Komatsu PC128UU-2 Shop Manual PDF

SEBM018506
MACHINE MODEL
SERIAL NUMBER
PC128UU-2
5001 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
PC128UU-2 mounts the S4D102E-1 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
2003 1
All Rights Reserved
Printed in Japan 07-03(02)
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00-2-3
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SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol

is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
Always wear safety glasses when hitting

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

trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK

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

Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

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

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

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

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

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

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

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

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

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

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

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

but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a

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

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

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

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

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

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

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

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

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

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

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

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

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

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

metal, glass and plastic.
Used as sealant for machined

holes.
Used as heat-resisting sealant for

repairing engine.
Quick hardening type adhesive

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Code
WG
5
Color White & Green
Code
6
Color
n
n
n
n
n
n
n
n
n
n
n
n
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
RY
Black & Red Red & Yellow
n
n
n
n
RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
Red & Blue Yellow & White Green & Blue
n
n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
A
B
B
Millimeters to inches
1 mm = 0.03937 in
00-16
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon

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

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

Specifications .. ...............................................
Weight table ....................................................
List of lubricants and coolant ........................
PC128UU-2
01-2
01-4
01-7
01-S
01-l
GENERAL
GENERAL ASSEMBLY
DRAWING
GENERAL ASSEMBLY DRAWING

500mm-WIDE
SHOE SPECIFICATION (WITH ROAD LINER SHOE)

Unit : mm
2490
t--J
1245
9JB00124
The sizes in ( ) are applicable when the machine is equipped with the iron shoe.
%l : indicates the size when the offset is 0.
%2 : indicates the size when the cab is prevented from interference.
01-2
PC1 28UU-2
GENERAL ASSEMBLY DRAWING
GENERAL
600mm-WIDE
SHOE SPEClFlCATlOh
Unit : mm
7435
c
4960
2475
SJPO7601
The sizes in ( ) are applicable when the machine is equipped with the iron shoe.
II : indicates the size when the offset is 0.
%2 : indicates the size when the cab is prevented from interference.
PC128UU-2
01-3
SPECIFICATIONS
GENERAL
SPECIFICATIONS
Machine model
Serial No.
5001 and up
500mm-wide
shoe specification
600mm-wide
shoe specification
Bucket capacity (SAE)
m3
0.45
0.45
Operating weight
kg
13,400
13,500
Max. digging depth
mm
4,865 [4,800]
4,865 [4,880]
Max. vertical wall depth
mm
3,305 [3,240]
3,305 [3,240]
Max. digging reach
mm
7,285
7,285
Max. reach st ground level
mm
7,135
z
E
7,145 [7,1351
Max. digging height
mm
8,150 [8,215]
8,150 [8,215]
Max. dumping height
mm
5,850 [5,915]
5,850 [5,715]
Bucket offset amount

(left/right)
mm
1,170/1,150
1,170/1,150
Max. blade lifting amount
mm
465 [530]
465 [530]
Max. blade lowering amount
mm
520 [455]
520 [455]
KN (kg]
84.3 (8,600)
84.3 (8,600)
Swing speed
rpm
10
10
Swing max. slope angle
deg.
16
16
Travel speed (Hi/Lo)
km/h
4.613.2
4.613.2
Gradeability
deg.
35
35
kPa {kg/cm*]
36.7 (0.37)
36.7 (0.37)
Overall length (for transport)
mm
7,400
7,455 [7,4001
Overall width
mm
2,490
2,590
Overall width of track
mm
2,490
Overall height (for transport)
mm
2,755 [2,795]
2,755 [2,795]
Overall height to top of cab
mm
2,730 [2,795]
2,730 [2,795]
Ground clearance of counterweight
mm
855 [920]
855 [920]
Min. ground clearance
mm
390 [4551
390 [4551
Tail swing radius
mm
1,480
1,480
mm
1,345 (% 1,450)
1,345 (% 1,450)
Max. digging force (bucket)
Ground pressure
(standard shoe width: 500 mm)
Min. swing radius of work euipment

(when the offset is 0)
Height of work equipment at
min. swing radius
PC1 28UU-2
mm
6,285 [6,350]
6% 6,260 [6,325])
6,285 [6,350]
(% 6,260 [6,325])
Distance between centers of

idler and sprocket
mm
2,750
2,750
Track gauge
mm
1,990
1,990
Overall length of track
mm
3,480 [3,560]
3,480 [3,560]
Machine cab height
mm
1,935 [2,0001
1,935 [2,000]
Blade width x height
mm
2,490 x 590
2,490 x 590
he values shown in the [ ] are tt lose for the machines when the road I ter shoe is equipped.
The value marked with % indicates the size when the cab is prevented from interference.
01-4
PC128UU-2
SPECIFICATIONS
GENERAL
PC1 28UU-2
Machine model
500mm-wide
shoe specification
Serial No.
5001 and up
600mm-wide
shoe specification
S4D102E-1
Model.
4-cycle, water-cooled, in-line, vertical,

direct injection, with turbochatger
Type
No. of cylinders-bore
mm
x stroke
Piston displacement
3.92 (3,920)
Q{cc}
Flywheel horsepower
Maximum
4-102xl2u
64/2,200 (8712,200)
IV/rpm{HP/rpm)
torpue
329/I ,300 {33.5/1,300)
High idling speed
rpm
2,400
Low idling speed
vm
950
j/kWh{g/HPh}
224 {I 65)
Min. fuel consumption
ratio
Starting motor
Alternator
Battery
Radiator type
24U, 4.5 kw
24U, 25A
12U,64Ahx2
12U, 72Ah x 2
I
CFI 9-4
1 on each side
Carrier roller
7 on each side
Track roller
Asembly-type triple grouster, 42 on each side

[Road liner, 42 on each side]
Track shoe
HPU95 (105cc/rev.)
Variable displacement
Type x no.
Discharge
Set pressure (at operation)
piston type x 1
Q /min
226
VIPa {kg/cm?
31.9 (325)
34.8 (355)
(at traveling)
8-spool type x 1
Type x no.
Hydraulic type
Control method
GM18UL-J
Travel motor
Variable displacement piston type

(with brake valve, parking brake) x 2
KMF40AEL-3
Fixed displacement piston type
(with shockless safety valve, holding brake) x 1
Swing motor
Hydraulic tank
Hydraulic filter
Hydraulic oil cooler
he values shown in the [
PC128UU-2
1 are
lose for the machines
when the road liner shoe is equipped.
SPECIFICATIONS
GENERAL
PC128UU-2
Machine model
Serial No.
5001 and up
Reciprocating
Type
cylinder (inside diameter)
mm
105
Diameter of pistonrod
mm
70
Stroke
mm
1,055
Max. distance between pins
mm
2,555
Min. distance between pins
mm
1,500
Reciprocating
fype
Cylinder (inside diameter)
mm
115
mm
75
Stroke
mm
272.5
mm
1,230.5
mm
958
Reciprocating
Type
mm
90
mm
60
Stroke
mm
885
mm
2,263
mm
1,378
Reciprocating
Type
mm
130
mm
70
Stroke
mm
346
mm
1,818
iin.
mm
1,472
distance between pins
Reciprocating
Type
01-6
mm
115
mm
75
Stroke
mm
181
mm
870
mm
689
piston
piston
piston
piston
piston
PC128UU-2
WEIGHT TABLE
GENERAL
WEIGHT TABLE
This mass list is for reference
in handling
or transporting
these components.
Machine model
PC1 28UU-2
Serial No.
5001 and up
Engine assembly (without water and oil)

Engine (without water and oil)
385
Engine mount
5.8
PTO
4.1
Hydraulic pump
80
Revolving frame
54
1,500
Operator cab
220
Operator seat
12.6
Fuel tank (without fuel)
98
Hydraulic tank (without hydraulic oil)
92
Control valve
106
Self pressure reducing valve
4.8
Counterweight
ko
510
Radiator/oil cooler assembly
Unit:
1,880
Swing motor (with brake valve)
26
Swing circle
155
Swing machinery
72.2
Center swivel joint
43.6
Track frame assembly
2,590
Track fram.e
1,438
Idler assembly
81 x2
Recoil spring assembly
Carrier roller
11 x2
Track roller
21 x 14
Travel motor (with speed reducer)
144x2
Sprocket
33.7 x 2
72.9 x 2
Track shoe assembly

l
Road liner (500mm)
770 x 2
Triple grouser shoe (500mm)
740 x 2
Triple grouser shoe (600mm)
830 x 2
Triple grouser shoe (700)
925 x 2
Swamp shoe (750mm)
875 x 2
Flat shoe (480mm)
760 x 2
PC1 28UU-2
01-7
WEIGHT TABLE
GENERAL
Unit: kg
Machine model
PC1 28UU-2
Serial No.
5001 and up
Boom assembly
l
1st boom
536
2nd boom
337
3rd bracket
217
Sub-link
51
Arm assembly
300
Bucket link assembly
85.6
Bucket assembly (with 955mm-wide

Blade assembly
Boom cylinder assembly
side cutter)
369
647
106.3x2
Arm cylinder assembly
136.9
Bucket cylinder assembly
75.8
Offset cylinder assembly
86.1
Blade cylinder assembly
67.2 x 2
01-8
PC1 28UU-2
GENERAL
LIST OF LUBRICANTS
AND COOLANT
LIST OF LUBRICANTS AND COOLANT

RESERVOIR
KIND OF
FLUID
AMBIENT TEMPERATURE
22
30
-4
-20
14
-10
32
0
50
10
68
20
86
30
104F
40C
CAPACITY (!2)
jpecified
Refill
Engine oil pan
17.5
17.0
PTO case
0.75
0.75
2.5
2.5
2.5
2.5
0.090
Swing machiney case

Final drive casse (each)
!ngine oil
Idler (each)
~.lOO-0.115
Track roller (each)
I I I
Carrier roller (each)
I I I I I
Hydraulic system
0.072
120
69
195
18.2
iydraulic
Iii
Fuel tank
3iesel fue
Cooling system
Zoolant
PC128UU-2
Add antifreeze
01-9
LIST OF LUBRICANTS
GENERAL
AND COOLANT
NOTE:
(1) When fuel sulphur
content is less than 0.5%,

change oil in the oil pan every periodic maintenance hours described in manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Fuel sulphur content
Change interval of oil in

enaine oil Dan
0.5 to 1 .O%
l/2 of regular interval
Above 1.0%
l/4 of regular interval
(2) When starting the engine in an atmospheric temperature of lower than OC, be sure to use engine
oil of SAE 1OW, SAEI OW-30 and SAEI 5W-40, even
though an atmospheric temperature goes up to
10C more or less in the day time.
Use
API classification CD as engine oil and if API
(3)
classification CC, reduce the engine oil change
interval to half.
There
is no problem if single grade oil is mixed
(4)
with multigrade oil (SAEIOW-30,15W-401,
but be
sure to add single grade oil that matches the temperature in the table on the left.
We
recommend Komatsu genuine oil which has
(5)
been specifically formulated and approved for use
in engine and hydraulic work equipment applications.
*
For the H046-HM,
use the oil recommended
by
Komatsu.
ASTM:
SAE:
API:
American Society of Testing and Material

Society of Automotive Engineers
American Petroleum Institute
Specified capacity: Total amount of oil including oil

for components and oil in piping.
Refill capacity: Amount of oil needed to refill system
during normal inspection and maintenance.
01-10
PC128UU-2
10 STRUCTURE AND FUNCTION
PTO ..............................................................
Radiator and oil cooler ...............................
Power train.. ................................................
Swing circle ................................................
Swing machinery .......................................
Track frame .................................................
Idler cushion ...............................................
Hydraulic equipment layout drawing.. .....
Valve control ...............................................
Hydraulic tank and filter.. ...........................
Hydraulic pump (Piston pump). ................
Control valve.. .............................................
Suction safety valve ...................................
CLSS ............................................................
Self pressure reducing valve.. ...................
Center swivel joint.. ....................................
Travel motor ....................... t.. .....................
Swing motor.. .............................................
Solenoid valve ............................................
EPC solenoid valve .....................................
PPC accumulator ........................................
PPC valve ....................................................
Air-conditioner
piping ....... .;.......................
Electric equipment layout drawing.. .........
Engine control ............................................
Electric control system.. .............................
Qsystem ......................................................
Monitor system ................. .:.......................
PC1 28UU-2
IO- 2
lo3
lo5
IO- 6
lo7
lo8
lo9
lo- IO
IO- 12
IO- 13
lo- 14
lo- 35
lo- 46
lo- 47
lo- 84
lo- 90
IO- 91
IO-100
1O-l 08
1O-l 10
IO-1 15
1O-l 16
lo-127
lo-128
lo-132
IO-140
1O-l 51
lo-174
10-l
STRUCTURE
AND FUNCTION
PTO
PTO
A-A
B-B
9JA01326
1.
2.
3.
4.
Coupling
Shaft
Breather
Gauge
1o-2
5.
6.
7.
Hydraulic pump
Oil filler plug
Level plug
PC128UU-2
STRUCTURE
AND FUNCTION
RADIATOR AND OIL COOLER
9JA01327
PC128UU-2
1o-3
STRUCTURE
AND FUNCTION
Y
9JA01328
1. Oil cooler
2. Radiator
3. Shroud
4. Reservoir tank
5. Oil cooler outlet
6. Oil cooler inlet
*
7. Radiator cap
8. Radiator inlet hose
9. Radiator outlet hose
10. Drain valve
11. Fan
1o-4
SPECIFICATION
Radiator
Core type : CF19-4
Fin pitch : 3.5/2 mm
Total heat dissipation surface : 34.06 m*
Pressure valve cracking pressure :
49.0 + 14.7 kPa (0.5 & 0.15 kg/cm?
Vacuum valve cracking pressure :
-4.9 - 0 kPa (-0.05 - 0 kg/cm*)
Oil cooler
Core type : CF40-1
Fin pitch : 4.512 mm
Total heat dissipation surface : 8.79 m*
PC128UU-2
STRUCTURE
POWER TRAIN
AND FUNCTION
POWER TRAIN
9JAOl329
1.
2.
3.
4.
5.
6.
7.
Idler
Control valve
Self pressure reducing valve
PPC lock solenoid valve
2-speed travel changeover solenoid valve
Swing hold brake solenoid valve
2-stage relief solenoid valve
PC1 28UU-2
8.
9.
10.
11.
12.
13.
14.
Travel motor
Hydraulic pump
Engine
Swing motor
Center swivel joint
Swing machinery
Swing circle
1o-5
STRUCTURE
AND FUNCTION
SWING CIRCLE
SWING CIRCLE
5
4
3
A-A
B-B
c-c
l--A
9JA01330
1.
2.
4.
5.
6.
Greasing to swing circle bearing

Greasing to swing circle pinion
Seal
Ball
Inner race
a.
b.
Inner race soft zone position

Outer race soft zone position
1 O-6
Specification
Reduction ratio : 90/l 1 = 8.182
Grease : G2-LI
Amount of filled grease : 9.1 f?
PC1 28UU-2
STRUCTURE
SWING MACHINERY
AND FUNCTION
SWING MACHINERY
---I
--L
:\c
iK
l\i
\
A-A
.I
9JA01331
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
13.
14.
Swing pinion (number of teeth : 1 I)

Case
No. 2 sun gear (number of teeth : 17)
No. 2 planetary carrier (number of teeth
Ring gear (number of teeth : 61)
No. 1 planetary carrier (number of teeth
No. 1 sun gear (number of teeth : 14)
Oil filler port
Swing motor
Level gauge
No. 1 planetary gear (number of teeth :
No. 2 planetary gear (number of teeth :
: 17)
: 17)
Specification
Reductionratio:(14+61)/14x(17+61)/17=24.58
Swing reduction ratio : 201.11
: 12 rpm
Swing speed
Lubricating oil : EOBO-CD
Lubricating oil amount : 2.5 k?
24)
22)
Drain plug
Swing circle (number of teeth : 90)
PC1 28UU-2
1o-7
STRUCTURE
AND FUNCTION
TRACK FRAME
TRACK FRAME
i
9JEOO125
1.
2.
3.
4.
idler
Track frame
Carrier roller
Travel motor
1 O-8
5.
6.
7.
8.
Sprocket
Track roller
Idler cushion
Track shoe
PC1 28UU-2
STRUCTURE
AND FUNCTION
IDLER CUSHION
IDLER CUSHION
F==---
-__
__~__
______
95800126
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Idler
support
Yoke
Cylinder
Recoil spring
U-packing
Pilot
Nut
Valve
Grease fitting
PC1 28UU-2
Specification
Grease : G2-LI
Amount of filled grease : 140 cc
1o-9
STRUCTURE
HYDRAULIC
AND FUNCTION
HYDRAULIC EQUIPMENT
EQUIPMENT
LAYOUT DRAWING
LAYOUT DRAWING
-I1. Bucket cylinder

2. Arm cylinder
3. Offset cylinder
4. Boom cylinder
5. Hydraulic tank
6. Swing motor
7. Hydraulic pump
8. Oil cooler
9. L.H. travel motor
10. L.H. work equipment PPC valve
11. Blade PPC valve
12. R.H. work equipment PPC valve
13. Center swivel joint
14. Travel PPC valve
15. Offset PPC valve
16. 5-spool EPC solenoid valve
l
Boom lower stop EPC valve
l Arm curl stop EPC valve
l
Boom raise stop EPC valve
l
Offset left stop solenoid valve
l
Offset right stop solenoid valve
Blade
cylinder
17.
Self
pressure
reducing valve
18.
Control
valve
19.
20. 4-spool solenoid valve
2-speed travel changeover solenoid valve
Swing holding brake solenoid valve
9JBOO127
10-10
PC128UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
EQUIPMENT
LAYOUT DRAWING
9J800128
P;c128UU-2
10-11
STRUCTURE
VALVE CONTROL
AND FUNCTION
VALVE CONTROL
7
I6
1. Control valve
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
R.H. work equipment PPC valve

Blade PPC valve
5-spool EPC solenoid valve
4-spool solenoid valve
R.H. work equipment control lever
-(for controlling boom and bucket)
Blade control lever
L.H. work equipment control lever
(for controlling arm and swing)
L.H. work equipment PPC valve
Safety lock lever
Travel accelerator pedal
L.H. travel pedal
R.H. travel pedal
Travel PPC valve
Left travel lever
Right travel lever
Offset PPC valve
Offset pedal
10-12
I5
i4
13
I2
II
9JBOO129
Lever and pedal position

(I) HOLD
(2) Boom LOWER
(3) Boom RAISE
(4) Bucket CURL
(5) Bucket DUMP
(6) HOLD
(7) Arm DUMP
(8) Arm CURL
(9) Swing LEFT
(10) Swing RIGHT
(11) L.H. travel FORWARD
(12) L.H. travel REVERSE
(13) R.H. travel FORWARD
(14) R.H. travel REVERSE
(15) PPC FREE
(16) PPC LOCK
.
(17) Blade RAISE
(18) Blade LOWER
(I 9) Travel Lo
(20) Travel Hi
(21) Offset LEFT
(22) Offset RIGHT
PC128UU-2
HYDRAULIC
TANK AND FILTER
HYDRAULIC TANK AND FILTER
10
A-A
9JA01337
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hydraulic tank
Filter rlement
Bypass valve
Bypass strainer
Suction strainer
Drain plug
Sight gauge
Oil filler cap
Pressure valve
Vacuum valve
PC1 28UU-2
Specification
Tank capacity : 99 f?
Hydraulic oil amount in tank : 69 f?
Pressure valve cracking pressure :
16.7 + 6.9 kPa (0.17 f 0.07 kg/cm?
Vacuum valve cracking pressure :
-0.49 - 0 kPa (-0.005 - 0 kg/cm*}
Bypass valve set pressure :
103 f 19.6 kPa (1.05 f 0.2 kg/cm*}
10-13
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
HYDRAULIC PUMP (PISTON PUMP)

MAIN PUMP
Type : HPV95 (for 105cdrev.j
PD
PLS
PB
PA
A
_i
1.
2.
3.
4.
5.
Main pump
LS valve
PC valve
Fixed throttle valve
PC-EPC valve (for changing
10-14
PC mode)
IM :
PA :
PB :
PD :
PEPC
PLS :
PS :
9JUOOO74
PC mode changeover current

Main pump delivery
Main pump pressure input
Main pump drain
: EPC valve source pressure inlet
Control valve LS pressure inlet
Main pump absorption
PC1 28UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
A-A
PUMP
IO
D4
D-D
B-B
1.
2.
3.
4.
5.
6.
7.
Shaft
Cradle
Case
Rocker cam
Shoe
Piston
Cylinder block
PC128UU-2
8.
9.
10.
11.
12.
13.
9JUOOO76
Valve plate
End cap
Spring
Servo last chance filter
Servo piston
Slider
10-15
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
Function
l
This pump converts engine rotation and
torque transmitted
to the pump shaft into
hydraulic energy anddischarges pressurized
oil according to load.
l
This pump can change delivery when the
swash plate angle is changed.
IO
A-A
9JUOOO77
Structure
The cylinder block (7) is supported to the shaft
l
(1) with the spline a, and the shaft (1) is supported with the front and rear bearings.
The
shoe (5) is punched to the tip of the pisl
ton (6) with a concave ball so that the piston
(6) and the shoe (5) form a spherical bearing.
The
shoe (5) is always pressed to the plane A
l
of the rocker cam (4) and slides in a circle.
The rocker cam (4) leads highly pressurized
oil together with the cylindrical plane B with
the cradle (2) fixed to the case, forms a static
pressure bearing and slides.
The piston (6) moves in the axial direction relal
tively in each cylinder of the cylinder block
l
(7).
The cylinder block (7) rotates relatively while
sealing pressurized oil against the valve plate
(8), and the plane is designed to balance the
oil pressure properly.
Oil in each cylinder of the cylinder block (7) is
absorbed and discharged through the valve
plate (8).
JO-16
PC1 28UU-2
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
Operation
1. Pump Operation
l
The shaft (1) rotates together with the cylinder block (71, and the shoe (5) slides on the
plate A. When the rocker arm (4) moves along
the cylindrical plane B, the inclination ato the
centerline X of the rocker cam (4) and the axial
direction of the cylinder block (7) changes.
The inclination
a is called swash plate
angle.
SLPOOl63
When the swash plate angle of the center line

X of the rocker cam (4) is a to the axial direction of the cylinder block (71, the plane A works
like the cam against the shoe (5).
Therefore, the piston (6) slides inside the cylinder block (71, and the capacities E and F of
the cylinder block (7) come to change differently. Then, the pump absorbs and discharges
the difference E-F.
When the capacity in the E chamber contracts
as the cylinder block (7) rotates, the pump discharges oil during the process. On the other
hand, when the capacity in the F chamber increases, the pump absorbs oil during the process. (The figure shows the end of the absorbing process in the Chamber F and the end of
the discharging process in the Chamber E.
When the centerline X of the rocker cam (4)
comes to the axial direction of the cylinder
block (7) (when the swash plate angle is 01,
the difference between the capacities E and F
in the cylinder block (7) comes to 0. And the
pump comes to stop absorbing or discharging oil, i.e., the pump stops. (However, the
swash plate angle never comes to 0 practically.)
In the other words, the swash plate angle a
and the pump delivery are in the proportional
relations.
PC128UU-2
SLPOOl64
9JUOOO80
10-17
HYDRAULIC
PUMP
Delivery Control
When the swash plate angle a increases, the
difference between the capacities E and F becomes larger and the delivery Q increases.
The servo piston (12) changes the swash plate
angle a.
The servo piston moves in the direction of
according to signal
straight reciprocation
This
pressures of the PC and LS valves.
straight motion is transmitted to the rocker
arm (4) through the slider (131, and the rocker
cam (4), which is supported with the cylindrical plane to the cradle (2), slides in the direction of rotation.
9JUOOO81
The servo pistons (12) area receiving the pressure is different on the right and left sides,
and the discharge (self) pressure PP from the
main pump is always led to the pressure
chamber of the small diameter piston.
The output pressure Pen of the LS valve is
led to the pressure chamber of the large diameter piston.
Motions of the servo piston are controlled according to the relations between the small
diameter piston pressure PP and the large diameter piston pressure Pen and the rate of
area receiving pressure of the small diameter
piston to that of the large diameter piston.
12
I3
9JUOOO82
lo-18
PC128UU-2
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
LS AND PC VALVES
LS Valve
PiS
PA
PLP
PPL
PD
PS IG
PA
9JUOOO84
1.
2.
3.
4.
5.
6.
7.
8.
Plug
Lock nut
Sleeve
Spring
Seat
Spool
Piston
Sleeve
A
PD
PLP
PLS
PPL
PSIG
: Pump discharge pressure inlet

: Drain pressure outlet
: LS valve signal pressure outlet
: Control valve LS pressure inlet
: PC valve signal pressure inlet
: EPC valve output pressure inlet of LS control
PC Valve
9JUOOO85
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Piston
Spring
Seat
Spring
Seat
Spool
Piston
Sleeve
Lock nut
Plug
Lock nut
PC1 28UU-2
PA
PA2
PD
PM
PPL
:
:
:
:
:
Pump discharge pressure inlet

Pump discharge pressure inlet
Drain pressure outlet
PC mode switching pressure inlet
PC valve signal pressure outlet
10-19
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
FIXED THROTTLE VALVE
POUT
PIN
9JUOOO86
1. Plug
2. Plug
PA
: Drain pressure outlet
POUT : Control pressure outlet
PIN
: LS valve signal pressure inlet
1O-20
PC1 28UU-2
STRUCTURE
Function
1. LS Valve
.
The LS valve controls pump delivery to stroke
of the control lever, i.e., requested flows of
the actuator.
.
The LS valve detects requested flow of the
actuator from the differential pressure, APLS,
between the pump discharge pressure, PP,
and the control valve outlet pressure, PLS, to
control the pump delivery Q. (Discharge pressure is called PP, the LS pressure PLS and the
LS differential pressure APLS.)
.
This valve detects pressure loss (=LS differential pressure APLS) caused by pump flow
passing through the opening area of the control valve spool, controls the pump delivery
Q so that the pressure loss remains constant
all the time and supplies pump deliveries requested by the actuator.
.
The relations between the LS differential pressure (APLS) between the pump discharge
pressure PP and the LS pressure (PLS) and
the pump delivery Q are as shown in the right
figure.
2.
.
PC Valve
When the pump discharge pressure PP rises,
the control valve spool stroke will increase
and the opening area will enlarge. So, the PC
valve controls the pump delivery Q so that
the delivery Q does not increase above a certain level depending on the discharge pressure PP. The valve also controls the pump
absorbing hydraulic horsepower to approximately equal horsepower so that the pump
absorbing horsepower does not exceed the
engine horsepower.
This means that, when a load to the actuator
increases during operation and the pump discharge pressure PP rises, this valve will reduce the pump delivery 0, or when the pump
discharge pressure PP drops, this valve will
increase the delivery 0.
In this case, the relations between the pump
discharge pressure PP and the pump delivery Qchange as shown in the right figure since
the current value given to the PC-EPC valve
solenoid is regarded as a parameter.
However, some PC valves have the function
to sense actual engine speeds in the heavyduty operation mode and to reduce the pump
delivery and recover the speed when the
speed reduces due to increase of load.
In the other words, when an increase of load
reduces the engine speed below the set value,
the command current from the controller to
the PC-EPC valve solenoid will increase as the
engine speed reduces and will reduce the
pump swash plate angle.
PC1 28UU-2
HYDRAULIC
AND FUNCTION
k/m
PUMP
i n)
z
c
I
2. 2122.
LS differential
51
IMPaIta/cll)
Dressure
SVPO7602
Q
c
z
:
X=0.
PumP discharge
Pressure
26A
PP
SDP02556
10-21
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
Operation
lin
ve
Direction
small
1.
to
diameter
SVPO7604
LS Valve
1) When the control valve is at the center
value position
The LS valve is a 3-way selector valve, and
l
the pressure PLS (LS pressure) from the
control valve inlet is being led to the
spring chamber B and the pump discharge pressure PP is being led to the H
port of the sleeve (8).
The spool (6) position is determined del
pending on the force of the LS pressure
PLS + the force of spring (4) 2 and the force
of the pump discharge pressure (self-pressure) PP.
1o-22
PC1 28UU-2
STRUCTURE
Before the engine starts, the servo piston

(12) is pressed to the right side. (See the
right figure.)
If the control lever is at the centervalue
position when the engine starts, the LS
pressure PLS will be 0 MPa (0 kg/cm*).
(The LS valve interconnects to the drain
circuit through the control valve spool.)
At the time, the spool (6) is pressed to the
left side and the C port is connected to
the D port. The pump discharge pressure
enters from the K port to the piston large
diameter side and from the J port to the
piston small diameter side respectively.
So, the area difference of the servo piston (12) minimizes the swash plate angle.
PC1 28UU-2
HYDRAULIC
AND FUNCTION
A-A
PUMP
9JUOOO89
1 O-23
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
PLS
@--I
Direction
to
large
diameter
a
.
1 O-24
Operation
in the direction to increase
pump delivery
When the difference between the pump
discharge pressure PP and the LS pressure PLS, i.e., LS differential
pressure
APLS, reduces (for example, when the
control valve opening area increases and
the discharge pressure PP drops), the
combined force of the LS pressure PLS
and the spring (4) force will push the spool
(6) to the right side.
When the spool (6) moves, the circuit between the D port and the E port will open
and the LS valve will be connected to the
PC valve. At the time, the PC valve is connected to the drain port, and the drain
pressure PT is applied to the circuit D-K.
(The operation of the PC valve will be explained later.)
SVPO7605
Therefore, the pressure on the large diameter side of the servo piston (12) becomes equal to the drain pressure PT.
Since the pump discharge pressure PP is
applied to the J port on the small diameter side, the servo piston (12) is pushed
to the right side and the swash plate is
moved in the direction where the delivery increases.
PC1 28UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
PC valve
PUMP
PT
PLS
lin
ve
@--I
Direction
to
small
diameter
3)
l
Operation in the direction to reduce pump

delivery
When the servo piston (12) moves to the
left side (in the direction to reduce the
pump delivery), the LS differential pressure APLS will increase (for example, the
control valve opening area decreases and
the pump discharge
pressure
PP increases) and the force of the discharge
pressure PP will push the spool (6) to the
left side.
When the spool (6) moves, the pump discharge pressure PP will be forwarded
from the C port to the D port and will come
from the K port to the piston large diameter side.
PC128UU-2
SVPO7606
Since the pump discharge pressure PP is

applied to the J port on the piston small
diameter side, the servo piston (12) is
pressed to the left side due to the area
difference between the large diameter
side and the small diameter side of the
servo piston (12). So, the swash plate is
moved in the direction where the delivery is reduced.
1 O-25
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
in
ve
PEN
-0
ii
SVPO7607
4)
l
1 O-26
When the servo piston balances

Suppose that the area receiving pressure
on the piston large diameter side is Al,
the area on the piston small diameter side
is A0 and the pressure applied to the piston large diameter side is PEN.
When the pump discharge pressure PP of
the LS valve balances with the combined
force of the LS pressure PLS and the
spring (4) force 2 and the relations A0 x
PP = Al x PEN hold, the servo piston (12)
will stop at the position and the swash
plate angle will be held at the intermediate position. (The openings of the D port
to the E port and of the C port to the D
port of the spool (6) stop almost at the
same position.)
At the time, the relations of the areas receiving pressure at the both ends of the
servo piston are A0 : Al = 1 : 1.75. When
they balance with each other, the pressures applied to the both ends of the piston are related as follows: PP : PEN + 1.75
: 1.
The spring (4) force has been adjusted so
that the spool (6) balance stop position is
determined at the center of the standard
when PP-PLS = 2.21 MPa (22.5kg/cm2).
PC1 28UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
0 m ain
-
//
I,
Emergency
drive
switch
I^
Direct
small
Pump
ibn to
diameter
0 F F ,,
va
IVe
Di rect;on
to
large
diameter
Pump
controller
I,
I
ON
Resistor
SVPO7608
2.
PC Valve
1) When the pump controller is normal, the
load to the actuator is small and the pump
discharge pressure PP is low
a. Function of PC-EPC Valve Solenoid (1)
l
The pump controller provides a command current to the PC-EPC valve solenoid (1). This command current actuates the PC-EPC valve and outputs
a signal pressure. When receiving the
signal pressure, the PC valve changes
the force given to the piston (2).
l
The spool (3) stops where the force to
the piston (2) balances with the combined force of the spring setting force
of the springs (4) and (6) on the opposite side and the force given to the
spool (3) by the pump discharge pres-
PC128UU-2
sure PP. And the pressure output from

the PC valve (the pressure at the C
port) varies with the spool position.
The value of the command current X
is determined depending on type of
work (lever control), selection of working mode, set point of engine speed
and actual speed.
1 O-27
STRUCTURE
HYDRAULIC
AND FUNCTION
Pi lot
PUMP
Pressure
main
valve
-
Emergency
pump
drive
switch
SVPO7609
b.
l
1 O-28
Function of Spring
The loads to the springs (4) and (6) of
the PC valve are determined depending on swash plate position.
As the servo piston (9) moves, the piston (7) connected
to the slider (8)
moves to the right or the left.
When the piston (7) moves to the left,
the spring (6) will be contracted. If the
piston moves further to the left, the
spring will be brought to the seat (5)
and be fixed there.
Thereafter, the
spring (4) will only move. This means
that the spring load changes as the
piston (7) extends or contracts the
springs (4) and (6).
Also, since the pressing force of the

piston (2) changes as the command
current input to the PC-EPC valve solenoid (1) changes, the load to the
springs (4) and (6) changes depending on the value of the command current.
PC1 28UU-2
STRUCTURE
PC1 28UU-2
AND FUNCTION
HYDRAULIC
PUMP
The C port of the PC valve is connected

to the E port of the LS valve. The self
pressure PP is provided to the A port,
the small diameter side of the servo
piston (9) and the B port.
When the pump discharge pressure
PP is small, the spool is located at a
position in the left direction.
At the
time, the C port is connected to the D
port, and the pressure to the LS valve
becomes the drain pressure PT. If the
E port of the LS valve is connected to
the G port at the time, the pressure
from the J port to the large diameter
side of the piston will become the
drain pressure PT. And the servo piston will moves to the right side. Then,
the pump delivery will come to increase.
Also, as the servo piston (9) operates,
the slider (8) moves the piston (7) to
the right side, and the spring force
becomes weak because the springs (4)
and (6) expand. As the spring force
becomes weak, the spool (3) moves
to the right side to disconnect the C
port from the D port. Then, the pump
discharge pressure ports B and C are
connected.
As a result, the pressure at the C port
rises and the pressure on the large
diameter side of the piston rises as
well, and the servo piston (9) stops
moving to the right side. This means
that the stop position of the servo piston (9) (= pump delivery)
is determined where the pressing
force
caused the pressure PP to the spool
(3), the pressing force of the PC-EPC
valve solenoid and the forces of the
springs (4) and (6) balance with each
other.
1 O-29
STRUCTURE
HYDRAULIC
AND FUNCTION
Pilot
PUMP
pressure
0 main
valve
-
Emergency
Pump
SVPO7610
2)
When the pump controller is normal, the

load to actuator is large and the pump
discharge pressure PP is high
When the load is large and the pump discharge pressure is high, the force pushing the spool (3) to the left side increases
and the spool (3) comes to the position
shown in the above figure.
Then, the pressure flowing from the C port
to the LS valve becomes about 315 of the
pump discharge pressure PP because the
pressure from the A port partly flows from
the C port to the D port through the LS
valve as shown in the above figure.
1O-30
When the E port of the LS valve is connected to the G port, this pressure is led
from the J port to the large diameter side
of the servo piston (9) and the servo piston comes to stop.
When the pump discharge pressure PP increase and the spool (3) moves further to
the left side, the discharge pressure PP will
flow to the C port so as to minimize the
pump delivery.
PC1 28UU-2
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
When the servo piston (9) moves to the

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

PC-EPC valve solenoid increases, the relations between the pump discharge pressure PP and the pump delivery Q will
move in parallel in relation to the pushing force of the PC-EPC valve solenoid.
Therefore, the force of the PC-EPC valve
solenoid (1) will be added to the leftward
pressing force of the discharge pressure
PP to the spool (31, and the relations between PP and Q will move from @ to @
as X increases.
PC1 28UU-2
Pump
discharge
pressure
PP
SDP02559
Pump
discharge
pressure
PP
SDP02560
10-31
STRUCTURE
HYDRAULIC
AND FUNCTION
Pilot
PUMP
Dressure
To Main
Direction
to
large
diameter
SVPO7611
3)
1 O-32
When the pump controller is out of order

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

(3) balances at a position in the left
side.
At the time, the C port has the same
pressure as the drain pressure at the
D port, and the drain pressure PT is
led to the large diameter side of the
servo piston (9) through the LS valve.
Then, the servo piston (9) moves in
the diction where the delivery
increases because the pressure on the
small diameter side of the piston is
large.
PC128UU-2
STRUCTURE
HYDRAULIC
AND FUNCTION
Pilot
PUMP
pressure
in
ve
Direction
to
small
diameter
SVPO7612
b.
l
PC1 28UU-2
In case of heavy load to main pump

When the PC redundant switch is set
to ON just like in the previous paragraph, a constant command current is
sent to the PC-EPC valve solenoid (1).
So, the piston (2) pushes the spool (3)
with a constant force.
When the pump discharge pressure
PP rises, the spool will moves further
to the left side than when the main
pump is lightly loaded and will balance at the position shown in the
above figure.
In this case, since the pressure from
the A port is led to the C port, the servo
piston (9) will move to the left side
(small delivery) and will stop at a position further to the left than when the
pump is lightly loaded.
1o-33
STRUCTURE
HYDRAULIC
AND FUNCTION
This means that the current, which is

