 60 z Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [DW45KB] Swing brake sol short
Related circuit diagram
PC128US-8
40-175
40 Troubleshooting Failure code [DW91KA] Travel junction sol discon
Failure code [DW91KA] Travel junction sol discon User code
Failure code
—
DW91KA
Trouble
1
Travel junction solenoid system disconnection (Pump controller system)
Contents of trouble
• When output to travel junction solenoid was turned ON, disconnection was detected in circuit.
Action of controller
• None in particular. (Since no current flows, solenoid does not operate.) • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Machine is not steered easily during travel.
Related information
• Operating condition of travel junction solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. Cause Defective travel junction 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V04 (male)
Resistance
Between (1) – (2)
20 – 60 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (110) 2 or defective contact in con- – V04 (female) (2) nector) Wiring harness between C02 (female) (115), (117), (120) – V04 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C02 (female)
Resistance
Between (110) – (115), (117), (120)
20 – 60 z
Related circuit diagram
40-176
PC128US-8
40 Troubleshooting Failure code [DW91KB] Travel junction sol short
Failure code [DW91KB] Travel junction sol short User code
Failure code
—
DW91KB
Trouble
1
Travel junction solenoid system short (Pump controller system)
Contents of trouble
• When output to travel junction solenoid was turned ON, short circuit was detected in circuit.
Action of controller
• Turns output to travel junction solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Machine is not steered easily during travel.
Related information
• Operating condition of travel junction solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. Cause
Defective travel junction 1 solenoid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V04 (male)
Resistance
Between (1) – (2)
20 – 60 z
Between (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C02 (female) (110) Resiscircuit) Min. 1 Mz – V04 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C02 (female)
Resistance
Between (110) – (115), (117), (120)
20 – 60 z
Between (110) – chassis ground
Min. 1 Mz
Related circuit diagram
PC128US-8
40-177
40 Troubleshooting Failure code [DWJ0KA] Merge-divider sol discon
Failure code [DWJ0KA] Merge-divider sol discon User code
Failure code
—
DWJ0KA
Trouble
1
Merge-divider solenoid disconnection (Pump controller system)
Contents of trouble
• When merge-divider EPC solenoid was driven, disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Single operation speed of work equipment and swing is high in lifting mode (L).
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Defective merge-divider EPC 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V05 (male)
Resistance
Between (1) – (2)
7 – 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (112) Resis2 Max. 1 z or defective contact in con- – V05 (female) (2) tance nector) ResisWiring harness between C02 (female) (115), Max. 1 z (117), (120) – V05 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C02 (female)
Resistance
Between (112) – (115), (117), (120)
7 – 14 z
Related circuit diagram
40-178
PC128US-8
40 Troubleshooting Failure code [DWJ0KB] Merge-divider sol short
Failure code [DWJ0KB] Merge-divider sol short User code
Failure code
—
DWJ0KB
Trouble
1
Merge-divider solenoid short (Pump controller system)
Contents of trouble
• When merge-divider EPC solenoid was driven, short circuit was detected in circuit.
Action of controller
• Turns output to merge-divider EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Single operation speed of work equipment and swing is high in lifting mode (L).
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Defective merge-divider EPC 1 solenoid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V05 (male)
Resistance
Between (1) – (2)
7 – 14 z
Between (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (112) circuit) – V05 (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C02 (female)
Resistance
Between (112) – (115), (117), (120)
7 – 14 z
Between (112) – chassis ground
Min. 1 Mz
Related circuit diagram
PC128US-8
40-179
40 Troubleshooting Failure code [DXA8KA] PC-EPC sol discon
Failure code [DXA8KA] PC-EPC sol discon User code
Failure code
E02
DXA8KA
Trouble
1
PC-EPC solenoid system disconnection (Pump controller system)
Contents of trouble
• When PC-EPC solenoid was driven, disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• If pump load increases, engine speed lowers largely and engine may stall.
Related information
• Drive current of PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. Cause
1
Defective PC-EPC solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male)
Resistance
Between (1) – (2)
7 – 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump 2 drive switch (Internal disconnection)
S25 (male) Between (3) – (2) Between (6) – (5)
Possible causes and standard value in normal state
Emergency pump drive switch
Resistance
Normal
Max. 1 z
Emergency
Min. 1 Mz
Normal
Max. 1 z
Emergency
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between C02 (female) (96) – S25 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
(117), (120) – S25 (female) (6)
Resistance
Max. 1 z
Wiring harness between S25 (female) (5) – V11 (female) (2)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between S25 (female) (2) – 3 or defective contact in con- V11 (female) (1) nector) Wiring harness between C02 (female) (115),
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller
40-180
C02 (female)
Resistance
Between (96) – (115), (117), (120)
7 – 14 z
PC128US-8
40 Troubleshooting Failure code [DXA8KA] PC-EPC sol discon
Related circuit diagram
PC128US-8
40-181
40 Troubleshooting Failure code [DXA8KB] PC-EPC sol short
Failure code [DXA8KB] PC-EPC sol short User code
Failure code
E02
DXA8KB
Trouble
1
PC-EPC solenoid system short (Pump controller system)
Contents of trouble
• When PC-EPC solenoid was driven, short circuit was detected in circuit.
Action of controller
• Turns output to PC-EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• If pump load increases, engine speed lowers largely and engine may stall.
Related information
• Drive current of PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. Cause
Defective PC-EPC solenoid 1 (Internal short circuit or ground fault)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V11 (male)
Resistance
Between (1) – (2)
7 – 14 z
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective emergency pump 2 drive switch (Internal short circuit or ground fault) Possible causes and standard value in normal state
S25 (male)
Emergency pump drive switch
Between (2), (3) – (4) Between (2), (3) – chassis ground
Resistance Min. 1 Mz
Normal
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between C02 (female) (96) 3 ness (Contact with GND cir– S25 (female) (3) cuit) Wiring harness between S25 (female) (5) – V11 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller
40-182
C02 (female)
Resistance
Between (96) – (115), (117), (120)
7 – 14 z
Between (96) – chassis ground
Min. 1 Mz
PC128US-8
40 Troubleshooting Failure code [DXA8KB] PC-EPC sol short
Related circuit diagram
PC128US-8
40-183
40 Troubleshooting Failure code [DXE4KA] Service current EPC discon
Failure code [DXE4KA] Service current EPC discon User code
Failure code
—
DXE4KA
Trouble
1
Service current EPC solenoid disconnection (Pump controller system)
Contents of trouble
• When service EPC solenoid was driven, disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC solenoid can be checked with monitoring function. (Code: 01700 Service solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective service EPC sole1 noid (Internal disconnection) V30 (male) Resistance Between (1) – (2) Possible causes and standard value in normal state
7 – 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (97) 2 or defective contact in con- – V30 (female) (1) nector) Wiring harness between C02 (female) (115), (117), (120) – V30 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C02 (female)
Resistance
Between (97) – (115), (117), (120)
7 – 14 z
Related circuit diagram
40-184
PC128US-8
40 Troubleshooting Failure code [DXE4KB] Service current EPC short
Failure code [DXE4KB] Service current EPC short User code
Failure code
—
DXE4KB
Trouble
1
Service current EPC solenoid short (Pump controller system)
Contents of trouble
• When service EPC solenoid was driven, short circuit was detected in circuit.
Action of controller
• Turns output to service EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC solenoid can be checked with monitoring function. (Code: 01700 Service EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause
Defective service EPC sole1 noid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V30 (male)
Resistance
Between (1) – (2)
7 – 14 z
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C02 (female) (97) Resiscircuit) Min. 1 Mz – V30 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
C02 (female)
Resistance
Between (97) – (115), (117), (120)
7 – 14 z
Between (97) – chassis ground
Min. 1 Mz
Related circuit diagram
PC128US-8
40-185
40 Troubleshooting Failure code [DY20KA] Wiper working abnormality
Failure code [DY20KA] Wiper working abnormality User code
Failure code
—
DY20KA
Trouble
1
Wiper working abnormality (Pump controller system)
Contents of trouble
• When windshield wiper works, W signal of working ends is not input.
Action of controller
• Turns working output to wiper motor OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Wiper motor does not work.
Related information
• Condition of W contact signal of wiper working area can be checked with monitoring function. (Code: 02204 Switch input 5) • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective wiper motor (Inter1 nal disconnection)
M05 (female)
Wiper blade
Resistance
Operating range top
Max. 1 z
Between (6) – (5)
Other than operating range top
Min. 1 Mz
Between (1) – (3)
All range
Max. 20 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Wiring harness between C01 (female) (56) – M05 (male) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
– M05 (male) (1)
Resistance
Max. 1 z
Wiring harness between C02 (female) (119) – M05 (male) (3)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between M05 (female) (5) – 2 or defective contact in con- J01 – chassis ground (T09) nector) Wiring harness between C02 (female) (114)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C01 (female) 3 Defective pump controller
40-186
Wiper blade
Resistance
Operating range top
Max. 1 z
Between (56) – chasOther than operating sis ground range top
Min. 1 Mz
Between (114) – (119)
Max. 20 z
All range
PC128US-8
40 Troubleshooting Failure code [DY20KA] Wiper working abnormality
Related circuit diagram
PC128US-8
40-187
40 Troubleshooting Failure code [DY20MA] Wiper parking abnormality
Failure code [DY20MA] Wiper parking abnormality User code
Failure code
—
DY20MA
Trouble
1
Wiper parking abnormality (Pump controller system)
Contents of trouble
• When windshield wiper parks, P signal of storage area is not input.
Action of controller
• Turns parking output to wiper motor OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Wiper motor does not park.
Related information
• Condition of P contact signal of wiper parking area can be checked with monitoring function. (Code: 02204 Switch input 5) • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective wiper motor (Internal disconnection)
M05 (female) Between (4) – (5) Between (1) – (3)
Wiper blade
Resistance
Storage area
Max. 1 z
Working area
Min. 1 Mz
All range
Max. 20 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Wiring harness between C01 (female) (75) – M05 (male) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
– M05 (male) (1)
Resistance
Max. 1 z
Wiring harness between C02 (female) (119) – M05 (male) (3)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between M05 (female) (5) – 2 or defective contact in con- J01 – chassis ground (T09) nector) Wiring harness between C02 (female) (114)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
40-188
C01 (female)
Wiper blade
Resistance
Between (75) – chassis ground
Storage area
Max. 1 z
Working area
Min. 1 Mz
Between (114) – (119)
All range
Max. 20 z
PC128US-8
40 Troubleshooting Failure code [DY20MA] Wiper parking abnormality
Related circuit diagram
PC128US-8
40-189
40 Troubleshooting Failure code [DY2CKA] Washer drive discon
Failure code [DY2CKA] Washer drive discon User code —
Failure code DY2CKA
Trouble
1
Window washer drive system disconnection (Pump controller system)
Contents of trouble
• When output to window washer drive system was turned OFF (when ground circuit was connected), disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, washer motor does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Window washer does not operate.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defective fuse No. 4
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective washer motor 2 (Internal short circuit or ground fault)
Defective assembled-type 3 diode D02 (Internal short circuit) Possible causes and standard value in normal state
M06 (male)
Resistance
Between (1) – (2)
5 – 20 z
Between (1), (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D02 (female)
Continuity (Resistance)
Between (3) – (7)
No continuity (Min. 1 Mz)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (4) – J05 – 4 or defective contact in con- M06 (female) (1) nector) Wiring harness between C01 (female) (3) – J01 – M06 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between F01 (4) – J05 – 5 ness (Short circuit with GND M06 (female) (1), – D02 (female) (3) circuit) Wiring harness between C01 (female) (3) – J01 – M06 (female) (2), – D02 (female) (7)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective pump controller
40-190
C01 (female)
Voltage
Between (3) – chassis ground
20 – 30 V
PC128US-8
40 Troubleshooting Failure code [DY2CKA] Washer drive discon
Related circuit diagram
PC128US-8
40-191
40 Troubleshooting Failure code [DY2CKB] Washer drive short
Failure code [DY2CKB] Washer drive short User code —
Failure code DY2CKB
Trouble
1
Window washer drive system short (Pump controller system)
Contents of trouble
• When output to window washer drive system was turned ON (ground circuit was disconnected), short circuit was detected in circuit.
Action of controller
• Turns output to washer motor OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Window washer does not operate.
Related information
• Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
Cause Defective washer motor 1 (Internal short circuit) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M06 (male)
Resistance
Between (1) – (2)
5 – 20 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between C01 (female) (3) – Voltage Max. 1 V J01 – M6 (female) (2), – D02 (female) (7) 3 Defective pump controller
40-192
Standard value in normal state/Remarks on troubleshooting
If causes 1 and 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DY2CKB] Washer drive short
Related circuit diagram
PC128US-8
40-193
40 Troubleshooting Failure code [DY2DKB] Wiper drive (for) short
Failure code [DY2DKB] Wiper drive (for) short User code
Failure code
—
DY2DKB
Trouble
1
Wiper motor drive forward system short (Pump controller system)
Contents of trouble
• When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
Action of controller
• Turns output to wiper motor drive forward side OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Windshield wiper does not operate.
Related information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
Cause
Defective wiper motor (Inter1 nal short circuit or ground fault) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female)
Resistance
Between (3) – (1)
There is continuity
Between (3) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (119) circuit) – M05 (male) (3) 3 Defective pump controller
40-194
Standard value in normal state/Remarks on troubleshooting
Resistance
Min. 1 Mz
If causes 1 and 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DY2DKB] Wiper drive (for) short
Related circuit diagram
PC128US-8
40-195
40 Troubleshooting Failure code [DY2EKB] Wiper drive (rev) short
Failure code [DY2EKB] Wiper drive (rev) short User code
Failure code
—
DY2EKB
Trouble
1
Wiper motor drive reverse system short (Pump controller system)
Contents of trouble
• When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
Action of controller
• Turns output to wiper motor drive reverse side OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Windshield wiper does not operate.
Related information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
Cause
Defective wiper motor (Inter1 nal short circuit or ground fault) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. M05 (female)
Continuity/Resistance
Between (1) – (3)
There is continuity
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (114) circuit) – M05 (male) (1) 3 Defective pump controller
40-196
Standard value in normal state/Remarks on troubleshooting
Resistance
Min. 1 Mz
If causes 1 and 2 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting Failure code [DY2EKB] Wiper drive (rev) short
Related circuit diagram
PC128US-8
40-197
40 Troubleshooting Before carrying out troubleshooting of electrical system
Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting of electrical system
1
Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally. Type of power supply
Switch power supply
Switch power supply
Switch power supply
Constant power supply
Switch power supply
40-198
Fusible link
F02 (45A)
F02 (45A)
F02 (45A)
F03 (45A)
Starting switch ACC
Fuse No.
Fuse capacity
1
10A
Emergency operating circuit
2
30A
Solenoid valve
3
15A
Cigarette lighter
Destination of power
4
10A
Windshield washer
5
10A
Horn
6
5A
Working lamp relay, horn relay
7
10A
Revolving lamp (If equipped)
8
20A
Working lamp
9
10A
Radio, speaker
10
5A
Air conditioner
11
20A
Air conditioner unit
12
10A
Optional power supply (1)
13
10A
Optional power supply (2), power supply of 12 volt
14
10A
Spare
15
5A
Air conditioner
16
10A
Radio backup, room lamp
17
20A
Machine monitor, pump controller, starting switch
18
30A
Engine controller
19
5A
Engine controller
20
5A
PPC oil pressure lock solenoid
PC128US-8
40 Troubleshooting Before carrying out troubleshooting of electrical system
Locations of fusible links
Location of fuse box and fuse Nos.
PC128US-8
40-199
40 Troubleshooting Information in troubleshooting table
Information in troubleshooting table a
1
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information
Trouble which occurred in the machine Information related to detected trouble or troubleshooting Cause
Standard value in normal state/Remarks on troubleshooting <Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment
1
Possible causes and standard value in normal state
<Troubles in wiring harness> • Disconnection Connector is connected imperfectly or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Hot short Wiring harness which is not connected to power source (24 2 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally. Possible causes of trouble (Given numbers are refer- <Precautions for troubleshooting> ence numbers, which do 1) Method of indicating connector No. and handling of Tnot indicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of “male” and “female”, 3 disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 4 • Connect positive (+) lead to pin No. or wiring harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.
Related circuit diagram This drawing is a part of the circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow ( ): Roughly shows the location on the machine.
40-200
PC128US-8
40 Troubleshooting Information in troubleshooting table
PC128US-8
40-201
40 Troubleshooting E-1 When starting switch turned ON, machine monitor displays nothing
E-1 When starting switch turned ON, machine monitor displays nothing 1 Trouble Related information
• When starting switch turned ON, machine monitor displays nothing. • When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password (if set), screen to check breaker mode (if set), screen of check before starting, screen to check working mode and travel speed, and ordinary screen in order. • When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1 Low charge level of battery
Battery voltage (2 pieces)
Electrolyte specific gravity (1 piece)
Min. 24 V
Min. 1.26
2
Defective fusible link F03 or fuse No. 17
If fusible link or fuse is broken, circuit probably has ground fault. (See Cause 5.)
3
Wrong connection of connec- Machine monitor connector may be connected wrongly. Check it tor directly. (Check mounting bracket plate with connector.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (–) – chassis ground
Resistance
Max. 1 z
Wiring harness between battery (+) – RB – F03 (male) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between CM01 (female) (3), (4) – chassis ground (T09)
Resistance
Max. 1 z
Wiring harness between F01-17 – H15 (female) (1)
Resistance
Max. 1 z
Wiring harness between H15 (female) (5) – J05 – CM01 (female) (14)
Resistance
Max. 1 z
Disconnection in wiring har- Wiring harness between F03 (male) (2) – ness (Disconnection in wiring F01-15D 4 or defective contact in con- Wiring harness between F01-17 – J07 – nector) CM01 (female) (1), (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery (+) – RB – F03 (male) (1)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between F01-17 – H15 (female) (1)
Resistance
Min. 1 Mz
Wiring harness between H15 (female) (5) – J05 – CM01 (female) (14)
Resistance
Min. 1 Mz
Wiring harness between F03 (male) (2) – Ground fault in wiring harF01-15D 5 ness (Short circuit with GND Wiring harness between F01-17 – J07 – circuit) CM01 (female) (1), (2)
a Prepare with starting switch OFF, then hold starting switch OFF and ON and carry out troubleshooting in each case. 6 Defective machine monitor
40-202
CM01
Starting switch
Voltage
Between (1), (2) – (3), (4)
OFF
20 – 30 V
Between (14) – (3), (4)
ON
20 – 30 V
PC128US-8
40 Troubleshooting E-1 When starting switch turned ON, machine monitor displays nothing
Related circuit diagram
PC128US-8
40-203
40 Troubleshooting E-2 When starting switch turned ON (before starting engine), basic check item lights up
E-2 When starting switch turned ON (before starting engine), basic check item lights up Trouble Related information
• Engine oil level monitor lights up red. • Condition of engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2) Cause 1
Lowering of engine oil level (When system is normal)
Defective engine oil level 2 switch (Internal disconnection) Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting Engine oil level may be low. Check it and add oil if necessary. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P44 (male)
Engine oil level
Resistance
Between (1) – chassis ground
Between H – L
Max. 1 z
Below L
Min. 1 Mz
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 3 or defective contact in con- Wiring harness between CM02 (female) (2) ResisMax. 1 z nector) – P44 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective machine monitor
CM02
Engine oil level
Voltage
Between (2) – chassis ground
Between H – L
Max. 1 V
Below L
20 – 30 V
Related circuit diagram
40-204
PC128US-8
40 Troubleshooting E-3 Engine does not start (Engine does not turn)
E-3 Engine does not start (Engine does not turn) Trouble Related information
1
• Engine does not start (Engine does not turn). • Engine starting circuit has following 2 start lock mechanisms. 1) Start lock with password of machine monitor 2) Start lock with lock lever Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1 Low charge level of battery
2 Defective fuse No. 20
3
Defective starting switch (Internal disconnection)
Battery voltage (2 pieces)
Electrolyte specific gravity (1 piece)
Min. 24 V
Min. 1.26
If fuse is broken, circuit probably has ground fault. (See cause 10.) a Prepare with starting switch OFF, then keep starting switch OFF and turn it to START and carry out troubleshooting in each case. H15 (male)
Starting switch
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
Between (1) – (4)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
Defective lock lever switch (Internal disconnection)
S14 (female)
Lock lever
Resistance
Free
Min. 1 Mz
Lock
Max. 1 z
Between (1) – (3)
Possible causes and standard value in normal state
Defective starting motor cutout relay R06 or R07 (Inter5 nal disconnection or short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R06 (male), R07 (male)
Resistance
Between (1) – (2)
300 – 600 z
Between (3) – (4)
Max. 1 z
Between (3) – (5)
Min. 1 Mz
a Prepare with starting switch OFF (with only terminal C disconnected), then turn starting switch to START and carry out troubleshooting. Safety relay terminal
6
Defective starting motor safety relay (Internal defect)
Voltage
Between B – E
Power supply
20 – 30 V
Between R (R17-2) – E
Generation input
Max. 1 V
Between S (R17-1) – E
Starting input
20 – 30 V
Between C (R18) – E
Starting output
20 – 30 V
If power supply, generation input, and starting input are normal but starting output is not normal, starting motor safety relay is defective. a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Starting motor terminals 7
Defective starting motor (Internal defect)
Voltage
Between B – chassis ground
Power supply
20 – 30 V
Between C (E10) – chassis ground
Starting input
20 – 30 V
If power supply and starting input are normal but starting motor does not turn, starting motor is defective.
PC128US-8
40-205
40 Troubleshooting E-3 Engine does not start (Engine does not turn)
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
8
Defective alternator (Internal short circuit)
Alternator Between L (AR-1) – chassis ground
Generation output
Voltage Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between H15 (male) (4) – R06 (female) (5)
Resistance
Max. 1 z
Wiring harness between R06 (female) (3) – R07 (female) (4)
Resistance
Max. 1 z
Wiring harness between R07 (female) (3) – R17 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between starting motor safety relay C – starting motor C (E10)
Resistance
Max. 1 z
Wiring harness between F01-20 – S14 (male) (1)
Resistance
Max. 1 z
Wiring harness between S14 (male) (3) – R06 (female) (1)
Resistance
Max. 1 z
Wiring harness between R06 (female) (2) – J02 – chassis ground (T08)
Resistance
Max. 1 z
Wiring harness between starting motor Disconnection in wiring har- safety relay B – heater relay – battery relay ness (Disconnection in wiring B 9 or defective contact in conWiring harness between starting motor nector) safety relay E – chassis ground
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between H15 (male) (4) – R06 (female) (5), – circuit branch end
Resistance
Min. 1 Mz
Wiring harness between R06 (female) (3) – R07 (female) (4)
Resistance
Min. 1 Mz
Wiring harness between R07 (female) (3) – R17 (female) (1) Ground fault in wiring har10 ness (Short circuit with GND Wiring harness between starting motor circuit) safety relay B – heater relay – battery relay B
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between starting motor safety relay C – starting motor C (E10)
Resistance
Min. 1 Mz
Wiring harness between F01-20 – S14 (male) (1)
Resistance
Min. 1 Mz
Wiring harness between S14 (male) (3) – R06 (female) (1)
Resistance
Min. 1 Mz
11
40-206
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between R17 (female) (2) – Voltage Max. 1 V alternator L (AR-1), – circuit branch end
PC128US-8
40 Troubleshooting E-3 Engine does not start (Engine does not turn)
Related circuit diagram
PC128US-8
40-207
40 Troubleshooting E-4 Preheater does not operate
E-4 Preheater does not operate Trouble
Related information
1
(1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash. • Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds after to notify completion of preheating (It stops flashing about 10 seconds after). • If engine coolant temperature is below 20°C, automatic warm-up system operates and preheating monitor lights up for up to 30 seconds. • Condition of starting switch (preheating) signal can be checked with the monitoring function. (Code: 04500 Monitor input 1) Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case.
1
Defective starting switch (Internal disconnection)
H15 (female) Between (1) – (3)
Possible causes and standard value in normal state
Starting switch OFF
Resistance Min. 1 Mz
HEAT Max. 1 z Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) ResisMax. 1 z nector) (16) – J04 – H15 (female) (3) tance a Prepare with starting switch OFF, then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. 3 Defective machine monitor
CM01 Between (16) – chassis ground
Starting switch OFF
Voltage Max. 1 V
HEAT
20 – 30 V
Trouble
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm.
Related information
• Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-1 Engine does not start (Engine does not turn)). Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF (with wiring harness connected), then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. Continuity/ResisHeater relay Starting switch tance Defective heater relay (Inter1 nal disconnection) Between R15 – OFF There is continuity chassis ground
Possible causes and standard value in normal state
2
Defective intake air heater (Internal disconnection)
Between power supply terminal – HEAT Max. 1 z R16 a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting in each case. E01 Starting switch Voltage Between terminal – chassis ground
HEAT
20 – 30 V
If voltage is normal but heater mounting part does not become warm, intake air heater is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisDisconnection in wiring har- Wiring harness between H15 (female) (3) – Max. 1 z tance ness (Disconnection in wiring J04 – heater relay R15 3 or defective contact in con- Wiring harness between battery relay RM – ResisMax. 1 z nector) heater relay contact terminal (F04) tance Wiring harness between heater relay R16 – intake air heater E01
40-208
Resistance
Max. 1 z
PC128US-8
40 Troubleshooting E-4 Preheater does not operate
Related circuit diagram
PC128US-8
40-209
40 Troubleshooting E-5 Automatic warm-up system does not operate (in cold season)
E-5 Automatic warm-up system does not operate (in cold season) Trouble
Related information
1
• Automatic warm-up system does not operate (in cold season). • When engine coolant temperature is below 30°C automatic warm-up system raises engine speed to 1,300 rpm. • If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after engine is started, automatic warm-up system is turned OFF. (Automatic warm-up system stops automatically after operating for 10 minutes.) • If engine coolant temperature is below 10°C turbocharger protection function operates to keep the engine speed at low idle. Cause
Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting. Monitoring code
Possible causes and standard value in normal state
Defective engine coolant 1 temperature signal system
04107 Engine coolant temperature
Engine coolant temperature
Coolant temperature level
105°C
6 (a: Red)
102°C
5 (a: Red)
100°C
4 (a: Blue)
85°C
3 (a: Blue)
60°C
2 (a: Blue)
30°C
1 (a: White)
If level of coolant temperature gauge is different from actual coolant temperature, carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally. 2 Defective engine controller
If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Engine coolant temperature gauge and engine coolant temperature monitor
40-210
PC128US-8
40 Troubleshooting E-5 Automatic warm-up system does not operate (in cold season)
PC128US-8
40-211
40 Troubleshooting E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 1 Trouble
(1) All work equipment, swing, and travel mechanism do not move.
Related information Cause 1 Defective fuse No. 20
Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
Defective lock lever switch (Internal disconnection)
S14 (female) Between (1) – (2)
Defective PPC lock solenoid 3 (Internal disconnection or short circuit)
Possible causes and standard value in normal state
Defective assembled-type 4 diode D01 (Internal short circuit)
Lock lever
Resistance
Lock
Min. 1 Mz
Free
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V01 (male)
Resistance
Between (1) – (2)
20 – 60 z
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D01 (male)
Resistance (Continuity)
Between (4) – (8)
Min. 1 Mz (No continuity)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between F01-20 – S14 ness (Disconnection in wiring (male) (1) 5 or defective contact in con- Wiring harness between S14 (male) (2) – nector) V01 (female) (2) Wiring harness between V01 (female) (1) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between F01-20 – S14 6 ness (Short circuit with GND (male) (1), – circuit branch end circuit) Wiring harness between S14 (male) (2) – V01 (female) (2), – D01 (female) (4)
40-212
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
PC128US-8
40 Troubleshooting E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked
Trouble
(2) All work equipment, swing, and travel mechanism cannot be locked.
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
1
Defective lock lever switch (Internal short circuit)
S14 (female) Between (1) – (2)
2
Lock lever
Resistance
Lock
Min. 1 Mz
Free
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between S14 (male) (2) – V01 (female) (2), – D01 (female) (4)
Voltage
Max. 1 V
Related circuit diagram
PC128US-8
40-213
40 Troubleshooting E-7 Precaution lights up while engine is running
E-7 Precaution lights up while engine is running Trouble Related information
(1) Charge level monitor lights up red. • Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage) Cause Defective generation by 1 alternator (when system is normal)
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. AR (male)
Engine speed
Voltage
Between (L) – chassis ground
Middle or higher
27.5 – 29.5 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) ResisMax. 1 z nector) (11) – J06 – AR (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CM01 (female) circuit) (11) – J06 – AR (female) (1), – circuit branch end
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective machine monitor
40-214
CM02
Engine
Voltage
Between (11) – chassis ground
Running
Min. 7.8 V
PC128US-8
40 Troubleshooting E-7 Precaution lights up while engine is running
Related circuit diagram
PC128US-8
40-215
40 Troubleshooting E-7 Precaution lights up while engine is running
Trouble Related information
(2) Fuel level monitor lights up red. • Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage) Cause
Possible causes and standard value in normal state
Trouble Related information
Possible causes and standard value in normal state
1
Low fuel level (when system Fuel level may be low (below about 41 l). Check it and add fuel if is normal) necessary.
2
Defective fuel level gauge system
Related information
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause
Standard value in normal state/Remarks on troubleshooting
Insufficient warm-up of 1 machine (when system is normal)
If monitor lights up white, engine coolant temperature may be low (below about 30°C). Warm up engine. • Lighting up white: Engine coolant temperature is low. • Lighting up blue: Engine coolant temperature is proper.
Defective engine coolant temperature gauge system
If cause 1 is not detected, engine coolant temperature gauge system may be defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally.
(4) Hydraulic oil temperature monitor lights up white. • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause
Possible causes and standard value in normal state
Insufficient warm-up of 1 machine (when system is normal)
2
40-216
If cause 1 is not detected, fuel level gauge system may be defective. Carry out troubleshooting for E-11 Fuel level gauge does not indicate normally.
(3) Engine coolant temperature monitor lights up white.
2
Trouble
Standard value in normal state/Remarks on troubleshooting
Defective hydraulic oil temperature gauge system
Standard value in normal state/Remarks on troubleshooting If monitor lights up white, hydraulic oil temperature may be low (below about 20°C). Warm up engine. • Lighting up white: Hydraulic oil temperature is low. • Lighting up blue: Hydraulic oil temperature is proper. If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally.
PC128US-8
40 Troubleshooting E-8 Emergency stop item lights up while engine is running
E-8 Emergency stop item lights up while engine is running Trouble Related information
(1) Engine coolant temperature monitor lights up red. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause
Possible causes and standard value in normal state
Related information
Possible causes and standard value in normal state
Trouble Related information
Possible causes and standard value in normal state
Carry out troubleshooting for S-14 Coolant temperature becomes too high (overheating). Defective engine coolant temperature gauge system
If cause 1 is not detected, engine coolant temperature gauge system may be defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally.
(2) Hydraulic oil temperature monitor lights up red. • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause
Standard value in normal state/Remarks on troubleshooting
1
Overheating of hydraulic oil (when system is normal)
If monitor lights up red, hydraulic oil temperature may be high (above about 102°C). Cool down hydraulic oil (Run engine at low idle). • Lighting up red: Hydraulic oil temperature is high (overheating). • Lighting up blue: Hydraulic oil temperature is proper.
2
Defective hydraulic oil temperature gauge system
If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally.
(3) Engine oil pressure monitor lights up red. • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine monitor through communication system. Cause
Standard value in normal state/Remarks on troubleshooting
Lowering of engine oil pres1 sure (when system is normal)
Engine oil pressure may be low. If it is low, carry out troubleshooting for S-12 Oil pressure lowers.
2
PC128US-8
Standard value in normal state/Remarks on troubleshooting
If monitor lights up red, engine coolant temperature may be high (above about 102°C). Cool down engine coolant (Run engine at low idle). Overheating of engine cool- • Lighting up red: Engine coolant temperature is high 1 (overheating). ant (when system is normal) • Lighting up blue: Engine coolant temperature is proper.
2
Trouble
1
Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may switch system be defective. Carry out troubleshooting for failure code [CA435].
40-217
40 Troubleshooting E-9 Engine coolant temperature gauge does not indicate normally
E-9 Engine coolant temperature gauge does not indicate normally
1
Trouble
(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C). (2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
Related information
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature)
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective engine coolant temperature sensor system
If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].
2 Defective machine monitor
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
1
Trouble
(3) Display of coolant temperature gauge is different from actual engine coolant temperature. (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.
Related information
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause
Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.
Possible causes and standard value in normal state
Engine coolant temperature 1 Defective machine monitor
Coolant temperature Color of monitor light level (a)
105°C
6
102°C
5
100°C
4
85°C
3
60°C
2
30°C
1
Red
Blue White
Engine coolant temperature gauge and engine coolant temperature monitor
40-218
PC128US-8
40 Troubleshooting E-10 Hydraulic oil temperature gauge does not indicate normally
E-10 Hydraulic oil temperature gauge does not indicate normally
1
Trouble
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C). (2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related information
• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P22 (male)
Resistance
Between (1) – (2)
3.5 – 90 kz
Between (2) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (29) 2 or defective contact in con- – P22 (female) (2) nector) Wiring harness between C01 (female) (46) – P22 (female) (1) Possible causes and standard value in normal state
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (29) Resiscircuit) Min. 1 Mz – P22 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (29) Voltage Max. 1 V – P22 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective pump controller
6 Defective machine monitor
C01 (female)
Resistance
Between (29) – (46)
3.5 – 90 kz
Between (29) – chassis ground
Min. 1 Mz
If causes 1 – 5 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Related circuit diagram
PC128US-8
40-219
40 Troubleshooting E-10 Hydraulic oil temperature gauge does not indicate normally
Trouble
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor.
Related information
• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature) Cause
Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.
Possible causes and standard value in normal state
Hydraulic oil temperature 1 Defective machine monitor
Hydraulic oil temper- Color of monitor light ature level (a)
105°C
6
102°C
5
100°C
4
85°C
3
40°C
2
20°C
1
Red
Blue White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-220
PC128US-8
40 Troubleshooting E-11 Fuel level gauge does not indicate normally
E-11 Fuel level gauge does not indicate normally Trouble Related information
1
(1) While fuel is added, fuel level gauge does not rise from red range (E). (2) While fuel level is low, fuel level gauge does not lower from green range top (F) • Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor voltage) Cause
Defective fuel level sensor 1 (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P21 (male)
Fuel level
Resistance
Between (1) – chassis ground
FULL
7 – 11 z
EMPTY
85 – 95 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between CM01 (female) (9) ResisMax. 1 z nector) – P21 (female) (1) tance Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CM01 (female) (9) Resiscircuit) Min. 1 Mz – P21 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between CM01 (female) (9) Voltage Max. 1 V – P21 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective machine monitor
CM01 (female)
Fuel level
Resistance
Between (9) – chassis ground
FULL
7 – 11 z
EMPTY
85 – 95 z
Related circuit diagram
PC128US-8
40-221
40 Troubleshooting E-11 Fuel level gauge does not indicate normally
Trouble Related information
(3) Display of fuel level gauge is different from actual fuel level. (4) Display of fuel level gauge is different from display of fuel level monitor. • Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor voltage) Cause
Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.
Possible causes and standard value in normal state
Quantity of fuel
1 Defective machine monitor
Reading of fuel level Color of monitor light gauge (a)
139 l
6
116 l
5
96 l
4
66 l
3
52 l
2
33 l
1
Blue
Red
Fuel level gauge and fuel level monitor
40-222
PC128US-8
40 Troubleshooting E-12 Contents of display by machine monitor are different from applicable machine
E-12 Contents of display by machine monitor are different from applicable machine Trouble
1
Contents of display by machine monitor are different from applicable machine.
Related information Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting (with monitoring function).
1 Defective model code signal
Monitoring code 00200 Controller model code
2 Defective machine monitor
Normal display Blade spec
PC128/138US-a
Not blade spec
PC128/138US-a BL
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
E-13 Machine monitor does not display some items Trouble Related information
• Machine monitor does not display some items. • The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. Cause
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting.
Defective machine monitor 1 (LCD panel)
2
Defective machine monitor (body)
When following switches are operated, if all LCD panel is lighted up (all surface becomes white), LCD panel is normal. • Operation of switches: [4] + [F2] (Press simultaneously) If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
E-14 Function switch does not work Trouble Related information Possible causes and standard value in normal state
PC128US-8
1
• Function switch does not work. • Condition of signal of function switch can be checked with monitoring function. (Code: 04503 Monitor function switch) Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-223
40 Troubleshooting E-15 Auto-decelerator does not operate normally
E-15 Auto-decelerator does not operate normally Trouble Related information Possible causes and standard value in normal state
Trouble Related information
1
(1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off. • Condition of signal of auto-decelerator switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) Auto-decelerator is not operated or reset with lever. • Set speed of auto-decelerator is 1,400 rpm. If fuel control dial is not set above this speed, autodecelerator is not operated or reset. Cause
Standard value in normal state/Remarks on troubleshooting a Start engine and carry out troubleshooting (with monitoring function). Monitoring code
Item
Normal display
Swing Travel 01900 Pressure switch 1 1
Defective PPC pressure signal
Possible causes and standard value in normal state
Boom lower Boom raise Arm curl
When lever is operated: ON When lever is in neutral: OFF
Arm dump Bucket curl 01901 Pressure switch 2
Bucket dump Service
When lever is operated: ON When lever is in neutral: OFF
If display of monitoring is abnormal, carry out troubleshooting for E-25 Monitoring function does not display lever control signal normally.
40-224
2 Defective machine monitor
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
3 Defective pump controller
If cause 1 is not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
4 Defective engine controller
If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting E-16 Working mode does not change
E-16 Working mode does not change Trouble Related information Possible causes and standard value in normal state
Trouble
1
(1) When working mode switch is operated, working mode selection screen is not displayed. • Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information Cause Possible causes and standard value in normal state
PC128US-8
Standard value in normal state/Remarks on troubleshooting
1 Defective machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
2 Defective pump controller
Pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-225
40 Troubleshooting E-17 Travel speed does not change
E-17 Travel speed does not change Trouble Related information Possible causes and standard value in normal state
Trouble Related information
(1) When travel speed switch is operated, travel speed monitor does not change. • Condition of signal of travel speed switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When travel speed is shifted, actual travel speed does not change. • If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo. Cause
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between C02 (female) (87) Voltage Max. 1 V – V02 (female) (2) 2 Defective machine monitor
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
3 Defective pump controller
If cause 1 is not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Related circuit diagram
40-226
PC128US-8
40 Troubleshooting E-18 Alarm buzzer cannot be stopped
E-18 Alarm buzzer cannot be stopped Trouble Related information Possible causes and standard value in normal state
PC128US-8
1
• Alarm buzzer cannot be stopped. • Condition of signal of alarm buzzer cancel switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-227
40 Troubleshooting E-19 Windshield wiper and window washer do not operate
E-19 Windshield wiper and window washer do not operate Trouble
(1) When wiper switch is operated, wiper monitor does not light up or go off.
Related information
• Condition of wiper switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)
Possible causes and standard value in normal state
Trouble Related information
Cause 1 Defective machine monitor
1
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When wiper switch is operated, wiper does not operate. • Condition of window rear limit switch signal can be checked with monitoring function. (Code: 02204 Switch input 5) Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective window rear limit switch (Internal short circuit)
W03 (male)
Between (1) – (2)
Front window
Resistance
When installed to front
Min. 1 Mz
When retracted to rear
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective wiper motor (Inter2 nal disconnection) M05 (female) Continuity Between (1) – (3)
There is continuity
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (119) 3 or defective contact in con- – M05 (male) (3) nector) Wiring harness between C02 (female) (114) – M05 (male) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Resiscircuit) C01 (female) (57) – W03 (female) (1) Min. 1 Mz tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective pump controller (Rear limit switch system)
Between (57) – chassis ground
5
Defective pump controller (Wiper motor system)
40-228
C01 (female)
Front window
Resistance
When installed to front
Min. 1 Mz
When retracted to rear
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C02 (female)
Continuity
Between (119) – (114)
There is continuity
PC128US-8
40 Troubleshooting E-19 Windshield wiper and window washer do not operate
Related circuit diagram
PC128US-8
40-229
40 Troubleshooting E-19 Windshield wiper and window washer do not operate
Trouble Related information Possible causes and standard value in normal state
40-230
(3) When window washer switch is operated, window washer does not operate. • Condition of window washer switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Cause 1 Defective machine monitor
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
PC128US-8
40 Troubleshooting E-19 Windshield wiper and window washer do not operate
PC128US-8
40-231
40 Troubleshooting E-20 Swing holding brake does not operate normally
E-20 Swing holding brake does not operate normally Trouble Related information
(1) When swing lock switch is operated, swing lock monitor does not light up or go off. • Condition of swing lock switch signal can be checked with monitoring function. (Machine monitor system code: 04502 Monitor input 3) (Pump controller system code: 02200 Switch input 1) Cause Defective swing lock switch 1 (Internal disconnection or short circuit)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (male) Between (5) – (6)
Swing lock switch OFF
Resistance Min. 1 Mz
ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (5) Resis2 Max. 1 z or defective contact in con- – J01 – S04 (female) (5) tance nector) Wiring harness between S04 (female) (6) – ResisMax. 1 z J02 – chassis ground (T08) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CM02 (female) (5) Resiscircuit) – J01 – S04 (female) (5), – C01 (female) Min. 1 Mz tance (19)
4 Defective machine monitor
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CM02 Swing lock switch Voltage Between (5) – chassis ground
Trouble
1
OFF ON
20 – 30 V Max. 1 V
(2) When swing lock switch is turned ON, swing lock does not operate. (Hydraulic drift of swing occurs on slope.)
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
1
Defective swing lock switch (Internal short circuit)
S04 (male) Between (3) – (4)
Possible causes and standard value in normal state
Defective swing holding 2 brake release switch (Internal short circuit)
Swing lock switch OFF
Resistance Min. 1 Mz
ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Swing holding brake S25 (male) Resistance release switch Between (13) – (14)
Lock Release
Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
40-232
Hot short (Short circuit with Wiring harness between D01 (female) (3) – 24V circuit) in wiring harness J04 – S04 (female) (3), – S25 (female) (14)
Voltage
Max. 1 V
Wiring harness between S04 (female) (4) – V03 (female) (2), – D03 (female) (3)
Voltage
Max. 1 V
PC128US-8
40 Troubleshooting E-20 Swing holding brake does not operate normally
Related circuit diagram
PC128US-8
40-233
40 Troubleshooting E-21 Travel alarm does not sound or does not stop sounding
E-21 Travel alarm does not sound or does not stop sounding Trouble
1
• Alarm does not sound during travel. • Alarm does not stop sounding while machine is stopped.
Related information Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (107) Resis1 Max. 1 z or defective contact in con- – M14 (female) (1) tance nector) Wiring harness between C02 (female) (115) ResisMax. 1 z (117) (120) – M14 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 2 ness (Short circuit with GND Wiring harness between C02 (female) (107) Resiscircuit) Min. 1 Mz – M14 (female) (1) tance Defective travel alarm (Inter3 If causes 1, 2 are not detected, travel alarm is defective. nal defect)
Related circuit diagram
40-234
PC128US-8
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
E-22 Air conditioner does not operate normally (including air conditioner abnormality record) Trouble Related information Possible causes and standard value in normal state
Trouble
1
(1) When air conditioner switch is operated, air conditioner control screen is not displayed. • Condition of air conditioner switch signal can be checked with monitoring function. (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch) Cause 1 Defective machine monitor
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(2) When air conditioner switch is operated, air conditioner does not operate at all.
Related information Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective fuse No. 15
If fuse is broken, circuit probably has ground fault. (See cause 4.)
2 Defective fuse in unit
If fuse in unit is broken, circuit in unit probably has ground fault. (See cause 4.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01-15 – fuse in 3 or defective contact in con- unit – ACW (wiring side) (6) nector) Wiring harness between ACW (wiring side) (16) – chassis ground (T14) Possible causes and standard value in normal state
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har4 ness (Short circuit with GND Wiring harness between F01-15 – fuse in Resiscircuit) Min. 1 Mz unit – ACW (wiring side) (6), – circuit branch tance end a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
Defective air conditioner controller
ACW (wiring side)
Voltage
Between (6) – (16)
20 – 30 V
If above voltage is normal, air conditioner controller may be defective. 6 Defective machine monitor
PC128US-8
If causes 1 – 5 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-235
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble
(3) Air does not come out (Air flow is insufficient).
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side). R20 (male)
1
Resistance
Between (1) – (3) 140 – 340 z Defective blower relay (Intera Prepare with starting switch OFF, then turn starting switch ON nal disconnection) and carry out troubleshooting (contact side). R20
Air conditioner switch
Voltage
Between (4) – chassis ground
Air blow position
20 – 30 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
Defective power transistor (Internal defect)
Fan switch Operate between Low and Medium and High.
If air flow changes according to operation of fan switch, power transistor is normal.
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
3
Defective blower motor (Internal defect)
MB (wiring side)
Air conditioner switch
Voltage
Between (1) – (2)
Air blow position
20 – 30 V
If above voltage is normal and blower motor does not revolve, blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-10 – fuse in unit – R20 (female) (1)
Resistance
Max. 1 z
Wiring harness between R20 (female) (3) – ACW (wiring side) (36)
Resistance
Max. 1 z
Wiring harness between F01-11 – R20 (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
– PTR (wiring side) (3)
Resistance
Max. 1 z
Wiring harness between PTR (wiring side) (1) – chassis ground (T14)
Resistance
Max. 1 z
Wiring harness between PTR (wiring side) (2) – ACW (wiring side) (8)
Resistance
Max. 1 z
Wiring harness between PTR (wiring side) (4) – ACW (wiring side) (7)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between R20 (female) (2) – 4 or defective contact in con- MB (wiring side) (1) nector) Wiring harness between MB (wiring side) (2)
40-236
PC128US-8
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between R20 (female) (3) – ACW (wiring side) (36)
Possible causes and standard value in normal state
PC128US-8
Ground fault in wiring harWiring harness between R20 (female) (2) – 5 ness (Short circuit with GND MB (wiring side) (1) circuit) Wiring harness between MB (wiring side) (2) – PTR (wiring side) (3) Wiring harness between PTR (wiring side) (2) – ACW (wiring side) (8)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
6
If causes 1 – 5 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
7
If causes 1 – 5 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume of Shop Manual, Air tem conditioner, Troubleshooting.
40-237
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble
(4) Air is not cooled (Cooling performance is insufficient).
Related information Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side).
1
Defective compressor relay (Internal disconnection)
2 Defective internal air sensor
R21 (male)
Resistance
Between (1) – (3)
140 – 340 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (contact side). R21
Air conditioner switch
Voltage
Between (2) – chassis ground
Cooling position
20 – 30 V
Internal air sensor may be defective. Carry out troubleshooting for Abnormality in internal air sensor.
3
Defective high and low pres- High and low pressure switches may be defective. Carry out trousure switches bleshooting for “Abnormality in refrigerant”.
4
Defective compressor clutch Compressor clutch may be defective. Check it directly. (Internal defect)
5
Defective compressor (InterCompressor may be defective. Check it directly. nal defect)
Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F01-10 – fuse in unit – R21 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
(female) (4)
Resistance
Max. 1 z
Wiring harness between R21 (female) (2) – AC02 (female) (1)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between R21 (female) (3) – 6 or defective contact in con- ACW (wiring side) (35) nector) Wiring harness between F01-11 – R21
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between R21 (female) (3) – 7 ness (Short circuit with GND ACW (wiring side) (35) circuit) Wiring harness between R21 (female) (2) – AC02 (female) (1)
40-238
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
8
If causes 1 – 7 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
9
If causes 1 – 7 are not detected, air conditioner system may be Defective air conditioner sysdefective. See Machine Component Volume of Shop Manual, Air tem conditioner, Troubleshooting.
PC128US-8
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble
(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communication condition “Abnormal”
Related information
• While abnormality in communication is being detected, “CAN disconnection” is displayed. • If abnormality in communication has been detected and reset, “Abnormality” is displayed. • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, condition of other items is not displayed. • Method of reproducing abnormality record: Turn starting switch ON. Cause
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between N10 (female) (1) – Resis1 Max. 1 z or defective contact in con- CM02 (female) (8), (9) tance nector) Wiring harness between N10 (female) (2) – ResisMax. 1 z CM02 (female) (10) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between N10 (male) (1) – CM02 (female) (8), (9), – C01 (female) (45), Ground fault in wiring har– CE02 (female) (1), – K02 (female) (A), – 2 ness (Short circuit with GND N08 (male) (3) circuit) Wiring harness between N10 (female) (2) – CM02 (female) (10), – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
3
Hot short (Short circuit with 24V circuit) in wiring harness
Defective CAN terminal 4 resistance (Internal short circuit or disconnection)
N10 (male) (1) – CM02 (female) (8), (9), – C01 (female) (45), – CE02 (female) (1), – K02 (female) (A), – N08 (male) (3)
Voltage
Max. 5.5 V
Wiring harness between N10 (female) (2) – CM02 (female) (10), – C01 (female) (64), – CE02 (female) (21), – K02 (female) (B), – N08 (male) (10)
Voltage
Max. 5.5 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. K02 (male)
Resistance
Between (A) – (B)
47 – 67 z
If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be 5 troller carried out.) 6 Defective machine monitor
PC128US-8
If causes 1 – 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-239
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble
Related information
(6) Air conditioner abnormality record: Setting condition “Abnormality” • If setting of air conditioner controller model is different from setting of machine monitor model, “Abnormality” is displayed. • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON. Cause
Possible causes and standard value in normal state
Trouble Related information
1
Standard value in normal state/Remarks on troubleshooting
Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in troller system, troubleshooting cannot be carried out.)
2 Defective machine monitor
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
(7) Air conditioner abnormality record: Internal air sensor “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective internal air sensor 1 (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (device side)
Resistance
Between (1) – (2)
300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side) 2 or defective contact in con- (11) – THI (wiring side) (2) nector) Wiring harness between ACW (wiring side) (27) – THI (wiring side) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND ResisWiring harness between ACW (wiring side) circuit) Min. 1 Mz tance (11) – THI (wiring side) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between ACW (wiring side) Voltage Max. 1 V (11) – THI (wiring side) (2) 5
40-240
If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
PC128US-8
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble Related information Possible causes and standard value in normal state
Trouble Related information
(8) Air conditioner abnormality record: External air sensor “Unused” • External air sensor is not used in air conditioner system of this machine. • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. Cause
Standard value in normal state/Remarks on troubleshooting
1 Normal display
Since external air sensor is not used in air conditioner system of this machine, above display is normal.
(9) Air conditioner abnormality record: Air flow sensor “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause Defective air flow sensor 1 (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THF (device side)
Resistance
Between (1) – (2)
100 z – 115 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side) 2 or defective contact in con- (12) – THF (wiring side) (2) nector) Wiring harness between ACW (wiring side) (27) – THF (wiring side) (1)
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND ResisWiring harness between ACW (wiring side) circuit) Min. 1 Mz tance (12) – THF (wiring side) (2)
4
5
PC128US-8
Resistance
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between ACW (wiring side) (12) – THF (wiring side) (2)
Voltage
Max. 1 V
If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
40-241
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble Related information
(10) Air conditioner abnormality record: Daylight sensor “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1
Defective daylight sensor (Internal defect)
Standard value in normal state/Remarks on troubleshooting Daylight sensor may be defective.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side) Max. 1 z 2 tance or defective contact in con- (36) – P31 (female) (1) nector) ResisWiring harness between ACW (wiring side) Max. 1 z (15) – P31 (female) (2) tance Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between ACW (wiring side) 3 ness (Short circuit with GND (3) – P31 (female) (1), – circuit branch end circuit) Wiring harness between ACW (wiring side) (15) – P31 (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
5
40-242
Hot short (Short circuit with Wiring harness between ACW (wiring side) 24V circuit) in wiring harness (3) – P31 (female) (1), – circuit branch end
Voltage
Max. 1 V
Wiring harness between ACW (wiring side) (15) – P31 (female) (2)
Voltage
Max. 1 V
If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
PC128US-8
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble Related information
(11) Air conditioner abnormality record: Air outlet damper “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1
Defective air outlet servomotor (Internal defect)
Standard value in normal state/Remarks on troubleshooting Air outlet servomotor may be defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV1 (wiring side) (1) – ACW (wiring side) (27)
Resistance
Max. 1 z
Disconnection in wiring har- Wiring harness between MV1 (wiring side) ness (Disconnection in wiring (3) – ACW (wiring side) (3) 2 or defective contact in con- Wiring harness between MV1 (wiring side) nector) (5) – ACW (wiring side) (9)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between MV1 (wiring side) (6) – ACW (wiring side) (23)
Resistance
Max. 1 z
Wiring harness between MV1 (wiring side) (7) – ACW (wiring side) (24)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV1 (wiring side) (1) – ACW (wiring side) (27), – circuit branch end Possible causes and standard value in normal state
Wiring harness between MV1 (wiring side) Ground fault in wiring har(5) – ACW (wiring side) (9), – circuit branch 3 ness (Short circuit with GND end circuit) Wiring harness between MV1 (wiring side) (6) – ACW (wiring side) (23), – circuit branch end Wiring harness between MV1 (wiring side) (7) – ACW (wiring side) (24), – circuit branch end
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between MV1 (wiring side) (1) – ACW (wiring side) (27), – circuit branch end
Voltage
Max. 1 V
Wiring harness between MV1 (wiring side) Hot short (Short circuit with (5) – ACW (wiring side) (9), – circuit branch 4 24V circuit) in wiring harness end
Voltage
Max. 1 V
Wiring harness between MV1 (wiring side) (6) – ACW (wiring side) (23), – circuit branch end
Voltage
Max. 1 V
Wiring harness between MV1 (wiring side) (7) – ACW (wiring side) (24), – circuit branch end
Voltage
Max. 1 V
5
PC128US-8
If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
40-243
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble Related information
(12) Air conditioner abnormality record: A/M damper “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective air mix servomotor Air mix servomotor may be defective. (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MAM (wiring side) (1) – ACW (wiring side) (27)
Resistance
Max. 1 z
Disconnection in wiring har- Wiring harness between MAM (wiring side) ness (Disconnection in wiring (3) – ACW (wiring side) (3) 2 or defective contact in con- Wiring harness between MAM (wiring side) nector) (5) – ACW (wiring side) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between MAM (wiring side) (6) – ACW (wiring side) (21)
Resistance
Max. 1 z
Wiring harness between MAM (wiring side) (7) – ACW (wiring side) (22)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MAM (wiring side) (3) – ACW (wiring side) (3), – circuit branch end Possible causes and standard value in normal state
Wiring harness between MAM (wiring side) Ground fault in wiring har(5) – ACW (wiring side) (2), – circuit branch 3 ness (Short circuit with GND end circuit) Wiring harness between MAM (wiring side) (6) – ACW (wiring side) (21), – circuit branch end Wiring harness between MAM (wiring side) (7) – ACW (wiring side) (22), – circuit branch end
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between MAM (wiring side) (3) – ACW (wiring side) (3), – circuit branch end
Voltage
Max. 1 V
Wiring harness between MAM (wiring side) Hot short (Short circuit with (5) – ACW (wiring side) (2), – circuit branch 4 24V circuit) in wiring harness end
Voltage
Max. 1 V
Wiring harness between MAM (wiring side) (6) – ACW (wiring side) (21), – circuit branch end
Voltage
Max. 1 V
Wiring harness between MAM (wiring side) (7) – ACW (wiring side) (22), – circuit branch end
Voltage
Max. 1 V
5
40-244
If causes 1 – 4 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
PC128US-8
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble Related information
(13) Air conditioner abnormality record: Refrigerant “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Accordingly, this condition is not displayed. • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON. Cause 1
Insufficient refrigerant (gas) (when system is normal)
Defective high and low pres2 sure switches (Internal disconnection) Possible causes and standard value in normal state
Refrigerant (gas) may be insufficient. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P17 (male)
Resistance
Between (1) – (2)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side) Max. 1 z 3 tance or defective contact in con- (4) – P17 (female) (1) nector) Wiring harness between P17 (female) (2) – ResisMax. 1 z chassis ground (T08) tance 4
PC128US-8
Standard value in normal state/Remarks on troubleshooting
If causes 1 – 3 are not detected, air conditioner controller may be Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be troller carried out.)
40-245
40 Troubleshooting E-22 Air conditioner does not operate normally (including air conditioner abnormality record)
Related circuit diagram
40-246
PC128US-8
40 Troubleshooting E-23 While starting switch is in OFF position, service meter is not displayed
E-23 While starting switch is in OFF position, service meter is not displayed1 Trouble Related information
• When starting switch is turned OFF, service meter is not displayed. • While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] + [1] (Press simultaneously) Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
When starting switch is turned ON, if machine monitor displays Defective backup power sup- nothing, backup power supply system may be defective. In this 1 ply system case, carry out troubleshooting for “E-1 When starting switch turned ON, machine monitor displays nothing”. 2 Defective machine monitor
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
E-24 Machine monitor cannot be set in service mode Trouble Related information Possible causes and standard value in normal state
PC128US-8
1
• Machine monitor cannot be set in service mode. • If following switches are operated, machine monitor is set in service mode. Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order) Cause 1 Defective machine monitor
Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
40-247
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
E-25 Monitoring function does not display lever control signal normally1 Trouble Related information
(1) Boom raise operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective boom raise PPC 1 pressure switch (Internal disconnection or short circuit)
P03 (male) Between (1) – (2)
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Boom raise
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (53) 2 or defective contact in con- – P03 (female) (2) nector) Wiring harness between P03 (female) (1) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (53) Resiscircuit) Min. 1 Mz – P03 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (53) Voltage Max. 1 V – P03 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller
C01 (female) Between (53) – chassis ground
40-248
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Boom raise
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-249
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Trouble Related information
(2) Arm curl operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective arm curl PPC pres1 sure switch (Internal disconnection or short circuit)
P05 (male) Between (1) – (2)
Left work equipment control lever
Resistance
Neutral
Min. 1 Mz
Arm curl
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (17) 2 or defective contact in con- – P05 (female) (1) nector) Wiring harness between P05 (female) (1) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (17) Resiscircuit) Min. 1 Mz – P05 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (17) Voltage Max. 1 V – P05 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller
C01 (female) Between (17) – chassis ground
40-250
Left work equipment control lever
Resistance
Neutral
Min. 1 Mz
Arm curl
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-251
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Trouble Related information
(3) Bucket curl operation is not displayed normally by monitoring function. • Monitoring code: 01901 Pressure switch 2 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective bucket curl PPC 1 pressure switch (Internal disconnection or short circuit)
P04 (male) Between (1) – (2)
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Bucket curl
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (73) 2 or defective contact in con- – P04 (female) (2) nector) Wiring harness between P04 (female) (1) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (73) Resiscircuit) Min. 1 Mz – P04 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (73) Voltage Max. 1 V – P04 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller
C01 (female) Between (73) – chassis ground
40-252
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Bucket curl
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-253
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Trouble Related information
(4) Bucket dump operation is not displayed normally by monitoring function. • Monitoring code: 01901 Pressure switch 2 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective bucket dump PPC 1 pressure switch (Internal disconnection or short circuit)
P01 (male) Between (1) – (2)
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Bucket dump
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (34) 2 or defective contact in con- – P01 (female) (2) nector) Wiring harness between P01 (female) (1) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (34) Resiscircuit) Min. 1 Mz – P01 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (34) Voltage Max. 1 V – P01 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller
C01 (female) Between (34) – chassis ground
40-254
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Bucket dump
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-255
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Trouble Related information
(5) Boom lower operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective boom lower PPC 1 pressure switch (Internal disconnection or short circuit)
P06 (male) Between (1) – (2)
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Boom lower
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (14) 2 or defective contact in con- – P06 (female) (2) nector) Wiring harness between P06 (female) (1) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (14) Resiscircuit) Min. 1 Mz – P06 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (14) Voltage Max. 1 V – P06 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller
C01 (female) Between (14) – chassis ground
40-256
Right work equipment control lever
Resistance
Neutral
Min. 1 Mz
Boom lower
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-257
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Trouble Related information
(6) Arm dump operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective arm dump PPC 1 pressure switch (Internal disconnection or short circuit)
P02 (male) Between (1) – (2)
Left work equipment control lever
Resistance
Neutral
Min. 1 Mz
Arm dump
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (15) 2 or defective contact in con- – P02 (female) (2) nector) Wiring harness between P02 (female) (1) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (15) Resiscircuit) Min. 1 Mz – P02 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (15) Voltage Max. 1 V – P02 (female) (2) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller
C01 (female) Between (15) – chassis ground
40-258
Left work equipment control lever
Resistance
Neutral
Min. 1 Mz
Arm dump
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-259
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Trouble Related information
(7) Swing operation is not displayed normally by monitoring function. • Monitoring code: 01900 Pressure switch 1 Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective swing PPC pres1 sure switch (Internal disconnection or short circuit)
P07 (male) P08 (male)
Left work equipment control lever
Resistance
Neutral
Min. 1 Mz
Between (1) – (2)
Swing left Swing right
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (16) 2 or defective contact in con- – P07 (female) (2) or P08 (female) (2) nector) Wiring harness between P07 (female) (1) or P08 (female) (2) – chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C01 (female) (16) Resiscircuit) Min. 1 Mz – P07 (female) (2) or P08 (female) (2) tance
4
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (16) – P07 (female) (2) or P08 (female) (2)
Voltage
Max. 1 V
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective pump controller
C01 (female) Between (16) – chassis ground
40-260
Left work equipment control lever
Resistance
Neutral
Min. 1 Mz
Swing left Swing right
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-261
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Trouble Related information
(8) Service operation is not displayed normally by monitoring function. • Monitoring code: 01901 Pressure switch 2 Cause
Defective service front PPC 1 pressure switch (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. P14 (male) Between (1) – (2)
Defective service rear PPC 2 pressure switch (Internal disconnection or short circuit)
Service pedal
Resistance
Neutral
Min. 1 Mz
Forward
Max. 1 z
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. P15 (male) Between (1) – (2)
Service pedal
Resistance
Neutral
Min. 1 Mz
Reverse
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring har- Wiring harness between C01 (female) (52) ness (Disconnection in wiring – P14 (female) (1), – P15 (female) (1) 3 or defective contact in con- Wiring harness between P14 (female) (2) – nector) chassis ground (T08)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between P15 (female) (2) – chassis ground (T08)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (52) Resiscircuit) Min. 1 Mz – P14 (female) (1), – P15 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (52) Voltage Max. 1 V – P14 (female) (1), – P15 (female) (1) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 6 Defective pump controller
40-262
C01 (female)
Service pedal
Resistance
Between (52) – chassis ground
Neutral
Min. 1 Mz
Forward or reverse
Max. 1 z
PC128US-8
40 Troubleshooting E-25 Monitoring function does not display lever control signal normally
Related circuit diagram
PC128US-8
40-263
40 Troubleshooting E-26 KOMTRAX system does not operate normally
E-26 KOMTRAX system does not operate normally Trouble Related information
1
• KOMTRAX system does not operate normally. • If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry out following troubleshooting. • Even if KOMTRAX system has trouble, it does not particularly appear on machine. • Carry out all troubleshooting on service menu screen of machine monitor. Cause
Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and check “Setting condition or terminal” screen.
1 Defective communication 1
Check item
Normal display
Communication start check
Completion
a Turn starting switch ON and check “Condition of positioning and communication” screen. Check item 2 Defective GPS Possible causes and standard value in normal state
Normal display N ###,##,## (Latitude)
Positioning
E ###,##,## (Longitude) In positioning
If latitude and longitude are not displayed in 5 minutes on open ground, notify KOMTRAX service hot line. a Turn starting switch ON and check “Condition of positioning and communication” screen. 3
Defective communication environment
Check item
Normal display
Communication
Zone level 1 – Zone level 3
If zone level 1 – 3 is not displayed within communication zone of ORBCOMM, notify KOMTRAX service hot line. a Turn starting switch ON and check “Condition of positioning and communication” screen. 4 Defective communication 2
a
Check item
Normal display
Number of items not transmitted
0 – 9 (Normally 0)
Select “Terminal Status” from “12 Display of KOMTRAX setting” in the service menu of the machine monitor.
40-264
a
Select “GPS & Communication Status” from “12 Display of KOMTRAX setting” in the service menu of the machine monitor.
PC128US-8
40 Troubleshooting Information contained in troubleshooting table
Troubleshooting of hydraulic and mechanical system (H-mode) Information contained in troubleshooting table a
1
Troubleshooting table collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Trouble Related information
Phenomena occurring on machine Information on occurred failures and troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting
1
2 Possible causes and standard value in normal state
Cause for presumed failure (The attached No. for 3 filing and reference purpose only. It does not stand for any priority) 4
<Contents> • The standard values in normalcy by which to judge "good" or "no good" about presumed causes. • References for making judgement of "good" or "no good"
5
PC128US-8
40-265
40 Troubleshooting System chart for hydraulic and mechanical systems
System chart for hydraulic and mechanical systems
40-266
1
PC128US-8
40 Troubleshooting System chart for hydraulic and mechanical systems
a
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.
PC128US-8
40-267
40 Troubleshooting H-1 Speed or power of all work equipment, swing, and travel are low
H-1 Speed or power of all work equipment, swing, and travel are low Trouble Related information
1
• Speed or power of all work equipment, swing, and travel are low. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1 Malfunction of unload valve
a
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Unload pressure
All levers in NEUTRAL
2.8 ± 1.0 MPa {28 ± 10 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control lever
2
Defective adjustment or operation of main relief valve
Main relief pressure 34.8 +2.0 –1.0 MPa
Arm relieved in IN direction
2 {355 +20 –10 kg/cm }
If the oil pressure cannot be set normally by adjustment, the main relief valve may be malfunction or may have an internal defect. Check the main relief valve directly. a 3
Malfunction of self-pressure reducing valve
a
Possible causes and standard value in normal state
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Control circuit basic pressure
All levers in NEUTRAL
3.2 ± 0.5 MPa {33 ± 5 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Measured oil pressure
4
Defective adjustment or operation of PC valve
Pump discharge pressure PC valve output pressure
Measurement conditions Swing lock: ON Arm: Relieved in IN direction
Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the PC valve may be malfunction or may have an internal defect. Check the PC valve directly. Measured oil pressure
Defective adjustment or 5 operation of LS valve
Pump discharge pressure LS valve output pressure
Oil pressure ratio All levers in NEUTRAL Almost same pressure
Bucket curled (Lever at stroke end) 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the LS valve may be malfunction or may have an internal defect. Check the LS valve directly.
40-268
6 Malfunction of servo piston
The servo piston may have malfunction. Check it directly.
7 Piston pump defective
If there is none of the causes listed above, the piston pump may have problems of lowering of performance, malfunction, internal defect, etc.
PC128US-8
40 Troubleshooting H-2 Engine speed sharply drops or engine stalls
H-2 Engine speed sharply drops or engine stalls Trouble
• Engine speed sharply drops or the engine stalls.
Related information
• Conduct the troubleshooting in working mode P. Cause
1
Standard value in normal state/Remarks on troubleshooting a
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control lever
1
Defective adjustment or operation of main relief valve
Main relief pressure 34.8 +2.0 –1.0 MPa
Arm relieved in IN direction
2 {355 +20 –10 kg/cm }
If the oil pressure cannot be set normally by adjustment, the main relief valve may be malfunction or may have an internal defect. Check the main relief valve directly. a
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Measured oil pressure
Possible causes and standard value in normal state
2
Defective adjustment or operation of PC valve
Pump discharge pressure PC valve output pressure
Measurement conditions Swing lock: ON Arm: Relieved in IN direction
Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the PC valve may be malfunction or may have an internal defect. Check the PC valve directly. Measured oil pressure
Defective adjustment or 3 operation of LS valve
Pump discharge pressure LS valve output pressure
Oil pressure ratio All levers in NEUTRAL Almost same pressure
Bucket curled (Lever at stroke end) 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the LS valve may be malfunction or may have an internal defect. Check the LS valve directly. 4
Orifice or filter in servo equipment clogged
5 Malfunction of servo piston
PC128US-8
The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself. The servo piston may have malfunction. Check it directly.
40-269
40 Troubleshooting H-3 No work equipment, travel and swing move
H-3 No work equipment, travel and swing move Trouble Related information
• No work equipment, travel and swing move. • Set the working mode at P mode for the troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Possible causes and standard value in normal state
1
Malfunction of PPC lock solenoid valve
a 2
Malfunction of self reducing pressure valve
Stop engine for preparations. Start troubleshooting at engine high idle. Work equipment lock lever
Solenoid output pressure
Locked
0 MPa {0 kg/cm2}
Released
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idle. Control lever
Control circuit source pressure
All control levers in NEUTRAL position
3.2 ± 0.5 MPa {33 ± 5 kg/cm2}
3 Piston pump defective
The piston pump is suspected of malfunction or an internal failure. Diagnose it in the following manner. • Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal condition.
4 Damper defective
It is presumed that the pump shaft does not rotate due to some internal failure of the dumper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump Trouble Related information
• An abnormal noise is heard from around the hydraulic pump. — Cause 1 Hydraulic oil level lowered 2 Quality of hydraulic oil bad
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting Make a visual check. Air may have get mixed with the oil. Make a visual check.
3
Hydraulic tank cap breather clogged
It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside the tank. Make a visual check.
4
Hydraulic tank strainer clogged
It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective
40-270
1
The piston pump is suspected of an internal failure. Check the pump itself.
PC128US-8
40 Troubleshooting H-5 Fine control mode does not function
H-5 Fine control mode does not function Trouble Related information
1
• Fine control mode does not function. • Set the working mode at P mode for the troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting
1 Orifice in LS circuit clogged
The orifice in the LS circuit is presumed to be clogged. Check the orifice itself. a
Stop engine for preparations. Start troubleshooting at engine high idle. Oil pressure ratio
Possible causes and standard value in normal state
Oil pressure to be measured 2
Defective adjustment or malfunction of LS valve
Pump delivery pressure LS valve output pressure
All control levers in NEUTRAL
Nearly equal oil pressure
At bucket CURL (Control lever full stroke) 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunction of the LS valve or its internal failure is suspected. In that case, check the valve itself. 3 Malfunction of servo piston
PC128US-8
Malfunction of the servo piston is suspected. Check the piston itself.
40-271
40 Troubleshooting H-6 Speed or power of boom is low
H-6 Speed or power of boom is low Trouble Related information
• Speed or power of boom is low. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Malfunction of right PPC valve (boom circuit)
2
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Right work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Boom RAISE position Boom LOWER position
Above 2.7 MPa {Above 28 kg/cm2}
a
Possible causes and standard value in normal state
1
Malfunction of pump mergedivider solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Solenoid output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only (On either or both sides)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
3
Malfunction of pump merge- The pump merge-divider valve of the control valve may have a divider valve malfunction. Check it directly.
4
Malfunction of boom control valve (spool)
The spool of the boom control valve may have a malfunction. Check it directly (Including stroke limiting mechanism on RAISE side).
Malfunction of boom control 5 valve (pressure compensation valve)
The pressure compensation valve of the boom control valve may have a malfunction. Check it directly.
Malfunction of boom control valve (lock valve)
The lock valve of the boom control valve may have a malfunction. Check it directly.
6
Malfunction or defective The safety-suction valve of the boom control valve (on the head 7 sealing of boom control valve side) may have a malfunction or its sealing may be defective. (safety-suction valve) Check it directly. Malfunction or defective The suction valve of the boom control valve (on the bottom side) 8 sealing of boom control valve may have a malfunction or its sealing may be defective. Check it (suction valve) directly. Malfunction or defective The centralized safety-suction valve of the control valve may have 9 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 10 Boom cylinder defective
40-272
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Boom cylinder
Leakage from cylinder
Relieved in RAISE direction
15 cc/min
PC128US-8
40 Troubleshooting H-7 Speed or power of arm is low
H-7 Speed or power of arm is low Trouble Related information
• Speed or power of arm is low. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Malfunction of left PPC valve (arm circuit)
a
2
Possible causes and standard value in normal state
1
Malfunction of pump mergedivider solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Arm IN position Arm OUT position
Above 2.7 MPa {Above 28 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Solenoid output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only (On either or both sides)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
3
Malfunction of pump merge- The pump merge-divider valve of the control valve may have a divider valve malfunction. Check it directly.
4
Malfunction of arm control valve (spool)
The spool of the arm control valve may have a malfunction. Check it directly (Including stroke limiting mechanisms on IN side and OUT side).
Malfunction of arm control 5 valve (pressure compensation valve)
The pressure compensation valve of the arm control valve may have a malfunction. Check it directly.
Malfunction or defective 6 sealing of arm control valve (safety-suction valves)
The safety-suction valves of the arm control valve (on the bottom side and head side) may have a malfunction or their sealing may be defective. Check them directly.
Malfunction or defective The centralized safety-suction valve of the control valve may have 7 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 8 Arm cylinder defective
PC128US-8
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Arm cylinder
Leakage from cylinder
Relieved in IN direction
15 cc/min
40-273
40 Troubleshooting H-8 Speed or power of bucket is low
H-8 Speed or power of bucket is low Trouble Related information
• Speed or power of bucket is low. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Malfunction of right PPC valve (bucket circuit)
2
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Right work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Bucket CURL position Bucket DUMP position
Above 2.7 MPa {Above 28 kg/cm2}
a
Possible causes and standard value in normal state
1
Malfunction of pump mergedivider solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Solenoid output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only (On either or both sides)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
3
Malfunction of pump merge- The pump merge-divider valve of the control valve may have a divider valve malfunction. Check it directly.
4
Malfunction of bucket control The spool of the bucket control valve may have a malfunction. valve (spool) Check it directly.
Malfunction of bucket control The pressure compensation valve of the bucket control valve may 5 valve (pressure compensahave a malfunction. Check it directly. tion valve) Malfunction or defective The safety-suction valves of the bucket control valve (on the bot6 sealing of bucket control tom side and head side) may have a malfunction or their sealing valve (safety-suction valves) may be defective. Check them directly. Malfunction or defective The centralized safety-suction valve of the control valve may have 7 sealing of centralized safetya malfunction or its sealing may be defective. Check it directly. suction valve a 8 Bucket cylinder defective
40-274
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Bucket cylinder
Leakage from cylinder
Relieved in CURL direction
15 cc/min
PC128US-8
40 Troubleshooting H-9 Work equipment does not move in its single operation
H-9 Work equipment does not move in its single operation
Trouble
Related information
(1) The boom does not move when operated independently. • Work equipment does not move in its sin- (2) The arm does not move when operated indepengle operation dently. (3) The bucket does not move when operated independently. • Set the working mode at P mode for the troubleshooting. Cause
Standard value in normal state/Remarks on troubleshooting a
Possible causes and standard value in normal state
1 Malfunction of PPC valve
2
PC128US-8
1
Malfunction of work equipment control valve (spool)
Stop engine for preparations. Start troubleshooting at engine high idle.
Work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Operation
Above 2.7 MPa {Above 28 kg/cm2}
The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
40-275
40 Troubleshooting H-10 Hydraulic drift of work equipment is large
H-10 Hydraulic drift of work equipment is large Trouble Related information
• Hydraulic drift of work equipment is large.
Standard value in normal state/Remarks on troubleshooting a
Trouble Related information
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
1 Boom cylinder defective
Boom cylinder
Leakage from cylinder
Relieved in RAISE direction
15 cc/min
2
Defective sealing of boom control valve (lock valve)
Sealing of the lock valve of the boom control valve may be defective. Check it directly.
3
Defective sealing of centralized safety-suction valve
Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.
• Hydraulic drift of work equipment is large.
Standard value in normal state/Remarks on troubleshooting a
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
1 Arm cylinder defective
Trouble Related information
Leakage from cylinder
Relieved in IN direction
15 cc/min
3
Defective sealing of arm con- Sealing of the suction valve of the arm control valve (on the bottom trol valve (suction valve) side) may be defective. Check it directly.
4
Defective sealing of centralized safety-suction valve
Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.
• Hydraulic drift of work equipment is large.
(3) Hydraulic drift of bucket is large.
• Conduct the troubleshooting in working mode P. Standard value in normal state/Remarks on troubleshooting a 1 Bucket cylinder defective
40-276
Arm cylinder
Defective sealing of arm con- Sealing of the spool of the arm control valve may be defective. 2 trol valve (spool) Check it directly.
Cause
Possible causes and standard value in normal state
(2) Hydraulic drift of arm is large.
• Conduct the troubleshooting in working mode P. Cause
Possible causes and standard value in normal state
(1) Hydraulic drift of boom is large.
• Conduct the troubleshooting in working mode P. Cause
Possible causes and standard value in normal state
1
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Bucket cylinder
Leakage from cylinder
Relieved in CURL direction
15 cc/min
Defective sealing of bucket 2 control valve (spool)
Sealing of the spool of the bucket control valve may be defective. Check it directly.
3
Defective sealing of bucket control valve (suction valve)
Sealing of the suction valve of the bucket control valve (on the bottom side) may be defective. Check it directly.
4
Defective sealing of centralized safety-suction valve
Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.
PC128US-8
40 Troubleshooting H-11 Time lag of work equipment is large
H-11 Time lag of work equipment is large Trouble Related information
Possible causes and standard value in normal state
1
• Time lag of work equipment is large. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting
Malfunction of control valve 1 (regeneration valve) [Boom and arm]
The regeneration valve of the control valve may have a malfunction. Check it directly.
2
Malfunction of control valve (suction valve)
The suction valve of the control valve (on the head side) may have a malfunction. Check it directly.
H-12 Work equipment loaded more is slower during compound operation Trouble Related information
1
• Work equipment loaded more is slower during compound operation. — Cause
Standard value in normal state/Remarks on troubleshooting The pressure compensation valve of the work equipment loaded less may have a malfunction. Check it directly.
Possible causes and standard value in normal state
Malfunction of pressure com1 pensation valve of work equipment loaded less
Compound operation
More loaded side
Less loaded side
Boom RAISE + Arm IN
Boom
Arm
Boom RAISE + Arm OUT
Arm
Boom
Boom RAISE + Bucket CURL
Boom
Bucket
Arm IN + Bucket CURL
Arm
Bucket
Boom LOWER + Arm OUT
Arm
Boom
H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE Trouble Related information Possible causes and standard value in normal state
PC128US-8
1
• Boom RAISE speed is low in compound operation of swing + boom RAISE. • If the speed of single operation of the boom RAISE speed is slow, conduct troubleshooting for H-7 first.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Malfunction or defective sealing of LS selector valve
The LS selector valve of the control valve may have a malfunction or its sealing may be defective. Check it directly.
40-277
40 Troubleshooting H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel
H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel 1 Trouble Related information
• Travel speed lowers largely during compound operation of work equipment/swing + travel. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Possible causes and standard value in normal state
40-278
2
Malfunction of pump mergedivider solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Solenoid output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only (On either or both sides)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly.
Malfunction of work equipThe pressure compensation valve of the work equipment control 3 ment control valve (pressure valve may have a malfunction. Check it directly. compensation valve) Malfunction of swing control 4 valve (pressure compensation valve)
The pressure compensation valve of the swing control valve may have a malfunction. Check it directly.