sent to the PC-EPC valve solenoid
through the resistor when the PC redundant switch is set to On, determines the curve between the pump
discharge pressure PP and the delivcry Q as shown in the figure.
When the PC redundant switch is set
to ON, the curve @ is further to the
left than the curve 0 drawn when the
pump controller is normal.
Q
x
al
.-5
4
;
z
PUnID discharge
1o-34
PUMP
Pressure
PP
~~~07613
PC1 28UU-2
STRUCTURE
CONTROL VALVE
AND FUNCTION
CONTROL VALVE
OUTLINE
The following two control valves have been set
in the system :
l
8-spool valve (without service valve)
l
9-spool valve (8-spool valve + service valve)
*
Each service valve is of the add-on type and
can be added and removed halfway.
Appearance and section are shown for 8-spool
valve (without service valve) only.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Swing bleed valve

Travel junction valve
Arm regeneration valve
Boom hydraulic drift prevention
Cover
Offset valve
Bucket valve
Arm valve
Blade valve
Boom valve
R.H. travel valve
L.H. travel valve
Swing valve
PT port block
AA
Al
A2
A3
A4
A5
A6
A7
A8
Bl
B2
B3
B4
B5
B6
B7
B8
BP
LS
PA1
PA2
PA3
PA4
PA5
PA6
PA7
PA8
PBl
PB2
PB3
valve
PB4 : From boom LOWER PPC/EPC valve

PB5 : From blade RAISE PPC valve
PB6 : From arm IN PPC/EPC valve
PB7 : From bucket digging PPC valve
PB8 : From L.H. offset PPC/EPC valve
: From main pump
P
PP : To main pump
PX : From 2-stage relief solenoid valve
SA : From swing stroke regulating solenoid valve
SB : From swing stroke regulating solenoid valve
TSl : To tank
TS2: To tank
TB :Totank
TC : To oil cooler
TSW : To swing motor
: Pressure sensor port (with pressure sensor)

: To swing motor MB
: To L.H. travel motor A
: To R.H. travel motor A
: To boom cylinder bottom
: To blade cylinder bottom
: To arm cylinder head
: To bucket cylinder head
: To offset cylinder head
: To swing motor MA
: To L.H. travel motor B
: To R.H. travel motor B
: To boom cylinder head
: To blade cylinder head
: To arm cylinder bottom
: To bucket cylinder bottom
: To offset cylinder bottom
: From boom RAISE PPC valve
: To pump LS valve
: From swing L.H. PPC valve
: From L.H. travel forward PPC valve
: From R.H. travel reverse PPC valve
: From boom RAISE PPC/EPC valve
: From blade LOWER PPC valve
: From arm OUT PPC valve
: From bucket DUMP PPC valve
: From R.H. offset PPC valve
: From swing R.H. PPC valve
: From L.H. travel reverse PPC valve
: From R.H. travel forward PPC valve
PC1 28UU-2
1o-35
CONTROL VALVE
8-spool valve (without
service valve)
BB
AA
-rJ
I--
A7
A8 --Y
88
87
+A
A5
TS2
A3
A2
Al
PAl
-----l-x-BB--i
\
k-B
TB
-D
5
0
7
0
9
IO
11
12
13
14
TSW
PBl
TC
9JYOO291
PC128UU-2
CONTROL VALVE
Sectional view
* The figure shows an 8-spool valve (without service valve).
(l/9)
A-A
9JYOO292
1.
2.
3.
4.
5.
6.
7.
Safety valve with suction

Suction valve (L.H. travel A)
Suction valve (R.H. travel A)
Suction valve (boom bottom)
Safety valve with suction (blade bottom)
Suction valve (arm head)
Suction valve (bucket head)
PC128UU-2
8.
9.
10.
11.
12.
13.
14.
Safety valve with suction (offset head)

Suction valve (bucket bottom)
Suction valve (arm bottom)
Suction valve (boom head)
Suction valve (R.H. travel B)
Suction valve (L.H. travel B)
Lift check valve
1o-37
STRUCTURE
CONTROL VALVE
AND FUNCTION
B-B
9JYOO293
1.
2.
3.
4.
5.
6.
7.
8.
9.
Main
Spool
Spool
Spool
Spool
Spool
Spool
Spool
Spool
1 O-38
relief valve
(swing)
(L.H. travel)
(R.H. ravel)
(boom)
(blade)
(arm)
(bucket)
(offset)
PC1 28UU-2
STRUCTURE
AND FUNCTION
CONTROL VALVE
9JYOO294
1.
2.
3.
4.
5.
6.
7.
8.
9.
Pressure compensation
Unload valve
valve
valve
valve
valve
valve
valve
valve
valve
F
F
F
F
F
F
F
F
(swing)
(L.H. travel)
(R.H. travel)
(boom)
(blade)
(arm)
(bucket)
(offset)
10.
11.
12.
13.
14.
15.
16.
17.
Pressure
Pressure
Pressure
Pressure
Pressure
Pressure
Pressure
Pressure
compensation
compensation
compensation
compensation
compensation
compensation
compensation
compensation
valve
valve
valve
valve
valve
valve
valve
valve
R
R
R
R
R
R
R
R
(offset)
(bucket)
(arm)
(blade)
(boom)
(R.H. travel)
(L.H. travel)
(swing)
The above F and R means the following valves :

F : Flow control valve
R : Pressure reducing valve
PC128UU-2
TO-39
CONTROL VALVE
BB-BB
9JYOO295
1.
2.
3.
4.
5.
6.
7.
LS pressure detection plug

LS bypass plug
Pump pressure detection plug
Check valve (bucket head)
Check valve (arm head)
Check valve (boom bottom)
LS select valve
1O-40
PC 128UU-2
STRUCTURE
CONTROL VALVE
AND FUNCTION
W9)
F-F
G-G
1.
2.
3.
4.
5.
6.
7.
8.
Main relief valve

Couler bypass valve
Lift check valve
LS select valve
Spool (swing)
Swing bleed valve
PC1 28UU-2
9JUOO108
valve R
valve F
10-41
STRUCTURE
AND FUNCTION
CONTROL VALVE
9JUOO109
1.
2.
3.
4.
5.
6.
Suction valve (A)

Suction valve (B)
Spool (L.H. travel)
1 O-42
valve R
7.
8.
9.
10.
11.
Suction valve (A)

Suction valve (B)
Spool (R.H. travel)
valve R
valve F
valve F
PC128UU-2
STRUCTURE
AND FUNCTION
CONTROL VALVE
V/9)
K-K
9JYOO296
1.
2.
3.
4.
5.
Suction valve (A)

Boom hydraulic drift prevention valve
Suction valve (B)
Spool (boom)
Pressure compensation valve R
PC1 28UU-2
6.
7.
8.
9.
10.
Pressure compensation valve F

Spool (blade)
1o-43
STRUCTURE
CONTROL VALVE
AND FUNCTION
W9)
M-M
,!
IO
N-N
9JYOO297
1.
2.
3.
4.
5.
6.
Suction valve (A)

Suction valve (B)
Spool (arm)
Arm regeneration valve
1o-44
7.
8.
9.
10.
11.
Suction valve (A)

Suction valve (B)
Spool (bucket)
valve R
valve F
PC1 28UU-2
STRUCTURE
AND FUNCTION
CONTROL VALVE
W9)
AA-AA
1
9JYOO298
1.
2.
3.
4.
5.
6.

Spool (offset)
Pressure relief plug
Unload valve
PC128UU-2
1o-45
STRUCTURE
AND FUNCTION
SUCTION
SAFETY VALVE
SUCTION SAFETY VALVE

(SAFETY VALVE WITH SUCTION
FOR SERVICE PORT)
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve
8. Sleeve
9. Adjustment screw
IO. Lock nut
CT
9JUOO112
Specification
Part No. (Reference)
Set pressure
709-70-74600
24.5 MPa (250 kg/cm?

(at the time of 5fYmin.I
709-70-74700
17.2 MPa (175 kg/cm*)

(at the time of 5e/min.)
1O-46
Use
For crusher
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
CLSS
OUTLINE OF CL&
Features
CLSS stands for Closed Center Load Sensing System and is featured as follows :
l
Fine controllability without affect of load
l
Controllability that allows digging even in the fine control mode.
l
Ease of compound operation in which the flow distribution performance depends on spool opening
area during compound operation.
l
Saving of energy by variable pump control
Configuration
l
The CLSS consists of a variable displacement piston pump, a control valve and actuators.
l
The pump body consists of a main pump, a PC valve and an LS valve.
;___________________---I
I
PLS
Actuators
Control
valve
0
I
I
I_-________________
LS valve
-------
SDP02561
PC1 28UU-2
1o-47
STRUCTURE
AND FUNCTION
CLSS
Basic principle
1. Control of pump swash plate angle
l
The pump swash plate angle (pump delivery)
is controlled so that the LS differential pressure APLS, which is the difference between
the pump discharge pressure PP and the LS
pressure PLS (actuator load pressure) at the
control valve outlet, becomes constant.
(LS differential pressure APLS = Pump pressure PP - LS pressure PLS)
Actuator
Control
va I ve
Pump
Passage
i__________
Servo
Piston
APLS
II
It
(;
LS valve
SEP0.2562
When the LS differential pressure APLS reduces below the set pressure of the LS valve
(when the actuator load pressure is high), the
pump swash plate angle will move in the direction of maximum. When the set pressure
is raised (when the actuator load pressure is
low), the pump swash plate angle will move
in the direction of minimum.
For the detail of the operation, see the paragraph of Hydraulic Pump.
A
Q
-al
.z
m
z
m
X
=
:
x
Max.
LS valve
set Pressure
Min.
LS differential
Pressure
w
APLS
SDP02563
1 O-48
PC1 28UU-2
STRUCTURE
2..
l
CLSS
AND FUNCTION
Pressure compensation control

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

Pump pressure
detection
port
IC
LS PreSSUle
detection
port
sensor
ve
PAl'
_-L-_
PA&
--t--
rm
Safety
1Z.llPl
valve
30tdrd
Arm check
valve
Blade
m-#~t-yLm--~~~ 11
Boom
lock
valve
3oom
LB
_TSZ
PA4'
--t
l-03
iAs(Forward)
Reverse
R. H.
travel
L. H.
travel
v!! c
I L_
--_ L-
&.
Rever se
Swine
separarlon
~b
.valve
LJa*n
/check
.-----__
Swine
bleed
Galve
CL_.9
i_
/
Main
relife
1,. o/3.. (PI
0*6/,66t./c31
valve
I 9
i~Z371s
evalve
Tao3
valve
T--l
jTs
Safety
valve
36. IPI
<316L.,C&
Hydraulic
1O-50
circuit
diagram
SJPO7614
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
1. Unload valve
Set pressure : 3.38 MPa (34.5 kg/cm2}
2. Safety valve with suction
Set pressure : 35.8 MPa (365 kg/cm21
3. Pressure compensation valve
4. Suction valve
5. Main relief valve
Set pressure : normal : 31.9 MPa (325 kg/cm2)
Pressure rise : 34.8 MPa (355 kg/cm21
6. Lift check valve
7. Cooler bypass valve
8. LS select valve
9. Swing bleed valve
10. Travel junction valve
11. Boom hydraulic drift prevention valve
12. Arm regeneration valve
PC1 28UU-2
1o-51
STRUCTURE
CLSS
AND FUNCTION
UNLOAD VALVE
1. When the control valve is neutral
Function
When the control valve is neutral, the delivery 0 equivalent to the pump minimum swash plate angle
l
is released to the tank circuit. At the time, the pump discharge pressure PP is set to 2.45 MPa {25.0kg/
cm*} with the spring (3) inside the vale. (The LS pressure PLS is 0 MPa {Okg/cm2).)
SDP03735
Operation
The pump discharge pressure PP is applied
to the left end face of the spool (4) and the LS
pressure PLS is applied to the right end face.
Since the LS pressure PLS is 0 when the conl
trol valve is neutral, the pump discharge pressure PP is only applied and is set with the lead
to the spring (3).
When the pump discharge pressure PP rises
l
to the spring (3) load (2.45 MPa (25.0 kg/cm*}),
the spool (4) will move toward the right side
and the pump circuit PP will interconnect to
the tank circuit T through the drill hole.
Therefore, the pump discharge pressure PP
l
is set to 2.45 MPa (25.0 kg/cm*}.
l
1 O-52
1.
2.
3.
4.
Unload valve
Sleeve
Spring
Spool
PLS : LS circuit (pressure)

PP : Pump circuit (pressure)
T
: Tank circuit
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
2. When the control valve is in the fine control mode

Function
l
When the control valve is in the fine control mode and the requested flow of the actuator is less than
the pump minimum swash plate angle, the pump discharge pressure PP is set to the LS pressure PLS
+ 2.45 MPa (25.0 kg/cm2}.
When the differential pressure between the discharge pressure PP and the LS pressure PLS comes to
the spring (3) load (2.45 MPa (25.0 kg/cm2}), the unload valve will open and the LS differential pressure APLS will come to 2.45 MPa (25.0 kg/cm*}.
SDP03736
Operation
When the control valve is operated in the fine
control mode, the LS pressure PLS will occur
and will be applied to the right end face of
the spool (4). At the time the differential pressure between the LS pressure PLS and the
pump discharge pressure PP increases because the opening area of the control valve
spool is small.
l
When the differential pressure between the
pump discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45
MPa (25.0 kg/cm?), the spool (4) will move to
the right side and the pump circuit PP will interconnect to the tank circuit T.
l
This means that the pump discharge pressure
PP is set to the spring force (2.45 MPa (25.0
kg/cm*} + LS pressure PLS, and the LS differential pressure APLS comes to 2.45 MPa (25.0
kg/cm*}.
l
PC128UU-2
1.
2.
3.
4.
Unload valve
Sleeve
Spring
Spool

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

Function
l
If the required flow of the actuator increases over the pump minimum swash plate angle when the
control valve is operated, the flow to the tank circuit T will be interrupted and the pump delivery Q
will be completely flown to the actuator circuit.
SDP03737
Operation
l
When the control valve is operated with large
stroke, the LS pressure PLS will occur and will
be applied to the right end face of the spool
(4). At the time, the opening areas of the control valve spool is large and the difference
between the LS pressure PLS and the pump
discharge pressure PP is small.
l
So, the differential
pressure between the
pump discharge pressure PP and the LS pressure PLS does not reach the spring (3) load
(2.45 MPa (25.0 kg/cm*)) and the spring (3)
pushes the spool (4) to the left side.
l
Then, the pump circuit PP and the tank circuit
Tare interrupted, and the pump delivery Q is
completely flown to the actuator circuit.
1o-54
1.
2.
3.
4.
Unload valve
Sleeve
Spring
Spool

T
: Tank circuit
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
LEADING OF LS PRESSURE
Function
The LS pressure is load pressure to the actuator on the outlet side of the control valve.
In case of a work equipment valve, the pressure reducing valve (3) of the pressure compensation valve reduces the pump discharge
pressure PP to the same level as the actuator
circuit pressure A and leads the pressure to
Work equipment
the LS circuit PLS. Also, the orifice C is

mounted on the piston (5) halfway from the
pump circuit PP to the pressure reducing valve
(3), and the orifice has the damper function.
The travel valves leads the actuator circuit
pressure A directly to the LS circuit PLS.
valve (boom, arm, bucket, swing blade and offset)
SDP03738
Operation
l
When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator
circuit A through the bridge passage b from
the flow control valve (2) and the spool notch
a.
l
Since the pressure reducing valve (3) moves
to the right at the same time, the pump discharge pressure PP led from the orifice c is
reduced due to pressure loss at the notch d
and is led to the LS circuit PLS and to the
spring chamber PLSl.
l
At the time, the LS circuit PLS is connected to
the tank circuit Tfrom the LS bypass plug (4).
PC1 28UU2
The both end face areas of the pressure reducing valve (3) are the same (SA = SLS), and
the actuator circuit pressure PA (= A) is applied to the SA side and the reduced pump
discharge pressure PP is applied to the SLS
side on the opposite side.
Therefore, the pressure reducing valve balances at the position where the actuator circuit pressure PA becomes equal to the pressure of the spring chamber PLSl. The pump
discharge pressure PP reduced at the notch d
comes to the actuator circuit pressure A and
is led to the LS circuit PLS.
1o-55
STRUCTURE
2.
AND FUNCTION
CLSS
Travel valve
PP
SDP03739
Operation
When the spool (1) is operated, the pump disl
charge pressure PP will be led to the actuator
circuit A through the bridge passage b from
the flow control valve (2) and the spool notch
a.
At the same time, the actuator circuit presl
sure PA moves the pressure reducing valve
(3) to the right side, and the notches c and d
interconnect to the travel junction circuit e and
the LS circuit PLS respectively.
So, the actuator circuit pressure PA (= A) is
l
led from the notch c to the LS circuit PLS
through the notch d.
The travel circuit is different from the work
*
equipment circuit, the actuator circuit pressure PA is directly led to the LS circuit PLS.
1 O-56
PC128UU-2
STRUCTURE
CLSS
AND FUNCTION
LS BYPASS PLUG
Function
l
This plug released residual pressure of the LS
pressure PLS.
l
This plug slows the rising speed of the LS
pressure PLS, causes pressure losses at the
spool and the throttle of the shuttle valve by
the discarded throttled flow and reduces the
effective LS differential pressure for higher
safety.
PLS
SDP03740
Operation
l
Pressurized oil in the LS circuit PLS flows from
the clearance filter a in the space between the
LS bypass plug (1) and the valve body to the
tank circuit T through the orifice b.
PC1 28UU-2
1.
LS bypass plug

T
: Tank circuit (pressure)
1o-57
STRUCTURE
AND FUNCTION
PRESSURE COMPENSATION
CLSS
VALVE
Function
l
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).
Aa
(Coyyensated
Pi.3
SVPO7773
1 O-58
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Operation
l
When the load pressure of another actuator
side (the upper side) rises during a compound
operation, the flow in the actuator circuit A
on this side (the lower side) is apt to increase.
l
In this case, the LS pressure PLS of another
actuator is applied to the spring chamber PLSl
and pushes the pressure reducing valve (1)
and the flow control valve (2) to the left side.
l
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.
l
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 (I) and PLS becomes the same as
the pressure loss between PP before and after the flow control valve and PPA.
l
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.
PC1 28UU-2
1o-59
STRUCTURE
AND FUNCTION
AREA RATIO OF PRESSURE COMPENSATION
CLSS
VALVE
Function
The pressure compensation valve slightly adjust the ratio (WSI)

of the area Sl on the left side of the
flow control valve (2) and the area S2 on the right side of the pressure reducing valve (1) to suite the
characteristics of each actuator and determines the compensation characteristics.
Sl : Area of the flow control valve (2) - area of the piston (3)
S2 : Area of the pressure reducing valve (I) - area of the piston (3)
l
9JUOOl26
Area ratio (Sl:S2) and compensation characteristics

l
When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pressure PPB] + [LS circuit pressure PLS -Actuator circuit pressure PA (= A)] can
be held, and the flow is distributed as per the spool opening area ratio.
l
When the ratio is more than 1 .OO: The expression PP - PPB > PLS - PA (= A) can be held, and the flow
is distributed less than the spool opening area ratio.
l
When the ratio is less than 1.00 : The expression PP - PPB c PLS - PA (= A) can be held, and the flow
is distributed more than the spool opening area ratio.
1 O-60
PC1 28UU-2
STRUCTURE
AND FUNCTION
BOOM HYDRAULIC DRIFT PREVENTION
CLSS
VALVE
Function
l
This valve prevents boom bottom oil from
leading from the spool (I) and prevents the
boom from falling naturally when the boom
lever is out of operation.
1.
At boom raise
QJUOO127
Operation
l
When the boom is raised, the main pressure
from the control valve will push the poppet
(5) upward. And the main pressurized oil from
the control valve will flow to the boom cylinder bottom through the valve inside.
PC1 28UU-2
lo-61
STRUCTURE
2.
AND FUNCTION
CLSS
Boom lever at neutral
9JUOO128
Operation
l
When the control lever is returned to NEUTRAL while the boom is raised, the holding
pressure on the boom cylinder bottom is confined with the poppet (5). At the same time,
the pressurized oil flown in the inside through
the orifice a is confined with the pilot spool
(3). Then, the boom is held neutral.
1 O-62
PC1 28UU-2
STRUCTURE
3.
AND FUNCTION
CLSS
At boom lower
9JUOOl29
Operation
l
When the boom is lowered, the pilot pressure
Pl from the PPC valve will push the pilot spool
(3) and drain pressurized oil from the b chamber inside the poppet.
l
The pressurized oil from the boom cylinder
bottom raises the oil pressure in the Ab port
but reduces the pressurized oil in the b chamber through the orifice a.
l
When the pressure in the b chamber drops
below the pressure in the Aa port, the poppet
(5) will open, and the pressurized oil from the
Ab port will be led to the Aa port and flow in
the control valve.
PC1 28UU-2
1O-63
STRUCTURE
AND FUNCTION
CLSS
13ooM REGENERATION CIRCUIT

1. At boom lower and own weight fall
Function
l
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.
9JUOO130
Operation
l
When the boom is lowered and falls due to
its own weight, the bottom side pressure A in
the boom cylinder (1) will rise above the head
side pressure B.
1O-64
At the time, part of the return flow on the bottom side passes through the regeneration
passage a of the boom spool (2), pushes the
check valve (3) to open it and flows to the head
side.
This increases the boom lower speed.
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
2. At boom lower load process

Funiztion
l
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
ioad process, the check valve (3) will be
closed, and the circuits on the head side and
the bottom side will be interrupted.
9JUOOl31
Operation
When the boom is lowered and is in the load
process, the head side pressure B of the boom
cylinder (1) rises above the bottom side pressure A.
PC1 28UU-2
At the time, the head side pressure B and the

spring (4) close the check valve (31, and the
circuits on the head side and the bottom side
are interrupted.
1O-65
STRUCTURE
CLSS
AND FUNCTION
ARM REGENERATION CIRCUIT

1. At arm in and own weight fall
Function
When the arm falls due to its own weight bel
cause 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.
PLS
9JYOO300
Operation
When the arm falls for digging due to its own
l
weight, the head side pressure A in the arm
cylinder (1) will rise above the bottom side
pressure B.
At the time, part of the return flow on the head
l
side passes through the regeneration passage
a of the arm spool (21, pushes the check valve
(3) to open it and flows to the bottom side.
This increases the arm digging speed.
l
1O-66
1.
2.
3.
Arm cylinder
Arm spool
Check valve
A : Head circuit (pressure)

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

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

1.
When traveling
CLSS
circuit)
straight
SJPO7615
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Function
l
When the L.H. and R.H. travel spool is operated to compensate flow errors in the L.H. and
R.H. travel circuits during straight travel, the
junction circuit will open.
l
Then, theflows to the L.H. and R.H. travel motors will become the same during the straight
travel, and travel deviation will decrease.
l
At the time of steering, load pressure difference brings back the pressure reducing valve
of the travel valve inside the steering and
closes the spool notch opening of the travel
junction valve to close the junction circuit for
steering.
Operation
l
When the L.H. and R.H. travel spool (I) is operated, the pump delivery will flow from the
pump circuit PP to A through the actuator circuit PA.
l
When traveling straight, the actuator circuit
PA will be equalized and the L.H. and R.H.
pressure reducing valves (2) will be pressed
the same stroke to the right. Then, the notch
a and the junction circuit will open.
l
The L.H. travel forward oil pressure Pl and
the R.H. travel forward oil pressure P2 are led
to the spring chamber on the both end of the
travel junction valve spool (4) through the respective shuttle valves (5). So, Pl = P2, and
the spool is at the neutral position, and the
notch d is lopen?.
l
Then, the L.H. and R.H. travel actuator circuits
are interconnected with the junction circuit.
When any difference occurs in the flows to
the L.H and R.H. travel motors, this valve will
compensate them and will reduce occurrence
of travel deviations.
PC 128UU-2
1 O-69
STRUCTURE
CLSS
AND FUNCTION
..
2.
When operating
travel steering
~X11111,,,,,,,
PP
1O-70
5/
Pl
d:rz
SJPO7616
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Operation
l
When the L.H. travel spool (L.H. 1) is returned
to the neutral side from the straight traveling
state and the steering is operated, there will
occur any difference in the load pressures in
the L.H. and R.H. travel actuator circuits PA
(R.H. A > L.H. A). The LS pressure PLS will
become the same as the R.H. A on the higher
load pressure side.
l
Therefore, the flow control valve on the L.H.
travel side is pressed to the left side with the
LS pressure PLS, i.e., the load pressure on the
R.H. travel side, and the notch a closes to interrupt the L.H. and R.H. travel circuits. Also,
since the pressures in the spring chambers
on the both ends of the travel junction valve
spool (4) become different and Pl becomes
higher than P2, the spool (4) moves to the PI
side and the notch d closes. Then, the steering can be operated.
l
The damper is provided to relax the transition characteristics of the junction circuit at
the time of abrupt operation.
PC1 28UU-2
1o-71
STRUCTURE
AND FUNCTION
CLSS
TRAVEL LS BYPASS CIRCUIT

1.
At normal operation
9JUOO13
1 O-72
16
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
Function
When an actuator is operated during travel,
this circuit will increase the discarded throttled
flow of the LS circuit PLS, loosen the pressure compensation accuracy of the travel circuit and limits reduction of the travel speed
to small extent.
The bypass circuit is closed in case of independent travel or independent operation of
an actuator.
Operation
When the boom spool (I) is operated, the LS
circuit PLS will come to the same pressure as
the boom circuit pressure Al.
At the same time, the LS circuit pressure PLS
is led to the spring chamber PLSI of the pressure reducing valve (2) of the travel valve.
Since the travel spool is not operated, the
travel actuator circuit PA is closed and the
check valve (4) inside the flow control valve
(3) is also closed.
Therefore,
the travel LS bypass circuit is
closed in case of independent operation of the
boom.
PC1 28UU-2
1o-73
STRUCTURE
2.
AND FUNCTION
At operation
CLSS
of travel + other actuator
9JYOO
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Operation
When the boom spool (I) is operated, the LS
circuit PLS will come to the same pressure as
the boom circuit pressure Al.
Since the actuator circuit pressure is generally higher at boom RAISE than during travel
(Al > A2), the pressure in the spring chamber
PLSl of the flow control valve (3) on the travel
side is higher than the travel circuit pressure
PA.
So, the pressure reducing valve (2) moves to
the left side, and the LS pressure of the spring
chamber PLSl pushes the check valve (4) from
the orifice a to open it and flows to the travel
circuit PA through the passages b and c.
Therefore, when the LS circuit pressure PLS,
which has been as high as the boom circuit
pressure Al, flows to the travel circuit A2, the
pressure will drop.
PC1 28UU-2
1o-75
STRUCTURE
CLSS
AND FUNCTION
3. At simultaneous operation of boom + swing

Function
l
When the boom is raised at the time of swinging, the swing pool stroke will be controlled
and the flow to the boom will be distributed
more to raise the boom more.
1)
When the boom is not raised
9JYOOO24
Operation
l
Since the SA and SB ports are interconnected
to the drain and no force is given to the piston (2), the stroke of the spool (1) is not controlled.
So, the spool (1) comes to the cases
(4) and (5) and the stroke increases by STl.
This increases the filtering oil flow.
1 O-76
1.
2.
3.
4.
5.
Spool (swing)
Piston
Plug
Case
Case
ST1 : Spool stroke
PC128UU-2
STRUCTURE
2)
AND FUNCTION
At simultaneous
operation
CLSS
of boom RAISE
ST0
ST0
9JYOOO25
Operation
l
When the boom RAISE PPC pressure is led to
the piston (2) as the stroke control pilot pressure PS through the SA and SB ports, the piston (2) will be pressed in the inner direction.
l
At the time, the maximum stroke of the spool
(1) will shorten (by STO) due to control of the
piston (2). Boom RAISE OFF ST1 > Boom
RAISE ON ST0
l
The spool (I) stroke is controlled and shortens. If the boom is raised at the time of swing
(hoist swing), the notch a opening area will
decrease.
So, the flow distribution
to the
boom will increase and the boom will rise
higher at the time of hoist swing.
PC1 28UU-2
1o-77
STRUCTURE
CLSS
AND FUNCTION
SWING BLEED VALVE

Function
l
For swing operation, a bleed valve is provided
to the pressure reducing valve to raise the LS
pressure slowly and to smooth the swing operation.
1.
Swing at neutral position
Bleed-off
circuit
SVPO7617
Operation
l
Since the notch a of the pressure reducing
valve (1) and the LS circuit are closed and the
bleed-off circuit and the LS circuit are also
closed, the LS pressure PLS is not affected by
operation of other work equipment.
l
The pump discharge pressure PP is also interrupted from the bleed-off circuit with the
piston (2) and is not affected.
l
The notch b of the bleed spool (3) and the
bleed-off circuit are interconnected each other.
1 O-78
PC128UU-2
STRUCTURE
2.
AND FUNCTION
At swing fine control
CLSS
Bleed-off
circuit
SVPO7616
Operation
The pressure reducing valve moves in the
right direction, and the notch a and the LS
circuit interconnect
each other. Also, the
pump circuit PP, the bleed-off circuit and the
LS circuit interconnect each otherthrough the
piston (2).
The bleed spool (3) moves in the left direction in proportion to raise of the swing PPC
pressure PA. But the notch b throttles and
interconnect to the bleed-off circuit in the fine
control region and determines the intermediate pressure before the pump discharge pressure PP is reduced and applied to the LS pressure PLS.
Therefore, the intermediate
pressure is set
lower than the pump discharge pressure PP
and rises as the bleed spool (3) moves.
So,
the LS pressure PLS rises slowly.
PC1 28UU-2
1o-79
STRUCTURE
3.
AND FUNCTION
CLSS
At full swing operation
LS circuit
L4
Jt2
M
PLS
PP
Bleed-off
circuit
SVP07619
Operation
l
When the swing PPC pressure PA comes to
the maximum, the notch b of the bleed spool
(3) interrupt the bleed-off circuit. The intermediate pressure becomes equal to the pump
discharge pressure PP, and the LS pressure
PLS becomes equal to the actuator circuit
pressure.
1 O-80
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
VARIABLE PRESSURE COMPENSATION

(forservice
VALVE
valve)
Function
l
Jn compound operation of the service valve (for attachment) and work equipment valve like boom
RAISE, this variable pressure compensation valve can adjust flow distribution to the service valve.
(The equivalent area ratio is variable.)
l
Spring (4) force can be adjusted with the screw (5).
1.
In case of compound
operation
with high load work equipment
(like boom RAISE)
To SPOOI
SJPO7620
Operation
The pump discharge pressure PP and the LS
pressure PLS depends on other work equipment.
When the pressure in the a chamber reaches
the set pressure of the spring (4), the poppet
(3) will open, and the throttle b maintains the
pressure in the a chamber below the pump
discharge pressure PP.
Therefore, the force F, which is required for
the pressure reducing valve (2) to close the
flow control valve (I), becomes smaller.
This means that the flow control valve (1)
moves in the right direction and the flow from
the pump to the service valve increases just
like the area ratio has reduced.
PC1 28UU-2
1.
2.
3.
4.
5.
6.
7.
Flow control valve

Pressure reducing valve
Poppet
Spring
Screw
Lock nut
Polyethylene cap
lo-81
STRUCTURE
AND FUNCTION
CLSS
LS SELECT VALVE
Function
l
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.
1.
During normal operation
To LS valve
SVPO7621
Operation
l- The pilot pressure is not generally applied to
the pilot port BP except for boom RAISE operation.
l
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.
1 O-82
PC1 28UU-2
STRUCTURE
2.
AND FUNCTION
At simultaneous
operation
CLSS
of swing + boom RAISE
9JYOOO31
Operation
. At the simultaneous
operation of swing +
boom RAISE, the signal pressure of the PPC
circuit is led to the pilot port BP.
. 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 (I) will close
and the pump discharge pressure PP will not
come to flow to the pressure reducing valve
(4) of the swing valve.
. Then, the swing pressure does not cause LS
pressure PLS, but the LS pressure PLS cause
the boom RAISE pressure is led to the pump
LS valve, and the pump delivery is controlled
with the boom RAISE LS pressure.
. The pilot pressure BP depends on the control
lever stroke.
PC128UU-2
1 O-83
STRUCTURE
SELF PRESSURE REDUCING
AND FUNCTION
VALVE
SELF PRESSURE REDUCING VALVE
PR
pi
0
0
9JUOOO62
PI : From pump
PR : Supply to solenoid valve, PPC valve and EPC
va Ive.
T : To hydraulic tank
1 O-84
PC1 28UU-2
STRUCTURE
AND FUNCTION
VALVE
A-A
Id
3
B-B
1.
2.
3.
4.
5.
6.
Control valve block

Valve (sequence valve)
Spring
Screw
Poppet
Spring (pressure reducing valve pilot)
PC1 28UU-2
7.
8.
9.
10.
11.
ii
9JUOOO63
Spring (pressure reducing valve main)

Valve (pressure reducing valve)
Spring (safety valve)
Ball
Filter
1 O-85
STRUCTURE
AND FUNCTION
VALVE
__-_--__-__
Function
The self pressure reducing valves reduces the
l
discharge pressure of the main pump and
supplies it to the solenoid valve, the PPC valve,
etc. as the control pressure.
M IN3. 66MPa
ort
PI P
ort
T Port
Hydraulic
circuit
SVP07622
1.
At engine stop (total low pressure)
SVP07623
Operation
The spring (6) pushes the poppet (5) t the seat,
l
and the circuit between the ports PR and T is
closed.
The spring (7) pushes the valve (8) to the left
l
side, and the circuit between the ports Pl and
PR is open.
1O-86
The spring (3) pushes the valve (2) to the left

side, and the circuit between the ports Pl and
P2 is closed.
PC128UU-2
STRUCTURE
AND FUNCTION
VALVE
2. At neutral and reduction of load pressure P2 (at own weight fall in boom LOWER and arm IN)
Note : When the load pressure P2 is lower than the output pressure PRof the self pressure reducing valve.
SVP07624
Operation
l
The spring (3) and the PR pressure (0 MPa (0
kg/cm21 at the time of engine stop) pushes
the valve (2) in the direction to close the circuit between the ports Pl and P2. When the
hydraulic oil enters the Pl port, the expression (Pl pressure G Spring (7) force + (ad area
x PR pressure)) holds, and the self pressure
reducing valve will adjust the openings of the
ports Pl and P2 so that the Pl pressure can
be maintained higher than the PR pressure.
l
When the PR pressure rises above the set
pressure, the poppet (5) will open and the hydraulic oil flows through the route from the
PR port, the hole a in the spool (8), the poppet (5) opening to the tank port T.
PC1 28UU-2
Therefore, there will occur a differential pressure around the hold a in the spool (8) and
the spool will move in the direction to close
the port Pl and the PR opening. Then, the Pl
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and
is supplied as the PR pressure.
1 O-87
STRUCTURE
3.
AND FUNCTION
VALVE
At raise of load pressure P2
SVP07625
Operation
l
When the load pressure P2 rises due to digging or other operations, the pump delivery
will increase and the Pl pressure will rise.
Then, the expression (Pl pressure > Spring
(7) force + (ad area x PR pressure)) will hold,
and the valve (2) will move to the right side
till the stroke end. As a result, the opening
between the ports Pl and P2 will increase, the
passage resistance will become smaller to
reduce engine loss horsepower.
1O-88
When the PR pressure rises above the set

pressure, the poppet (5) will open and the hydraulic oil will flow through the route from
the PR port, the hole a in the spool (81, the
poppet (5) opening to the tank port T.
Therefore, there will occur a differential pressure around the hold a in the spool (8) and
the spool will move in the direction to close
the port Pl and the PR opening. Then, the Pl
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and
is supplied as the PR pressure.
PC1 28UU-2
STRUCTURE
4.
AND FUNCTION
At occurrence
of abnormal
VALVE
high pressure
SVP07626
Operation
l
When the PR pressure of the self pressure reducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports PR + T so as to reduce the PR
Then, the equipment (PPC valve,
pressure.
solenoid valve, etc.), to which the oil pressure
is supplied, is.protected from the abnormal
high pressure.
PC1 28UU-2
1 O-89
STRUCTURE
AND FUNCTION
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
Rl
E2
c2
A2
F2
DR2
9JAOl352
1.
2.
3.
4.
5.
Al
A2
Bl
B2
Cl
C2
Dl
02
Cover
Body
Slipper seal
Dust seal
Shaft
: From control
: To R.H. travel
: From control
: To L.H. travel
: From control
: To R.H. travel
: From control
: To L.H. travel
1O-90
: From travel 2nd speed selector solenoid

valve
E2 : To L.H./R.H. travel motor D
: From control valve (Blade LOWER)
Fl
F2 : To L.H./R.H. blade cylinder bottom
: From control valve (Blade RAISE)
Gl
G2 : To L.H./R.H. blade cylinder head
DRl : To hydraulic tank
DR2 : From L.H. travel motor Cl, R.H. travel motor C2
El
valve (R.H.
motor B
valve (L.H.
motor A
valve (R.H.
motor A
valve (L.H.
motor B
travel Forward)
travel Forward)
travel Reverse)
travel Reverse)
PC128UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
TRAVEL MOTOR (FINAL DRIVE)
I-
!_
iI_
i- iT
I-Iu.
i_
9JA01338
A : From control valve (L.H./R.H. travel)

B : From control valve (L.H./R.H. travel)
Cl : To hydraulic tank (L.H. travel motor)
Plug (R.H. travel motor)
C2 : Plug (L.H. travel motor)
To hydraulic tank (R.H. travel motor)
D : From travel 2nd speed selector solenoid valve
PC1 28UU-2
1o-91
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
A-A
34
B-B
9JA01339
1. Plug
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Check valve spring

Check valve
Return spring
Counterbalance valve
Safety valve
Safety valve spring
End cover
Regulator valve
Spring
Brake piston
Cylinder
Spring
Swash plate
Pivot
Crankshaft
RV gear A
1 O-92
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
RV gear B
Cover
Driven gear
Drive gear
Drain plug
Hub
Regulator piston
Spindle
Piston
Floating seal
Plate
Disc
Valve plate
Spring
Piston
Plug
Check valve
PC1 28UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
SPECIFICATION
Type : GM18VL-J
Theoretical delivery (Hi) : 37.2 cm3/rev{37.2 cc/rev}
(Lo) : 52.7 cm3/rev{52.7 cc/rev}
Rated speed (Hi) : 2916.3 rpm
(Lo) : 2147.3 rpm
Brake releasing pressure : 0.68 MPa (6.94 kg/cm*}
Speed change pressure : 2.94 MPa (30 kg/cm*}
Reduction ratio : 72
OUTLINE
Travel speed change
9JA01340
The swash plate has two planes x and y on

the back and is supported with the pivot (15).
To change the travel speed, the pressurized
oil in the control chamber a is sent to the regulator piston (24) to maximize or minimize the
angle of the swash plate (14).
PC1 28UU-2
1o-93
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
OPERATION
Operation of motor
At slow speed (the motor swash plate angle is maximized.)
Z-Staae
selection
Travel
so
speed
SVPO7774
Since the travel 2nd speed selector solenoid

valve is demagnetized,
the pressurized oil
from the main pump does not flow to the D
port.
Therefore, the spring (IO) has pressed the
regulator valve (9) to the left side.
So, the regulator valve (9) stops the main pressurized oil led from the control valve to the
end cover by pushing the check valve (34).
The pressurized oil in the control chamber
drains in the motor case through the passage
b of the regulator valve (9).
Then, the main pressurized oil from the cylinder c chamber pushes the swash plate (14) in
the direction to maximize the swash plate
angle and the motor capacity is increased to
the maximum for slow speed travel.
1o-94
PC1 28UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
At high speed (the motor swash plate angle is minimized.)
SVPO7775
When the travel 2nd speed selector solenoid

valve is energized, the pilot pressure from the
main pump will flow in the D port and push
the regulator valve (9) in the right direction.
Therefore, the main pressurized oil from the
control valve passes through the passage b
of the regulator valve (9), flows in the control
chamber a and pushed the regulator piston
(24) in the left direction.
Then, the swash plate (14) is pressed in the
direction to minimize the swash plate angle,
and the motor capacity is minimized for high
speed travel.
PC128UU-2
1o-95
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
Operation of brake valve

l
The brake valve consists of the check valves
(3a) and (3b), the counterbalancevalve
(5) and
the safety valve (6), and the circuit configuration is as per the right figure.
l
Functions and operations of these components are as follows :
3a
SJP07627
Counterbalance valve, check valve

Function
l
When traveling down a slope, the own weight
falling force will make the machine travel
So, traveling
faster than the motor rotation.
with reduced engine speed is very dangerous
because the motor idles and runs away.
These valves let the machine travel at a speed
appropriate for the engine speed (pump delivery) to prevent this danger.
3a
Operation at oil supply

l
When the travel lever is operated, the pressurized oil from the control valve will be supplied to the PA port, push and open the check
valve (3a) and flow from the MA port on the
motor inlet side to the MB port on the motor
outlet side.
Since the motor outlet circuit is closed with
the check valve (3b) and the counterbalance
valve (51, however, the supply-side pressure
will rise.
SJP07628
1 O-96
PC1 28UU-2
STRUCTURE
AND FUNCTION
The pressurized oil on the supply side flows

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

l
If the machine is going to run away when traveling downhill, the motor will idle to reduce
the oil pressure on the motor inlet side and
the pressure in the Sl chamber through the
orifice El.
When the pressure in the Sl chamber drops
below the switching pressure of the counterbalance valve, the counterbalance
valve (5)
will be returned in the left direction with the
return spring (4), and the outlet side MB port
will be throttled.
Then, the pressure on the outlet side will rise
and rotation resistance will occur to the motor to prevent the machine from running
away.
This means that the counterbalance valve (5)
moves to a position where the machine own
weight and the inlet side pressure balance
with the pressure at the outlet side MB port,
and the outlet circuit is throttled to control
the speed to the pump delivery.
PC1 28UU-2
SJPO7630
1o-97
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
Safety valve
Function
l
When stopping a travel (or traveling downhill), the counterbalance valve (5) will close
the inlet and outlet circuits of the motor. Since
the motor keeps rotating by inertia, however,
the pressure on the outlet side of the motor
will rise abnormally and the motor and pipes
may be damaged. Then, the safety valve leads
the abnormally high pressure to the inlet side
of the motor to prevent the equipment from
being damaged.
Operation
When the pressurized oil being supplied from
the PA port is stopped flowing at the time of
travel stop, the return spring (4) will return
the counterbalance
valve (5) from the right
side to the left side (the neutral position).
Though the counterbalance
valve (5) closes
the a chamber on the outlet side circuit, the
inertia lets the motor rotate and the pressure
in the a chamber rises.
The highly pressurized oil in the a chamber
passes through the throttle b of the safety
valve (6a) and enters in the d chamber from
the c chamber.
The pressurized oil entered
in the d chamber moves the piston (32) to the
left side. Meantime, the safety valve (6a) is
pushed to open by the pressurized oil in the a
chamber, and the pressurized
oil in the a
chamber flows in the f chamber through the
e port. Therefore, the pressurized oil in the a
chamber flows in the f chamber at a comparatively slow speed to control the pressure in
the a chamber and also to prevent cavitation
in the f chamber at the same time.
When the piston (32) reaches the stroke end,
the pressures in the d and c chambers will
rise, the safety valve (6a) will be closed again
and the pressure in the a chamber will rise
further.
Then, the safety valve (6b) will open and the
pressurized oil in the a chamber will flow in
thef chamber from the g chamber. The pressure in the a chamber can be controlled in
two stage as mentioned above, and the hydraulic motor can be smoothly braked to stop.
SJP07631
[
/
SJP07632
1 O-98
PC1 28UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
Operation of parking brake

When operating travel
When the travel lever is operated, the presl
surized oil from the pump will work on the
counterbalance valve (51, open the circuit a
to the parking brake and flow in the b-chamber of the brake piston (11).
pressure in the b chamber overcomes the
The
l
spring (31) and pushed the brake piston (11)
in the left direction.
This will eliminate the press force to the plate
l
(28) and the disc (29), and the plate (28) and
the disc (29) will separate, and the brake force
will be released.
SJP07633
When positioning travel neutral

When the travel lever is brought to the neul
tral position, the counterbalance valve (5) will
return to the neutral position and the circuit a
to the parking brake will be closed.
The pressurized oil in the b chamber of the
l
brake piston (11) will be drained in the case,
and the spring (31) will push the brake piston
in the right direction.
Therefore, the plate (28) and the disc (i9) will
l
be pushed to each other, and the brake will
come to work.
SJP07634
PC1 28UU-2
10-99
STRUCTURE
AND FUNCTION
SWING MOTOR
SWING MOTOR
TYPE : KMF4OAEL-3
MB
MA
9JYOO302
B
S
T
MA
MB
: From swing
: From control
: To tank
: From control
: From control
10-100
brake solenoid valve

valve
valve
valve
Specification
Type : KMF40AEL-3
Theoretical delivery : 40.2 cm3/rev
Safety valve set pressure : 27.5 MPa (280 kg/cm2)
Rated speed : 2,011 rpm
Brake releasing pressure :
1.4 - 2.2 MPa(l4 - 22 kg/cm2}
PC1 28UU-2
SWING MOTOR
20
B-B
li
ti
il io
A-A
9JYOO303
1.
2.
3.
4.
5.
6.
7.
8.
9.
Drive shaft
Spacer
Case
Disc
Plate
Brake ring
Brake piston
Housing
Reverse prevention
PC128UU-2
valve
IO.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Center spring
Cylinder
Valve plate
Piston
Center shaft
Safety valve
Check valve
Check valve spring
Shuttle valve
Shuttle valve spring
Brake spring
10-101
STRUCTURE
AND FUNCTION
SWING
MOTOR
SWING BRAKE
1. When solenoid valve is demagnetized
Operation
l
When the solenoid valve of the swing brake
is demagnetized, the pressurized oil from the
control pump will be interrupted and the B
port will be connected to the tank circuit.
l
Then, the brake piston (7) will be pressed
downward with the brake spring (8) and will
push the disc (4) and the plate (5) to work the
brake.
Ive
SJP07635
2. When solenoid valve is energized

Operation
l
When the solenoid valve of the swing brake
is energized, the valve will be changed over
and the pressurized oil from the control pump
will enter the B port and will flow in the brake
chamber A.
l
The pressurized oil in the A chamber will push
the brake spring (8) and the brake piston (7)
will move upward. Then, the disc (4) and the
plate (5) will separate to release the brake.
SJP07636
10-102
PC1 28UU-2
STRUCTURE
AND FUNCTION
SWING
MOTOR
BRAKE VALVE
Outline
l
The brake valve consists of the check valve
(15), the shuttle valve (17) and the modulating relief valve (19).
Function
l
When the swing stops, the control valve will
close the outlet circuit of the motor, but the
inertia will keep the motor rotating. So, the
motor output pressure rises abnormally and
the motor is damaged.
So, the brake valve
leads the abnormally high pressure from the
outlet side (high pressure side) to the S port
to prevent the motor from being damaged.
1. When swing starts
Operation
l
When the swing operation lever is turned to
the right, the pressurized oil from the pump
will be led to the MA port through the control
valve. Then, the pressure at the MA port will
rise, generate starting torque to the motor and
start the motor rotating.
The oil from the
motor outlet will return to the tank from the
MB port through the control valve.
SJP07771
2. When swing stops

Operation
When the swing operation lever returns to the
neutral position, the pressurized oil from the
pump will not be led to the MA port. Since
the control valve closes the return circuit to
the tank, the oil from the motor outlet will raise
the pressure at the MB port and generate rotation resistance to the motor to work the
brake.
When the pressure at the MB port rises above
the one at the MA port, the shuttle valve (17a)
is pressed and the pressure in the C chamber
will rise as high as the one at the MB port.
Also, it will be raised to the set pressure of
the modulating relief valve (19). So, a high
brake torque will work on the motor and stop
it. (No. 2 Figure)
While the modulating relief valve (19) is operating, the oil relieved from the safety valve
and the oil from the S port are led to the MA
port side through the checkvalve (15b) to prevent cavitation from occurring in the MA port.
SJP07772
PC1 28UU-2
10-103
STRUCTURE
SWING MOTOR
AND FUNCTION
OPERATION OF MODULATING
RELIEF VALVE
Function
l
The characteristic of the swing motor relief
valve is to restrain sharp rise of relief valve as
shown in the right figure and to reduce shocks
at the times of starting and stopping swing.
-:ModuIatina
-------:Normal
relief
relief
valve
valve
SJP07776
1. When circuit pressure is PO

Operation
l
The relief valve does not work.
D2
2. When circuit pressure rises sharply

Operation
When the circuit pressure reaches Pl, the oil
pressure will push the spring (4) due to the
area difference (DbD3) of the valve (3). Then,
the valve (3) will start opening.
At the time, the oil pressure will work on the
seat (1) due to the area difference (D2>Dl),
and the seat will be apt to follow the valve
(3).
But the seat is going to compress the oil in
the a chamber and moves more slowly than
the valve (3) because the passage through
which the oil escapes to the S port is throttled