Malfunction of travel control 5 valve (pressure compensation valve)
The pressure compensation valve of the travel control valve may have a malfunction. Check it directly.
PC128US-8
40 Troubleshooting H-15 Machine deviates during travel
H-15 Machine deviates during travel Trouble Related information
• Machine deviates during travel. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Malfunction of self-pressure reducing valve
a
2
Malfunction of travel PPC valve
a
3
Malfunction of pump mergedivider valve
a Possible causes and standard value in normal state
4
Malfunction of travel junction solenoid valve
a 5 Malfunction of unload valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Control circuit basic pressure
All levers in NEUTRAL
3.2 ± 0.5 MPa {33 ± 5 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
PPC valve output pressure
Forward or reverse position
Above 2.7 MPa {Above 28 kg/cm2}
Difference in above output between both sides
Below 0.4 MPa {Below 4 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Solenoid valve output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only (On either or both sides)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Solenoid valve output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only on either side
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Unload pressure
All levers in NEUTRAL
2.8 ± 1.0 MPa {28 ± 10 kg/cm2}
6
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly.
7
Malfunction of travel junction The travel junction valve may have a malfunction. Check it directly. valve
8
Malfunction of travel control lever (spool)
The spool of the travel control lever may have a malfunction. Check it directly. a
9 Travel motor defective
PC128US-8
1
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Leakage from travel motor
Travel circuit relieved
1.65 l/min
10 Final drive defective
The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
Defective adjustment of 11 travel deviation adjustment plug
Adjust travel deviation adjustment plug. For details, see Testing and adjusting, "Testing and adjusting travel deviation".
40-279
40 Troubleshooting H-16 Travel speed is low
H-16 Travel speed is low Trouble Related information
1
• Travel speed is low. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Malfunction of self-pressure reducing valve
a
2
Malfunction of travel PPC valve
a
3
Possible causes and standard value in normal state
Malfunction of pump mergedivider valve
a 4 Malfunction of unload valve
Control levers
Control circuit basic pressure
All levers in NEUTRAL
3.2 ± 0.5 MPa {33 ± 5 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
PPC valve output pressure
Forward or reverse position
Above 2.7 MPa {Above 28 kg/cm2}
Difference in above output between both sides
Below 0.4 MPa {Below 4 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Solenoid valve output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only (On either or both sides)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Control levers
Unload pressure
All levers in NEUTRAL
2.8 ± 1.0 MPa {28 ± 10 kg/cm2}
5
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly.
6
Malfunction of travel control lever (spool)
The spool of the travel control lever may have a malfunction. Check it directly.
Malfunction of travel control 7 lever (pressure compensation valve)
The pressure compensation valve of the travel control lever may have a malfunction. Check it directly.
Malfunction of travel control lever (suction valve)
The suction valve of the travel control lever may have a malfunction. Check it directly.
8
a 9 Travel motor defective
10 Final drive defective
40-280
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Leakage from travel motor
Travel circuit relieved
1.65 l/min
The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
PC128US-8
40 Troubleshooting H-17 Machine cannot be steered easily or steering power is low
H-17 Machine cannot be steered easily or steering power is low Trouble Related information
• Machine cannot be steered easily or steering power is low. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Malfunction of travel PPC valve
a
2
Malfunction of pump mergedivider valve
a
3 Possible causes and standard value in normal state
Malfunction of travel junction solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
PPC valve output pressure
In NEUTRAL on both sides
0 MPa {0 kg/cm2}
Operated on either side
Above 2.7 MPa {Above 28 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Solenoid valve output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only (On either or both sides)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Solenoid valve output pressure
All levers in NEUTRAL
0 MPa {0 kg/cm2}
Position for travel only on either side
2.84 – 3.43 MPa {29 – 35 kg/cm2}
4
Malfunction of hydraulic pump (check valve)
The check valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly.
5
Malfunction of hydraulic pump (shuttle valve)
The shuttle valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly.
6
Malfunction of pump merge- The pump merge-divider valve may have a malfunction. Check it divider valve directly.
7
Malfunction of travel junction The travel junction valve may have a malfunction. Check it directly. valve
8
Malfunction of travel control lever (spool)
The spool of the travel control lever may have a malfunction. Check it directly.
Malfunction of travel control 9 lever (pressure compensation valve)
The pressure compensation valve of the travel control lever may have a malfunction. Check it directly.
Malfunction of travel control lever (suction valve)
The suction valve of the travel control lever may have a malfunction. Check it directly.
Malfunction of travel motor 11 (safety and check valve)
The safety and check valve of the travel motor may have a malfunction. Check it directly. (It may be checked by exchanging the front and rear motors or the right and left motors and checking change of the phenomenon.)
10
PC128US-8
1
40-281
40 Troubleshooting H-18 Travel speed does not change or it is kept low or high
H-18 Travel speed does not change or it is kept low or high Trouble Related information
• Travel speed does not change or it is kept low or high. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
Possible causes and standard value in normal state
1
1
2
Malfunction of travel speed selector solenoid valve
Malfunction of travel motor (speed-changer unit)
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel speed
Travel lever
Solenoid valve output pressure
Lo
In NEUTRAL
0 MPa {0 kg/cm2}
Hi
Operated
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The speed-changer unit of the travel motor may have a malfunction. Check it directly.
H-19 Track does not move (Only either side) Trouble Related information
1
• Track does not move (only either side). • Conduct the troubleshooting in working mode P. Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective seat of travel con- The suction valve seat of the travel control lever may be defective. trol valve (suction valve) Check it directly.
Defective seat of travel conThe safety and check valve seat of the travel control lever may be 2 trol valve (safety and check defective. Check it directly. valve) Possible causes and standard value in normal state
3
Malfunction of travel motor (counterbalance valve)
a 4 Travel motor defective
5 Final drive defective
40-282
The counterbalance valve of the travel motor may have a malfunction. Check it directly. Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Travel lever
Leakage from travel motor
Travel circuit relieved
1.65 l/min
The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
PC128US-8
40 Troubleshooting H-20 Machine does not swing
H-20 Machine does not swing Trouble Related information
1
• Machine does not swing.
(1) Machine does not swing in either direction.
• Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Possible causes and standard value in normal state
2
Malfunction of swing holding brake solenoid valve
Malfunction of swing motor (holding brake)
Right work equipment control lever
Solenoid valve output pressure
In NEUTRAL
0 MPa {0 kg/cm2}
Operated for swing
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The holding brake of the swing motor may have a malfunction. Check it directly. a
3 Swing motor defective
4 Swing machinery defective
Trouble Related information
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever
Leakage from swing motor
Swing circuit relieved
Below 6 l/min
The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
• Machine does not swing.
(2) Machine does not swing in only one direction.
• Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Possible causes and standard value in normal state
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
2
Malfunction of swing PPC valve
Malfunction of swing control valve (spool)
Left work equipment control lever
PPC valve output pressure
In NEUTRAL
0 MPa {0 kg/cm2}
Operated for swing
Above 2.7 MPa {Above 28 kg/cm2}
The spool of the swing control valve may have a malfunction. Check it directly. a
Defective adjustment or mal3 function of swing motor (safety valve)
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Swing lock switch ON
4
PC128US-8
Defective sealing of swing motor (suction valve)
Left work equipment Swing relief pressure control lever (Pump pressure) Swing circuits relieved (separately on both sides)
29.2 ± 1.5 MPa {298 ± 15 kg/cm2}
Sealing of the suction valve of the swing motor may be defective. Check it directly.
40-283
40 Troubleshooting H-21 Swing acceleration or swing speed is low
H-21 Swing acceleration or swing speed is low Trouble Related information
• Swing acceleration or swing speed is low.
Cause
Standard value in normal state/Remarks on troubleshooting
Malfunction of swing control 1 valve (pressure compensation valve)
The pressure compensation valve of the swing control valve may have a malfunction. Check it directly.
Malfunction of swing motor (holding brake)
The holding brake of the swing motor may have a malfunction. Check it directly. a
3 Swing motor defective
4 Swing machinery defective
Trouble Related information
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever
Leakage from swing motor
Swing circuit relieved
Below 6 l/min
The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
• Swing acceleration or swing speed is low.
(2) Swing acceleration or swing speed is low in only one direction.
• Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Possible causes and standard value in normal state
(1) Swing acceleration or swing speed is low in both directions.
• Conduct the troubleshooting in working mode P.
2 Possible causes and standard value in normal state
2
Malfunction of swing PPC valve
Malfunction of swing control valve (spool)
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever
PPC valve output pressure
In NEUTRAL
0 MPa {0 kg/cm2}
Operated for swing
Above 2.7 MPa {Above 28 kg/cm2}
The spool of the swing control valve may have a malfunction. Check it directly. a
Defective adjustment or mal3 function of swing motor (safety valve)
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Swing lock switch ON
40-284
1
Left work equipment Swing relief pressure control lever (Pump pressure) Swing circuits relieved (separately on both sides)
29.2 ± 1.5 MPa {298 ± 15 kg/cm2}
4
Defective sealing of swing motor (suction valve)
Sealing of the suction valve of the swing motor may be defective. Check it directly.
5
Malfunction of swing motor (reverse prevention valve)
Sealing of the reverse prevention valve of the swing motor may be defective. Check it directly.
PC128US-8
40 Troubleshooting H-22 Excessive overrun when stopping swing
H-22 Excessive overrun when stopping swing Trouble Related information
• Excessive overrun when stopping swing.
Trouble Related information
Standard value in normal state/Remarks on troubleshooting a
1 Swing motor defective
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever
Leakage from swing motor
Swing circuit relieved
Below 6 l/min
• Excessive overrun when stopping swing.
(2) Overrun of upper structure is large in only one direction.
• Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
1
Possible causes and standard value in normal state
(1) Overrun of upper structure is large in both directions.
• Conduct the troubleshooting in working mode P. Cause
Possible causes and standard value in normal state
Malfunction of swing PPC valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever
PPC valve output pressure
In NEUTRAL
0 MPa {0 kg/cm2}
Operated for swing
Above 2.7 MPa {Above 28 kg/cm2}
2
The swing PPC slow return valves may be clogged. Check them Clogging of swing PPC slow directly. (They may be checked by exchanging with each other return valves and checking change of the phenomenon.)
3
Malfunction of swing control valve (spool)
The spool of the swing control valve may have a malfunction. Check it directly. a
Defective adjustment or mal4 function of swing motor (safety valve)
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Swing lock switch ON
PC128US-8
1
Left work equipment Swing relief pressure control lever (Pump pressure) Swing circuits relieved (separately on both sides)
29.2 ± 1.5 MPa {298 ± 15 kg/cm2}
5
Defective sealing of swing motor (suction valve)
Sealing of the suction valve of the swing motor may be defective. Check it directly.
6
Malfunction of swing motor (reverse prevention valve)
Sealing of the reverse prevention valve of the swing motor may be defective. Check it directly.
40-285
40 Troubleshooting H-23 When upper structure stops swinging, it makes large shock
H-23 When upper structure stops swinging, it makes large shock Trouble Related information
• When upper structure stops swinging, it makes large shock. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
Possible causes and standard value in normal state
1
Malfunction of swing PPC valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Left work equipment control lever
PPC valve output pressure
In NEUTRAL
0 MPa {0 kg/cm2}
Operated for swing
Above 2.7 MPa {Above 28 kg/cm2}
2
Malfunction of swing PPC slow return valves
The swing PPC slow return valves may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)
3
Malfunction of swing motor (safety valve)
The safety valve of the swing motor may have malfunction. Check it directly.
H-24 When upper structure stops swinging, it makes large sound Trouble Related information
Possible causes and standard value in normal state
40-286
1
1
• When upper structure stops swinging, it makes large sound. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting
1
Malfunction of back pressure check valve
The back pressure check valve may have a malfunction. Check it directly.
2
Malfunction of swing motor (safety valve)
The swing motor (safety valves) may have a malfunction. Check the valves directly.
3
Malfunction of swing motor (suction valves)
The swing motor (suction valves) may have a malfunction. Check the valves directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)
4 Swing machinery defective
The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
PC128US-8
40 Troubleshooting H-25 Hydraulic drift of swing is large
H-25 Hydraulic drift of swing is large Trouble Related information
• Hydraulic drift of swing is large.
(1) When swing holding brake is operated
• If the swing lock switch is turned ON or the swing holding brake release switch is in the normal position, the swing holding brake operates and the disc brake holds the upper structure. • Conduct the troubleshooting in working mode P. Cause
Standard value in normal state/Remarks on troubleshooting a
Possible causes and standard value in normal state
1
1
Malfunction of swing holding brake solenoid valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting.
Right work equipment control lever
Solenoid valve output pressure
In NEUTRAL
0 MPa {0 kg/cm2}
Operated for swing
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunction or internal defect The holding brake of the swing motor may have a malfunction or 2 of swing motor (holding an internal defect. Check it directly. brake)
Trouble Related information
• Hydraulic drift of swing is large.
• If the swing holding brake release is in the emergency position, the swing holding brake is released and the upper structure is held with only hydraulic pressure. • Conduct the troubleshooting in working mode P. Cause
Possible causes and standard value in normal state
PC128US-8
(2) When swing holding brake is released
Standard value in normal state/Remarks on troubleshooting
1
Defective sealing of swing control valve (spool)
Sealing of the spool of the swing control valve may have a malfunction. Check it directly.
2
Defective sealing of swing motor (safety valve)
The safety valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)
3
Defective sealing of swing motor (suction valve)
The suction valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)
Malfunction or defective 4 sealing of swing motor (reverse prevention valve)
The reverse prevention valve of the swing motor may have a malfunction or its sealing may be defective. Check it directly.
40-287
40 Troubleshooting H-26 Flow rate in attachment circuit cannot be adjusted
H-26 Flow rate in attachment circuit cannot be adjusted
1
When attachment is installed Trouble Related information
Possible causes and standard value in normal state
40-288
• Flow rate in attachment circuit cannot be adjusted. • If an attachment is installed, the flow rate in the service circuit changes according to the selected working mode. • How to adjust the flow rate in modes B and ATT is different from that in mode B. For details, see Operation manual. Cause
Standard value in normal state/Remarks on troubleshooting
Malfunction of attachment 1 flow rate adjustment EPC valve
The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly. a
Malfunction of service PPC 2 valve
Keep the engine stopped for the preparations, and keep it running at high idle during the troubleshooting. Wiring harness connector
Disconnect connector V30 of attachment flow rate adjustment EPC valve.
Service pedal
PPC valve output pressure
In NEUTRAL
0 MPa {0 kg/cm2}
Operated
Above 2.7 MPa {Above 28 kg/cm2}
PC128US-8
40 Troubleshooting H-26 Flow rate in attachment circuit cannot be adjusted
PC128US-8
40-289
40 Troubleshooting Method of using troubleshooting chart
Troubleshooting of engine (S-mode) Method of using troubleshooting chart
1
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. Questions Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. Check items Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the right. Causes Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. Troubleshooting Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w. E : Causes to be referred to for questions and check items Q : Causes related to questions and check items w : Causes highly probable among ones marked with Q a When narrowing the "causes", apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
40-290
PC128US-8
40 Troubleshooting Method of using troubleshooting chart
PC128US-8
40-291
40 Troubleshooting Method of using troubleshooting chart
<Example of troubleshooting> Exhaust gas is black Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].
40-292
PC128US-8
40 Troubleshooting Method of using troubleshooting chart
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in the [Causes] section. The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is explained according to Step 1 – Step 3 shown below.
PC128US-8
40-293
40 Troubleshooting S-1 Starting performance is poor
S-1 Starting performance is poor
1
General causes why starting performance is poor Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck, seized supply pump plunger
Clogged fuel filter
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Clogged air cleaner element
Defective contact of valve and valve seat
Causes
q
Confirm recent repair history Degree of use of machine Operated for long period
E
E
Q w w
Q
E w
Engine starts easily when warm
w
Q Q Q
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
w Q Q w
Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally
w w w
During operation, charge level monitor indicates abnormal charge w
Dust indicator is red
w
Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping
w
Q
When priming pump is operated, it makes no reaction or it is heavy
w Q w
Starting motor cranks engine slowly
Check items
While engine is cranked with starting motor,
If air bleeding plug of fuel filter is removed, fuel does not flow out
w w
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w Q Q
Engine does not pick up smoothly and combustion is irregular
w Q w Q
There is hunting from engine (rotation is irregular) w
Blow-by gas is excessive q
Inspect air cleaner directly
q q
When compression pressure is measured, it is found to be low
q
Troubleshooting
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q
When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with engine at low idle?
q
Yes
q
No
q Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
Clean
Remedy
Replace
When specific gravity of electrolyte and voltage of battery are measured, they are low
Replace
Questions
Starting performance
Became worse gradually
*1: Displayed failure codes [CA559] and [CA2249] 40-294
PC128US-8
40 Troubleshooting S-2 Engine does not start
S-2 Engine does not start
1
a) Engine does not turn General causes why engine does not turn q Seized parts inside engine o See “S-4 Engine stops during operations” q Defective electrical system
Degree of use of machine
Operated for long period
Condition of horn when starting switch is turned ON
Horn does not sound
Q
When starting switch is turned to START, starting pinion does not move out
Q
Defective steering circuit wiring
Defective starting motor (motor section)
Defective safety relay
Defective starting switch
w
w
w
Speed of rotation is low w
Makes grating noise
w w
Soon disengages again Q
Makes rattling noise and does not turn
Q Q
q
When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 – 30 V) between battery relay terminal B and terminal E
q
When terminal B and terminal C of starting switch are connected, engine starts
q
When terminal B and terminal C at safety relay outlet are connected, engine starts
q
Replace
Replace
Remedy
Replace
q Replace
When terminal at safety switch and terminal B at starting motor are connected, engine starts Replace
q
Replace
Even if terminal B and terminal C at safety relay outlet are connected, engine does not start
Carry out troubleshooting on E-mode
q
Inspect flywheel ring gear directly
PC128US-8
Q
w Q
Turn starting switch OFF, connect cord, and carry out troubleshooting at ON
w
w
When starting switch is turned ON, there is no operating sound from battery relay
When starting switch is turned to START, starting pinion moves out, but
Q
w
Horn volume is low
Battery terminal is loose
Check items
Defective battery relay
E E
Battery electrolyte is low
Troubleshooting
Defective connection of battery terminal
Defective or deteriorated battery
Confirm recent repair history
Correct
Questions
Broken flywheel ring gear
Causes
—
40-295
40 Troubleshooting S-2 Engine does not start
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)
Defective fuel injector
Defective common rail pressure limiter
Defective operation of overflow valve (Does not close)
Defective supply pump MPROP
Stuck, seized supply pump plunger
Broken supply pump shaft
Seized, abnormally worn feed pump
Clogged fuel filter
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Use of improper fuel
Causes
Confirm recent repair history E E
Operated for long period
w Q w w
Exhaust smoke suddenly stopped coming out (when starting again) Fuel other than specified one is used
w
Non-specified fuel is being used
w
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Q
Q E
E E
w
Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is not fuel in it Check items
E
w
When fuel tank is inspected, it is found to be empty
w
Fuel is leaking from fuel piping
w
When priming pump is operated, it makes no reaction or it is heavy
w Q
If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills
Q
Q
w Q
Q
w w w
Q
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly Troubleshooting
w
E
q
Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code
q q
Carry out troubleshooting according to “Abnormality in supply pump IMV (*2)” indicated by code
q q
Inspect overflow valve directly
q
Engine can be started in reduced cylinder mode Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Replace
Remedy
Replace
q
Fuel flows out when pressure limiter return piping is disconnected
Replace
Questions
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA271] and [CA272]
40-296
PC128US-8
40 Troubleshooting S-2 Engine does not start
c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel
Defective intake air heater system
Defective coolant temperature sensor, wiring harness
Defective, deteriorated battery
Clogged injector, defective spray
Stuck, seized supply pump plunger
Clogging of fuel filter
Leaking or clogged fuel system, entry of air
Clogged air breather hole of fuel tank cap
Use of improper fuel
Worn piston ring, cylinder
Worn dynamic valve system (Valve, rocker lever, etc.)
Clogged air cleaner element
Causes
Confirm recent repair history E
Operated for long period
E
w
Suddenly failed to start
E w
Q
Q Q
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
w w
Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally
w w
Dust indicator is red
Q
Air breather hole of fuel tank cap is clogged
w
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is not fuel in it Fuel is leaking from fuel piping
w
When priming pump is operated, it makes no reaction or it is heavy
w Q w
Starting motor cranks engine slowly w
Check items
When engine is cranked, abnormal sound is generated around cylinder head If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills
Q
w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w
q
Inspect air cleaner directly
q
Inspect dynamic valve system directly
q
When compression pressure is measured, it is found to be low Troubleshooting
w
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code
q q
Engine can be started in reduced cylinder mode
q
When specific gravity of electrolyte and voltage of battery are measured, they are low
q
Coolant temperature gauge does not indicate normally
q Replace
Replace
Replace
Replace
Replace
Correct
Clean
Replace
Replace
Clean
Remedy
Replace
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Questions
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249] PC128US-8
40-297
40 Troubleshooting S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly
1
General causes why engine does not pick up smoothly Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
Clogged injector, defective spray
Stuck, seized supply pump plunger
Clogging of fuel filter
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Improper valve clearance
Defective contact of valve and valve seat
Clogged air cleaner element
Seized turbocharger, interference of turbocharger
Causes
q
Confirm recent repair history E E
Operated for long period
E w
Engine pick-up suddenly became worse
E Q Q
Q w w w
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
w w
Oil must be added more frequently w
Dust indicator is red
w
Air breather hole of fuel tank cap is clogged
w
Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping
w
When priming pump is operated, it makes no reaction or it is heavy
w Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is
Q w w
Blue under light load w Q
Black
w w
When engine is cranked, interference sound is generated around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied
Q
w
There is hunting from engine (rotation is irregular)
Q
Q
Q
w
Blow-by gas is excessive q
Inspect air cleaner directly
q
When compression pressure is measured, it is found to be low Troubleshooting
w
w
When engine is cranked, abnormal sound is generated around cylinder head
q q
Inspect valve clearance directly
q
When turbocharger is rotated by hand, it is found to be heavy
q
When air is bled from fuel system, air comes out
q
Inspect fuel filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code
q q Clean
Replace
Correct
Clean
Replace
Replace
Adjust
Clean
Remedy
Correct
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
Replace
Questions
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249]
40-298
PC128US-8
40 Troubleshooting S-4 Engine stops during operations
S-4 Engine stops during operations General causes why engine stops during operations q Internal parts of engine seized q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine
1
Defective starting switch wiring
Defective hydraulic pump
Defective engine controller power supply wiring
Broken auxiliary equipment (pump, compressor, etc.)
Stuck, seized supply pump plunger
w
Broken supply pump shaft
Q w Q w
Broken, seized feed pump
Clogging feed pump gauze filter
Clogging of fuel filter
Leaking, clogged fuel piping
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Broken, seized gear train
Broken, seized crankshaft bearing
Broken, seized piston, connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes
Confirm recent repair history E E
Operated for long period
Condition when engine stopped
w w w w w Q
Engine overheated and stopped
Q
Engine stopped slowly
w
Q Q
Q Q
There was hunting and engine stopped
w Q
Q Q Q
Q Q
Non-specified fuel is being used
Q Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w w
Fuel level monitor indicates low level
w
When fuel tank is inspected, it is found to be empty
w w
Air breather hole of fuel tank cap is clogged
w
Fuel is leaking from fuel piping
w w
Check items
Rust and water are found when fuel tank is drained Metal particles are found when oil pan is drained
w w
Does not turn at all
w w
When engine is cranked by hand
Q
Q Q
w
Turns in opposite direction
w
Moves by amount of gear backlash
w w
Supply pump shaft does not turn
w
Engine turns, but stops when load is applied to machine q
Inspect dynamic valve system directly
q
Inspect piston, connecting rod directly
q
Troubleshooting
Inspect crankshaft bearing directly
q
Inspect gear train directly
q
Inspect fuel filter directly
q
Inspect feed pump gauge filter directly
q
Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
q q q
q
Check controller power supply wiring
q Correct
—
Replace
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Add
Replace
Replace
Replace
Remedy
Replace
Check starting switch wiring
Correct
Questions
Abnormal noise was heard and engine stopped suddenly
Carry out troubleshooting on applicable machine
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249]
PC128US-8
40-299
40 Troubleshooting S-5 Engine does not rotate smoothly
S-5 Engine does not rotate smoothly
1
General causes why engine does not rotate smoothly Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)
Defective Bkup speed sensor, wiring harness
Defective Ne speed sensor, wiring harness
Clogging of fuel filter
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Clogged injector, defective spray (dirt in injector)
Causes
q
Confirm recent repair history E
Operated for long period
Q Q
Occurs at a certain speed range
Q Q Q Q Q
Occurs at low idle Q
Occurs even when speed is raised
Q Q
w
Occurs on slopes
w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
When fuel tank is inspected, it is found to be empty Check items
Fuel is leaking from fuel piping
w
When priming pump is operated, it makes no reaction or it is heavy
w Q
Troubleshooting
w
Air breather hole of fuel tank cap is clogged
When air is bled from fuel system, air comes out
q
Q
Rust and water are found when fuel tank is drained
q
Inspect fuel filter directly
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q
Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” indicated by code
q Replace
Replace
Replace
Add
Remedy
Clean
Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” indicated by code
Replace
Hunting
Replace
Questions
Degree of use of machine
*1: Displayed failure code [CA689] *2: Displayed failure code [CA778]
40-300
PC128US-8
40 Troubleshooting S-6 Engine lacks output (or lacks power)
S-6 Engine lacks output (or lacks power) General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
1 Defective boost pressure sensor, wiring harness
Q
Q Q
Clogged fuel spill piping
Defective installation of boost pressure sensor (air leakage)
Defective drive of injector (signal, solenoid)
Clogged injector, defective spray (dirt in injector)
Stuck, seized supply pump plunger
Clogging of fuel filter
Leaking, clogged fuel piping
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Improper valve clearance
Defective contact of valve and valve seat
Seized turbocharger, interference of turbocharger
Air leakage from air intake piping and aftercooler
Clogged air cleaner element
Causes
Confirm recent repair history E
E
E
Q
Q
Q
Q w
Suddenly Q
Gradually
Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
w Q
Oil must be added more frequently
Q
w w
Dust indicator is red
w
Air breather hole of fuel tank cap is clogged
w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation
w
Black
w w
Blue under light load
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w w w
When engine is cranked, interference sound is generated around turbocharger
w
When engine is cranked, abnormal sound is generated around cylinder head
Q
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is applied w w
Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular)
w
Blow-by gas is excessive
w Q Q
Q Q
w
Q Q Q
Q Q
w
q
Inspect air cleaner directly
q
Inspect air intake piping directly
q q q
When boost pressure is measured, it is found to be low
q
When compression pressure is measured, it is found to be low
q q
Inspect valve clearance directly Troubleshooting
Q
Q Q Q
Non-specified fuel is being used
Color of exhaust gas is
Q
q
Inspect fuel piping
q
Inspect fuel filter directly
q
Inspect spill port check valve directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q
Inspect charge pressure sensor mount directly Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” indicated by code
Correct
Replace
Replace
Replace
Replace
Correct
Clean
Replace
Adjust
Correct
Replace
Clean
Correct
Remedy
q Replace
Power was lost
E
Operated for long period
Replace
Questions
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA122] and [CA123]
PC128US-8
40-301
40 Troubleshooting S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black q Insufficient intake of air q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
1 Defective coolant temperature sensor, wiring harness
Improper fuel injection pressure
Improper injection timing
Abnormally worn injector
Clogged, seized injector
Stuck, seized supply pump plunger
Worn piston ring, cylinder
Crushed, clogged muffler
Leakage of air between turbocharger and cylinder head
Improper valve clearance
Defective contact of valve and valve seat
Seized turbocharger, interference of turbocharger
Clogged air cleaner element
Causes
Confirm recent repair history E
Operated for long period
Questions
Color of exhaust gas is
E
E
w
Suddenly became black
w
w
Gradually became black
Q
Q w
Blue under light load
Q Q
Non-specified fuel is being used w
Oil must be added more frequently Power was lost
E Q Q Q
w
Suddenly Q
Gradually
Q Q
Q
Q Q Q
w
Dust indicator is red
w
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened
Q Q Q
Engine is operated in low-temperature mode at normal temperature
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Q w w
When engine is cranked, interference sound is generated around turbocharger
w
When engine is cranked, abnormal sound is generated around cylinder head
Q
Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal
Q
w
Engine does not pick up smoothly and combustion is irregular
Q
Q Q Q
Q Q w w
Blow-by gas is excessive
w
If spill hose from injector is disconnected, abnormally much fuel spills q
Inspect air cleaner directly
q
When turbocharger is rotated by hand, it is fount to be heavy
q
Troubleshooting
When compression pressure is measured, it is found to be low
q q
Inspect valve clearance directly
q
When muffler is removed, exhaust sound improves Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code
q
q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated by code
q
Replace
Replace
Replace
Replace
Replace
Correct
Replace
Adjust
Correct
Clean
Replace
Remedy
Replace
q q
Confirm with monitoring function
Replace
Degree of use of machine
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145]
40-302
PC128US-8
40 Troubleshooting S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of pats in lubrication system
1 Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn, damaged rear oil seal
Worn piston ring, cylinder
Broken piston ring
Clogged breather, breather hose
Turbocharger Worn seal at blower end
Worn seal at turbine end
Worn, damaged valve (stem, guide, seal)
Dust sucked in from intake system
Causes
E E E
Operated for long period
E w
Oil consumption suddenly increased
Q
Oil must be added more frequently
w
Oil becomes contaminated quickly
Q Q w
Q w w w w w
Outside of engine is dirty with oil w
There are loose piping clamps in intake system
w
Inside of turbocharger intake outlet pipe is dirty with oil Q w
w
There is oil in coolant w
Oil level in clutch chamber or damper chamber is high w w
Exhaust smoke is blue under light load
w w w
None q
When intake manifold is removed, dust is found inside
q
When intake manifold is removed, inside is found to be dirty abnormally Troubleshooting
Q
q q
Excessive play of turbocharger shaft
q
Check breather and breather hose directly
q q
When compression pressure is measured, it is found to be low
q
Inspect rear oil seal directly
q q
Pressure-tightness test of oil cooler shows there is leakage
q q q q
PC128US-8
Replace
Replace
Replace
Replace
Replace
Clean
Replace
Replace
Correct
Remedy
Replace
There is external leakage of oil from engine
Correct
Amount of blow-by gas
Q
Excessive
Correct
Check items
Inside of turbocharger exhaust outlet pipe is dirty with oil
Correct
Degree of use of machine
Correct
Questions
Confirm recent repair history
40-303
40 Troubleshooting S-9 Oil becomes contaminated quickly
S-9 Oil becomes contaminated quickly
1
Degree of use of machine
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
E E E
Operated for long period
Q
Non-specified fuel is being used
Q
w
Oil must be added more frequently Metal particles are found when oil filter is drained
Q Q
Inside of exhaust pipe is dirty with oil
w
w w
Color of exhaust gas is Amount of blow-by gas
w
Blue under light load
w
Black Q Q w
Excessive
Q w
None q
Excessive play of turbocharger shaft
q q
When compression pressure is measured, it is found to be low
q
Check breather and breather hose directly
See S-7
Check items
Clogged oil filter
Confirm recent repair history
Engine oil temperature rises quickly
Troubleshooting
Clogged oil cooler
Clogged breather, breather hose
Worn piston ring, cylinder
Worn valve, valve guide
Defective seal at turbocharger turbine end
Causes
q
Inspect oil cooler directly
q
Inspect oil filter directly
q
Spring of oil filter safety valve is hitched or broken
q
40-304
Replace
Replace
Replace
Clean
Replace
Replace
Remedy
Replace
Inspect turbocharger lubrication drain tube directly
Clean
Questions
General causes why oil becomes contaminated quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load
—
PC128US-8
40 Troubleshooting S-10 Fuel consumption is excessive
S-10 Fuel consumption is excessive
1
General causes why fuel consumption is excessive Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel
Improper injection timing
Defective operation of injector
Defective spray by injector
Defective common rail pressure
Defective supply pump plunger
Defective feed pump oil seal
Fuel leakage from fuel filter, piping, etc.
Fuel leakage inside head cover
Defective coolant temperature sensor, wiring harness
Causes
q
E E
Operated for long period
Condition of fuel consumption
E Q
More than for other machines of same model Q
Gradually increased Q Q
Suddenly increased
w
There is external leakage of fuel from engine
w
Combustion is irregular w
w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w Q
Low idle speed is high
Q
Torque converter stall speed or pump relief speed is high Color of exhaust gas is
Q Q
Black
Q Q
Q
White
q
Remove head cover and inspect directly
q
Inspect feed pump oil seal directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code
q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q
If spill hose from injector is disconnected, much fuel spills Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated by code
q
Replace
Replace
Replace
Correct
Correct
Remedy
q Replace
q
Confirm with monitoring function
Replace
Check items
Engine oil level rises and oil smells of diesel fuel
Troubleshooting
Q Q Q Q
Replace
Degree of use of machine
Replace
Questions
Confirm recent repair history
*1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA144] and [CA145]
PC128US-8
40-305
40 Troubleshooting S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 General causes why oil is in coolant q Internal leakage in lubrication system q Internal leakage in cooling system
Broken oil cooler core, O-ring
Holes caused by pitting
Cracks inside cylinder block
Broken cylinder head, head gasket
Causes
Oil level
E E
Operated for long period Q
Suddenly rose
Q Q Q
Gradually rose
Q Q
Hard water is being used as coolant
Q Q w
There are excessive air bubbles in radiator, coolant spurts back
w
Pressure-tightness test of cylinder head shows there is leakage
q q q
Inspect cylinder block, liner directly
q Remedy
40-306
Replace
Pressure-tightness test of oil cooler shows there is leakage Replace
Troubleshooting
Check items
Oil level has risen and oil is milky
Replace
Degree of use of machine
Replace
Questions
Confirm recent repair history
PC128US-8
40 Troubleshooting S-12 Oil pressure drops
S-12 Oil pressure drops
1
General causes why oil pressure drops q Leakage, clogging, wear or lubrication system q Defective oil pressure control q Improper selection of fuel (improper viscosity) q Deterioration of oil due to overheating
Defective oil level sensor, wiring harness
Leaking, crushed, clogged hydraulic piping
Clogged oil filter
Defective regulator valve
Defective oil pump
Clogged, broken pipe in oil pan
Clogged strainer in oil pan
Coolant, fuel in oil
Lack of oil in oil pan
Worn journal of bearing
Causes
Degree of use of machine
E
Operated for long period
E
E Q w
Oil pressure monitor indicates low oil pressure Q
Non-specified oil is being used
Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Indicates pressure drop at low idle Oil pressure monitor (if installed)
w
Indicates pressure drop at low, high idle
Q
Indicates pressure drop on slopes
w
w w w Q w
Oil level monitor indicates oil level drop
w
Oil level in oil pan is low
w
Q w w
External hydraulic piping is leaking, crushed w
Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained
w
Metal particles are found when oil filter is drained
w
Metal particles are found in oil filter
q
Q
Inspect oil pan strainer, pipe directly
See S-13
Troubleshooting
Check items
Sometimes indicates pressure drop
Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged
q q q q q
Inspect oil filter directly
q
PC128US-8
Correct
Replace
Replace
Replace
Clean
—
Clean
Add
Remedy
Replace
If oil level sensor is replaced, oil level monitor indicates normally
Replace
Questions
Confirm recent repair history
40-307
40 Troubleshooting S-13 Oil level rises (Entry of coolant or fuel)
S-13 Oil level rises (Entry of coolant or fuel)
1
General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Degree of use of machine
Check items
Defective seal of auxiliary equipment (pump, compressor)
Defects in supply pump
Broken oil cooler core, O-ring
Worn, damaged rear oil seal
Holes caused by pitting
Cracks inside cylinder block
E
Operated for long period
E E
E
w
Fuel must be added more frequently
w
Coolant must be added more frequently
Q
There is oil in coolant
Q Q Q Q
Q w
w
Oil smells of diesel fuel Oil is milky
Q
When engine is started, drops of water come from muffler
Q
w Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w or coolant spurts back
Q Q
Exhaust smoke is white
w
Oil level in damper chamber is low
w
Oil level in hydraulic tank is low q
When compression pressure is measured, it is found to be low Troubleshooting
Broken injector, O-ring
Confirm recent repair history
q
Remove injector and inspect O-ring.
q q
Inspect cylinder block, liner directly
q
Inspect rear oil seal directly
q
Pressure-tightness test of oil cooler shows there is leakage
q
Remove and inspect supply pump directly
q
40-308
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
Inspect seal of auxiliary equipment directly
Replace
Questions
Broken cylinder head, head gasket
Causes
PC128US-8
40 Troubleshooting S-14 Coolant temperature becomes too high (overheating)
S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation, damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system
1
Rise in hydraulic oil temperature
Defective coolant temperature gauge
Slipping fan belt, worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged, crushed radiator fins
Defective operation of thermostat
Broken water pump
Lack of coolant
Clogged, broken oil cooler
Holes caused by pitting
Broken cylinder head, head gasket
Causes
Questions
Confirm recent repair history Degree of use of machine Condition overheating Coolant temperature gauge
E E
Operated for long period
E E Q w
Sudden overheated
Q Q w w
Always tends to overheat Q
Rises quickly
Q
w w
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level w Q
Engine oil level has risen, oil is milky
w
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
Check items
There are excessive air bubbles in radiator, coolant spurts back When light bulb is held behind radiator core, no light passes through
w
Radiator shroud, inside of underguard side are clogged with dirt or mud
w
w
w
Coolant is leaking because of cracks in hose or loose clamps
w
Coolant flows out from radiator overflow hose
w
Fan belt whines under sudden acceleration Hydraulic oil temperature enters red range faster than engine coolant temperature
w
q
When compression pressure is measured, it is found to be low
q
Inspect oil cooler directly
q
Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is carried out, it does not open at cracking temperature
q q
Temperature difference between upper and lower tanks of radiator is slight
q
Inspect radiator core directly
q
When operation of radiator cap is carried out, its cracking pressure is low
q
Inspect fan belt, pulley directly
q
PC128US-8
Correct
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Remedy
Replace
When coolant temperature is measured, it is found to be normal
Replace
Troubleshooting
Carry out troubleshooting on H-mode
q
Inspect cylinder liner directly
—
40-309
40 Troubleshooting S-15 Abnormal noise is made
S-15 Abnormal noise is made
1
General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 3 seconds. This does not indicate abnormality, however.
Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)
Dirt caught in injector
Clogged, seized injector
Deformed cooling fan, loose fan belt, interference of fan belt
Removed, seized bushing
Improper gear train backlash
Excessive wear of piston ring, cylinder
Improper valve clearance
Defective inside of muffler (dividing board out of position)
Broken dynamic valve system (valve, rocker lever)
Interference of turbocharger, seized turbocharger
Leakage of air between turbocharger and cylinder head
Causes
Degree of use of machine Condition of abnormal noise
E
Operated for long period
Q
Gradually occurred
Q Q
Non-specified fuel is being used Oil must be added more frequently
w
Metal particles are found when oil filter is drained
w
w
w
Air leaks between turbocharger and cylinder head
w
When engine is cranked, interference sound is generated around turbocharger
w
When engine is cranked, abnormal sound is generated around cylinder head
w w
When engine is cranked, beat noise is generated around muffler Check items
Q
Q Q
Suddenly occurred
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is
w Q w
Blue under light load Q w
Black
Q w
Engine does not pick up smoothly and combustion is irregular Q
Abnormal noise is loud when engine is accelerated
Q Q
q
When turbocharger is rotated by hand, it is found to be heavy
q
Inspect dynamic valve system directly
q
When muffler is removed, abnormal noise disappears Troubleshooting
Q w
Blow-by gas is excessive
q
Inspect valve clearance directly
q
When compression pressure is measured, it is found to be low
q q
Inspect gear train directly
q
Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q q q
Abnormal noise is heard only when engine is started
q
40-310
Replace
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Remedy
Replace
Confirm with monitoring function
Replace
Questions
Confirm recent repair history
PC128US-8
40 Troubleshooting S-16 Vibration is excessive
S-16 Vibration is excessive
1
General causes why vibration is excessive q Defective parts (abnormal wear, breakage) q Misalignment between engine and chassis q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for “S-15 Abnormal noise is made”, too.
Broken output shaft, parts in damper
Loose engine mounting bolts, broken cushions
Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)
Worn camshaft bushing
Improper gear train backlash
Worn main bearing, connecting rod bearing
Stuck dynamic valve system (valve, rocker lever)
Causes
E
E
E
Q
Q
Q
Non-specified oil is being used
Q
Q
Metal particles are found when oil filter is drained
w
w
Metal particles are found when oil pan is drained
w
w
Oil pressure is low at low idle
Q
Q
Degree of use of machine Condition of vibration
Operated for long period Q
Suddenly increased Gradually increased
Q
Q Q
Vibration occurs at mid-range speed Q
Vibration follows engine speed Exhaust smoke is black
w
Inspect dynamic valve system directly
q
Q Q Q
q
Inspect main bearing and connecting rod bearing directly
q
Inspect gear train directly
q
Inspect camshaft bushing directly
q
Confirm with monitoring function
q
Inspect engine mounting bolts and cushions directly
q
PC128US-8
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
Inspect output shaft or inside of damper directly
Replace
Troubleshooting
Check items
Questions
Confirm recent repair history
40-311
40 Troubleshooting S-16 Vibration is excessive
40-312
PC128US-8
HYDRAULIC EXCAVATOR PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
50 Disassembly and assembly1
PC128US-8
50-1
50 Disassembly and assembly
Contents General information on disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-4
How to read this manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-4
Coating materials list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-6
Special tool list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-9
Sketch of special tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-13
Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-15
Removal and installation of fuel supply pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-15
Removal and installation of fuel injector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-17
Removal and installation of front oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-20
Removal and installation of rear oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-22
Removal and installation of cylinder head assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-25
Removal and installation of radiator assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-32
Removal and installation of aftercooler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-34
Removal and installation of work equipment oil cooler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-36
Removal and installation of engine and work equipment pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-39
Removal and installation of fuel tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-44
Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-46
Removal and installation of travel motor and final drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-46
Disassembly and assembly of travel motor and final drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-48
Removal and installation of swing motor and swing machinery assembly - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-84
Disassembly and assembly of swing motor and swing machinery assembly - - - - - - - - - - - - - - - - - - - - - - - - -
50-86
Removal and installation of swing circle assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-92
Undercarriage and frame- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-93
Disassembly and assembly of track roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-93
Disassembly and assembly of idler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-96
Disassembly and assembly of recoil spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
50-99
Spreading and installation of track shoe assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-102 Removal and installation of sprocket- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-104 Removal and installation of revolving frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-105 Removal and installation of counterweight assembly (Machine without add-on weight) - - - - - - - - - - - - - - - - - 50-107 Removal and installation of counterweight assembly (Machine with add-on weight) - - - - - - - - - - - - - - - - - - - 50-109 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-111 Removal and installation of center swivel joint assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-111 Disassembly and assembly of center swivel joint assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-113 Removal and installation of hydraulic tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-114 Removal and installation of hydraulic pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-117 Removal and installation of control valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-121 Disassembly and assembly of control valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-126 Disassembly and assembly of work equipment PPC valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-136 Disassembly and assembly of travel PPC valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-139 Disassembly and assembly of hydraulic cylinder assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-141 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-147 Removal and installation of work equipment assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-147 Cab and its attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-150 Removal and installation of operator cab assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-150 Removal and Installation of operator's cab door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-152 Removal and installation of operator's cab glass (stuck glass)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-155 Removal and installation of front window assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-164
50-2
PC128US-8
50 Disassembly and assembly
Removal and installation of floor frame assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-165 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-172 Removal and installation of air compressor assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-172 Removal and installation of air conditioner condenser - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-173 Removal and installation of air conditioner unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-174 Removal and installation of machine monitor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-177 Removal and installation of pump controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-178 Removal and installation of engine controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-179 Removal and installation of KOMTRAX communications module- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-180
PC128US-8
50-3
50 Disassembly and assembly How to read this manual
General information on disassembly and assembly How to read this manual 1.
(Rev. 2009.01) 1
Removal and installation of assemblies Special tools q Special tools which are necessary for r e mo v a l or i n s ta l l at i o n o f pa r ts a r e described as A1,•••X1 etc. and their parts numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
Removal q In "Removal" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in "Removal" section are explained and listed below. k :
Precautions related to work safety
a: Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in "Installation" section. 6 :
Amount of oil or coolant to be drained
4:
Weight of part or component
Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in "Removal" section. q Common tools that are necessary for installation are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the "Installation" section stand for the following. k :
Precautions related to work safety
a: Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
50-4
PC128US-8
50 Disassembly and assembly How to read this manual
2.
Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1,•••X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They have a new part number respectively. R : Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
Disassembly q In "Disassembly" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Disassembly" section are as follows. k :
Precautions related to work safety
a: Guidance or precautions for the work 6: Amount of oil or coolant drained
Assembly q In "Assembly" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2] ••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Assembly" section are as follows. k :
Precautions related to work safety
a: Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
PC128US-8
50-5
50 Disassembly and assembly Coating materials list
Coating materials list
(Rev. 2009.08) 1
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Category
Komatsu code
Part No.
Capacity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
LT-2
790-129-9040
Main features and applications q
Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
q
Polyethylene container
Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
50 g
Polyethylene q container q
Features: Resistance to heat and chemicals. Use to fix and seal bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardener)
Adhesive: 1 kg Hardener: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene q container
Holtz MH 705
790-129-9120
75 g
Tube
50 g
Polyethylene q container q
2g
Polyethylene q container
ThreeBond 1735
790-129-9140
q
790-129-9130
Heat-resistant seal used to repair engines.
q
Instanetaneous adhesive. Curing time: From 5 sec. to 3 min. Use mainly to bond metals, rubbers, plastics, and woods. Instanetaneous adhesive. Quick-curing type (max. strength is obtained after 30 minutes) Use mainly to bond rubbers, plastics, and metals. Features: Resistance to heat and chemicals. Use for fitted portions subjected to high temperature. Use to seal various threaded portions, pipejoints, and flanges. Use to seal taper plugs, elbows, and nipples for hydraulic piping. Features: Silicon-based heat and cold-resistant sealant. Use to seal flange surfaces and threaded portions. Use to seal oil pan, final drive case, etc. Features: Silicon-based quick-curing sealant. Use to seal flywheel housing, intake manifold, thermostat old, oil pan, thermostat housing, etc. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Use to seal transfer case, etc. Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc. Can be coated with paint.
q
Loctite 64879A-129-9110 50
q
50 cc
Polyethylene q container
1 kg
Polyethylene container q
q
LG-5
790-129-9080
q
Liquid gasket
LG-6
200 g
Tube
q q q
LG-7
790-129-9170
1 kg
Tube
LG-8 ThreeBond 1207B
419-15-18131
100 g
Tube
LG-9 ThreeBond 1206D
50-6
790-129-9160
q q q q
790-129-9310
200 g
Use to seal plugs for blank holes
q
q
Aron-alpha 201
Use to bond and seal metal, glass and plastics.
Tube q
PC128US-8
50 Disassembly and assembly Coating materials list
Seizure Molybdenum disulfide prevention compound lubricant
Liquid gasket
Category
Komatsu code LG-10 ThreeBond 1206E LG-11 ThreeBond 1121 ThreeBond 1211 LM-P
Capacity
Container
790-129-9320
200 g
Tube
Main features and applications q q q
200 g
Tube
q
790-129-9090
100 g
Tube
q
Liquid gasket used to repair engine.
q
Use to prevent galling and seizure of press-fitted portions, shrinkage-fitted portions, and threaded portions. Use to lubricate linkages, bearings, etc. Spray type Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from galling. Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.
09940-00040
200 g
Tube
q
—
09995-00250
190 g
Can q
q
LC-G NEVERSEEZ
—
—
Can
G2-LI G0-LI (*) *: For cold district
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG0-400LI-A (*) SYG0-160CNLI (*)
Various
Various
SYG2-400M SYG2-400M-A SYGA-16CNM
SYG2-400T-A Hyper White SYG0-400T-A G2-T, (*) G0-T (*) SYG2-16CNT *: For cold SYG0-16CNT district (*) Biogrease G2-B SYG2-400B G2-BT (*) SYG2-400BT *: For use at (*) high temper- SYGA-16CNB ature and SYGA-16CNBT under high (*) load G2-S ThreeBond 1855
—
400 g × 10 400 g × 20 16 kg
400 g 16 kg
400 g 16 kg
200 g
q
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc. Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
q
Feature: Lithium grease with extreme pressure lubrication performance, general purpose type.
q
Use for parts under heavy load. Caution: q Do not use this grease for rolling bearings like swing circle bearings, etc. and spline. q Use this grease for work equipment pins only when installing them, but do not use it afterward.
q
q
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Bellows-type q container Can
Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.
q
Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. Use for oil seals of the transmission, etc.
Bellows-type container Can
Bellows-type container Can
Tube q
PC128US-8
Use as lubricant/sealant when installing the radiator hoses to the water tubes. Can be coated with paint. Feature: Can be used together with solid gaskets. Use for covers of the transmission case and steering case etc.
790-129-9330
q q
Molybdenum disulfide grease LM-G (G2M) Grease
Part No.
50-7
50 Disassembly and assembly Coating materials list
Category
Komatsu code
Part No.
Capacity
Container
Main features and applications
SUNSTAR PAINT PRIMER580 417-926-3910 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT 22M-54-27230 PRIMER 435-95
Caulking material
Adhesive
SUNSTAR GLASS PRIMER 435-41
50-8
22M-54-27240
SUNSTAR SASH 22M-54-27250 PRIMER GP-402 SUNSTAR PENGUINE SEAL580 417-926-3910 SUPER "S" or "W" Sika Japan, Sikaflex 20Y-54-39850 256HV SUNSTAR PENGUINE 22M-54-27210 SUPER 560 SUNSTAR PENGUINE 417-926-3920 SEAL No. 2505 SEKISUI SILICONE 20Y-54-55130 SEALANT GE TOSHIBA SILICONES 22M-54-27220 TOSSEAL3 81
2 kg
Can q
20 ml
Glass container
20 ml
Glass container
20 ml
Glass container
150 ml
Can
20 ml
Glass container
For adhered window glass
G2-U-S 427-12-11871 ENS grease
Feature: Urea (organic system) grease with heat resistance and long life, can be packed into the confined space and left intact until next overhaul. Use for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease. q
Use as primer for painted cab sheet metal surface. (Effective period: four months after date of manufacture)
q
Use as primer for glass. (Effective period: four months after date of manufacture)
q
Use as primer for painted cab sheet metal surface. (Effective period: four months after date of manufacture) Use as primer for black ceramic-coated glass surface and for hard polycarbonatecoated surface. (Effective period: four months after date of manufacture) Use as primer for sash (anodized aluminum surface). (Effective period: four months after date of manufacture) Use "S" in high-temperature season and "W" in low-temperature season as adhesive for glass. (Effective period: four months after date of manufacture) Use as adhesive for glass. (Effective period: six months after date of manufacture) Use as adhesive for glass. (Effective period: six months after date of manufacture)
q
q
q
320 ml
Polyethylene container
310 ml
Polyethylene container
320 ml
Ecocart (Special container)
320 ml
Polyethylene container
333 ml
Polyethylene container
333 ml
Cartridge
q
For adhered window glass
Primer
Grease
q
q
q
Use to seal glass-to-glass joints. (Effective period: four months after date of manufacture)
q
Use to seal front window. (Effective period: six months after date of manufacture)
q
Use to seal glass-to-glass joint. Translucent white seal. (Effective period: 12 months after date of manufacture)
PC128US-8
50 Disassembly and assembly Special tool list
Special tool list
(Rev. 2009.01) 1
Engine front oil seal
Engine rear oil seal
1
2
Engine rear oil seal
3
D 1
2
Swing machinery
F
1
Push tool (Kit)
790-101-5271
• Plate
1
790-101-5221
• Grip
1
01010-51225
• Bolt
1 t
1
795-931-1100
Seal puller assembly q
1
790-101-5401
Push tool (Kit)
t
1
790-101-5421
• Grip
1
01010-51240
• Bolt
1
795T-221-1020 Plate
t
1
796-460-1210
Oil stopper
q
1
Sketch
t
790-101-5201
Nature of work, remarks
Instllation front oil seal Q Removal rear oil seal
Instllation rear oil seal Q
795-799-1131
Adapter
q
1
Stop oil supply from hydraulic tank
790-201-2750
Spacer
t
1
Removal split collar
790-101-5201
Push puller (Kit)
q
1
790-101-2510
• Block
1
790-101-2550
• Leg
1
790-101-2560
• Nut
2
790-101-2570
• Plate
4
790-101-3101
Bearing puller
q
1
790-101-4200
Puller (294 kN {30 ton})
q
1
790-101-1102
Hydraulic oil pump
q
1
790-101-5401
Push tool (Kit) (C)
q
1
Instllation Bearing outer race For main bearing For sub bearing
790-101-5461
• Plate
1
790-101-5441
• Plate
1
790-101-5421
• Grip
1
01010-51240
• Bolt
1
4
790-201-2850
Spacer
t
1
5
790-201-2750
Spacer
t
1
3
PC128US-8
Part Name
795T-221-1010 Push tool
A
Hydraulic oil tank
Part No.
New/remodel
Symbol
Q’ty
Component
Necessity
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be made locally). a Necessity : t . . . . . Special tools that cannot be substituted and should always be used : q . . . . . Special tools that will be useful if available and are substitutable with tools available on the market a New/Remodel: N . . . . . Tools newly developed for this model. They have a new part number respectively. : R. . . . . . Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. : Blank . . Tools already available for other models. They can be used without any modification. a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketches of special tools").
Removal bearing
Instllation Bearing inner race
50-9
F 6 1
2
Disassembly, assembly L of idler recoil spring
3
1
Disassembly, assembly M of track roller 2
Expansion, installation of track shoe
R
796T-426-1140 Push tool
t
1
790-201-2680
Plate
q
1
791-675-1510
Installer
t
1
791-600-2001 or 791-685-8006
Compressor (A)
791-635-3160
Extension
t
1
790-201-2770
• Spacer
t
1
790-101-1600
Cylinder (686 kN {70 ton})
t
1
790-101-1102
Pump
t
1
790-201-1500
Push tool (Kit)
q
1
790-201-1590
• Plate (Periphery ø74)
1
790-201-1610
• Plate (Periphery ø79)
1
790-101-5021
• Grip
1
Part Name
Q
Nature of work, remarks
Instllation oil seal Application of floating seal
1 t
Compressor (B)
1 Compression of spring
Press fit of piston dust seal
01010-50816
• Bolt
790-434-1650
Installer
t
1
Application of floating seal ø88
791-601-1000
Oil pump
q
1
Sealing of oil and checking of air leak
791-620-3000
Remover and installer
t
1
791-635-3110
• Frame
1
791-635-3120
• Support
1
791-635-3130
• Nut
1
791-635-3140
• Screw
1
791-635-3150
• Hook
1
1
791-635-3160
• Extention
1
791-635-3170
• Nut
1
791-635-3180
• Screw
1
791-635-3190
• Screw (for fixation)
1
791-635-3210
• Pilot
1
791-630-3220
• Adapter
1
791-620-3260
• Pin pusher
1 t
1
790-101-1300 or 790-101-1600
Cylinder (980 kN {100 ton}) Cylinder (686 kN {70 ton})
t
1
790-101-1102
Pump
t
1
796T-432-1010 Guide
50-10
Sketch
Swing machinery
Part No.
New/remodel
Symbol
Q’ty
Component
Necessity
50 Disassembly and assembly Special tool list
Removal and pressfit of master pin
N
Q
PC128US-8
Disassembly of center swivel joint
T
1 2
3
Disassembly, assembly U of hydraulic cylinder
5
1
Push puller
790-101-2510
• Block
1
790-101-2520
• Screw
1
790-101-2540
• Washer
1
791-112-1180
• Nut
1
790-101-2630
• Leg
2
790-101-2570
• Washer
4
790-101-2560
• Nut
2
790-101-2650
• Adapter
2
790-502-1003
Repair stand
t
1
790-101-1102
Pump
t
1
790-102-4300
Wrench assembly
t
1
790-201-4310
Pin
t
1
790-201-1702
Push tool (Kit)
t
1
790-201-1791
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1702
Push tool (Kit)
790-201-1811
• Push tool
1
790-101-5021
• Grip
1
t
Nature of work, remarks
Disconnection of rotor from shaft
Disassembly, assembly of cylinder Removal, installation of piston
Press fit of bucket cylinder roll bushings
1
01010-50816
• Bolt
790-201-1702
Push tool (Kit)
790-201-1821
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1500
Push tool (Kit)
Press fit of boom cylinder roll bushings
1 t
q
1
• Push tool
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1500
Push tool (Kit)
790-201-1620
• Push tool
1
790-101-5021
• Grip
1
q
Press fit of arm and blade cylinder roll bushings
1 1
Application of bucket cylinder dust seal
1 Application of boom cylinder dust seal
01010-50816
• Bolt
790-201-1500
Push tool (Kit)
790-201-1630
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-720-1000
Expander
t
1
Extension of piston ring
796-720-1660
Ring
t
1
07281-01159
Clamp
t
1
Bucket cylinRemoval, der installation of Arm, boom, blade cylinder piston ring
6
PC128US-8
q
790-101-2501
790-201-1610
4
Part Name
Sketch
Part No.
New/remodel
Symbol
Q’ty
Component
Necessity
50 Disassembly and assembly Special tool list
1 q
1 Application of arm and blade cylinder dust seal
50-11
Counterweight assembly
50-12
X
Z
t
1
Remover
796-270-1110
• Adapter
1
790-101-4000
Puller (490 kN {50 ton})
1
790-101-1102
Pump
1
1
793-498-1210
Lifter (Suction cup)
t
2
2
20Y-54-13180
Seat
t
2
Commercially availably
Impact wrench
q
1
Commercially availably
Soket wrench (width q across flats: 65 mm)
1
Sketch
Part Name
792-785-1100 Removal, installation, of work equipment and V 1 boom
Operator’s cab glass (stuck glass)
Part No.
New/remodel
Symbol
Q’ty
Component
Necessity
50 Disassembly and assembly Special tool list
Nature of work, remarks
Removal of boom foot pin
Removal and installation operatiors cab glass (stuck glass) For machine without add-on weight
PC128US-8
50 Disassembly and assembly Sketch of special tool
Sketch of special tool
1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A1 Push tool
a
Unless otherwise specified, there shall be no burrs or flushes at the corner.
A3 Plate
PC128US-8
50-13
50 Disassembly and assembly Sketch of special tool
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. F6 Push tool
a
Unless otherwise specified, there shall be no burrs or flushes at the corner.
R Guide
50-14
PC128US-8
50 Disassembly and assembly Removal and installation of fuel supply pump assembly
Engine and cooling system
6)
Removal and installation of fuel supply pump assembly 1
7) 8)
Removal
k Disconnect the negative (–) terminal of the
Loosen sleeve nuts (12) and (13) and remove high pressure pipe (14). [*2] Remove the pin and disconnect spill hose (15). Remove joint bolts (16), (17) and (18) and remove fuel tubes (19) and (20). [*3]
battery beforehand. 1.
Remove the counterweight, referring to "Removal and installation of counterweight."
2.
Disconnecting engine controller and frame assembly 1) Remove engine controller mounting bolts (1) from the upper frame (2). 2) Remove 4 lower frame mounting bolts (3). 3) Disconnect the engine controller frame assembly (4). 4.
3.
Removal of supply pump and pump holder assembly 1) Remove 4 mounting bolts (21) from the gear case. 2) Loosen mounting bolts (22) completely from the pump holder side. [*4] a At this stage, mounting bolts (22) cannot be removed between the supply pump and the pump holder. 3) Remove supply pump and pump holder assembly (23).
Disconnecting wiring and piping 1) Disconnect pump regulator sensor connector PREG (5). 2) Disconnect wiring clamps (6), (7) and (8). 3) Disconnect clamp (10) from fuel hoses (9). 4) Disconnect fuel hose (9) from the fuel filter. 5) Remove two boots (11) from the injector and supply pump. [*1]
PC128US-8
50-15
50 Disassembly and assembly Removal and installation of fuel supply pump assembly
5.
Removal of supply pump assembly 1) Loosen nut (24) and pull out supply pump gear (25) using gear puller [1]. [*5]
Installation q
Carry out the installation in the reverse order of removal.
[*1] a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. [*2]
k Never
2)
Remove 3 nuts (26) and remove supply pump (27) from pump holder (28).
bens a high-pressure pipe for the convenience sake. k The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. k Be sure to install the boot to the sleeve nut after installing the high-pressure pipe. a Before installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. q No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2 mm inside the tip). q No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).
3 Sleeve nut (12) on the common rail side:
25.5 – 29.4 Nm {2.6 – 3.0 kgm}
3 Sleeve nut (13) on the supply pump side:
18 – 23 Nm {1.9 – 2.3 kgm} [*3]
3 Joint bolts (16) and (17):
24.5 – 34.3 Nm {2.5 – 3.51 kgm} 3 Joint bolt (18):
19.6 – 17.7 Nm {2.0 – 1.8 kgm} [*4] a For mounting bolt (22), install M6 bolt with LT2A. [*5]
3 Pump gear mount nut:
65 – 75 Nm {6.6 – 7.6 kgm} 50-16
PC128US-8
50 Disassembly and assembly Removal and installation of fuel injector assembly
Removal and installation of fuel injector assembly 1 Removal
k Disconnect the negative (–) terminal of the
battery beforehand. 1.
Open engine hood (1).
2.
Disconnection of air conditioner compressor hose clamp and aftercooler hose a When removing injector assemblies No. 3 and No. 4, completing the following procedures in advance makes the work for Procedure 3 and onward easier. 1) Disconnect air conditioner compressor hose clamps (2) and (3) and keep the hose out of the way. 2) Disconnect aftercooler hose (4) on the side of the air intake connector and keep it out of the way.
PC128US-8
3.
Removal of the high-pressure pipe a The following indicates the removal of injector assembly of cylinder No. 1 for example. 1) Remove clamp (5) from the high-pressure pipe. 2) Remove boot (6) from the injector and common rail sides. [*1]
3)
4) 5)
Remove injector wiring connector (7). Connector No. Cylinder No. 1: CN1 Cylinder No. 2: CN2 Cylinder No. 3: CN3 Cylinder No. 4: CN4 Remove pin (8) and disconnect spill hose (9). Loosen sleeve nut (10) both on the injector side and common rail side and remove high-pressure pipe (11). [*2]
50-17
50 Disassembly and assembly Removal and installation of fuel injector assembly
4.
Removal of injector assembly 1) Remove holder mounting bolt (12) and remove holder (13). [*3] 2) Remove injector assembly (14). [*4]
Installation q
Carry out the installation in the reverse order of removal.
[*1] a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. [*2]
k Never
bend a high-pressure pipe for the convenience sake. k The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. k Be sure to install the boot to the sleeve nut after installing the high-pressure hose. a Before Installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. q No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2mm inside the tip). q No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).
3 Sleeve nut (10):
25.5 – 29.4 Nm {2.6 – 3.0 kgm} [*3]
3 Holder mounting bolt (12):
27 – 30 Nm {2.8 – 3.1 kgm}
50-18
PC128US-8
50 Disassembly and assembly Removal and installation of fuel injector assembly
[*4] q
When reusing injector, always replace Oring (15) and gasket (16) with new ones.
PC128US-8
50-19
50 Disassembly and assembly Removal and installation of front oil seal
Removal and installation of front oil seal 1
A 1
Part name
Loosen fan belt adjust bolt (3) and remove fan belt (4). [*1]
4.
Remove engine speed sensor connector (5).
5.
Remove speed sensor mounting bolt (6) and remove speed sensor (7). [*2]
6.
Remove crankshaft pulley mounting bolt (8) and remove crankshaft pulley (9). [*3]
7.
Remove front oil seal (10).
t 1
790-101-5201
Push tool (kit)
790-101-5271
• Plate
1
790-101-5221
• Grip
1
01010-51225
• Bolt
795T-221-1010 Push tool
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
3.
1 t 1
Removal 1.
Remove the engine assembly, referring to "Removal and installation of engine assembly."
2.
Remove fan mounting bolt (1) and remove fan (2).
50-20
PC128US-8
50 Disassembly and assembly Removal and installation of front oil seal
Installation 1.
Use tool A1 (outside diameter of 89 mm) to press front oil seal (10) in gear case (11). 1) Check the crankshaft end corner and the oil seal lip sliding surface for flaws, burrs, scars, or rust, before installing the oil seal. 2) Fill about 2 cc of grease to between the oil seal lips. 2 Front oil seal: grease (G2-LI)
2.
Install the crankshaft pulley. a Align key (a) of crankshaft (12) with key groove (b) of crankshaft pulley (9) and install the pulley.
3.
For the rest of the installation work, carry out the installation in the reverse order of removal.
[*1] Confirm the direction of the fan. [*2]
2 Speed sensor mounting bolt (6):
7.0 – 11 Nm {0.7 – 1.1 kgm} [*3]
2 Crankshaft pulley mounting bolt (8):
343 – 402 Nm {35 – 41 kgm}
PC128US-8
50-21
50 Disassembly and assembly Removal and installation of rear oil seal
Removal and installation of rear oil seal 1
2) 3)
Temporarily lift flywheel (3). Remove 7 flywheel mounting bolts (4) except one. [*2]
4)
Loosen flywheel mounting bolt (4). k Leave 3 threads or 4 engaged to prevent the flywheel from suddenly shooting out in the following procedure. Pull out the flywheel by prying with a bar, etc. Checking that flywheel (3) is manually removable, remove the flywheel mounting bolt (4). Lift flywheel (3) and remove it. 4 Flywheel: 25 kg
2
A 3
Part name
795-931-1100
Seal puller assemq 1 bly
790-101-5401
• Push tool (kit)
790-101-5421
• Grip
1
01010-51240
• Bolt
1
795T-221-1020 Plate
t 1
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
Removal 1.
2.
Remove the hydraulic pump assembly, referring to "Removal and Installation of Hydraulic Pump Assembly." Removal of the flywheel 1) Remove coupling mounting bolt (1) and remove coupling (2). [*1]
50-22
5) 6)
7)
PC128US-8
50 Disassembly and assembly Removal and installation of rear oil seal
3.
Removal of the rear oil seal 1) Screw the tip of tool A4 into the metal ring of seal (5) and pull it out with the impact of a slide hammer [1]. a For the ease of pulling out the seal, slightly hammer it in to unfasten it from the housing before pulling it out. a Do not use a drill as chips may enter the engine.
(Photo shows work on a single unit of engine, but the procedures are the same.)
Installation 1.
Rear oil seal mounting procedure Use tool A3 (outside diameter of 120 mm) to install rear oil seal to flywheel housing. a Fill about 3 cc of grease to between the rear oil seal lips. 2 Front oil seal: grease (G2-LI)
2.
For the following installation work, carry out the installation in the reverse order of removal.
[*1]
3 Coupling mounting bolt:
98 – 122.6 Nm (10 – 12.5 kgm) [*2] q
Tighten the flywheel mounting bolts according to the following procedure: 1) Apply engine oil to the bolt threads. 2 Mounting bolt threads: Engine oil (EO30) 2) Tighten the bolts in the order of 1 to 6 as shown in the diagram (CPP14824). 3) Tighten the bolts each in two actions by applying torque as specified in the order of item 2) above. 3 Mounting bolt: Unit: Nm{kgm}
procedure
target
1st time
88.2 {9.0}
range 58.7 – 117.7 {6.0 – 12.0}
2nd time 191.3 {19.5} 186.4 – 196.2 {19.0 – 20.0}
PC128US-8
50-23
50 Disassembly and assembly Removal and installation of rear oil seal
[*3] q
Measuring radial runout of flywheel 1) Install dial gauge [2] to the flywheel housing. 2) Set the probe of the dial gauge at right angles to the spigot joint (a) or the outer periphery of the flywheel. 3) Rotate the crank shaft one full turn and measure the difference of the maximum values of runout of the needle. a Check that the position of needle remains in its original position after the flywheel is rotated one full turn. Radial runout: Max. 0.15 mm
q
Measuring face runout of flywheel 1) As with the measurement of radial runout, set the probe of the dial gauge at right angles to end face (b) close to the outer periphery of the flywheel. a For measurement, move the crank shaft forward or backward to prevent error caused by an end play. 2) Rotate the crank shaft one full turn and measure the difference of the maximum values of runout of the needle. Face runout: Max. 0.25 mm
50-24
PC128US-8
50 Disassembly and assembly Removal and installation of cylinder head assembly
Removal and installation of cylinder head assembly 1
4.
Disconnect aftercooler hose (11) from the air intake connector (12) side.
5.
Remove 4 mounting bolts (13) and remove the air conditioner compressor mounting bracket.
6.
Remove bolts (14) and (15) and remove fuel filter (18). [*1] a Bolt (14) tightens the clamp of wiring to the air conditioner compressor together. a Bolt (15) tightens bracket (19) together.
7.
Remove bolts (16) to (18) and remove bracket (19). [*2] a Bolt (18) tightens the clamp of wiring to the injector together.
Removal
k Disconnect the negative (–) terminal of the
battery beforehand. 1.
Remove the counterweight assembly, referring to "Removal of counterweight assembly."
2.
Removal of engine controller frame assembly 1) Remove engine controller mounting bolts (1) from the upper frame (2). 2) Remove 4 lower frame mounting bolts (3). 3) Disconnect engine controller frame assembly (4).
3.
Removal of air conditioner compressor 1) Disconnect wiring connector AC02 (5). 2) Disconnect air conditioner hose clamps (6) at two locations. a Do not disconnect the air conditioner hoses. 3) Remove air conditioner compressor drive belt protective cover (7). 4) Loosen air conditioner compressor mounting bolts (8) and remove drive belt (9). 5) Remove air conditioner compressor mounting bolts (8) and remove air conditioner compressor (10). (Keep the compressor out of the way.)
PC128US-8
50-25
50 Disassembly and assembly Removal and installation of cylinder head assembly
8.
9.
Disconnection of wiring 1) Disconnect heater wiring E01 (20). 2) Disconnect injector wiring CN1 to CN4 (21). 3) Disconnect boost pressure sensor connector PTIM (22).
Removal of air intake connector and electrical intake air heater assembly 1) Remove 4 bolts (23) to (26) and remove air intake connector (27). [*3] a Because oil level gauge pipe bracket (28) is tightened together with bolt (24), tie the disconnected oil level gauge pipe with a string to keep it out of the way. a Bolt (25) tightens grounding (29) together. 2) Remove electrical intake air heater assembly (30). [*4]
6)
Remove 8 air intake manifold mounting bolts (37) and remove air intake manifold (38). [*7]
11. Removal of injector assembly 1) Remove 4 injector mounting bolts (39) and remove 4 holders (40). [*8] 2) Remove injector assembly (41). [*9]
12. Removal of muffler 1) Remove upper covers (42) and (43).
10. Removal of high-pressure pipe and air intake manifold 1) Remove coolant temperature sensor wiring clamp (31). 2) Remove spill hose mounting pin (32) and disconnect spill hose (33). 3) Remove high-pressure pipe clamps (34) at 2 locations. 4) Remove 8 boots (35) both from the cylinder head side and common rail side. [*5] 5) Loosen the sleeve nuts and remove 4 high-pressure pipes (36). [*6] 50-26
PC128US-8
50 Disassembly and assembly Removal and installation of cylinder head assembly
2)
Remove 2 clamp mounting bolts (44) and remove clamp (45). [*10]
3) 4)
Remove divider board (46). Remove rubber covers (47) and (48).
5)
Remove muffler drain tube (49). a Remove the lower clamp in advance. Remove 4 bracket mounting bolts (50). Lift muffler bracket assembly (51) and remove it. 4 Muffler bracket assembly: 22 kg
6) 7)
PC128US-8
13. Removal of turbocharger and exhaust manifold assembly 1) Remove cover (52).
2) 3)
Disconnect blowby tube (53). Remove 3 mounting nuts (54) and remove cylinder head cover (55). [*11]
50-27
50 Disassembly and assembly Removal and installation of cylinder head assembly
4)
5)
6)
7) 8)
Remove mounting bolts (56) and disconnect turbocharger lubricant inlet port tube (57). [*12] Remove 2 mounting bolts (58) and disconnect turbocharger lubricant return tube (59). Remove 3 mounting bolts (60) and disconnect connector (61) between the turbocharger and aftercooler hose from the turbocharger. Remove 8 exhaust manifold mounting bolts (62). [*13] Lift turbocharger and exhaust manifold assembly (63) and remove them. 4 Turbocharger and exhaust manifold assembly: 15 kg
14. Removal of water pump 1) Disconnect coolant temperature sensor connector TWTR (64). 2) Disconnect radiator upper hose (65), heater hoses (66) and (67) and radiator lower hose (68). 3) Remove fan belt (69). 4) Remove 6 fan pulley mounting bolts (70). 5) Remove fan pulley assembly (71).
6) 7)
50-28
Remove 3 water pump mounting bolts (72). [*14] Remove water pump (73).
PC128US-8
50 Disassembly and assembly Removal and installation of cylinder head assembly
15. Removal of rocker arm assembly 1) Loosing lock nut (74) and fully loosen adjustment screw (75). [*15] a Loosen the air intake and exhaust adjustment screws on all cylinders. 2) Remove 8 mounting bolts (76) and remove rocker arm assembly (77). [*16]
Installation q
Carry out the installation in the reverse order of removal.
[*1] [*2] a When installing fuel filter mounting bolts (14), tighten wiring clamp (81) for the air conditioner compressor together. a When installing bracket mounting bolts (18), tighten wiring clamp (21) for the injector together.
16. Removal of cylinder head assembly 1) Pull out 8 push rods (78). 2) Remove 17 cylinder head mounting bolts (79). [*17] [*3] [*4] When installing air intake connector (27) and electrical intake air heater (30), pay attention to the following matters: a When installing the air intake connector and electrical intake air heater, replace the gasket with new one. a When installing air intake connector mounting bolts (24), tighten it together with oil level gauge pipe bracket (28). a When installing air intake connector mounting bolts (25), tighten it together with oil level gauge pipe bracket (29). a If grounding (29) is removed from electrical intake air heater (30) by removing grounding mounting bolt (81), install the grounding mounting bolt (82) with the following torque: 3 Grounding mounting bolt (82): 4.9 – 5.9 Nm {0.5 – 0.6 kgm}
q
3)
Lift cylinder head assembly (80) and remove it. 4 Cylinder head assembly: 30 kg
PC128US-8
50-29
50 Disassembly and assembly Removal and installation of cylinder head assembly
[*5] [*6] q Precautions when installing high-pressure piping k Never bend a high-pressure pipe for the convenience sake. k The clamp used for fixing a high-pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque. k Be sure to install the boot to the sleeve nut after installing the high-pressure hose. a Set the boot slit facing outward and downward. a The boot is designed with fire safety to prevent fuel from splashing onto the hot engine if fuel leaks. a Before Installing a high-pressure pipe, confirm the following points. If any abnormality was found, replace it with new one. Otherwise, leakage of fuel can result. q No visible striations (b) or patchy dents (c) in the taper seal portion of the connection ( (a) portion: area 2mm inside the tip). q No deformation in portion (d) (at the end of the taper seal portion: 2 mm inside the tip).
[*7] a Apply gasket sealant to the air intake manifold before installation. Apply gasket sealant for about 1 mm of wire diameter. 2 Mounting face: Gasket sealant (LG-7) [*8] [*9] Injector mounting procedure: 1) Install seal (82) to injector (41). 2) Install copper gasket (84) to injector (41). 3) Insert injector (41) to the cylinder head. 4) Install holder (40) to injector (41). 5) Tighten holder (40) with mounting bolt (39). a Before tightening the bolt, check that holder (40) is securely installed to groove(a)of injector (41). 3 Holder mounting bolt: 27 – 30 Nm {2.8 – 3.1 kgm}
q
[*10] Assembly of turbocharger and muffler ( 1) A ppl y hea t-r es i stan t s ea l (b ) (H olts "FIREGUM" or equivalent) on the whole circumference of inserting part (a) of the exhaust pipe end as shown in the following figure.
q 3 Sleeve nut on the supply pump side:
18 – 23 Nm {1.9 – 2.3 kgm}
3 Sleeve nut on the common rail side:
25.5 – 29.4 Nm { 2.6 – 3.0 kgm}
(2) Install muffler (c) to exhaust pipe (a).
50-30
PC128US-8
50 Disassembly and assembly Removal and installation of cylinder head assembly
(3) Replace the clamp with the new one and install clamp mounting bolt according to the following procedure. 3 Clamp mounting bolt: 1st time: 39.2 – 49 Nm {4 – 5 kgm} 2nd time: 68.6 - 122.5 Nm {7 – 12.5 kgm} [*11]
3 Cylinder head cover mounting nut:
7.84 – 9.8 Nm {0.8 – 1.0 kgm} [*12]
3 Lubricant inlet port tube mounting bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm} [*13] Exhaust manifold mounting procedure: 1) Attach the guide bolt to the cylinder head and set the gasket. a Install the manifold with the gasket face stamped 6205 on the side of the manifold. 2) Install the exhaust manifold and tighten the mounting bolt. 3 Exhaust manifold mounting bolt: 34.3 – 53.9 Nm {3.5 – 5.5 kgm}
q
[*17] q Tightening procedure for the cylinder head mounting bolt Apply molybdenum disulphide lubricant (LM-P) to the threads of cylinder head mounting bolt, and tighten the bolts in the order shown in the diagram. 3 Cylinder head mounting bolt: 1st time: 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm} 2nd time: 107.8 ± 4.9 Nm {11.0 ± 0.5 kgm} 3rd time: Mark the bolt head and cylinder head, and turn the cylinder head by 90° (+30/0°) to tighten. a After tightening, stamp a punch mark (n), indicating the number of tightening, on the bolt head. a If a bolt has 5 punch marks, do not reuse. Replace it with a new one.
[*14] a One (1) of the water pump mounting bolts is tightened together with the alternator mounting bracket. [*15] [*16] a Before installing rocker arm assembly (77), loosen lock nut (74) and fully loosen adjustment screw (75). a When installing rocker arm assembly (77), tighten the mounting bolts alternately by checking that the adjustment screw ball fits to the push rod socket. 3 Rocker arm mounting bolt (76): 19.6 – 29.4 Nm {2.0 – 3.0 kgm} q For adjustment of the valve clearance, refer to "Adjusting valve clearance" in Testing and adjusting.
(In the diagram, (F) indicates the front of engine, (R) the rear and (b) a plastic region turning angle tightening bolt.)
(In the diagram, (p1) indicates a cylinder head marking and (p2) the bolt head.)
PC128US-8
50-31
50 Disassembly and assembly Removal and installation of radiator assembly
Removal and installation of radiator assembly 1
6.
Open covers (9) and (10).
7.
Disconnect radiator overflow hose (11).
8.
Disconnect radiator upper hose (12).
9.
Remove 2 plate mounting bolts (13) and remove plate (14).
Removal k Stop
the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. k Disconnect the negative (–) terminal of the battery beforehand. 1.
Remove lower cover (1).
[*3]
10. Remove 2 radiator mounting bolts (15).
2.
Open the coolant drain valve (2) to drain. [*1] 6 Coolant: 12.4 l
3.