with the ball (2).
So, the relief pressure will rise slowly from
Pl to P2 until the seat (1) comes to the sleeve
(5).
03
Dl
9JYOO306
9JYOO307
P2
9JYOO306
10-104
PC1 28UU-2
REVERSE PREVENTION
SWING MOTOR
VALVE
1
0
--I-___
_-J
5
A-A
1.
2.
3.
4.
5.
6.
7.
MA
L____
Tl
T2
MB
Z
9JUOOO72
Valve body
Spool (MA side)
Spring (MA side)
Plug (MA side)
Spool (MB side)
Spring (MB side)
Plug (MB side)
MA :
MB:
Tl :
T2 :
Port
Port
Port
Port
PC128UU-2
10-105
STRUCTURE
AND FUNCTlON
Effect explanation
SWING MOTOR
drawing
:With
reversal
rotation
Prevention
valve
,Without
reversal
rotation
Prevention
valve
MA Pressure
MB Pressure
Motor
rotat
ion
Start
Brake
Time
SJPO7637
10406
PC128UU-2
STRUCTURE
SWING MOTOR
AND FUNCTION
Function
l
This function is used for reducing swing back
generated on a swing body that can result
from factors such as inertia of the swing body,
backlash and rigidity of the machinery system and compressibility of hydraulic oil.
l
This function helps preventing loose loads at
the end of swing or cutting lead time (better
positioning performance allows you to proceed to the next operation within a shorter
time).
I
/
II
I I
MB
Not/ch L!J
SJP07777
1. When MB port pressure is generated

Operation
l
MB pressure is conducted to d room via the
cutout. Utilizing difference of space (Dl>D2),
the pressure compresses the spring (6) and
drives the spool (5) leftward to interconnect
MB+e.
l
Since MA pressure at this time is lower than
the pressure set on the spring (3), the spool
(2) is not moved and pressurized oil remains
closed. Thus, the braking force is maintained.
SDP02.036
2. When the motor is once stopped

Operation
The motor is reverse rotated by charging pressure generated on the MB port (1st reverse
rotation).
At this time, reversing pressure is generated
on the MA port. MA pressure conducted to a
room interconnects MA + b by compressing
the spring (3) and driving the spool (2) rightward.
The pressure
is then conducted
through
drilled hole on the spool (5) to interconnect b
+ f. Reversing pressure on the MA port is
bypassed to the T port to disable the 2nd reverse rotation.
PC1 28UU-2
n
c
f
SDP02037
10-107
STRUCTURE
SOLENOID
AND FUNCTION
VALVE
SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND P-STAGE
RELIEF SOLENOID VALVE.
Al
A4
A3
A2
A-A
10
9JA01353
1.
2.
3.
4.

2nd travel speed select solenoid valve
Solenoid valve
5. Push pin
6. Coil
7. Gauge
8. Spool
9. Block
10. Spring
Al
A2
A3
A4
ACC
PI
T
: To PPC valve
: To 2-stage relief valve
: To swing hold brake
: To 2nd travel speed select valve
: To accumulator
: From self-pressure reducing valve
: To hydraulic oil tank
Check valve
11. Plug
12. Spring
13. Plunger
lo-108
PC128UU-2
STRUCTURE
AND FUNCTION
SOLENOID
VALVE
Operation
When solenoid is demagnetized
l
The coil (6) remains demagnetized as long as
signal current to it is stopped..
l
Thus, the spool (8) is pushed leftward by the
spring (10).
l
Since ports P to A are closed by this spool,
flow of pilot oil pressure to the actuator is
blocked. At the same time, oil from the actuator. is lead from A port to T port, then
drained to the hydraulic oil tank.
SJP07636
When solenoid is magnetized

The coil (6) is magnetized by signal current
conducted to it.
Thus, the spool (8) is pushed rightward by the
push pin (5).
As the result, pilot oil pressure is conducted
from P port through the cage (7) and A port
up the actuator.
At the same time, T port is closed, thereby
blocking flow of oil to the hydraulic oil tank.
Excit
I)
.
SJP07639
PC1 28UU-2
10409
EPC SOLENOID VALVE
EPC SOLENOID VALVE

FOR 4-SYSTEM
CONTROL
A-A
I6
I5
I4
I3
I2
A-A
9JBOOl30
10-110
PC128UU-2
STRUCTURE
1.
2.
3.
4.
5.
AND FUNCTION
EPC SOLENOID
VALVE
Offset right stop solenoid valve

Offset left stop solenoid valve
Boom up stop EPC valve
Arm retract stop EPC valve
Boom down stop EPC valve
EPC valve
6. Coil (proportional
7. Push pin
8. Valve spool
9. Guide
10. Return spring
11. Valve body
type)
Solenoid valve
12. Return spring
13. Guide
14. Valve spool
15. Push pin
16. Coil (ON - OFF type)
Check valve
17. Plug
18. Spring
19. Ball
Al : From offset PPC valve RIGHT
A2 : From offset:PPC valve LEFT
A3: From right work equipment
PPC valve
BOOM UP
A4 : From right work equipment PPC valve ARM
RETRACT
A5: From right work equipment
PPC valve
i
BOOM DOWN
Bl : To operation valve OFFSET RIGHT
B2 : To operation valve OFFSET RIGHT
B3 : To operation valve BOOM UP
B4 : To operation valve ARM RETRACT
B5 : To operation valve BOOM DOWN
T : To hydraulic oil tank
PC 128UU-2
10-111
STRUCTURE
EPC SOLENOID
AND FUNCTION
VALVE
OPERATION
Solenoid valve
When solenoid is demagnetized
(circuit is isolated)
l
The coil (1) is demagnetized when signal current from the controller to it is stopped.
l
Thus, the spool (2) is pushed up by the return
spring (4).
l
As the result, A port is closed, thereby stopping flow of oil pressure from PPC valve to
the operation valve.
At the same time, oil from the operation valve
is conducted to B port through T port and finally drained to the tank.
SJPO7640
When solenoid is magnetized

(circuit is in connection)
l
The coil (1) is magnetized by signal current
conducted to it from the controller.
l
Thus, the spool (2) is pushed down by the
push pin (3).
l
As the result, pressurized oil from the PPC
valve is conducted to A portthrough the spool
(2) and B port up to the operation valve.
blocking oil flow to the tank.
Control
valve
SJPO7641
10-112
PC1 28UU-2
STRUCTURE
AND FUNCTION
EPC SOLENOID
VALVE
EPC valve
When signal current is maximized (coil is magnetized and circuit pressure at maximum level)
l
The coil (1) is magnetized when signal current is conducted to it from the controller.
Thrust of the coil (1) is maximized at this time.
l
Thus, the spool (2) is pushed down by the
push pin (3).
l
As the result, all the pressurized oil from the
PPC valve is conducted to A port through the
spool (2) and B port up to the operation valve.
blocking flow of oil to the tank.
SJP07642
When signal current is reduced (coil is magnetized and circuit pressure at a reduced level)
l
If signal from the controller to the coil (1) is
reduced, the coil thrust is reduced in proportion to the reduction in signal current though
the coil (1) still remains magnetized.
l
Thus, the push pin (3) pushes the spool (2)
downward, thereby conducting pressurized
oil from A port to B port.
l
If working force of the spool (2) against face a
becomes greater than thrust of the coil (1)
because of increased pressure on B port, the
spool (2) is pushed up thereby disconnecting
A port from B port and, at the same time, connecting A port to T port.
l
As the result, the spool (2) moves up and
down so that thrust of the coil (1) and pressure on B port may be balanced.
l
Circuit pressure between PPC valve and operation valve is, as seen above, adjusted in
proportion to magnitude of signal current.
SJP07643
PC1 28UU-2
10-113
STRUCTURE
AND FUNCTION
EPC SOLENOID
VALVE
Signal current 0 (coil is demagnetized and circuit

in isolation)
l
If signal current from the controller to the coil
goes to 0, the coil (1) is demagnetized.
l
Thus, the spool (2) is pushed up by the return
spring (4).
l
As the result, A port is closed, thereby blocking flow of pressurized oil from the PPC valve
to the operation valve.
At the same time, oil from the operation valve
is passed through B and T ports, and finally
drained to the tank.
:
Control
valve
wit
,,,i
SJP07644
Signal current 0 + increased + maximum

l
Operation takes place in the above order of 3
*2+1.
10-114
PC128UU-2
STRUCTURE
PPC ACCUMULATOR
AND FUNCTION
PPC ACCUMULATOR
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
SBPOO290
Specifications
Gas used : Nitrogen gas
Gas capacity : 0.3~?
Charged gas pressure :
1.18 MPa (12 kg/cm*) at 80C
Maximum
operating pressure :
6.86 MPa (70 kg/cm*)
PC1 28UU-2
10-115
STRUCTURE
AND FUNCTION
PPC VALVE
PPC VALVE
FOR SWING OF WORK EQUIPMENT
9JYOOO39
P : From main pump

Pl : Left: Arm for dump/Right : Boom down
P2 : Left : Arm for digging/Right : Boom up
lo-116
P3 : Left : Swing right/Right : Bucket for digging

P4: Left : Swing left/Right : Arm for dump
T :Totank
PC1 28UU-2
PPC VALVE
A-A
D-D
E-E
SBPO0274
1. Spool
2. Metering spring
3. Centering spring
4. Piston
PC1 28UU-2
5.
6.
7.
8.
Disk
Nut (for linking the lever)
Joint
Plate
9. Retainer
10. Body
11. Filter
10-117
STRUCTURE
AND FUNCTION
PPC VALVE
Operation
1. In the neutral mode
l
Pl and P2 ports of the operation valves A and
B and the PPCvalve are connected to the drain
room D via the fine control hole on the spool
(1).
:::
2.
.
In the fine control mode

(neutral 4 fine control)
When the piston (4) is pushed by the disk (5),
the retainer (9) is also pushed, thereby driving the metering spring (2) down via the spool
(1).
As the result, the fine control holef is isolated
from the drain room D and, almost at the same
time, it is connected to the pump pressure PP.
Then, pilot pressurized oil for the main pump
is conducted from Pl port to A port via the
fine control hole f.
As pressure on Pl port is increased, the spool
(1) is pushed back thereby disconnecting the
fine control hole f from the pump pressure
room PP. The disconnected spool (1) is in no
time connected to the drain room D, resulting in relieving pressure on Pl port.
Thus, the spool (1) is moved up and down so
that force of the metering spring (2) and pressure on Pl port may be balanced. Positional
relationship between the spool (1) and body
(IO) (fine control hole f is situated at mid point
between the drain room D and pump pressure room PP) remains unchanged until the
retainer (9) is contacted against the spool (1).
Therefore, the metering spring (2) is compressed in proportion to strokes of the operation lever. So, pressure on Pl port is also increased in proportion to strokes of the operation lever.
As the result, the operation valve spool is
moved up to the position where pressure in
A room (the same pressure level as that on
Pl port) and force of the operation valve spool
return spring is balanced.
lo-118
/
L!zD
5::
~u,u,,,::
:
I
5
: Pl
:
/,I
5::
//,
:::
P2;
::
5, ,//////,
:
5
(Fig
1)
SEP0.2569
(Fig
2)
SEP02570
PC128UU-2
,STRUCTURE
3.
l
4.
l
AND FUNCTION
In the fine control modeloperating

lever
shifted back to its original position)
As the disk (5) starts returning, the spool (1)
is push up by force of the centering spring (3)
and pressure of Pl port.
Thus, passage between the fine control hole
f and drain room D becomes, thereby relieving pressurized oil of Pl port.
If Pl port pressure goes excessively low, the
spool (1) is pushed down by the metering
spring (2) and passage between the fine control hole f and the drain room D is shut down.
And, almost at the same time, the hole is connected to the pump pressure room PP and
starts supplying pump the pressure. This supply continues until the Pl port pressure is recovered to the level equivalent to the lever
position.
When the operation valve returns, oil in the
drain room D flows in through the fine control hole f on the not moving side valve. Oil
is then conducted via P2 port to the room B
to fill it up.
PPC VALVE
Control
valve
(Fig
3)
SEP02571
In the full stroke mode

When the disk (5) pushes down the piston (4)
and the retainer (9) pushes down the spool
(I), connection of the fine control hole f is
switched from the drain room D to the pump
pressure room PP.
Thus, pilot pressurized oil from the control
pump passes through the fine control hole f
and conducted to A room via Pl pot-t to push
the operation valve spool.
Return oil from B room is conducted from P2
port to the drain room D via the fine control
hole P.
Control
(Fig
PC1 28UU-2
valve
4)
SEP02572
10-119
STRUCTURE
PPC VALVE
AND FUNCTION
FOR TRAVEL
Pi
P2
/
Pi
P : From main pump

Pl : L.H reverse
P2 : L.H forward
10420
\
P3
9JYOOO44
P3 : R.H reverse
P4 : R.H forward
T :Totank
PC128UU-2
STRUCTURE
AND FUNCTION
PPC VALVE
A-A
B-B
c-c
1.
2.
3.
4.
Plate
Body
Piston
Collar
PC1 28UU-2
D-D
5.
6.
7.
9JYOOO45
Metering spring
Centering spring
Valve
10-121
STRUCTURE
PPC VALVE
AND FUNCTION
Operation
l
Pl and P2 ports of the operation valves A, B
and PPC valve are connected to the drain
room D via the fine control holef on the spool
(1).
(Fis.
2.
.

(neutral + fine control)
As the piston (4) is pushed by the disk (51, the
retainer (9) is pushed, too. At the same time,
the spool (1) is also pushed down via the
metering spring (2).
By this move, connection of the fine control
hole f is switched from the drain room D to
the pump pressure room PP, and pilot pressurized oil for the main pump is conducted
from PI port to A port.
As Pl port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure room PP to the drain room D, thereby
relieving PI port pressure.
down so that force of the metering spring (2)
and Pl port pressure may be balanced.
Positional relationship between the spool (I)
and body (10) (fine control hole f is situated
at mid point between the drain room D and
pump pressure room PP) remains unchanged
until the retainer (9) is contacted against the
spool (1).
The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the Pl port pressure, too,
increases in proportion to strokes of the operation lever.
As the result, the operation valve spool moves
to the position where pressure of A room (the
same as Pl port pressure) is balanced against
force of the operation valve spool return
spring.
10-122
1)
SElPO3497
ISelf-Reducing
111 v@f/
lsressure
valve]~
(F i s. 2)
SBPO3498
PC128UU-2
STRUCTURE
3.
.
4.
l
AND FUNCTION
PPC VALVE
In the ffine control mode (when operation lever is shifted back to its original position)
As the disk (5) starts returning, the spool (1)
is pushed up by force of the centering spring
(3) and Pl port pressure.
By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of Pl port to it.
If Pl port pressure goes excessively low, the
spring (2) and passage between the fine control holef and the drain room D is shut down.
starts supplying pump the pressure. This supply continues until the PI port pressure is recovered to the level equivalent to the lever
position.
When the operation valve spool returns, oil
in the drain room D flows in through the fine
control hole f on the not moving side valve.
Oil is then conducted via P2 port to the room
6 to fill it up.
(Fig.

(l), connection of the fine control hole f is
pressure room PP.
and conducted to A room via Pl port to push
hole f.
3)
SBPO3499
1 Pressure
valvd
j/f$Q
(F i o. 3)
SBPO3495
PC1 28UU-2
10423
STRUCTURE
PPC VALVE
AND FUNCTION
FOR BLADE, OFFSET
A-A
1.
2.
3.
4.
5.
6.
7.
8.
9.
Spool
Metering spring
Centering spring
Piston
Lever
Plate
Retainer
Body
Filter
P
PI
P2
T
: From main pump

:::Totank
lo-124
9JUOOO15
PC1 28UU-2
STRUCTURE
PPC VALVE
AND FUNCTION
Operation
Pl and P2 ports of the operation valves A, 6
l
and PPC valve are connected to the drain
room D via the fine control hole f on the spool
(1).
Pl
2.
.

(Neutral + fine control)
As the piston (4) is pushed by the disk (5), the
retainer (7) is pushed, too. At the same time,
the spool (1) is also pushed down via the
metering spring (2).
By this move, connection of the fine control
hole f is switched from the drain room D to
the pump pressure room PP, and pilot pressurized oil for the control pump is conducted
from PI port to A port.
As Pl port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure room PP to the drain room D, thereby
relieving Pl port pressure.
down so that force of the metering spring (2)
and Pl port pressure may be balanced.
Positional relationship between the spool (1)
and body (8) (fine control hole f is situated at
mid point between the drain room D and
pump pressure room PP) remains unchanged
until the retainer (7) is contacted against the
spool (1).
The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the Pl port pressure, too,
increases in proportion to strokes of the operation lever.
As the result, the operation valve spool moves
to the position where pressure of A room (the
same as Pl port pressure) is balanced against
valve spool return
force of the operation
spring.
PC1 28UU-2
SJP07646
SJPO7647
1O-l 25
STRUCTURE
3.
l
PPC VALVE
AND FUNCTION
In the fine control mode (when the operation

lever is shifted back to its original position)
As the lever (5) starts returning, the spool (1)
is pushed up by force of the centering spring
(3) and Pl port pressure. By this move, the
fine control hole f is connected to the drain
room D and relieves pressurized oil of PI port
to it.
If PI port pressure goes excessively low, the
spring (2) and passage between the fine control hole f and the drain room D is shut down.
starts supplying pump the pressure. This supply continues until the Pl port pressure is recovered to the level equivalent to the lever
position.
When the operation valve spool returns, oil
in the drain room D flows in through the fine
control hole f on the not moving side valve.
Oil is then conducted via P2 port to the room
B to fill it up.
SJP07648
4.
l

(l), connection of the fine control hole f is
pressure room PP.
and conducted to A room via Pl port to push
hole f.
Control valve
SJP07649
lo-126
PC128UU-2
STRUCTURE
AIR CONDITIONER
AND FUNCTION
AIR CONDITIONER
PIPING
PIPING
9JA01358
1.
2.
3.
4.
5.
6.
7.
8.
Hot water take-off piping

Air conditioner compressor
Condenser
Refrigerant piping
Receiver tank
Air conditioner unit
Hot water return piping
Duct
A: Hot air/cold air spurting hole

B: Inner air circulation hole
PC1 28UU-2
lo-127
STRUCTURE
ELECTRIC EQUIPMENT
AND FUNCTION
ELECTRIC EQUIPMENT
LAYOUT DRAWING
LAYOUT DRAWING
I!
30-
29
28
27
26
25
24
9JBOOl32
lo-128
PC1 28UU-2
STRUCTURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
AND FUNCTION
ELECTRIC EQUIPMENT
LAYOUT DRAWING
Expanded light (optional)

Fuel level sensor
Left working lamp
PC-EPC solenoid valve
Safety relay
Starter
Engine speed sensor
Coolant temperature sensor
Alternator
Ribbon heater
Engine oil pressure sensor
Air conditioner compressor
Heater relay
Engine stop solenoid valve
Condenser
Washer tank
Battery relay
Battery
Fusible link
Controller
Emergency arm retracting resistor (IOQ)
Emergency boom lifting resistor (5R)
Light relay
Emergency pump driving resistor (30R)
Air conditioner unit
Travel acceleration pedal
Deceleration controller
Travel pressure switch
Swing hold brake relief switch
Emergency pump driving switch
Attachment select connector [Arm]
Horn
Boom potentiometer
Left swing pressure switch
Right swing pressure switch
Boom down pressure switch [No. 11
Arm retract pressure switch
Boom up pressure switch
Arm potentiometer
2nd travel speed select solenoid valve
Right working lamp
Offset right solenoid valve
Offset left solenoid valve
Boom up EPC valve
Arm retract EPC valve
Boom down EPC valve
Offset potentiometer
Travel alarm (optional)
Boom down pressure switch [No. 21
PC1 28UU-2
1O-l 29
ELECTRIC EQUIPMENT LAYOUT DRAWING
62
63
9JBOOl
10-130
33
PC128UU-2
STRUCTURE
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.
AND FUNCTION
ELECTRIC EQUIPMENT
LAYOUT DRAWING
Hot air control switch

Air flow selector switch
Air conditioner switch
Horn switch
Monitor panel
Setup switch
Mode selector switch
One-touch deceleration pilot lamp
Starter switch
Fuse box
Fuel adjusting motor
Expanded light switch (optional)
Wiper controller
Car heater switch (Heater specification)
Wiper controller
Lamp switch
Travel speed selector switch
PPC lock switch
One-touch deceleration switch
Expanded light relay
Emergency work equipment operation switch
Alarm buzzer
Room lamp
Antenna
Car radio
Speaker
Wiper motor
PC1 28UU-2
10431
STRUCTURE
AND FUNCTION
ENGINE CONTROL
ENGINE CONTROL
Z
9JA01361
1.
2.
3.
4.
5.
6.
Fuel adjust motor

One-touch deceleration
Fuel adjust dial
Starter
Starter switch
Engine stop solenoid
pilot lamp
7.
8.
9.
10.
11.
12.
Deceleration controller
Battery relay
Battery
Governor
Fuel injection pump
switch
10-132
PC128UU-2
STRUCTURE
AND FUNCTION
ENGINE CONTROL
OPERATING SYSTEM
STARTING ENGINE
Enaina
stop
solenoid
valve
(Operation)
w&&
Lo
Ii
Engine
i(Power
.a
SUPPIY)
deceleration
I_
1 +l
switch
deceleration
~1 Fuel control
box
Battery
dial
1, 1 1
Bat terv
SJPO7650
When the starter switch is shifted to the ON

position, the engine stop solenoid drives the
governor stop lever to the OPERATION position. Should an error develop in the electric
system, this arrangement
stops the engine
operation that functions as a fail-safe mechanism.
Shifting the starter switch to the START position conducts signal current to the starter. The
starter is rotated by this current to turn on the
engine operation.
Since the fuel adjust dial is linked with the
fuel adjust motor, the engine is driven at the
speed set on the fuel adjust dial.
PC128UU-2
10-133
STRUCTURE
AND FUNCTION
ENGINE CONTROL
ENGINE SPEED CONTROL
Enaina
stop
solenoid
valve
-(Operation)
Engine
Hi Lo
Yh
(Cable
extended/contracted)
deceleration
switch
ontrol
dial
Fuel contra
motor
relay
III
:
SJPO7721
The fuel adjust dial is linked with the fuel adjust motor.
The fuel adjust motor drives the cable so that
the governor lever position may correspond
to that of the fuel adjust dial.
10-134
PC1 28UU-2
STRUCTURE
AND FUNCTION
ENGINE CONTROL
ENGINE STOP
Ensing
stop
solenoid
valve
(StoPPing)
Engine
eceleration
switch
ontrol
dial
Fuel contra
mtar
relay
_I I
SJP07722
If you shift the starter switch to the OFF position, the engine stop solenoid drives the governor stop lever to the STOP position to stop
the engine.
PC1 28UU-2
1o-1 35
STRUCTURE
AND FUNCTION
ONE-TOUCH
ENGINE CONTROL
DECELERATION
Ene ins stop
solenoid
valve
(Operation)
qwi
(Cableextended)
I(Power
SUPPIY)
deceleration
SW itch
deceleration
-SJP07723
Pressing the one-touch deceleration switch

conducts the deceleration signal to the deceleration controller.
The deceleration controller turns on the onetouch deceleration pilot lamp and, at the same
time, drives the fuel adjust motor to slow
down the engine speed to low idling level.
Pressing the one-touch deceleration switch
once turns on low idling and pressing it again
restores the speed set on the fuel adjust dial.
The one-touch deceleration function applied
to stop the engine is cancelled at the next start.
Namely, when you resume your operation, the
engine operation will be driven at the speed
set on the fuel adjust dial.
As long as the one-touch deceleration mode
is continued, you cannot change the engine
speed from the fuel adjust dial, namely the
engine speed remains at the low idling.
10436
Engine
Speed (r pm)
Decelerated
Speed
Max. I--
Deceleration
ON
-Time (Sec. 1
Deceleration
OFF
SJP07778
PC1 28UU-2
STRUCTURE
SYSTkM
ENGINE CONTROL
AND FUNCTION
COMPONENTS
FUEL ADJUST DIAL
IGH
ii
!I
A-*
I!
9JA01366
1.
2.
3.
4.
Fuel adjust dial
Boss
Boss
PC1 28UU-2
pilot lamp
5.
6.
7.
8.
Shaft
Joint
Bracket
Fuel adjust motor
1o-1 37
STRUCTURE
AND FUNCTION
FUEL ADJUSTING
ENGINE CONTROL
MOTOR
A-A
9JA01367
1.
2.
3.
Motor assembly
Cable
Connector
10438
PC128UU-2
STRUCTURE
ENGINE CONTROL
AND FUNCTION
DECELERATION CONTROLLER
SFP06891
Input/output
signal
M-2P [CN-K161
Pin No.
1
2
Signal name
Deceleration
Deceleration
pilot lamp (+I

pilot lamp (-1
SWP-6P [CN-K18]
Signal name
Pin No. 1
I Motor (+)
1
1 Deceleration signal
PC128UU-2
I/O signal
output
X-4P [CN-K17]
Signal name
Pin No. 1
1 Power SUDDIV (24V)
1
1 GND
2
1 NC
3
1 One-touch deceleration
4
1I/O signal
I InDut
I
I
switch 1
InDut
Input
1 I/O signal
1 OUtDUt
1 Outbut
1o-1 39
STRUCTURE
AND FUNCTION
ELECTRIC CONTROL SYSTEM

OVERALL SYSTEM DIAGRAM
I rave I speea
selec tor switch
1 II
Swing holding i
brake
!
- -
Travel
_-_-_----___
E- i
I ! L---:
I_:
m
____ 2-stage
vdv=I
--_--_I_!
! I----
III
-rator
-
relief/
+=5l
I
^,,
;,____:_
-Qm!__i
[~~
,:_____;______~
-__-_______i
.___r____l
Monitor
Panel
Alarm
buzzer
Emergency Pump
Start
switch
ina
.:
a .f
rminal
SJP07725
PC128UU-2
STRUCTURE
AND FUNCTION
PUMP CONTROL FUNCTION
Boom
Bucket
R. H. PPC
valve
i
I
L. H.
R. H.
i-._______________~
I
I
I
I
Control
Main relief
valve
valve
Ensin
PC-EPC
va I ve
Offset
Offset
PPC
va I ve
p
---
i-i
!_______
______J
;_--------_-!
&._______________a
Blade
Blade
PPC
va I ve
Battery
(Rotation
sisnall
(Boom LOWER signal)_
. IEioo~
RAISE signal)_
(Travel
signal)
(Swing
signal),
(Arm CURL
signal)_
(Power
SUP~IY)
&
AIS
Battery
relay
LOWE
Fuse
box
!
t
Emergency pump
drive switch
1YI1
Controller
Resistor
SJPO7726
PC128UU-2
10-141
STRUCTURE
AND FUNCTION
Function
The controller sets up a pump absorption
l
torque corresponding to the engine speed.
As the engine speed goes high, it enhances
the pump operating performance by increasing its absorption torque. When the engine
speed goes low, the controller reduces the
pump absorption torque to prevent the engine from stopping.
Engine torque
64kW/2.200rPm
(87PS/2.200r~ml
,
z
z
At travel I ins
.-z
-z
At operat ina
D=:
CCI
Engine
Emergency pump drive

If normal operation of the pump became unl
available due to failure on the controller, you
can fix the situation temporarily and resume
your operation by operating the emergency
pump drive switch.
(1) In normal operation.
(2) When a failure occurred.
Pump absorption
torsue
speed
SJP07727
pum
Emergency
switch
drive
Swing
brake
holding
release
SJPO7728
lo-142
PC1 28UU-2
STRUCTURE
AND FUNCTION
RELIEF FUNCTION
Control
valve
Main relief
valve
___ ___ ___-- - i
Self Pressure
-------7
reducing valve
Engine
L. H.
travel
I
)
I
1
II
I
;2-stage
I solenoid
relief
valve
R. H.
travel
w
__---_-_---__--------------__-_______I_______~
:j:;&-&+
-y_j
Oi I
I
Pressure
switch
i-+-i
1-J
I
(Travel
signal)
Controller
(Drive
signal:
(Power SUPPIY)
SJP07729
Function
2-stage relief
l
Relief pressure during normal operation is
31.9 MPa (325 kg/cm2}. When the 2-stage relief function is turned on, it goes up to 34.8.
MPa (355 kg/cm*}, thereby increasing hydraulit power.
PC1 28UU-2
Relief pressure
Condition
I
During
31.9 MPa (325 kg/cm21
travel
1
34.8
MPa (355
kg/cm*)
10-143
STRUCTURE
AND FUNCTION
SWING CONTROL FUNCjlON
Swing
holding
brake!-
I I
1
Swing
-7I
I
Ens i
L. H. PPC
va I ve
Swing
brake
,F____________-----_____I
I
Arm
Swing
holding
solenoid
valve
Main
Pump
II
I=
I z
I =
I .-m
___________________________-_------___-----_-_________~2
.Oi I Pressure
switch
Controller
Battery
Battery
relay
[:ze
Swine holding brake

release switch
SJPO7730
10-144
PC1 28UU-2
STRUCTURE
AND FUNCTION
Fun&m
Swingholding
brake
l
As soon as swing is stopped, the swing hold
brake is automatically
activated to prevent
hydraulic drift on slopes.
*
Wlien the swing hold brake is open, the hydraulic brake via the safety valve alone is
turned on after swing is stopped. In this case,
therefore, reasonable care must be exercised
to prevent hydraulic drift.
*
The swing hold brake must be cancelled while
the arm retract operation is continued.
Parking brake or relation

release switch
Swing hold
brake cancel switch
ON
(automatic)
ing the swing

(1)
During
(2) When
hold brake cancel
normal
failure
OFF
(cancel)
holding
brake
Operation
Swing holding brake release switch

l
Should the control fail, thereby disabling normal performance
of the swing hold brake during your operation, you can turn on swing
again by canceling the swing hold brake us-
swing
switch.
operation.
Shift the swing operation lever or the

arm retract lever to neutral, and the
swing hold brake will be turned on in
approximately 4 seconds.
You can cancel the swing hold brake
and free the swing operation from
control of the brake by operating the
swing operation lever or arm retract
lever.
Should an error develop in he swing
hold brake system, shift the swing
hold brake cancel switch to the OFF
position to free the swing operation
from control of the brake.
In this case, however, you cannot activate the swing hold brake again by
returning the swing operation lever or
arm retract lever back to the neutral
position.
occurred.
Emergency
Pump
drive
switch A
Swing
brake
holding
release
SJPO7728
PC128UU-2
10-145
STRUCTURE
AND FUNCTION
TRAVEL CONTROL FUNCTION
j Travel
speed
1selection
I solenoid
valve
L. H.
travel
Oi I
Pressure
.I
swi rcn
Travel
speed
selector
switch
R. H.
travel
(Travel
sisnal)
(Trave
-ration
I
Controller
I act
sianal)
(Power SUPPIY)
L
SJP07732
Function
Travel speed selection
l
Travel speed is switched according to changes
in the motor capacity that you can cause from
the travel speed selector switch or acceleration pedal.
Travel speed
selector switch
Motor capacity
(cc/rev)
Travel speed
(km/h)
Travel motor angle of
inclination
lo-146
LOW
1
HIGH
(low speed) (high speed)
52.7
37.2
3.2
4.6
Max.
Min.
PC1 28UU-2
STRUCTURE
AND FUNCTION
PPC LOCK FUNCTION
L. H.
travel
R. H.
travel
Trave
PPC
va I ve
L. H.
PPC
va 1ve
Battery
r4-44
IC
Fuse
Battery
re,aY
4-k-m-m
I@l
hnv
uA
(Power
SUPPI
Controller
SJP07733
Function
l
The PPC lock switch is linked with the safety
lock lever. And, shifting the safety lock lever
to the LOCK position turns the PPC lock switch
to the OFF position.
l
As the PPC lock switch is turned OFF, current
to the PPC lock solenoid valve is shut down,
thereby making it inoperable from the work
equipment operation lever.
PC1 28UU-2
10-147
STRUCTURE
AND FUNCTION
SYSTEM COMPONENTS
Engine speed sensor
SBPOO365
Function
l
The engine speed sensor is installed on the
ring gear of the engine flywheel.
It electritally counts number of gear teeth that pass
its front side and sends the counting to the
pump controller.
Remarks:
l
Number
1.
2.
3.
4.
5.
Wire
Magnet
Terminal
Housing
Connector
of ring gear teeth is 127.
For the count, a magnet is used which generates current every time a gear tooth passes
its front side.
lo-148
PC128UU-2
STRUCTURE
AND FUNCTION
PPC hydraulic switch
: SBPOO366
Specification
Contact configuration : Normally open contact
Operating (ON) pressure :
490 f 98.1 kPa (5.0 + 1 .O kg/cm*}
Reset (OFF) pressure :
294 f 49.0 kPa (3.0 f 0.5 kg/cm*}
1.
2.
3.
Plug
Switch
Connector
Function
l
A total of six PPC hydraulic switches are provided on the pressure switch bracket. They
monitors operation of respective actuators by
detecting PPC pressure and send data to the
controller.
l
Another PPC hydraulic switch is installed on
the PPC travel valve to monitor travel operations by detecting PPC pressure. The controller uses this data for driving the 2-stage relief
valve.
PC128UU-2
10-149
STRUCTURE
AND FUNCTION
Controller
Resistor
*
Refer to the section
tern.
describing
Monitor panel
Refer to the section describing
*
System.
PC valve
LS valve
PC-EPC valve
Refer to the section describing
*
lic Pump (Piston pump).
the 4-Sys-
the Monitor
the Hydrau-

2nd speed select solenoid valve
Refer to the section describing the Solenoid
*
Valve.
10-150
PC128UU-2
STRUCTURE
4-SYSTEM
AND FUNCTION
4-SYSTEM
l
The 4-system
is intended
to ensure
work
safety and to facilitate operationg
performance. It is consisted of the following subsystems; Interference
Prevention
System,
Depth Measurement
System, Automatic
Boom/Arm Stop System and Offset Position
Setup System.
CONTROL FUNCTIONS
-I
Reduction function
Stop/alarm
Interference
prevention system
function
Emergency stop/alarm
function
Canceling function
Reset function
r-i
Depth-from-ground-surface
function
Depth measurement
4-system
display
system
Depth-from-datum-plane
function
display
Height setup function

Automatic
boom/ar
Depth setup function
Offset position setup system
Offset position setup function
Boom end cushioning function
Arm end cushioning function
Self-test function
PC1 28UU-2
10-151
STRUCTURE
AND FUNCTION
CSYSTEM
SYSTEM DIAGRAM
Arm
EPC
so I en
va I ve
Boom
I
t
8
1
.mIN
I
t
t
t
I
lPPC
lock
!solenoid
;
jj----d
LEFT:
Offset
valve
&ID_j
fset
LEFT
:*
___:
llllllr--+LIJl
I
I
I
I
I
Arm
Swing!
!____,
fset
RIGHT
I
I
r---i
.J
-4gl .--.
t
I
7f
II
Offset
Offset
II
PPC
If
I va I ve
I I____________
&+
___
___A
Mon i
Pane
I. .
Blade
1 IAttachment%
cknnector
Blade
PPC
va I ve
:I
Controller
Ll
tExtrrinr inkier
ce creel small
Terlinet for exterior

ieterfereece cancel iloxe
I
..
SJP07734
1O-l 52
PC128UU-2
STRUCTURE
4-SYSTEM
AND FUNCTION
INTERFERENCE PREVENTION
SYSTEM
Cab interference prevention system

Structure of the machines work equipment can introduce interference of the bucket against the cab
when you turn on the left offset operation or operation of the work equipment.
This ,interference
potentially occurs at front side and right side of the cab.
The interference prevention system constantly monitors the bucket position in order to automatically stop move of the work equipment and sound the alarm buzzer if the bucket approaches any of
these interfering zones.
This function ensures work safety and operating performance in the left offset area.
SJP07735
The controller constantly calculates X, Y and

2 coordinates of point A referencing output
signal from the potentiometer
on rotation
angle of the boom, arm or offset. The potentiometer is provided for each of the boom, arm
and offset.
If point A approaches the interfering zone
(namely, if it enters reduction zone), the system reduces move speed of the work equipment (except the offset).
If the controller or one of the potentiometers
fails, the system stops move of the work
equipment by stopping supply of power to respective solenoid valves. In this case, you can
resume the work equipment
operation by
turning on the emergency work equipment
operation switch.
X-
Arm
Potentiometer
Z
I
tio
r
SJP07736
PC1 28UU-2
10-153
STRUCTURE
4-SYSTEM
AND FUNCTION
Overall operation diagram

The bucket position in the diagram is somewhat
*
descriptions of the system function.
Safety
zone
Reduction
(~QOOm)
zone
Stop
modified from that in actual operations
zone
to facilitate
Emergency
stop zone
\
SJP07737
10-154
PC1 28UU-2
STRUCTURE
1.
.
2.
.
Ir
3.
.
4-SYSTEM
AND FUNCTION
Reduction function
Speed of the bucket is reduced when it passes
through the safety zone and enters the reduction zone. The system ensures smooth reduction of the bucket without introducing
undesirable impacts by reducing the boom
up and arm retract speeds.
In order to reduce the speed, EPC valve reduces output pressure from PPC valve to the
operation valve.
When the bucket speed is lower than the Stan-
dard value, the above reduction control is not
turned on.
No speed reduction zone or function is provided for the offset.
Bucket
speed
(Standard
value)
.------_____-_____----------------
Bucket
position
interference
Safety
zone
Reduction
zone
_ _zone
SJPO7738
Reduction operation
Boom
Arm
up
retract
Stop/alarm function
If the bucket passes through the reduction
zone and enters the interference
zone, its
move is automatically stopped and the alarm
buzzer is turned on.
The solenoid and EPC valves cut off output
pressure from PPC valve to the operation
valve to stop the bucket move.
You can resume the bucket move by driving
the bucket out of the stop zone using the operation not currently disabled.
Emergency stop/alarm function
If the bucket does not stop at the predetermined stop point due to failures on the solenoid valve or EPC valve and enters the emergency stop zone, the system stops every actuator and sounds the alarm buzzer.
When this function is turned on, failure must
be present on any of the equipment.
In this
case, the system notifies the operator of the
trouble by flashing the monitor panel electronic system caution lamp and displaying
error code 91 mon the depth indicator.
Using the solenoid valve, the system cuts off
the source pressure from the control pump
to the PPC valve. Thus, every operation using the PPC circuit will be disabled.
When this function has been turned on, you
need to resort to the cancel function for the
recovery. See the Cancel Function in Section 4.
PC1 28UU-2
Stop operation
Every actuator
Alarm buzzer
Quick sounding interval

(once every 0.6 seconds)
Electronic
system
caution system
Quick flashing
(once every 0.6 seconds)
Depth indicator
Error 91 II is displayed
10-155
STRUCTURE
4.
.
Cancel function
If the emergency stop function is turned on,
or if the controller or any of the potentiometers fails, the controller will stop action of
every actuator by cutting off signal current to
the solenoid valve and EPC valve.
This situation requires your immediate checkups. In case the machine must be moved to a
safe place before starting the checkups, use
the emergency work equipment
operation
switch situated under the operator seat. Turning this switch on allows you to move the
work equipment to any desired location.
As soon as the emergency work equipment
operation
switch is turned on, the alarm
buzzer will start sounding and the electronic
system caution lamp will also start flashing
to notify the operator that the cancel function
has been turned on.
When you want to swing the work equipment,
turn on the swing/park brake release switch
at the same time.
If any failure is present in the electric system
of the solenoid valve or EPC valve, this cancel function is not available.
When the error code Failure in Solenoid System is displayed on the monitor panel depth
indicator, you must not turn on the emergency
work equipment operation switch.
If you turn on the emergency workequipment
operation switch after removing the controller, boom up/down and arm retract (EPC valve
system) operation wont be cancelled.
The emergency work equipment operation
switch is an auto-return type. Namely, if you
move your hand off the switch in the ON position, it will automatically return to the OFF
position.
1O-l 56
4-SYSTEM
AND FUNCTION
tmereencv
work eaurpmenr
operation
swi
SJP07739
Stop cancel operation
Every actuator
Alarm buzzer
Sounded for 7 seconds
Electronic
system
caution lamp
Delayed flashing intervals (once every second)
PC128UU-2
STRUCTURE
5.
4-SYSTEM
AND FUNCTION
Reset function
1) Input signal (potentiometer mount angle)
reset function
. If a potentiometer is mounted in an inappropriate angle in its replacement or replacement of a work equipment, error in
input signal can result due to error in the
mount angle.
This reset function allows you to correct
the error through a single switch operation without measuring output voltage
level or resorting to fine adjustment of the
potentiometer.
For the correction, enter the input reset
signal while maintaining the boom up,
arm retract and offset right at the stroke
end. And, the computer will determine
the difference between the angle computed based actual output voltage from
respective potentiometers and the specified angle on the computer (mounting
error). The difference will be stored in
memory as the compensation value.
2) Automatic fore-and-aft stop position reset function
. When an error has resulted in the automatic cab fore stop position from errors
in measuring the work equipment
size
(used in the bucket position calculation)
or computer calculation error, this function allows you to correct it in a single
switch operation.
. For the correction, stop the bucket in the
specified position, then enter the automatic fore-and-aft stop position reset signal. And this function, referencing the
actual output voltage from respective potentiometers, will calculate the difference
(calculation error) between the computed
value and the standard value and stores
it in memory
as the compensation
value.
3) Automatic left-and-right stop position reset function
. When an error has resulted in the automatic side stop position of the cab from
errors in measuring the work equipment
size (used in the bucket position calculation) or computer calculation error, this
function allows you to correct it in a single
switch operation.
.
This function can also be used for correcting the stop position when an optional
narrower or wider bucket is worn.
.
For the correction, stop the bucket in the
specified position, then enter the automatic left-and-right stop position reset signal. And this function, referencing the
actual output voltage from respective potentiometers, will calculate the difference
(calculation error) between the computed
it in memory
as the compensation
value.
.
PC128UU-2
CI
SJPO7740
SJP07742
10-157
STRUCTURE
4)
l
Ir
AND FUNCTION
4-SYSTEM
Depth indication reset function

When an error has resulted in the depth
indication from errors in measuring the
work equipment size (used in the bucket
position calculation) or computer calculation error, this function allows you to
correct it in a single switch operation.
For the correction, place the bucket on the
ground surface at points A and then B,
then enter the depth indication reset signal when the bucket is at A as well as at
B. And this function will determine the
difference (calculation error) between the
actual depth and the depth calculated
based on the output voltage from respective potentiometers
and stores it in
memory as the compensation value.
A compensation value once stored will remain undeleted if you turn off the starter
switch.
If the work equipment positioned significantly away from the specified position,
the compensation value becomes 0 (zero).
In this case, the position control is turned
on without a compensation value.
The system will display an applicable error code on the depth indicator to urge
the operator to retry the reset function.
For detailed procedures of the resetting,
refer to the Checkups and Adjustment
section.
SJP07743
1O-l 58
.
PC1 28UU-2
STRUCTURE
AND FUNCTION
4-SYSTEM
Right side exterior interference prevention system

1
l
When the right offset operation or operation of the work equipment is turned on, the bucket can
interfere with the right side exterior, deck, revolving frame, hand rail or step in certain areas. It dues
from structure of the machines work equipment.
l
If the bucket approaches an interference zone, the interference prevention system, through its electronic control, automatically the boom down, arm retract or offset right operation and turns on the
alarm buzzer.
l
Safety in the right offset area is ensured by this function.
B (50-I 50md
S!PO7744
Dimension
Dimension
l
A is when Arm is retracted.

B is when Boom is down.
Referencing output from respective potentiometers, the controller detects rotation angle
of the boom, arm and offset. And, if the work
equipment approaches near to the interference zone (reduction zone), it reduces the
work equipment move speed (except the offset).
If point A enters the interference zone, the
controller automatically stops the work equipment and sounds the alarm buzzer to prevent
interference.
If the controller or one of the potentiometers
fails, the system stops move of the work
equipment by stopping supply of power to respective solenoid valves. In this case, you can
resume the work equipment
operation by
turning on the emergency work equipment
operation switch.
Arm
Potentiometer
Boom
Potentiometer
I
\
WX
Cab
SJP07745
PC128UU-2
10-159
STRUCTURE
CSYSTEM
AND FUNCTION
Overall operation diagram

*
The bucket position in the diagram is somewhat
descriptions of the system function.
modified from that in actual operations
to facilitate
Safety
zone
Reduction
zone
loo--2om,,
!I
StoPaarm
point
Stop
Fis
zone
(Interference)
2
SJPO7746
Figure 1 : When Boom is up.

Figure 2 : When Arm is retracted.
lo-160
PC128UU-2
STRUCTURE
1.
.
4-SYSTEM
AND FUNCTION
Speed red&ion
function
Speed of the bucket after leaving the safety
zone and entering the reduction zone is reduced. The system ensures smooth reduction of the bucket without undesirable impacts
by reducing the boom up and arm retract
speeds.
In order to reduce the speed, EPC valve reduces output pressure from PPC valve to the
operation valve.
No reduction zone or reduction function is
provided for the offset right.
Bucket
speed
(Standard
value)
.------------_--~-~~~~~~~~~~~~~~-Bucket
position
Safety
zone
_ Reduction
Ir
Stop/alarm function
If the bucket passes through the reduction
zone and enters the interference
zone, its
move is automatically stopped and the alarm
buzzer is sounded at the same time.
In order to stop move of the bucket, output
pressure from the PPC valve to the operation
valve is shut down by the solenoid and EPC
valves.
You can resume operation of the currently
stopped bucket by turning on the operation
not disabled.
PC1 28UU-2
Ir$Erference
z.
L
I-
SJP07747
Reduction operation
2.
zone
Boom down
Arm retract
Stop operation
Boom down
Arm retract
Offset right
Alarm buzzer
Delayed sounding
intervals
(once every second)
lo-161
STRUCTURE
3.
.
Cancel function
If the controller or any of the potentiometers
fails, the controller will stop action of every
actuator by cutting off signal current to the
solenoid valve and EPC valve.
This situation requires your immediate checkups. In case the machine must be moved to a
safe place before starting the checkups, use
operation
the emergency work equipment
switch situated under the operator seat. Turning this switch on allows you to move the
work equipment to any desired location.
As soon as the emergency work equipment
switch is turned on, the alarm
operation
buzzer will start sounding and the electronic
system caution lamp will also start flashing
to notify the operator that the cancel function
has been turned on.
When you want to swing the work equipment,
turn on the swing/park brake release switch
at the same time.
If any failure is present in the electric system
of the solenoid valve or EPC valve, this cancel function is not available.
When the error code Failure in Solenoid System is displayed on the monitor panel depth
indicator, you must not turn on the emergency
work equipment operation switch.
If you turn on the emergency work equipment
operation switch after removing the controller, boom up/down and arm retract (EPC valve
system) operation wont be cancelled.
The emergency work equipment operation
switch is an auto-return type. Namely, if you
move your hand off the switch in the ON position, it will automatically return to the OFF
position.
lo-162
4-SYSTEM
AND FUNCTION
position)
hornal
work eauiwnt
Emergency
Stop cancel operation
operation
SWI
Every actuator
PC1 28UU-2
STRUCTURE
4.
l
CSYSTEM
AND FUNCTION
Reset function
This function is used for correcting errors in
the work equipment dimensions, controllers
calculation errors, or errors in the bucket stop
position resulting from special attachments
installed.
Correction of a bucket stop position is done
by correcting stop positions of the boom and
arm stop angles.
1) Automatic
.
.
.
boom down stop position reset function

When an error has resulted in the automatic side stop position of the right side
exterior from errors in measuring
the
This function can also be used for correcting the stop position when an optional
narrower or wider bucket is worn.
specified position, then enter the automatic exterior stop position reset signal.
And this function, referencing the actual
output voltage from respective potentiometers, will calculate the difference (calculation error) between the computed
the difference in memory as the compensation value.
-Caluculated
-Standard
Position
Position
SJP07749
2) Automatic
.
.
.
arm retract stop position reset function

When an error has resulted in the automatic side stop position of the right side
exterior from errors in measuring
the
This function can also be used for correcting the stop position even when an optional narrower or wider bucket is worn.
specified position, then enter the automatic exterior stop position reset signal.
And this function, referencing the actual
output voltage from respective potentiometers, will calculate the difference (calculation error) between the computed
it in memory
as the compensation
value.
PC1 28UU-2
SJPO7750
10-163
STRUCTURE
4-SYSTEM
AND FUNCTION
DEPTH MEASUREMENT
SYSTEM
This system facilitates your operations by displaying a current digging depth or depth of a
target of measurement on the monitor panel.
Two depth indication approaches are available
from the depth measurement system. One is
a measurement from the ground level (G. L)
and the other is that from the datum plane.
When the starter switch is turned on, a measurement from the ground level is automatically turned on.
(Mode
selector
switch)
SJPO7751
1.
.
Depth-from-Ground-Level
display function
When this function is turned on, depths measured from the ground level (G.L) are displayed on the monitor panel depth indicator
as long as your operation is continued.
Ground
level
[Setup procedure]
l
Turn the starter switch on and this function
will be automatically started.
[Display method]
.
Depth under the ground level is displayed in
0.1 mm step.
*
Fractions are rounded off at two decimal
places.
. A height above the ground level is preceded
by the indication UP.
*
You must stretch the bucket straight when setting the zero point in this display system. If
the bucket is in any other position, discrepancy can result from the displayed and actual
depth.
*
If you select the Depth-from-Datum-Plane
Display Function, this function will be cancelled.
SJP07752
SJPO7753
lo-164
PC1 28UU-2
STRUCTURE
4-SYSTEM
AND FUNCTION
2. Depth-from-Datum-Plane
display function
[Depth 0 set mode]
l
This function displays a depth from any datum plane you set on the monitor panel depth
indicator as long as your operation is continued.
*