Remove 2 plate (3) mounting bolts (4) and remove the cover.
4.
Disconnect radiator lower hose (5).
[*2]
11. Lift radiator assembly (16) and remove it. [*4] 4 Radiator assembly: 10 kg
5.
Remove 4 cover mounting bolts (6) and remove covers (7) and (8).
50-32
PC128US-8
50 Disassembly and assembly Removal and installation of radiator assembly
Installation Carry out the installation in the reverse order of removal.
q
[*1]
5
Coolant: 12.4 l
[*2] [*3] 3 Radiator hose clamp bolt: (Both upper and lower hoses) 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*4] a When installing the radiator assembly, align the convex portion (a) on the bottom of the radiator assembly with the concave portion (b) on the machine.
PC128US-8
50-33
50 Disassembly and assembly Removal and installation of aftercooler assembly
Removal and installation of aftercooler assembly
4.
Loosen 2 clamps (6) and disconnect the air aftercooler upper hose (7).
5.
Remove 2 mounting bolts (8) and remove plate (9).
6.
Remove 2 air aftercooler mounting bolts (10).
7.
Pull out air aftercooler (11). [*1] a Take care not to damage sponge around the aftercooler.
1
Removal
k Disconnect the negative (–) terminal of the
battery beforehand. 1.
Remove lower cover (1).
2.
Remove 2 mounting bolts (2) and disconnect the air aftercooler lower hose (3).
3.
Remove 2 mounting bolts (4) and remove plate (5).
50-34
PC128US-8
50 Disassembly and assembly Removal and installation of aftercooler assembly
Installation q
Carry out the installation in the reverse order of removal.
[*1] a Take care not to damage sponge on the sides when installing the aftercooler. a When installing the radiator assembly, align the convex portion (a) on the bottom of the air aftercooler with the concave portion (b) on the machine.
PC128US-8
50-35
50 Disassembly and assembly Removal and installation of work equipment oil cooler assembly
a
Removal and installation of work equipment oil cooler assembly 1
When using tool D to stop oil, remove the hydraulic oil tank strainer in advance.
D
Part name
796-460-1210
Oil stopper
q 1
795-799-1131
Adapter
q 1
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Removal k Stop
the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. k Disconnect the negative (–) terminal of the battery beforehand. k Loosen the hydraulic oil tank cap gradually to release the pressure in the tank. a
Fasten tags to respective piping for identification to prevent any mistakes when re-installing.
1.
Remove the radiator assembly referring to "Removal and Installation of Radiator Assembly."
2.
Remove the air aftercooler assembly referring to "Removal and Installation of Air Aftercooler Assembly."
3.
Loosen hydraulic oil drain plug (1) to drain the work equipment oil. [*1] 6 Hydraulic tank: 69 l (Specified capacity: 120 l)
50-36
4.
Remove lower cover (2).
5.
Remove 2 oil cooler lower mounting bolts (3) and disconnect lower hose (4).
PC128US-8
50 Disassembly and assembly Removal and installation of work equipment oil cooler assembly
6.
Remove air cleaner (5).
7.
Remove connector (6).
8.
Remove air cleaner hose clamp (7).
9.
Remove 2 hose mounting bolts (8) and disconnect oil cooler upper hose (9).
11. Pull out oil cooler assembly (11).
10. Remove 2 oil cooler mounting bolts (10).
PC128US-8
50-37
50 Disassembly and assembly Removal and installation of work equipment oil cooler assembly
Installation Carry out the installation in the reverse order of removal.
q
[*1]
3 Hydraulic oil drain plug (1): 5
50-38
58.8 – 78.4 Nm {6 – 8 kgm} Hydraulic tank: 69 l (Specified capacity: 120 l)
PC128US-8
50 Disassembly and assembly Removal and installation of engine and work equipment pump assembly
Removal and installation of engine and work equipment pump assembly 1
3.
Open fuel drain valve (3) to drain fuel.
4.
Loosen hydraulic oil drain plug (4) to drain the work equipment oil. [*2] 6 Hydraulic tank: 69 l (Quantity of oil in hydraulic tank )
D
Part name
796-460-1210
Oil stopper
q 1
795-799-1131
Adapter
q 1
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Removal k Stop
the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. k Disconnect the negative (–) terminal of the battery beforehand. k Loosen the hydraulic oil tank cap gradually to release the pressure in the tank. 1.
Remove lower cover (1).
a
2.
When using tool D to stop oil, remove the hydraulic oil tank strainer in advance.
Drain coolant from the coolant drain port (2). [*1] 6 Coolant: 12.4 l
PC128US-8
50-39
50 Disassembly and assembly Removal and installation of engine and work equipment pump assembly
5.
Remove covers (5), (6) and (7).
6.
Open covers (8) and (9).
7.
Remove the counterweight, referring to "Removal and Installation of Counterweight."
8.
Removal of frame cover assembly 1) Temporarily lift the frame cover assembly. 2) Remove lock pin (10). 3) Disconnect air conditioner hose mounting clamp (12).
9.
4) 5)
6) 7)
50-40
Disconnect wiring (13) to (16) from the frame. Disconnect wiring (17) to the engine controller. (Disconnect connector CE02 from engine controller (p).) a Keep wiring (17) out of the way. Disconnect resistor connector K02 (18). Remove bracket mounting bolt (19) and disconnect the wiring mounting bracket.
8)
Remove frame mounting bolts (20), (21) and (22).
9)
Lift frame cover assembly (23) and remove it.
Removal of the engine upper hoses 1) Remove air conditioner hose mounting clamp (24). 2) Remove wiring clamp (25). 3) Remove air hose (26) between the turbocharger and air cleaner. [*3] 4) Remove after cooler hose (27). [*4] 5) Disconnect radiator hose (28). [*5]
10. Removal of air conditioner compressor 1) Disconnect wiring connector AC02 (29). 2) Remove drive belt protective cover (30). 3) Loosen drive belt adjusting and mounting bolts (31), and remove the drive belt (32).
PC128US-8
50 Disassembly and assembly Removal and installation of engine and work equipment pump assembly
4)
Remove adjustment and mounting bolts (31) and remove air conditioner compressor (33). a Do not disconnect the air conditioner hoses.
6) 7) 8) 9)
11. Disconnecting hoses and wiring from the L.H. side of the engine 1) Remove heater hose clamp (34) and disconnect heater hose (35). 2) Remove radiator lower hose clamp (35) and disconnect radiator lower hose (37). [*6]
3) 4) 5)
Disconnect electrical intake air heater connector E01 (38). Disconnect clamps (40) at 2 locations on wiring (39) and disconnect wiring (39) from the engine. Disconnect fuel hose (41) from the fuel tank.
PC128US-8
Disconnect starting motor wiring terminals (42) and (42a). [*7] Remove wiring bracket mounting bolt (43) and disconnect bracket (44). Disconnect wiring (45) from the engine block and keep it out of the way. Disconnect grounding wire (46).
12. Disconnecting hoses and wiring from the R.H. side of the engine 1) Disconnect alternator wiring (47). 2) Remove 3 bolts (48) and remove hose mounting connector (49) between the after cooler and turbocharger.
3)
Disconnect engine oil temperature sensor wiring connector (50).
50-41
50 Disassembly and assembly Removal and installation of engine and work equipment pump assembly
13. Remove 4 bracket mounting bolts (51) and disconnect engine oil filter and bracket assembly (52). a Tie the assembly with a string to keep it out of the way.
3)
Disconnect 6 hoses (56) to (61).
4)
Remove 4 bolts (62) and disconnect suction tube (63).
14. Disconnecting work equipment pump wiring and hoses 1) Remove rubber cover (53).
15. Remove 4 engine mounting bolts (64).
2)
50-42
[*8]
Disconnect oil temperature sensor wiring connector P22 (53) and EPC solenoid wiring connector A11 (54).
PC128US-8
50 Disassembly and assembly Removal and installation of engine and work equipment pump assembly
16. Lift engine and work equipment pump assembly (65) and remove it. 4 Engine and work equipment pump assembly: 470 kg
Installation Carry out the installation in the reverse order of removal.
q
[*1]
5
Coolant: 12.4 l
[*2]
3 Hydraulic oil drain plug (4):
5
58.8 – 78.4 Nm {6 – 8 kgm} Target: 68.6 Nm {7 kgm} Hydraulic tank: 69 l (Specified capacity: 120 l)
[*3]
3 Hose clamps between the turbocharger and
air cleaner: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} [*4]
3 Aftercooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm} [*5][*6] 3 Radiator hose clamp bolt: (Both upper and lower hoses) 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*7]
3 Starting motor wiring terminal (42):
17.7 – 24.5 Nm {1.8 – 2.5 kgm}
3 Starting motor wiring terminal (42a):
2.6 – 4.6 Nm {0.27 – 0.47 kgm}
3 Connector mounting bolt:
10 ± 2 Nm {1.02 ± 0.2 kgm} [*8]
3 Engine mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
PC128US-8
50-43
50 Disassembly and assembly Removal and installation of fuel tank assembly
Removal and installation of fuel tank assembly 1
7.
Removal of exterior parts 1) Remove hand rail (7). 2) Remove covers (8) to (11).
8.
Removal of fuel tank mounting bracket and mounting bolts 1) Remove fuel tank rear mounting brackets (12).
Removal k Stop
the machine on a level place and lower it to the ground. Stop the engine and set the lock lever to locked position. k Disconnect the negative (–) terminal of the battery beforehand. 1.
Open the inspection cover on the rear R.H. side, and open fuel drain valve (1) to drain fuel. Fuel (When fuel tank is full): 195 l
2.
Disconnect fuel level sensor connector P21 (2).
3.
Disconnect fuel level sensor wiring (3).
4.
Disconnect hose (4) from the radiator.
5.
Disconnect water assembly (5).
6.
Disconnect reservoir tank (6).
separator
and
bracket
2) 3)
50-44
Remove wiring and hose mounting brackets (13). Remove fuel tank front mounting brackets (14).
PC128US-8
50 Disassembly and assembly Removal and installation of fuel tank assembly
4) 5)
Disconnect hoses (15) and (16). Remove 4 fuel tank front mounting bolts (17).
Installation q
Carry out the installation in the reverse order of removal.
[*1]
2 Fuel tank mounting bolt:
liquid adhesive (LT–2)
3 Fuel tank mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
9.
Lift fuel tank assembly (18) and remove it. [*1] 4 Fuel tank assembly: 95 kg
PC128US-8
50-45
50 Disassembly and assembly Removal and installation of travel motor and final drive assembly
Power train
6.
Removal and installation of travel motor and final drive assembly 1 Removal 1.
Remove track shoe assembly. For details, see "Removal of track shoe assembly".
Lift off travel motor and final drive assembly (3). [*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
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). 3 Sprocket : 40 kg
4.
Remove travel motor cover.
5.
Disconnect 4 travel motor hoses (2).
50-46
[*1]
PC128US-8
50 Disassembly and assembly Removal and installation of travel motor and final drive assembly
Installation q
Carry out installation in the reverse order to 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 : Thread tightener (LT-2) 3 Travel motor and final drive assembly mounting bolt : 235 – 285 Nm {23.5 – 29.5 kgm}
a
Bleed the air from the travel motor. For details, see Testing and adjusting, "Bleeding air from travel motor".
q
Refilling with oil (hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
PC128US-8
50-47
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Disassembly and assembly of travel motor and final drive assembly
1
Component parts
50-48
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
PC128US-8
50-49
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
50-50
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
List of part name No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 22 23 24 27 28 29 30 31 32 33 34 35 36 102 103 104 105 106 107 108 109 110 112 113 114 115 116 132 135 139 145 149 150 151
Part name Hub Spindle Carrier A Sun gear A Planetary gear A Pin Carrier B Sun gear B Planetary gear B Pin Thrust washer A Thrust washer B Thrust plate Cover Coupling Pin Pin Lock washer Shim Ball bearing Bearing Bearing Floating seal Plug O-ring O-ring O-ring Dowel pin Hexagonal socket head bolt Ring Shaft Swash plate Cylinder block Piston Shoe Retainer plate Thrust ball Timing plate Washer Piston Spring Spring Disc Plate Oil seal O-ring O-ring THS snap ring Ball bearing Ball bearing Needle
PC128US-8
No. 161 162 167 171 185 201 202 203 204 205 206 207 208 209 210 211 212 213 301 323 324 325 326 327 328 329 330 331 336 341 343 352 353 354 357 358 359 363 366 376 377 378 379 380 381 383 384 396 398 399
Part name Piston Shoe Pivot Dowel pin Spring Valve seat Valve Relief valve Collar Plug Spring O-ring Ring O-ring Ring O-ring O-ring Shim Rear flange Spool Plug Spring retainer Plug Valve Spring Orifice Spring O-ring O-ring Dowel pin Hexagonal socket head bolt Plug Seal ball Hexagonal socket head plug Plug O-ring O-ring Spool Spring Orifice Filter Seal ball Plug Plug Piston O-ring Hexagonal socket head plug Hexagonal socket head plug Hexagonal socket head plug Plate
50-51
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Outline of maintenance 1.
Tools 1) Common tools No.
Part name
Model/Dimension
Q'ty
1
Hexagonal wrench
2.5 (M5), 3 (M6), 4 (NPTF 1/16), 5 (PF 1/8), 6 (PF 1/4), 8 (M10, PF 3/8), 10 (M12, PF 1/2)
2
Socket wrench handle
Gourd-shaped
1
3
Torque wrench
Dial type: 50 N Dial type: 100 N Dial type: 300 N Dial type: 560 N
1 each
4
Torque wrench adapter
–
1 each
5
Socket wrench
Width across flats: 24,41 mm
1
6
Extension bar
150 mm
1
7
Hammer
Various
1 each
8
Plastic hammer
L: 400 mm
1
9
Flat-head screwdriver
L: 50, 150 mm
1 each
10
Snap ring pliers
For shaft and hole
1 each
11
Pliers
200 mm
12
Sling
Lifting load: Min. 2,940 N {300 kg} Eyebolt (M16) Eyebolt (M12) Eyebolt (PF 1/2) Wire with hook
13
Container
Common vat, W450 x D300 x H120 mm
14
Leather gloves
–
2)
Bolts
No.
Hexagonal socket head bolt
3)
Materials Use/Part No.
Disassembly and assembly
1 set (2) (3) (2) (1) 2 1 pair
Model/Dimension
Q'ty
M12 (P1.5 x 40 mm)
Part name
2
Model/Dimension
Q'ty
Common work stand
–
1
Washing tank
Prewashing and finish washing
1
24, 104, 149
Press stand
(24) Press performance: Min. 9,800 N {1,000 kg} (104) Press performance: Min. 1,960 N {200 kg} (149) Press performance: Min. 1,960 N {200 kg}
1
149
Heating tank
Heating temperature: Min. 100 °C Capacity: Min. 500 x 500 x 500
1
Compressed air
Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm2}
–
Washing of parts
Drying of cleaned parts
50-52
1
Part name
1
1 each
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
4)
Tools to be manufactured Work stand [1] q Used to fix the travel motor for disassembly and assembly.
No. 1 holder [2] q Used to install spring (114), washer (110), and snap ring (145) to cylinder block (104). q Used to remove spring (114) from cylinder block (104).
Push tool [4] q Used to press fit oil seal (132) to spindle (2).
Jig [5] q Used to install lock washer [22] to the groove of spindle [2].
Push tool [6] q Used to press fit ball bearing (24) to hub (1). No. 2 holder [3] q Used to remove ball bearing (149) from shaft (102).
PC128US-8
50-53
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Steel bar [7] q Used to remove ball bearing (24) from hub (1).
No. 1 mounting jig [10] q Used to install floating seal (29) to hub (1).
Eyebolt [8] q Used to sling the travel motor, spindle (2), and hub (1).
No. 2 mounting jig [11] q Used to install floating seal (29) to hub (1) and spindle (2).
Use Hub Hub Spindle Travel motor
Dimension (A) M16 M10 M16 M16
No. 3 mounting jig [12] q Used to install floating seal (29) to spindle (2).
Spatula [9] q Used to remove timing plate (109) from rear flange (301).
50-54
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Pin punch [13] q Used to remove the outer race from ball bearing (24).
2.
Tightening torque Part No.
Nominal size of part
Part name
30, 357 Plug
3.
PF 1/2
35
Hexagonal socket head bolt M10 (P1.5)
203
Sleeve
PF 1/2
205
Plug
PF 1/4
324
Plug
M36 (P1.5)
343 352
Width across flats (mm)
Q'ty
Torque (Nm {kgm})
10
4
98.1 ± 19.6 {10.0 ± 2.0}
8
12
66.7 ± 3.92 {6.8 ± 0.4}
24 (Socket)
2
98.1 ± 19.6 {10.0 ± 2.0}
6
2
29.4 ± 4.90 {3.0 ± 0.5}
41 (Socket)
2
441 ± 39.2 {45.0 ± 4.0}
Hexagonal socket head bolt M12 (P1.75)
10
10
102 ± 15.7 {10.4 ± 1.6}
Plug
5
3
12.3 ± 2.45 {1.25 ± 0.25}
PF 1/8
354
Hexagonal socket head bolt NPTF 1/16
4
5
9.81 ± 1.96 {1.0 ± 0.2}
380
Plug
PF 3/8
8
2
58.8 ± 9.81 {6.0 ± 1.0}
396
Hexagonal socket head bolt PT 1/4
6
2
29.4 ± 4.90 {3.0 ± 0.5}
398
Hexagonal socket head bolt PT 1/8
5
5
12.3 ± 2.45 {1.25 ± 0.25}
Weight table Part No.
Part name
Weight (kg)
—
Travel motor assembly
150
1
Hub
50
2
Spindle
30
3 Others
Carrier (A) assembly
15
7 Others
Carrier (B) assembly
25
301 Others Rear flange assembly
15
PC128US-8
50-55
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Disassembly Preparatory items 1. Preparation before disassembly 1) Preparation of work stand q Prepare a work stand for disassembly and assembly of the travel motor. q Use a work stand so strong that you can disassemble, assemble, and place the internal parts of the travel motor on it. q Spread a rubber or vinyl sheet on the work stand. 2) Prepare the tools and materials described in the previous pages. 2.
General precautions for work k The disassembled internal parts are oiled and slippery. Accordingly, take care of handling them not to injure yourself or damage them by dropping them. k Flammable material such as kerosene is used to wash the parts. Since it is highly inflammable and can cause a fire or a burn, handle it with extreme care. 1) Before disassembling, well understand the inspection items and detected troubles, and then work according to the given working procedure. 2) Since each part is manufactured very precisely, take care of handling them. Do not hit the parts against each other or drop them. 3) Never remove the parts forcibly or prying them. If you do so, the parts may have burrs and may be broken, and that can make assembly impossible and lower the performance. 4) If the parts are left as disassembled, they may be rusted by moisture and dirt. When leaving them disassembled, be sure to take measures to protect them from rusting and dirt. 5) When disassembling, put match marks on the matching portions of the parts. 6) During the disassembly, arrange and store the removed parts neatly to protect them against damage and loss. 7) Once you remove the seals, do not reuse them but replace with new ones. 8) A typical model is used for the illustrations in the following explanation. Even if your machine is par tly di fferent fr om the machine indicated for those illustrations, its assembling procedure is the same.
50-56
a 1.
For the part Nos. not shown in the figures, see "Component parts". Washing of travel motor assembly 1) Install two eyebolts [8] to the mounting bolt holes of spindle (2). a Install two eyebolts [8] to symmetrical positions.
2)
3)
Sling the travel motor assembly and carry it to the washing tank. 4 Travel motor assembly: 150 kg Using a brush, wash the travel motor assembly with a brush thoroughly. a Wash the area between hub (1) and spindle (2) (mounting portion of the floating seal) thoroughly since there is dirt and sand there.
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
2.
Setting travel motor 1) Sling the travel motor assembly and set it onto the work stand [1]. a While aligning the bolt holes of hub (1) with those of work stand [1], set the travel motor assembly.
4.
2)
Install the two hexagonal socket head bolts to symmetrical positions. k Securely tighten the two hexagonal (38) socket head bolts (to prevent the travel motor assembly from falling off the work stand when it is turned over).
Removal of cover 1) Turn over the travel motor assembly to set the final drive side up. 2) Remove bolts (35). Since the mating faces of cover (14) and hub (1) are coated with sealing material, put a bar to the underside of the overhang of cover (14) and hit it up obliquely to remove the cover. k When the cover is hit up obliquely, it may jump and fall.Take care that the cover will not fall onto your foot.
3) 3.
Draining oil in final drive case 1) Set the travel motor assembly on its side with the drain plug down. 2) Loosen plug (30) of the oil filler port to release the internal pressure of the case and then tighten it lightly. (See "Component parts") a If the case is pressurized, oil may spout out when the drain plug is loosened. 3) If the drain does not flow out well, loosen the drain plug gradually. a Remove O-ring (31) of plug (30) and do not reuse it. (See "Component parts") a Set the oil container under the travel motor to receive the oil. 6 Final drive case: 2.1 l
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Install eyebolts [8] to ports (k) and lift up and remove cover (14) from the hub (1).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
5.
Removal of sun gear A 1) After removing thrust plate (13), remove sun gear A (4).
2)
50-58
6.
Removal of coupling 1) Remove coupling (15) from shaft (102). (See "Component parts")
7.
Removal of sun gear B 1) Install eyebolts [8] to the lifting taps (3 places) of carrier B (7) and remove the carrier assembly. 4 Carrier assembly: 25 kg a Set the center axes of the hub and carrier assembly vertically and lift up the carrier assembly slowly so that the internal teeth of the hub will not be damaged by the end of planetary gear B (9). (See "Component parts") 2) Remove sun gear B (8) from carrier B (7).
8.
Removal of lock washers 1) Fix hub (1) to work stand [1] by using hexagonal socket head bolts.
Install eyebolts [8] to the lifting taps (3 places) of carrier A (3) and remove the carrier assembly. a Set the center axes of the hub and carrier assembly vertically and lift up the carrier assembly slowly so that the internal teeth of the hub will not be damaged by the end of planetary gear A (5). (See "Component parts")
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
2)
9.
Put a flat-head screwdriver in the clearance between 2 lock washers (22) and hit it do wn obl iq uel y wi th a ham mer to remove the lock washers.
Removal of hub 1) Remove the hexagonal socket head bolts that fix hub (1) to work stand [1]. 2) Install eyebolts [8] to hub (1) and sling the hub. 4 Hub (1): 50 kg a Sling the hub gradually and slowly in parallel with the axis of spindle (2). k If the hub is slung obliquely, a large force is required and the sling or an eyebolt may be broken and that is dangerous. Accordingly, do not sling the hub forcibly but sling it by using a press, etc.
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10. Removal of floating seal 1) Hold the inside of floating seal (29) with your fingers and remove it up. a When removing the floating seal, put on gloves to protect your fingers from the edge of the floating seal. a If the floating seal is stuck with mud, etc., pry it up with a flat-head screwdriver, etc.
11. Removal of ball bearing 1) To remove ball bearing (24), apply pin punch [13] lightly at three to four places on the periphery of the outer race. a If the inner race is hit, the rolling surface of the ball bearing is damaged and the ball bearing cannot be reused. Accordingly, do not hit the inner race unless you are replacing the ball bearing. a Spread a rubber mat under ball bearing (24) which falls when the outer race is released from hub (1).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
12. Removal of rear flange 1) Turn over the travel motor assembly to set the travel motor side up. a The following work is preparatory work for disassembling of the inside components of the rear flange. a Loosen the plug to a degree that you can rotate it by hand. a When not disassembling the inside components of the rear flange, do not loosen the plug. 2) Loosen two plugs (324). a Since spring (328) is still compressed after plugs (324) are loosened, the plugs and spring may jump out. Take care. (See "Component parts")
4)
Remove two relief valve assemblys (18). a Do not reuse removed O-rings (207), (209), and (212) and rings (208) and (210). (See "Component parts")
5)
Remove ten hexagonal socket head bolts (343) from rear flange (301). Remove rear flange (301) from spindle (2). a Lift up rear flange (301) straight slowly with both hands to remove. a If you pry off or hit rear flange (301), timing plate (109) may fall to be damaged. Take care. (See "Component parts")
6)
3)
Loosen two plugs (380), two plugs (352), and plug (357).
7)
50-60
Remove two dowel pins (34) from spindle (2).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
8)
Remove two O-rings (33) and O-ring (32) from spindle (2). a Do not reuse removed O-rings (32) and (33).
13. Disassembly of rear flange 1) Set rear flange (301) on the work stand so that mating face (a) to the spindle faces top. 2) Remove timing plate (109) from rear flange (301). a If timing plate (109) is stuck because of the oil, put spatula [9] in the groove on the rear flange (301) to remove. (See "Tools 4) Tools to be manufactured") a If you use a sharp tool such as a flathead screwdriver, you may scratch mating face (a). Accordingly, do not use such a tool.
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3)
Remove ball bearing (150) from rear flange (301).
4)
Remove dowel pin (341) from rear flange (301).
14. Disassembly of brake valve 1) Remove two plugs (324) from rear flange (301).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
2) 3)
4)
Remove two spring retainers (325) and two springs (328) from rear flange (301). Remove spool (323) from rear flange (301). a If rear flange (301) is inclined, spool (323) comes out. Pick the end of the spool to remove.
Remove two O-rings (336) from two plugs (324). a Do not reuse removed O-rings (336).
3)
16. Disassembly of piston 1) Remove two plugs (380) from rear flange (301). 2) Remove two O-rings (383) from two plugs (380). (See "Component parts") a Do not reuse removed O-rings (383).
3) 15. Disassembly of 2nd travel speed selector spool 1) Remove plug (357) from rear flange (301). 2) Remove O-ring (359) from plug (357). a Do not reuse removed O-ring (359). (See "Component parts")
50-62
Remove spring (366) and spool (363) from rear flange (301). (See "Component parts")
Remove piston (381) from rear flange (301).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
17. Disassembly of seal ball 1) Remove two plugs (352) from rear flange (301). 2) Remove two O-rings (358) from two plugs (352). (See "Component parts") a Do not reuse removed O-rings (358).
3)
Remove two seal balls (353) from rear flange (301). a If the seal balls cannot be removed easily, use a magnet.
19. Disassembly of travel motor 1) Turn spindle (2) 90 degrees to set it in the horizontal position. a Prepare a container to receive the oil that will flow out of spindle (2). 2) Drain the oil from spindle (2). 3) Remove four plates (116) and three discs (115) from spindle (2).
18. Disassembly of parking brake 1) Supply compressed air through parking brake oil passage (b) of spindle (2) to take out piston (112). k If compressed air is blown suddenly, piston (112) jumps out, and that is dangerous. Accordingly, blow compressed air gradually. Place protective cover (19) for safety in advance. 2) Remove O-rings (135) and (139) from piston (112). a Do not reuse removed O-rings (135) and (139).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
4)
5)
6)
50-64
Rotate cylinder block (104) two to three turns alternately to separate swash plate (103) and shoe (106) which are stuck to each other because of the oil. (See "Component parts") Remove cylinder block (104) from shaft (102). a Take care that the parts (piston (105), shoe (106), etc.) in cylinder block (104) do not come off and fall into spindle (2) because of sticking of swash plate (103) and shoe (106). (See "Component parts")
Remove piston assemblies (pistons (105) and shoes (106)) and retainer plate (107) together from cylinder block (104). a Hold and remove retainer plate (107) with both hands. a Since piston (105) and shoe (106) are joined by drawing the shoe over the spherical portion of the piston. a Replace piston (105) and shoe (109) together always. (Hereinafter, this assembly is referred to as the piston assembly)
7)
Remove nine piston assemblies (pistons (105) and shoes (106)) from retainer plate (107).
8)
Remove thrust ball (108) from cylinder block (104).
9)
Remove three needles (151) from cylinder block (104).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
20. Removal of spring in cylinder block 1) Set cylinder block (104) on the press stand. a Remove spring (114) only when replacing it. a When removing spring (114), align No. 1 holder [2] with washer (110) and take care not to scratch cylinder block (104). a Before working, cover cylinder block (104) with vinyl sheet (20) for protection. 2) Set No. 1 holder [2] to upper washer (110) and secure it with the press. 3) Remove THS snap ring (145) from the snap ring groove of cylinder block (104). k If the press is released suddenly, spring (114) jumps out, and that is dangerous. Accordingly, release the press gradually.
4)
21. Removal of swash plate 1) Turn spindle (2) 90 degrees to set it in the horizontal position and remove swash plate (103) from shaft (102). a When removing swash plate (103), pivot (167) may stick to it. Take care that the pivot will not fall. (See "Component parts")
2)
3)
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Remove THS snap ring (145), washer (110), spring (114), and washer (110) from cylinder block (104). (See "Component parts")
Remove shaft (102) from spindle (2). a At this time, remove ball bearing (149), too. (See "Component parts") a Shaft (102) can be removed easily by hitting it lightly from the final drive side with a plastic hammer. Remove two pivots (167) and two dowel pins (171) from spindle (2). (See "Component parts")
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
23. Removal of spindle component parts 1) Remove shim (23) from spindle (2).
4)
Remove spring (185) and 2nd travel speed selection piston assembly (piston (161) and shoe (162)) from spindle (2). (See "Component parts")
22. Removal of ball bearing a Remove the ball bearing only when replacing it. 1) Set No. 2 holder [3] on the press stand and set shaft (102) in it. 2) Push out shaft (102) from ball bearing (149) with the press. a Do not reuse ball bearing (149).
50-66
2)
Remove floating seal (29) from spindle (2).
3)
Remove oil seal (132) from spindle (2). a Do not reuse removed floating seal (29) and oil seal (132). (See "Component parts")
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
24. Rough washing of parts 1) Separate hub (1), spindle (2), cover (14), and rear flange (301) from the other parts (hereinafter, referred to as the internal parts). (See "Component parts") 2) Put hub (1), spindle (2), cover (14), and rear flange (301) in the washing tank and wash them. a Wash each part thoroughly since they are coated with dirt and sand. 3) Put the internal parts in the prewashing tank containing kerosene and wash them k Flammable material such as kerosene is used to wash the parts. Since it is highly inflammable and can cause a fire or a burn, handle it with extreme care. a If you wash the parts immediately after putting them in the oil, they may be scratched. Leave them in the oil until the dirt, oil, grease, etc. are separated, and then wash.
25. Finish washing 1) Put each part in the finish washing tank containing kerosene and wash them to their inside while rotating them slowly. 2) Wipe off the kerosene from each part with clean cloths. 3) Dry the inside of hub (1) and spindle (2) by blowing air against them in a clean and dry place. 4) Dry the travel motor parts and gears naturally in a clean and dry place. a After drying the parts, apply power train oil (TO30) to them.
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Maintenance standard When disassembling and testing the travel motor, service it according to the following standard. Take care not to scratch the moving parts and sliding parts since they are precision parts. 1.
Handling of seals Once you remove the seals (O-ring, oil seal, and floating seal), replace them with new ones, regardless of the damage on them.
2.
Maintenance standard for worn parts 1) Replace all the parts having extreme visible damage with new ones. 2) Replace all the parts having the following problems (phenomena) with new ones.
Part No.
Part name
Phenomenon
Standard value
Permissible deviation
1
Hub
• There is serious damage on outside. • Tooth surface of ring gear is pitted. • There is abnormal wear such as galling.
—
—
2
Spindle
• There is serious damage on outside. • There is abnormal wear such as galling.
—
—
3, 7 Others Carrier assembly • There is abnormal wear such as galling.
—
—
—
—
4 8 5 9
Sun gear A • Tooth surface is pitted. Sun gear B • Rolling surface of bearing is flaked. Planetary gear A Planetary gear B
24
Ball bearing
• There is impression. • Rolling surface of ball bearing is flaked. • Worn unevenly.
—
—
301
Rear flange
• There are scratches on sliding surface of spools (323) and (363) and piston (381).
—
—
102
Shaft
• Contact surface against oil seal (132) is worn. • Spline portion is worn.
—
—
103
Swash plate
• Parts are seized.
—
—
104
Cylinder block
• Spline portion is worn. • Inside wall of cylinder is worn excessively. • Sliding surface against timing plate (109) is scratched and worn unevenly.
—
—
105 106
Piston assembly (Piston + Shoe)
• There is clearance between piston (105) and shoe (106) in axial direction. • Shoe (106) is worn abnormally and unevenly.
Clearance: 0.05 mm
Clearance: 0.15 mm
107
Retainer plate
• Sliding surface against shoe (106) is worn unevenly. • Sliding surface against thrust ball (108) is scratched and worn unevenly.
—
—
108
Thrust ball
• Spherical sliding surface against retainer plate (107) is worn unevenly.
—
—
109
Timing plate
• Sliding surface is seized and worn unevenly.
—
—
115 116
Disc Plate
• Both end faces are worn unevenly. • Specified torque is not obtained. • Parts are seized.
105
Piston
• There is scratch on outside surfaces.
50-68
Braking torque: Braking torque: Min. Min. 206 Nm {21.0 kgm} 206 Nm {21.0 kgm} —
—
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Part No.
Part name
Phenomenon • There is impression. • Rolling surface of bearing is flaked. • Parts are worn.
Standard value
Permissible deviation
—
—
—
—
149 150
Ball bearing
161 162
2nd speed selection piston • Outside surface is worn abnormally. assembly • Shoe is worn abnormally and unevenly. (Piston + Shoe)
323 363
Spool
• Outside surface is worn unevenly. • There is scratch on outside surfaces.
—
—
381
Piston
• There is scratch on outside surfaces.
—
—
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Assembly q
Perform installation in the reverse order to removal
Preparatory items 1. Preparation before assembly Prepare the tools and materials similarly to the preparatory items in "Disassembly". 2.
General precautions for work 1) Observe Disassembly, "2. General precautions for work". 2) Before assembling, wash all the parts to remove metal chips and foreign matter, and check that they are free from a burr, a scratch, etc. If any part has a burr or a scratch, remove it by using an oilstone. 3) Do not reuse the O-rings, oil seals and floating seals but replace them with new ones. 4) Pass a tap (M10, P1.5) through the threaded holes of hub (1) to remove the remaining adhesive.Then, wash and degrease the threaded holes and dry them by blowing compressed air. Replace hexagonal socket head bolt (35) with a new one. 5) When installing the O-rings, oil seals, and floating seals, apply a little amount of grease to them, and then install them carefully so that they are not damaged. 6) Be sure to apply power train oil (TO30) to the moving parts and sliding parts of the travel motor before assembly. 7) When assembling, do not put on cloth gloves. (Prevent malfunction caused by entry of a fiber of cloth gloves.) 8) Tighten the bolts and plugs according to "Tightening torque table". 9) Immediately after completing assembly, install plugs to all the ports to prevent entry of dirt. 10) A typical model is used for the illustrations in the following explanation. Even if your machine is par tly di fferent fr om the machine indicated for those illustrations, its assembling procedure is the same.
50-70
3.
Assembly procedure a When assembling after replacing some parts, the preload on the bearing must be adjusted. Accordingly, ensure that the following parts are replaced with new ones. Hub (1) Spindle (2) Ball bearing (24) a When assembling after replacing the above parts, be sure to use the parts that "have been adjusted independently". Use of unadjusted parts can cause malfunction and early breakage of the travel motor. Take care.
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
1.
Assembly of hub 1) Set hub (1) to cylinder (21) on the press stand. 2) Install ball bearing (24) to hub (1) and press fit it by using push tool [6]. 3) Reverse hub (1) and install ball bearing (24) on the opposite side similarly. a When installing ball bearing (24), check its direction.
4)
5)
Apply grease to the O-ring of floating seal (29) and install it to hub (1). 2 O-ring: Grease (G2-LI) a Remove the O-ring and apply grease thinly all over its surface. Set No. 1 mounting jig [10] and No. 2 mounting jig [11] to hub (1) in order and push in No. 2 mounting jig [11] until it touches No. 1 mounting jig [10]. a Remove No. 1 mounting jig [10] and No. 2 mounting jig [11]. a Check that the parallelism between the end face of hub (1) and the sealing face of floating seal (29) is 1 mm or below.
2.
Assembly of spindle assembly 1) Apply grease to the O-ring of floating seal (29) and install it to spindle (2). 2 O-ring: Grease (G2-LI) a Remove the O-ring and apply grease thinly all over its surface. 2) Set No. 3 mounting jig [12] and No. 2 mounting jig [11] to spindle (2) in order and push in No. 2 mounting jig [11] until it touches No. 3 mounting jig [12]. a Remove No. 3 mounting jig [12] and No. 2 mounting jig [11]. a Check that the parallelism between the end face of spindle (2) and the sealing face of floating seal (29) is 1 mm or below.
3)
4)
Install 2 eyebolts [8] to the mounting bolt holes of spindle (2). a Install 2 eyebolts [8] to symmetrical positions. Sling spindle (2) and install it to the work stand so that hexagonal socket head bolts (37) will be positioned symmetrically. 4
a
PC128US-8
Spindle (2): 30 kg Securely tighten the two hexagonal socket head bolts (to prevent the travel motor assembly from falling off the work stand when it is reversed).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
3.
4)
Adjustment of preload on bearing a If hub (1), ball bearing (24), and spindle (2) were replaced, adjust the preload on the bearing. (See "Component parts") 1) If the preload is not proper, the ball bearing may be broken in a short time. Install lock washer (22) to spindle (2) temporarily and measure dimension (c).
4.
2)
Measure assembly width (d) of ball bearing (24). a Before measuring, rotate hub (1) and ball bearing (24) to prevent them from floating.
3)
Select shim (23) from the following table so that clearance (e) will be +0.13 to +0.17 mm. q Clearance (e) = Dimension (c) – (d)
Symbol
Thickness (mm)
Symbol
A
0.9
G
1.5
B
1.0
H
1.6
C
1.1
I
1.7
D
1.2
J
1.8
E
1.3
K
1.9
F
1.4
L
2.0
50-72
Install shim (23) to spindle (2).
Installation of hub 1) Sling and lower hub (1) while aligning it with spindle (2) and press fit it into ball bearing (24). (See "Component parts") 4 Hub (1): 50 kg 2) Fix hub (1) to work stand [1] by using hexagonal socket head bolts. 3) Lightly hit ball bearing (24) on the final drive side to prevent it from floating. (See "Component parts")
Thickness (mm)
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
4)
Turn over the work stand and install lock washer (22) to the groove of spindle (2).
5)
Using jig [5], push lock washer (22) into the groove of spindle (2). a Push in lock washer (22) sufficiently so that carrier B (7) will not interfere with it when carrier B (7) is installed. (See "Component parts") Remove the hexagonal socket head bolts that fix hub (1) to the work stand. (See "Component parts") Rotate hub (1) two to three turns. a Perform this step to fit the sliding surface of floating seal (29) and prevent oil leakage. (See "Component parts") Turn over the work stand to set the travel motor side up.
6)
7)
8)
5.
Assembly of parts inside spindle 1) Use push tool [4] to press fit oil seal (132) to spindle (2). 2 Lip of oil seal (132): Grease (G2-LI) a When installing oil seal (132), check the direction it faces.
2) 3)
4)
5)
6)
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Install two dowel pins (171) to the holes of spindle (2). (See "Component parts") Install two pivots (167) to dowel pins (171). (See "Component parts") 2 Hemisphere of pivot (167): Grease (G2-LI) Install spring (185) to the piston assembly (piston (161) and shoe (162)). (See "Component parts") 2 Spring (185): Grease (G2-LI) Apply power train oil (TO30) to the sliding part of piston assembly and install it to the piston hole of spindle (2). Install two dowel pins (171) to the pin holes on the rear flange mating face of spindle (2). (See "Component parts")
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
6.
Installation of shaft 1) Heat ball bearing (149) in the heating tank and press fit it to shaft (102). Heating of ball bearing (149): 10 minutes at 100 ± 10°C k When heating and installing ball bearing (149), be sure to put on leather gloves to avoid getting burnt.