If you select this function, the Depth-fromGround-Level Display Function is automatically cancelled.
[Setup procedures]
l
Turn the mode select switch on to the [Depth
Display 0 Set] position.
l
Move the bucket to the datum plane.
l
Shift the setup switch to the SET position, then
make sure that 0.0 is displayed on the depth
indicator.
SJP07754
[Display method]
l
Depth below the datum plane is indicated in
0.1 step.
*
Fractions are rounded off at decimal places.
l
A depth above the datum will be preceded by
the indication UP.
[Canceling procedures]
l
Turn the mode select switch to the [Depth Display 0 Set] position.
l
Turn the setup switch to the CLEAR position.
*
Make sure that the bucket posture when the
datum plane is set is the same as that placed
on the measurement plane.
If the posture is not consistent, a displayed
depth may deviate from an actual value.
*
If you cancel this function, the Depth-fromGround-Level
Display Function will be restored on the depth indicator.
l
Explanatory notes on the depth

Ya : Depth from the boom foot
level (constant).
Yb : Depth from the boom foot
plane selected.
Yc : Depth from the boom foot
ment level.
measurement
to the ground
A
1
Boom
foot
Ground
level
(G. L)
to any datum
the measure-
Depth from the ground level (G.L) = Yc - Ya.

Depth from the datum plane = Yc - Yb.
SJP07755
PC1 28UU-2
10465
STRUCTURE
AUTOMATIC
AND FUNCTION
4-SYSTEM
HEIGHT AND DEPTH STOP SYSTEM

Monitor
The automatic height stop function is capable

of stopping move of the boom when it reaches
the predetermined height during operation.
The automatic depth stop function is capable
of stopping move of the boom when it reaches
the predetermined depth during operation.
These functions are helpful in ensuring work
safety and efficiency when working in job sites
where obstacles such as piping and electric
wires are present-;
Panel
Mode
selector
switch
Depth
Depth
indication
Oset
SJPO7751
Height setup function [height mode]

You can stop move of the boom during operation at any height you have previously set.
You can limit height of the work equipment
by setting limit on the boom lift height.
This function reduces speed of the boom prior
to the forced stop to minimize resulting shocks
or impacts.
Note that this function is not usable for limiting the bucket height.
Specif
height
[Setup procedures]
l
Shift the mode select switch to the Height.
l
Lift the boom up to the height where you want
to set the limit.
l
Turn the setup switch to the SET position
to make sure that the buzzer is sounded three
times and the indicator lamp comes on.
[Operation]
l
When the above setting is complete, lower
the boom once. Now, whenever the boom
reaches the specified height during operation,
its move will be stopped there.
l
This stop is caused by reducing and then shutting down the output pressure from the PPC
valve to the boom operation valve (UP side)
at the EPC valve.
l
Shift the mode switch to the Height.
l
Turn the setup switch to the CLEAR position, then make sure that the indicator lamp
is turned off.
10466
PC128UU-2
STRUCTURE
2.
.
.
*
*
4-SYSTEM
AND FUNCTION
Depth setup function [depth mode]

You can stop move of the arm top during operation at any depth you have previously set.
You can limit digging depth by limiting the
boom down move and the arm retract move
range.
This function reduces speed of the boom
down move and arm retract move prior to the
forced stop to minimize resulting shocks or
impacts.
Note that this function is not usable for specifying a bucket depth.
This function stops move of the arm top when
the lowered boom and retracted arm appreach the specified depth.
When the arm was forced to reach the specified depth during its dump operation because
of a posture of the work equipment, move of
the arm top is not stopped.
[Setup procedures]
l
Shift the mode select switch to the Depth.
l
Lower the boom and arm to the depth where
you want to set the limit.
l
to make sure that the buzzer is sounded three
[Operation]
When the above setting is complete, lower
the boom once. Now, whenever the boom
and arm reach the specified depth during operation, their move will be stopped there.
Boom stop is caused by reducing and then
shutting down the output pressure from the
PPC valve to the boom operation
valve
(DOWN side) at the EPC valve.
Arm stop is caused by reducing and then shutting down the output pressure from the PPC
valve to the arm operation valve (RETRACT
side) at the EPC valve.
Specified
depth
SJP07758
Upper
end
(Operable)
Lower
end
SJP07759
l
Shift the mode switch to the Depth.
l
Turn the setup switch to the CLEAR position, then make sure that the indicator is
turned off.
PC128UU-2
lo-167
STRUCTURE
CSYSTEM
AND FUNCTION
OFFSET POSITIONING
SYSTEM
Mon i or
Panel
Using this function, you can previously specify

the left side offset position to facilitate, for
instance, determining a side ditching position.
Offset setup function [offset mode]
You can stop move of the offset during operation at any left offset position you have previously set.
Limiting move range of the left offset allows
you to set the offset position easier in continuous operations.
[Setup procedures]
Shift the mode select switch to the Offset.
l
Implement the left offset up to the position
l
where you want to set the limit.
l
to make sure that the buzzer is sounded two
[Operation]
When the above setting is complete, implel
ment the right offset once. Now, you can stop
the left offset whenever it reaches the specified position during operation.
This stop is caused by reducing and then Shutl
ting down the output pressure from the PPC
valve to the offset operation valve at the EPC
(Mode
switch
selector
Depth
indication
LDePth
Indicator
IL
Depth
indication
0 set
SJP07751
ied
In
SPecif
positit
valve.
Shift the mode switch to the Depth.
l
Turn the setup switch to the CLEAR posil
tion, then make sure that the indicator is
turned off.
SJP07761
1O-l 68
PC1 28UU-2
STRUCTURE
CSYSTEM
AND FUNCTION
Boom end cushioning function

l
In the boom up move, this function reduces
speed of the boom before it reaches the stroke
end to lighten resulting impacts and, thus, to
prevent spillage of dirt or dust as well as
lighten load to the machine body and cylinder.
[Operation]
l
A cushioning
zone is provided before the
boom-up stroke end (approximately
10).
l
This fuhction reduces move speed of the
boom in this zone by reducing output pressure from the boom_PPC valve to the boom
operation valve (UP move) at the EPC valve.
l
This arrangement helps reducing undesirable
impacts at the stroke end.
9JB00160
Arm end cushioning function

l
In the arm retract move, this function reduces
speed of the arm before it reaches the stroke
to lighten resulting impacts and, thus, to prevent spillage of dirt or dust as well as lighten
load to the machine body and cylinder.
[Operation]
l
A cushioning zone is provided before the arm
retract stroke end (approximately 10).
l
This function reduces, move speed of the arm
in this zone by reducing output pressure from
the arm PPC valve to the arm operation valve
(RETRACT move) at the EPC valve.
l
This arrangement helps reducing undesirable
impacts at the stroke end.
Self-test function
The controller constantly monitors electronic
equipment consisting the system for normal
operation.
These components include the
controller itself, potentiometers to generate
input signals, and solenoid valves and EPC
valves to receive output signals.
If any of the electric equipment fails, the controller diagnoses the symptom and notifies
the results to the operator by displaying a corresponding error code on the monitor panel.
At the same time, it alerts the operator attention by flashing the electric system caution
lamp and sounding the alarm buzzer.
For further information on the display and remedial actions, refer to the Checkups and
Adjustment section.
PC1 28UU-2
9J800161
Monitor
(Caution
lamp)
Panel
(Depth indicator)
SJpO7762
lo-169
STRUCTURE
AND
FUNCTION
4-SYSTEM
SYSTEM COMPONENTS
Controlier
M I C-2
1 P
AMP040-20P
AMP040-16P
9JB00162
1.
Controller
2.
Self-test
indicator
Mode select table
Attachment
1 CN-C02-1
Depth display 0 set
Depth setup
Height setup
Offset setup
Set/clear
0
0
1 CN-C02-19
Standard arm
Lona arm
1 CN-C02-20
X
A lock
select table
Specification
1 CN-C02-3
select table
1 CN-C02-2
select table
1 CN-C02-4
Set
Clear
(Arm slide limit switch)

(Slide arm retract end)
(Other than above)
IO-170
1 CN-C03-5
I
0)
0:GND
x : OPEN
(Xl
PC1 28UU-2
STRUCTURE
CSYSTEM
AND FUNCTION
Input/output signals
MIC-21P [CN-CO11
Pin No. 1
Signal name
1
2
4
NC
PC-EPC valve (+)
8
9
10
11
12
13
14
output
output
-
Serial clock
Arm retract stop EPC (+I
6
7
output
Boom down stop EPC (+)
output
Boom up stop EPC (+)
output
-
Controller power (24V)

Controller ground
NC
tNC
Travel acceleration
NC
Boom down hydraulic switch
Input
Boom UD hvdraulic switch
InDut
-
ground
power (5V)
11
Offset stop and exterior stop

position reset signal
Input
12
Angle, depth and fore-aft stop

Dosition reset sianal
Input
13
4-system cancel signal
Input
14
Right side exterior interference

Drevention cancel signal
Input
output
18
Controller Dower (24V)
19
Controller ground
20
Offset left stop solenoid (+)
21
PPC lock solenoid (+)
output
output
15
output
NC
Travel hydraulic signal
output
18
Arm retract hvdraulic switch
19
20
[CN-CO31
Input
Slide volume potentiometer
Input
3
4
SDecification
InDut
5
6
Slide arm telescope switch
Input
Input
Serial strobe
2-stage relief solenoid (+)
output
Swing/park
output
9
10
11
Boom angle potentiometer
Input
Offset angle potentiometer
Input
Input
select
Engine speed sensor (+)
Input
InDut
1
1
Input
Input
Input
brake solenoid (+)
InDut
output
15
Offset right stop solenoid (+)
output
16
Auto-deceleration
OUtDUt
relav
select signal
select signal
I/O signal
Signal name
Arm angle potentiometer
Electric system caution
1 Attachment
1 Attachment
INC
16
17
PC128UU-2
Potentiometer
14
Input
Input
Potentiometer
Boom up/down stop EPC (-1

Controller power (for solenoid)
Left lever switch

Enaine SDeed sensor (-1
INC
Swing hydraulic switch
15
12
13
1 Kerosene mode
10
16
17
Pin No.
5
6
Input
-
switch
Arm retract stop EPC (-1

PC-EPC valve (-)
AMP040-16P
[CN-COP]
I OutDut
1 Serial data
3
5
AMP040-20P
1 I/O signal
10471
STRUCTURE
4-SYSTEM
AND FUNCTION
Potentiometer
SVP04525
1.
Body
4.
2.
3.
Rotor
Bearing
5.
6.
Functions
l
A potentiometer
is installed on each of the
boom foot, arm foot and second boom top to
detect their angle of the boom, arm and offset work equipment.
l
Utilizing resistance value of the variable resistor, potentiometers send angle data to the
controller by converting the supply voltage
(5V) into signal voltage according to the angle
of the work equipment.
Sensor
Cover
Connector
(V)
5-
4-
3-
l-
lo-172
Angle
(' )
SJP07763
PC1 28UU-2
STRUCTURE
CSYSTEM
AND FUNCTION
Resistor
SVPO4527
1.
2.
Resistor
Connector
Specification
System
Resistance value (a)

5
For boom up/down EPC valve

For arm retract EPC valve
10
30
For main DumD PC-EPC valve
Function
l
This resistor is used to conduct current to the
EPC valve appropriate to the intended operation.
PPC hydraulic switch
*
Refer to the Electric Control System.
Boom down stop EPC valve
Arm retract stop EPC valve
Boom up stop EPC valve
Offset left stop EPC valve
Offset right stop EPC valve
*
(See the (EPC) Solenoid
PC1 28UU-2
Valve.)
10-173
STRUCTURE
AND FUNCTION
MONITOR
SYSTEM
MONITOR SYSTEM
Buzzer
II
Buzzer
signal
Signal
Switch
sensors
Power
signal
SUPPIY
SJP07764
This system monitors the machine status using sensors installed on various parts of the
machine, processes the monitoring data and
displays it on the panel to notifies the current
machine status to the operator.
The monitor panel mainly consists of the following blocks:
1. Monitor
block that generates
alarms
should the machine fail.
2. Pilot block that displays status of the machine during operation.
3. Gauge block that constantly displays status of the machine status through in and
out of operation.
The monitor panel also equips with the 4-systern indicator and its operation switches.
10-174
PC1 28UU-2
STRUCTURE
AND FUNCTION
MONITOR
PANEL
AMP04?-1
MONITOR
6P
SYSTEM
KEQ-4P
\
KES-3P
9JBOO164
Overview
l
The monitor panel is provided with the monitor display function, gauge display function,
service meter function, 4-system display function and 4-system operation switch function.
l
It also equips with the CPU used to process
data as well as to display and output them.
Input/output
signals
AMPO40-16P
ICN-PO11
Pin No.
1
2
3
Signal name
Power supply (24V)
Strobe
Potentiometer
5
6
7
Start signal
Coolant temperature
Fuel level
Engine oil pressure
innut
-
10
11
12
Charge volume
Electric system signal
Serial lock
Input
Input
lnout
Input
Signal name
Select 1
3
4
Select 2
Ground
PC1 28UU-2
13
14
15
16
Signal name
Preheat
Enaine oil volume
( Alarm buzzer
1 Nighttime lighting
I/O signal
Input
Input
Input
Input
Input
lnout
1 output
( Input
KES-BP [CN-Cl21
KES-4P [CX-Cl I]
Pin No.1
1
I-
Pin No.
ground
1 Serial data
LCD is employed for the gauge indication

block.
An indication lamp is used on the monitor indication block.
LCD is employed for the 4-system indication
block and indicator.
I/O signal
I
1 Ground
1 I/O signal
output
output
-
Pin No. 1
1
1 Ground
2
3
( Clear.
I Set
Signal name
I I/O signal
-
I output
( output
10-175
MONITOR SYSTEM
Operation
SJPO7765
10476
PC128UU-2
STRUCTURE
No.
MONITOR
AND FUNCTION
Display class
Display item
Clock
time
Preheat
tiNhen preheat
turned on
is
_ED comes on (for about 18 secDnds) when ttie starter switch is at

iEAT. Then it goes off notifying preneat is complete.
Green
LED
Coolant temperature
See figure to the

left
3ne applicable segment comes on.

iOnly when the top level -15OC or
above - is reached, segment is
flashed and buzzer is sounded.)
Blue
LCD
3 - 99999.9 h
Gauge
411segments below the applicable

level come on. (Only when the lowest level - Empty - reached, segment
flashes.)
Fuel volume
See figure to the

left
%5
Setup switch
: Mode setup.
SET
CLEAR : Mode setup cancel.
Depth display 0 set :

Selects datum plane for depth display.
Depth :
Specifies boom move down volume.
Height :
Specifies boom move up volume.
Offset : Specifies left offset position.
Depth error code
0 to 9.9 m in 2 alphanumeric characters
w Displays
bucket depth from
ground level.
n Indicates UP when displaying
bucket height above ground level.
* In the Depth display 0 set mode,
depth from datum plane is displayed.
l When
Qsystem failed, a 2-digit
error code is displayed.
Offset stop
When left offset

position is specified
It comes on when mode select

switch is positioned at OFFSET.
Work equipment
heig-ht alarm
When boom up
move volume is
specified
It comes on when mode select

switch is positioned at HEIGHT.
%10
Depth alarm
When boom down

move volume is
specified
k comes on when mode select

switch is positioned at DEPTH.
%I1
Electric system
When
failed
Q-system
Charge volume
When
failed
charging
Engine
sure
If pressure goes
below 49 kPa IO.5
kg/cm21
Mode select switch
n6
%7
%9
Depth display
Indicator
--
Caution
emarks
Xration
of engine-in-operation
iwhen alternator power generation
s turned on).
Service meter
Pilot
jisplay
color
Display method
Display range
SYSTEM
oil pres-
Lamp remains on as long as starter

switch is turned on. It goes after
engine has been started.
Blue
LCD
Red
Lamp
..
For the display and operation of items with % marking, refer to the section of 4-system.
PC1 28UU-2
10-177
STRUCTURE
MONITOR
AND FUNCTION
SYSTEM
SENSGRS
l
Signal from a sensor is directly entered
to the
panel.
l
There are two types of sensors,

and resistance
contact
type
type.
One end of a contact type sensor is connected

to the ground on the machine body.
Display class
Sensor type
Sensing approach
When normal
When failed
Caution
Engine oil pressure
Contact
OFF (open)
ON (closed)
Resistance
Resistance
Coolant temperature
Gauge
Fuel level
ENGINE OIL PRESSURE SENSOR
@
Structure
of
circuit
SBDOl537
1. Plug
2. Contact ring
COOLANT TEMPERATURE
3.
4.
Contact
Diaphragm
5.
Spring
6.
Terminal
SENSOR
@f=D
Structure
1.
2.
3.
of
circuit
SBOO1538
Connector
Plug
Thermistor
lo-178
PC1 28UU-2
STRUCTURE
AND FUNCTION
MONITOR
SYSTEM
FUEL LEVEL SENSOR
FULL
a
a
F
Structure
&
EMPTY
E
Y
of
circuit
SEP02590
1.
2.
3.
4.
Float
Connector
Cover
Variable resistor
PC1 28UU-2
10-179
20

_
STANDADRD
VALUE TABLE
Standard value table for engine .. .. ... . .. .. .. . .. . .. 20-2

Standard value table for chassis . . ... ... ... ... . .. . .. 20-3
Standard value table for electrical parts .. . .. 20-13
TESTING
AND ADJUSTING
TROUBLESHOOTING
. ... .. . .. .. ... . ... .. .. .. . . 20-101
... . . . .. .. .. .. .. .. .. .. ... . ... .. .. . .. . 20-201
Note the following when making judgments using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of
wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
*
When carrying out testing, adjusting, or troubleshooting,

park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC128UU-2
20-l
0
TESTING
STANDARD
AND ADJUSTING
VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Machine
PC1 28U U-2
Model
S4D102E-1
Engine
Item
Engine speed
Unit
Standard value
for new machine
Service limit value
High idling
rpm
2,400 f 60
Low idling
rpm
900 *-I
Rated speed
rpm
2,200
Bosch
index
Max. 5.5
7.5
Max. 1.0
2.0
Measurement
conditiom
At sudden acceleration
Exhaust
gas color
Valve clearance
(cold)
Blow-by pressure
(SAE 30)
At high idling
Intake valve
mm
0.51
Exhaust valve
High idling
(At opreting range of tht
engine water temperature gauge)
0.25
Pa
mm H,OI
Max. 490 (501
980 {I 00)
343 - 588 13.5 - 6.0)
245 (2.5)
Min. 9.8 11.O)
69 (0.7)
Min. 78 IO.81
69 {0.7)
Max. 110
120
(Water temperature:
Operating range
At high idling
Oil pressure
At low idling (SAE30W)
KPa
kg/cm*1
At low idling (SAEIOW)
Oil temperature
Whole speed range

(inside oil pan)
Fuel injection timing
Before top dead center
Fan belt tension
Deflection when pressec

with finger force of
approx. 58.8 N 16 kg).
(Alternator pulley
-Fan pulley
20-2
0
iegree
14+1
mm
9.5-12.7
PC1 28UU-2
TESTING
STANDARD
AND ADJUSTING
VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

PC128UU-2
Machine model
Measurement
Item
son
conditions
Hydraulic oil temperature:
Engine oil pressure:
Unit
Standard value
for new machine
Service limit value
2,220 f 100
Min. 2,000
45 - 55 C
When 1 pump is
relieved
Boom control lever
In operating range
Engine coolant temperature:
In operating range
Relief of 1 pump: Relief of arm
Center of lever
grip
Read max.
value through
stroke.
Stop engine.
Arm control lever

Bucket control lever
Swing control lever
m-n
N + RAISE, LOWER
107.2 + 11
N + IN, OUT
107.2 + 11
N --f CURL, DUMP
107.2 Z!I11
107.2 f 11
N + RIGHT/LEFTSWING
mm
Blade control lever

Travel control lever
Play of control lever
N + RAISE, LOWER
60.7 It IO
N +
112+ IO
FORWARD,
REVERSE (Bothsides1
Work equipment,
swing
35
Travel
10+3
I
I
I
I
I
I
I
I
107.2 + 21
107.2 + 21
107.2 f 21
107.2 * 21
60.7 * 15
112+20
5-8
10+5
Max.19.6
(Max.2.0)
Max.27.5
(Max.2.8)
Max.19.6
(Max.2.0)
Max.27.5
(Max.2.8)
Bucket control lever
Max.17.7
(Max.l.8)
Max.24.5
(Max.2.5)
Swing control lever
MaxL17.7
{Max. I.81
Max.24.5
(Max.2.5)
Blade control lever
Max.24.5
(Max.2.51
Max.31.4
CMax.3.21
Travel control lever
Max.27.5
(Max.2.8)
Max.36.3
IMax.3.7)
2052
20*4
37+_4
37 +- 8
Max.96.1
(Max.9.8)
Max. 134.5
(Max.13.7)
Max.94.1
(Max.9.61
Max.131.7
IMax.13.41
Run engine at full throttle.

Oil temperature: 45 - 55 C
Install push-pull scale to center of
lever grip for measurement.
Read max. value through stroke.
Boom control lever

Arm control lever
Offset pedal
Travel pedal
Offset pedal
Travel pedal
l
PC1 28UU-2
TIP of pedal
Read max.
value through
stroke.
Stop engine.
N + RIGHT/LEFT
OFFSET
mm
N + FORWARD,
REVERSE (Both sides1

Oil temperature: 45 - 55Q
Install push-pull scale to tip of pedal
for measurement.
Read max. value through stroke.
20-3
0
STANDARD
.1.
Machine
catc
Item
wn
3oom
4rm
3ucket
model
Measurement
conditions
Jnit
PC128UU-2
Standard value
For new machine
31.87 kg6
j325+ ; )
Hydraulic oil temperature: 45 - 55 C

Pressure at pump outlet
Relieve only circuit to be measured.
ervice limit value

3 1.87+$:
{325- IO1
31.87 kg6
(325 ; )
31.87+ kg6
(325; }
31.38 + 0.98
(320 + IO}
Swing
31.87 kg6
(325: )
31ade raising
31ade lowering
32.36 f 1.47
(330 f 15 1
32.36 * 2.45
(330 * 25)
rravel
34.81 + 0.98
(355 f 10 1
34.81 + 1.96
1355 * 20)
_eft offset
VlPa
:g/cml
27.0 z!z1.47
(275 + 15 1
27.0 _+2.45
(275 f 25)
3.24 + 0.20
(33 f 2 )
3.24 f 0.49
(33 f 51
When control lever is

n neutral
3.43 f 0.98
{35f IO)
3.43 f 0.98
(35 f IO)
When pump is
elieved (Normal
operation)
15.98 f 1.47
{163* 15)
15.98 + 2.45
(163 + 251
2.75 + 0.98
{28+ IO}
I--_)
2.21 * 0.1
(22.5 * I}
(-1
3ight offset
&get
rlalue
Iange
Zontrol
Hydraulic oil
temperature:
45 - 55 C
Run engine at
full throttle.
31.87 ;g6
1325; 1
nput pressure
Df servo piston
LS differential
pressure
20-4
0
b Hydraulic oil
temperature:
45 - 55 C When all levers are
) Run engine at
in neutral
full throttle.
* LS differential
pressure =
Pump outlet
pressure - LS
When no travel load
pressure
is applied
When travel control
lever is operated harf
PC1 28UU-2
TESTING
AND ADJUSTING
STANDARD
Machine
PC128UU-2
model
Measurement
Item
-w
<
Unit
conditions
Standard value for
new machine
Service limit value
defer to figure A.
t Engine at full throttle

45 - 55C
* Hydraulic oil temperature:
one turn and
p Stop after swinging
measure distance that swing circle
moves
at
Figure in ( 1 shows movement
outside of swing circle
Overrun when
stopping swing
Deg.
mm)
Max. 55
(5351
defer to figure
Time taken to start

swing
A.
Engine at full throttle

45Hydraulic oil temperature:
55C
Time taken to swing 90 and
180 from starting position
Figure in ( ) shows time when
bucket is at rated load
2.5 k 0.3
(3.0 z!I0.3)
90
Sec.
3.5 f 0.4
(4.5 * 0.5)
180
Refer to figure
Time taken to swing

45 - 55C
Swing one turn, and measure time
taken to swing next 5 turns
Refer to figure
Hydraulic
swing
drift of
_eakage from swing

motor
A.
Sec.
30+2
Max. 36
B.
Engine stopped
45 -55C
Bucket at rated load (450 kg) or full
of soil.
Set machine on 15 slope, and set
upper structure at an uphill angle 01
45.
Make match marks on swing circle
outer race and track frame.
Measure distance that match marks
move apart after 15 minutes.

- Relieve swing circuit.
Deg.
YnmI
45 - 55C
Umin
Max. 3
PC1 28UU-2
20-5
0
TESTING
AND ADJUSTING
STANDARD
Applicable
cate
Item
model
Measurement conditions
PC1 28UU-2
Standard value for
Unit
-
new machine
Service limit value
Refer to figure C.
* Engine at full throttle
9 Hydraulicoil temperature: 45-55%
l
rravel speed (I)
Raise track on one side at a time,

rotate one turn, then measure time
taken for next 5 turns with no load.
-0
Sec.
Max. 39
48
Max. 29
36
Max. 23.7
29
Max. 16.7
20.2
Hi
Refer to figure D.
l
rravel speed (2)

l

Hydraulic oil temperature: 45 -55C
Run up for at least 10 m, and measure time taken to travel next 20 m
on flat ground.
Figure in ( ) is for rubber shoe specification
-0
Sec.
Hi
Refer to figure D & E.
9 Engine at full throttle

Hydraulicoil temperature:45-55%
Run up for at least 10 m, and measure deviation when traveling next
20 m on flat ground.
* Use a hard horizontal surface.
l
rravel deviation
mm
Max. 200
220
mm
?/min
Max. 1.1
1.65
Refer to figure F.
iydraulic
ravel
drift of
.eakage from travel

notor
20-6
a
9 Engine stopped
b Hydraulicoil temperature: 45-55C
b Stop machine on 12 slope with
sprocket facing straight up the
slope.
n Measure the distance the machine
moves in 5 minutes.
9 Engine at full throttle

Hydraulicoil temperature:45_55C
Lock shoes and relieve travel circuit.
l
PC128UU-2
TESTING
AND ADJUSTING
STANDARD
Machine
Item
defer to figure
Total work
equipment
Boom cylinder
(amount of
retraction of
cylinder)
model
Measurement
conditions
mm
Bucket cylinder
(amount of
retraction of
cylinder)
PC128UU-2
PC1 28U U-2
Standard value for

new machine
Service limit value
G.
Arm cylinder
(amount of
extension of
cylinder)
Blade
(hydraulic drift
at tip of blade)
Unit
Place in posture and measure extension or retraction of each cylinder and downward movement at tip
of bucket teeth.
Horizontal, flat ground
Bucket: Rated load (720 kg)
Levers at HOLD
Engine stopped
Hydraulicoil
temperature:45-55C
Start measuring
immediately
after
setting.
Measure hydraulic drift every 5 minutes, and judge from results for 15
minutes.
Iefer to figure
Max. 500
700
Max. 15
23
Max. 50
75
Max. 40
60
Max. 31
47
G.
Engine stopped
45 -55C
Set blade at maximum lifting height
and measure downward movement
at edge of blade for 15 minutes.
20-7
0
STANDARD VALUE TABLE FOR CHASSIS
Machine model
LOWER
3.5 0.35
4.7
IN
RAISE
4.7
(Untill touching
chshion)
3.6 0.3
(Untill touching
chshion)
(Untill touching
chshion)
OUT
Cylinder fully
extended
39 0.4
(Untill touching
chshion)
2.6 0.3
(Untill touching
chshion)
3.5
(Untill touching
chshion)
CURL

Hydraulic oil temperature: 45 55C
2.7 0.3
4.0
2.2 0.2
3.0
5.5 0.6
6.5
5.6 0.6
6.6
1.3 03
2.5
1.3 0.2
2.5
Refer to figure I.
Arm
Cylinder fully
retracted

Offset to right so that clearance between right end of operators cab
and bucket will be about 350 mm.
Refer to figure J.
Bucket
Cylinder fully
retracted

DUMP
Work equipment speed
Work equipment
Fully extended
Fully extended
Refer to figure P.
Offset
Cylinder fully
retracted

Fully extended
Refer to figure K.
Blade
Blade in contact
with ground
Blade fully raised
20-8
(6)

Standard value for

Service limit value
new machine
Left offset
Refer to figure H.
Unit
Right offset
Boom
Bucket teeth in
contact with
ground
Measurement conditions
RAISE
Item
LOWER
Category
PC128UU-2
4.5
Sec
PC128UU-2
STANDARD
Machine
- lcate
Item
wp
model
Measurement
conditions
Unit
PC128UU-2
itandard value for

new machine
ervice limit value
Max. 3
Max. 2
Max. 2
Max. 2
Max. 3.5
15
Max. IO
50
3efer to figure L.
pEngine at low idling

1Hydraulic oil temperature: 45 - 55C
pFully retract arm and bucket cylinders,
then lower boom from maximum height
and measure time taken from point
where bucket contacts ground to point
where chassis rises from ground
Boom
defer to figure M.
1Engine at low idling

8Set top surface of boom horizontal,
retract bucket cylinder fully, then extend

arm cylinder and measure time taken for
;:;;;stm~rt
moving again after stopping
Arm
Set
iq
defer to figure N.
1Engine at low idling

bSet top surface of boom horizontal,
retract arm cylinder fully, then extend

bucket cylinder and measure time taken
for bucket to start moving again after
stopping at bottom.
Bucket
Refer to figure 0.
l
l
l
Blade
Engine at low idling

Hydraulic oil temperature: 45 - 55C
Lower blade from maximum height and
measure time taken from point where
blade contacts ground to point where
chassis rises from ground
Each cylinder
Leakage
Swivel joint
PC1 28UU-2
Hydraulic oil
temperature:
45 - 55Y
Engine at full
throttle.
Apply relief
pressure to port
being mesured.
:c/mir
20-9
0
STANDARD
Figures related to standard valve table

tFia
Posture
measur
kFia
when
ine
Posture
when
Posture
when
TJP02243
PC1 28UU-2
TESTING
:Fie
lriie
Posture
rFia
when
Posture
rFia
M
when
J
Posture
*Fig
*Fig
Posture
*Fig
Posture
measur
when
when
Posture
tFia
STANDARD
AND ADJUSTING
when
when
ina
TJP02241
PC128UU-2
20-11
0
TESTING
STANDARD
AND ADJUSTING
Pump performance
curve
Wm i n)
Upper
Lower
19. 6
12001
cz
Pump
iimi
discharge
limit
29. 4
(3001
MPa
:z
i ke/cml
Pressure(MPa(ke/cml)
TJ PO0242
20-12
0
PC1 28UU-2
TESTING
AND ADJUSTING
STANDARD
STANDARD
VALUE TABLE FOR ELECTRICAL PARTS
-l-
Name of
component
SF
ten
ower source voltage
Coni:ctor
Judgment
Measurement
conditions
table
If the condition is as shown in the table

below, it is normal
co1
[Between (81,(171,(18) and chassis120 - 30 V 1

below, it is normal
Standard
Qtachment
selection
-1
wi

below, it is normal
Between offset (3) and chassis
co3
Between mono boom (3)

and chassis
4- 6V
co2
l
lITurn
starting
switch ON.
?)Insert T-adapter.
Max. 1 V

below, it is normal
Left, right resetting signal
seset signal
lITurn
starting
switch ON.
?IInsert T-adapter.
co2
/Lolprrm
specification selecion
lITurn
starting
switch ON.
!) Insert T-adapter.
When
normal
Between (I 1) chassis
O-IV
When
resetting
Between (I I) chassis
20-30V
I)Turn
starting
switch ON.
?)Insert T-adapter.
Angle, direction, depth resetting signal
*I

below, it is normal
soom potentiometer
co3
Between CO2 (IO) - (9)
4.9 -5.1 v
Between CO3 (9) - CO2 (9)
0.54- 0.82V

below, it is normal
km potentiometer
PC1 28UU-2
lITurn
starting
switch ON.
!I Insert T-adapter.
%)End of boom
RAISE stroke.
lITurn
starting
switch ON.
!) Insert T-adapter.
%)End of arm IN
stroke.
co3
20-13
0
STANDARD
sys
ten
Name
of component
Zonnector
No.
Judgment
table
Measurement
conditions
f the condition is as shown in the table

)elow, it is normal
l)Turn
starting
switch ON.
2) insert T-adapter.
1 4.9 -5.1 v 1 3) End of right off1Between CO2 (10) - (9)
set stroke.
Between CO3 (10) - CO2 (9) 12.99 - 4.11 V
3ffset potentiometer
ii
;;
Feft offset stop

solenoid

)elow. it is normal
1)Turn
starting
switch ON.
2) Insert T-adapter.

Ielow, it is normal
l)Turn
starting
switch ON.

lelow, it is normal
l)Turn
starting
switch ON.
2)lnsertT-adapter.

oelow, it is normal
l)Turn
starting
switch ON.
co1
%
Right offset stop
solenoid
Swing holding brake

solenoid
co3
co3
E
..!z
ii
z
2-stage relief
solenoid
co3
Note:
Actuated
for the items marked % in the Judgment
Table indicates that the solenoid
(relay) is actuated.
When carrying out testing and adjusting of the actuation at the machine end, see MEASUREMENT
OF SOLE-
NOID VALVE OUTPUT PRESSURE.
20-14
0
PC128UU-2
TESTING
7::
STANDARD
AND ADJUSTING
Judgment
Name of component
Measurement
conditions
table

below, it is normal
1Between (3) - (2)
Boom
potentiometer
Between (2) - (I)

Between (3) - (I)
1)Turn
starting
switch OFF.
/0.2-7k.Q
1 2) Disconnect connector.
0.2 - 7 kS;1
4-6kQ

below. it is normal
Arm
potentiometer
C23 (male)
1Between (I) - (2)
10.2-7
I Between (2) - (3)
10.2-7
1Between (I) - (3)
1 4-6kQ
1)Turn
starting
switch OFFS
kfi 1 2) Disconnec ;tconnectar.
kQ 1

below, it is normal
Offset
potentiometer
C22 (male)
Between (3) - (2)
0.2 - 7 k0
Between (2) - (1)
0.2 - 7 kQ
I Between (3) -(I)
Boom RAISE stop EPC

solenoid
Arm IN stop EPC solenoid

below. it is normal
I Between (I) - (2)
Cl6 (male)
Cl5 (male)
1 4-6ka
Between (I), (2) -chassis
??z
zs
3 .II
rs
1 5-25Q
Min. 1 MQ

below, it is normal
Between (I) - (2)
Between (I ), (2) - chassis
5-25s2
Cl4 (male)
I Between (I) - (2)

1 5-25Q
Right offset EPC solenoid
PC1 28UU-2
Cl7 (male)
1Between (I) - (2)

Cl8 (male)
lITurn
starting
switch OFF.
lITurn
starting
switch OFF.
2) Disconnect connector.
1)Turn
starting
switch OFF.
2) Disconnect con1
nector.
1Min. 1 MQ

below, it is normal
Left offset stop EPC
solenoid
Min. 1 MQ

below, it is normal
Boom LOWER stop EPC
solenoid
1)Turn
starting
switch OFF.
I35-8OQ
1)Turn
starting
switch OFF.
2) Disconnect con1
nector.
Min. 1 MQ

$?
= c below, it is normal
m
35-8OQ
Between (I) - (2)
g.5
r;
Min. 1 MQ
Between (I ), (2) - chassis
1)Turn
starting
switch OFF.
20-15
0
TESTING
SY
ter
AND ADJUSTING
Name of component
PC hydraulic
solenoid
lock
STANDARD
Zonnector
No.
Judgment
tron
nethod
V07 (male)
1Between
brake
rravel boost solenoid
C-EPC solenoid
V04 (male)
V05 (male)
Cl3 (male)
$ g
mB
$.I?
r;
23
3=
a3
3.
r;
speed sensor
t;
5
Q
20-M
0
/35-8OQ
1)Turn
starting
switch OFF.
Min. 1 MQ
in the table
35-8OsZ
(I) - (2)
35-8Os2
Between
(I ), (2) - chassis
Min. 1 ML2
If the condition
is within the range shown
in the table below, it is normal
Between
(I) - (2)
Between
(I), (2) -chassis
8-15Q
1)Turn
starting
switch OFF.
1)Turn
starting
switch OFF.
Min. 1 MQ
If the condition
Between
(I) - (2)
500 - 1000 52
Between
(2) - chassis
Min. 1 Ma
with AC range
(I) - (2)
1)Turn
starting
switch OFF.
Min. 1 MQ
Between
Between
E07 (male)
in the table
If the condition
Measure
ingine
K24 - K25
K24, K25 - chassis
If the condition
is as shown
$ g below, it is normal
(u
Between (1) - (2)
$;;
al .r;
f g
a9
3.
rz
Measurement
conditions
table
If the condition
is as shown
below, it is normal
Between
swing holding
;olenoid
0.5 - 3.ov
1)Turn
starting
switch OFF.
I) Start engine.
1)Screw in rotation sensor until it contacts

ring gear, then turn back WI/6 turns.
2) It must work normally when adjusted as
above.
PC1 28UU-2
TESTING
SYS
tern
STANDARD
AND ADJUSTING
Name of
component
Judgment
Measurement
conditions
table

below, it is normal
Boom. arm. bucket. and other levers
(PPC oil pressure switch)

Travel
so1
Boom RAISE
so2
.-Fl
Boom LOWER
SIO
Arm IN
so5
Swing left
SO8
E
z?
z
3
r
Swing right
s30
1)Stat-t engine.
2) CXscXs;
nect con-
ti
Between
(1) - (2)
Min. 1 MQ

below, it is normal
lITurn
starting
switch ON.
2) InsertT-adapter.

below. it is normal
1)Turn
starting
switch ON.
1)Turn
starting
switch ON.
Kerosene mode
Travel boost
co1
I below, it is normal
Mode SET/CLEAR
co2
II
At SET
Between (3) chassis
At CLEAR
Between (4) chassis
O-IV
% When switch is not operated: 20 - 30 V

below, it is normal
Mode selection
co2
1Depth
1 20-30V
1Height
1 O-IV
1 20-30V
Offset
PC1 28UU-2
O-IV
O-IV
1)Turn
starting
switch ON.
O-IV
20-17
0
TESTING
sy:
ter
AND ADJUSTING
Name
of component
STANDARD
nspecbon
nethod
ConKtor
Judgment
the condition is as shown

elow, it is normal
Svstem cancel sianal
lance1 signal
Measurement
conditions
table
in the table
1)Turn
starting
switch ON.
co2
Interference
When
normal
When
canceled
prevention
cancel sional
Between (14)
- chassis
O-IV
Ii 20-30V
20-18
0
PC1 28UU-2
TESTING
sys
ten
STANDARD
AND ADJUSTING
Name of
component
:onnector
No.
nspection
method
Judgment
Measurement
conditions
table
the condition
is as shown in Table 1 and Table 2, the monitor
Inel is normal.
tble 1 (CHECK, CAUTION section)
Monitor item
(input connector)
Engine oil pressure
PO1 (9)
:HECK, CAUTION
;ection
M~~~~~t~enesnt
Display
IIConnectTadapter.
Sensor signal
input
Engine started
Battery charge
PO1 (IO)
Preheating
PO1 (13)
Engine stopped
ON
20-3OV
OFF
Max. 1 V
1)Turn
starting
switch OFF, and
insert dummy
resistance,
or
measure resistance of sensor.
2)Turn
starting
switch ON, and
check display.
3) Connect socket.
able 2 (Gauges)
Display level resistance
(Monitor panel input
resistance)
Position of gauge
display
itatting
switch
Starting switch OFF
ON
Min. - Max.
Measure
resistance
between coolant
temperature
gauge PO1
(female) (6) - (3)
3au,ges
Left
side
(kQ)
3.95 - 6.75
6.36 - 10.05
2
1
Min.
- Max.
0
Right
side
Measure
resistance
between fuel
level gauge PO1
(female) (7) - (3)
Display
losition
J,
Left
side
PC128UU-2
7
I-i
H
I
4
3
1
H
2
All OFF
I I
I
51 .O - 77.2
72.0 - 800
I 500 - Disconnection
I
I
I
20-19
a
STANDARD
systern
Name of
component
Judgment
1 .
.g
Engine oil pressure

sensor
20
?F
:z
3
=%G
T3
IL
Measurement
conditions
table
I VDkconnect
ter-
1If the condition is as shown in the table

below. it is normal
I
;Save 68.6 kPa Max , Q
Between
.7 kg/cm*)
sensor
terminal
- chassis
?low 29.4 kPa

$ .3 kg/cm*)
Min , Mn
1)Turn
starting
switch OFF.

below, it is normal
CN22
(male)
Alternator
CN18
(male)
Between
alternator
terminal R chassis
% I When engine is running

g
$
g
2
startinn
switch OFF.
CN21
(male)

below, it is normal
Fuel level sensor
I lITurn
I If the condition is as shown in the table

1below, it is normal
$
Coolant temperature
sensor
minal.
2)Start engine.
I
i
Z
Engine oil level sensor
1)Turn
starting
switch OFF.
I 2) Disconnect connector.
1)Start engine.
(l/2 throttle or above) < 27.5 - 29.5 V

% If the battery is old, or after starting in
cold areas, the voltage may not rise for
some time.
PC1 28UU-2

Tools for testing, adjusting, and troubleshooting ................................................................................ 20-102
Measuring engine speed ........................................................................................................................ 20-103
Measuring exhaust color ........................................................................................................................ 20-104
Adjusting valve clearance ....................................................................................................................... 20-105
Measuring blow-by pressure ................................................................................................................. 20-106
Measuring engine oil pressure .............................................................................................................. 20-106
Testing and adusting fuel injection timing ............................................................................................ 20-107
Testing and adjusting air conditioner compressure belt tension ........................................................ 20-108
Adjusting engine speed sensor .............................................................................................................. 20-108
Adjusting fuel control cable ................................................................................................................... 20-109
Adjusting engine stop solenoid linkage ................................................................................................ 20-110
Testing clearance of swing circle bearing ............................................................................................. 20-111
Measuring wear of sprocket ................................................................................................................... 20-112
Testing and adjusting track shoe ........................................................................................................... 20-113
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ......................... 20-114
Testing and adjusting PC valve output pressure (Servo piston input pressure) ................................ 20-117
Testing and adjusting LS valve output pressure
(Servo piston input pressure) and LS diffrencial pressure ................................................................ 20-119
Testing and adjusting control circuit oil pressure ................................................................................ 20-122
Testing solenoid valve output pressure ................................................................................................ 20-123
Measuring PPC valve output pressure .................................................................................................. 20-126
Adjusting PPC valve ................................................................................................................................ 20-127
Testing and adjusting travel deviation .................................................................................................. 20-128
Testing parts which cause hydraulic drift of work equipment ............................................................ 20-129
Measuring oil leakage of swing motor .................................................................................................. 20-130
Measuring oil leakage of travel motor .................................................................................................. 20-130
Bleeding from each part ......................................................................................................................... 20-131
Releasing residual pressure from hydraulic circuit .............................................................................. 20-133
Releasing residual pressure from hydraulic tank ................................................................................. 20-133
Procedure of testing diode ..................................................................................................................... 20-134
Resetting procedure of electric system and check of its operation .................................................... 20-135
Replacement procedure of potentiometers .......................................................................................... 20-149
Pm clinic inspection table ....................................................................................................................... 20-150
PC128UU-2
20-101
(6)
TESTING
TOOLS FOR TESTING,
AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING,

Check or measurement
item
iymbol
Part No.
ADJUSTING,
AND TROUBLESHOOTING
AND TROUBLESHOOTING
Remarks
Part Name
L : 60 - 2,000 rpm
Digital
display
Engine speed
R : 60 - 19,999 rpm
Water and oil temperatures
799-101-1502
Digital
799-101-5002
Hydraulic
799-261-1203
Digital
799-401-2320
Hydraulic
temperature
gauge
tester
3
Hydraulic
C
~
pressure
790-261-1311
790-261-1321
hydraulic
tester
Pressure gauge : 2.5, 5.9,39.2,

58.8 MPa {25,60,400,600 Kg/cm3
Pressure gauge :
68.6 MPa 1700 kg/cm?
1.O M Pa {I 0 kg/cm*)
gauge
Male, female both 18 x 1.5

(female PT l/8)
(female PT l/8)
(female PT l/8)
Adapter
1 790-261-1331 1
l
1 4 1 799-401-2701
-50 - 1,200C
1 Differential
pressure
gauge
(female PT l/8)
For 14 x 15 blind
For blind
Fuel injection timing
Valve clearance
Blow-by
pressure
Valve clearance
I 799-2OI-ISM
Commercially
available
I Blow-by
checker
1
2
0 - 294.2 N {O - 30 kg)
Feeler gauge
color
_t
0 - 4.9 KPa 10 - 500 mm Hz01

Discoloration 0 - 70%
(with standard color)
(Discoloration % x l/IO k
Bosch index)
I
Exhaust
1Gear
~-1110
0 - 490.3 N (0 - 50 kg)
Operating
Stroke,
effort
hydraulic
Work equipment
drift
speed
Measuring voltage and

resistance values
Troubleshooting
of wiring
harnesses and sensors
El
Push-pull
Commercially
available
Commercially
available
20- 102
0
wear of sprocket
Scale
Stop watch
79A-264-02 IO
Tester
799-601-8000
T-adapter
799-601-7370
Adapter
For 6-pin relay
799-601-7050
Adapter
For SW-6P
799-601-7080
799-601-7310
kit
Adapter
For M-IP
E-7320
Measuring
scale
Adapter
For SW-12P
I Adapter
For SW-16P
799-60 I-7340
Adapter
For M-16P
799-6-l -7540
Adapter
For 070-18P
796-427-l
Wear gauge
1 IO
PC128UU-2
TESTING
MEASURING
AND ADJUSTING
MEASURING
ENGINE SPEED
Measure the engine speed under the following

conditions.
.
Engine coolant temperature:
In operating range
.
Hydraulic oil temperature: 45 - 55 C
1.
Remove the air conditioner
top cover.
2.
Remove the air conditioner
compressor
3.
Remove cover (I) on the timing gear case side.
4.
Install sensor A2 of multi-tachometer

A to the
speed pickup port, then connect it to multi-tachometer A.
5.
Start the engine and set the measuring condition,

then measure the engine speed.
1) Measuring low idling and high idling speeds:
Set the fuel control lever to the low idling and
high idling positions, and measure the engine
speed at each position.
2) Measuring pump relief speed
Run the engine at full throttle and relieve the
main pump, and measure the engine speed
at this time.
3) Measuring engine speed near rated speed
Run the engine at full throttle and operate the
arm lever, and measure the engine speed
when the arm cylinder is relieved.
PC1 28UU-2
ENGINE SPEED
belt.
20-103
0
TESTING
AND ADJUSTING
MEASURING
EXHAUST
COLOR
MEASURING EXHAUST COLOR

. When measuring in the field when there is no air
or power supply, use smoker checker Gl; when
recording official data, use smoke meter G2.
*
a
1.
2.
Raise the coolant temperature to the operating range before measuring.

When removing or installing the measuring
equipment, be careful not to touch any high temperature parts.
Measuring with handy smoke checker Gl

1) Fit filter paper in tool Gl.
2) Insert the exhaust gas intake port into the exhaust pipe, accelerate the engine suddenly,
and at the same time operate the handle of
tool Gl to catch the exhaust gas on the filter
paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
Measuring
with smoke meter G2
1) Insert-probe @I into the outlet port of exhaust

2)
3)
4)
5)
6)
7)
pipe (I), then tighten the clip to secure it to

the exhaust pipe.
Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
*
The pressure of the air supply should be
a maximum of 1.47 MPa {I5 kg/cm2}.
Connect the power cord to the AC outlet.
*
When connecting the port, check first that
the power switch of tool G2 is OFF.
Loosen the cap nut of the suction pump, then
fit the filter paper.
*
Fit the filter paper securely so that the
exhaust gas does not leak.
Turn the power switch of tool G2 ON.
Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool 62 and catch the exhaust gas color on
the filter paper.
Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (IO
sheets or more) inside the filter paper holder,
and read the indicated value.
BLPO1274
20- 104
0
PC1 28UU-2
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
VALVE CLEARANCE
VALVE CLEARANCE
1.
Remove the cylinder head cover.
2.
Using cranking tool D, rotate the crankshaft in the

normal direction until timing pin (I) enters the
hole in the gear.
*
This position is the compression top dead center for the No. 1 cylinder.
BEP01219
3.
When No. 1 cylinder is at top dead center, adjust

the valves marked 0. Next, rotate the crankshaft
one turn (360C) in the normal direction and adjust the valve clearance of the remaining valves
marked 0.
*
Make a match mark on the crankshaft pulley
or damper, then rotate 360.
Valve arrenaement
TKP00642
4.
To adjust the valve clearance, loosen locknut (41,

then insert feeler gauge F between rocker lever
and valve stem (5), and turn adjustment screw
(6) until the clearance is a sliding fit. Then tighten
locknut (7) to hold the adjustment screw in position.
w
Locknut : 24 Nm (2.4 kgm)
After adjusting No. 1 cylinder at compression top

dead center, it is also possible to turn the crankshaft 180 each time and adjust the valve clearance of each cylinder according to the firing order.
Firing order : l-342
l
--II-
II I
BEW005 16
There is no timing mark on the front pulley, so

set to the compression top dead center as follows
i) Following the firing order, No. 3 cylinder
comes after No. 1 cylinder, so watch the movement of the valve of the No. 2 cylinder and
rotate in the normal direction.
ii) When the valve clearance of both the intake
and exhaust valve of the No. 2 cylinder is 0,
the No. 3 cylinder is at compression top dead
center.
(When setting the No. 2 cylinder,
watch the movement of the No. 3 cylinder.)
PC1 28UU-2
20-105
TESTING
AND ADJUSTING
MEASURING
MEASURING
MEASURING
BLOW-BY PRESSURE
ENGINE OIL PRESSURE
BLOW-BY PRESSURE
Measure the blow-by pressure under the following conditions.

.
Coolant temperature: Within operating range
.
Hydraulic oil temperature: 50 - 80C
1.
Install the nozzle of blow-by checker E to the blowby hose.
2.
Connect the nozzle and gauge with the hose.
3.
Run the engine at full throttle and relieve the arm

circuit.
4.
Measure the blow-by pressure when the gauge

indicator remains steady.
BLP01278
MEASURING
PRESSURE
ENGINE OIL
Measure the engine oil pressure under the following conditions.

.
Coolant temperature: Within operating range
1.
Remove engine oil pressure sensor (I), install the

adapter inside oil pressure gauge kit Cl, then install oil pressure gauge C2 (0.98 MPa {IO kg/cm*)).
2.
Start the engine, and measure the oil pressure

with the engine at low idling and high idling.
-F-
BLPO1289
20- 106
0
PC128UU-2
TESTING
AND ADJUSTING
FUEL INJECTION
TIMING
FUEL INJECTION TIMING
1.
Testing
1) Using cranking tool D, rotate the crankshaft
in the normal direction until timing pin (I)
enters the hole in the gear.
2) Remove plug (21, reverse timing pin (31, and
check that pin (3) meshes with timing pointer
(4) at the fuel injection pump end.
2.
Adjusting
.
If the timing pin does not mesh.
i) Remove the fuel injection pump.
For details, see REMOVAL OF FUEL INJECTION PUMP ASSEMBLY.
ii) Rotate the fuel injection pump camshaft
and mesh timing pin (3) with timing pin
pointer (4).
iii) Install the fuel injection pump assembly.
For details, see INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY.
9JFOO287
PC128UU-2
20-107
0
TESTING
AND ADJUSTING
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION

ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING AIR CONDITIONER

COMPRESSOR BELT TENSION
*
1.
2.
3.
4.
If the deflection of the belt is not within the standard value when it is pressed at a point midway
between the crankshaft pulley and the compressor pulley, or the belt has been replaced or other
maintenance has been carried out, adjust the tension as follows.
Remove 2 mounting bolts (2) of compressor assembly (1) and 2 adjustment plate bolts (3).
Move compressor assembly (I 1to adjust the belt
tension.
When the position of compressor assembly (I) is
decided, tighten adjustment plate bolts (3) and
mounting bolts (2) to hold in position.
After adjusting the belt tension, repeat the inspection procedure to check that the belt tension has
been adjusted to the standard value.
Compressor ~ulleu
12-15mm
Crankshaft ~ullev
TKP00643
ADJUSTING
SENSOR
ENGINE SPEED
Screw in sensor (I) until it contacts the tip of gear

(2).
2. After sensor (I) contacts gear (21, turn it back 1 +
l/6 turns.
3. Tighten locknut (3).
Ir Be extremely careful to set the sensor wiring so