7.
2)
Turn the travel motor assembly 90 degrees to set it horizontally and install shaft (102) to spindle (2).
3)
Press fit shaft (102) into ball bearing (149) with the press. a When installing shaft (102), take care not to damage the lip of oil seal (132) installed before. a Damage of the lip of oil seal (132) can cause oil leakage and early breakage of the travel motor. (See "Component parts") Install swash plate (103) to shaft (102). 2 Mating faces of spindle (2) and swash plate (103): Grease (G2-LI) a Install two pivots (167) while aligning them with the mounting holes of the swash plate (103). (See "Component parts")
4)
50-74
Assembly of cylinder block 1) Install washer (110), spring (114), washer (110) and THS snap ring (145) to cylinder block (104) in order. a Face the acute angle side of washer (110) on the THS snap ring (145) side upward. a Face the acute angle side of THS snap ring (145) upward. (See "Component parts") 2) Set cylinder block (104) on the press stand. 3) Set No. 1 holder [2] to upper washer (110) and secure it with the press. 4) Install THS snap ring (145) to the snap ring groove of cylinder block (104). k If the end of the snap ring pliers comes off the hole of THS snap ring (145), THS snap ring (145) jumps out, and that is dangerous. Use care for the installation. a When pressing spring (114), align No. 1 holder [2] with washer (110) and take care not to scratch cylinder block (104). a Before working, cover cylinder block (104) with vinyl sheet (20) for protection.
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
8.
2)
Install thrust ball (108) to cylinder block (104).
3)
Install nine piston assemblies (pistons (105) and shoes (106)) to retainer plate (107). a After installing, soak all the parts in power train oil (TO30).
4)
Install piston assemblies (pistons (105) and shoes (106)) and retainer plate (107) together to cylinder block (104). a Hold and install retainer plate (107) with both hands. a Securely contact the retainer plate (107) with the spherical portion of thrust ball (108). (See "Component parts")
Assembly of travel motor 1) Install three needles (151) to cylinder block (104).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
5)
Install cylinder block (104) to shaft (102). a Install cylinder block (104) while matching it to the spline of shaft (102).
3)
6)
9.
After installing cylinder block (104), rotate cylinder block (104) by hand and check for play between cylinder block (104) and shaft (102). a If there is play, check. a After installing cylinder block (104), do not lift it up. (If the cylinder block is lifted up, thrust ball (108) comes off and the motor does not rotate normally.) (See "Component parts".)
Assembly of parking brake 1) Turn the travel motor assembly 90 degrees to set the travel motor side up. 2) Install discs (115) and plates (116) alternately to cylinder block (104). (See "Component parts") a Soak discs (115) in power train oil (TO30) in advance.
50-76
4)
Install O-rings (135) and (139) to piston (112). 2 O-rings (135) and (139): Grease (G2-LI) Install piston (112) to spindle (2). a If piston (112) does not enter easily, hit it lightly with a plastic hammer. a When installing the piston, take care not to damage O-rings (135) and (139).
10. Assembly of 2nd travel speed selector spool 1) Install spring (366) and spool (363) to rear flange (301). (See "Component parts") 2) Install O-ring (359) to plug (357). (See "Component parts") 2 O-ring (359): Grease (G2-LI)
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
3)
Install plug (357) to rear flange (301) and fasten them partially.
11. Assembly of seal ball portion 1) Install two O-rings (358) to two plugs (352). (See "Component parts") 2 O-ring (358): Grease (G2-LI) 2) Install two seal balls (353) to rear flange (301).
3)
Install two plugs (352) to rear flange (301).
PC128US-8
12. Assembly of piston portion 1) Install two O-rings (383) to two plugs (380). (See "Component parts") 2 O-ring (383): Grease (G2-LI) 2) Install piston (381) to rear flange (301).
3)
Install two plugs (380) to rear flange (301).
13. Assembly of brake valve portion 1) Install the spool (323) to rear flange (301). 2 Spool (323): Power train oil (TO30) a Insert spool (323) carefully in the spool hole of rear flange (301). a When spool (323) is inserted, if spool (323) or spool hole of rear flange (301) is scratched, oil may leak and travel motor performance may be decreased. 2) Install two O-rings (336) to two plugs (342). 2 O-ring (336): Grease (G2-LI) 3) Install two washers (325) and two springs (328) to two plugs (324).
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50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
14. Assembly of rear flange 1) Install ball bearing (150) to rear flange (301). 2 Ball bearing (150): Grease (G2-LI)
4)
50-78
2)
Install dowel pin (341) to the pin hole of rear flange (301).
3)
Install timing plate (109) to rear flange (301) by using the dowel pin as a guide. 2 Mating faces of rear flange (301) and timing plate (109): Grease (G2-LI) a Check that timing plate (109) and rear flange (301) are stuck with the grease. a Perform this step to prevent timing plate (109) from falling when rear flange (301) is installed to spindle (2). (See "Component parts")
Tighten two plugs (324) into rear flange (301). a When tightening plugs (324), take care that spring (328) is not deformed.
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
4)
Install ten springs (113) to rear flange (301). 2 Spring (113): Grease (G2-LI) a Apply the grease sufficiently to prevent the springs from falling when the rear flange is installed.
15. Installation of rear flange 1) Install two O-rings (33) and O-ring (32) to spindle (2). a Do not apply grease to O-rings (32) and (33). (If grease is applied, it may ooze out through the mating faces of rear flange (301) and spindle (2) during operation and you may mistake it for oil leakage.) (See "Component parts".) 2) Supply oil to spindle (2). 5
3)
Install two dowel pins (34) to spindle (2).
4)
Install rear flange (301) to spindle (2). a Install rear flange (301) while matching installation hole on rear flange to dowel pins (34) (See "Component parts") Lightly tighten ten hexagonal socket head bolts (343) into spindle (2).
5)
In spindle (2) (Power train oil): 1.0 l (TO30)
6)
PC128US-8
Tighten ten hexagonal socket head bolts (343) to rear flange (301). 3 Hexagon socket head bolt (343): 102 ± 15.7 Nm {10.4 ± 1.6 kgm}
50-79
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
7)
Tighten two plugs (324). 3 Plug (324): 44.1 ± 3.92 Nm {45.0 ± 4.0 kgm}
8)
Tighten two plugs (380), two plugs (352) and plug (357). 3 Plug (380): 58.8 ± 9.81 Nm {6.0 ± 1.0 kgm} 3 Plug (352): 12.3 ± 2.45 Nm {1.25 ± 0.25 kgm} 3 Plug (357): 98.1 ± 19.6 Nm {10.0 ± 2.0 kgm}
17. Assembly of sun gear B 1) Reverse work stand to set the final drive side up. 2) Install sun gear B (8) to carrier B (7). (See "Component parts") 3) Install eyebolts [8] to the lifting taps (3 places) of carrier B (7), and sling and install the carrier assembly. 4 Carrier assembly: 25 kg a Set the center axes of the hub and carrier assembly vertically and lift down the carrier assembly slowly so that the internal teeth of the hub will not be damaged by the end of planetary gear B (9). See "Component parts")
a
Install the carrier so that planetary gear B (9) and port (f) of rear flange (301) are shown in the following figure. Port (f): For hydraulic piping Hole (g): For 2nd travel speed selection piston
16. Installation of relief valve assembly 1) Tighten two relief valve assemblies (18). 3 Relief valve assembly (18): 98.1 ± 19.6 Nm {10.0 ± 2.0 kgm}
50-80
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
18. Installation of coupling 1) Install coupling (15) to shaft (102). (See "Component parts")
19. Assembly of sun gear A 1) Install eyebolts [8] to the lifting taps (3 places) of carrier A (3), and sling and install the carrier assembly. a Set the center axes of the hub and carrier assembly vertically and lift down the carrier assembly slowly so that the internal teeth of the hub will not be damaged by the end of planetary gear A (5).
2)
Install sun gear A (4) while matching it with the spline of coupling (15). (See "Component parts") a If sun gear A (4) cannot be installed because of interference with the tooth tips of planetary gear A (5), lift up carrier assembly slowly until sun gear B (8) is disconnected from the gear coupling, and then install sun gear A (4). (See "Component parts")
3)
Install thrust plate (13) to carrier A (3).
20. Installation of cover 1) Apply liquid adhesive to mating face (h) of hub (1) against cover (14). 2 Mating face (h): Adhesive (LOCTITE No. 515 or equivalent) a Apply liquid adhesive continuously.
PC128US-8
50-81
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
2)
Install eyebolts [8] to ports (k) and install cover (14) to hub (1) while matching the bolt holes.
3)
Tighten hexagonal socket head bolts (35). 2 Mounting bolt: Adhesive (LOCTITE No. 242 or equivalent) 3 Mounting bolt: 66.7 ± 3.92 Nm {6.8 ± 0.4 kgm}
2)
Tighten three plugs (30). 3 Plug (30): 98.1 ± 19.6 Nm {10.0 ± 2.0 kgm}
22. Removal of travel motor 1) Turn over the travel motor assembly to set the travel motor side up. 2) Remove the mounting bolts of the travel motor from work stand [1]. (See "Component parts") 3) Install eyebolts [8] to the threaded holes of spindle (2) and lift off the travel motor assembly. 4 Travel motor assembly: 150 kg
21. Adding oil 1) Add oil through oil filler port (j). 5
50-82
Final drive case: 2.1 l
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel motor and final drive assembly
Performance check test After completing the service of the travel motor, perform the performance check test according to the following procedure. Necessary tools
q
1.
No. 1
Part name
Q'ty
Pressure gauge (3.43 MPa {35 kg/cm }) 2
2
2
Measuring cylinder (5 l)
1
3
Stopwatch
1
2.
Test procedure
1)
Installation of travel motor and piping
Install the travel motor to the machine and connect the piping. Do not install the tracks. [To perform performance test of travel motor (no-load operation)]
a Connect the piping so that you can install the pressure gauge (to the main circuit) and measure the draining rate from the hydraulic motor. a Do not install the travel motor by hitting it with a hammer, etc. but install it carefully by using the bolt holes.
2)
Running-in of travel motor
Selection
Travel motor speed
Low speed
10 rpm
High speed
3)
Pressure
Rotation direction
Operating time
No load
Left/Right
Min. 1 minute in each direction
20 rpm
Performance check test of travel motor Running-in before test ---- Perform running-in until the temperature increases as follows. 1] • Hydraulic oil temperature: 45 – 55 °C • External temperature of hub of reduction gear unit: 40 – 80 °C Check test --------- Measure the following items at low speed and judge the result. 2] Criteria acceptance: Difference in travel motor drive pressure ----- Max. 1.57 MPa {16 kg/cm2}/10 rpm Draining rate from hydraulic motor: Max. 1.2 l/min/10 rpm
PC128US-8
Accepted
Rejected
Install tracks
Disassemble and adjust again
50-83
50 Disassembly and assembly Removal and installation of swing motor and swing machinery assembly
Removal and installation of swing motor and swing machinery assembly 1
4.
Remove mounting bolt (9).
5.
Remove swing motor and swing machinery assembly (10) from the machine using forcing screw [1].
6.
Lift and remove swing motor and swing machinery assembly (10). [*1] a Lift the assembly carefully to prevent interference with the surrounding hoses. 4 Swing motor and swing machinery assembly: 95 kg
Removal
k Park the machine on a level place and lower
the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. k Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." k Disconnect the negative (–) terminal of the battery beforehand. a
Fasten tags to respective piping for identification to prevent any mistakes when reinstalling.
1.
Disconnect oil level pipe clamp (1).
2.
Remove covers (2) and (3).
3.
Disconnect hoses (4) to (8).
50-84
PC128US-8
50 Disassembly and assembly Removal and installation of swing motor and swing machinery assembly
Installation q
Carry out the installation in the reverse order of removal.
q
Refilling oil (Hydraulic tank) a Fill oil up to the specified level, start the engine to circulate oil in the pipe and check the oil level again.
q
Bleeding air a Bleed air from the piping, referring to "Bleeding air from each part" in Testing and adjusting.
[*1]
3 Wing machinery mounting bolt:
277 ± 31.9 Nm {28.25 ± 3.25 kgm}
PC128US-8
50-85
50 Disassembly and assembly Disassembly and assembly of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
1 New/Remodel
Necessity
Special tools
1
790-201-2750
Spacer
t 1
790-101-5201
Push puller (Kit)
q 1
790-101-2510
• Block
1
4)
790-101-2550
• Leg
1
5)
790-101-2560
• Nut
2
790-101-2570
• Plate
4
2
Part name
Bearing puller
790-101-4200
Puller q 1 (294 kN {30 ton})
790-101-1102
Hydraulic oil pump
790-101-5401
Push tool (Kit) (C) q 1
790-101-5461
• Plate
1
790-101-5441
• Plate
1
790-101-5421
• Grip
1
01010-51240
• Bolt
1
4
790-201-2850
Spacer
t 1
5
790-201-2750
Spacer
t 1
3
6
q 1
796T-426-1140 Push tool
t 1
790-201-2680
q 1
Plate
Disconnect swing motor assembly (4) using forcing screw [1]. Lift and remove swing motor assembly (4).
q 1
790-101-3101
F
Sketch
Part No.
Q'ty
Symbol
3.
Q
Carrier No. 1 and Sun gear No. 2 assembly 1) Remove sun gear No. 1 (5). 2) Remove carrier No. 1 and sun gear No. 2 assembly (6).
Disassembly 1.
Oil drain Remove the drain plug and drain oil from the swing machinery. 6 Swing machinery case: 2.5 l
2.
Swing motor assembly 1) Remove oil level pipe (1). 2) Remove hose (2). 3) Remove 15 swing motor mounting bolts (3).
50-86
PC128US-8
50 Disassembly and assembly Disassembly and assembly of swing motor and swing machinery assembly
3)
Sub-disassembly of carrier No. 1 and sun gear No. 2 assembly 1] Remove snap ring (7) and remove thrust washer (8), gear (9), bearing (10) and thrust washer (11).
2]
3]
Drive pin (12) in and punch out shaft (13). a Remove the shaft, then remove pin (12). Remove snap ring (14) and remove sun gear No. 2 (15) from carrier (16).
4.
Ring gear Remove ring gear (17).
5.
Carrier No. 2 assembly 1) Remove spacer (18). 2) Remove carrier No. 2 assembly (19).
PC128US-8
3)
6.
Sub-disassembly of carrier No. 2 assembly. 1] Press pin (20) in and punch out shaft (21) from carrier (22). a Remove the shaft, then remove pin (20). 2] Remove thrust washer (23), gear (24), bearing (25) and thrust washer (26).
Retainer and collar 1) Remove retainer (27). 2) Set the shaft and case assembly to the press, and push 2-piece collar (28) using a push tool to press bearing (29). 3) Remove 2-piece collar (28).
50-87
50 Disassembly and assembly Disassembly and assembly of swing motor and swing machinery assembly
7.
Shaft assembly 1) Set the shaft and case assembly (30) to block [2], and remove shaft assembly (31) with the press using push tool [3]. 2) Remove bearing (29).
3)
8.
2)
Use puller [4] to remove bearing outer races (37) and (38) from case (36).
Use tool F2 to remove bearing (32) and collar (33) from shaft (34).
Oil seal and bearing outer race 1) Remove oil seal (35) from case (36).
50-88
PC128US-8
50 Disassembly and assembly Disassembly and assembly of swing motor and swing machinery assembly
Assembly 1.
Bearing outer race Use push tool F3 to press outer races (37) and (38) to case (36).
2.
Shaft assembly 1) Install O-ring to inside collar (33) and install to shaft (34). 2) Use push tool F4 to press bearing (32) with the press.
3) 4)
Set case (39) to shaft assembly (31). Use push tool F5 to press bearing (29) with the press to the position where the 2piece collar can be entered. a Press-fit force: 11,760 N {1,200kg} a Press the bearing gradually by rotating the case.
PC128US-8
5) 6)
Install 2-piece collar (28). Screw in bolt (12 mm, P=1.75) to the case. Using push-pull scale [5] to measure the tangential force in the direction of rotation. a Tangential force: Max. 176.4 N {18kg} a Tangential force refers to a maximum value at the start of rotation.
3.
Oil seal Using tool F6 to press oil seal (35). a Replace the oil seal with a new one. 2 Circumference of oil seal: LG-6 a Be careful not to allow LG-6 to attach to the lip and shaft. 2 Oil seal lip portion: Grease (G2-LI)
4.
Retainer Install retainer (27).
50-89
50 Disassembly and assembly Disassembly and assembly of swing motor and swing machinery assembly
5.
Carrier No. 2 assembly 1) Sub-disassembly of carrier No. 2 assembly 1] Assemble bearing (25) to gear (24). 2] Install thrust washer (23) and (26) and set gear assembly to carrier (22).
3]
4]
2) 3)
50-90
6.
Ring gear Install O-ring (40) to the shaft and case assembly, and install ring gear (17).
7.
Carrier No. 1 and sun gear No. 2 assembly 1) Sub-disassembly of carrier No. 1 and sun gear No. 2 assembly 1] Install carrier No. 1 (16) to sun gear No. 2 (15) and Install snap ring (14). 2] Align the shaft to the carrier pin hole position, and install shaft (21) by lightly hammering with a plastic hammer, etc. 3] Insert pin (12). a Insert the pin, then caulk the pin of the carrier. a Check that difference (a) between the shaft and carrier is 0.2 mm or less.
Align the shaft to the carrier pin hole position, and install shaft (21) by lightly hammering with a plastic hammer, etc. a Install the shaft by turning the planetary gear. Be careful not to damage the thrust washer. Insert pin (20). a Insert the pin, then caulk the pin of the carrier.
Install carrier No. 2 assembly (19) to the shaft and case assembly. Install spacer (18).
PC128US-8
50 Disassembly and assembly Disassembly and assembly of swing motor and swing machinery assembly
4]
Install thrust washer (11), bearing (10), gear (9) and thrust washer (8), and install snap ring (7). a Use new snap ring. a When installing the snap ring, do not allow the mating space to expand wider than 11 mm to prevent the snap ring from deforming. a After installation, check that the snap ring is firmly in place.
8.
Swing motor assembly 1) Install swing motor assembly (4). 2) Install 15 swing motor mounting bolts (3). 3 Swing motor mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm} 3) Install hose (2). 4) Install oil level pipe (1).
9.
Refilling with oil Tighten the drain plug, and refill engine oil EO30 from the oil filler port. 5
2) 3)
Install carrier No. 1 and sun gear No.2 assembly (6) to the shaft case assembly. Install sun gear No. 1 (5).
PC128US-8
Swing machinery case: 2.5 l
50-91
50 Disassembly and assembly Removal and installation of swing circle assembly
Removal and installation of swing circle assembly 1
Installation q
Removal
k Gradually loosen the hydraulic oil tank cap
to bleed the air from the tank after grounding the work equipment and stopping the engine and lock the safety lock lever. 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
50-92
[*2]
Installation is performed in the opposite way to removal.
[*1]
2 Swing circle mounting bolt:
Liquefied adhesive (LT-2)
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 grease (G2-LI)
PC128US-8
50 Disassembly and assembly Disassembly and assembly of track roller
Undercarriage and frame Disassembly and assembly of track roller
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).
5.
Remove collar (8) from shaft (5).
6.
Remove bushings (9) and (10) from roller (4).
1
M
Part name
1
790-434-1650
Installer
t 1
2
791-601-1000
Oil pump
q 1
Disassembly 1.
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Remove pin (1), then remove collar (2).
PC128US-8
50-93
50 Disassembly and assembly Disassembly and assembly of track roller
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).
50-94
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.
8.
Assemble collar (2) to shaft (5), and install pin (1).
9.
Using tool M2, apply standard pressure to roller oil filler port and check air leakage. a Standard pressure: 0.1 MPa {1 kg/cm²} a Method of checking: The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.
PC128US-8
50 Disassembly and assembly Disassembly and assembly of track roller
10. Using tool M2, fill track roller assembly with oil, then tighten plug (11). 5
Track roller oil: 75 – 85 cc (EO30-CD)
PC128US-8
50-95
50 Disassembly and assembly Disassembly and assembly of idler assembly
Disassembly and assembly of idler assembly
1
L 1
791-675-1510
Part name
Installer
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
Disassembly 1.
Remove dowel pin (1), then remove support (2).
5.
Remove dowel pin (8), then remove support (7) from shaft (5).
2.
Remove floating seal (3) from support (2) and idler (4).
6.
Remove bushings (9) and (10) from 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).
50-96
PC128US-8
50 Disassembly and assembly Disassembly and assembly of idler assembly
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.
4.
Assemble shaft (5) and support assembly (7) to idler (4).
5.
Add oil between shaft (5) and idler (4). 5
Oil: 90 – 105 cc (EO30)
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.
6.
PC128US-8
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.
50-97
50 Disassembly and assembly Disassembly and assembly of idler assembly
7.
Install O-ring, then install support (2) with dowel pin (1).
50-98
PC128US-8
50 Disassembly and assembly Disassembly and assembly of recoil spring
Disassembly and assembly of recoil spring
1
2
L
3
Part name
791-600-2001 or 791-685-8006
Compressor (A)
791-635-3160
Extension
t 1
790-201-2770
• Spacer
t 1
790-101-1600
Cylinder (686 kN {70 ton})
t 1
790-101-1102
Pump
t 1
790-201-1500
Push tool (Kit)
q 1
790-201-1590
• Plate (Periphery ø74)
1
790-201-1610
• Plate (Periphery ø79)
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
1 t
Compressor (B)
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
1
Disassembly
PC128US-8
50-99
50 Disassembly and assembly Disassembly and assembly of recoil spring
1.
Remove lock plate (1), then remove seat (2) and valve (3). a Do not remove grease fitting (17) from the 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. k The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. a Installed load of spring: 84,300 N {8,600 kg}
2)
3) 4)
4.
Apply hydraulic pressure slowly to compress spring, then remove nut (6). a Compress the spring to a point where the nut becomes loose. a Release the hydraulic pressure slowly to remove the spring tension. Remove pilot (8), and spring (7). Remove snap ring (10), dust seal (11) and bush (12) from cylinder (9).
Disassembly of yoke piston (5) assembly 1) Remove snap ring (14), then remove Upacking (15). 2) Remove wear ring (16) from yoke piston (13).
50-100
PC128US-8
50 Disassembly and assembly Disassembly and assembly of 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).
5)
3) 4)
Assemble cylinder (9) and pilot (8) to spring (7), and set to tool L2. Apply hydraulic pressure slowly to compress spring, and tighten nut (6) so that installed length of spring is dimension (a). a Installed length (a) of spring: 390 mm
PC128US-8
Remove recoil spring assembly (4) from tool L2.
3.
Assemble yoke piston assembly (5) to recoil spring assembly (4). 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)
50-101
50 Disassembly and assembly Spreading and installation of track shoe assembly
Spreading and installation of track shoe assembly
2.
Lower the work equipment to the ground and loosen lubricator (3) to decrease the track shoe tension. [*1] k Since the internal pressure of the adjustment cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not come out sufficiently, move the machine forward and in reverse.
3.
Remove 2 shoes (4) above and in front of the master pin. [*1]
4.
Using tool R, pull out the master pin.
5.
Using tool R, pull out the temporary pin and remove the dust seal. Move the machine in reverse to spread track shoe assembly (5). [*3]
1
R
791-620-3000
Remover and installer
791-635-3110
• Frame
1
791-635-3120
• Support
1
791-635-3130
• Nut
1
791-635-3140
• Screw
1
791-635-3150
• Hook
1
791-635-3160
• Extension
1
791-635-3170
• Nut
1
791-635-3180
• Screw
1
791-635-3190
• Screw (for fixing)
1
791-635-3210
• Pilot
1
791-630-3220
• Adapter
1
791-620-3260
• Pin pusher
1
796T-432-1010 Guide
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
t 1 N Q
790-101-1300 or 790-101-1600
Cylinder (980kN {100ton}) t 1 Cylinder (686kN {70ton})
791-101-1102
Pump
t 1
Spreading 1.
Move master pin (1) to above the idler (2).
50-102
[*2]
PC128US-8
50 Disassembly and assembly Spreading and installation of track shoe assembly
Installation Carry out installation in the reverse order to removal.
q
[*1] a Adjust the track shoe tension. For detail, see Testing and adjusting, "Testing and adjusting track shoe tension". q
1.
2.
Procedure for tightening shoe bolts and nuts Install each shoe nut (6) so that its (R) end is fitted to the seat on the link side. a If the shoe nut is installed reversely, its corner interferes with the seat on the link side and it will not be fitted to the seat, and that can loosen the bolt. Tighten the bolts. a Check that the mating faces are fitted, and then retighten the bolts. Tightening torque Triple grouser shoe
Road liner
1st time
196 ± 20 Nm {20 ± 2 kgm}
176 ± 20 Nm {18 ± 2 kgm}
2nd time
90° ± 10°
60° ± 5°
[*2] a Using tool R, press fit the master pin so that its projection will be dimension (a). Projection (a) of master pin: 3 ± 2 mm
Remarks
Angle tightening
[*3] a When installing the dust seal, apply grease (G2-LI-1) to its contact face to the bushing. a When press fitting the master pin, apply grease (G2-LI-1) to the inside of the master bushing. a If the rubber part of the road liner specification (rubber pad type) is worn and broken to damage the mounting bolt heads, replace the shoe with new one immediately. If the bolt heads are crushed, the bolts cannot be removed.
PC128US-8
50-103
50 Disassembly and assembly Removal and installation of sprocket
Removal and installation of sprocket
Installation
1
Removal 1.
Expand the track shoe assembly. For details, see Expansion of track shoe assembly.
2.
Swing the work equipment by 90° and push up the machine with it, and then set blocks [1] between the track frame and track shoe.
3.
Remove the 15 mounting bolts and lift off sprocket (1). [*1] 4 Sprocket: 35 kg
50-104
q
Carry out installation in the reverse order to removal.
[*1]
2 Threads of sprocket mounting bolt: 3 Sprocket mounting bolt:
Adhesive (LT-2)
323.6 – 362.8 Nm {33 – 37 kgm}
PC128US-8
50 Disassembly and assembly Removal and installation of revolving frame assembly
Removal and installation of revolving frame 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.
1
Removal
k Disconnect the negative (–) terminal of the
battery. 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]
10. Disconnect plate (14) from revolving frame.
11. Remove mounting bolts (15), leaving one each at front and rear. [*2]
5.
Lift boom cylinder assembly (6) to remove it. 4 Boom cylinder assembly: 120 kg
6.
Remove operator cab assembly (7) by referring to "Removal of operator cab assembly".
PC128US-8
50-105
50 Disassembly and assembly Removal and installation of revolving frame assembly
12. Lift revolving frame assembly (16) to loosen remaining bolts (15). a Carefully remove the remaining bolts by balancing them using the crane. a Carefully lift and remove them to prevent them from coming in contact with the center swivel joint or other parts. 4 Revolving frame assembly: 6,100 kg
Installation q
Installation is performed in the opposite way to removal.
[*1]
2 Surface inside bushing during pin assembly:
Hyper white grease (G2-T)
2 Greasing after pin assembly:
Hyper white grease (G2-T) k Never put your finger in the pin hole when
a
adjusting the position. Adjust the clearance between the mount on the boom cylinder bottom and the frame using the shims so that it becomes 1mm or less.
[*2]
2 Swing circle contacting face:
Liquefied gasket (LG-1)
2 Revolving frame mounting bolt screw:
Liquefied adhesive (LT-2)
3 Revolving frame mounting bolt:
277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}
50-106
q
Supplying oil (hydraulic oil tank) Supply oil from the oil filler port to the specified level, start the engine to circulate oil in the piping and recheck the oil level.
q
Bleeding air Bleed the air. For details , see Testing and adjusting, "Bleeding air from each part".
PC128US-8
50 Disassembly and assembly Removal and installation of counterweight assembly (Machine without add-on weight)
Removal and installation of counterweight assembly (Machine without add-on weight) 1
3.
Disconnect monitor camera wiring (7).
4.
Disconnect flywheel case lubrication hose (8).
5.
Using 3 sling bolts (M36 x 3 mm), temporarily lift the counterweight, and remove 3 mounting bolts (9). [*1]
6.
Lift and remove counterweight assembly (10). a Shift the counterweight horizontally to backward before lifting so that it will not interfere with the machine main body. 4 Counterweight assembly : 2,900 kg (standard specification) : 2,400 kg (Blade specification)
Z
a
Part name
Commercially available
Impact wrench
Commercially available
Socket wrench (Width across flats: q 1 65 mm)
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
q 1
Use the impact wrench and socket wrench corresponding to the specified torque for mounting bolts.
Removal
k Stop the machine on a level ground, stop
the engine, and lower the work equipment to the ground. k Disconnect the cable from the negative (-) terminal of the battery. 1.
2.
Remove monitor camera wiring protection cover (1). Remove engine upper covers (2) to (5).
PC128US-8
50-107
50 Disassembly and assembly Removal and installation of counterweight assembly (Machine without add-on weight)
Installation q
Carry out installation in the reverse order to removal.
[*1]
2 Counterweight mounting bolt (M42 x 3 Width
across flats: 65 mm): Adhesive (LT-2)
3 Counterweight mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm} Target: 3,626 Nm {370 kgm}
50-108
PC128US-8
50 Disassembly and assembly Removal and installation of counterweight assembly (Machine with add-on weight)
Removal and installation of counterweight assembly (Machine with add-on weight)
6.
Sling the counterweight and remove 3 mounting bolts (5). [*2]
7.
Using 3 sling bolts (M36 x 3 mm), lift off counterweight assembly (6). a First, move the counterweight assembly horizontally toward the rear so that it will not interfere with the machine body, and then lift it up. 4 Counterweight assembly : 2,900 kg (Standard specification) : 2,400 kg (Blade specification)
1
Removal
k Stop the machine on a level ground, stop
the engine, and lower the work equipment to the ground. k Disconnect the cable from the negative (-) terminal of the battery. 1.
Perform steps 1 – 4 of "Removal and installation of counterweight assembly (Machine without add-on weight)
2.
Remove the 2 monitor camera mounting bolts to remove the monitor camera.
3.
Remove mounting bolt (2) on the top of the add-on weight.
4.
Using 2 sling bolts (M20 x 2.5 mm) sling addon weight (3) and remove 2 mounting bolts (4) from its side.
5.
Lift off add-on weight (3). 4 Add-on weight: 510 kg
PC128US-8
[*1]
50-109
50 Disassembly and assembly Removal and installation of counterweight assembly (Machine with add-on weight)
Installation q
Carry out installation in the reverse order to removal.
[*1] Installation procedure for add-on weight 1) Put faces (X) and (Y) to the insert boss of the counterweight. 2) Install top bolt (2) and tighten it lightly. 2 Add-on weight mounting bolt: Adhesive (LT-2) 3) Adjust clearance (a) to 10 ± 3 and install side bolts (4). 2 Add-on weight mounting bolt: Adhesive (LT-2) 3 Add-on weight mounting bolt: 1,860 – 3,040 Nm {190 – 310 kgm} 4)
Tighten the top bolt. 3 Add-on weight mounting bolt: 1,860 – 3,040 Nm {190 – 310 kgm}
[*2]
2 Counterweight mounting bolt:
Adhesive (LT-2)
3 Counterweight mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm} Target: 3,626 Nm {370 kgm}
50-110
PC128US-8
50 Disassembly and assembly Removal and installation of center swivel joint assembly
Hydraulic system Removal and installation of center swivel joint assembly 1 Removal
k Gradually loosen the hydraulic oil tank cap
to bleed the internal air after completely grounding the work equipment and stopping the engine. k Disconnect the negative (–) terminal of the battery. 1.
Remove cover (1), (2) at rear of boom.
2.
Remove filter and bracket assembly (3). (for attachment specification)
3.
Disconnect hoses (4) – (9) between travel motor and swivel joint.
4.
Remove elbow (10).
5.
Disconnect drain hose (11).
6.
Disconnect hoses (12) – (15) between control valve and swivel joint.
7.
Disconnect hose (16) from solenoid valve.
8.
Remove plate (17).
PC128US-8
9.
Disconnect hoses (for changing the speed) (18) and (19) between both travel motors and swivel joint.
10. Remove mounting bolts and lift off center swivel joint assembly (20). [*1] a Sling the joint assembly temporarily, then remove the bolts. 4 Center swivel joint assembly : 30 kg (Standard specification) : 45 kg (Blade specification)
50-111
50 Disassembly and assembly Removal and installation of center swivel joint assembly
Installation q
Installation is performed in the opposite way to removal.
[*1]
2 Mounting bolt screw: 3 Mounting bolt:
Liquefied adhesive (LT-2)
98.1 – 123.0 Nm {10.0 – 12.5 kgm} q
Bleeding air Bleed air from the swing motor. For details, see Testing and adjusting, "Bleeding air from each part".
50-112
PC128US-8
50 Disassembly and assembly Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
1
T
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
q 1
790-101-2501
Push puller
790-101-2510
• Block
1
790-101-2520
• Screw
1
790-101-2540
• Washer
1
Assembly
791-112-1180
• Nut
1
1.
790-101-2630
• Leg
2
Fit slipper seals (7) and O-rings (6) to swivel rotor.
790-101-2570
• Washer
4
2.
790-101-2560
• Nut
2
791-112-2650
• Adapter
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}
Disassembly 1.
Remove cover (1).
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).
PC128US-8
50-113
50 Disassembly and assembly Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic tank assembly
a
When using tool D to stop oil, remove the hydraulic oil tank strainer in advance.
2.
Removal of exterior parts 1) Removal handrail(2) 2) Removal cover(3) – (6).
3.
Tank rear wiring, hose and clamps 1) Disconnect drain hose (7). 2) Disconnect hydraulic pump suction hose (8).
1
D
796-460-1210
Oil Stopper
q 1
795-799-1131
Adapter
q 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Removal
k Park the machine on a level place and lower
the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. k Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." k Disconnect the negative (–) terminal of the battery beforehand. 1.
Loosen hydraulic drain plug(1) and drain the hydraulic oil. [*1] 6 Hydraulic oil tank: 69 l (Capacity: 120 l)
50-114
PC128US-8
50 Disassembly and assembly Removal and installation of hydraulic tank assembly
3)
4) 5)
Remove engine oil filter bracket (9). a Move the filter assembly close to the engine. Disconnect hose (10) from radiator. Disconnect fuel level sensor wire (11).
7.
Removal of hydraulic oil tank mounting bracket and mounting bolts. 1) Remove fuel tank rear mounting brackets (23).
2) 4.
Disconnect 8 return hoses (12) to (19) in front of the tank. a Record the installed position of respective hoses.
5.
Disconnect swing machinery oil level pipe clamp (20).
6.
Disconnect 2 drain hoses (21) and clamps (22).
PC128US-8
3)
4)
Remove wiring and hose mounting brackets (24). Remove fuel tank front mounting brackets (25).
Remove 4 hydraulic oil front mounting bolts (26). [*2]
50-115
50 Disassembly and assembly Removal and installation of hydraulic tank assembly
8.
Lift and remove hydraulic oil tank assembly (27). 4 Hydraulic oil tank assembly: 95 kg
Installation Carry out the installation in the reverse order of removal.
q
[*1]
3 Drain plug (1): 58.8 – 78.4 Nm {6 – 8kgm} 5
Target: 68.6 Nm {7 kgm} Hydraulic oil tank: 69 l (Capacity: 120 l)
[*2]
2 Thread of hydraulic oil tank mounting bolt:
Adhesive (LT-2)
3 Hydraulic oil tank mounting bolt (27):
245 – 309 Nm {25 – 31.5 kgm}
50-116
PC128US-8
50 Disassembly and assembly Removal and installation of hydraulic pump assembly
Removal and installation of hydraulic pump assembly
a
When using tool D to stop oil, remove the hydraulic oil tank strainer in advance.
2.
Remove covers (2) and (3).
3.
Remove radiator sub tank (4).
4.
Disconnect water assembly (6).
5.
Remove engine oil filter bracket (5). a Move the filter assembly close to the engine.
1
D
796-460-1210
Oil Stopper
q 1
795-799-1131
Adapter
q 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Removal
k Park the machine on a level place and lower
the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. k Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." k Disconnect the negative (-) terminal of the battery beforehand. 1.
Loosen hydraulic drain plug(1) and drain the hydraulic oil. 6 Hydraulic oil tank: 69 l (Capacity: 120 l)
PC128US-8
separator
and
bracket
50-117
50 Disassembly and assembly Removal and installation of hydraulic pump assembly
6.
Disconnect damper case oil filler hose(7).
7.
Removal of muffler assembly 1) Remove divider boards (8) and rubber covers (9) and (10).
3)
9. 2) 3) 4)
8.
Remove muffler drain tube (11). Remove 4 muffler mounting bolts (12). Lift and remove muffler assembly (13).
Disconnect 6 hoses(17) to (22). a Record the installed position of respective hoses.
Disconnection hydraulic pump 1) Temporarily lift the pump (23) and remove mounting bolts (24). a Temporarily lift the pump by the engine side using chain block [1] and by the near side using wire rope [2]. 2) Lift and disconnect hydraulic pump (23) from engine. 4 Hydraulic pump assembly: 110 kg
Disconnecting wiring and hoses 1) Disconnect EPC solenoid wiring connector V11(14) and hydraulic oil temperature sensor wiring connector P22 (15). 2) Removes suction tube (16) from hydraulic pump.
50-118
PC128US-8
50 Disassembly and assembly Removal and installation of hydraulic pump assembly
10. Removal procedures of work equipment pump Remove work equipment pump by pulling it toward the front according to the following procedures. 1) Shift the pump closer to the front end until wire rope [2] almost makes contact with the counterweight.
4)
Install wire rope [2] to the work equipment pump from outside the counterweight. a Apply rubber plates or cloth [3] to the counterweight to prevent it from being damaged by wire rope.
5)
Lower chain block [1] and hold the work equipment pump in level state. Shift the pump closer to the front end until chain block [1] almost makes contact with the counterweight.
6) 2) 3)
Pull chain block [1] up and loosen wire rope [2]. Disconnect wire rope [2] from the work equipment pump.
7)
PC128US-8
Lower the chain block [1] and loosen chain block [1].
50-119
50 Disassembly and assembly Removal and installation of hydraulic pump assembly
8)
50-120
Disconnect chain block from the work equipment pump, shift the work equipment pump (23) forward to the front and remove it.
Installation q
Carry out the installation in the reverse order of removal.
PC128US-8
50 Disassembly and assembly Removal and installation of control valve assembly
Removal and installation of control valve assembly
a
When using tool D to stop oil, remove the hydraulic tank strainer in advance.
2.
Removal of exterior parts 1) Removal handrail(2) 2) Removal cover (3) and (6).
3.
Removal of solenoid valve frame 1) Disconnect hoses (5) to (12). (Index No. , Color band , Hose Name) (5); (Red-Green) PPC basic pressure (6); (Red) Travel HI/LO (7); (Red-Red) Swing paring brake (8); (–) Merge-divider valve selection signal (9); (–) Travel junction valve (10); (–) P1Pilot pressure (11); (–) Travel junction valve (12); (–) Pilot pressure #3
1
D
796-460-1210
Oil Stopper
q 1
795-799-1131
Adapter
q 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Removal
k Park the machine on a level place and lower
the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. k Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in "Testing and adjusting." k Disconnect the negative (–) terminal of the battery beforehand. a a
1.
The following procedure explain about "Attachment and multi-pattern specifications." Fasten tags to respective connecters and piping for identification to prevent any mistakes when re-installing. Loosen hydraulic drain plug (1) and drain the hydraulic oil. 6 Hydraulic oil tank: 69 l (Capacity: 120 l)
PC128US-8
50-121
50 Disassembly and assembly Removal and installation of control valve assembly
2)
3) 4)
50-122
Disconnect connectors (13) to (23). (13): V10 (Bucket dump solenoid) (14): M14 (ravel alarm buzzer)
(15): V1 (PPC Basic pressure) (16): V2 (Travel HI/LO) (17): V3 (Swing paring brake) (18): V4 (Travel junction valve) (19): V5 (Merge-divider valve selection signal) (20): P25 (Pump pressure sensor) (21): P26 (Travel right rear pressure sensor) (22): P27 (Travel left rear pressure sensor) (23): P29 (Dummy) Disconnect clamp (24) from solenoid valve frame. Remove solenoid valve frame assembly (25).
4.
Removal of pressure switch connector 1) Disconnect wiring connectors (26) to (32). (26): P01 (Bucket dump switch) (27): P02 (Arm dump switch) (28): P03 (Boom raise switch) (29): P04 (Bucket digging switch) (30): P05 (Boom digging switch) (31): P06 (Boom lower switch) (32): P07 (Right swing switch) 2) Remove pressure switch mounting bracket (33).
5.
Disconnection of multi-valve assembly wiring and hose (for machines installed with the assembly) 1) Disconnect connectors (34) and (35). (34): (P08) Left swing switch (35): (P67) Right swing switch a Connector P67 is connected to connector P07. a For a machine without the multi-valve assembly, connector P08 is positioned under P07 of the pressure switch connector mounting bracket.
PC128US-8
50 Disassembly and assembly Removal and installation of control valve assembly
2)
6.
Disconnect hoses (36) to (39). (Index No. , Color band , Hose Name) (36); (Orange) Arm dump (37); (White) Swing left (38); (Red) Bucket dump (39); (Red-Yellow) Boom raise
Disconnection of control valve connectors and hoses (Connectors) 1) Disconnect connectors (40) to (42) from right side of control valve. (40): P64 (Bucket digging switch) (41): P65 (Arm digging switch) (42): P66 (Boom lower switch)
2)
Disconnect connectors (43) to (47) from left side (operator cab side) of control valve. (43): P61 (Bucket dump switch) (44): P62 (Arm dump switch) (45): P63 (Boom raise switch) (46): P09 (Right travel forward switch) (47): P10 (Left travel forward switch)
PC128US-8
(Hoses) 3) Disconnect 15 hoses (48) to (62) right and front side of control valve. (48); (–) (49); (Blue) (50); (Blue) (51); (Green) (52); (Green) (53); (Black) (54); (Black) (55); (–) (56); (Yellow) (57); (Yellow) (58); (Brown) (59); (–) (60); (–) (61); (Black) (62); (Black)
50-123
50 Disassembly and assembly Removal and installation of control valve assembly
(78); (Yellow- Black) (79); (Yellow- Green) (80); (Yellow- Brown) (81); (Yellow- Orange) (82); (White) (83); (Brown)
4)
5)
50-124
Disconnect 5 hoses (63) to (67) left side (operator cab side) of control valve. (63); (–) (64); (Red- Red) (65); (Red) (66); (Black- Yellow) (67); (Brown- Yellow)
Disconnect all of hoses (68) to (83) back side(engine side) of control valve. (68); (White) (69); (Brown) (70); (Red) (71); (Blue) (72); (Orange) (73); (Green) (74); (–) (75); (Black) (76); (–) (77); (–)
7.
Disconnect attachment select valve connecting hose (84).
8.
Remove 3 multi-valve mounting bolts (85) and remove multi-valve assembly (86).
PC128US-8
50 Disassembly and assembly Removal and installation of control valve assembly
9.
Remove bracket mounting bolt (87) and r emov e multi - val ve as sem bly mo unti ng bracket (88).
Installation q
Carry out the installation in the reverse order of removal.
10. Loosen 4 control valve mounting bolt(89) and lift and remove control valve assembly (90). 4 Control valve assembly: 95 kg
PC128US-8
50-125
50 Disassembly and assembly Disassembly and assembly of control valve assembly
Disassembly and assembly of control valve assembly
1
Assembly
50-126
PC128US-8
50 Disassembly and assembly Disassembly and assembly of control valve assembly
The appearance and section of only the 8-spool valve (blade + service valve) are shown here. A1 : To swing motor A2 : To blade cylinder bottom A3 : To left travel motor A4 : To right travel motor A5 : To boom cylinder bottom A6 : To arm cylinder head A7 : To bucket cylinder head A8 : To attachment B1 : To swing motor B2 : To blade cylinder head B3 : To left travel motor B4 : To right travel motor B5 : To boom cylinder head B6 : To arm cylinder bottom B7 : To bucket cylinder bottom B8 : To attachment LS : To pump LS valve P1 : From main pump P2 : From main pump PP : To main pump PR : To solenoid valve, PPC valve and EPC valve PS : From solenoid valve of merge-divider valve TB : To tank TC : To oil cooler BP1: From boom raise PPC valve LS1: LS1 pressure pickup port LS2: LS2 pressure pickup port
LS3 : LS3 pressure pickup port PA : From swing left PPC valve PA2 : From blade lower PPC valve PA3 : From left travel forward PPC valve PA4 : From right travel forward PPC valve PA5 : From boom raise PPC valve PA6 : From arm dump PPC valve PA7 : From bucket dump 1 PPC valve PA8 : From service PPC valve PB1 : From swing right PPC valve PB2 : From blade raise PPC valve PB3 : From left travel reverse PPC valve PB4 : From right travel reverse PPC valve PB5 : From boom lower PPC valve PB6 : From arm in PPC valve PB7 : From bucket curl PPC valve PB8 : From service PPC valve PMAX: Pressure sensor port PP1 : PP1 pressure pickup port PP2 : PP2 pressure pickup port PPI1 : Pump 1 pressure pickup port PPI2 : Pump 2 pressure pickup port PRI : PR pressure pickup port PST : From travel junction solenoid valve TS1 : To tank PS2 : To tank TSW : To swing motor TSW : To swing motor
1. 2. 3. 4. 5. 6. 7. 8. 9.
10. Block 11. Swing bleed valve 12. LS check valve 13. Travel junction valve + LS check valve 14. Arm regeneration valve 15. Boom hydraulic drift prevention valve 16. Merge-divider valve block 17. Nut 18. Bolt
Cover Service valve Bucket valve Arm valve Boom valve Right travel valve Left travel valve Blade valve Swing valve
PC128US-8
50-127
50 Disassembly and assembly Disassembly and assembly of control valve assembly
a
In this section, only the precautions for assembling the control valve assembly are described.
q
Before assembling the parts, apply engine oil to their sliding surfaces. 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).
q
Install cover (1): Tighten the 4 nuts (17) in the diagonal order ([1] – [4]) according to the following procedure. 1st time: 3 58.8 – 68.6 Nm {6 – 7 kgm} 2nd time: 3 78.5 – 88.3 Nm {8 – 9 kgm} 3rd time: 3 98.1 – 113 Nm {10 – 11.5 kgm} The height of the stud top above the nut top: 0.5 – 3 mm
a
q
Assembling block (10): Tighten the 4 bolts (18) in the diagonal order ([1] – [4]) according to the following procedure. 1st time: 3 19.6 – 29.4 Nm {2 – 3 kgm} 2nd time: 3 39.2 – 49.0 Nm {4 – 5 kgm} 3rd time: 3 58.8 – 73.5 Nm {6 – 7.5 kgm}
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.
50-128
PC128US-8
50 Disassembly and assembly Disassembly and assembly of control valve assembly
PC128US-8
50-129
50 Disassembly and assembly Disassembly and assembly of control valve assembly
50-130
PC128US-8
50 Disassembly and assembly Disassembly and assembly of control valve assembly
PC128US-8
50-131
50 Disassembly and assembly Disassembly and assembly of control valve assembly
50-132
PC128US-8
50 Disassembly and assembly Disassembly and assembly of control valve assembly
PC128US-8
50-133
50 Disassembly and assembly Disassembly and assembly of control valve assembly
AA1. Safety-suction valve (Service) AA2. Suction valve (Bucket) AA3. Suction valve (Arm) AA4. Suction valve (Boom) AA5. Lift check valve AA6. Suction valve (Right travel) AA7. Suction valve (Left travel) AA8. Suction valve (Blade) AA9. Safety-suction valve (Blade) AA10. Suction valve (Left travel) AA11. Suction valve (Right travel) AA12. Main relief valve AA13. Suction valve (Boom) AA14. Suction valve (Arm)
AA15. Suction valve (Bucket) AA16. Safety-suction valve (Service) AA17. Safety-suction valve BB18. Spool (Service) BB19. Spool (Bucket) BB20. Spool (Arm) BB21. Spool (Boom) BB22. Spool (Right travel) BB23. Spool (Left travel) BB24. Spool (Blade) BB25. Spool (Swing) BB26. Unload valve BB27. Unload valve
CC1 CC2. DD3. DD4. DD5. DD6. DD7.
LS selector valve Cooler bypass valve Pressure compensation valve R (Service) Pressure compensation valve R (Bucket) Pressure compensation valve R (Arm) Pressure compensation valve R (Boom) Pressure compensation valve R (Right travel) DD8. Pressure compensation valve R (Left travel) DD9. Pressure compensation valve R (Blade) DD10. Pressure compensation valve R (Swing)
DD11. Pressure compensation valve F (Swing) DD12. Pressure compensation valve F (Blade) DD13. Pressure compensation valve F (Left travel) DD14. Pressure compensation valve F (Right travel) DD15. Merge-divider valve spool DD16. Pressure compensation valve F (Boom) DD17. Pressure compensation valve F (Arm) DD18. Pressure compensation valve F (Bucket) DD19. Pressure compensation valve F (Service)
FF1. LS selector valve FF2. Pressure compensation valve F (Swing) FF3. Spool (Swing) FF4. Pressure compensation valve R (Swing) FF5. LS bleed valve FF6. Safety-suction valve (Blade) FF7. Suction valve (Blade) FF8. Spool (Blade) FF9. Pressure compensation valve R (Blade) FF10. Pressure compensation valve F (Blade)
FF11. Pressure compensation valve R (Left travel) FF12. Suction valve (Left travel) FF13. Suction valve (Left travel) FF14. Spool (Left travel) FF15. Pressure compensation valve F (Left travel) FF16. LS check valve
50-134
F: R:
Flow control valve Pressure reducing valve
PC128US-8
50 Disassembly and assembly Disassembly and assembly of control valve assembly
JJ1. JJ2. JJ3. JJ4. JJ5. JJ6. JJ7. JJ8.
Pressure compensation valve F (Right travel) Suction valve (Right travel) Suction valve (Right travel) Spool (Right travel) Pressure compensation valve R (Right travel) Travel junction valve + LS check valve Unload valve LS bypass valve
NN1. Pressure compensation valve F (Arm) NN2. Suction valve (Arm) NN3. Suction valve (Arm) NN4. Spool (Arm) NN5. Pressure compensation valve R (Arm) NN6. Hydraulic drift prevention valve (Arm) NN7. Pressure compensation valve F (Bucket) NN8. Suction valve (Bucket) NN9. Suction valve (Bucket) NN10. Spool (Bucket) NN11. Pressure compensation valve R (Bucket)
PC128US-8
JJ9. JJ10. JJ11. JJ12. JJ13. JJ14. JJ15. JJ16. JJ17. JJ18.
Merge-divider valve spool Main relief valve Cooler bypass valve Lift check valve Pressure compensation valve F (Boom) Suction valve (Boom) Hydraulic drift prevention valve (Boom) Suction valve (Boom) Spool (Boom) Pressure compensation valve R (Boom)
NN12. Pressure compensation valve F (Service) NN13. Safety-suction valve NN14. Safety-suction valve NN15. Spool (Service) NN16. Pressure compensation valve (Service) NN17. Safety-suction valve NN18. Pressure release plug F: R:
Flow control valve Pressure reducing valve
50-135
50 Disassembly and assembly Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of work equipment PPC valve assembly (For boom, bucket, arm, swing control)
1
Disassembly 1.
Remove nut (13), then remove disc (12), nut (11) and boot (15).
2.
Remove bolts, then remove plate (5). a Do not remove joint (10) unless it is to be replaced.
3.
Remove seal (16) and collar (17).
4.
Pull out piston (8), and remove retainer (18), springs (7), (6) and (5), and shim (4). a Spring (6), (5) and spring (7), (5) consists of each one of two types of springs with different installed loads in four places, so check the mounting position (oil pressure port) and mark with tags to prevent mistakes when installing.
5.
Pull out valve (19) from body (1). a Do not remove plugs (2), (3).
50-136
PC128US-8
50 Disassembly and assembly Disassembly and assembly of work equipment PPC valve assembly
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 (G2LI) to its outside and the inside of the body hole.
4.
Install spring (5) with its small diameter side on the shim (4) side. q Diameter of spring (Inside diameter) Small diameter side: ø4.9, Large diameter side: ø5.4
5.
When installing springs (6) and (7), note that they are different and they must be installed to different hydraulic ports. q Installed height: 34 mm (Common to both springs) q Installed load: Spring (6) (P1, P2): 29 N {3 kg} Spring (7) (P3, P4): 17.7 N {1.8 kg} 3 Bolt (9): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
PC128US-8
50-137
50 Disassembly and assembly Disassembly and assembly of work equipment PPC valve assembly
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
50-138
9.
Installation of disc (12) 1) Install disc (12) so that each bolt (9) will be the center of each side of disc (12) and they will not interfere with each other during compound operation. (Error: ± 3 °) 2) When installing disc (12), adjust it so that the play of the lever end will be 0.5 – 3 mm (at 200 mm from the center of rotation of the lever). 3) Fixing disc (12) with [1], tighten nut (13). a At this time, give play to body (1) or plate (14) and lock with [2]. 3 Nut (13): 93.1 – 112.7 Nm {9.5 – 11.5 kgm}
PC128US-8
50 Disassembly and assembly Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
1
Disassembly 1.
Remove screw (13) to remove lever (9).
2.
Remove pin (5) from plate (8), and remove the plate (8) from the lever (9).
3.
Remove mounting bolt (15) to remove case shaft assembly (17).
4.
Remove shaft (6) from the case.
5.
Remove lever (7), bushing (4) and pin (5) from the case.
6.
Remove mounting bolt (16) to remove plate (18) together with damper assembly (19). a Check the thickness and the mounting position of washer (10).
7.
Remove mounting bolt (12) to remove damper assembly (19) from plate (18).
8.
Remove seal (20) and collar (21).
9.
Remove piston (1) to remove retainer (22), springs (23) and (2) and shim (3). a Store shim (3) after checking the thickness and the number of shims at each mounting position.
10. Remove valve (24) from body (25). a Do not remove plug (11).
PC128US-8
50-139
50 Disassembly and assembly Disassembly and assembly of travel PPC valve assembly
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 (G2LI) to its outside and the inside of the body hole.
2.
Install spring (2) with its small diameter side on the shim (3) side. q Diameter of spring (Inside diameter) Small diameter side: 4.9, Large diameter side: 5.55
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°.) q 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} q Bolt (12): 3.9 – 4.9 Nm {0.4 – 0.5 kgm} (Apply LOCTITE #262.) q Screw (13): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} q Plug (14): 4 – 9 Nm {0.4 – 0.9 kgm} q Bolt (15): 25 – 30 Nm {2.5 – 3.2 kgm} q Bolt (16): 27 – 34 Nm {2.8 – 3.5 kgm} q
50-140
PC128US-8
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly
1
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. 1] Set piston rod assembly (2) on tool U1.
1 2
3
U
4
5 6
790-502-1003
Repair stand
t 1
790-101-1102
Pump
t 1
790-102-4300
Wrench assembly t 1
790-201-4310
Pin
t 1
790-201-1702
Push tool (Kit)
t 1
790-201-1791
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
790-201-1702
Push tool (Kit)
790-201-1811
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1702
Push tool (Kit)
790-201-1821
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1500
Push tool (Kit)
790-201-1610
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1500
Push tool (Kit)
790-201-1620
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1500
Push tool (Kit)
790-201-1630
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-720-1000
Expander
t 1
796-720-1660
Ring
t 1
07281-01159
Clamp
t 1
PC128US-8
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
1 t 1
t 1
q 1
q 1
q 1
50-141
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
2]
50-142
Remove piston assembly lock screw (3). Screw size M12 x 1.75 pitch: Boom, arm and blade M10 x 1.5 pitch: Bucket
4] 5] 6]
7]
a
If screw (3) is caulked too tightly to be removed, force the screw in once and then tap it to remove it.
3]
Use tool U2 to remove piston assembly (4). q If tool (U2) is not used, use the four drill holes (diameter = 10) to loosen the piston assembly.
2.
Remove plunger (5). q Arm cylinder and boom cylinder. Remove collar (6). q Arm cylinder and boom cylinder. Remove the head assembly (7).
Remove cap (8) to remove eleven balls (9) and cushion plunger (10). q For the arm cylinder only. a Since cap (8) is made of nylon, tighten a screw into it and pull it out with pliers.
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).
PC128US-8
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
3.
Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).
Assembly a a
1.
PC128US-8
Be careful not to damage the packing, the dust seal, the O-ring or the like Do not forcibly insert the backup ring but make it warm with hot water (50 to 60°C) before insertion. Sub-assembly of cylinder head assembly 1) Press fit bushing (20) using tool (U3). 2) Engage buffer ring (19). 3) Engage rod packing (18). 4) Mount dust seal (17) using tool (U4) and fix it with snap ring (16). 5) Mount the backup ring and O-ring (15).
50-143
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
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) 4) 5)
3.
Mount the backup ring and O-ring (14). Engage wear ring (12). Engage ring (11). a Be careful not to expand the ring abutment joint too much. 2 Ring groove: Grease (G2-LI)
Piston rod assembly 1) Set piston rod assembly (2) on tool (U1).
50-144
2) 3)
4)
5)
6)
Assemble head assembly (7). Fit O-ring and backup ring to collar (6), and assemble. q Arm cylinder and boom cylinder. Assemble plunger (5). q Arm cylinder and boom cylinder. a Check that there is a small amount of play at the tip of the plunger.
Set cushion plunger (10) on the piston rod and engage 11 balls (9) and fix them using cap (8). q For the arm cylinder only. Assemble piston assembly (4) in the following procedure. q When the rod and piston assembly (2) are reused a Completely wash them and clear them of cut powder or dust. 1] Screw piston assembly (4) and tighten it using tool U2 until the screw hole position completely fits. a Eliminate screw burrs using a file or the like. 2] Tighten screw (3). 2 Screw (3): LOCTITE No. 262 3 Screw (3) : Boom, arm and blade : 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} Bucket: 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
PC128US-8
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
2]
3]
q
Caulk the screw at two points through punching.
Cylinder
Tap drill diameter
Boom, arm and blade
10.3
27
12 x 1.75
20
Bucket
8.5
27
10 x 1.5
20
3] 4]
When new rod or/and piston assembly (2) is/are used a For the bottom cushion-equipped rod, mark the cap hole (8) on the rod end surface. q For the arm cylinder only. 5]
1]
Drill a hole for mounting screw (3). a Engage the drill with the screw Vshaped grooves of piston (4) and rod (2) for horizontal processing. a Process the bottom cushionequipped cylinder (arm cylinder) on other part than the cap hole (8). Tap drill depth Tap used
Tap depth
Clear it of cut powder and dust and completely wash it after processing. Tighten screw (3). 2 Screw thread: LOCTITE No. 262 3 Screw (3) : Boom, arm and blade : 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} Bucket: 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm} Caulk the screw at four points through punching.
Screw piston assembly (4) until it comes in contact with rod (2) end surface (a). 3 Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm} a q
PC128US-8
After tightening the piston, make sure that there is some play with plunger. For the boom and arm cylinders only.
50-145
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
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 :
9)
50-146
Cylinder
Tightening torque
Bucket
172 ± 25 Nm {17.5 ± 2.5 kgm}
Arm
270 ± 39 Nm {27.5 ± 4.0 kgm}
Boom
172 ± 25 Nm {17.5 ± 2.5 kgm}
Blade
270 ± 39 Nm {27.5 ± 4.0 kgm}
Mount the piping.
PC128US-8
50 Disassembly and assembly Removal and installation of work equipment assembly
Disconnect working lamp wiring connector (6) and clamp (7).
Removal and installation of work equipment assembly 1
4.
Remove guard (8).
Special tools
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).
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.
Symbol
V 1
Part No.
Part name
792-785-1100
Remover
t 1
796-270-1110
• Adapter
1
790-101-4000
Puller (490 kN {50 ton})
1
790-101-1102
Pump
1
New/Remodel
3.
Necessity Q'ty
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. k Disconnect the cable from the negative (–) terminal of the battery. 1.
2.
Remove handrail (1), then remove covers (2) and (3). Remove undercovers (4) and (5) from boom mounting section.
[*1]
10. Remove plug (17) from boom foot pin (19). 11. Remove mounting bolts to remove lock plate (18).
PC128US-8
50-147
50 Disassembly and assembly Removal and installation of work equipment assembly
12. Set tool V to boom foot pin (19).
Installation q
Carry out installation in the reverse order to removal.
[*1] a When tightening the locknut, tighten so that the clearance (a) between the plate and nut is 0.5 – 1.5 mm.
13. Sling work equipment assembly(20) slightly,then remove pin(19) by using tool V. [*3] a Lift off work equipment assembly from revolving frame by using crane. 4 Work equipment assembly: 1,860 kg
[*2]
2 Inside surface of bushing when assembling
pin: Molybdenum disulphide lubricant (LM-P) 2 Grease after assembling pin : Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust the shim thickness so that clearance (b) between cylinder rod (21) and plate (22) is less than 1 mm. a Standard shim thickness: 1.0 mm
50-148
PC128US-8
50 Disassembly and assembly Removal and installation of work equipment assembly
[*3]
2 Inside surface of bushing when assembling
pin : Molybdenum disulphide lubricant (LM-P) 2 Grease after assembling pin : Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the pin hole. a Adjust the shim thickness so that clearance (c) between boom (23) and bracket (24) is less than 0.5 mm. a Standard shim thickness: 0.5, 1.0, 2.0 mm
q
Bleeding air Bleed the air. For details, see Testing and adjusting, "Bleeding air from hydraulic cylinder".
q
Refilling with oil (hydraulic tank) Run the engine to circulate the oil through the system. Then add oil to the specified level.
PC128US-8
50-149
50 Disassembly and assembly Removal and installation of operator cab assembly
Cab and its attachments Removal and installation of operator cab assembly
7.
Remove cover (11).
8.
Remove cover (12) and duct (13).
9.
Disconnect cover (14).
1
Removal
k Park the machine on a level place and lower
the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. k Disconnect the negative (–) terminal of the batterybeforehand. 1.
Remove floor mat (1).
2.
Remove machine monitor (2), referring to "Removal and installation of machine monitor assembly."
3.
Remove covers (3) to (6). a When removing cover (5), simultaneously remove cigar lighter wiring connector that attached to the back of the cover.
4.
Remove ducts (7) and (8).
5.
Loosen R.H. console (9) and shift toward the inside.
10. Remove cover (15).
11. Disconnect KOMTRAX antenna cable (16). 12. Disconnect wiring connectors (17) to (21).
6.
Disconnect window washer hose (10).
50-150
PC128US-8
50 Disassembly and assembly Removal and installation of operator cab assembly
13. Removal of operator cab mounting bolts and nuts. 1) Remove 6 mounting bolts (22b) (marked with *) and 4 nuts (22n) (marked with #) from inside the operator cab. a Nuts (22n) tightens floor frame together.
14. Lift and remove operator cab assembly (27). a Before removing the operator cap assembly, make sure that all wiring and piping are disconnected. 4 Operator cab assembly: 380 kg
Installation 2)
Remove L.H. side cover (23).
3)
Remove lock plate mounting bolt (24) and remove plate (25). Remove cab tip-over stopper mounting bolt (26).
4)
PC128US-8
q
Carry out the installation in the reverse order of removal.
50-151
50 Disassembly and assembly Removal and Installation of operator's cab door
Removal and Installation of operator's cab door
1
This section describes only caution at the installation of operator's cab door. 1.
Confirm that the level difference between cab side face and door side face is within ± 3 mm when closing the door. a If it is not maintained within ± 3 mm, adjust the mounting position of the upper roller (2) by moving it to left or right direction (3) of the machine. 3 Upper roller mounting bolt: 34 – 74 Nm {3.5 – 7.5 kgm}
2.
Confirm the clearance (4) between cab and door is within 5 mm ± 2 mm. a If it is not maintained within 5 mm ± 2 mm, adjust the mounting position of the center roller (5) by moving it to front or rear direction of the machine. 3 Center roller mounting bolt: 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
3.
Confirm the step (6) of door is within ± 3 mm. a If it is not maintained within ± 3 mm, adjust the mounting position of the center roller (5) by moving it to upward or downward direction.
4.
Check that there is a clearance (8) between cab and lower bracket (7). a If cab interferes with lower bracket, adjust the mounting position of the lower bracket by moving it to downward direction. 3 Lower bracket mounting bolt: 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
5.
Confirm the stopper (9) is in tight contact with the door inside face (11) when the door is closed. a Deflection of the stopper is approximately 0.5 mm. a If the stopper is not in tight contact with the door inside face, loosen the nut (10) to adjust the position of the stopper, and tighten it again. 3 Stopper mounting screw: 59 – 74 Nm {6 – 7.5 kgm}
50-152
PC128US-8
50 Disassembly and assembly Removal and Installation of operator's cab door
6.
7.
8.
Check that the center of the striker (12) is engaged into the groove center (13) of the lock assembly when the door is locked. a If the center of the striker is not engaged into the groove center of the lock assembly, adjust the mounting position of the striker. 3 Striker mounting bolt: 54 – 74 Nm {5.5 – 7.5 kgm}
Check that the upper and lower dove tails (14a) (14b) on the front side of the door get fixed at the same time, when closing the door. a If these dove tails do not get fixed at the same time, adjust the mounting position of the dove tails. Check that the upper and lower dove tails (14c) (14d) on the rear side of the door get fixed at the same time, when closing the door. a If these dove tails do not get fixed at the same time, adjust the mounting position of the dove tails. 3 Dove tail mounting bolt: 9.8 – 14.7 Nm {1 – 1.5 kgm} 2 Dove tail mounting bolt: Liquid adhesive (LT-2)
PC128US-8
9.
Check that there is no clearance between door trim and cab when the door is closed.
10. Confirm that the door opening or closing is smooth and there is no backlash when opening or closing the door. 11. Confirm that the latch can be locked when upper and lower dove tails are fixed, when opening the door. a If the latch can not be locked, adjust the mounting position of the rear striker (15).
12. Check that the stopper (16) contacts with center portion of the catcher (17) mounted on door side. a If center is misaligned, loosen the nut while latch is locked, adjust the mounting position of stopper to left or right direction (18) of the machine, align the center and tighten the nut at the position where the deflection of the stopper is 2 mm. 3 Stopper mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
50-153
50 Disassembly and assembly Removal and Installation of operator's cab door
13. Open and close the door to check abnormal noise or interference, and confirm that the door can be opened and closed smoothly and easily. 14. Apply grease to the rails of upper, middle and lower portions, and dove tails on the front and rear, and the stopper. 2 Grease (G2-LI)
50-154
PC128US-8
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
Removal and installation of operator's cab glass (stuck glass)
a
Amoung the panes of window glass on the 4 sides of the operator’s 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 operator’s cab.) For the procedure for replacing the front window assembly, see "Removal and installation of front window assembly".
PC128US-8
1
( 1 ): Right side window glass ( 2 ): Left side rear window glass ( 3 ): Door upper window glass ( 4 ): Door lower window glass ( 5 ): Front window glass ( 6 ): Front window assembly (Front window glass + Front frame) ( 7 ): Both-sided adhesive tape (16): Center trim seal
50-155
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
a
X
Part name
1
793-498-1210
Lifter (Suction cup) t 2
2
20Y-54-13180
Seat
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 2
a
If the window glass is broken finaly, it may be removed with knife [4] and a screwdriver. Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4].
(The figure shows the operator’s cab of a wheel loader.)
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 operator’s cab (metal sheet) (8).
2.
a
Remove the window glass.
If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.
(The figure shows the operator’s cab of a wheel loader.)
50-156
PC128US-8
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
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 operator’s cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfac e s. ( If th e pai nt ed s ur f ac es ar e scratched, adhesion will be lowered.) (The figure shows the operator’s cab of a wheel loader.) 3.
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-8
Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Disc ar d t h e p r i m e r 2 4 ho u r s a ft e r i t i s packed.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a dry before stirring it. (If the primer is unpacked just after taken out of the refrigertor, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.
50-157
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
3)
a q
50-158
a
Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator’s 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.)
Parts to be coated with primer: Apply the primer all over dimension (a). Dimension to apply primer (a): 25 mm
a a
4)
As for right side window glass (1), apply the primer to only the periphery of the glass to stick the both-sided adhesive tapes and the areas out of it to apply the adhesive. q Part (b) After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. Never apply wring primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
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.)
PC128US-8
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
a
a
a a
Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (7) and operator’s cab (8). Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. After applying the primer, leave it for at least 5 minutues (within 8 hours) to dry. Never apply wring the primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
a
1)
a q
4.
Stick both-sided adhesive tape (7) along the inside edge of the glass sticking section. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before stiking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.
PC128US-8
2)
When sticking both-sided adhesive tape (7) around a frame, do not lap its finishing end over the starting end but make clearance e of about 5 mm between them. Stick both-sided adhesive tape (7) for right side window glass (1) as shown in the figure.
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
Stick both-sided adhesive tape (7) for left side rear window glass (2) as shown in the figure.
50-159
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
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)
50-160
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
q
5.
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).
Possition the new window glass. 1) Check the clearance between the window glass and the operator’s cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operator’s 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 operator’s cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator ’s cab before installing the window glass.
PC128US-8
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
a
6.
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.
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 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part from the nozzle tip.
PC128US-8
1)
Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
2)
Cut the tip of the adhesive nozzle (14) so that dimension (q) and r will be as follows. q Dimension (q): 10 mm q Dimension (r) : 15 mm
3)
Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.
50-161
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
4) 5)
Remove the release tape of the bothsided adhesive tape on the glass side. Apply adhesive (15) to the outside of bothsided adhesive tape (7) of the operator’s cab.
a
a a
a
50-162
Apply adhesive (15) to dimensions s and t of both-sided adhesive tape (7) of operator’s cab (8). q Dimension (s): 10 mm q Dimension (t) : 15 mm Apply adhesive (15) higher than bothsided adhesive tape (7). Apply the adhesive evenly.
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 operator’s cab with suction cup X1. (The figure shows the operator's cab of PC200-7.)
As for the right side window glass, apply the adhesive to the outside of the both-sided adhesive tape on the periphery of the glass.
PC128US-8
50 Disassembly and assembly Removal and installation of operator's cab glass (stuck glass)
a
After installing front window glass (5), install the center trim seal to its bottom. Then, apply caulking material all a r ou nd t he g la s s to fi ll par t ( U) between the glass and center trim seal. a When caulking, neatly arrange the form of the adhesive at the right and left ends with a rubber spatula. 2 Adhesive: Sikaflex 256HV manufactured by Sika Japan
(The figure shows the operator's cab of PC2007.)
2)
Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape of fit them completely. (The figure shows the operator's cab of PC2007.)
9.
8.
Fix the window glass. 1) After installing right window glass (1) to the operator’s cab, insert seat 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-8
After installing the window glass, remove the primer and adhesive from the operator’s 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 20°C 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.
50-163
50 Disassembly and assembly Removal and installation of front window assembly
Removal and installation of front window assembly 1 k Lower
a
the work equipment to the ground and stop the engine. To replace the front window glass, the front window assembly must be removed from the operator’s 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).
2.
Remove left lower block (1) and right lower block (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.
50-164
Installation q
Carry out installation in the reverse order to removal.
PC128US-8
50 Disassembly and assembly Removal and installation of floor frame assembly
Removal and installation of floor frame assembly 1
1.
Remove lower cover (1).
2.
Open the coolant drain valve (2) and drain coolant. 6 Coolant: 12.4 l
3.
Removal of exterior parts 1) Remove handrail (2). 2) Remove covers (3) and (4).
X 3
Part name
799-703-1200
Service tool (Kit)
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1111
Vacuum pump (220V)
t 1
799-703-1121
Vacuum pump (240V)
t 1
799-703-1401
Gas leak detector
t 1
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Removal
k Park the machine on a level place and lower
the work equipment stably to the ground. Stop the engine and set the lock lever to locked position. k Release the remaining pressure from the hydraulic circuit, referring to "Bleeding residual pressure from hydraulic circuit" in Testing and adjusting. k Disconnect the negative (–) terminal of the battery beforehand. a
Fasten tags to respective connecters and piping for identification to prevent any mistakes when re-installing.
PC128US-8
50-165
50 Disassembly and assembly Removal and installation of floor frame assembly
3)
4.
Remove covers (111), (112) and (113).
Disconnecting wiring and hoses around the solenoid valve 1) Disconnect bucket damp solenoid wiring connector V10 (5) and travel alarm M14 (6).
50-166
2)
3)
4)
Disconnect wiring connectors (8) to (16) around the solenoid valves connected to wring (7). (8) : V01 (PPC basic pressure) (9) : V02 (Travel HI/LO) (10): V03 (Swing paring brake) (11) : V04 (Travel junction valve) (12): V05 (Merge-divider valve selection signal) (13): P25 (Pump pressure sensor) (14): P26 (Travel right rear pressure sensor) (15): P27 (Travel left rear pressure sensor) (16): P29 (Dummy) Remove wiring mounting clamp and disconnect wiring (7) from solenoid valve mounting frame assembly (17). Disconnect PPC basic pressure hose (18) (color band: Red-Green).
PC128US-8
50 Disassembly and assembly Removal and installation of floor frame assembly
5.
Disconnecting pressure switch and pressure sensor connector wiring 1) Disconnect wiring connectors (20) to (29) connected to wiring (19). (20): P01 (Bucket dump switch) (21): P02 (Arm dump switch) (22): P03 (Boom raise switch) (23): P04 (Bucket digging switch) (24): P05 (Boom digging switch) (25): P06 (Boom lower switch) (26): P07 (Right swing switch) (27): P08 (Left swing switch) (Multi-valve-installed machine) (28): P67 (Right swing switch) (Multi-valve-installed machine) a Connector P67 is connected to connector P07. a For a machine without the multivalve, connector P08 is positioned under P07 of the pressure switch connector mounting bracket. (29): P12 (Pressure sensor) 2)
Remove wiring mounting clamps and disconnect wiring (19) from the pressure switch connector mounting bracket (30).
6.
Disconnection of control valve assembly wiring and hoses (R.H. side of control valve-inspection cover side-) 1) Disconnect hose (31) to the attachment. (Machine with the attachment) (Band color: Blue-Blue) 2) Disconnect wiring connectors (32) to (34). (32): P64 (Bucket digging switch) (33): P65 (Arm digging switch) (34): P66 (Boom lower switch)
3)
4)
PC128US-8
Disconnect wiring connectors (35) and (36). (35): P26 (Right travel reverse) (36): P27 (Left travel reverse) Disconnect hoses (37) and (38). (37): (Yellow-Green) (Right travel reverse) (38): (Yellow-Orange) (Left travel reverse)
50-167
50 Disassembly and assembly Removal and installation of floor frame assembly
(Operator cab side) 5) Disconnect wiring connectors (39) to (41). (39): P61 (Bucket dump switch) (40): P62 (Arm dump switch) (41): P63 (Boom raise switch) 6) Disconnect hose (42) to the attachment. (Machine with the attachment) (Color band: Red-Red)
7)
8)
50-168
Disconnect travel switch connectors (38) and (39). (43): (Black-Yellow) (44): (Brown-Yellow) Disconnect travel motor hoses (40) and (41). (Color band) (45): (Black-Yellow) (46): (Brown-Yellow)
7.
Disconnect 8 hoses (47) to (54) from the operation pattern select valve assembly. (Machine with the select valve) (From the upper side of operator cab) (47): Brown (Swing right) (48): Green (Arm digging) (49): White (Swing left) (50): Orange (Arm dump) (From the upper side of the hydraulic tank) (51): Yellow (Boom raise) (52): Black (Boom lower) (53): Red (Bucket dump) (54): Blue (Bucket digging) a For a machine without the operation pattern select valve, disconnect 8 hoses installed in the following order from the top to the solenoid valve installation frame as s hown i n Procedure 4- 4 (Photo No. CPP15287). Red (Bucket dump) Orange (Arm dump) Yellow (Boom raise) Blue (Bucket digging) Green (Arm digging) Black (Boom lower) White (Swing left) Brown (Swing right)
PC128US-8
50 Disassembly and assembly Removal and installation of floor frame assembly
8.
Disconnect PPC drain hose (55).
12. Disconnect buzzer wiring connector (60). 13. Disconnect buzzer wiring clamp (61) and disconnect the buzzer wiring.
9.
Disconnect wiring A13 (56) and A08 (57). a
How to remove clamp (61) Hold a flat-head screwdriver [1] to section (a) and push it downward. Simultaneously br ing whole clamp (61) upwar d and unhook it from plate (b).
10. Disconnect boom bottom pressure sensor connector P46 (58). 11. Disconnect wiring clamp (59) and disconnect the wiring.
PC128US-8
50-169
50 Disassembly and assembly Removal and installation of floor frame assembly
14. Remove operator cab assembly, referring to "Removal of operator cab assembly." 15. Disconnecting floor lower wiring and clamps 1) Disconnect wiring and hose clamps (62) to (73).
2) 3) 4)
5)
50-170
Disconnect air conditioner Hi-Lo pressure switch wiring connector (74). Disconnect air conditioner hoses (75) and (76). Disconnect heater hoses (77) and (78).
Pull out wiring lock pad (79) and draw out wiring (80).
PC128US-8
50 Disassembly and assembly Removal and installation of floor frame assembly
6)
Disconnect grounding wire (81).
Installation q
16. Lift and remove floor frame assembly (82). a Before lifting the floor frame assembly, check that every wiring connector and clamp is disconnected. a Pull out the control valve wiring while lifting floor frame assembly (82) little by little. a When pulling out the wiring on the control valve side, it may catch obstacles on the way to resist smooth removal. Do not pull by force. Manage to evade obstacles patiently. 4 Floor frame assembly: Approx. 210 kg
PC128US-8
Carry out the installation in the reverse order of removal.
[*1] a Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. a Make sure that O-ring is installed to the pipe joint section of the air conditioner hoses before installing a Check the O-ring for scratches or degradation. a When installing O-ring, apply the compressor oil (Denso: ND-OIL8 or ZEXEL: ZXL100PG (PAG46 or equivalent)). 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm} q
Filling of air conditioner gas Fill the air conditioner circuit with the air conditioner gas (R134a). a Filling capacity: 800 (+50/0) g
50-171
50 Disassembly and assembly Removal and installation of air compressor assembly
Electrical system
Installation
Removal and installation of air compressor assembly
q
1
Special tools
X 3
[*1]
Part name
799-703-1200
Service tool (Kit)
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1111
Vacuum pump (220V)
t 1
799-703-1121
Vacuum pump (240V)
t 1
799-703-1401
Gas leak detector
t 1
Q'ty
Part No.
New/Remodel
q
Necessity
Symbol
Carry out the installation in the reverse order of removal.
a a
q
Precautions when installing piping Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. When jointing the air conditioner piping, apply compressor oil (Denso ND-01L8 equivalent) to the threaded portions. 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm} Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a).
[*2]
3 Air compressor mounting bolt:
24.5 – 29 Nm {2.5 – 3.0 kgm}
Removal k Stop
the machine on a level place and lower the work equipment to the ground. Stop the engine and set the lock lever to locked position. k Disconnect the negative (–) terminal of the battery beforehand. k Bleed the air conditioner gas using the special tool. 1.
Disconnect wiring connector AC02 (1).
2.
Disconnect air conditioner pipes (2) and (3). [*1]
3.
Loosen drive belt tension adjust bolt (4).
4.
Remove drive belt protective cover (6).