that there is no excessive force on the wiring.
Sr Be careful not to make any scratches or let any
iron particles stick to the tip of the sensor.
1.
20-108
a
BEP01149
PC1 28UU-2
ADJUSTING
FUEL CONTROL CABLE
-k :When the fuel injection pump or starting motor is replaced, or when the engine speed is
not in the specified range, adjust the fuel control cable according to the following procedure.
1.
Loosen locknuts (2) and (3) of cable (I).
2.
Turn the starting switch to the ON position

and set the fuel control dial to the FULL position.
3.
.Pull the outer part of cable (I) to the left until

governor lever (4) comes in contact with the
full stopper, then tighten locknuts (2) and (3)
temporarily.
*
Check that the cable is not loosened.
*
Make a mark on locknut (2) with white
paint.
4.
Return locknut (2) by 4 turns.

*
At this time, check that clearance b between bracket (5) and locknut (2) is 5 mm.
5.
Tighten locknut (3).

,*
Check that the cable boot is not twisted.
:w
PC128UU-2
Locknut:
9.8 - 14.7 Nm {IO0 - 150 kgcm)
ADJUSTING
FUEL CONTROL CABLE
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
ENGINE STOP SOLENOID
LINKAGE
ENGINE STOP SOLENOID LINKAGE
Testing
1.. Turn the starting switch on, and check that the
clearance between lever (I) and stopper (2) is 1 2 mm when in the operating condition.
Adjusting
1. Loosen the mounting bolts of solenoid (31, move
solenoid assembly (3) to adjust the clearance between lever (I) and stopper (21, then tighten the
mounting bolts.
*
There is an oblong hole at the bracket end.
BEP01424
20-110
0
PC128UU-2
TESTING
CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF SWING CIRCLE BEARING

Method of testing clearance of swing circle bearing
when mounted on machine
1. Fix a magnet-type dial gauge to the outer circle
(or inner circle) of the swing circle, and put the tip
of the probe in contact with the inner circle (or
outer circle)..
Set the dial gauge at the front or rear.
Or
rame
frame
Di al 0
TLP00733
2.
to the maximum
Extend the work equipment
to the same
bucket
reach, and set the tip of the
frame.
revolving
the
of
height as the bottom
will tiltforstructure
upper
the
When this is done,
rear will
the
and
down
go
will
ward, so the front
rise.
3.
Set the dial gauge to the zero point.
TXP07.245
4.
5.
Set the arm more or less at right angles to

ground surface, then lower the boom until
front of the machine comes off the ground.
When this is done, the upper structure will
back, so the front will rise and the rear will
down.
tilt
go
Read the value on the dial gauge at this point.

The value on the dial gauge is the clearance of
the swing circle bearing.
g
6.
the
the
When carrying out the measurement, do not

put your hand or feet under the undercarriage.
150i200mm
BWPO4406
Return to the condition in Step 2, and check that

the dial gauge has returned to the zero point. If it
has not returned to the zero point, repeat Steps 2
to 5.
PC128UU-2
20-111
0
TESTING
MEASURING
AND ADJUSTING
MEASURING
WEAR OF SPROCKET
WEAR OF SPROCKET
Wear limit line
TLP01303
1.
Remove the track shoe assembly.

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

*
Align the benchmark
line, then align
pattern.
3.
wave
Judge the wear of the sprocket.

*
If the sprocket wave pattern is adove the wear
limit line, it is possible to use the sprocket as
it is.
*
If the sprocket wave pattern has reached the
wear limit line, replace the sprocket with a
new part.
20-112
0
PC128UU-2
TESTING
AND ADJUSTING HYDRAULIC PRESSURE IN

WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, TRAVEL CIRCUIT :
1.
a
Measuring
*
Oil temperature when measuring: 45 - 55C
Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK position.
.
Remove pressure pick-up plug (1) (Thread
dia.=lOmm, Pitch=1.25mm) from the circuit to
be measured, then install oil pressure gauge
Cl (58.8 MPa (600 kg/cm2}).
Measuring unload hydraulic pressure

Run the engine at full throttle and measure the
hydraulic pressure when the control levers are at
HOLD.
Measuring main relief (pump relief) pressure

1. Run the engine at full throttle and relieve each
actuator, and measure the hydraulic pressure at
this time.
.
Set each actuator under the following condition.
1) When relieving oil by operating the work
equipment, set each cylinder at the stroke end.
2) When relieving oil by swinging, dig a hole and

3)
lower the bucket.

When relieving oil by traveling, put block (1)
against the grouser of the track shoe, or put
block (2) between the sprocket and frame to
lock the track shoe, then measure one side at
a time.
*
The set pressure of the swing motor safety
valve is lower than the set pressure of the
main relief valve. Accordingly, if the oil is
relieved by swinging, the set pressure of
the safety valve is measured.
BLP00170
20-114
0
BLPOOl71
PC128UU-2
TESTING
AND ADJUSl-lNG
TESTING
AND ADJUSTING HYDRAULIC PRESSURE IN

Adjusting
1. Adjusting main relief valve
Disconnect the hose for setting high pressure.
high set pressure
Adjusting
I)
.
Loosen locknut (2) of main relief valve (I)
and turn holder (3) to adjust the high set
pressure.
If the holder is
*
.
is
the pressure
Turned clockwise,
heightened.
.
Turned counterclockwise, the pressure
is lowered.
After adjusting, check the pressure again
*
according to the above testing procedure.
Pressure changed by 1 turn of holder :
*
Approx. 12.6 MPa 1128 kg/cm21
l
Locknut:
53.9 - 63.7 Nm I5.5 - 6.5 kgm)
If the high set pressure is adjusted, the low

set pressure is changed. Accordingly, adjust the low set pressure.
Adjusting low set pressure
Loosen locknut (4) of main relief valve (1)
and turn holder (5) to adjust the low set
pressure.
If the holder is
*
.
is
the pressure
Turned clockwise,
heightened.
.
Turned counterclockwise, the pressure
is lowered.
After adjusting, check the pressure again
*
according to the above measuring procedure.
Pressure changed by 1 turn of holder:
*
Approx. 12.6 MPa (128 kg/cm*)
*
2)
Locknut : 39.2 - 49.0 Nm I4 - 5 kgm}
2.
9JFOO261
Adjusting swing motor safety valve

If the swing relief pressure is not normal, ad*
just the swing motor safety valve according
to the following procedure.
1) Loosen locknut (7) of swing motor safety valve
(6) and turn adjustment screw (8) to adjust the
swing relief pressure.
If the adjustment screw is
*
is
the pressure
turned clockwise,
heightened.
turned counterclockwise, the pressure
is lowered.
Pressure changed by 1 turn of adjustment
*
screw: Approx. 14.0 MPa I143 kg/cm*}
l
PC128UU-2
20-115
a
TESTING
AND ADJUSTING
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN

2) After adjusting, tighten locknut (7).

B
Locknut:
53.9 - 73.5 Nm I5.5 - 7.5 kgm}
After adjusting, check the pressure again according to the above measuring procedure.
9JFOO253
20-116
0
PC128UU-2
TESTING
TESTING
AND ADJUSTING
TESTING AND ADJUSTING PC

VALVE OUTPUT PRESSURE
(SERVO PISTON INPUT
PRESSURE)
Measuring
*
Oil temperature
for measurement:
45 - 55 C
1. Remove oil pressure pickup plugs (I) and (2) (IO

mm, P = 1.251, then install oil pressure gauges Cl
(39.2 MPa (400 kg/cm2)).
2.
Turn the swing
3.
Run the engine at full throttle and relief the arm

cylinder (by IN operation), and measure the pressure at this time.
lock switch
to the ON position.
[Reference]
If the LS valve or servo piston is defective, the
servo piston input pressure is about the same
as the pump discharge pressure or almost 0.
PC128UU-2
AND ADJUSTING PC VALVE OUTPUT PRESSURE

(SERVO PISTON INPUT PRESSURE)
TESTING
AND ADJUSTING
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE

Adjusting
*
If the engine speed lowers as the load increases
or if the work equipment speed is low while the
engine speed is normal and the pump discharge
pressure, LS differential pressure, etc. are normal,
adjust PC valve (6) according to the following procedure.
I)
If the speed is low, loosen locknut (4) and turn

screw (5) clockwise.
If the engine speed
low, turn screw (5) counterclockwise.
2) Remove oil pressure pickup plugs (I) and (2)
(IO mm, P = 1.25), then install oil pressure
gauges Cl (39.2 MPa (400 kg/cm2)).
3) Turn the swing lock switch to the ON position.
1.
Run the engine at full throttle and relief the arm

cylinder (by IN operation), and measure the pressure at this time.
BKPOIOIS
[Reference]
If the LS valve or servo piston is defective, the
servo piston input pressure is about the same
as the pump discharge pressure or almost 0.
20-118
0
PC128UU-2
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING LS VALVE OUTPUT PRESSURE

AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING LS VALVE OUTPUT

PRESSURE (SERVO PISTON INPUT
PRESSURE) AND LS
DIFFERENTIAL PRESSURE
*
1.
Oil temperature
for measurement:
45 - 55 C
Measuring LS valve output pressure (servo piston input pressure)

1) Remove oil pressure pickup plugs (I) and (2)
(10 mm, P = 1.251, then install oil pressure
gauges Cl (39.2 MPa I400 kg/cm*)).
2) Push up the track shoe on one side with the
work equipment.
3) Run the engine at full throttle and move the
track shoe with no load on it and measure the
hydraulic pressure at this time (hydraulic pressure when one track is moved with no load
on it).
Neutral
2.94kO.49
{30f5)
Servo inlet
pressure
Remarks
MPa{kg/cm*}
4bout same
pressure
4.41f0.98 Pressure of
about 315
I45+ IO)
PC128UU-2
TESTING
TESTING
2.
AND ADJUSTING
AND ADJUSTING LS VALVE OUTPUT PRESSURE

Measuring LS differential pressure

1). Measuring with differential pressure gauge
i)
Remove oil pressure pickup plugs (1) and
(2) (10 mm, P = 1.251, then install differential oil pressure gauge Cl.
*
Connect pump discharge pressure
side (1) to the high pressure side of
the differential pressure gauge and
connect LS differential pressure side
(2) to the low pressure side.
ii) Push up the track shoe on one side with
the work equipment.
iii) Run the engine at full throttle and measure the LS differential pressure under the
following condition.
LS differential pressure when travel
lever is in neutral :
2.75 f 0.98 MPa (28 f 10 kg/cm*}
The LS differential pressure when the
*
travel lever is in neutral is the same
as the unload pressure.
LS differential pressure when travel
lever is operated halfway (when machine travels with no loads) :
1.57 f 0.1 MPa (16 It 1 kg/cm*}
2) Measuring with oil pressure gauges
*
Since the differential pressure is 1.96
MPa (20 kg/cm*) at most, measure it
with oil pressure gauges of the same
l
type.
Remove oil pressure pickup plugs (I)
and (2) (IO mm, P = 1.251, then install
oil pressure gauges Cl.
ii) Install pressure gauge Cl (39.2 MPa
(400 kg/cm*)) to the pump discharge
pressure pickup plug.
*
Use a pressure gauge graduated
in 0.98 MPa I10 kg/cm*).
iii) Push up the track shoe on one side
with the work equipment.
iv) Run the engine at full throttle and
measure the pump discharge pressure under the condition of 1 j-31.
*
Read the pointer accurately from
its front side.
VI Run the engine at full throttle and
measure the LS pressure under the
condition of I)- iii).
*
Read the pointer accurately from
its front side.
vi) Calculate the LS differential pressure
from the pump discharge pressure
and LS pressure [(LS differential pressure) = (Pump discharge pressure) (LS pressure)].
i)
20-120
0
9JFOO120
;_
BLP01284
PC128UU-2
TESTING
TESTING
3.
AND ADJUSTING
AND ADJUSTING
LS VALVE OUTPUT PRESSURE
Adjusting LS valve
Sr If the LS differential
pressure is not normal,
adjust the LS valve according to the following procedure.
1) Disconnect hose (8) from LS valve (7).
2) Loosen locknut (9) and turn adjustment screw
(10) to adjust the LS differential
pressure.
*
If the adjustment
screw is
turned
clockwise,
the pressure
is
heightened.
turned counterclockwise,
the pressure
is lowered.
*
Pressurechanged
by 1 turn of adjustment
screw: 1.30 MPa (13.3 kg/cm*) (LS differential pressure)
3) After adjusting, tighten locknut (8).
l
w
*
Locknut
: 59 + 10 Nm (6 + 1 kgm)
After adjusting,
check the LS differential
pressure again according to the above
measuring procedure.
BWPO4497
PC1 28UU-2
20-121
0
TESTING
AND ADJUSTING

CONTROL CIRCUIT OIL
PRESSURE
Measuring
*
Oil temperature
for measurement:
Lower the work equipment to

stop the engine. Then, loosen
slowly to release the internal
hydraulic tank. Set the safety
LOCK position.
CONTROL CIRCUIT OIL PRESSURE
45 - 55 C
the ground and

the oil filler cap
pressure of the
lock lever to the
1.
Remove the valve top cover.
2.
Disconnect hose (I) connected to the solenoid

valve, then install adapter C3 and oil pressure
gauge Cl (5.9 MPa (60 kg/cm?).
3.
Run the engine at full throttle

control circuit oil pressure.
and measure the
Adjusting
*
If the control circuit oil pressure is not normal,
adjustthe control relief valve according to the following procedure.
1.
Loosen locknut (2) and turn adjustment screw (3)

to adjust the control circuit oil pressure.
*
If the adjustment screw is
Turned clockwise, the pressure is heightened.
Turned counterclockwise, the pressure is
lowered.
*
Pressure changed by 1 turn of adjustment
screw: 0.98 MPa {IO kg/cm?
l
2.
After adjusting,
9JFOO266
tighten locknut (2).
Locknut : 19.6 - 24.5 Nm {2.0 - 2.5 kgm}
Jr
After adjusting, check the control circuit oil

pressure again according to the above measuring procedure.
20- 122
0
t-
PC128UU-2
TESTING
TESTING SOLENOID
AND ADJUSTING
TESTING SOLENOID VALVE

OUTPUT PRESSURE
Measuring
*
Oil temperature
for measurement:
45 - 55 C
1. Measuring output pressure of EPC solenoid valve

for automatic stop and control of work equipment
1) Remove oil pressure pickup plug (I).
2) Install oil pressure
gauge
Cl (5.88 MPa 160
kg/cm?).
3) Measure the output pressure under the conditions shown in Table 1.
*
The component
valves of the 5-spool solenoid valve assembly are lined in the following order from the top.
(I) Boom LOWER stop EPC solenoid
valve
(2) Arm IN stop EPC solenoid valve
(3) Boom RAISE stop EPC solenoid valve
valve
(4) LEFT offset stop EPC solenoid
(5) RIGHT offset
stop
EPC solenoid
valve
Table 1
Solenoid
1
name
BoomRA~SEstop
Measuring
condition
During boom RAISE operation

________-___--______----_._---____-___--_
Stops automatically
in automatic stop range
During boom LOWER operation

BoomLOWERstop_---__---__------__-Stops automatically
in automatic
Arm IN stop
PC1 28UU-2
Oil pressure
During arm IN operation

________---_--------Stops automatically
in automatic
____.____
stop range
(MPa {kg/cm*))
Remarks
2.94 f 0.49 (30 * 5)

0
2.94 f 0.49 130 * 5)
---_------_
0
2.94 * 0.49 (30 + 5)

---_--------------stop range
0
20-123
0
TESTING
2.
AND ADJUSTING
TESTING
SOLENOID
Measuring ON-OFF solenoid valve output pressure

1) Disconnect hose (2) from the 4-spool or 5spool solenoid valve assembly.
2) Using adapter C3 in the oil pressure gauge
kit, install nipple C2 and oil pressure gauge
C1 (5.88 MPa {60 kg/cm*)).
3) Measure the solenoid valve output pressure
under the conditions shown in Table 2.
Table 2
Solenoid
valve
IO.
PPC oil
1 pressure
lock
Travel
speed
selector
2-stage
relief
Left offset
stop
Right offset
stop
f
Note)
Each solenoid valve is operated as follows.

ON : Power is applied (Oil pressure is generated).
OFF : Power is not applied (Oil pressure is 0).
Only the LS bypass solenoid valve is operated as follows, however.
ON : Power is applied (Oil pressure is 0).
OFF: Power is not applied (Oil pressure is 30 + 5).
20- 124
0
PC128UU-2
TESTING
AND ADJUSTING
The component
valves of the 4-spool solenoid
valve assembly are lined in the following
order
from the top.
(I) PPC oil pressure lock ON-OFF solenoid valve
(2) Travel speed selector ON-OFF solenoid valve
(3) Swing holding brake ON-OFF solenoid valve
(4) 2-stage relief ON-OFF solenoid valve
The component
valves of the 5-spool solenoid
valve assembly are lined in the following
order
from the top.
(1) Boom LOWER stop EPC solenoid valve
(2) Arm IN stop EPC solenoid valve
(3) Boom RAISE stop EPC solenoid valve
(4) LEFT offset stop EPC solenoid valve
(5) RIGHT offset stop EPC solenoid valve
PC1 28UU-2
TESTING
SOLENOID
20-125
0
TESTING
MEASURING
AND ADJUSTING
PPC VALVE OUTPUT
PRESSURE
MEASURING PPC VALVE

OUTPUT PRESSURE
for measurement:
45 - 55 C
Oil temperature
1.
Measuring PPC valve output pressure

1) Disconnect
PPC hose (1) of the circuit to be
measured.
2) Install adapter C3 between
the elbow and
hose.
3) Install oil pressure gauge Cl (5.88 MPa (60
kg/cm211 to adapter C3.
4) Run the engine at full throttle and operate the
control lever of the circuit to be measured,
and measure the output pressure.
J,
Measuring points (From top of main control

a : (Service)
b : (Service)
c : RIGHToffset
d : LEFT offset
e : Bucket DUMP
f : Bucket CURL
g : Arm OUT
h : Arm IN
i : Blade LOWER
j : Blade RAISE
k : Boom RAISE
I : Boom LOWER
m : RIGHT reverse travel
n : RIGHT forward travel
o : LEFT forward travel
p : LEFT reverse travel
q : Swing LEFT
r : Swing RIGHT
valve)
BWP04498
20-126
0
PC128UU-2
TESTING
ADJUSTING
*
ADJUSTING
AND ADJUSTING
PPC VALVE
PPC VALVE
If the work equipment control lever or swing lever has excessive play, adjust it according to the
following procedure.
Lower the work equipment to the ground and
stop the engine. Then, loosen the oil filler cap
slowly to release the internal pressure of the hydraulic tank. Set the safety lock lever to the LOCK
position.
1. Remove the PPC valve.

2.
Remove boot (1).
3.
Loosen locknut (2) and tighten disc (3) until it

comes in contact with the heads of 4 pistons (4).
*
Do not move the pistons at this time.
4.
Fix disc (3) and tighten

fied torque.
w
5.
Locknut:
locknut (2) to the speci-
107.9 f 9.8 Nm {II
f 1 kgm}
Install boot (1).

*
The clearance between disc (3) and piston (4)
is eliminated by the above adjustment.
BVPO3436
PC1 28UU-2
20-127
0
TESTING
TESTING
AND ADJUSTING

TRAVEL DEVIATION
1.
Travel
AND ADJUSTING
TRAVEL DEVIATION
posture
Measuring when traveling

1) Set the machine in the travel posture.
*
When setting the machine in the travel
posture, extend the bucket and arm cylinder rods fully, and hold the boom at an
angle of 45.
2) Travel for lOm, then measure dimension a the
deviation for the next 20m when traveling with
the engine at full throttle.
*
Measure at full throttle.
*
Install an oil pressure gauge and measure
the pump discharge pressure at the same
time.
TLP00731
Make a mark
at the IOm midpoint
Make
a mark
0
Lay
out,
10m midpoint
strine
-I
Mark
/\
Measure
dimension
this
deviation
of lMark
TLP00732
20-128
0
PC128UU-2
TESTING
PARTS WHICH CAUSE HYDRAULIC

DRIFT OF WORK EQUIPMENT
TESTING PARTS WHICH CAUSE

HYDRAULIC DRIFT OF WORK
EQUIPMENT
* Oil temperature for measurement: 45 - 55 C
1.
Work equipment cylinder

*
If the hydraulic drift of the work equipment
is
out of the standard range, measure the internal leakage of the cylinder according to the
following
procedure to see if the cause of the
hydraulic drift is on the control valve side.
. If the leakage is below the standard value, the
cause of the leakage is on the control valve
side.
. If the leakage is above the standard value, the
cause of the leakage is on the cylinder side.
1) Fully extract the rod of the cylinder to be measured, then stop the engine.
2) Disconnect the hose on the head side and plug
the hose on the machine side.
Boom cylinder: Hose (I)
Arm cylinder: Hose (2)
Offset cylinder: Hose (3)
Bucket cylinder: Hose (4)
A
3)
4)
2.
Take care not to disconnect

the bottom side.
Arm CY I inder.
offset
cylinder
the hose on
TXP02246
Run the evgine at full throttle and apply relief

pressure to the bottom side of the cylinder.
Sr Boom cylinder: RAISE operation
Arm cylinder: IN operation
Offset cylinder: RIGHT offset operation
Bucket cylinder: CURL operation
After 30 seconds, measure the oil leakage for
1 minute.
Testing PPC valve

If the hydraulic
drift varies with the position
of the safety lock lever (while the engine is
running), the PPC valve is defective.
Disconnect
PC1 28UU-2
TEP0033;
20-129
0
TESTING
AND ADJUSTING
MEASURING
MEASURING
OIL LEAKAGE FROM SWING MOTOR

OIL LEAKAGE FROM TRAVEL MOTOR
MEASURING OIL LEAKAGE

FROM SWING MOTOR
:
* Oil temperature for measurement : 45- 55 C
1.
Disconnect drain hose (I) of the swing motor and

install a plug to the tank.
2.
Have the bucket dig into the ground to lock the

swing mechanism.
3.
Run the engine at full throttle to relief the oil from

the swing motor.
4.
After 30 seconds, measure the oil leakage for 1

minute.
*
After measuring one time, swing the work

equipment
by 180 degree, then measure
again.
MEASURING OIL LEAKAGE

FROM TRAVEL MOTOR
* Oil temperature for measurement: 45 155Ae
1.
Disconnect drain hose (I) of the travel motor and

install a plug to the tank.
2.
Put block @ against the grouser of the track shoe

or put block @ between the sprocket and frame
to lock the track shoe.
3.
Run the engine at full throttle to relief the oil from

the travel motor.
A
4.
Since a mistake in operation of the lever can

cause an accident, make and confirm signs
securely.
9JFOOO95
After 30 seconds, measure the oil leakage for 1

minute.
*
Measure the oil leakage several times, moving the motor little by little (changing the relative positions of the valve plate and cylinder
and those of the piston and cylinder).
20- 130
0
PC128UU-2
TESTING
BLEEDING FROM EACH PART
AND ADJUSTING

Air bleeding
Contents
of work
Replacing hydraulic
Cleaning strainer
Replacing
return
oil
filter element
Replacing/Repairing
Removing suction
Replacing/Repairing
control
Replacing/Repairing
Removing cylinder
cylinder
piping
l
l
procedure
pump
piping
valve
Replacing/Repairing
swing motor
Removing swing motor piping
Replacing/Repairing
travel motor
and swivel
Removing
travel motor and swivel
piping
Note: Bleed the air from the swing and travel motors only when the oil inside the motor case has been
drained.
1.
Bleeding air from pump

1) Loosen air bleeder (I) to bleed air through itself.
*
If oil containing no air flows out, stop
bleeding.
2) Tighten air bleeder (I).
w
*
2.
Bleeder:
17.16 + 2.45 Nm (1.75 + 0.25 kgm}
Caution for starting engine
After the above work, run the engine
low idling for about 10 minutes.
at
Bleeding air from cylinder

I) Start and run the engine at low idling for about
5 minutes.
2) Raise and lower the boom 4 - 5 times with
the engine speed low.
*
Move the piston rod to about 100 mm
before the stroke end and never relief the
oil.
3) Perform the operation of 2) above with the
engine at full throttle. Then, run the engine
at low speed and move the piston rod to the
stroke end to relief the oil.
4) Bleed air from each of the arm, bucket, swing,
and blade cylinders by performing above operations of 2) and 3).
PC128UU-2
20-131
0
3.
Bleeding air from swing motor

1) Turn ON the swing lock switch and run the
engine at low idling.
*
Bleed air from the swing motor with the
pressure at port S.
2) Disconnect hose (1) from the swing motor and
plug it.
3) Run the engine at low idling and check that
oil flows out of elbow (2).
Jc If oil does not flow out of elbow (2), repeat I) above.
4) Connect hose (1).
4.
Bleeding air from travel motor

1) Disconnect motor drain hose (2).
2) Run the engine at low idling and check that
oil oozes through the nipple.
3) After oil oozes, connect hose (2).
20-132
0
PC128UU-2
TESTING
AND ADJUSTING
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK
RELEASING RESIDUAL
PRESSURE FROM HYDRAULIC
CIRCUIT
*
When disconnecting the piping between the hydraulic cylinder and control valve, release the residual pressure from the circuit. Since the travel
circuit is open, any pressure is not kept in it. Accordingly, just remove the oil filler cap.
1.
Operate the control lever (with the starting switch

at the ON position and the safety lock lever at the
FREE position).
Operate the control lever 2 - 3 times, and the
*
pressure in the accumulator is released.
2.
Loosen the oil filler cap gradually

pressure from the tank.
3.
Run the engine at low idling for about 5 seconds

and stop it. Then, operate the control lever.
Repeat the above operation 2 - 3 times, and
*
the all residual pressure is released.
to release the
RELEASING RESIDUAL
PRESSURE FROM HYDRAULIC
TANK
A The hydraulic tank is enclosed and pressurized.
When removing a hose, plug, etc. connected to

the hydraulic tank, release the residual pressure
in the hydraulic tank according to the following
procedure.
I.
Lower the work equipment to the ground and stop

the engine.
2.
Loosen the oil filler cap or oil filler plug of the

hydraulic tank gradually to release the residual
pressure from the tank.
PC1 28UU-2
20-133
0
PROCEDURE OF TESTING
DIODE
PROCEDURE OF TESTING
DIODE
Diode
l
1.
as
individual
Part
Test a diode unit or a harness containing a diode

according to the following procedure.
Use a digital tester having a diode measuring
range.
Apply the red (+I test pin to the anode (PI side of
the diode and the black (-1 test pin to the cathode
(N) side.
*
A flow mark is printed on the diode.
*
If an ordinary tester is set in the diode range,
the voltage of the battery in itself is indicated.
If this voltage
. does not change +
There is not continuity.
. changes +
There is continuity. (Normal) (Note)
. is 0 or almost 0 *
Diode is shorted internally.
Note)
TLP00663
Diode
included
in
wiring
harness
In the case of a silicon diode, the tester

indicates a value of 400 - 600 or 0.4 - 0.6,
depending on its characteristics.
TLP00664
BLP01357
20-134
0
PC1 28UU-2
RESETTING
TESTING
AND ADJUSTING
PROCEDURE OF ELECTRIC SYSTEM AND

CHECK OF ITS OPERATION
RESETTING PROCEDURE OF
ELECTRIC SYSTEM AND
When any of the following works is performed
or when any error code is displayed, reset the
electric system according to the flow chart
shown below.
1) When the work equipment
is removed
and installed for repair.
2) When the work equipment
is replaced
with a long arm.
3) When the controller is replaced.
4) When a potentiometer
is removed, installed, or replaced.
5) When an error code of the reset signal system is displayed.
Flow chart of resetting
Reset the potentiometer mounting angle first,

then reset the front stop position, depth display, left side stop, and prevention of interference of exterior parts (Boom LOWER and
arm IN operations).
Sr The Nos. in boxes refer to the Nos. in the
resetting procedure.
*
Items marked with % need to be only
checked.
of electric system
Erroh
-____
Check and
reset
automatic
stop in arm
IN direction
for
Exee$on oi
interference
Check and
reset
automatic
stop in
boom
lowering
direction for
prevention
of external
interference
Check
automatic
stop in rigth
offset
direction for
prevention
of external
interference
~____l____,
; Automatic
;
stop
I
1position is I
I nearer than i
I specified
1
;_p_:$io_n___;
1
7------i
I
$Zi-rYit~~ -I
; stop
I position is
I in specified
l!?!?!e ____A
I
i stop
t
I position is ;
~farfrom
I
I spe$fied
Ip_o_slfo__
__1
1
r------7
I
Error
.--+J
I
stop
I
I position is 1
; in specified I
I.____T----:
range
I
8
Move bucket to right and left to check automatic
PC128UU-2
t
stop position
20-135
0
RESETI-ING
TESTING
1.
AND ADJUSTING
Resetting of potentiometer
input signal
1) Set the work equipment in the following position.
i) Boom: RAISE stroke end
ii) Arm: IN stroke end
iii) Offset: RIGHT offset stroke end
*
Be sure to turn on the emergency work
equipment operation switch and check
that the all cylinders at the stroke end.
2) Turn the starting switch to the OFF position
to stop the engine, then turn it to the ON position again.
3) Set the mode selector switch to 0 setting of
depth and connect reset power terminal (1)
and reset terminal (2).
*
The reset terminal is taped onto the harness at the rear of the panel.
*
The reset power terminal (CN-KIO) (I) is
a plug (green harness) and the input reset terminal (CN-K8) (2) is a socket (Yellow and blue harness which is not taped).
4) Check that the electric system caution lamp
of the monitor panel starts flashing at intervals of 1 second after 2 seconds.
*
If the input signal (voltage) of the potentiometer is out of the standard range, an
error code between 10 and 19 is displayed
on the monitor panel.
If
any
error code is not displayed, disconnect
5)
terminal (CN-KIO) (I) and (CN-K8) (21, then
turn the starting switch to the OFF position.
*
If the starting switch is turned to the OFF
position without disconnecting the terminals, the electric system caution lamp
starts flashing again when the starting
switch is turned to the ON position next
time.
6) Turn the starting switch to the ON position,
and the resetting operation is finished.
7) After finishing the resetting operation, tape
the reset terminal as before.
20-136
0

BWPO4414
PC128UU-2
RESElTING

2.
If an abnormality
display (error code) was
given in Item 1 (reset potentiometer input signal)
.
If the potentiometer input signal (voltage)
is not within the range in the table below
when the work equipment is set to the posture in Item 1, an abnormality display will
be given during the resetting operation,
and it will be impossible to reset the system.
*
If an abnormality display appears during
the resetting operation, turn the starting
switch OFF with the abnormality display
still displayed, then turn the starting switch
ON again. This will delete the input signals that are in the memory.
Therefore,
I)
if an abnormality
o54-o*82
2)
lame
of
croup
is
given, remove all the causes and reset the

system properly.
Potentiometer input signal (when normal)
WI
Arm
Boom
display
Table 1
STD
0.65-1.43
Long
arm
0~4-1.52
2g9_4,,
Reenact
system
11
Defective resetting of boom angle
12
Defective resetting of arm angle
,3

+ arm angle
cl
14
Defective resetting of offset angle
[7
,5

+ offset angle
,6
Defective resetting of arm angle +

offset angle
,7

+ arm angle + offset angle
cl
2,
Defective resetting of front face

stop position
Offset
[Measurement]
Boom: Between C21 (2) and (1)
Arm:
Between C23 (2) and (3)
Offset: Between C22 (2) and (I)
The value will change if an option (long
arm) is installed.
Content of abnormality display
Depending on the nature of the abnormality, one of the displays in Table 1 will be
given.
i) Abnormality
in one system (inside
bold lines)
The display is one of 1 I, 12, or 14.
ii) Simultaneous
abnormality in two or
more systems (inside thin lines)
The last digits are added and the total
is displayed.
If the resetting operation has not been
*
carried out properly, when the reset
power source terminal and input reset
terminal are disconnected, the abnormality display and electrical system
caution lamp will flash in a 0.6-second
cycle, and the buzzer will also sound
in a 0.6-second cycle.
In Table 1, all the error codes for the
*
reset groups are shown.
PC128UU-2
Abnormal
leset
cl
I
I
2*
Defective resetting of side face

stop position
cl
24
of depth
cl
25

stop position + defective compensation of depth display
[7
26
Defective resetting of side face

stop position + defective compensation of depth display
17
Defective resettiqg of front face

stop posltron + side face stop
position + defective compensation
of depth display
*,
Defective compensation
display
The bold lines indicate displays for individual

systems.
20-l 37
0
RESETTING
TESTING
3)
AND ADJUSTING

Actions to take when error code is displayed

*
Check that the rod is not bent or scuffed.
Reference :
Distance a between boom potentiometer rod pins: 280 + 2 mm
Distance b between arm potentiometer
rod pins: 416 f 4 mm
.
Boom potentiometer (I)
Check the reset position of the work equipment again. If the position is normal but
the error code is still displayed, replace
the assembly of potentiometer
(1) and
case.
.
Arm potentiometer (2) and offset potentiometer (3)
i) Set the work equipment in the reset position and see if the error code is displayed
again.
Boom : RAISE stroke end
Arm : IN stroke end
Offset : RIGHT offset stroke end
ii) Remove the potentiometer case assembly.
iii) Install a new potentiometer.
iv) Measure the potentiometer
input signal
(voltage), and check that it is in the standard range.
For the standard value, see 2).
*
l
l
20-138
0
PC128UU-2
RESETTING PROCEDURE OF ELECTRIC SYSTEM AND

3. Check of automatic stop of LEFT offset

After the potentiometer input signal is reset
in 1 above, keep the work equipment in the
present position and check automatic stop of
the LEFT offset.
fl Standard distance L: 150 - 200 mm
1) Run the engine at low speed and press the
pedal fully to move the offset from the right
offset stroke end to the left. Check that the
offset stops automatically.
2) Run the engine at full throttle and perform the
above check.
4. Check of automatic stop of forward operation and
stopping distance (Arm OUT operation)
1) Check of automatic stop
i) Set the work equipment in the following
position.
Boom: Set boom back vertical.
Bucket: Set bucket horizontal (when
stopped).
Offset: Bring center of bucket to right
end of cab.
ii) Run the engine at low speed and operate
the arm control lever OUT. Check that the
arm stops automatically.
iii) Run the engine at full throttle and perform
the above check.
2) Check of stopping distance
Check that distance L between the
bucket tooth tip and cab is in the standard
range when the arm is stopped with the
engine at full throttle.
fl Measure distance L when the height
above the left deck cover top is C.
Height C: 700 mm
Standard distance L: 300 350 mm
fl After the arm stops automatically, if the bucket
is not horizontal, set it horizontal, then measure distance L.
PC128UU-2
20-139
(6)
RESETTING
5.
When automatic stopping distance is shorter

than standard value
*
Even if the automatic stopping distance is a
little out of the standard range, it does not
make difference to the actual work. Accordingly, it is not necessary to reset (adjust) the
stopping distance, except a particular case
(e.g. when required by the customer).
.
Reset (Adjust) the stopping distance according to the following procedure.
1) Move the arm OUT to increase distance d
between the bucket and cab by about 500 mm.
2) Set emergency work equipment operation
switch (4) to the EMERGENCY position and
move the arm IN slowly to adjust distance L
between the cap and bucket tooth tip to 350
mm.
Adjust distance L while the height
*
Height C: 700 mm
The bucket moves IN about 50 mm fur*
ther than the set position because of its
inertia. Count in this distance in advance.
4) Set the mode selector switch to Depth and
connect reset power terminal (I) and reset
terminal (2).
The reset power terminal (CN-KIO) (1) is
*
a plug (green harness) and the reset terminal (CN-K8) (2) is a socket (Yellow and
blue harness which is not taped).
(CN-KIO) (I) and (CN-K8)
6) Disconnectterminal
(21, then turn the starting switch to the OFF
position.
Run the engine at full throttle and have
*
stop automatically to
the workequipment
check stopping distance L.

6WPO442
BWP04422
TKP00656
PC128UU-2
RESETTING
TESTING AND ADJUSTlNG
6.
When automatic stopping distance is longer

than standard value
*
Even if the automatic stopping distance is a
little out of the standard range, it does not
make difference to the actual work. Accordingly, it is not necessary to reset (adjust) the
stopping distance, except a particular case
(e.g. when required by the customer).
. Reset (Adjust) the stopping distance according to the following procedure.
I) Move the arm OUT to increase distance d
between the bucket and cab by about 500 mm.
2) Set emergency work equipment operation
switch (4) to the EMERGENCY position and
move the arm IN slowly to adjust distance L
between the cap and bucket tooth tip to 350
mm.
*
Adjust distance L while the height
Height C: 700 mm
*
The bucket moves IN about 50 mm further than the set position because of its
Turn
the starting switch to the OFF position
3)
4) Set the mode selector switch to Depth and
connect reset power terminal (I) and reset
terminal (2).
*
a plug (green harness) and the reset terminal (CN-K8) (2) is a socket (Yellow and
blue harness which is not taped).
(CN-KIO) (1) and (CN-K8)
position.
*
the workequipment

BWP0442
PC128UU-2
BWP04422
TKP00656
20-141
RESETTING
TESTlNG
7.
AND ADJUSTING
If an abnormality display (error code) is given for

Items 5 or 6 (reset automatic stop output signal)
+ For details of the abnormality display, see Item
2, Table 1.
The adjustment range for the automatic stop
position is 300 mm to the front and rear of
the automatic stop position, so with the normal reset, there is no reset error, but if an abnormality display is given, carry out the resetting operation within a range that does
not give any abnormality display.
*
Adjustment range: Automatic stop position If: e
Dimension e: 300 mm
*
If the above resetting operation causes any
problem with normal operation, carry out the
resetting operation again from 1.
Reset
potentiometer input signal.
*
If an abnormality display appears during the
resetting operation, remove all the causes,
then reset the system properly.

BWPO4425
8.
Move position of bucket to left and right and

check automatic stop position
.
If the automatic stopping distance has been
reset in Item 5 or Item 6, move the bucket to
the maximum left offset and the center of the
cab, carry out the automatic stop, and check
that there is no extreme difference between
the distance set previously and the actual
distance from the tip of the bucket teeth to
the cab.
1) Set the bucket to maximum left offset position (I 1 and carry out the automatic stop.
2) Set the bucket in line with cab center (2) and
carry out the automatic stop.
* When measuring
after stopping,
set the
bucket in a horizontal position.
20- 142
0
BWP04426
PC128UU-2
RESElTING
9. Reset compensation for depth display

I) Set the work equipment in the following posture.
Set the bucket to the end of the DUMP stroke,
operate the arm so that the top of the bucket
is perpendicular to the ground, and lower the
boom to set the bucket teeth in contact with
the ground.
2) Set the mode selection switch to HEIGHT.
Ir Do not stop the engine.
Connect
reset power source terminal (1) and
3)
reset terminal (2).
*
Reset power source terminal (CN-KlO)(l)
is a female l-pin connector (green wiring
harness).
Reset terminal (CN-K8)(2) is a male l-pin
connector (yellow/blue wiring harness, no
taping).
Check
that electrical system caution lamp (5)
4)
on the monitor panel starts to flash 2 seconds
later in a l-second cycle.
*
If abnormality display code 1241 is given,
carry out the operation again from 1.
Reset potentiometer input signal.
and (CN5) Disconnect terminals (CN-KlO)(l)
K8)(2).
.6) Set the work equipment in the following posture.
Set the arm to the end of the OUT stroke, operate the bucket so that the top of the bucket
is perpendicular to the ground, and lower the
boom to set the bucket teeth in contact with
the ground.
,7) Set the mode selection switch to OFFSET.
*
Do not stop the engine.
8) Repeat Steps 3) to 5).
9) When the starting switch is turned OFF, then
ON again, the resetting operation is completed.
10) After finishing the operation, tape the reset
terminals to their original position.

BWPO4492
node selection\
TKP00659
BWP04427
PC128UU-2
20-143
0
RESElTlNG
TESTING
AND ADJUSTING

TKP00661
10. Check operation of work equipment automatic

control
*
Carry out the operation on a horizontal surface as far as possible.
1) Depth display (function for displaying depth
from ground level)
i) Set the bucket vertical and in contact with
the ground, and check that the depth display shows 10.01.
ii) Use the work equipment to raise the chassis and check that the depth display
changes.
2) Depth display 0 set mode (function for displaying depth from standard surface)
i,
Raise the bucket to a point 1 m above the
ground and check that the depth display
shows UP.
ii) In the above posture, set the mode selection switch to DEPTH DISPLAY 0 SET and
turn the setting switch to the SET position. Check.that the depth display changes
to [O-O1when this is done.
iii) Lower the bucket to the ground and check
that the depth display changes to i1.01.
iv) Turn the setting switch to the CLEAR position to cancel the setting.
3) Depth mode (function for setting depth)
i) Raise the bucket so that the tip of the teeth
is 0.5 m above the ground.
ii) Set the mode selection switch to DEPTH
and turn the setting switch to the SET
position.
*
When this is done, the buzzer will
sound twice and the indicator will light
TXP02249
BWP04426
UP.
iii) Raise the boom, then run the engine at
full throttle and operate the lever fully to
lower the boom and check that it stops at
the original position.
20-144
3
BWP04429
PC128UU-2
RESElTlNG
4)
5)
Height mode (function for setting height)

*
This mode is not available on the mono
boom specification machine.
i) Move the arm out fully, then raise the
boom until the back face of the boom is
perpendicular.
ii) Set the mode selection switch to HEIGHT
and turn the setting switch to the SET
position.
*
When this is done, the buzzer will sound
twice and the indicator will light up.
iii) Lower the boom, then run the engine at
full throttle and operate the lever fully to
raise the boom and check that it stops at
the original position.
Offset mode (function for setting left offset)

Set the offset to the left offset position.
Stop just before the end of the stroke.
ii) Turn the setting switch to the SET position.
*
When this is done, the buzzer will sound
twice and the indicator will light up.
iii) Offset the bucket to the right side of the
center line of the boom, then run the engine at fult throttle and operate the pedal
fully to offset the work equipment to the
left and check that it stops at the original
position.

BWPO4430
i)
*
PC128UU-2
ElWPO443 I
20-145
0
RESETTING
11. Resetting of correction of side stop

:
. When the bucket is replaced with one having
different width and the distance between the
new bucket and cab is narrowed
1) Move the offset slowly to the left to adjust distance L between the bucket and cab to 260
mm.
It The bucket moves IN about 50 mm further than the set position because of its
3) Connect reset power terminal (I) andlateral
reset terminal (3).
*
Set the mode selector switch to Depth.
*
a plug (green harness) and the lateral reset terminal (CN-KS) (3) is a socket (Yellow and blue harness which is taped).
*
If error code 22 is displayed, perform
the above procedures again from 1 Resetting of potentiometer input signal.
5) Disconnect terminals (CN-KIO) (I) and (CNK9) (31, then turn the starting switch: to the
OFF position.
*
the work equipment stop automatically to
When the bucket is replaced with narrow one
and the distance between the new bucket and
cab is widened
8) Do not reset the correction after the narrow
bucket is installed, as a rule. If the correction
needs to be reset for replacement of the controller, etc., however, set distance L by the
following formula.
L=260+(6-A)/2)(mm)
A : Width of narrow bucket
B : Width of standard bucket
. 9) Perform the above procedures from 2) to 7).

BWPO4432
TKP00655
Narrow
bucket
bucket
TXP02250
20-146
a
PC128UU2
RESElTING
12. Resetting of right exterior parts interference prevention control (Boom LOWER stop angle)
1) Set the work equipment in the follovving position.
Raise the boom to the top (It is not necessary
to move the cylinder to the stroke end) and
move the offset to the right end and move
the arm to the inner end.
a% Operate the emergency work equipment
operation switch, and check that the offset cylinder is at the RIGHT stroke end and
the arm cylinder is at the IN stroke end.
2) Lower the boom or curl or dump the bucket
to bring the work equipment to the desired
lowering stop position, taking care not to interfere with the right exterior parts.
*
Adjust distance e between the right
exterior parts and bucket tooth tip to 50 150 mm.
*
The bucket moves IN by some distance
further than the set position because of
its inertia. Count in this distance in advance.
4) Connect reset power terminal (I) and reset
terminal (3).
*
Set the mode selector switch to Height.
*
a plug (green harness) and the reset terminal (CN-KS) (3) is a socket (green harness which is taped).
*
If error Fl (Boom angle reset trouble)
is displayed, the correction value is out
of the adjustment range (+30 degrees, 10 degrees).
In this case, perform the
above procedures again from 2).
(CN-KIO) (I) and (CN-KS)
position.
*
the workequipment
check that it stops at the desired position.
PC128UU-2

BWP04434
TKP00659
20-147
0
RESETTING
TESTING
AND ADJUSTING
13. Resetting of right exterior parts interference prevention control (Arm IN stop angle)
1) Set the work equipment in the following position.
Set the offset boom horizontal and move
the offset to the right end.
*
Operate the emergency work equipment
operation switch, and check that the offset cylinder is at the RIGHT stroke end.
2) Move the arm IN or OUT or curl or dump the
bucket to bring the work equipment to the desired lowering stop position, taking care not
to interfere with the right exterior parts.
*
Adjust distance f between the right exterior parts and bucket tooth tip to 100 200 mm.
*
The bucket moves IN by some distance
further than the set position because of
its inertia. Count in this distance in advance.
4) Connect reset powerterminal (I) and resetterminal (3).
*
Set the mode selector switch to Depth.
*
The reset power terminal (CN-KIO) (I) is
a plug (green harness) and the reset terminal (CN-KS) (3) is a socket (green harness which is taped).
*
If error F2 (Arm angle reset trouble) is
displayed, the correction value is out of
the adjustment range (+30 degrees, -10
degrees). In this case, perform the above
procedures again from 2).
6) Disconnect terminal (CN-KIO) (I) and (CN-KS)
position.
*
the workequipment
check that it stops at the desired position.
20- 148
0

BWPO4435
Mode
selection
TKP00656
PC128UU-2
TESTING
AND ADJUSTING
REPLACEMENT
PROCEDURE OF POTENTIOMETERS
REPLACEMENT PROCEDURE OF
POTENTIOMETERS
* Itis impossible to replace only the potentiometers.
Accordingly,
if the potentiometers
need to be replaced, replace the case assemblies.
If the case assemblies need to be used again, fix
levers (41, (51, and (6) to the potentiometer
bodies
before removing them.
I.
Remove potentiometer
assemblies (I), (21, and (3)
from the work equipment.
Boom potentiometer
(I)
Arm potentiometer
(2)
Bucket potentiometer
(3)
*
Do not swing a removed potentiometer
assembly around its lever or turn the lever unnecessarily.
l
2.
Install
potentiometer
assemblies
Arm
(I), (21, and (3).
3.
Be sure to reset the input and output signals.

Ir For details, see Resetting procedure of input
and output signals of electric system and
check of its operation.
Sr Linkages (7) and (8) of the arm potentiometer
and
boom potentiometer
can be connected even if levers (4) and (5) of the potentiometers
are inverted.
Accordingly,
take care of the positions of the potentiometers
particularly
when the linkages are
disconnected.
Reference :
Distance a between boom potentiometer
rod pins: 280 f 2 mm
Distance b between arm potentiometer rod
pins: 416 +_4 mm
*
If the linkages are connected to the opposite side,
when the starting switch is turned to the ON position, error code 32 is displayed and the buzzer
sounds. In this case, turn the starting switch to
the OFF position
and connect the linkages correctly.
PC1 28UU-2
20-149
0
Pm CLINIC INSPECTION TABLE
PC128UU-2 # 5001 and up

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

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

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

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

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

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

Unit
Standard
MeasureService limit
value for
ment
Good
value
new machine
result
925 975
rpm
2,340 2,460
2,120 2,320
Min. 2,000
Max. 0.49
{Max. 50}
0.34 0.59
{3.5 6.0}
Min. 0.10
{Min. 1.0}
0.34 0.59
{3.5 6.0}
Min. 0.08
{Min. 0.8}
Max. 0.98
{Max. 100}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
Min. 0.25
{Min. 2.5}
Min. 0.07
{Min. 0.7}
3.5 4.3
Max. 4.7
2.3 2.9
Max. 3.5
3.3 3.9
Max. 4.5
2.4 3.0
Max. 4.0
Offset to left (Right Left)
4.9 6.1
Max. 6.5
Offset to right (Left Right)
5.0 6.2
Max. 6.6
1.0 1.6
Max. 2.5
27.0 33.0
24.0 36.0
Max. 29
Max. 36
Max. 39
Max. 48
Max. 500
Max. 700
Item
Condition
Low idling
Engine speed
Engine
Arm IN relief
Blow-by pressure
kPa
{mmAq}
Arm IN relief
SAE30
SAE15W-40
Lubricating oil
pressure
High idling
Low idling
MPa
{kg/cm2}
High idling
SAE10W
Low idling
Work equipment speed
Hydraulic oil
45 55 C
temperature
Boom raised
No load applied and
(to just before cushion) extended to end
Boom in horizontal
Arm out
position and offset to
(to just before cushion) right (until clearance
between right end of
operators cab and
Arm in
is about 350
(to just before cushion) bucket
mm)
Bucket curled
Bad
Boom and arm in

horizontal positions
sec
Blade raised
Left
5-turn swing
Engine at full
throttle
Right
Left
High speed
Right
5-turn travel
Left
Low speed
Right
Hydraulic drift of
work equipment
20-150
Rated load applied and engine stopped
mm/15min
PC128UU-2
(6)
Oil
pressure
PC128UU-2 # 5001 and up

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

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

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

pressure
Bucket-CURL circuit
relieved
Control lever in neutral
LS 1-side track running idle

Travel speed: Hi
Travel lever in half
position
PC128UU-2
(6)
Main oil pressure
Engine at full
throttle
LS differential
pressure
< >: Reference value

Standard
MeasureService limit
value for
ment
Unit
Good
value
new machine
result
<2.45 3.43> <2.45 3.43>
{<25 35>}
{<25 35>}
3.04 3.43
2.75 3.73
{31 35}
{28 38}
<2.45 3.43>
{<25 35>}
31.9 33.8
30.9 33.8
{325 345}
{315 345}
31.9 33.8
30.9 33.8
{325 345}
{315 345}
31.9 33.8
30.9 33.8
{325 345}
{315 345}
31.9 33.8
30.9 33.8
{325 345}
{315 345}
25.5 28.4
24.5 29.4
{260 290}
{250 300}
30.4 32.4
28.9 32.9
{310 330}
{295 335}
30.4 32.4
28.9 32.9
{310 330}
{295 335}
MPa
31.9 33.8
30.9 33.8
{kg/cm2} {325 345}
{315 345}
30.9 33.8
29.9 34.8
{315 345}
{305 355}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
33.8 35.8
32.9 36.8
{345 365}
{335 375}
2.45 4.41
2.45 4.41
{25.0 45.0} {25.0 45.0}
14.5 17.5
13.5 18.4
{148 178}
{138 188}
1.77 3.73
{18.0 38.0}
2.11 2.30
{21.5 23.5}
Bad
20-151
TROUBLESHOOTING
Knowledge of troubleshooting
Points to remember when troubleshooting ......................................................................................... 20-202
Sequence of events in troubleshooting .............................................................................................. 20-203
Points to remember when carrying out maintenance ........................................................................ 20-204
Checks before troubleshooting ............................................................................................................ 20-212
Types and locations of connectors ...................................................................................................... 20-214
Connector arrangement diagram ........................................................................................................ 20-218
Connection table for connector pin numbers ..................................................................................... 20-222
Explanations of control mechanism of electrical system .................................................................. 20-235
Display method for monitor panel, controller .................................................................................... 20-241
Method of using troubleshooting charts ............................................................................................. 20-247
Troubleshooting of controller, electrical system (E-mode) .................................................................. 20-301
Troubleshooting of controller input signal system (F-mode) .............................................................. 20-401
Troubleshooting of hydraulic, mechanical systems (H-mode) ............................................................ 20-501
Troubleshooting of monitor panel system (M-mode) .......................................................................... 20-601
Troubleshooting of engine (S-mode)..................................................................................................... 20-701
PC128UU-2
20-201
(6)
TROUBLESHOOTING
POINTS TO REMEMBER
WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

a
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
Be extremely
When disconnecting
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.
careful not to touch any hot parts or to get caught in any rotating parts.
wiring, always disconnect the negative
(-1 terminal
of the battery first.
The aim of troubleshooting

is to pinpoint the basic cause of the failure, to carry out repairs swiftly,
and to prevent reoccurrence of the failure.
When carrying out troubleshooting,
and important point is of course to understand the structure
and function. However, a short cut to effective troubleshooting
is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.

do not
hurry to disassemble the components.
If components are disassembled immediately
any failure occurs:
.
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
.
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out through
prior investigation
and to carry out troubleshooting in accordance with the fixed procedure.
Points to ask user or operator
I) Have any other problems occured apart
from the problem that had been reported?
2) Was there anything strange about the machine before tha failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred before?
Check before troubleshooting
1) Check the oil level.
20-202
0
2)
4.
5.
6.
Check for any external leakage of oil from

the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve
spool.
5) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
Confirming failure
Confirm the extent of the failure yourself,
and judge whether to handle it as a real failure or as a problem with the method of operation, etc.
*
When operating the machine to reenact
the troubleshooting
symptoms, do not
carry out any investigation or measurement that may make the problem worse.
Troubleshooting
Use the results of the investigation and inspection in Items 2 - 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the
failure exactly.
*
The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
Measures to remove root cause of failure
Even if the dailure is repaired, if the root
cause of the failure is not repaired, the same
failure will occur again.
To prevent this, always investigate why the
problem occureed. Then, remove the root
cause.
PC128UU-2
SEQUENCE
TROUBLESHOOTING
OF EVENTS
IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEWOO180
1) When a request for repairs is received, first

ask the following points.
.
Name of customer
.
Type, serial number of machine
.
Details of jobsite, etc.
2) Ask questions to gain an outline of the problem.
*
Condition of failure
.
Work being carried out at the time of the
failure
.
Operating environment
.
Past history, details of maintenance, etc.
TEW00181
step 1
Examination, confirmation of symptoms
-------------
Ring
Ring
TEWO0182
Step 2
IDetermining probable location of caus
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
tools.
.
T-adapter
.
Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the necessary replacement parts.
TEWO0183
1) Before starting troubleshooting, locate and
Step 4
PC128UU-2
Was there anything strange about the machine before the failure occurred?
Did the failure occur suddenly?
20-203
0
TROUBLESHOOTING
POINTS TO REMEMBER
WHEN CARRYING
OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting,
and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling
electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil).
1.
POINTS TO REMEMBER
ELECTRIC EQUIPMENT
WHEN HANDLING
1)
Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore,
during
inspection and repair operations, they are frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harness

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.
Improper
insert
ion
TEW00192
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.
Improper
I
20-204
0
compress
TEW00193
PC128UU-2
TROUBLESHOOTING
WHEN CARRYING
POINTS TO REMEMBER
OUT MAINTENANCE
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.
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 conon the direction of the
nector, depending
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be shortcircuited by the water, so if any water gets
the connector or take
in, immediatelydry
before passing elecaction
other appropriate
it.
through
tricity
TEW00194
b\
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.
When wiping the mating portion of the
*
connector, be careful not to use excessive force or deform the pins.
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.
PC128UU-2
20-205
0
TROUBLESHOOTING
POINTS TO REMEMBER
2)
Removing, installing,
wiring harnesses
Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the connectors apart.
*
Never pull with one hand.
OUT MAINTENANCE
and drying connectors and
Lock steppe
TEW00197
When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
*
If the connector is twisted up and down
or to the left or right, the housing may
break.
I
0
WHEN CARRYING
TBW00485
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.
*
If the machine is left disassembled
for a
long time, it is particularly
easy for improper contact to occur, so always cover
the connector.
TEWOO198
20-206
0
PC128UU-2
TROUBLESHOOTING
POINTS TO REMEMBER
Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check that there is no deformation, defective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or breakage to the outside of the connector.
*
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.
*
If there is any damage or breakage, replace the connector.
WHEN CARRYING
OUT MAINTENANCE
Cliks
into position
TEW00199
Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
Correct any protrusion of the boot and any
misalignment of the wiring harness

any
correct
boots,
with
fitted
connectors
For
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.
If the connector cannot be corrected eas*
ily, remove the clamp and adjust the
position.
If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
PC1 28UU-2
TBwoo487
20-207
0
TROUBLESHOOTING
POINTS TO REMEMBER
WHEN CARRYING
OUT MAINTENANCE
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.
@ Disconnect the connector and wipe off the
water with a dry cloth.
Sr If the connector is blown dry with compressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the compressed air before blowing with air.
TEW00196
Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
*
Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connector.
TEW00202
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.
*
After completely drying the connector,
blow it with contact restorer and reassemble.
T-adapter
TEW00203
20-208
0
PC1 28UU-2
TROUBLESHOOTING
3)
POINTS TO REMEMBER
WHEN CARRYING
OUT MAINTENANCE
Handling control box

The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
Do not open the cover of the control box
unless necessary.
TEWOO204
Do not place objects on top of the control

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

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors connected to the control box. Fit an arc welding
ground close to the welding point.
I
2.
Points to remember
when troubleshooting
II
TEWOO206
electric circuits
1) Always turn the power OFF before disconnecting or connect connectors.

2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
*
3) Always connect any disconnected connectors before going on to the next step.
*
If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
of circuits (measuring the voltage, resistance, continuity, or
4) When carrying out troubleshooting
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
If there is any change, there is probably defective contact in that circuit.
*
PC1 28UU-2
20-209
0
TROUBLESHOOTING
3.
POINTS TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
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
Avoid adding
repairing the
places where
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 confirm the performance after repairs,
so it is desirable to use unit exchange. Disassembly and main-tenance
of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance
should be confirmed with special test equipment.
3)
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leaking oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4)
Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210
0
the operating environment.

hydraulic oil, replacing filters, or
machine in rain or high winds, or
there is a lot of dust.
TEW00207
PC1 28UU-2
TROUBLESHOOTING
POINTS TO REMEMBER
5)
is
Change hydraulic oil when the temperature
high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as possible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the hydraulic oil.
6)
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
sludge, and old oil
remove the contaminants,
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.
WHEN CARRYING
OUT MAINTENANCE
Flushing
oil
TEWOOZIO
7)
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3~) particles that the filter
built into the hydraulic equipment cannot remove, so it is an extremely effective device.
TEW00211
PC128UU-2
20-211
0
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Item
Judgment
value
Action
1. Check fuel level, type of fuel
Add fuel
2. Check for impurities in fuel
Clean, drain
3. Check hydraulic oil level
Add oil
4. Check hydraulic strainer
Clean, drain
5. Check swing machinery oil level
Add oil
6. Check engine oil level
Add oil
7. Check coolant level
Add water
8. Check dust indicator for clogging
Clean or replace
Replace
9. Check hydraulic filter

10. Check final drive oil level
Add oil
11. Check for looseness, corrosion of battery terminal, wiring
Tighten or replace
12. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
13. Check for looseness, corrosion of starting motor terminal,

wiring
Tighten or replace
14. Check operation of instruments
Repair or replace
15. Check for abnormal noise, smell
Repair
16. Check for oil leakage
Repair
17. Carry out air bleeding
Bleed air
24 - 26V
Replace
19. Check battery electrolyte level
Add or replace
20. Check for discolored, burnt, exposed wiring
Replace
21. Check for missing wiring clamps, hanging wiring
Repair
22. Check for water leaking on wiring (be particularly careful

attention to water leaking on connectors or terminals)
23. Check for blown, corroded fuses
18. Check battery voltage (engine stopped)
24. Check alternator voltage (engine running at l/2 throttle or

a hove)
25. Sound of actuation of battery relay (when starting switch is
turned ON, OFF)
20-212
a
After running for

several minutes:
27.5 - 29.5 V
-
Disconnect
connector and dry
Replace
Replace
-
PC1 28UU-2
TROUBLESHOOTING
TYPES AND LOCATIONS
TYPES AND LOCATIONS OF CONNECTORS

* Each addresses in the following table refers to the address in the
(single
view
arrangement
drawing
drawing).
I I
Address
Location
( B3
connector
OF CONNECTORS
1KESI ) 4
1 Intermediate
connector
Location
:N-92
Limit switch
Radio
:N-502AMP040 18
Wiper motor control relay box
21
Controller
DO1 YAZAKI
Diode
CO2 AMP040 20
Controller
DO2 YAZAKI
Diode
CO3 AMP040 .I6
Controller
DO3 YAZAKI
Diode
CO4
Register
DO4 YAZAKI
Diode
CO5
Emergency pump drive switch
DO5 YAZAKI
Diode
CO6
KESI
DO6 (YAZAKII
2 1 Diode
co9
Attachment selector connector
DO7 YAZAKI
Diode
Cl1
KES
Mode selector
DO8 YAZAKI
Diode
Cl2
KES
Set/Clear
~09 IYAzAKII
2 I Diode
Cl3
EPC valve for PC
B4
MIC
co1
switch
switch
D14 IYAZAKI~ 2 I Diode

I Cl7
I x I 2 I Left
21
C20
offset solenoid
valve
SWP
12
Intermediate
connector
CN-1
SWP
16
Intermediate
connector
D21
YAZAKI
Diode
CN-2
SWP
12
Intermediate
connector
D22
YAZAKI
Diode
CN-3
Intermediate
connector
CN-4
Intermediate
connector
CN-5
SWP
14
Intermediate
connector
CN-6
SWP
Intermediate
connector
El2
Terminal
Revolving
El3
Terminal
Starting
El4
ITerminal\
El5
Intermediate
connector
El6
Intermediate
connector
El7
Intermediate
connector
E20
SWP
Intermediate
connector
11
CN-76
Additional
headlamp
CN-77
Headlamp
(L.H)
) Limit switch
ICN-911 Relay I
20-214
0
(R.H)
frame
ground
motor
1 ) Heater relay
PC128UU-2
TYPES AND LOCATIONS
TROUBLESHOOTING
I I
Address
Location
1 E30
~Terrninal~ I
KIO
Plug
Kll
K12
K13
SWP
I K14
1 Safety
I 2 I Travelspeed increase selector switch I
M40 I
I 2 I One-touch decelerationl~/
M41 I
1 6 I Intermediate
connector
M45
Intermediate
connector
Reset terminal
PO1
AMP040
Monitor
Switch to resetonly prevention of

exterior part interference
Switch to reset only prevention of
exterior part interference
PO2
Light switch
PO4
Alarm
Lever
~05
I Register
UP/DOWN
Decelerator
controller
1 K17
1 X
1 4
1 Decelerator
controller
K18
SWP
Decelerator
controller
K19
Fuel control
dial
) 2 I Deceleration
1 Boom working
lamp
SO4
1 2
1 Boom LOWER pressure switch (No. II I
SIO
I 2 I Intermediateconnector
SIO
lamp
Ml2
KESI
Heater
S13
Ml6
I M26
Connector 1
x
Connector
Boom LOWER pressure switch (No. 2)
PPC oil pressure
lock switch
ITerminal I 1 I PPC oil pressure lock switch I
S14 1 M
1 2 1 Fusible link
2
I Light
S12
buzzer
I Relay I 6
Fusible link
Ml5
R03
panel
Fuel level sensor
Ml1
I Ml4
Engine water temperature sensor
K16
M39
2 I Register
Register
I MO9 I
B)
switch
Address
I I
Location
relay (Terminal
K15
I K20
OF CONNECTORS
1 2
Intermediate
connector
Fusible link
Horn (High tone)
I 6 I Air conditioner
M28
Washer tank motor
M30
Optional
power supply
Electromagnetic
TO1 /Terminal1
TO2
Terminal
TO2
Terminal
TO3
Terminal
#TO5
Terminal
TO6 ITerminal1
clutch for air
Engine stop solenoid
(-1
Ground
Kerosene mode selector connector

M37
Kerosenemode selector connector
M38
Light switch
PC128UU-2
Tll
ITerminal/
Cab ground
20-215
0
TROUBLESHOOTING
TYPES AND LOCATIONS
Location
T12
ITerminal1 1
Starting switch (Terminal ACC)
T29
Terminal
Swing holding brake reset switch
T30
Terminal
Swing holding brake reset switch
VO4
Swing holding brake solenoid
VO5
Travel speed selection lock solenoid
V06
vo7
1 2-stage
relief valve solenoid
Address
Location
PPC oil pressure lock solenoid
20-216
OF CONNECTORS
PC1 28UU-2
CONNECTOR
TROUBLESHOOTING
CONNECTOR ARRANGEMENT
ARRANGEMENT
DIAGRAM
DIAGRAM
MO9
,
\\
8
*
l\
FOl
V06
20-218
0
PC1 28UU-2
TROUBLESHOOTING
CONNECTOR
ARRANGEMENT
DIAGRAM
PO6
'Tl
cti-2
cbi-4
5
BWP04440
PC128UU-2
20-2 19
0
TROUBLESHOOTING
CONNECTOR
ARRANGEMENT
DIAGRAM
M.2
K13
KlO
ROS
K6
Tll
PO4
M46
M40
ctq-91
ct+92
DO4
K16
T29
T30
R03
K16
Z
20-220
0
BWP04441
PC128UU-2
TROUBLESHOOTING
CONNECTOR
ARRANGEMENT
DIAGRAM
PO7
Dl 6%
El4
E20
804
Ch-76-l
803
W-76
/
BWP04442
PC128UU-2
20-221
0
TROUBLESHOOTING
CONNECTION
TABLE FOR CONNECTOR
PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female
housing
refer to the mating portion of the housing.

No.
of
pins
X type connector
Male (female housing)
Female (male housing)
BEH0014B
BEH00149
I
TEwoo221
TEW00222
TEW00223
TEW00224
TEWO0225
20-222
0
PC1 28UU-2
CONNECTION
TROUBLESHOOTING
No.
of
pins
TABLE FOR CONNECTOR
PIN NUMBERS
SWP type connector

Male (female
Female
housing)
(male
housing)
6
TEwoo235
BLFQ0033
m
0
12
___
.__
_____-
Cl
0
TEW00238
12
BLPOOO35
BLPOOO34
11
io
14
11
14 Id
14
TEW00239
TEwOO240
16
BLPOO036
PC1 28UU-2
20-223
0
CONNECTION
TROUBLESHOOTING
No.
of
pins
TABLE FOR CONNECTOR
PIN NUMBERS
M type connector

2
BLFO0036
TEwoo243
TEwoo244
Bi$
2
2
TEWO0246
TEW00245
I!!!$
3
TEWOO247
TEW00246
6Lmoo4i
20-224
0
PC128UU-2
CONNECTION
TROUBLESHOOTING
No.
of
pins
TABLE FOR CONNECTOR
PIN NUMBERS
S type connector
El
1
io
TEW00249
TEWOO250
10
TEW00251
10
IO
BEL00117
PC128UU-2
;2
EEL00113
BELO
12
BEL00114
20-225
0
CONNECTION
TROUBLESHOOTING
No.
of
pins
12
TABLE FOR CONNECTOR
PIN NUMBERS
S type connector
3i
BLP00043
12
BEL00114
IS
BEP01698
16
7
1
BEP01697
16
20-226
0
PC128UU-2
CONNECTION
TROUBLESHOOTING
No.
of
pins
AMP040
Male (female
TABLE FOR CONNECTOR
PIN NUMBERS
type connector
housing)
Female
(male
housing)
BLFQOO54
12
BLFOOO55
12
16
BLFQOO55
16
ii
i
TEW00234
PC128UU-2
20-227
0
TROUBLESHOOTING
No.
of
pins
CONNECTION
AMP070
TABLE FOR CONNECTOR
PIN NUMBERS
type connector
12
12
BWPO3901
BWP03902
14
BLPO0069
18
18
BLPOO062
1
I
IO
20
20
BWP03903
20-228
0
BWPO3904
PC1 28UU-2
CONNECTION
TROUBLESHOOTING
No.
of
pins
Automobile
TABLE FOR CONNECTOR
PIN NUMBERS
connector
2
BLPco066
BLFOOO6-9
PC1 28UU-2
BLpoOO69
BLPO0070
BLPO0071
BLPOOO72
20-229
0
CONNECTION
TROUBLESHOOTING
No.
of
pins
TABLE FOR CONNECTOR
PIN NUMBERS
MIC connector

3
lr
uou
BLFOOO45
BLFflOO46
BLFO0047
BLFOOO46
13
13
BLWO049
BLF30050
9
17
17
21
20-230
0
TEwoo259
TEW00260
PC128UU-2
CONNECTION
TROUBLESHOOTING
TABLE FOR CONNECTOR
PIN NUMBERS
L type connector
No.
of
pins
TEW00257
Connector
No.
of
pins
TEW00258
for PA
rl
5
BEH00156
No.
of
pins
9
BEH00157
Bendix MS connector
10
BWWO1218
BWW01219
PC128UU-2
20-231
0
TROUBLESHOOTING
No.
of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Connector
for relay (Socket type)
Relay (male housing)
BLP00074
BLPOOO73
___
m
0
i
m
______
BLPOO075
20-232
0
BLPOO076
PC128UU-2
CONNECTION
TROUBLESHOOTING
No.
of
pins
PIN NUMBERS
F type connector
f=7
PC128UU-2
TABLE FOR CONNECTOR
I@c
3
BWPO3905
BWPO3906
20-233
0
EXPLANATIONS
TROUBLESHOOTING
EXPLANATIONS
SYSTEM
OF CONTROL MECHANISM
OF ELECTRICAL SYSTEM
OF ELECTRICAL
This section gives the necessary knowledge for troubleshooting

of the electrical system, and explains
the functions and nature of checks for the monitor panel and controller.
1.
Explanation of functions
The control mechanism of the electrical system consists of the monitor panel and controller. It carries out various controls such as stopping the work equipment in the interference area, setting the
working range (height, depth, offset), displaying the depth.
The monitor panel and controller each input the necessary signals, and at the same time, together
with the signals selected and set by the monitor panel, the controller inputs and outputs the necessary signals to control the stopping of the work equipment, the setting of the working range (height,
depth, offset), displaying the depth.
Input/output signal system for monitor and controller
Attachment
selection
selection
Engine
speed
Pressure
connector
switch
Z
3LT-
signal
signal
Specification
selection
Z-Stage
swing
brake
sional
PC-EPC
&Boom
&rm
Depth
Mode
Potent
iomete
Buzzer
-3
setting
Boom
RAISE
signal
Boom
LOWER stop
signal
signal
Le.ft
offset
stop
solenoid
valve
solenoid
Right
System
cancel
PC128UU2
stop
signal
system
code
iometer
otentiometer
signal
Electrical
Error
signal
valve
Potentiomet
i:IIent
le setting
relief
holding
LS bypass
signal
valve
offset
stop
cancel
TJP02188
20-235
0
TROUBLESHOOTING
EXPLANATIONS
When troubleshooting
:
The controller is equipped with a self-diagnostic function, and troubleshooting
is carried out as far as
possible by the controller itself.
When troubleshooting
is carried out, the error codes are displayed on the monitor panel depth display
and the controller display.
At the same time, the electrical system caution lamp flashes and the alarm buzzer sounds intermittently
to warn the operator of the failure mode. The following actions are also carried out.
l
Abnormal
system and details of display and action
Abnormality in systems @ @ @ (error codes: 31, 32, 34)

Stops operations @ @ @ (makes it impossible to move towards
l
interference)
Abnormality in systems @ @ @ (error codes: 52,71,81)

Stops operations @ @ @ (makes it impossible to move towards interference)
l
Abnormality in system @ (error code: 51)

Error code 51: Stops operation @ (this is the PPC basic pressure,
equipment, travel, and swing is impossible)
l
\
so movement
When spool of solenoid valve in systems @ @ @ does not close (error code: 91)
Stops operation @ (this is the PPC basic pressure, so movement of all work equipment,
and swing is impossible),
l
of all work
/
travel,
Abnormality in systems @ @ (error codes: 1 I- 17,21- 27 and Fl, F2)

Makes compensation value 0 for potentiometer mount angle and bucket front face stop position, side face stop position, and depth display compensation, but allows normal movement.
Abnormality in systems @ @ @ @ (error codes: 54, 61, 62, 64, 68,72)

Stops only each respective operation (has no influence on other circuits)
l
Abnormality in system @ (error code: 41)

Controls operation @ not as actual engine speed but as a certain speed (risk of engine stopping as low idling)
l
\
*
For all error codes except 91, the condition is kept if it is judged that there is a failure, but for error
code 91 only, if the location of the failure is reset, the system returns to the normal mode and the
display also goes out.
20-236
0
PC128UU-2
TROUBLESHOOTING
EXPLANATIONS
OF CONTROL
MECHANISM
Even if there is any abnormality in input signal systems @ to 0, no abnormality display is given in the
display portion, but the controller has a monitor function that checks the input signal.
When there is an input signal, the controller starts the movement and gives the monitor display in the
display portion. Therefore, when investigating if the cause is in the electrical system or in the hydraulic
or mechanical system, there are cases where there is no abnormality display in the display portion but
In such cases, the first step when
there is an abnormality in the operation of the work equipment.
is to use the method in Section 2 Checking operation of electrical system to
carrying out troubleshooting
check if the necessary signal is being input correctly to the controller.
For pressure signal switch 0, if the 2 switches for boom RAISEand LOWER are switched ON simul*
taneously for a certain period of time, error code Cl is displayed to inform the operator that the
switch is stuck.
PC128UU2
20-237
0
EXPLANATIONS
TROUBLESHOOTING
2.
Check items (when normal)
Turn starting
switch
OFF
Monitor
l
ON + 3 set
l
Turn starting
switch
ON
After 3 set +
until starting
After 5 set
Checking operation of electrical system (4 system)

When a sequence of operations is carried out using the procedure below, if the monitor panel and
controller carry out the actions given below, the input and output signals, and the monitor panel and
controller are normal.
Sequence of operation and condition of machine

3
Start engine
(engine
panel
Controller
All OFF
All OFF
All displays light up for

approx. 3 set
Buzzer sounds for approx. 1 set
Engine oil pressure,
lamp light up
charge
lo.01 is displayed in self-diagnostic display portion

Note:
Specification,
attachment code is displayed
(see
monitor display)
When bucket is above ground

level, IUPI is displayed,
and
when it is below ground level,
a number is displayed
All caution
lamps OFF
Possible
to operate
equipment freely
Buzzer does not sound
at low idling)
l
Work equipment
stops
specified position
Buzzer sounds in approx.
second cycle
Bring bucket close to cab from front or side

l
Move
bucket away from cab
l-
Set the machine to the right maximum offset position, then move the bucket from the
front upper position toward the right exterior parts and handrail.
* The bucket stops at the specified position.

The buzzer sounds at interval
of about 1 sec.
Move the bucket away from the right exterior parts and handrail.
*The bucket moves freely in the

direction to move away from
the right exterior
parts and
handrail.
(Arm OUT, boom
RAISE, left offset)
Set the machine to the neutral offset position and curl the arm to the end and keep
the offset boom level, then move the bucket
toward the right exterior parts and handrail by setting the machine to the right offset position.
Move the bucket away from the right exterior parts and handrail.
20-238
0
The bucket stops at the specified position.

The buzzer sounds at interval
of about 1 sec.
*
60
at
Movement
is possible in direction away from cab (arm
OUT, right offset)
Buzzer sounds until bucket is
sufficient
distance from cab
(canopy), and does not sound
after that
work
The bucket
tally in the
away from
parts and
OUT, boom
moves automatidirection to move

the right exterior
handrail.
(Arm
RAISE, left offset)
PC1 28UU-2
EXPLANATIONS
TROUBLESHOOTING
Sequence
of operation
Turn system
and condition
Check
of machine
cancel switch ON
Monitor
l
v
@
Carry out @ and @
U
Turn system cancel switch OFF
@I
Raise work equipment 0.5 m from ground,

set mode selection switch to DEPTH, then
turn setting switch to SET
u
Raise boom, then lower it
Raise work equipment 1 m from ground, set
mode selection switch to HEIGHT, then turn
setting switch to SET
II
Lower boom, then raise it.
Offset arm to left, set mode selection switch
to OFFSET, then turn setting switch to SET
items
(when
Controller
Buzzer sounds
Electrical system lamp flashes

in approx. l-second cycle
Electrical system lamp flashes
in approx. l-second cycle
Depth
up
mode
indicator
lights
l
l
Height mode indicator lights

up
l
l
Offset mode indicator

up
lights
l
l
l
.
l
Lower bucket to ground

@
Turn starting switch OFF
PC1 28UU-2
Work equipment can be oper

ated freely (but there is nc
automatic stop)
Electrical system lamp goes

OFF
Offset arm to right, thUenoffset it to left

Raise work equipment 1 m from ground, set
mode selector switch to DEPTH DISPLAY 0
SET, then turn settingUswitch to SET
for approx. i
set
normal)
panel
Depth
display
&o&s
Buzzer sounds twice

Work equipment stops near
set position
Buzzer sounds twice
Buzzer sounds twice
Arm stops near set position
Buzzer sounds twice
[o.o]
Value on depth display

creases from 10.11
All OFF
Buzzer sounds twice

Work equipment stops near
set position
Buzzer sounds twice
in-
All OFF
20-239
0
TROUBLESHOOTING
EXPLANATIONS
Work equipment posture

Operating procedure 0, @ (front)
Operating
procedure @
BWPO4419
Operating
BWPO4430
Operating
procedure 0, @ (side)
procedure @
BWP04431
BWP0443:2
Operating
20-240
0
Operating
procedure 0
BWP04429
procedure @
BWP04428
PC1 28UU-2
DISPLAY METHOD
TROUBLESHOOTING
FOR MONITOR
PANEL, CONTROLLER
DISPLAY METHOD FOR MONITOR

PANEL, CONTROLLER
1.
Monitor panel
1) Machine monitor portion
When the starting switch is turned ON, all
monitors and gauges light up for approx. 3
seconds, and the buzzer sounds for approx. 1
second. The monitor itself carries out selfdiagnosis, and displays the specification and
attachment
codes for 3 seconds to 5 seconds.
The specification code and attachment
code are indicated as H or L as follows.
i) The first digit shows the specification and
the second digit shows the attachment.
l
Specification
Display code
Offset specification
-1
Example of display
If the machine has the offset specification and
is equipped with the standard arm, [H.H] is
displayed.
2) Mode indicator portion
The settings for the depth mode, height mode,
and offset mode light up.
*
Multiple mode settings are possible.
*
When the starting switch is turned OFF,
all the settings are cleared.
3) Depth display portion
i) Depth display (normal display)
The depth from the ground level or the
depth set from the standard level is displayed as follows.
When the bucket is below the ground
level or the standard level, a numeral
is displayed.
When it is above the ground level or
the standard level, [UP] is displayed.
<Example when depth is 2.5 m>
TJP02189
Display for depth
from ground level
Display for depth

from standard level
Display
Above ground level
Above standard level
UP
Ground level
Standard level
0.0
1Below ground level 1Below standard level
PC128UU-2
2.5
20-241
a
DISPLAY METHOD
TROUBLESHOOTING
ii)
Self-diagnostic display (abnormality display)

When the self-diagnostic function of the controller detects an abnormality, an error code
is displayed on the controller itself, and at the
same time, it is also displayed on the depth
display.
The display is the same as for the controller, and is given as an error code from
11 to 91 and Cl.
Note that no dot is displayed between letters.
*
For details of the error codes that are displayed, see 2. Controller
The display on the right gives an example
of error code 31 (abnormality
in boom
potentiometer system).
FOR MONITOR
PANEL, CONTROLLER
Example
of display
Display
Code
Abnormal
system
Controller
31
Monitor
panel
Abnormality
in
boom potentiometer system
Display
If a communications
error occurs with an abnormality in the depth display signal system
and mode setting signal system, the monitor
itself displays error code [EEI.
iii) Monitoring mode
If the work equipment control lever is operated with the SET/CLEAR switch at the
CLEAR position, the controller display
shows the applicable monitor code. (For
1 second only)
l
Table of code numbers

Monitor code
System
Boom RAISE pressure
switch
Boom LOWER pressure

Swing
left, right pressure
Arm IN pressure
Travel pressure
20-242
0
switch
switch
switch
switch
PI
P2
P3
P5
P7
PC128UU-2
TROUBLESHOOTING
2.
DISPLAY METHOD
FOR MONITOR
PANEL, CONTROLLER
Controller
1) Normal display
After the starting switch is turned ON, code
[OO] is displayed if the condition is normal.
When normal
2)
O0
Self-diagnostic
Display
Code
Condition
display
(abnormality
/
1
dis-
play)
If any abnormality occurs in the controller
itself or in the input signal system and output signal system, the controller displays
the appropriate error code continuously.
Display
Abnormality in single system
The error code for the system with
the abnormality
is displayed directly.
Abnormality in two or more systems
i) Abnormalities in same group
The first digit of the error code (the
group code) is kept for the first digit,
and the total for the second digits (the
individual code) is displayed as the
second digit.
<Example of display7
31 (Boom potentiometer system) + 32
(Arm potentiometer system): Display
= 33
ii) Abnormalities in different groups
Priority is given to the display for the
lower group (the group with the larger
group code).
<Example of display7
31 (Boom potentiometer system) + 41
(Rotation sensor system): Display = 41
*
However, if there are abnormalities
in the 30 group (potentiometer system) and 91 (valve open system),
priority is given to the display for
the 30 group.
BDP01232
PC128UU-2
Re-enacting display
Once the starting switch is turned OFF, the
error codes are cleared, so carry out the
check with the starting switch ON.
Ir When checking, turn the cancel switch
OFF.
If the starting switch is turned OFF, it
is possible to re-enact the abnormality display as follows.
4: Turn the starting switch ON.
c]: Start the engine, set the work equipment to the reset posture, then connect the reset terminal.
A: Start the engine and bring the
bucket closer to the interference area.
*
During normal operations, if there is a
disconnection
in any of the ON/OFF
solenoid group, the output for that system may stop without any abnormality display being given.
However, for the PPC lock solenoid system, swing holding brake solenoid system, it is not possible to re-enact a disconnection.
Monitor display
In addition to the information displayed in
the monitoring
mode on the monitor
panel, [Hi] is displayed when the travel
boost switch is ON, and [UPI is displayed
when the optional knob switch is ON.
l
3)
20-243
0
TROUBLESHOOTING
DISPLAY METHOD
FOR MONITOR
PANEL, CONTROLLER
boom stop position
boom angle + arm angle
angle + offset angle

Defective
17
2,
resetting
boom angle+
offset angle
Defective
of
arm angle+
resetting
of front
face stop position

z
z.?
CT
22
Defective
resetting
of side
face stop position

Defective
resetting
23
face stop position

face stop position
24
Defective
compensation
Defective
resetting
face stop position

defective
Single
Single
21+22
of front
+ side
of
depth display
25
II+12
+ ,4
Single
21 +24
c]
Defective
compensation
of
53
resetting
of side
+
compensation
of
22 +24
depth display
9
E
Q)
0
tc
54
resetting
face stop position

27
20-244
0
of front
+ side
face position
+ defective
compensation
display
of depth
: The bold lines indicate
PPC hydraulic
+ left offset
Defective swing
brake solenoid
Defective
55
Defective
Defective
lock solenoid
51+52
Single
51+54
52 + 54
stop solenoid
face stop position

defective
PPC hydraulic
of front
+
depth display
26
Defective
occurrence
21+22
+ 24
Defective
cl
56
PPC hydraulic
lock solenoid
holding
holding
+ swing
brake solenoid
left offset
solenoid + swing
brake solenoid
holding
of a single abnormality.
PC1 28UU-2
TROUBLESHOOTING
Nad;t
grouF
rror
ode
DISPLAY METHOD
Abnormal
system
Single,
multipll
FOR MONITOR
PANEL,
CONTROLLER
Renac
-
Defective PPC hydraulic

5,
lock solenoid + left offset
51+5i
stop solenoid + swing
+ 24
holding brake solenoid

62
63
Defective LS bypass
solenoid
Defective LS-EPC solenoid
+ LS bypass solenoid
64
Defective 2-stage relief

solenoid (opt)
6B
Defective swift slow-down

controller signal system
Single
61 +6i
Single
Single
7,
Defective boom RAISE EPC

Single
solenoid
72
Defective boom LOWER
u
.-
6
z
EPC solenoid
cn
Single
73

solenoid + boom LOWER
71 +72
EPC solenoid
74
Defective PC-EPC solenoid
75
solenoid
Single

+ PC-EPC sole-
71+34
noid
76

EPC solenoid + PC-EPC
72 i- 74
solenoid
77
solenoid
+ boom RAISE
EPC solenoid + PC-EPC
71 +72
f 74
solenoid
6,
Defective arm IN EPC

solenoid
9,
Defective valve open

system
c
.;
C,
Boom pressure switch

(RAISE) and (LOWER) input
simultaneously
than 3 sec.
PC1 28UU-2
for more
Single
Single
Single
* The bold lines indicate occurrence of a single abnormality.
20-245
0
TROUBLESHOOTING
3.
Chart showing
alarm
DISPLAY METHOD
pattern of actuation for monitor
Monitor
stop is
is ON
When automatic
mode is set
control
When automatic control is

actuated (automatic stop)
When abnormality
Abnormality
in communications circuit system
and
Alarm
buzzer
Sounds (Isecond cycle)

Sounds (I
second cycle)
Error code [911

displayed
Flashes (0.6second cycle)
Sounds (0.6second cycle)
Error code displayed when

abnormality
occurs
Error code displayed when

abnormality
occurs
Flashes (Isecond cycle)
Sounds (for 7
seconds only)
Becomes IO.01
when DEPTH
MODE 0 SET is set
Error code displayed
Error code [EEI

displayed
OFF
Error code [EEI

displayed
Sounds (2 times
in 0.4-second
cycle)
(Does not
sound in DEPTH
DISPLAY 0 SET
mode)
Abnormality
in electric
system signal system
Lights up
When reset (when normal)
Flashes (Isecond cycle)
._
lamp,
Error code [911

displayed
occurs
Abnormality
in controller
power source system
caution
Electric system
caution lamp
When R.H. interference

prevention
is actuaterd
Controller
When cancel switch
5
(D
panel
z
05
Cz=
x
E
;
system
When emergency
actuated
-z
t(
a,
ii
u
.u,
electric
When cab interference

prevention
is actuated
(automatic
stop)
:
g
controller,
PANEL, CONTROLLER
buzzer
Item
.+
=
panel,
FOR MONITOR
When reset (when abnormal)
When reset terminal is

disconnected
in case of above
abnormality
ii
$
5
:
5
_
g
._
b
When starting switch is

turned OFF, and then ON
E
w
again without disconnecting

reset terminal after resetting
For operations not listed here, the normal operation

Monitor panel: Depth is displayed
Controller: Normal code 00 is displayed
Electric system caution lamp: OFF
Alarm buzzer: Does not sound
lashes 2
Does not sound
seconds after
starting switch
is turned ON
from 2 seconds
after starting
switch is turned
ON
and display is given for each component.
l
l
20-246
0
PC128UU-2
TROUBLESHOOTING
METHOD
OF USING TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING

1.
Category of troubleshdoting
Troubleshooting
2.
CHARTS
CHARTS
code number
Code No
Component
E-00
Troubleshooting
of electrical
F-00
Troubleshooting
of pump controller
H-00
Troubleshooting
of hydraulic,
M-00
Troubleshooting
of machine
system
input signal system
mechanical
monitor
system
system
Method of using troubleshooting

table
1) Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting
code number and the problem
with the machine.
2) Distinguishing conditions
Even with the same problem, the method of troubleshooting
may differ according to the model,
component, or problem. In such cases, the troubleshooting
chart is further divided into sections
marked with small letters (for example, a), b)), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting
from the first check
item.
3) General precautions
When using the troubleshooting
chart, precautions that apply to all items are given at the top of
the page and marked with *.
The precautions marked J, are not given in then
but must always be followed when carrying
out the check inside the 0.
chart
4) Method of following troubleshooting
YES
. Check or measure the item inside a0
, and according to the answer follow either the
YES line or the NO line to go to the next I.
(Note: The number written at the top right
corner of then
is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy column on the right.
Below the n
there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the n
are correct or the answer to the question
inside the 0
is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
Below them
is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item I).
Troubleshooting tools
When carrying out the troubleshooting,
prepare the necessary troubleshooting
tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number connection.
see this chart for details of the connector
pin number and location for inspection and measurement
of the wiring connector number appearing in the troubleshooting
flow chart.
l
5)
6)
PC1 28UU-2
20-247
0
METHOD
TROUBLESHOOTING
OF USING TROUBLESHOOTING
CHARTS
<Example>
@ E-l
o*
Before carrying out troubleshooting,
*
0
Error code [EE] (abnormality

communications system)
Always connect any disconnected
in controller power source system or
check that all the related connectors

connectors
are properly inserted.
before going on to the next step.
a) Abnormality
*
in controller power source system

The monitor panel displays [EE] and none of the work equipment
blade and travel work).
or swing move (only the
Cause
1 YES
Is voltage between
CO1 (8). (17), (18)
-2O-30V
-Turn starting switch
ON.
20-248
0
NO
Remedy
Defective controller
Replace
Defective contact, or
disconnection in wiring
harness between fuse(2)CO1 (female) (8). (17). (18)
Repair wiring
harness, or
PC128UU-2
TROUBLESHOOTING
OF CONTROLLER,
ELECTRICAL SYSTEM
(E MODE)
Action taken by self-diagnostic
function
and problems on machine
.................................................
20-304
Judgement
table for 4 system .. __..........................................................................................................
20-308
Judgement
table for chassis related
20-310
parts ............................................................................................
Electrical circuit diagram for controller

Points to remember
Precautions
when carrying
when handling
and work equipment
system ....................................................................................
out troubleshooting
cancel switch when abnormality
stops ....... _ .....................................
E- 1 Error code [EEI (Abnormal-y

or communications
of controller
in controller
system)
is displayed
a) Abnormality
in controller
b) Abnormality
in communications
20-312
system .................................
20-314
display is given
......................................................................
20-317
power source system

.....................................................................................
20-318
power source system ....................................................................
20-318
system ................................................................................
E- 2 Error code 1311 (Abnormality
in boom potentiometer
E- 3 Error code [32] (Abnormal-w
in arm potentiometer
E- 4 Error code 1341 (Abnormal-m
in offset potentiometer
20-320
system) is displayed .............................
20-321
................................
20-322
............................
.20-323
E- 5 Error code 1411 (Abnormal-&y
in engine speed sensor system) is displayed .............................
20-324
E- 6 Error code [511 (Abnormal-rty
in PPC hydraulic
system) is displayed
lock solenoid
E- 7 Error code [521 (AbnormaliEgr in left offset stop solenoid
................ .20-325
....................... .20-326
E- 8 Error code 1541 (Abnormal-ity
in swing holding brake solenoid
E- 9 Error code [621 (Abnormal-w
in offset stop solenoid system) is displayed.. .............................
E-10 Error code 1641 (Abnormal-m
in 2-stage relief solenoid system) is displayed.. ........................ .20-329
E-l 1 Error code 1711 (Abnormal-&y
in boom RAISE stop EPC solenoid system) is displayed..
........ .20-330
E-12 Error code [721 (Abnormal-y
in boom LOWER stop EPC solenoid
....... .20-331
E-13 Error code [741 (Abnormal-&y
in PC-EPC solenoid system) is displayed ....................................
20-332
E-14 Error code 1811 (Abnormal-&y
in arm IN stop solenoid system) is displayed.. ...........................
20-333
E-15 Error code [Cl] (3 seconds

simultaneously)
E-16 Abnormality
is displayed
system) is displayed..
........... .20-327
20-328
passed after boom LOWER and RAISE pressure switches were input
__........................................................
in travel speed selection
.. .. .. . .. .. .. . .. .. . . .. .. .. . . ... .. . ... ... . ... ... 20-333
solenoid system
(Travel speed does not rise or does not decrease) . .. .. .. .. .. .. . . .. ... . .. .. .. . . .. ... . .. .. .. . . .. . .. . . ... ... . ... ... .... .. . 20-334
a) Travel speed does not Gse (but keeps low) .. ... . ... . .. . .. .. . .. . .. . ... . .. .. .. . . .. ... . .. .. .. .. .. . .. . .. .. . ... ... . ... ... . .. 20-334
b) Travel speed does not ioorver (but keep high) .. . .. .. .. .. ... .. .. . .. . .. ... . .. . .. . .. .. .. .. . .. . .. . .. .. . . ... .. .. .. ... .. .. ... 20-335
E-17 Work equipment
does not move after work equipment
E-18 Work equipment
moves amberwork equipment
lock lever is released . . .. . .. .. .. ... . ... ... . ... 20-336
lock lever is set in LOCK position . .. ..._.........
20-337
E-19 Depth mode, height mode, offset mode do not work properly
(go beyond set position before
E-20 Impossible
stopping
or stop before reaching set position) . .. . ... . .. ... . ... ... . .. 20-338
to select and sep depth display 0 set mode, depth mode, height mode,
offset mode . .. .. ... . ... .. .. ..__._------.......................................................................................................
PC1 28UU-2
20-339
20-301
0
E-21 Cancel switch is not turned ON, but alarm buzzer sounds for 7 seconds
and electrical system caution lamp flashes.. ......................................................
E-22 Automatic
:
i.. .......................
20-340
stop is not carried out for boom RAISE, LOWER, arm IN, left offset, right offset
20-341
(when error code 1911 is not displayed) ........................................................................................

a) All operations
stop immediately
b) There is interference
before interference
..................................
I.. .......................
.................................................................................................................
20-341
20-341
E-23 Swing does not work (when no error display is given). ..............................................................
20-342
E-24 Excessive hydrauli,c drift of swing.. ...............................................................................................
20-343
E-25 Offset does not work (particularly
left offset). ..............................................................................
20-344
E-26 Offset does not work (Particularly,
right offset) ...........................................................................
20-345
E-27 Engine does not start .....................................................................................................................
20-346
a) When starting motor does not rotate ......................................................................................
20-346
does not work .......................................................................................
20-350.
b) Engine stop solenoid
E-28 Engine does not stop.. ....................................................................................................................
20-351
E-29 Wiper does not operate.. ................................................................................................................
20-352
E-30 Engine control is abnormal.. ..........................................................................................................
20-353
a) When engine does not start or it starts but stops soon . . .. .. . ... . ... .. .. . ... .. . .. .. .. . .. .. ... . ... . .. ... .. . .. .. . 20-353
b) Swift slow-down does not work . ... . .. .. .. . .. ... .. .. .. ... ... .. .. .. .. .. . . .. ... . .. ... .. . ... .. .. . .. .. . .. ... . ... .. .. . .. ... . .. . ... 20-355
c) Works at near idling speed, but does not work up to full throttle (load becomes high)..... 20-355
20-302
0
PC1 28UU-2
ACTION TAKEN BY SELF-DIAGNOSTIC

FUNCTION
AND PROBLEMS ON MACHINE
TROUBLESHOOTING

LEMS ON MACHINE
&play
code
Abnormal
31
Boom potentiometer
32
Arm potentiometer
34
37
Potemtionmenter
system
FUNCTION AND PROBNature of abnormality
system
I) Disconnection
in wiring harness (in one of three wiring
harnesses)
2) Short circuit between wires in wiring harness (two of
three wiring harnesses)
3) Wiring harness short circuiting with ground
4) Defective potentiometer
system
system
system
power
I) Short circuit
2) Hot short
source
in power
source wiring
1) Disconnection
in wiring harness
2) Defective adjustment
or defective
41
51
52
Rotation
harness
rotation
sensor
sensor system
PPC hydraulic
lock solenoid
Left offset stop solenoid
system
1) @ end of solenoid (between VO7(1) - COl(21)) short

circuiting with ground
2) Short circuit inside solenoid
3) Contact between wiring harness at ground end and @