5.
Remove drive belt protective cover (6).
6.
Remove drive belt (7).
7.Remove mounting bolts (8) and remove air compressor assembly (9). [*2]
50-172
PC128US-8
50 Disassembly and assembly Removal and installation of air conditioner condenser
Removal and installation of air conditioner condenser
X 3
799-703-1200
Service tool (Kit)
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1111
Vacuum pump (220V)
t 1
799-703-1121
Vacuum pump (240V)
t 1
799-703-1401
Gas leak detector
t 1
Q'ty
Part name
Removal k Lower
the work equipment to the ground completely. k Remove the negative (–) terminal from the battery. 1.
Collect air conditioner gas (R134a) from air conditioner circuit.
2.
Remove air cleaner cover (1) and remove the element.
3.
Loosen bolts and remove the wire harness clamp (2).
PC128US-8
5.
Remove 4 bolts and remove condenser (4).
New/Remodel
Necessity
Part No.
Disconnect 2 hoses (3). a Put blind caps to prevent the entry of dirt or water into hoses and compressor.
1
Special tools Symbol
4.
Installation q
Carry out installation in reverse oder to remaval.
q
Filling air-conditioning gas Using tool X3, charge air conditioner gas (R134a) to air conditioner circuit.
50-173
50 Disassembly and assembly Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner unit assembly
X 3
799-703-1200
Service tool (Kit)
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1111
Vacuum pump (220V)
t 1
799-703-1121
Vacuum pump (240V)
t 1
799-703-1401
Gas leak detector
t 1
Q'ty
Part name
New/Remodel
Necessity
Part No.
Removal
k Park the machine on a level place and lower
the work equipment to the ground. Stop the engine and set the lock lever to locked position. k Disconnect the negative (–) terminal of the battery beforehand. k Bleed the air conditioner gas using the special tool. 1.
Disconnect wiring connector (2) of the air conditioner high and low pressure switch.
3.
Disconnect air conditioner hoses (3) and (4). [*1]
4.
Disconnect heater hoses (5) and (6).
5.
Remove floor mat (7).
6.
Remove machine monitor (8), referring to "Removal and installation of machine monitor assembly."
7.
Remove covers (9) to (12). a When removing cover (11), simultaneously remove cigar lighter wiring connector that attached to the back of the cover.
8.
Remove ducts (13) and (14).
1
Special tools Symbol
2.
Remove side cover (1).
50-174
PC128US-8
50 Disassembly and assembly Removal and installation of air conditioner unit assembly
9.
Remove cover (15).
10. Remove cover (16).
14. Remove cover (23).
15. Remove 3 cover mounting bolts (24) on the left and right.
11. Remove duct (17). 12. Remove covers (18) and (19).
16. Lift cover (25) using 3 forcing bolts [1].
13. Disconnect connectors (20), (21) and (22) and disconnect the wiring clamps.
PC128US-8
17. Remove 3 air conditioner unit mounting bolts (26) in front and rear, and remove air conditioner unit (27).
50-175
50 Disassembly and assembly Removal and installation of air conditioner unit assembly
Installation q
Carry out the installation in the reverse order of removal.
[*1] q
a
q
Precautions when installing piping Care must be exercised in the installation so that dusts, dirt or water may not enter the hose of the air conditioner circuit. Filling of air conditioner gas Using tool X3, fill the air conditioner circuit with the air conditioner gas (R134a). a Filling capacity: 800 (+50/-0) g
50-176
PC128US-8
50 Disassembly and assembly Removal and installation of machine monitor assembly
Removal and installation of machine monitor assembly
1
3.
Disconnect connector (3) to (5).
4.
Remove 3 mounting bolts (6) and remove machine monitor assembly (7).
Removal
k Disconnect the negative (–) terminal of the
battery beforehand. 1.
Remove the 2 mounting bolts and cover (1). a One of the mounting bolts is installed inside the cap on the right of the daylight sensor. a While removing cover (1), simultaneously disconnect wiring connector P31 of the daylight sensor. a A level gauge is installed to the top of the monitor panel on the machine of arm crane specifications. Remove the level gauge.
Installation q
2.
Carry out the installation in the reverse order of removal.
Remove duct (2).
PC128US-8
50-177
50 Disassembly and assembly Removal and installation of pump controller assembly
Removal and installation of pump controller assembly 1 Removal
k Disconnect the negative (–) terminal of the
5.
Disconnect wiring (5) and (6). a Pull each connector lever (a) and (b) inward.
6.
Remove 4 mounting bolts (7) and 2 mounting bolts (8), and remove pump controller assembly (9).
battery beforehand. 1.
Remove cover (1).
2.
Remove cover (2).
3.
Remove duct (3).
4.
Remove cover (4).
Installation q
50-178
Carry out the installation in the reverse order of removal.
PC128US-8
50 Disassembly and assembly Removal and installation of engine controller assembly
Removal and installation of engine controller assembly
Installation
1
Removal
k Disconnect the negative (–) terminal of the
battery beforehand. 1.
Open the engine hood.
2.
DReferring to "Removal and installation of air compressor assembly," disconnect air conditioner compressor (1). a Do not disconnect the air conditioner hoses from the air conditioner compressor.
3.
Remove wiring connectors CE01 (2), CE02 (3) and CE03 (4). [*1]
4.
Remove mounting bolts (5) and remove engine controller (6).
PC128US-8
q
Carry out the installation in the reverse order of removal.
[*1]
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
50-179
50 Disassembly and assembly Removal and installation of KOMTRAX communications module
Removal and installation of KOMTRAX communications module
1
5.
Disconnect wiring connector CK02 (5), CK01 (6) and antenna (7).
6.
Remove 4 mounting bolts (8) and remove KOMTRAX communications module (9).
Removal
k Disconnect the negative (–) terminal of the
battery beforehand. 1.
Remove cover (1).
Installation q
2.
Remove cover (2).
3.
Remove duct (3).
4.
Remove cover (4).
50-180
Carry out the installation in the reverse order of removal.
PC128US-8
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC128US-8
Machine model
Serial number
PC128US-8
20001 and up
90 Diagrams and drawings
1
PC128US-8
90-1
90 Diagrams and drawings
Contents Hydraulic diagrams and drawings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
90-3
Symbols used in hydraulic circuit diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
90-3
Hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
90-5
Electrical diagrams and drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
90-9
Symbols used in electric circuit diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
90-9
Electrical circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
90-13
Connectors table and arrangement drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
90-25
90-2
PC128US-8
90 Diagrams and drawings Symbols used in hydraulic circuit diagrams
Hydraulic diagrams and drawings Symbols used in hydraulic circuit diagrams Symbol
Substance Main piping line Pilot or drain line Flexible pipe (hose, etc.) Lines intersecting without joining Lines joining (junction with a round black mark) Direction of flow Throttle in passage. Variable Electricity Spring Take-off port Take-off port and pressure gauge Check valves Suction (with strainer) Tank and return pipe Filter
Oil cooler Stop valve
Drive shaft䋨unidirectional䋩
Drive shaft䋨bidirectional䋩
PC128US-8
90-3
90 Diagrams and drawings Symbols used in hydraulic circuit diagrams
Symbol
Substance Pump Note : Black triangle shows outlet port䋩
Variable capacity hydraulic pump Hydraulic motor (The figure shows bidirectional type.) Note䋺Two black triangles in the figure show direction of oil entering hydraulic motor 㩷㩷㩷㩷㩷㩷㩷㩷㩷depending on the oil entry port, the direction of rotation is reversed. Servo piston PPC valve
Control valve Single-acting solenoid
Hydraulic pilot valve
Hydraulic two-stage pilot valve
Lock valve
Drain valve
Pressure regulator valve/ Safety valve/ Abnormal pressure prevention valve Pressure regulator valve/Safety valve/ Abnormal pressure prevention valve 䋨When the figure shows air pressure, being released to atmosphere.䋩 Bypass valve
Accumulator
Cylinder
Component group
90-4
PC128US-8
Hydraulic circuit diagram PC128US-8
PC128US-8
Hydraulic circuit diagram PC128US-8
90-5
Hydraulic circuit diagram PC128US-8 (Blade specification and machine ready for attachment)
PC128US-8
Hydraulic circuit diagram PC128US-8 (Blade specification and machine ready for attachment)
90-7
90 Diagrams and drawings Symbols used in electric circuit diagrams
Electrical diagrams and drawings Symbols used in electric circuit diagrams Symbol
Substance
Electric wire
Electric wire 䋨Wires intersecting without connecting䋩
Electric wire 䋨Wires intersecting and connecting (junction) with a round black mark 䋩 Electric wire (Bundled drawing style)
Terminal
Chassis ground
Chassis ground using terminal
Contact Switch Push-button type switch (N.O. type) *N.O.: Normally Open Push-button type switch (N.C. type) *N.C.: Normally Close Pull-button type switch (N.O. type) *N.O.: Normally Open Pull-button type switch (N.C. type) *N.C.: Normally Close
Variable
Resistance (resistor)
Variable resistance (variable resistor)
PC128US-8
90-9
90 Diagrams and drawings Symbols used in electric circuit diagrams
Symbol
Substance
Diode
Light emitting diode (LED)
Photo diode
Constant voltage diode (Zener diode)
Transistor (PNP type)
Transistor (NPN type)
Coil
Battery
Fuse
Connector 䋨Note䋩 䊶Convex side of connecting portion (right in figure): male 䊶Concave side of connecting portion (left in figure): female *Figure shows a line disconnection status.
Plug and receptacle type connector (left: male, right: female) Note: Figure shows a line connection status.
Solenoid
Motor
90-10
PC128US-8
90 Diagrams and drawings Symbols used in electric circuit diagrams
Symbol
Substance
Lamp
Pressure switch (N.O. type) *N.O.: Normally Open Pressure switch (N.C. type) *N.C.: Normally Close Potentiometer
Fuel dial
Temperature sensor
Starting switch
Backup alarm
Horn
Buzzer
Antenna
PC128US-8
90-11
90 Diagrams and drawings Symbols used in electric circuit diagrams
90-12
PC128US-8
Electrical circuit diagram (1/6)
PC128US-8
Electrical circuit diagram (1/6) PC128US-8
90-13
Electrical circuit diagram (2/6)
PC128US-8
Electrical circuit diagram (2/6) PC128US-8
90-15
Electrical circuit diagram (3/6)
PC128US-8
Electrical circuit diagram (3/6) PC128US-8
90-17
Electrical circuit diagram (4/6)
PC128US-8
Electrical circuit diagram (4/6) PC128US-8
90-19
Electrical circuit diagram (5/6)
PC128US-8
Electrical circuit diagram (5/6) PC128US-8
90-21
Electrical circuit diagram (6/6)
PC128US-8
Electrical circuit diagram (6/6) PC128US-8
90-23
Connectors table and arrangement drawing
PC128US-8
Connectors table and arrangement drawing PC128-8
Connector No.
Model
Type of connector
A08
DT-T
6
A13
DT-T
Address
Connector No.
Model
Type of connector
Intermediate connector
F-9
P32
YAZAKI
2
Air conditioner daylight sensor
H-1
2
Intermediate connector
F-9
P44
DT-T
2
Engine oil level sensor
H-9
Component name
Component name
Address
AB
Terminal
1
Alternator (Terminal B)
H-9
P61
X
2
Pressure switch(Buket dump)
-
AC01
YAZAKI
10
Air conditioner unit
AB-4
P62
X
2
-
-
AC02
X
1
Air conditioner compressor electromagnetic clutch
J-9
P63
X
2
-
-
ACC
Terminal
1
Starter switch
-
P64
X
2
-
-
AR
SUMITOMO
3
Alternator
H-9
P65
X
2
-
-
B
Terminal
1
Starter switch
-
P66
X
2
-
-
BNC
-
1
Orbcomm
-
P67
X
2
-
-
BR
Terminal
1
Starter switch
-
PAMB
AMP
3
Ambient pressure sensor
AF-5
BR
Terminal
1
Battery relay
L-7
PFUEL
BOSCH
3
Common rall pressure sensor
AG-5
C
Terminal
1
Starter switch
-
POIL
FRAMA TOME
1
Engine oil pressure switch (Low pressure)
AD-6
C01
AMP
81
CH700 controller
Z-4
PREG
BOSCH
2
Supply pump solenoid (IMV)
AD-7
C02
AMP
39
CH700 controller
Z-5
PTIM
BOSCH
4
Boost pressur/temp.
AD-8
CAN
FRAMA TOME
3
Engine Bkup speed sensor
AF-1
R1
Terminal
1
Starter switch
-
CE01
DRC
60
Engine controller
AE-9
R05
RELAY
5
Relay for light
X-9
CE02
DRC
60
Engine controller
K-9
R06
RELAY
5
Relay for Starter cut(Ppc lock)
Z-5
CE03
DTP
4
Engine controller
L-8
R07
RELAY
5
Relay for Starter cut(Personal cood)
Z-4
CK01
AMP
14
KOMTRAX communication module
AB-7
R10
RELAY
5
Relay for OPT. light
Y-8
CK02
AMP
10
KOMTRAX communication module
AA-7
R14
Terminal
1
Ribon heater relay
M-5
CM01
070
18
Machine monitor
O-6
R15
Terminal
1
Ribon heater relay
N-5
CM02
070
12
Machine monitor
O-6
R16
Terminal
1
Ribon heater relay
N-5
CM03
070
18
Machine monitor
O-5
R17
X
2
-
H-1
CM05
B60
8
Machine monitor
-
R18
Terminal
1
-
J-1
CN1
DT
2
Injector #1
AF-9
R19
Terminal
1
-
J-1
CN2
DT
2
Injector #2
AF-9
R20
RELAY
4
Blower relay
AB-4
CN3
DT
2
Injector #3
AG-9
R21
RELAY
4
Compressor relay
AB-5
CN4
DT
2
Injector #4
AG-9
R23
RELAY
5
Relay for CM2100(1)
AB-4
D01
SWP
8
Battery relay
AA-7
R24
RELAY
5
Relay for CM2100(2)
AB-4
D02
SWP
8
Ribbon heater relay/washer motor
Z-6
RB
Terminal
1
Battery relay
L-7
D03
SWP
8
Monitor light switch
Z-6
RE
Terminal
1
Battery relay
L-6
D10
-
2
Diode
AB-7
RM
Terminal
1
Battery relay
L-7
D11
-
2
Diode
AB-7
S02
SWP
6
Light switch
R-8
E01
Terminal
1
Ribbon heater
I-9
S04
SWP
6
Swing lock switch
R-8
E10
Terminal
1
Starting motor
I-9
S07
SWP
6
Beacon
S-8
F01
-
20
Fuse
X-9
S10
Y090
2
Right knob switch
Q-7
F02
L
2
Fuse(45A)
L-6
S14
M
3
PPC hydraulic lock switch
W-9
F03
L
2
Fuse(450A)
L-6
S21
-
5
Emergency pump drive switch
Y-8
F04
Terminal
1
Fuse
L-4
S22
-
5
Emergency swing parking brake release
Y-8
F05
Terminal
1
Fuse(50A)
K-1
S25
090
16
Intermediate connector
AA-7
F06
Terminal
1
Fuse(120A)
L-4
T01
Terminal
1
Floor frame
W-1
GT5
-
1
Antenna
F-1
T02
Terminal
1
Cab GND
L-5
H08
M
4
Intermediate connector
Y-5
T03
Terminal
1
GND
X-2
H09
M
8
Intermediate connector
Y-5
T04
Terminal
1
Floor frame
G-1
H15
S090
22
Intermediate connector
T-9
T05
Terminal
1
Revolving frame
G-1
H16
S
12
Intermediate connector
Y-3
T06
Terminal
1
GND
AF-5
J01
SUMITOMO
20
Junction connector (Pink)
T-9
T07
Terminal
1
GND
AE-5
J02
SUMITOMO
20
Junction connector (Pink)
U-9
T08
Terminal
1
Revolving frame
I-1
J03
SUMITOMO
20
Junction connector (Pink)
U-9
T09
Terminal
1
Revolving frame
I-1
J04
SUMITOMO
20
Junction connector (Black)
U-9
T10
Terminal
1
Revolving frame
I-1
J05
SUMITOMO
20
Junction connector (Green)
V-9
T11
Terminal
1
Revolving frame
H-1
J06
SUMITOMO
20
Junction connector (Black)
V-9
T12
Terminal
1
Revolving frame
H-1
J07
SUMITOMO
20
Junction connector (Pink)
V-9
T14
Terminal
1
Revolving frame
V-1
K01
M
2
Pump resistor
Z-7
TNC
-
1
FOMA
L-5
K02
DT-T
3
CAN terminal resistance
K-9
TWTR
PACKARD
2
Engine water temperature sensor
AE-9
L01
-
2
Working lamp (Boom)
B-9
V01
DT-T
2
PPC lock solenoid valve
C-9
L03
M
2
Cab light
I-9
V02
DT-T
2
Travel speed shifting solenoid valve
C-9
M01
PA
9
Radio
X-2
V03
DT-T
2
Swing holding brake solenoid valve
C-9
M02
M
2
Speaker(left)
J-9
V04
DT-T
2
Travel junction solenoid valve
B-8
M03
M
2
Speaker(right)
I-9
V05
DT-T
2
Confluece solenoid valve
A-8
M04
-
2
Cigar lighter
O-6
V10
DT-T
2
Bucket dump lock solenoid valve
E-9
M05
M
6
Wiper motor
"E-1,O-5"
V11
DT-T
2
PC-EPC valve
G-9
M06
KES
2
Window washer motor
K-1
V30
DT-T
2
Att current
Q-1
M07
090
2
Horn (High tone)
E-1
W03
M
2
Limit switch
J-9
M09
M
2
Optional power supply connector (1)
S-9
-
TAJIMI
8
Rear view camera
-
M10
M
2
Optional power supply connector (2)
W-2
M11
M
4
DC/DC converter
M12
M
2
12V outlet
-
M13
M
2
Optional power supply connector (12 V)
-
M14
DT-T
2
Travel alarm
D-9
M40
X
2
Head light(STD)
G-9
-
M41
X
2
Head light(OPT)
E-9
N08
DT-T
12
Service coneeector
X-9
N10
SUMITOMO
4
Air conditioner unit
AB-3
NE
FRAMA TOME
3
NE sensor
AF-1
P01
X
2
Pressure switch(Buket dump)
A-6
P02
X
2
Pressure switch(Arm dump)
A-5
P03
X
2
Pressure switch(Boom UP)
A-5
P04
X
2
Pressure switch(Buket digging)
A-5
P05
X
2
Pressure switch(Arm digging)
A-5
P06
X
2
Pressure switch(Boom down)
A-5
P07
X
2
Pressure switch(Left swing)
A-4
P08
X
2
Pressure switch(Right swing)
A-4
P09
AMP
3
-
C-1
P10
AMP
3
-
D-1
P11
AMP
3
-
D-1
P12
DT-T
6
Intermediate connector
B-1
P13
X
2
Intermediate connector
R-1
P14
X
2
Pressure switch(Service)
Q-1
P15
X
2
Pressure switch(Service)
Q-1
P17
S 090
2
A/C HI/LO pressure switch
T-1
P20
M
3
Fuel dial
Q-9
P21
X
1
Fuel level sensor
F-9
P22
DT-T
2
Hydraulic oil temperature sensor
G-9
P25
AMP
3
Pump pressure sensor
A-6
P26
AMP
3
-
A-6
P27
AMP
3
-
A-6
P28
AMP
3
-
A-1
P29
DT-T
6
Intermediate connector
A-7
P31
YAZAKI
2
Sunshine sensor
O-6
PC128US-8
90-25
Index
Index A Adjusting mirrors ..................................................... 30-54 Adjusting play of work equipment and swing PPC valves .......................................................................... 30-43 Adjusting valve clearance ....................................... 30-11 Air conditioner ....................................................... 10-160
B Before carrying out troubleshooting of electrical system ........................................................................ 40-198 Bleeding air from each part ..................................... 30-52 Bleeding air from fuel circuit.................................... 30-21
C Cab and its attachments ............... 10-160, 30-54, 50-150 Carrier roller ............................................................ 10-16 Center swivel joint ................................................. 10-136 Checking and adjusting air conditioner compressor belt tension............................................................... 30-25 Checking and adjusting track shoe tension............. 30-27 Checking cab tipping stopper.................................. 30-54 Checking exhaust gas color .................................... 30-10 Checking fuel circuit for leakage ............................. 30-23 Checking parts which cause hydraulic drift of work equipment.......................................................... 30-44 Checks before troubleshooting ............................... 40-10 Classification and procedures for troubleshooting .. 40-11 CLSS....................................................................... 10-68 Coating materials list................................................. 50-6 Connection table of connector by No. of pins ......... 40-17 Connectors table and arrangement drawing ........... 90-25 Control valve ........................................................... 10-56 Conversion table ..................................................... 00-43 Cooling system.......................................................... 10-6
D Dimensions of components................................... 10-154 Disassembly and assembly of center swivel joint assembly ......................................................... 50-113 Disassembly and assembly of control valve assembly ........................................................................ 50-126 Disassembly and assembly of hydraulic cylinder assembly ......................................................... 50-141 Disassembly and assembly of idler assembly......... 50-96 Disassembly and assembly of recoil spring ............ 50-99 Disassembly and assembly of swing motor and swing machinery assembly.......................................... 50-86 Disassembly and assembly of track roller............... 50-93 Disassembly and assembly of travel motor and final drive assembly ........................................................... 50-48 Disassembly and assembly of travel PPC valve assembly ........................................................................ 50-139 Disassembly and assembly of work equipment PPC valve assembly ......................................................... 50-136
E E-1 When starting switch turned ON, machine monitor displays nothing............................................... 40-202 E-2 When starting switch turned ON (before starting engine), basic check item lights up ................. 40-204
PC128US-8
E-3 Engine does not start (Engine does not turn) . 40-205 E-4 Preheater does not operate ............................ 40-208 E-5 Automatic warm-up system does not operate (in cold season)............................................................ 40-210 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ......................... 40-212 E-7 Precaution lights up while engine is running... 40-214 E-8 Emergency stop item lights up while engine is running ......................................................................... 40-217 E-9 Engine coolant temperature gauge does not indicate normally ........................................................... 40-218 E-10 Hydraulic oil temperature gauge does not indicate normally ........................................................... 40-219 E-11 Fuel level gauge does not indicate normally. 40-221 E-12 Contents of display by machine monitor are different from applicable machine.................................. 40-223 E-13 Machine monitor does not display some items ......................................................................... 40-223 E-14 Function switch does not work...................... 40-223 E-15 Auto-decelerator does not operate normally. 40-224 E-16 Working mode does not change ................... 40-225 E-17 Travel speed does not change ..................... 40-226 E-18 Alarm buzzer cannot be stopped .................. 40-227 E-19 Windshield wiper and window washer do not operate ......................................................................... 40-228 E-20 Swing holding brake does not operate normally ......................................................................... 40-232 E-21 Travel alarm does not sound or does not stop sounding .......................................................... 40-234 E-22 Air conditioner does not operate normally (including air conditioner abnormality record) .................. 40-235 E-23 While starting switch is in OFF position, service meter is not displayed...................................... 40-247 E-24 Machine monitor cannot be set in service mode ......................................................................... 40-247 E-25 Monitoring function does not display lever control signal normally................................................. 40-248 E-26 KOMTRAX system does not operate normally ......................................................................... 40-264 Electrical circuit diagram ........................................ 90-13 Electrical diagrams and drawings.............................. 90-9 Electrical system ...........................10-172, 30-56, 50-172 Electronic control system ...................................... 10-172 Engine and cooling system ...................10-4, 30-8, 50-15 Explanation of terms for maintenance standard...... 00-16
F Failure code [989L00] Engine controller lock caution 1 ........................................................................... 40-64 Failure code [989M00] Engine controller lock caution 2 ........................................................................... 40-64 Failure code [989N00] Engine controller lock caution 3 ........................................................................... 40-65 Failure code [AB00KE] Charge voltage low ............ 40-66 Failure code [B@BAZG] Eng oil press. low ............ 40-68 Failure code [B@BAZK] Eng oil level low ............... 40-68 Failure code [B@BCNS] Eng coolant overheat ...... 40-69 Failure code [B@HANS] Hydr oil overheat ............. 40-69 Failure code [CA111] ECM critical internal failure... 40-70 Failure code [CA115] Eng. Ne and Bkup speed sensor error ................................................................... 40-73
1
Index Failure code [CA122] Charge air press sensor high error ........................................................................... 40-74 Failure code [CA123] Charge air press sensor low error ........................................................................... 40-76 Failure code [CA131] Throttle sensor high error ..... 40-78 Failure code [CA132] Throttle sensor low error ...... 40-80 Failure code [CA144] Coolant temp. sensor high error ........................................................................... 40-81 Failure code [CA145] Coolant temp. sensor low error ........................................................................... 40-82 Failure code [CA153] Charge air temp. sensor high error ........................................................................... 40-83 Failure code [CA154] Charge air temp. sensor low error ........................................................................... 40-84 Failure code [CA1633] KOMNET datalink timeout error ......................................................................... 40-126 Failure code [CA187] Sensor sup. 2 volt. low error ........................................................................... 40-85 Failure code [CA2185] Throttle sens. sup. volt. high error ......................................................................... 40-128 Failure code [CA2186] Throttle sens. sup. volt. low error ......................................................................... 40-130 Failure code [CA221] Ambient air press. sensor high error ........................................................................... 40-86 Failure code [CA222] Ambient air press. sensor low error ........................................................................... 40-88 Failure code [CA2249] Rail press. very low error.. 40-130 Failure code [CA227] Sensor sup. 2 volt. high error ........................................................................... 40-90 Failure code [CA2311] Abnormality in IMV solenoid ......................................................................... 40-131 Failure code [CA234] Eng. overspeed .................... 40-91 Failure code [CA238] Ne speed sensor sup. volt. error ........................................................................... 40-92 Failure code [CA271] IMV/PCV1 short error ........... 40-94 Failure code [CA272] IMV/PCV1 open error ........... 40-95 Failure code [CA322] Injector #1 (L #1) system open/short error ................................................................... 40-96 Failure code [CA324] Injector #3 (L #3) system open/short error ................................................................... 40-98 Failure code [CA331] Injector #2 (L #2) system open/short error ................................................................. 40-100 Failure code [CA332] Injector #4 (L #4) system open/short error ................................................................. 40-102 Failure code [CA351] Inj. drive circuit error........... 40-104 Failure code [CA352] Sensor sup. 1 volt. low error ......................................................................... 40-107 Failure code [CA386] Sensor sup. 1 volt. high error ......................................................................... 40-108 Failure code [CA435] Abnormality in engine oil pressure switch............................................................... 40-110 Failure code [CA441] Battery voltage low error .... 40-111 Failure code [CA442] Battery voltage high error ... 40-111 Failure code [CA449] Rail press. very high error .. 40-112 Failure code [CA451] Rail press. sensor high error ......................................................................... 40-114 Failure code [CA452] Rail press. sensor low error ......................................................................... 40-116 Failure code [CA553] Rail press. high error .......... 40-116 Failure code [CA559] Rail press. low error ........... 40-117 Failure code [CA689] Eng. Ne speed sensor error ......................................................................... 40-120
2
Failure code [CA731] Eng. Bkup speed sensor phase error ................................................................. 40-122 Failure code [CA757] All persistent data lost error ......................................................................... 40-122 Failure code [CA778] Eng. Bkup speed sensor error ......................................................................... 40-124 Failure code [D110KB] Battery relay drive short ... 40-132 Failure code [D19JKZ] Personal code relay abnormality ......................................................................... 40-134 Failure code [D862KA] GPS antenna discon ........ 40-136 Failure code [DA22KK] Pump solenoid power low error ......................................................................... 40-138 Failure code [DA25KP] 5V sensor 1 power abnormality ......................................................................... 40-140 Failure code [DA26KP] 5V sensor 2 power abnormality ......................................................................... 40-143 Failure code [DA2RMC] CAN discon (Pump controller detected).......................................................... 40-144 Failure code [DAF8KB] Short circuit in camera power supply .............................................................. 40-146 Failure code [DAFGMC] GPS module error .......... 40-148 Failure code [DAFRMC] CAN discon (Monitor detected) ......................................................................... 40-150 Failure code [DGH2KB] Hydr oil sensor short....... 40-152 Failure code [DHPAMA] Pump press sensor abnormality ......................................................................... 40-154 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality .......................................... 40-156 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality .......................................... 40-158 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality .......................................... 40-160 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality .......................................... 40-162 Failure code [DHSKMA] Blade raise PPC press sensor abnormality ...................................................... 40-164 Failure code [DHSLMA] Blade lower PPC press sensor abnormality ...................................................... 40-166 Failure code [DHX1MA] Overload sensor abnormality (Analog) ........................................................... 40-168 Failure code [DV20KB] Travel alarm S/C.............. 40-169 Failure code [DW43KA] Travel speed sol discon .. 40-170 Failure code [DW43KB] Travel speed sol short .... 40-171 Failure code [DW45KA] Swing brake sol discon ... 40-172 Failure code [DW45KB] Swing brake sol short ..... 40-174 Failure code [DW91KA] Travel junction sol discon ......................................................................... 40-176 Failure code [DW91KB] Travel junction sol short.. 40-177 Failure code [DWJ0KA] Merge-divider sol discon ......................................................................... 40-178 Failure code [DWJ0KB] Merge-divider sol short ... 40-179 Failure code [DXA8KA] PC-EPC sol discon.......... 40-180 Failure code [DXA8KB] PC-EPC sol short ............ 40-182 Failure code [DXE4KA] Service current EPC discon ......................................................................... 40-184 Failure code [DXE4KB] Service current EPC short ......................................................................... 40-185 Failure code [DY20KA] Wiper working abnormality ......................................................................... 40-186 Failure code [DY20MA] Wiper parking abnormality ......................................................................... 40-188 Failure code [DY2CKA] Washer drive discon........ 40-190 Failure code [DY2CKB] Washer drive short .......... 40-192
PC128US-8
Index Failure code [DY2DKB] Wiper drive (for) short ..... 40-194 Failure code [DY2EKB] Wiper drive (rev) short..... 40-196 Failure code table.................................................... 40-58 Foreword and general information ............................ 00-9 Functions and operation by valve ........................... 10-72 Fuse locations ......................................................... 40-62
G General information on disassembly and assembly.. 50-4
Hydraulic system .............................10-24, 30-29, 50-111 Hydraulic tank and filter........................................... 10-28
I Idler ......................................................................... 10-14 Idler cushion ............................................................ 10-13 Index.......................................................................... 00-2 Information contained in troubleshooting table...... 40-265 Information in troubleshooting table ........... 40-12, 40-200
H
K
H-1 Speed or power of all work equipment, swing, and travel are low ................................................... 40-268 H-2 Engine speed sharply drops or engine stalls.. 40-269 H-3 No work equipment, travel and swing move... 40-270 H-4 Abnormal noise is heard from around hydraulic pump ........................................................................ 40-270 H-5 Fine control mode does not function .............. 40-271 H-6 Speed or power of boom is low ...................... 40-272 H-7 Speed or power of arm is low......................... 40-273 H-8 Speed or power of bucket is low .................... 40-274 H-9 Work equipment does not move in its single operation ........................................................................ 40-275 H-10 Hydraulic drift of work equipment is large .... 40-276 H-11 Time lag of work equipment is large............. 40-277 H-12 Work equipment loaded more is slower during compound operation........................................ 40-277 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE ...................................... 40-277 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel .... 40-278 H-15 Machine deviates during travel..................... 40-279 H-16 Travel speed is low....................................... 40-280 H-17 Machine cannot be steered easily or steering power is low ............................................................... 40-281 H-18 Travel speed does not change or it is kept low or high.................................................................. 40-282 H-19 Track does not move (Only either side) ....... 40-282 H-20 Machine does not swing............................... 40-283 H-21 Swing acceleration or swing speed is low .... 40-284 H-22 Excessive overrun when stopping swing...... 40-285 H-23 When upper structure stops swinging, it makes large shock ............................................................... 40-286 H-24 When upper structure stops swinging, it makes large sound............................................................... 40-286 H-25 Hydraulic drift of swing is large..................... 40-287 H-26 Flow rate in attachment circuit cannot be adjusted ........................................................................ 40-288 Handling fuel system parts...................................... 30-17 Handling of connectors newly used for engines...... 00-27 Handling of electric equipment and hydraulic component .......................................................................... 00-18 Handling voltage circuit of engine controller ......... 30-108 Holding valve......................................................... 10-146 How to proceed in troubleshooting............................ 40-8 How to read electric wire code ................................ 00-30 How to read the shop manual ................................. 00-14 How to read this manual ........................................... 50-4 Hydraulic circuit diagram........................................... 90-5 Hydraulic cylinder.................................................. 10-158 Hydraulic diagrams and drawings ............................. 90-3 Hydraulic equipment layout drawing ....................... 10-24 Hydraulic pump ....................................................... 10-30
KOMTRAX system ................................................ 10-219
PC128US-8
M Method of disassembling and connecting push-pull type coupler............................................................... 00-36 Method of using troubleshooting chart .................. 40-290 Monitor system ...................................................... 10-205
P Phenomena looking like troubles and troubleshooting Nos. ................................................................... 40-14 Pm Clinic service................................................... 30-115 Pm-Clinic ............................................................... 30-115 Points to remember when performing troubleshooting ............................................................................. 40-6 Power train ..........................................10-8, 30-26, 50-46 PPC accumulator .................................................. 10-144 PPC valve.............................................................. 10-102 Precautions when carrying out operation ................ 00-33 Preparation work for troubleshooting of electrical system ......................................................................... 30-109 Procedure for testing diodes ................................. 30-114 PTO ........................................................................... 10-5
R Related information on testing and adjusting ............ 30-3 Related information on troubleshooting..................... 40-6 Releasing residual pressure from fuel system ........ 30-17 Releasing residual pressure from hydraulic circuit.. 30-48 Removal and installation of aftercooler assembly ... 50-34 Removal and installation of air compressor assembly ......................................................................... 50-172 Removal and installation of air conditioner condenser ......................................................................... 50-173 Removal and installation of air conditioner unit assembly ......................................................................... 50-174 Removal and installation of center swivel joint assembly ......................................................................... 50-111 Removal and installation of control valve assembly ......................................................................... 50-121 Removal and installation of counterweight assembly (Machine with add-on weight).......................... 50-109 Removal and installation of counterweight assembly (Machine without add-on weight)..................... 50-107 Removal and installation of cylinder head assembly ........................................................................... 50-25 Removal and installation of engine and work equipment pump assembly ................................................. 50-39 Removal and installation of engine controller assembly ......................................................................... 50-179
3
Index Removal and installation of floor frame assembly ......................................................................... 50-165 Removal and installation of front oil seal................. 50-20 Removal and installation of front window assembly ......................................................................... 50-164 Removal and installation of fuel injector assembly ........................................................................... 50-17 Removal and installation of fuel supply pump assembly ........................................................................... 50-15 Removal and installation of fuel tank assembly ...... 50-44 Removal and installation of hydraulic pump assembly ......................................................................... 50-117 Removal and installation of hydraulic tank assembly ......................................................................... 50-114 Removal and installation of KOMTRAX communications module............................................................. 50-180 Removal and installation of machine monitor assembly ......................................................................... 50-177 Removal and installation of operator cab assembly ......................................................................... 50-150 Removal and Installation of operator's cab door ... 50-152 Removal and installation of operator's cab glass (stuck glass) ............................................................... 50-155 Removal and installation of pump controller assembly ......................................................................... 50-178 Removal and installation of radiator assembly........ 50-32 Removal and installation of rear oil seal ................. 50-22 Removal and installation of revolving frame assembly ......................................................................... 50-105 Removal and installation of sprocket .................... 50-104 Removal and installation of swing circle assembly . 50-92 Removal and installation of swing motor and swing machinery assembly.......................................... 50-84 Removal and installation of travel motor and final drive assembly ........................................................... 50-46 Removal and installation of work equipment assembly ......................................................................... 50-147 Removal and installation of work equipment oil cooler assembly ........................................................... 50-36
S S-1 Starting performance is poor .......................... 40-294 S-2 Engine does not start...................................... 40-295 S-3 Engine does not pick up smoothly.................. 40-298 S-4 Engine stops during operations ...................... 40-299 S-5 Engine does not rotate smoothly .................... 40-300 S-6 Engine lacks output (or lacks power).............. 40-301 S-7 Exhaust smoke is black (incomplete combustion) ......................................................................... 40-302 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................. 40-303 S-9 Oil becomes contaminated quickly ................. 40-304 S-10 Fuel consumption is excessive..................... 40-305 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................................. 40-306 S-12 Oil pressure drops ........................................ 40-307 S-13 Oil level rises (Entry of coolant or fuel)......... 40-308 S-14 Coolant temperature becomes too high (overheating) ................................................... 40-309 S-15 Abnormal noise is made ............................... 40-310 S-16 Vibration is excessive ................................... 40-311 Safety notice ............................................................. 00-9 Sensor................................................................... 10-221
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Sketch of special tool .............................................. 50-13 Sketches of special tools........................................... 30-7 Solenoid valve ....................................................... 10-140 Special functions of machine monitor...................... 30-56 Special tool list .......................................................... 50-9 Specification and technical data................................ 01-3 Specification dimension drawing ............................... 01-3 Specifications ............................................................ 01-5 Spreading and installation of track shoe assembly ......................................................................... 50-102 Sprocket .................................................................. 10-17 Standard service value table ..................................... 20-3 Standard tightening torque table ............................. 00-39 Standard value table for chassis related parts .......... 20-4 Standard value table for engine related parts ........... 20-3 Swing circle ............................................................... 10-9 Swing machinery ..................................................... 10-10 Swing motor .......................................................... 10-119 Symbols used in electric circuit diagrams ................. 90-9 Symbols used in hydraulic circuit diagrams .............. 90-3 System chart for hydraulic and mechanical systems ......................................................................... 40-266
T Table of contents....................................................... 00-2 Table of fuel, coolant and lubricants........................ 01-10 T-box and T-adapter list .......................................... 40-54 Testing and adjusting alternator belt tension........... 30-24 Testing and adjusting oil pressure in pump LS control circuit ................................................................. 30-36 Testing and adjusting oil pressure in pump PC control circuit ................................................................. 30-33 Testing and adjusting oil pressure in work equipment, swing, and travel circuits.................................... 30-29 Testing and adjusting travel deviation ..................... 30-46 Testing blow-by pressure ........................................ 30-15 Testing compression pressure ................................ 30-13 Testing control circuit basic pressure ...................... 30-32 Testing engine oil pressure ..................................... 30-16 Testing engine speed ................................................ 30-8 Testing exhaust temperature..................................... 30-9 Testing fuel pressure............................................... 30-18 Testing fuel return rate and fuel leakage................. 30-19 Testing oil leakage .................................................. 30-49 Testing PPC valve output pressure......................... 30-41 Testing solenoid valve output pressure................... 30-40 Testing swing circle bearing clearance ................... 30-26 Tools for testing, adjusting, and troubleshooting....... 30-3 Track frame ............................................................. 10-12 Track roller .............................................................. 10-15 Track shoe............................................................... 10-18 Travel motor .......................................................... 10-127 Troubleshooting by failure code .............................. 40-64 Troubleshooting of electrical system (E-mode) ..... 40-198 Troubleshooting of engine (S-mode)..................... 40-290 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................... 40-265
U Undercarriage and frame ..................10-12, 30-27, 50-93
PC128US-8
Index
V Valve control ........................................................... 10-26
W Weight table .............................................................. 01-8 Work equipment ....................................... 10-152, 50-147 Working range diagram............................................. 01-4
PC128US-8
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PC128US-8 HYDRAULIC EXCAVATOR Form No. WEN00003-00
© 2015 KOMATSU All Rights Reserved Printed in Japan 06-15 (01)
PC128US-8