end of solenoid
I) @end of solenoid (between C17(2)

2) Disconnection
at @ end of solenoid
COl(21))
(if internal resistance of solenoid is
4) Disconnection
inside solenoid
5) Contact between wiring harness at
end of solenoid
system
- COl(21)) short
(between
extremely
ground
C17(2) low)
end and @
1) @ end of solenoid (between VO4(1) - CO3(8)) short

2) F;;p8l;ection
at @ end of solenoid (between VO4(1) 54
62
64
20-304
0
Swing
holding
brake solenoid
Right offset stop solenoid
2-stage relief solenoid
system
system
system

(if internal resistance of solenoid is extremely
low)
4) Disconnection
inside solenoid
5) Contact between wiring harness at ground end and @
end of solenoid
I) @ end of solenoid (between C18(2) - CO3(15)) short

2) Disconnection
at @ end of solenoid (between C18(2) CO3(15))
3) Disconnection
or short circuit inside solenoid
I) @end of solenoid (between VO6U) - CO3(7)) short
2) Disconnection
or defective contact inside solenoid
PC1 28UU-2

FUNCTION
TROUBLESHOOTING
Condition
(voltage,
when
current,
Action
normal
when
is detected
by controller
abnormality
resistance)
I) Turn off outputs for solenoids to

stop raising boom, moving arm
in, and moving offset to left
.
(Reduce current to OA).
Ir Display fault continuously
even
Voltage between CO3 (I) and CO2 (9)
after faulty parts is repaired
(Operation is kept stopped).
[C23 (2) and (1 )I: 0.3 - 4.7 V
Voltage between CO3 (9) and CO2 (9)

LC21 (2) and (I)]: 0.3 - 4.7 V
Problem that appears on machine

when there is abnormality
I) Machine cannot raise boom,
move arm in, and move offset
to left.
Voltage between CO3 (IO) and CO2 (9)

[C22 (2) and (I)]: 0.3 -4.7 V
Voltage
between
CO2 (IO) and
(Power source): 4.9 - 5.1 V
(9)
I) Resistance betweenC03 (4) and

(12) IE07 (I) and (211:500 - 1,000 Sz
!) Voltage between K3 (4) and (12)
[CN20 (I) and (2)l: 0.5 - 0.3 V *
Use AC range.
I) Recognize engine speed as

partial output [Output a current
equivalent
to engine partial
output (535 f 20 mA) to PC-EPC
solenoid.1
I) Pump absorption
horsepower
is
insufficient
(Production
is
insufficient).
2) Engine stalls when its speed is
lowered.
I) Turn off outputs for solenoids to

* This system does not check for
wire breakage by itself (Work
equipment stops without displaying fault).
1) Machine cannot move work

equipment, travel, swing, and
move blade.
1) Turn off outputs for solenoids to

* Even if wire is broken during
operation, this system does not
display any fault, but offset
operation stops.
I) Machine cannot raise boom,

move arm in, and move offset
to left.
I) Turn off output for swing holding

brake solenoid.
* Even if wire is broken during
operation, this system does not
display any fault and release
swing holding brake.
I) Machine does not switch

(Swing holding brake is not
released).
* If solenoid is broken, swing
holding brake is not released
even if swing holding brake
release switch is operated. Take
care.
Resistance of solenoid: 35 - 80 Q
I) Turn off output to solenoid to

stop offset to right.
Machine cannot offset to right.
Resistance of solenoid: 35 - 80 Q
I) Turn off output for 2-stage relief

solenoid.
Resistance of solenoid: 37 - 60 Sz
<esistance of solenoid: 35 - 80 Sz
Resistance of solenoid: 37 - 60 S2
PC128UU-2
Relief pressure does not rise

when travel force is required.
Accordingly, travel force is
insufficient.
20-305
0

FUNCTION
TROUBLESHOOTING
Iisplay
code
71
72
Abnormal
Boom
Boom
Nature of abnormality
system
RAISE stop solenoid
EPC system
LOWER stop EPC solenoid
system
1) Disconnection
inside solenoid
2) Short circuit inside solenoid or short circuit with
ground
3) Disconnection
in wiring harness between C16(1), (2) COI, or short circuit with ground
1) Disconnection
inside solenoid
ground
3) Disconnection
in wiring harness between C14(i),
COI, or short circuit with ground
(2) -
1) Disconnection
inside solenoid
74
81
91
PC-EPC solenoid
3) !%z%fnection
in wiring harness between
CO1(5), (15), or short circuit with ground
system
Arm IN stop solenoid
EPC system
1) @ end of solenoid (between C15(1) - COl(3)) short

ground
3) Disconnection
in wiring harness between C15(1), (2) CO1(3), (14), or short circuit with ground
1) Valve for solenoids for boom RAISE stop, arm IN stop,

offset stop blocked by dirt and staying open (bucket
inside interference
range)
2) Water inside connectors
(K18, K50, K52) of boom, arm,
and offset potentiometers
Valve open system
Defective
Cl
EE
20-306
0
C13(1), (2) -
boom
RAISE or boom
LOWER pressure
switch
Boom RAISE pressure switch and

boom LOWER pressure switch input at
same time for more than 3 seconds
Communications
system
power source system
or controller
1) Defective contact or disconnection

between CO1 (I) and PO1 (I)
between CO1 (2) and PO1 (12)
between CO3 (6) and PO1 (2)
4) When power source is not input to
5) When voltage is more than 38V or
in wiring
harness
in wiring
harness
in wiring
harness
controller
less than 9.5V
PC128UU-2

FUNCTION
TROUBLESHOOTING
Condition when normal

(voltage, current, resistance)
I) Resistance of solenoid: 5 - 25 d
2) Voltage between CO1 (16) - (9):
ob;7c5kk,3.0V (in safe range for
Action
when
is detected
by controller
abnormality
Problem that appears on machint

when there is abnormality
1) Turns output OFF (current OA) to

solenoids for boom RAISE stop,
arm IN stop, left offset stop
j: Even when the location of the
failure is restored, the abnormality display continues to be
displayed.
(The operation
also
remains stopped)
I) Boom RAISE, arm IN, and left

offset cannot be operated
Turns output OFF (current OA) to

solenoid for boom LOWER stop
solenoid
Boom LOWER cannot
1) Resistance of solenoid: 10 - 22 Q
2) Voltage between CO1 (5) - (15)
engine full, lever N : 0 - 5 V
engine siow, lever N : 6 - 13 V
1) Turns output OFF (current OA) to

PC-EPC solenoid
* Even when the location of the
displayed.
(The operation also
remains stopped)
I) Excessive drop in engine speed

when there is heavy load
I) Resistance of solenoid: 5 - 25 s2
2) Voltage between CO1 (14) - (9):
ob;7c5k,t;.0 V (in safe range for
I) Turns output OFF (current OA) to

solenoids for boom RAISE stop,
arm IN stop, left offset stop
* Even when the location of the
displayed.
(The operation also
remains stopped)
I) Boom RAISE, arm IN, and left

offset cannot be operated
z Impossible
system
I) Turns output OFF (current OA) to

PPC lock solenoid
* If the location of the failure is
restored, the abnormality
display
goes out, and it returns to normal
operation.
All operations
Does not carry out any particular

action.
1) When boom RAISE switch is

stuck, there is no particular
change
2) When boom LOWER switch is
stuck, boom does not go up
I) Communications
system:
Does not carry out any particular
action.
2) Controller
power source system:
Stops all functions, but if power
source voltage becomes normal,
it returns to normal operation.
* The abnormality
display also
goes out.
1) Communications
system:
Operations are possible in
normal way, but
(I) F; display is given except
I) Between
At boom
Lever at
2) Between
At boom
Lever at
l
to measure
CO2 (7) and chassis:

LOWER: Max. 1 V
HOLD: 20 - 30 V
CO2 (8) and chassis:
LOWER: Max. 1 V
HOLD: 20 - 30 V
1) Resistance between
(8): Max. IO Q
(12): Max. 10 Q
(2): Max. IO Q
4) Voltage: 24 - 30 V
PC1 28UU-2
electrical
CO1 (I) - PO1

CO1 (2) - PO1
CO3 (6) - PO1
be operated
stop
(2) Buzzer does not sound

2) Controller
power source
system:
None of the work equipment
swing can be operated
(travel, blade still work)
or
20-307
0
TROUBLESHOOTING
JUDGEMENT
JUDGEMENT
TABLE FOR 4 SYSTEM
TABLE FOR 4 SYSTEM

Self-diagnostic display (abnormality display)
EE
Failure mode
31
32
\E
Boom RAISE does not work
Boom LOWER does not work
E-2
E-3
E4
Arm IN does not work

Left offset does not work
Right offset does not work
Boom RAISE does not carV out
automatic stop properly
Arm IN does not carry out automatic stop properly
Left & right offset do not carry

out automatic stop properly
All operations stop immediately
before interference
There is interference
before interference
before interference
Depth mode cannot be used

Height mode cannot be used
Offset mode cannot be used
Automatic stop distance is too close (during operation)
Automatic stow distance is too far (durina oPeration)
Abnormality in depthmodesop
(after setting, during operation)
Abnormality in height mode stop

Abnormality in offset mode stop

Goesto0 far beforestopping

Stops too soon
Goes too far before stopping
Goes too far before stopping

Stops too SOOn
When automatic stop is carried out

3uzzer does not sound
When cancel switch is ON

When setting mode, stopped
During self-diagnostic display (display is given)
;;;x&switch
is not turned ON, but buzzer sounds for 7 seconds and electric system lamf
ilectric system caution lamp keeps flashing

4utomatic stop is not carried out for
,oom RAISE, arm IN, left offset *2
before interference
Work equipment moves even when work equipment lock lever is at LOCK position
froubleshooting
code when abnormality display is given
froubleshooting
code when abnormality is confirmed by monitoring
*1
*2
E-l
EE is displayed on monitor panel, but no display is given on the controller panel.

When error code I91 I is not displayed
20-308
0
PC128UU-2
TROUBLESHOOTING
JUDGEMENT
TABLE FOR 4 SYSTEM
H-l 1
H-30
H-30
H-30
H-29
E-20
E-20
M-l 1
(a)
E-21
M-14
E-22
E-21
PC128UU-2
20-309
0
TROUBLESHOOTING
JUDGEMENT
JUDGEMENT
TABLE FOR CHASSIS
RELATED PARTS
TABLE FOR CHASSIS RELATED PARTS

Self-diagnostic
display (abnormality display)
* : Option
Failure mde
\I
Speeds of all work equipment
\m
Error code
EE
32
51
52
62
swing travel are slow or lack power
There is excessive drop in engine speed, or engine stalls

No work eauioment, travel, swinq move
1Abnormal noise aenerated (around ourno)
Fine control ability is poor or response is poor
Boom is slow or lacks power
Arm is slow or lacks power
Bucket is slow or lacks power
1Excessive hvdraulic drift
Travel deviation
E
E
6
Deviation is excessive
Deviation is excessive when starting
Travel soeed is slow
Steering is difficult to turn or lacks power
Travel speed does not switch or is faster than set speed

Does not move (one side only)
Does not swing
Swing acceleration is poor
1 Both left and right
Both left and right

One direction only
E
z
z
Excessive overrun when stopping swing
F
,-
Excessive abnormal noise when stopping swing
Excessive hydraulic drift of swing
Both left and right

One direction only
07
When brake is ON
When brake is OFF
1Blade is slow or lacks power

Excessive hydraulic drift of blade
Troubleshooting code when error code is displayed
Troubleshooting code when abnormality isconfirmed
by monitorins
With the left offset stop solenoid system, disconnections are not detected during actuation, so if the operation stops but no abnormality
display is given, carry out troubleshooting for E-27.
20-310
0
PC128UU-2
TROUBLESHOOTING
JUDGEMENT
TABLE FOR CHASSIS
RELATED PARTS
H-l
H-13
H-15
H-16
H-24
I
I I
1 E-11 1 E-12 1 E-13 1 E-14 ( H-30 1
H-25
) E-161
IF-1 1 F-2
PC128UU-2
F-3 1 Fa
F-5 1 F-6
20-311
0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM

1.
FOR CONTROLLER
SYSTEM
FOR CONTROLLER SYSTEM
4 system
COntlDIler
co1(MlC7.1)
. _...
CN-S14
CN-SIO
PPC lock
rritch
(HZ)lmls)
iWP)lfsmls)
ention
diode
RIotIt
offset
__-__
TJP02190
20-312
a
PC1 28UU-2
TROUBLESHOOTING
FOR CONTROLLER
(KESl
SYSTEM
2) (MI
;;i
-<
:
_;
L
so5 (X2)
-1
TJP02192
PC128UU-2
20-3 13
a
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT

TROUBLESHOOTING
OF CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE:

SHOOTING OF CONTROLLER SYSTEM
l
1.
The controller for interference prevention and automatic control mounted on this machine has special control features that do not appear on conventional machines, such as automatic stop of the
work equipment and reducing the speed before carrying out the automatic stop.
For this reason, particular phenomena appear on this machine which do not appear on conventional
machines.
The following types of phenomena are not failures, so it is important to confirm the operating condition properly before carrying out troubleshooting.
After the machine has carried out automatic stop,

the boom RAISE, arm IN, and left offset operations cannot be carried out even when the work
equipment is moved a to the front or right direction. (The diagram shows movement
to the
front.)
a:50-IOOmm
;
At 50 - 100 mm, the work equipment is still
inside the interference range, so operations
will be possible if the work equipment
is
moved further.
BWP04448
2.
After automatic stop, even when the work equipment is moved less than b to the front, when the
boom RAISE and arm IN are operated, the speed
is slow.
b:700 mm
*
The work equipment is still inside the reduced
speed area, so the speed will return to normal if it is moved further.
l
BWP04449
3.
After automatic stop with the left offset operation, the work equipment automatically stops if
the arm is moved to the front and an attempt is
made to return to the original posture.
*
The work equipment is still inside the interference area in the left offset direction, so operations will become possible if it is offset
approx. 50 mm to the right.
20-314
0
PC128UU-2
TROUBLESHOOTING
4.

TROUBLESHOOTING
After automatic stop, if the cancel switch is turned

ON, the bucket is brought closer to the cab
(canopy), and then the cancel switch is turned OFF,
the self-diagnostic display shows error code 1911,
. and it becomes impossible to operate the work
equipment or swing.
*
If the cancel switch is turned ON and the
bucket is moved away from the cab (canopy),
the operating condition will return to normal
and the error code will go out.
BWPO4450
5.
When the cutting edge or bottom of the bucket is

put in contact with the ground, the depth display
does not show fO.01.
*
The ground surface is sloping or the machine
is at an angle.
BLP01370
6.
The depth display varies according to the position where the bucket is put in contact with the
ground.
BLP01371
7.
When the potentiometers

are removed and installed again, the automatic stop position is out
of place.
*
Reset the input/output signal and the condition will return to normal.
For details, see TESTING AND ADJUSTING.
PC1 28UU2
20-3 15
0
TROUBLESHOOTING
8.

TROUBLESHOOTING
When the interference prevention function and

automatic control function are actuated in cold
areas, the automatic stop position is out of place.
*
Error code 1911 may also be displayed, but
when the oil temperature rises, the condition
will return to normal.
Points to remember if problems are reset during operations

In the following cases, there is a high probability of
the same problem occurring again, so be sure to follow up the situation properly.
1)
2)
The abnormality was naturally reset, or

During the troubleshooting operation after the
abnormality occurred, the connectors were
disconnected and a T-adapter was inserted,
or the T-adapter was removed and the connector was returned to its original position,
and the service code display went out. Or
the monitor became normal.
20-316
0
PC128UU-2
TROUBLESHOOTING
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN

ABNORMALITY
DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT
STOPS
If error codes [521, [711, [721, or [811 are displayed and the work equipment stops when there is an
abnormality in the solenoid system, if the cancel switch is turned ON and fuse 3 blows, check the
solenoid system where the abnormality occurred, and also check the related diode at the same time.
<Reference>
The cause of the abnormality in the solenoid system may be a shot-t circuit inside the solenoid or a
short circuit between the ground and wiring harness between the controller and the solenoid.
In
such cases, when the cancel switch is turned ON, an excessive current will flow, and before the fuse
burns out, the resistance inside the diode may become 0.
*
The PPC lock solenoid system checks only for a short circuit inside the solenoid or a short circuit
between the ground and the wiring harness at the positive end, so if error code 1511 is shown, do not
turn the cancel switch ON under any circumstances.
Carry out the troubleshdoting
first.
l
Abnormal system
62
Right offset stop solenoid
71
Boom RAISE stop solenoid
72
Boom LOWER stop solenoid
81
Arm IN stop solenoid
PC128UU-2
0
0
0
0
20-317
a
E-l
TROUBLESHOOTING
E-l
Error code [EE] (Abnormality in controller power source system or

communications system) is displayed
*
*

check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
a)
Abnormality in controller power source system

*
The monitor panel displays [EEI and nothing works.
1 YES
Is voltage between
_ Co1 (8). (17).
t=t=
I_
(18)
I_
*20-30V
*Turn starting switch
ON.
NO
Replace
harness between fuse(2)CO1 (female) (S), (17). (18)
Repair wiring
harness, or
-c-1
E-l a) Related electric circuit diagram
Fusible
link
+IBattery
Controller
-I
CO1 (040161
Power source
input
(+24V\ @j-l
GND
Battery
Solenoid
Power source
input
Power
input
source
relay
(t24V)
TJPO2194
PC128UU-2
20-3
0
19
TROUBLESHOOTING
b)
Abnormalityjn
E-l
communications
system
Cause
2 YES
Remedy
Replace
ditions as when
IT
measuring Item l?
System
YES
3
1With svstem in
Ly JwLL 1 1which ihere is
1
II
* Turn starting switch

ON.
Table 1
Monitor panel
Controller
Between CO1 (I) -chassis
Between PO1 (8) -chassis
Between CO1 (2) -chassis
Between PO1 (12)
Between CO3 (6) -chassis
Between PO1 (2) -chassis
- chassis
. Min. 1 MQ
* Disconnect connectors at both controller and monitor
panel end.
OFF.
N(
is reset
harness between monitor
panel and controller
?.epair wiring
larness, or replace
Defective monitor panel
Replace
Wiring harness between

monitor panel and controller
short circuiting with ground
qepair wiring
iamess, or replace
Voltage (V)
16-20
E-l b) Related electric circuit diagram
:ontroller
Monitor Panel
co1 blICi1)
Serial
PO i (040 16)
clock
I
CO3 (04016)
Serial
clock
TJPOZI 95
20-320
0
PC128UU-2
E-2
TROUBLESHOOTING
E-2
*
*
Error code [31] (Abnormality

played
in boom potentiometer
system) is dis-

I
I
YE
H
2 YES
Table 1
electric
circuit
Reolace
System is reset
1Defective contact. or disconnection in wiring.harness

between CO2 (female) (10).
(9X20 (male) (3). (1) or
wiring harness short
wiring harness beYEiS tween CO3 (female)

(9) and C20 (male)
(2) normal, and is
circuit insulated
3
Is resistance between C20 (female:

(3) - (1). and (2) (1) as shown in
Table l?
* Disconnect C20.
* Turn starting
switch OFF.
E-2 Related
Remedy
Is [31 I displayed
under same
conditions as whlen
measuring Item 1?
-Turn starting swi tch NO

ON.
- 0.3 - 4.7 v
. Turn starting switch
ON.
Cause
Defective contact, or disconnection in wiring harness

between CO3 (female) (9) -
<epair wiring
larness, or replace
Tepair wiring
larness, or replace
.
. Resistance Galue of
wiring harness:
Max. 1 Q
. Between wiring harness

and chassis: Min. 1 MR
_._
NC)
Defective boom
potentiometer
Replace
diagram
Controller
co2 (04O;O)
Potentiometer
Potentiometer
GND
Power source
co3 (040 16)
Boom Potentiometer
Signal
CN6 (SWPB) C20 LSWP121 C21 (X3)

@
Boom Potent i;ometer
GND
TJP02196
PC1 28UU-2
20-32 1
0
E-3
TROUBLESHOOTING
E-3
*
*

played
in arm potentiometer
system) is dis-

Remedy
2+_~
leplace
Is [321 displayed
YES
ON.
Is voltage between
CO3 (I) and (12)
normal?
wiring harness be-
3
1Is resistance between C23 (male)
(1) - (3). and (2) (3) as shown in
Table 1
Resistance
Between(3)-(1)
Between (2) -
(1)
4-6kQ
epair wiring
arness, or replace
* 0.3 - 4.7 v
ON.
C23 (male)
I Defective contact. or disconnection in wiring harness

between CO2 (female) HO),
(9) - C23 (female) (1). (3) or
. Disconnect C23.
* Turn starting
switch OFF.
(2) normal, and is

circuit insulated
Resistance value of
wiring harness:
Max. 1 L2
Between wiring harness
and chassis: Min. 1 MQ
Defective arm potentiometer
NC
0.2 - 7 kR

between CO3 (female) (1) -
R,epair wiring
harness, or replace
. FSeplace
E-3 Related electric circuit diagram
Controller
I
co2 (04OiO)
m!
Potentiometer
IP8)
Power source
(SWP12)
c21 (X3)
ter
co3 (040 16)

pzzy-p$
TJP02197
20-322
0
PC128UU-2
TROUBLESHOOTING
E-4
*
*
E-4

played
in offset potentiometer
system) is dis-

Cause
YES
Remedy
Replace
YE S
El-
ON.
Is voltage between
CO2 (10) and (12)
normal?
* 0.3 - 4.7 v
ON.
Is resistance between C23 (male)

(3) - (I), and (2) y;;s, s$own rn
F
Table 1
C23 (male)
Between (3) - (1)
4-6kS2
Between (2) - (1)
E-4 Related
* Disconnect C23.
* Turn starting
switch OFF.
Resistance
0.2-7
electric
Is resistance in
wiring harness between CO3 (female)
(IO) and K52 (female)
(2) normal, and is
circuit insulated
from chassis?
Defective contact, ordisconnection in wiring harness

between CO2 (female) (10).
S (9) -C23 (female) (1). (3) or
_I
- Disconnect CO3 and C2:

-Turn starting switch OFF
* Resistance value of
wiring harness:
Max. 1 C
. Between wiring harnes: 5
and chassis: Min. 1 MD
kQ
circuit
System is reset
. Turn starting switch NO
Repair wiring
harness, or replacc

between CO3 (female) (10) C23 (female) (2!, or wiring
harness short crrcuiting with
ground
Repair wiring
harness, or replace
Defective offset
potentiometer
Replace
diagram
Controller
0 (SWPl21
C23 (X31
t iometer
CO3 (040 16)

Offset
potentiometer
Signal
GND
TJP02198
PC1 28UU-2
20-323
0
TROUBLESHOOTING
E-5
*
*
E-5

played
in engine speed sensor system) is dis-

Always connect any disconnected connectors before going
on tc he next steo.
Remedy
Cause
2 YES
YES
I
~500-1OOOR
*Turn starting switch NO
OFF.
* Disconnect E07.
Is resistance between ~03 (female) _

(4) and (12)
Iefective controller
leplace
Xsconnection in wiring
larness between CO3
female) (4), (12) - E07 (13).
14)wiring harness short
Srcuiting with ground
leplace or repai
viring harness
Defective engine speed

iensor
7eplace
Controller
Engine
speed
sensor
TJPO.2199
20-324
0
PC128UU-2
TROUBLESHOOTING
E-6
*
*
*
*
E-6

is displayed
in PPC hydraulic lock solenoid system)

This detects only short circuits between wires or the wiring harness between the controller and the
solenoid circuiting with the ground.
If movement stops but no abnormality display is given, go to E-l 5.
Remedy
Cause
2 YES
Is there continuity in
harness between CO1

YES (female) (21) and v07 _
1
/%%?$&ulated
from chassis?
#I
J
t
l
(1) and (2) normal
. Between VO7 (male)

(1) and (2) : 35 -80Q~o
- Between V07 (male)
(1). (2) and chassis:
Min. 1 Q
* Disconnect V07.
- Turn starting switch
OFF.
NO
* Disconnect CO1
and V07.
* Measure on CO1 (female) side in diode
range (Note).
*Turn starting switch OFF.
Short circuit with chassis

ground in wiring harness
between CO1 (female) (21) V07 (female) (1)
Defective PPC lock solenoid
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When
a harness containing a diode is checked with this tester, if this voltage does not change, there is
not continuity, and if this voltage changes, there is continuity.
TJP02200
PC1 28UU-2
20-325
0
TROUBLESHOOTING
E-7
*
*
*
E-7

displayed
in left offset stop solenoid system) is

check that all the related connectors.are properly inserted.
If the wiring harness between the controller and the solenoid is short circuiting with the ground, a
display is given during operations. In the case of a disconnection, no display is given, but the work
equipment stops. [If this happens, carry out troubleshooting
for E-23.1
Cause
3 YEE
YE
zYEk
Is there continuity
in harness between
CO1 (female) (20)
and Cl7 (female)
(2)? Is harness
insulated from
chassis?
Is resistance
between Cl7
(female) (1) and
chassis ground
normal?
Remedy
Ilefective controller
Replace
Defective contact or
harness between Cl7
(female) (1) -chassis groun
Sepair or replace
iarness
Defective contact,
disconnection or short
circuit with chassis ground
CO1 (female) (20) - Cl7
(female) (2)
Xepair or replace
larness
Defective diode DO9
Replace
Defective left offset stop

solenoid
Replace
Nf
* Max. 1R
* Disconnect C17.
OFF.
* Disconnect CO1 and

07.
NO
- Measure on CO1 (female) side
in diode range (Note).
* Between Cl7 (male)
(I) and (2): 35 - 9OQ
(1). (2) and chassis:
Min. 1 MC
- Disconnect CO1 and
c17.
OFF.
DO9
Controller
CO1 (MlC21)
00
ctq5 (SWP14)
Cl7 (x2)
Left offset
stop
solenoid
valve
$iJ
7%
20-326
0
TJPOZZOI
PC1 28UU-2
TROUBLESHOOTING
E-8
E-8

tern) is displayed
in swing holding- brake solenoid sys-

Always connect any disconnected connectors before going on
Remedy
to the next step.
If the wiring harness between the controller and the solenoid is
?
short circuiting with the ground, a display is given during operations. In the case of a disconnection, no
L \,F..
lc3 Defective controller
Replace
display
is given,
but the
Isresistance between
swing stops. [If this happens,
*YEs_v04 (female) (2) and _
chassis ground
carry
out troubleDefective contact or
Is there continuity
normal?
disconnection
in wiring
Repair or replace
shooting for E-21 .I
in harness between
YES
~03 (female) (8) and _ * Max. IQ

V04 (female) (l)? Is
OFF.
harness insulated
* Disconnect V04.
from chassis?
. zsure
on co3 (fe/E)
side in diode range (Note).

+ Between V04 (male)
(1) and (2): 35 - SOL2I
~0
harness between V04

(female) (2) - chassis groutnd
narness
Defective diode DO3

Defective contact,
disconnection or short circ :ui
with chassis ground in
wiring harness between
CO3 (female) (8) - V04
(female) (1)
Replace
Repair or replace
harness
I
Replace
* Disconnect V04.

CNi (SWP16)
vo4 (X2)
Swine holding
brake
Controller
r*&
TJP02202
PC1 28UU-2
20-327
0
TROUBLESHOOTING
E-9
*
*
*
E-9
Error code 1621 (Abnormality

played
in offset stop solenoid system) is dis-

If the wiring harness between the controller and the solenoid is short circuiting with the ground, a
display is given during operations. In the case of a disconnection, no display is given, but the work
equipment stops. (If this happens, carry out troubleshooting
for E-23.)
Cause
3 YE!
Remedy
Replace
Is resistance between
4
t-t ft=
I%
Cl8 (female) (1) and _
~_
chassis ground
normal?
harness between
*
Max. I!,2
NO
_
YES_ ~03 (female) (15)
and Cl8 (female) (2)?
- Disconnect C18.
Is harness insulated
from chassis?
OFF.
1
Is resistance
between Cl8 (male)
NO
C18.
_ * Measure on CO3 (female)
. (I) and (2) normal
and are they
side in diode range (Note).
insulated from..
* Turn starting switch OFF.
chassis?
. Between Cl8 (male)
(1) and (2) :
35 - 8OQ
. Between Cl8 (male)
(1). (2) and chassis :
Min. 1 MQ
-Disconnect C18.
OFF.
harness between Cl8
(female) (I) -chassis ground
Defective contact,
(female) (2)
Defective diode D23
Defective right offset stop

solenoid
Repair or replac
harness
Replace
Replace
D23
Controller
CO3 (040;61
mRbll'."::i;'
cN5 (SWP14)
-3
Cl8 (X2)
Right offset stop

solenoid valve
3
3
TJP02203
20-328
0
PC128UU-2
TROUBLESHOOTING
E-10
E-10 Error code 1641 (Abnormality

played
*
*
Before carrying
Always connect
in 2-stage relief solenoid system) is dis-
out troubleshooting,
are properly
any disconnected
connectors
inserted.
Cause
3 YES
e.E,tweenI
(female) (2) and

I Ichassisground
1L
,~,_,__,,~~_L.,_,,
,c,,~~~?Trm -1 *Turn=-ingswitch
* Max. 10 Q
/ -Ezonnect
* Between C03(female)
(7) and chassis :
NO
Min. 1 M Q
- uisconnect V06.
?H
____
*35-8051
* Between V06
(male) (I), (2) and
NO
chassis : Min. IMR
* Disconnect V06.
OFF.
E-10 Related electric
Replace
l-l
11
V06 (male) (1) and (2)

normal and are they
insulated from
K28.
Remedy
NO
harness between V06
(female) (2) -chassis grounc
Repair or replace
Defective contact,
CO3 (female) (7) - V06
(female) (1)
Repair or replacr

solenoid
Replace
diagram
circuit
II-4
@(I)
Controller
I
CO3 (04Oi6)
pzxiJy&
DO5
CN2 (SWP12)
3
V06 (X2)
Two-stage
relief
TJP02204
PC128UU2
20-329
0
E-II
TROUBLESHOOTING
E-l 1 Error code [71] (Abnormality

tem) is displayed
*
in boom RAISE stop EPC solenoid sys-

J,
i,
YE
1
harness between
CO1 (female) (7) and
Cl6 (female) (l)?
1from chassis?
C16.
. Measure on CO1
(female) side in
diode range (Note).
OFF.
1from chassis?
*.I
* Between harnEaTs;;u
* Between harness and
,-hrae&.r
.. .. . .. 1 MO
..___.. Min
Defective contact,
circuit with chassis around
co1 (female) (16) - c16
(female) (2)
IU
I
replace
Replace
Defective diode D12

(I) and (2) : 5 - 25R
* Between Cl6 (male) ! -1
(I), (2) and chassis :
Min. 1 MC
* Disconnect C16.
OFF.
replace
L%tL%;
boom RAISE stop
Replace
E-l 1 Related electric circuit diagram
D12
Controller
CO1 (MlCil)
LrLl
CN5 (SWP14)
Cl6 (X2)
Boom RAISE stop

EPC valve
Boom-RAISE, LOWER
stop EPC(+I
TJP02205
20-330
0
PC1 28UU-2
E-12
TROUBLESHOOTING
E-12 Error code [72] (Abnormality

tem) is displayed
*
*
in boom LOWER stop EPC solenoid sys-

Cause
3 YE:
l-33
-
harness between
YE .S Cl4 (female) (2) and
CO1 (male) (16)? Is
2
harness insulated
Isthere continuity in
YES harness between
N(
* Max. 1R
- Disconnect CO1 and C14.
- Cl4 (female) (l)? Is - -Turn aarting switch OFF
harness insulated
- Turn emerqency work
from chassis?
1
equipment-operating
switch OFF.
*
Disconnect
CO1
and
c14.
Cl4 (male) (1) and (2)
N IO
. normal and are they - - Max. IOR
insulated from
* Measure on CO1 (female) side in
chassis?
diode range (Note).
(1) and (2): 35 - 80R
* ,l;~2~ar$ch;;s;~
NO
Min. 1 MQ
- Disconnect C14.
OFF.
From
A{=[
4 YE:
- Switch
NC
OFF: Max. IQ
ON: Min. 1 MQ
OFF.
* Disconnect switch
terminal.
Remedy
Replace
GotoA
Defective contact,
(female) (I)
Repair or replace
harness

stop EPC solenoid
Replace
Defective contact,
(female) (2)
Defective diode D13
Repair or replacf
harness
Defective switch
Replace
Replace
Note:
If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When
a harness containing a diode is checked with this tester, if this voltage does not change, there is not
continuity, and if this voltage changes, there is continuity.
Controller
D13
CN5 (SWP14)
C14 (X2)
Boom LOWERstop
EPC valve
Boom RAISE, LOWER

stop EPC(-1
Emergency work equipment

operation switch
TJP02206
PC1 28UU-2
20-33 1
0
TROUBLESHOOTING

*:
*.
Before carrying
Always connect
in PC-EPC solenoid system) is displayed

inserted.
are properly
step.
next
the
to
on
before going
connectors
any disconnected
Cause
Is resistance between3 YES

y2ES_ Cl3 (female) (I)
normal and are they
insulated from
Are resistance
chassis?
between CO5
Max. 1Q
NC
YES (male) (1) and (2)
_ and resistance
- * Between CO1 (female) (5)
(3)
and
between (2)
and chassis: Min. 1 MD
normal and are
Turn starting switch OFF.
they insulated from
* Disconnect CO1 and C13.
chassis?
* Max. IQ
Cl3 (male) (1) and (2)
NO
* Turn emeraencv
normal and are they
pump drivkswikh OFF.
* Disconnect C05.
* Between Cl3 (malt
l
Remedy
GotoA
Defective contact,
Kl (female) (5) - Cl3
(female) (I)
Repair or replao
harness
Min. 1 MD
OFF.
* Disconnect C13.
4 YES
* Max.lR
NO
* Between CO1 (female)
(15) and chassis :
Min. 1 MD
starting switch
*:Tu:u~r;:
Defective emergency pump

drive switch
Replace
Defective PC-EPC solenoid
Replace
Replace
Defective contact,
(female) (2)
Repair or replace
harness
* Disconnect CO1 and Cl3
operation
Fuse
F7iz-l
PC-EPC
(+I
TJP02207
20-332
0
PC1 28UU-2
E-14, E-15
TROUBLESHOOTING

played :
in arm IN stop solenoid system) is dis-
-)r Before carrying out troubleshooting,

*
I
3 YES
YE5
2
Is there continuih/ in
harness between
CO1 (female) (3) and _
Cl5 (female) (I)? Is
harness insulated
from chassis?
YE
Cl5 (female) (2)
normal and are they
insulated from
chassis?
Cause
Mm.
Replace
Defective contact,
disconnection or short circui
with chassis ground in
* Between harn;a=$;QNO wiring harness betvveen CO1
(female) (14) - Cl5 (female)
* Between harness and
(2)
chassis: Min. 1 MQ
qepair or replace
larness
- Disconnect CO1 and C15.

Defective contact,
qepair or replace
OFF.
disconnection or short circus larness
~iijf2~~~itch
~/Fi%EJY;~g:ZY~
(female) side in diode range (Note).

(I) and (2): 5 - 25Q
(I), (2) and chassis :
__
- --
Remedy
3eplace
Defective arm IN stop

solenoid
Replace
1 Ml2
* Disconnect Cl 5.
OFF.
Note: If an ordinali/ tester is set in the diode range, the voltage of the battery in itself is indicated. When
CN5 (SWP14)
Cl5 (X2)
Arm IN stop
EPC valve
3
3
TJP02208
E-15 Error code [Cl] (3 seconds passed after boom LOWER and RAISE
pressure switches were input simultaneously) is displayed
I.
2.
For inspection
For inspection
PC128UU-2
of boom RAISE pressure switch, see F-l.

of boom LOWER pressure switch, see F-2.
20-333
0
TROUBLESHOOTING
E-16 Abnormality in travel speed selection solenoid system (Travel speed

does not rise or does not lower)
*
*

a)
Travel speed does not rise (but keeps low)

Remedy
chassis normal?
YES
Is voltage between
r-l V05 (1) and chassis

1 Inormal?
Is resistance
020-3~.
Turn starting
between M25 or
switch ON.
M39 (male) (1) and (2) normal?
2
YES
l-
harness between M25
(female) (1) or M39 (female)
(1) -chassis ground
.epair or replace
arness
Breakage of fuse (2)

harness between fuse (2) V05 (female) (1)
NO
eplace fuse
eplace wiring
arness
_ Defective travel speed

selector switch
,eplace
Defective travel speed

selection solenoid
leplace
*Turn startin switch OFF

* Disconnect a 25 (Seesaw switch)
or M39 (Pedal switch).
* Between V05
(male) (1) and (2) :
35 - 8052
* Between V05
(male) (11, (2) and
chassis: Min. 1 MD
Turn starting
switch OFF.
* Disconnect V05.
(Seesaw switch) or
When sw~~is,o~~
epair or replace
arness
* When switch is ON:

Max. X2
V05 (male) (1) and (2)
normal and are they insulated from
chassis?
harness between V05
(female) (2) - M25 (female)
(2) or M39 (female) (2)
NO
E-16 a) Related electric circuit diagram
m-2
Controller
CO1 (MIC21)
(SWPl2) vo5 (x2)
Trave
select
I speed
ion
yj
.a
-----.-a
Ml39 (M2)
Trave I speed
selection
switch
OFF ON
Q2
0
-
Travel
20-334
0
speed
selection
M25 (M2)
Travel
Hi-Lo
selection
switch
TJP02209
PC1 28UU-2
E-16
TROUBLESHOOTING
b)
Travel speed does not lower (but keeps high)
2,
I
Is resistance
between M25 or
1 - M39 (female) (2)
and chassis normal?
*.I
Remedy
Go to troubleshooting of
hydraulic, mechanical
system (See H-21)
YES
_
Is resistance
between M25 or
M39 (male) (1) and
2 normal?
Cause

between M39 (female) (2)
V05 (female) (2)
Min. 1 MR
NO
* Disconnect M25 (Seesaw switch)
or M39 (Pedal switch) and V05.
l

selector switch
*When switch is ON:

Max. 1Q NO
*When switch is OFF:
Min. 1 MD
OFF.
Disconnect M25
(Seesaw switch) or
M39 (Pedal switch).
Repair or replace
harness
Replace
E-16 b) Related electric circuit diagram
Controller
CN-2 (SWP12) V05 (X2)
Travel
select
speed
ion
3
3
Ml39 (M2)
:(
Fuse
Travel
PC128UU-2
DO7
speed
selec
K&l
tion
Travel
speed
selection
switch
OFF ON
8'
M25 (M2)
Trave I Hi-Lo
select ion switch
TJP02209
20-335
0
TROUBLESHOOTING
E-17
E-17 Work equipment

released
*
*
*
*
does not move after work equipment
lock lever is
When error code 1911 (Valve open) is not displayed.

are properly inserted.
Wire breakage of this system is not checked or displayed by the self-diagnosis system.
Cause
2 YES
YE
See H-3
Is resistance
between S13 and
chassis ground
normal?
harness between S13 and
chassis ground
Between harne;;zshNO
Disconnect S13.
Turn starting switch OFF.
5YES
Is voltage between
lock switch inlet
:S
4
*When lever is locked:

20-30V
*When lever is
released: Max. 1V
ON.
YE
1R
NC
. Disconnect S12 and V07.
OFF.
$zEj
-35-80R
I
- Disconnect V07.
NIO
OFF.
-When lever is locked:

Min. 1 MR
*When lever is
released: Max. 1R
OFF.
E-17 Related
electric
circuit
iepair or replace
iarness
harness between S12 and
V07 (female) (2)
iepair or replace
larness
Defective PPC oil pressure

lock solenoid
Ieplace

lock switch
teplace
diagram
PPC lock
PPCDo?ck
D20
--
m
Y
$13
2
Controller
iepair or replace
iarness
Defective diode D4
iii%GJH
- Max.
3
Is resistance of lock
switch normal?
Remedy
::
s
5314 (maI e) (M2)

SlO (female) (M2)
8%
R&
TJP02210
20-336
0
PC1 28UU-2
TROUBLESHOOTING
E-18
E-18 Work equipment

LQCK position
*
*
Before carrying
Always connect
moves after work equipment
any disconnected
lock lever is set in

are properly
connectors
Cause
2 YES
YES
-
_
Is resistance of
lock switch
normal?
I
Is resistance
between S12 and
chassis normal?
inserted.
Remedy
Malfunction of solenoid
valve spool (Go to H-3)
*Min. 1 MQ
NO
-Turn starting switch OFF.
* Disconnect S12 and V07.

betweenS12andV07
(female) (2)
Repair or replace
harness

lock switch
Replace
* When lever is
locked: Min. 1 MR
NO
* When lever is released:
Max. 1Q
. Turn starting switch OFF.
ock
-1
6!
,
Controller
1
co1 (MlCil)
S14 (male)
SlO(femaIe)
(M2I
(M2)
p?x%-p
CN6 (SWP14)
TJP02210
PC1 28UU-2
20-337
0
TROUBLESHOOTING
E-19
E-19 Depth mode, height mode, offset mode do not work properly (go
beyond set position before stopping or stop before reaching set position)
*
*

check that all the related
connectors are properly inserted.
Always connect any disconnected connectors before going on
to the next step.
Cause
YES
Loose potentiometer
. Bent linkage
1
Is potentiometer
and linkage mount loose or bent?
_
NO
Remedy
2 YES
-S
Is voltage of
potentiometer
signal as shown in
Table l?
moun
tepair or replace
Cjefective operation of
olenoid valve in defective
S ystem
lepair or replace
Potentiometer
V oltage
NO
with defecti\
is defective
lepair or replace
Table 1
Measurement
posture
Boom potentiometer
Arm potentiometer
Between C21 (2) - (1)
% Between C23 (2) - (1)
Between C22 (2) - (1)
Offset
boom
Boom: End of RAISE aroke

Arm: End of IN stroke
0.73 - 1.01 v
Offset: End of right offset stroke
STD
0.65 - 1.43 V
Long
0.74 - 1.52 V
2.99-4.11
% The value depends on the optional attachment (long arm)
Left
offset
stop
solenoid
valve
_
.
b?roencr
Offset
potentiomete
Riht
offset stop solenoil(t)
Boom
RAISE
work
Boom
Potent
iometer
Arm
Potent
iometer
Offset
Potent
iometer
TJP02211
20-338
0
PC1 28UU-2
TROUBLESHOOTING
E-20 Impossible to select and set depth display 0 set mode, depth mode,
height mode, offset mode :
Ir
*
*

Check that the selection
and setting is being carried out outside the interference area.
Cause
YES
2
Is voltage between
CO2 (3),(4), and (9)
as shown in Table
2?
YES
Is continuity
p
between
- setting/resetting
ON.
NO switch terminals as
shown in Table 2?
Is voltage between
CO2 U).(2). and (9)
as shown in Table
Replace
Defective contact, or discon

nection in wiring harness
between Cl2 (female) (2).
(3) and CO2 (female) (4), (3)
qepair wiring
iarness, or
.eplace
harness between Cl 1
(female) (1). (2) and CO2
(female) (2). (1)
4 YES
Defective setting switch
* Turn starting switch NO

OFF.

ON.
Remedy
Is continuity
between mode
selection switch
terminals as shown
in Table l?
qepair wiring
larness, or
*eplace
Defective selection switch

OFF.
Table 2
Table 1
Terminal No. of controller CO2
1 Terminal No. of controller CO2 1
0
C
2
P
E r
g g
E Z
ag.c
I=
$
0
(Max. 1 V) (Max. 1 V)
Offset
(GNU
SET
Neutral
(Min. 16V) (Max. 1 V)

(Min. 16 V) (Min. 16 V)
CLEAR
IMax. 1 VI (Min. 16 VI
Mode selection
Controller
I@
3
Switch terminal No.
Cl.1 (KES4)
switch
Mode selection
Mode selection
Cl2 (KES3)
PC128UU-2
TJP02212
20-339
0
TROUBLESHOOTING
E-21
E-21 Cancel switch is not turned ON, but alarm buzzer sounds for 7 seconds and electrical system caution lamp flashes
*
-k

Cause
2
YES
1
Is voltage between
CO2(13) and (9)
normal?
Is voltage between
CO3 (14) and (12)
normal?
YES
-Cancel switch
NO
*Whennormal: 6 - 10 V
*When abnormal: Max. 1 V
ON.
3 YES
* Cancel switch
Is continuity
*When OFF:
between K13(male)
Max. 1 V
NO between (1) - (2) as
*When ON:
shown in Table l?
20-30V
ON.
OFF.
Remedy
Replace
Wiring harness behveen CO:

3epair wiring
(female) (13) - K13 (female)
qarness, or
(1) in contact with power
replace
source wiring harness
Defective emergency
operation switch for work
equipment
NO
Table 1
E-21 Related
electric
circuit
diagram
Emergency work
operation
To each
circuit
Controller
equipment
switch
cancel
A
K13
(SWP6)
PO5 (X2)
CO2 (040201
System
cancel
1 Signal
GND
switch
!d
Monitor
CN2 (SWP 12)
)h
PO1 (04016)
CO3 (040 16)
Buzzer
Electrical
Signal
Panel
output
system
GND
I
TJP02213
20-340
0
PC1 28UU-2
TROUBLESHOOTING
E-22
E-22 Automatic stop is not carried out for boom RAISE, LOWER, arm IN,
left offset, right offset (when error code [911 is not displayed)
*
*
*

Always connect any disconnected connectors before noina on to the next step.
Check that error cobe [911 is not being displayed.
-
a)
All operations
b)
stop immediately
before interference
Cause
Remedy
Internal resistance of diode

Dl5isO
Replace
Go to E-17
PPC lock
DO4
PPC lock
D20
(ma I e) (M2)
SlO (female) (M21
S14
1)
- -bid
I
r1
T,,
co2
(04Oi
CN2 (SWP12)
vo7
(X2)
ppc OCk
.
cnlonnid
valve
CN5 (SWP14)
FBl
q&J
Fuse
D15
PPC lock
PC1 28UU-2
Emereencv
operation
work
equipment
switch
TJP02214
20-34 1
0
E-23
TROUBLESHOOTING
E-23 Swing does not work (when no error display is given)

*
*
J,

The controller does not detect disconnection of the wiring in the solenoid system, so use this flow
chart to check.
Remedy
Cause
* Defective
.Odefective contact or disconnection in wiring

harness between CO3
(female) (8) - V04 (female)
(l), or defective contact or
harness between V04
(female) (2) and chassis
ground
2 YES
Is resistance
YES
1
Is monitor display
of pressure switch normal?
between V04
(male) (1) and (2)
normal?
Defective swing holding

brake solenoid
*35-8021
NO
OFF.
* Disconnect V04.
electric
circuit
Replace
diagram
Controller
)ioo*
Replace or repair
wiring harness
Defective pressure switch on

side where display is
defective when lever is
operated (See F Mode)
* Swing : P3
* Start engine.
NO
- Operate swing lever.
* Check in monitoring
mode.
.%See the section on the
monitor panel display
in the TROUBLESHOOTING Volume.
E-23 Related
diode (D03)
Swing
Chl (SWP16)
holding
brake
I-
I
I
5 (X2)
7h-TO3
Arm IN Pressure
switch
3 (X21
Left
swine
Pressure
switch
DO3
Swing
holding
brake
DO6
Swine
;;;;knB
3 1x21
Right
swing
Pressure
switch
TJP02215
20-342
0
PC1 28UU-2
E-24
TROUBLESHOOTING
E-24 Excessive hydraulic drift of swing

Ir
*
*

Carry out out troubleshooting
for the swing holding brake release switch at the CANCEL position.
Cause
So to troubleshooting
lydraulic, mechanical
system (See H-29)
YES
4YES
1
YES
V04 (1) and chassis
Is resistance
YES between swing
5 sec. after
- holding brake
release switch
lever is returned to
2
p
terminals normal?
neutral: Max. 1 V
p
*When lever is
Is monitor display
* Automatic position:
operated: 20 - 30 v _ of pressure switch Min. 1 MR
* Start engine.
NO normal?
* Cancel position :
Max. 1 .Q
I
NO
between CO3
- (female) (8) and
chassis when CO3

is disconnected?
* Approx.
* Swing : P3
*Start engine.
* Operate swing
lever.
Is there voltage
it-
of
iNiring harness between CO:

[female) (8) - V04 (female)
(1) in contact with power
source wiring harness
eplace or repail
firing harness
:eplace

brake release switch
;eplace
NC
* Lever at neutral:
Max. 1 V
* Turn starting switch ON.
* Disconnect C03.
NO
Remedy
_-Defective pressure switch

system on side where
display is defective when
lever is operated (See F
Mode)
SrlnP
~1888ur8
Switch
holding
holding
Pressure
switch
Pressure
switch
TJP02215
PC128UU-2
20-343
0
E-25
TROUBLESHOOTING
E-25 Offset does not work (particularly

*
*
*
left offset)

chart to check.
Cause
Remedv
Defective diode (DOS)

1 YES
Eefective contact or
harness between CO1 (male)
(20) - Cl7 (male) (2)
Is resistance
between Cl7 (male) (1) - (2) normal?
*35-80R
*zTur starting switch
Defective left offset stop

solenoid
NO
Replace wiring
harness
Replace
* Disconnect C17.
DO9
Controller
I?),
CN5(SWP14)
p-J
C17tX2)
Left
offset
stop
solenoid
valve
g)
3
TJP02201
20-344
0
PC1 28UU-2
E-26
TROUBLESHOOTING
E-26
*
*
*
Offset does not work (particularly right offset)

chart to check.
Or
YES
harness between CO3
(female) (15) - Cl8 (female)
(2)
Is resistance
between Cl8 (male) (1) - (2) normal?
Defective right offset stop

solenoid
NO
-35-8022
OFF.
* Disconnect C18.
Replace wiring
harness
Replace
023
Controller
1
co3 (040 16)

solenoid(t)
Ctl5 (SWP14)
m(7)
1
$J
Cl8 (X2)
Right
offset
stop
solenoid
valve
3
3
TJ PO2203
PC1 28UU-2
20- 345
0
E-27
TROUBLESHOOTING
E-27 Engine does not start

*
*
*
check that all the related connectorsare properly inserted.

before going on to the next.step.
connectors
disconnected
any
connect
Always
check the circuit related to fuse 1 for short circuit with
broken,
is
it
(If
broken.
not
is
1
fuse
that
Check
chassis ground.)
a)
When starting
motor does not rotate

YES
4
YES
-
Is voltage between
terminal B of
starting motor and chassis ground
normal?
_
*20-30V
* Turn starting
switch ON.
No
YES
5
Is voltage b.et-ween
terminal M of
battery relay and
chassrs ground
normal?
*20-30V
* Turn starting
NO
switch ON.
YES
6
Is voltage between
terminal B of
battery relay and
chassis ground
normal?
NO
*20-30V
ON.
ES
Is jumping out
sound of starting
motor pinion
heard?.
Turn starting switch

between ON and
START positions.
YI
YES
Is voltage between
terminal C of
safety relay and
chassis ground
l--lnormal?
*20-30V
to START.
.20-30V
ON.
l
YES
-
Is operating sound
of battery relay
heard?
starting motor and
NO
*Turn starting
switch between ON
and START
positions.
and specific gravity

of battery fluid
I
* Check while engine

is running.
NO
20-346
0
PC1 28UU-2
E-27
TROUBLESHOOTING
Cause
Remedy
eplace
lepair or replace
Leplace
- harness between battery
terminal t+) - battery relay
terminal B
lepair or replace
harness between safety
relay terminal C-starting
motor terminal S
lepair or replace
leplace
lepair or replace
Is voltage betwee
*Max. 13V
*Turn starting
switch ON.
* Max. 13 V
Disconnect terminal Ft.
* Turn starting switch ON.
Defective contact,
circuit with power source in
alternator terminal R - MO2
(female) (2)
leplace
Defective alternator
lepair or replace
harness between starting
switch terminal C (TQ) - MO2
(female) (1)
leplace
Defective starting switch

(C circuit)
;epair or replace
Defective starting motor
Ieplace
*20-30V
to START.
h
13 YES
Is voltage between
terminal C (TO9) of
starting switch and chassis ground
normal?
*20-30V
NO
to START.
GotoA
Insufficient battery capacity
PC128UU-2
-ill up or replace
20-347
a
E-27
TROUBLESHOOTING
Cause
15 YES
Is there continuity
in harness between
terminal E of
battery relay and
chassis ground?
YES
r
14
Is voltage between
terminal BR of
battery relay and
chassis ground
normal?
l20-30V
-y
*Turn starting switch NO
OFF.
-
YES
16
Is voltage between
terminal BR of
- starting switch and NO chassis ground
normal?

ON.
Defective battery relay
qeplace
harness between battery
relay E -chassis ground
Repair or replace
switch terminal BR (T7) battery relay terminal BR
Repair or replace

(BR circuit)
Replace
harness between outlet of
fuse 1 - starting switch
terminal B (T6)
Repair or replace
terminal (+) - inlet of fuse 1
Repair or replace
Is voltage between
*20-30V
ON.
starting switch and
.20-30V
OFF.
l
18YEh
Is voltage between
inlet of fuse 1 and
chassis ground
normal?
*20-30V
Na
OFF.
20-348
0
Remedy
PC128UU-2
E-27
TROUBLESHOOTING
Startine
switch
D14
(KEsi 2)
Ml1 (L2)
link
Fusible
Safety
ry
re lay
relay
Battery
Startins
PC1 28UU-2
motor
Alternator
TJP02218
20-349
0
TROUBLESHOOTING
E-27
b): Engine stop solenoid does not work
2 YES
resistance
ttween engine
op solenoid
rminal (T2) and
iassis normal?
!rminal (T2).
--- ---ting switch OFF.
3 YES
l20-30V
ON.
NO
Is voltage between
starting switch
terminal ACC and
chassis normal?
*20-30V
NO
ON.
Defective engine stop

solenoid
harness between solenoid
terminal (T2) and chassis
Replace wiring
harness
switch terminal ACC (T12) solenoid terminal (Tl)
Replace wiring
harness

(between B and ACC)
Replace
E-27 b) Related electric circuit diagram
Sta
TJP02219
20-350
0
PC1 28UU-2
TROUBLESHOOTING
E-28
E-28 Engine does not stop

Ir
*
Before carrying dut troubleshooting,

Cause
YES
1 I
1 Is voltaae between II
engineStop
solenoid termipal
;;r)z;$
chassis
* Max. 1 V
-Turn starting
switch OFF.
N&
2 YES
Is voltage between
starting switch
terminal ACC (T12) and chassis
normal?
- Max.
NO
1V
OFF.
E-28 Related
electriccircuit
Remedy
Defective engine stop

solenoid
leplace
Contact of 24 V line with

starting switch terminal
ACC (T12) - solenoid
terminal (Tl)
leplace wiring
larness

(between B and ACC)
{eplace
diagram
Sta
TJ PO22 I9
PC1 28UU-2
20-351
0
E-29
TROUBLESHOOTING
D-29 Wiper does not operate

*
Before carrying

connectors before going on to the next step.
Remedy
Cause
4 YES Defective
Is resistance
between CN502
YES
- (female) (2). (3)
3
and CN75 (female)
(1). (4) normal?
Is resistance
p
Max. 1Q
YES_ between Ml8
NO
* Disconnect CN502 and
(female) (1) and (2)
CN75.
2
normal?
Is voltage between
OFF.
*Wiper switch
YES CN75 (3) and
1R
Max.
ON:
NO
chassis ground
OFF: Min. 1 ML2
normal?
* Disconnect M18.
1* Turn starting switch OFF.
-2O-30V
l
-.
Is voltage between
Ml8 (1) and
chassis ground
normal?
* pr.n starting switch NO
5 YES
*20-30V
ON.
NO
Is horn sound
wiper motor or
defective wiper motor
control rela; box
harness of circuit having
improper resistance
Replace
Replace harness
Defective wiper switch
Replace
harness between Ml8
(female) (1) - CN75 (female)
(3)
Replace harness
harness between fuse (3) Ml8 (female) (1)
Replace harness
Breakage of fuse
Replace
normal?
II

ON.

. .
,L:&
her
Limit
switch
relay
Windo~O;as
CN-92
Wiper
l-G--
motor
relay
control
I
T I
box
1
:ank
M16
Wip
switch
Horn
(high
sound)
TJP02221
20-352
0
PC1 281JU-2
E-30
TROUBLESHOOTING
E-30 Engine control is abnormal

f
*
*
f
When the controller does not indicate any abnormality

Check that fuel control cable is not damaged or bent sharply.
a) When engine does not start or it starts but stops soon

Remedy
ES
3 YES
between motors is
disconnected,
does
Malfunction
linkage
of fuel control
Fuel control
motor
Replace
Replace
Is voltage at K18
YES (female) terminal

2
as shown
l?
in Table
between
.
K,, (,) an,jchassis_ - Disconnect
Is voltage
ground
normal?
-2O-30V
*Turn starting
ON.
switch
K18 and NO
connect T-adapter to female side.
*Turn starting switch ON.
NO
Defective one-touch
deceleration controller
Replace
Breakage of fuse (3) or

harness between fuse (3) K17 (female) (I)
Repair or replace
harness
One touch
controller
Motor
decelerator
K19
K18 (SWPG)
Throttle
control
motor
drive
(+24v)
One touch
Motor
decelerator
drive
Accelerator
signal
Decelerator
signal
Power
signal
source
(+24V)
GND
Monitor
terminal
Decelerator
signal
~~40
K16 (M2)
Indicator
[t)
Indicator
(-)
One touch
(M2)1 decelerator
cwitr-h
K20 (M2)
w\
,--A&
TJP02222
PC128UU-2
20-353
0
E-30
TROUBLESHOOTING
Table 1 Checking actuation

Operation
of relay box (controller)

Voltage and connector pin No. at check end
and connector pin No. at operation end
Connector pin No.

K18 (female)
Type of
signal
Connector pin No.

K18 (female)
Operation
Voltage
20-30
Accelera_ Short (accelerator)

1
Between (2) - (5)
Between (2) - (6)
Between (2) - (3)

Press knob at same time
tor signal o
Between (1) - (4)
pen (neutral)
0 (both terminals +24V) %I

20-30
Decelera_ Short (decelerator)
%I: Both terminals
Between (4) - (I)
tar signal Open (neutral)

Swift
Short (swift slow-down)
slow-down
signal
Open (neutral)
1)
2)
3)
20-30
Between (4) - (I 1
0 (both terminals +24V) %I
are +24V, so 24V is measured between (1) and GND and between (4) and GND.
Note: The motor drive terminal voltage is reversed for acceleration

Method
0 (both terminals +24V) El
and deceleration.
of checking actuation
Disconnect K18 and connect a T-adapter to the (female) end only.
Do not disconnect K17.
Turn the starting switch ON, carry out the operation in Table 1,
and measure the motor drive
voltage.
Table 2 Check chart for continuity
between accelerator
motor teiminals
(when normal)
Fuel control dial position
Stop position of
fuel injection pump
governor lever
Between
(2) - (5)
(accelerator
signal)
FULL position
Slow speed position
Connector K18 (male)
Connector K18 (male)
Between
(2)- (6)
(decelerator
signal)
Between
(2) - (3)
(swift slowdown signal)
FULL position
Intermediate
position
Idling position
Between
(2) - (5)
(accelerator
signal)
Between
(2) - (6)
(decelerator
signal)
Between
(2) - (3)
(swift slowdown signal)
.A
Troubleshooting
procedure
1) Check the position where the fuel injection pump governor lever stops.
2) Connect a T-adapter to K18 (male).
3) Set the fuel control dial to the FULL or IDLING position, and measure the continuity between the
terminals.
*: 0 = Continuity A = No continuity
If the governor lever stops at the FULL position in the chart above:
i) The condition is normal if there is continuity between (2) and (3) when the fuel control dial is
at FULL, or between (2) and (6) and between (2) and (3) when the fuel control dial is at slow
speed position.
20-354
0
PC1 28UU-2
E-30
TROUBLESHOOTING
b)
Swift slow-down
does not work

Cause
2 YES
Is voltage of CN67
(female) terminal
as shown in Table
I?
YES
1-j
-,
Does deceleration
indicator light up?
L
Is voltage between
YES
41
I
* Engine at full
throttle
*Turn knob switch
ON.
*20-30V
Defective fuel control motor
Ieplace
Defective deceleration
controller
seplace
Defective contact or disconnection in wiring harness

between K3 (female) (16)
and Kll (female) (4)
lepair or replace
Defective chassis control

controller
seplace

between S21 (female) CNIO (7) - K3 (female) (I I),
or wiring harness short
or defective left knob switch
lepair or replace

ON.
* Disconnect CN67 and
connect T-adapter
Y
to (female) end.
* Engine at full
throttle
* Turn knob switch
ON.
Remedy
.xSame conditions
as Item 4.
* Disconnect S21.
NC
YES
GotoA
Defective contact or disconnection in wiring harness

between S21 (male) - CNIO
18) - CNI (2) -chassis
ground
lepair or replace
Defective left knob switch
teplace
Aj$Zj@JP
I
* Turn starting
NO
switch OFF.
*When knob switch is ON: Max. 1 Q
When knob switch is OFF: Min. 1 MD
* Disconnect S20 and S21.
c)
Works at near idling speed, but does not work up to full throttle
2 YES
Does fuel control
cable move lightly and smoothly?
YES
Is voltage between
K17 (1) and GND
normal?
%tDisconnect at motor NO
end and try to move
by hand.

ON.
NO
*20-30V
PC128UU-2
(load becomes high)
Insufficient fuel control

motor torque
Replace
Fuel control cable bent,

twisted, or defective
operation of governor lever
Adjust or replace
* Blown fuse (3) or

defective contact or disconnection in wiring
harness between fuse (3)
and K17 (female) (I)
Replace
Repair wiring
harness or
replace
20-355
0
E-30
TROUBLESHOOTING
E-30 b), cl Related electric circuit diagram
decelerator
One touch
ler
:ontrol
Motor
K18 (SWP6)
KlS
Throttle
control
motor
drive
k24V)
One touch
Motor
decelerator
drive
Accelerator
sional
Decelerator
sional
Power
sianal
source
(+24V)
GND
Monitor
terminal
signal
Decelerator
Indicator
(+I
Indicator
(-)
touch
One
decelerator
TJ PO2222
20-356
0
PC1 28UU-2
TROUBLESHOOTING OF CONTROLLER INPUT

SIGNAL SYSTEM
(F MODE)
*
%
When the monitoring mode is checked, if the following input signals are not displayed or do not light
up, carry out troubleshooting
for that item.
Note that no display is given on the monitor for problems F-6 ; the display appears only on the
controller.
F- 1 Monitor
does not display [PI I (Boom RAISE pressure switch) ..................................................
20-402
F- 2 Monitor
does not display [P21 (Boom LOWER pressure switch) ................................................
20-403
F- 3 Monitor
does not display [P31 (Swing pressure switch) .............................................................
20-404
F- 4 Monitor
does not display [P5] (Arm IN pressure switch) ............................................................
20-405
F- 5 Monitor
does not display [P71 (Travel pressure switch) ..............................................................
20-406
F- 6 Monitor
does not display [Hi] (Travel speed selector switch). ...................................................
.20-407
PC128UU-2
20-401
0
TROUBLESHOOTING
F-l
F-l
Monitor does not display [PI] (Boom RAISE pressure switch)
AWhen
*
*
*
measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
When [EE] is not displayed on the monitor panel.
I
YES
Cause
1 Defective controller
Remedy
Replace
Is voltage between
CO2 (8) and chassis
* Lever at neutral:
20-30V
Boom RAISE
operated:
Max. 1 V
* Start engine.
Is resistance
Is resistance in
wiring harness between SO2 (male)
_ (T) and (2) normal,
NIO and js circuit
msuta _pfrom
chas&:
- Boom
3
in wir-
YES
from chassis?
_
* BetweenSO (female) NO
(I) - COP(female) (8) : Max. 1 Q
* Between SOS(female) (1) -chassis
: Min. 1 MC
* Disconnect S02, C02.
harness between SO2
(female) (2) and chassis
Repair or replace

between SO2 (female) (1) CO2 (female) (St, or wiring
harness short crrcuiting with
ground
Repair or replace
Defective boom RAISE

pressure switch
RAISE
operated: Max. 1 R NO
* Lever at neutral:
Min. 1 MQ
* Start engine.
- Disconnect S02.
%lt is also possible to fit a short
connector and judge the
condition. In this case, check
the voltage between CO2 (8) and
the chassis.
If it is 20 - 3OV: Go to YES
* If it is less than IV: Go to NO
Replace
F-l
Related electric circuit diagram
Controller
I
CO2 (04020)
RAISE
Pressure
switch
Boom
CN6 (SWP8)
3
so2
-3
(X2)
Boom RAISE
Pressure switch
TJP0.2223
20-402
0
PC128UU-2
F-2
TROUBLESHOOTING
F-2
:
A
*
*
*
Monitor does not display [P2] (Boom LOWER pressure switch)
When measuring while the engine is running, operate the lever to a degree that the work equipment
does not move.
When [EEI is not displayed on the monitor panel
Cause
YES
Remedy
1
3 YES
Is voltage between
CO2 (7) and chassis ground normal?
Is resistance
between 94, SlO
(female) (1) and CO2 (female) (7) normal
and are they
insulated from
chassis?
YES
2
With lever in
Is resistance
neutral: 20 - 30 V
between S04, SlO
_
_ (male) (1) and (2)
* Boom LOWER
normal and are
~0
operation:
* Between SO4 or SlO NO
from
insulated
they
Max. 1V
(female) (1) and CO2 (female) (7): Max. 1R
chassis?
* Start engine.
* Between CO2 and chassis: Min. 1 MQ
* Boom LOWER
Disconnect S04, SlO, and C02.
operation: Max. 1Q
* With lever in neutral NO
: Min. 1 MD
* Start engine.
* Disconnect SO4 and SlO.
.X Short connector may be installed for
judgment.
In this case, if voltage between CO2 (7)
and chassis is
- 20-30V,gotoYES
* Below 1 V, go to NO
harness between SO4, SlO
(female) (2) -chassis
Repair or replace
Defective contact,
S04, SlO (female) (1) - CO2
(female) (7)
Repair or replace

$z.s;ure switch No. 1 or
Replace
F-2 Related electric circuit diagram
Controller
Pressure
switch
Boom LOWER
switch
Pressure
(NO. 1)
Boom LOWER
switch
Pressure
(NO. 2)
TJP02224
PC128UU-2
20-403
0
TROUBLESHOOTING
F-3
A
*
*
*
F-3
Monitor does not display [P3] (Swing pressure switch)
does not move.
When [FE] is not displayed on the monitor panel
Remedy
Cause
- Only swing to left
Defective left swing

pressure switch
. Only swing to right
Defective right swing

pressure switch
In what operation
does [P31
disappear from
monitor panel?
Replace
3YEs disconnection in wiring
harness between SOS, S30

(female) (2) -chassis groun
YE {F[
-With lever in
neutral: 20 - 30 V
. Turn startina switch
NC harness between CO2
(female) (6) -SOS, S30 (1)
4 YES
*With lever in
neutral: 20 - 30 V
*Turn starting
switch ON.
chassis normal?
* Disconnect C02.
* Min. 1 MD
OFF.

NO between CO2 (female) (6) SOS, S30 (female) (1)
Repair or replac
Repair or replac
Replace
Repair or replac
Controller
Swing
Pressure
left
switch
Swine
r ieht
Pressure
switch
TJP02225
20-404
0
PC1 28UU-2
TROUBLESHOOTING
F-4
A
*
*
*
F-4
Monitor does not display [P5] (Arm IN pressure switch)
does not move.
Cause
II
s With lever in
neutral: 20 - 30 V
* Arm IN operation:
Max. 1V
. Start enaine.
3
Is resistance
between SO5
(female) (1) and
CO2 (female) (18)
normal and are
they insulated
from chassis?
YES
2
Is resistance
between SO5 (male)
_ (1) and (2) normal
_
NO and are they
insulated from
sis?
*Arm IN operation:
-2:
YES
II
-
* Between SO5
(female) (1) and CO2 (!%ale) (18): Max. 1R
* Between SO5 (female) (1) and chassis:
Min. 1 MR
* Disconnect SO5 and C02.
Eer
in neutral: No
Min. 1 MQ
* Start engine.
* Disconnect SO5
% Short connector may be installed for
judgment.
In this case, if voltage between CO2 (18)
and chassis is
* 20-30V,gotoYES
- Below 1 V, go to NO
Remedy
Replace
harness between SO5
(female) (2) - chassis
Repair or replace
Defective contact,
SO5 (female) (1) - CO2
(female) (18)
Repair or replace
Defective arm IN pressure

switch
Replace
Controller
CO2 (04020)
Arm
IN
Pressure
switch
CN6 (SWP8)
so5
.a
-3
(X2)
Arm
IN
Pressure
switch
TJP02226
PC128UU-2
20405
0
TROUBLESHOOTING
F-5
A
*
*
*
F-5
Monitor does not display [p7] (Travel pressure switch)
does not move.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Remedy
Cause
YES
YES
Is resistance
between SO1
(female) (1) and CO2 (female) (17)
*With lever in
neutral: 20 - 30 V
* Right or left travel
between SO1 (male)
NO
* Between SO1
(female) (1) and CO2 (female) (17): Max. 1Q
f Between harness and chassis: Min. 1 MQ
* Disconnect SO1 and C02.
operation:
* Travel
._
_.
* lZtl:Er in neutral: No
Min. 1 MD
. Start engine.
* Disconnect SO1
I Short connector may be installed for
judgment.
In this case, if voltage between CO2
(17) and chassis is
* 20-30V,gotoYES
* Below 1 V, go to NO
Replace
harness between SO1
(female) (2) - chassis
Repair or replace
kir%%c%%tshort
SO1 (female) (2) - CO2
(female) (17)
Defective travel pressure
switch
Repair or replace
Replace

DO2
so1 (X2)
CN2 (SWP 121
Trave
Pressure
Travel
switch
alarm
Fuse
i
TJP02227
20-406
0
PC1 28UU-2
TROUBLESHOOTING
F-6
%
*
*
F-6
Monitor does not display [Hi] (Travel speed selector switch)
Displayed on only the display unit of the controller.

:
Cause
YES
*When switch is ON:
Max. 1 V
*When switch is OFF:
Min. 4 V
*Turn starting switchN
ON.
..
.-
1R
NO
* Disconnect M25 (seesaw switch)
* Max.
between M25 or
M39 (male) (1) and
(2) normal?
. When switch is ON:
Is resistance
between M25 or
M39 (female) (1)
chassis normal?
YES
or M39 (pedal switch).

. ?<n?witch
is OFF: NO
Min. 1 MQ
* Disconnect M25 (seesaw switch)
or M39 (pedal switch).
*Turn staning switch OFF.
Remedy
Iefective controller
ieplace
Iefective contact or
fisconnection in wiring
larness between M25 of
v139 (female) (2) - CO1
female) (12)
leplace harness
Iefective contact,
iisconnection or short
:ircuit with chassis ground
n wiring harness between
kl25 or M39 (female) (1) :hassis
teplace harness

selector switch
{eplace

Controller
CN-? (S,WP,l2)V05 (X2)
Travel
speed
CO1 (MICh
Travel
TT
Hi switch
I
FBl
mj
Fuse
selection
switch
OFF ON
02
M25 (M2)
DO7
Trave I speed
PC128UU-2
Ml39 (M2)
a-3
sel ect ion
Trave I Hi-Lo
select ion swi tch
TJP02209
20-407
0
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes . .. . ... . .. .. .. .. .. ... .. ... . .. . .. .. ... . . .. . . . .. .. .. . ... . .. .. ... .. . . ... . . .. .. .. . . .... .. ... .. . ... . .. .. .. .. . 20-502
H- 1 All work equipment,
travel, and swing speed or power is low ..................................
H- 2 Engine speed lowers remarkably

H- 3 Work equipment
. .............. 20-504
.20-505
or engine stalls.. ...................................................................
does not move at all and machine does not travel or swing .......................
or response is low.. .......................................................................................
H- 5 Fine controllability
20-506
20-506
sound comes out (from around pump) .....................................................................
H- 4 Abnormal
20-507
H- 6 Boom speed or power is low.. ......................................................................................................
20-507
H- 7 Arm speed or power is low ..........................................................................................................
20-508
.:.............. 20-509
H- 8 Bucket speed or power is low ......................................................................................
H- 9 Blade speed or power is low ........................................................................................................
20-509
H-10 Offset speed or power is low.. ......................................................................................................
20-510
H-l 1 Work equipment
or blade) does not move.. ........... .20-511
(Boom, arm, bucket, offset mechanism,
H-12 Hydraulic drift (Boom, arm, bucket, or blade) is large ...............................................................
20-51 1
H-13 Time lag is long (Engine speed is low) ........................................................................................
20-512
H-14 When work equipment
is relieved independently,
other work equipment
H-15 Speed of heavier operation is slower during compound

H-16 Boom RAISE speed is low during compound
boom SWING and RAISE operations..
H-17 Travel speed lowers during compound
equipment
H-18 Machine
or swinging
operation
move.. ................. .20-512

20-512
operation .........................................
of
20-513
.........................................................................................
operation
of work
and travel ...............................................................................................
20-513
i.. ............ 20-514
deviates.. ..........................................................................................................
20-515
H-19 Travel speed is low ........................................................................................................................

H-20 Steering condition
-20-516
is bad or steering force is low.. ...................................................................
20-518
H-21 Travel speed does not change ......................................................................................................

H-22 Machine
does not travel (Only one side). ....................................................................................
H-23 Machine
does not swing .............................................................................................
20-518
..- ............... 20-519
a) When machine does not swing in either direction.. ..............................................................
.20-519
b) When machine does not swing in only derection ..................................................................
20-519
H-24 Swing acceleration
or swing speed is low in either clirection ....................................
b) When swing acceleration
or swing is low in only one derection
H-25 Work equipment
20-520
or swing speed is low ..................................................................................
a) When swing acceleration
.........................
20-520
.:.............. 20-520
20-521
overruns ............................................................................................................
a) When work equipment
overruns
b) When work equipment
pverruns in only derection
in either direction
..............................................................
20-521
...............................................................
20-521
H-26 Large shock is made when machine stops swinging
(In only one direction)
H-27 Large noise is made when machine stops swinging
................................................................
..........................
H-28 Hydraulic drift of swing is large ...................................................................................................
20-522
.20-522
20-523
a) When swing holding brake is applied .....................................................................................
20-523
b) When swing holding brake is released ..................................................................................
.20-523
H-29 Error code [911 is displayed on monitor panel and all of boom RAISE,
arm IN, and offset LEFT operations
stop just before machine interferes .................................
H-30 Boom RAISE, arm IN, and offset LEFT operations

automatically
PC128UU-2
and machine interferes
20-524
do not stop
.........................................................................................
20-524
20-501
0
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES

-
Parts causing failure
Main pump
Control valve
-5
3
:
i
ii,
Failure mode
All work eauipment,
travel, and swina soeed or Dower is low
Enaine soeed lowers remarkablv
or enaine stalls
Work equipmentdoesnot moveat all and machinedoes not travel or swing

Abnormal
sound comes out (from around pump)
Fine controllability
or response is low
Bucket speed or power is low
Offset speed or power is low
Blade speed or power is low
Boom does not move
Arm does not move
Bucket does not move
does not work
Blade does not move

Hvdraulic drift (Boom, arm, bucket, or blade) is larae
laa is lona (Enaine soeed is low)
When work equipment is relieved independently, other work equipment move

Speed of heavier operation is slower during compound operation
Boom raising speed is low during compound
boom SWING and RAISE operations
Travel speed lowers during compound
equipment or swinging and travel
Machine deviates laraelv at start
Steering condition is bad or steering force is low

Travel speed does not change
Machine does not travel (Onlv one side)
Swing acceleration or swing speed is low
operation of work
Travel soeed is low
Machine does not swing
operation of
Machine deviates largely during constanttravel
Machine deviates
Arm soeed or Dower is low
iime
I
-
Boom speed or power is low
Offset mechanism
In either direction
In only one direction

In either direction
In Onlv one direction
Work equipment
overruns
In either direction
In only one direction
Lame shockis madewhen machinestoesswinaina(In onlv one direction)

Larae noise is made when machine stoos swinaina
Hydraulic drift of
swing is large
20-502
0
When swing holding brake is applied

When swing holding brake is released
F
6 f ? z
E F u 5
z : 2?
- Ei
E
?
&I
22
_c
1 dz
2
5
-
s
9 rn
zr
z- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- i
5
2 F
22
h F
6
z
e
zz- I
---z-- - - zI
- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- --- z- - - ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ----
i?!
F
s
1 .gj 5
b
5
:
0
5
g s
i: B
g ;
? <
I
-
5
6
6
i
z
-
I
-
PC128UU-2
Failure mode
Engine system
2-stage relief
PPC lock
cylinder
WNd
Hydraulic
Travel speed selector
Motor
Final drive
solenoid
valve
v)
-5%
SZ
5
8-I
Travel speed selector
valve and piston
ti
:
(P
Check valve
valve
Counterbalance
H-l
TROUBLESHOOTING
H-l
All work equipment,
travel, and swing speed or power is low
Before starting diagnosis, check that abnormal sound is not heard from the pump.
sound is heard, perform H-4.)
(If any abnormal
Cause
4 YES
-
Defective main pump.
Remedy
Rlepair or replace
YE
3
Is output pressure
of PC valve (input
pressure of servo
YE
2
l
YE
pressure (output
pressure reducing
* 3.24 * 0.49 MPa
I33 * 5 kg/cm21
* Run engine at full
throttle.
Is main pump relief

pressure normal?
* 31.87 :;j;
MPa {325+:zkg/cm?
* Run engine-at full
N
throttle.
*Relief arm.
*See TESTING AND

ADJUSTING.
See TESTING AND

ADJUSTING.
IO
6 YES
NC
Defective PV valve or PCEPC valve
A;epair or replace
Defective main relief valve
Rlepair or replace
Defective unload valve
Rlepair or replace
Defective self-pressure
reducing valve
R;epair or replace
FH_
* 2.7: i., MPa
NO
{28:&kg/cm2>
. Run engine at full throttle.
5 YES
[Pressure reducing valve, LS

:ircuit)
R,epair or replace
Malfunction of main valve
pressure normal?
NO
* 2.2 + 0.1 MPa
{22.5 f 1 kg/cm21
throttle.
Run travel mechanism
on one side idle.
Defective pump LS valve
Replace
Note: Referring to TESTING AND ADJUSTING,

devices of the control circuit.
20-504
0
Testing and adjusting control circuit oil pressure, test the
PC128UU-2
H-2
TROUBLESHOOTING
H-2
*
*
Engine speed lowers remarkably
or engine stalls
Before starting diagnosis, check that the emergency pump release switch is under the normal condition.
Before starting diagnosis, check that the main pump relief pressure is normal.
Cause
YE
Is orifice for pump

servo clogged?
YES
Remedy
Clogging of orifice for pump

servo
Clean
Defective servo piston
Xepair or replace
WIIs output pressure

of PC valve (input
pressure of servo
piston) normal?
% See below.
NO
Defective engine system

(Go to S mode
troubleshooting)
* See TESTING AND

ADJUSTING.
Defective PC valve
iepair or replace
Defective PC-EPC valve
seplace
Is output pressure
_ of PC-EPC valve
_
II normal?
.
NO
Engine speed to relieve pump when engine and pump are normal
Conditions
Engine speed to relieve arm

l
2,220 f 100 rpm

With arm at stroke end, operate lever
to FULL side slowly, and read lowest
engine speed during this operation.
PC1 28UU-2
20-505
0
H-3
TROUBLESHOOTING
H-3
Work equipment
or swing
does not move at all and machine does not travel
Cause
3 YES
Is voltage between
V07 (1) and chassis ground normal?
YES
YES
1
I Is main PPC
pressure (output
oressure of self-
Is PPC lock lever

limit switch
normal?
NO
Defective PPC lock solenoid

valve
Replace
Defective chassis harness
Repair or replace
Defective self-pressure
reducing valve
Repair or replace
Defective main pump
Repair or replace
Defective PTO
Repair or replace
II
u
YES
* 3.24 t 0.49 MPa
{33 * 5 kg/cm21
throttle.
Remedy
NO
If main pump
outlet hose is
disconnected, does oil flow out of
pump?
5 YES
p
Does main pump
NO
shaft rotate?
NO
20-506
0
PC128UU-2
H-4, H-5
TROUBLESHOOTING
H-4
Abnormal sound comes out (from around pump)
Cause
3 YES
Remedy
Go to 4.
j-
YE
NO
Hydraulic oil of bad quality
Replace
hydraulic oil
Clogging of suction strainer

with foreign matter (cloth,
etc.)
Remove foreign
matter
Are there bubbles

in hydraulic tank?
Is suction strainer
clogged with
foreign matter?
No
Is oil level in
hydraulic tank
normal?
% With foreigh
matter
5 ES Internal defect of main

1
Is suction strainer
clogged with
metalhc matter or
are metal chips
sticking to drain
plug?
pump
Operate for a while and see

i
NC change of condition.
Hydraulic oil of bad quality
H-5
Fine controllability
Repair or replace
Test again
(accordin to
change o9
condrtion)
Replace
hydraulic oil
or response is low
ES
Clogging of orifice for pump

servo
Clean
Defective LS valve
Replace
Defective servo piston
Replace
Is orifice for pump
2 YES
If LS valve is
_ replaced, does
1 pump operate
normally?
NO
PC1 28UU-2
20-507
0
TROUBLESHOOTING
H-6
H-6
Boom speed or power is low
5 YES
YE
YE
Is main pump relief

pressure normal?
FH_
* Max. 15 cc/min
*Run engine at full
throttle..
YES
2
YE
1
Does spool of
valve move smoothly?
I6
* 31 .BZ ;:;z
MPa I325 Z g kg/cm21
N
throttle.
YES
pressure reducing
valve piston free
NO
*This valve may be

replaced with
another one.
Note) Be sure to return borrowed
one after testing, however.
- control
I
Is pressure
compensation
valve (Pressure
reducin valve
piston, wow control
valve and pressure
reducing valve)
normal and does it
move smoothly?
NO
Is output pressure
1
valve normal?
NO
* 3.24 + 0.49 MPa

(33 f 5 kg/cm?)
throttle.
* Operate lever fully.
20-508
0
PC128UU-2
H-7, H-8, H-9
TROUBLESHOOTING
Cause
H-7
*
l
l
Replace
Defective hydraulic cylinder
Replace
Malfunction of flow control

valve or pressure reducing
valve
Repair or rep1
Malfunction of control valve

spool
Repair or repl
Develo&ent
Replace
PPC valve
Arm speed or power is low
Bucket speed or power is low
See diagnosis
H-9
Ir
Malfunction of suction valve
See diagnosis mode [H-6]. Add arm regeneration check valve to the Cause column on YES side of
Step 5, however. (The remedy column is not changed.)
H-8
*
Remedy
mode [H-61.
Blade speed or power is low
See diagnosis mode [H-6]. For the main pump relief pressure in Step 4, however, see the following.
Blade RAISE relief pressure: 31.87 i:g MPa 1325 i kg/cm21
Blade LOWER relief pressure: 32.36 + 1.47 MPa (330 + 15 kg/cm21
PC1 28UU-2
20-509
0
H-10
TROUBLESHOOTING
H-10 Offset speed or power is low
A YE!
J YES
Is output pressure
of PPC valve on
PPC valve side
1normal?
I
- 3.0 f 0.5 MPa

130 f 5 k&m21
- Run engine at full
throttle.
YES
hydraulic cylinder
. Max. 15 cc/min
throttle.
1
NO
20-5 10
0
u
3
Llalfunction of flow control

valve or pressure reducing
valve
Vlalfunction of control valve
NO
Vlalfunction of left offset

stop solenoid valve
Iefective
PPC valve
iepair or replace
iepair or replace
?eplace
ieplace
Vlalfunction of suction valvf
ieplace
ieplace

of unload valve
Replace
Defective pressure reducing

valve piston
Repair or replacr
NO
YES
valve piston free
Remedy
SPOOI
- 3.0 + 0.5 MPa

(30 * 5 kg/cm21
*Run engine at full
throttle.
pressure normal?
Is pressure
compensation
- Left offset:
valve (Pressure
31.87: A;%MPa
YES reducin valve
I325: $ kg/cm21
- piston, 8ow control - Right offset:
valve and pressure
27.0? 1.47 MPa
reducing valve)
2
normal and does it
1275 f 15 kg/cm21
move smoothly?
- Run engine at full
Does control valve
throttle.
* This valve may be
Yl 5 spool move
replaced with
NO
smoothly?
another one.
1
Note) Be sure to return borrowed
V
one after testing, however.
of PPC valve on
control valve side
Cause
PC1 28UU-2
H-II,
TROUBLESHOOTING
H-II
*
H-12
Work equipment (Boom, arm, bucket, offset mechanism, or blade)

does not move (Machine travels and swings normally, however)
When the boom, arm, bucket, offset mechanism,
or blade is operated singly
Cause
of PPC valve on
control valve side
* 3.0 + 0.5 MPa
(30 * 5 kg/cm21
throttle.
R
NO
- 3.0 ?r0.5 MPa
f30 f 5 kg/cm?
-Run engine at full throttle.
_ Arm OUT, bucket,
blade
Remedy
Defective control valve
Repair or replace
Defective solenoid valve for

stopping
Repair or replace
Defective PPC valve
Replace
Defective PPC valve
Replace
H-12 Hydraulic drift (Boom, arm, bucket, or blade) is large
Remedy
Cause
valve seat
YES
If suction valve or
suction safety valve
(blade) is replaced,
is hydraulic drift
normal?
Boom, arm, bucket
L Blade
hydraulic cylinder
Defective centralized safety

valve
iepair or replace
Repair or replacf
valve is replaced,
NO
_ Low oil-tightness of control

panel spool
Replace
Replace
Arm, bucket
Low oil-tightness of control

panel spool
Replace
Boom
Defective boom lock valve
Repair or replacl

throttle.
I
NO
PC1 28UU-2
N()
20-511
0
H-13, H-14, H-15
TROUBLESHOOTING
H-13 T?me lag is long (Engine speed is low)
Cause
m,.,
press_& reduding
valve piston move
smoothlv?
1 YES
valve may be NO
replaced with another
one.
* Be sure to return
borrowed one after
testing, however.
- Each
H-14 When work equipment

ment move
Remedy
Defective suction valve
Replace
Defective flow control valve,

pressure reducing valve, or
pressure reducing valve
piston
Repair or replace
is relieved independently,
other work equip-
*:r-..
InsufficIent pressure relieve from main spool
H-15 Speed of heavier operation is slower during compound operation

Compound
operation
Heavier load side
Lighter load side
Boom RAISE + Arm IN
Boom RAISE
Arm IN
Boom RAISE + Arm OUT
Arm OUT
Boom RAISE
Boom RAISE + Bucket CURL
Boom RAISE
Bucket CURL
Arm OUT + Bucket CURL
Arm OUT
5 ) Boom LOWER + Arm OUT
20-5 12
0
( Arm OUT
Bucket CURL
1 Boom LOWER
PC128UU-2
H-16,
TROUBLESHOOTING
H-16 Boom RAISE speed is low during compound

SWING and RAISE operations
*
When single swing operation
operation
H-17
of boom
is normal
Cause
1 YES
Is circuit pressure
of LS selector
valve normal?
NO
* 2.4 - 3.6 MPa
124 - 37 kg/cm?
-Run engine at full
throttle.
* Raise boom fully.
- Outlet of shuttle valve.
Remedy
Malfunction of LS selector
valve
Repair or replace
Defective boom RAISE PPC

valve
Repair or replace
H-17 Travel speed lowers during compound operation of work equipment

or swinging and travel
*
When swing operation
and single travel operation
are normal
Cause
1
If pressure reducing
valve of travel
pressure
compensation valve
is replaced, is travel
speed normal?
NO
Defective travel pressure

reducing valve
H
2 YES
If piston of swing
or work equipment
pressure reducing
valve is replaced,
is travel speed
normal?
NO
PC1 28UU-2
Remedy
Defective piston of swing or

travel pressure reducing
valve
Replace
Malfunction of travel flow

control valve
Replace
20-513
0
H-18
TROUBLESHOOTING
H-l 8 Machine deviates

a)
When machine deviates
during constant
travel
Cause
crefective
pressure
valve or
nialfunction of pressure
C ompensation valve spool
Repair or replace
refective travel motor

assembly
Repair or replace
hAalfunction of control valve

NC )s pool
Repair or replace
3 YES
Tlf flow control valve I
and pressure
reducing valve on
YE . both sides are
exchan ed with
each ot R r, does
machine deviate
inversely?
t
4 YE6 ic
YES interconnection
hJalfunction of
irlterconnection
UO
pressure between
both pilot signals
of interconnection
C ompensation
Does spool of
control valve on
slower side move
smoothly?
H
valve
lefective PPC valve

-(: Defective spring or check
,alve)
Remedy
Repair or replace
Replace
If travel PPC spring

case replaced,
i
NO does machine
travel normally?
NO
If interconnection
valve assembly is
replaced, does
machine travel
normally?
YES
When machine deviates
Replace
jefective main valve

Spool, spring)
NO
b)
cdefective ball check valve in

irIterconnection valve block
Replace
at start
Table 1
Cause
counterbalance
20-5
0
14
I
valve
Remedy
I Repair
or replace
I
I
PC128UU-2
TROUBLESHOOTING
H-19
H-19 Travel speed is low
Cause
3 YES
YE
NO
Malfunction of travel
pressure reducing valve
Replace
Malfunction of main spool
Replace
See MACHINE DEVIATES
Replace
Defective travel PPC
Replace
1
Low in only one
direction
Is travel PPC
pressure normal?
PC1 28UU-2
in both directions
Remedy
20-515
0
H-20
TROUBLESHOOTING
H-20Steering condition is bad or steering force is low
2
1
I
In both directions i
$~~~~i~~~s
4 YES
/
EH_
3
NO
When travel pump

is relieved, is
pump discharge
pressure normal?
Is steering
condition bad in
both directions or
in one direction?
5 YES
1
Nl
* 2.35 - 3.6 MPa

NO
(24 - 37 kg/cm?)
* Run engine at full throttle.
* Move travel lever a little.
6 YES
In only one direction _
If pressure
compensation valve
(flow control valve
+ pressure reducing
valve) on both sides _
are exchanged with
each other, is
steerin condition
normal.$
NO
YES
7
If suction valve of
control valve is
replaced, is
steering condition
inverted?
8 YES
If travel motor
suction valves are
Ng
:;$%R::,Th
steerin condition
normal.3
NO
20-5 16
0
PC128UU-2
TROUBLESHOOTING
H-20
PC128UU-2
Cause
Remedy
improper adjustment or
malfunction of pump PC
valve
Repair or replace
Defective center swivel joint
Repair or replace
Repair or replace

solenoid valve
Repair or replace
Malfunction of pressure
compensation valve or
pressure compensation
piston
Repair or replace
Malfunction of suction valve

of control valve
Repair or replace
Defective travel motor

check valve
Replace

safety valve
Replace
20-517
0
H-21, H-22
TROUBLESHOOTING
H-21 Travel speed does not change
1 YES
NO
* 2.4 - 3.6 MPa
{24 - 37 kg/cm21
throttle.
* Travel speed selector
switch: HIGH (ON)

speed selector valve and
piston
Replace

selector solenoid valve
Replace
H-22 Machine does not travel (Only one side)
Cause
YES
Is foreign matter
drained from final
YE
drive?
If suction valves of
control valves on
both sides are
exchanged with
each other, does
machine travel
2
N
Is draining rate of
-
NO
Defective final drive
Ieplace
Iefective suction valve of

:ontrol valve
Ieplace
QVE
Iefective safety valve of

ravel motor
Xeplace
Defective counterbalance
lalve of travel motor
Xeplace
Iefective travel motor
Xeplace
vES
If safety valves of
travel motor on
both sides are
exchanged with
travel motor
normal?
*lOe/min
throttle.
* Relieve travel
motor.
20-518
0
Remedy
Nl
NO
PC1 28UU-2
TROUBLESHOOTING
H-23
H-23 Machine does not swing

a)
When machine does not swing in either direction
Cause
3 YES
YE
2
NO
-320 C 10 kg/cm?
throttle.
brake solenoid
-2.35 - 3.6 MPa

(24 - 37 kg/cm*)
N'0
. Run engine at full
throttle.
. Swing lock switch: OFF
. Move swing lever or
arm IN lever a little.
b)
fective swing machinery
lepair or replace
fective swing motor or

ing holding brake
;epair or replace
fective swing motor

ety valve
lepair or replace
fective swing holding

rke solenoid valve
lepair or replace
EH_
YEiS
1
Remedy
When machine does not swing in only one direction
Cause
YES
2
YES
-
1
Is output pressure
If swing motor
suction valves are
exchanged with
each other, is
condition inverted?
p
* Exchange both
_
VdVeS
with each NO
other.
of PPC valve
* Exchange both
valves with each
other.
- 2.4
- 3.6 MPa
(24 - 37 kg/cm21
. Run engine at full
throttle.
-Operate lever fully.
PC1 28UU-2
NO
YES
If swing motor
check valves are
exchanged with
each other, is
condition inverted?
NO
Remedy
Defective swing motor

suction valve
Repair or replace

check valve
Repair or replace

spool
Repair or replace
Defective PPC valve
Repair or replace
20-519
0
H-24
TROUBLESHOOTING
H-24 Swing acceleration or swing speed is low

a)
When swing acceleration
or swing speed is low in either direction
Cause
Remedy

safety valve
Repair or replace
Defective swing motor or

parking brake
Repair or replace
replaced, swing
condition is
b)
When swing acceleration
or swing speed is low in only one direction
Cause
YES
I If swina motor
-11
vcc I suctiorTvalves are I I
IL=
ex;kan$
;ith
condition ihverted?
output pressure
of PPC valve
normal?
* 2.4 - 3.6 MPa

{24 - 37 kg/cm9
throttle.
* Operate lever fully.
20-520
0
Exchange both
with each
other.
VdVeS
t-l
1
NO
~0
YES
3
If swing motor
check valves are
exchanged with
each other, if
condition inverted?
I
* Exchanae
both
valves with each
other.
Remedy
Iefective swing motor

;uction valve
tepair or replace
Iefective swing motor

:heck valve
Iepair or replacs
II
NO
Iefective control valve

ipool
Defective PPC valve
Repair or replac
PC128UU-2
TROUBLESHOOTING
H-25
H-25 Work equipment

a)
overruns
When work equipment overruns in either direction

(When throttling of PPC circuit and operation of control valve spool are normal)
Cause
YES
1
If swing motor
safety valve is
replaced, does
work equipment
stop normally?

safety valve
Repair or replace
Repair or replace
NO
b)
Remedy
When work equipment
overruns in only one direction
Cause
Remedy
Defective PPC valve
Repair or replace

suction valve
Repair or replace

:heck valve
Repair or replace

WOOI
Repair or replace
If PPC valve hoses

are exchanged
with each other, is
condition
inverted?
2
suction valves are
3 YES
condition inverted?
p$jgiyJI
NO
PC1 28UU-2
20-521
0
H-26, H-27
TROUBLESHOOTING
H-26 Large shock is made when machine stops swinging (In only one direction)
Cause
1 YES
Remedy
Defective PPC valve
leplace
Malfunction of control valve

spool
leplace
Does control valve

spool move
smoothly?
NO
H-27 Large noise is made when machine stops swinging
Cause
YES

safety valve
If safety valve is
I
Y
replaced, does
2
N0
20-522
0
Remedy
Seplace
3efective swing motor

suction valve
3 YES
swing machinery?
NO
Defective swing machinery
iepair or replace
Jefective back pressure

valve
Repair or replac
PC128UU-2
H-28
TFtOUBLESHOOTlNG
H-28 Hydraulic drift of swing is large
a)
When swing holding brake is applied
Cause
YES
Isoutput pressure
of swing holding
brake solenoid
valve normal?
A
- 0 MPa {O kg/cm*)
NG
*Start engine.
-5 set or more after
swing lever is set in
neutral
b)
YES
Remedy

holding brake
Repair or replace

brake solenoid valve
Repair or replace
Defective swing PPC

pressure switch
Replace
Replace
Is swing PPC
pressureswitch
normal?
NO
When swing holding brake is released
Cause
YES
21
1
Ononly
large on only one

side or on both

suction valve
repair or replace

check valve
lepair or replace
Defective pressure
compensation valve and
pressure compensation
piston
tepair or replace

safety valve
Xepair or replace

spool
?eplace
iepair or replace
suction valves are
one side
YES
If swing motor
check valves are
exchanged with
NO each other, is
i condition Inverted?
NO
- On both sides
If swing motor
safety valves are
exchanged with
each other, is
condition inverted?
II
Is leakage from
swing motor
normal?
PC128UU-2
Remedy
l-l
II
I
kC
20-523
0
TROUBLESHOOTING
H-29, H-30
H-29 Error code [91] is displayed on monitor panel and all of boom RAISE,
arm IN, and offset LEFT operations stop just before machine interferes
Check that water is not in the potentiometer
(C21, C22, and C23).
connectors
of the boom, arm, and offset mechanism
Cause
Malfunction of solenoid
valve
H-30 Boom RAISE, arm IN, and offset LEFT operations

matically and machine interferes
*
Remedy
Repair or replace
do not stop auto-
If this failure occurs, the failure of H-32 occurs, too.
Cause
1 YES
Remedy
Replace
Malfunction of PPC lock

solenoid valve (It does not
return)
Repair or replace
Does PPC lock

solenoid valve
move smoothly?
NO
20-524
0
PC1 28UU-2
TROUBLESHOOTING OF MONITOR SYSTEM

(M MODE)
Electric circuit diagram of monitor system .. .. . ... .. . .. . .. . . .. .. .. ... ... .. .. .. . .. .. . .. . . . . .. .. .. . .. .. . .. ... . .. .. .. . . ... . .. . .. .. .. .. .. 20-602
M- 1
After starting switch is turned to ON position,
....................................
20-603
M- 2
After starting switch is turned to ON position, self-check items

(which should light up for 3 set) are turned on but not turned off.. .......................................
20-603
After starting switch is turned to ON position, some of self-check items

(which should light up for 3 set) are not turned on .................................................................
20-604
M- 3
M- 4
M- 5
nothing is displayed..
a) No gauges (Fuel, engine coolant temperature) are turned on

Pre-heatin pilot lamp does not light up.. ...............................................................................
b) Caution lamps (Engine oil pressure, charge) do not light up.. ............................................
c) Electric system caution lamp does not light up ...................................................................
After starting switch is turned to ON position
(before engine is started), charge caution lamp does not light up .........................................
20-604
20-604
20-604
20-605

(before engine is started), engine oil pressure caution lamp does not light up ....................
20-606
pilot lamp does not light up.. ... 20-607
M- 6
After starting switch is turned HEAT position, pre-heating
M- 7
Engine oil pressure caution lamp lights up while engine is running
M- 8
Charge caution lamp lights up while engine is running ..........................................................
20-609
M- 9
Abnormality
gauge .................................................................
20-610
in engine coolant temperature
.....................................
20-608
a) Even if engine is operated for long time, coolant temperature

level does not rise at all ..........................................................................................................
b) Level rises soon after engine is started (to red range while engine is not overheated).
c) Related electric circuit diagram
M-10
Abnormality
in fuel gauge ..........................................................................................................
a) All segments
M-l 1
.............................................................................................
of fuel gauge go off .........................................................................................
20-610
.. 20-610
20-610
20-611
20-611
b) Fuel gauge indicates full while fuel is lowered ....................................................................
20-611
c) Fuel gauge does not indicate full even if fuel tank is full.. ...................................................
20-612
Malfunction
of alarm buzzer .......................................................................................................
20-613
a) Buzzer does not sound ............. . .............................................................................................
20-613
b) Buzzer does not stop sounding.. ............................................................................................
20-613
Service meter does not operate while engine is running ........................................................
20-614
a) When charge level caution lamp does not light up .............................................................
20-614
b) When charge level caution lamp lights up ...........................................................................
20-614
Lamps do not light up at night ...................................................................................................
20-615
a) Lamp for gauges does not light up .......................................................................................
20-615
b) Lamp for service meter does not light up .............................................................................
20-615
M-14
Electric system caution lamp keeps lighting up .......................................................................
20-615
M-15
Heater does not work ..................................................................................................................
20-617
M-12
M-13
PC1 28UU-2
20-601
0
ELECTRIC CIRCUIT DIAGRAM
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF MONITOR
Controller
SYSTEM
SYSTEM
R05
2.2Kcl
,
.,
i
OF MONITOR
(~6)
...j
relay
ZL
d
itch
FBl
itch
PO2
(M2)
Light
PO4
relay
(M2)
Buzzer
CN-
Battery
D14
relavH
,06 (xII)
i7,
Fualfil
sensor
E20
(SWP8)
PO7
(X2)
Batte
itcJfiCOOlant
Alternator
(IDWuessard
temperature
wsens
TJP02228
20-602
0
PC1 28UU-2
M-l,
TROUBLESHOOTING
M-l
*
*
*
After starting switch is turned to ON:position,
M-2
nothing is displayed

check fuse 2.
VFS
PO1 (female) (1)

and (3) normal?
.20-30V
* Turn starting
switch ON.
harness between PO1
(female) (1) -fuse or
between PO1 (female) (3) chassis ground
2 YES
NO
Is fuse 2 normal?
Broken fuse 2
NO
M-l
Replace
Repair or replace
harness
Remove cause 01
breakage of fuse,
then replace fuse

Fusible
Monitor
link
Panel
~,po1),
Power
source
(+24V)
TJP02229
M-2
*
*
After starting switch is turned to ON position, self-check items (which

should light up for 3 set) are turned on but not turned off

check that all the related connectors are properly
PC1 28UU-2
inserted.
Replace
20-603
0
M-3
TROUBLESHOOTING
M-3
After starting switch is turned to ON position, some of self-check

items (which should light up for 3 set) are not turned .on

9~ Always connect any disconnected connectors before going on to the next step.
a)
No gauges (Fuel, engine coolant temperature)

Pre-heating pilot lamp does not light up
are turned on
Remedy
Cause
b)
Caution lamps (Engine oil pressure, charge) do not light up
Cause
IIs bulb broken?
YES
Broken bulb
II_
- Visually check bulb

for breakage.
c)
Replace
Remedy
Replace
Go to M-4.
NO
Electric system caution lamp does not light up

Cause
YES
Remedy
Ebroken bulb
Replace
IIefective monitor panel
Replace
Is bulb of items
which is not turned on broken?
. Visually check bulb
for breakage.
NO
20-604
0
PC 128UU-2
M-4
TROUBLESHOOTING
M-4
Ir
-k

started), charge caution lamp does not light up
(before engine is
:

check that all the related connectors tire properly inserted.
Cause
YES
1
Is voltage between
PO1 (female) (IO)
2 YES
and (3) normal?

* Start engine.
* 27.5 - 29.5 v
Is voltage between
alternator terminal
R and chassis
ground normal?
~0
Remedy
eplace
harness between PO1
(female) (10) -alternator
terminal R
tepair or replace
larness
Defective alternator
* Start engine.
* 27.5 - 29.5 V
M-4
Monitor
Panel
Alternator
PO1 (04016)
Battery
charge
TJP02230
PC1 28UU-2
20-605
0
M-5
TROUBLESHOOTING
M-5
*
*
After starting switch is turned to ON position (before engine is

started), engine oil pressure caution lamp does not light up

are properly
Cause
* Max. 0.5R
* Disconnect (+I
terminal of sensor
617).
OFF.
M-5
YES
* Disconnect POl.
OFF.
NO
inserted.
Remedy
Replace
harness between PO1
(female) (9) - S17 (Harness
side)
Repair or replace
harness
Defective engine oil

pressure switch
Replace
Monitor
Panel
I
PO1 (04016)
CbJ-2
(SWP12)
E20
(SWP8)
Engine oil
Pressure switch
TJP02231
20-606
0
PC1 28UU-2
TROUBLESHOOTING
M-6
f
*
M-6
After starting switch is turned HEAT position, pre-heating pilot lamp

does not light up

Cause
YES
I
Is voltage between
PO1 (13) and (3)
normal?

to HEAT position.
*20-30V
M-6
Related
Monitor
NO
electric
circuit
Remedy
Replace-
Breakage of harness
between PO1 (female) (13) starting switch terminal Rl
or defective starting switch
Rep&r. or replace
diagram
Panel
I
PO1 (04016)
Start
ina
switch
TJ PO2232
PC1 28UU-2
20-607
0
M-7
TROUBLESHOOTING
M-7
f
*
*
Engine oil pressure caution lamp lights up while engine is running

When the engine oil pressure
is normal.
Cause
YES
1
Does engine oil
pressure caution
lamp go off?
p
* Disconnect S17.
* Start engine.
2 YES
*
Defective engine oil

pressure switch
Replace
Replace
Is PO1 (female) (9)

_ insulated from
NO chassis ground?
, ground in harness between
NO
Repair or replace
harness
PO1 (female) (9) - S17
*Min. 1 MQ
* Disconnect PO1 and S17.
M-7
Remedy
Monitor
Panel
PO1 (04016)
w-2
(SWP12)
E20
(SWP8)
Eneine
oil
Pressure
switch
@cl-
TJP02231
20-608
0
PC128UU-2
M-8
TROUBLESHOOTING
M-8
*
*
*
Charge caution lamp lights up while engine is running

are properly
connectors
When the battery is charged normally.
Remedy
Cause
2 YES
II
. Defective monitor panel

ground in harness between
PO1 (female) (IO) - alternator
terminal R
Insufficient generation by
alternator
* Start engine.
I
- Measure voltage
NO
between alternator
terminal R and chassis
ground.
-27.5 - 29.5 V
M-8
inserted.
Replace
Repair or replace
Replace
Monitor
Panel
I
PO1 (04016)
w-2
(SWP12)
-yj
Alternator
El7 (X2)
3
-o
--oR
0
TJP02230
PC1 28UU-2
20-609
0
M-9
TROUBLESHOOTING
M-9
*
Abnormality
in engine coolant temperature
gauge
*
*

When the engine coolant temperature is normal.
a)
Even if engine is operated for long time, coolant temperature
level does not rise at all

Remedy
Cause
YES
Does level rise 1 by

1, then go off?
2 YES
- Turn starting switch _ Does level rise 1 by

NO 1, then go off?
ON.
*Connect shorting
I
connector to P07.
* Short PO1 (6) with (3)F10
* See Note 1).
See Note 1).
ON.
l
b)
Defective engine coolant

temperature sensor
Replace
harness between PO1
(female) (6) - P7 (female) (1)
or between P2 (female) (2) chassis ground
qepair or replace
larness
Replace
Note 1) If normal, level rises 1 by

1 at interval of 2 sec.
Level rises soon after engine is started (to red range while engine is not overheated)
Remedy
Cause
2
YE
1
PO1 (3) and chassis
YES
. Start engine.
* Min. 4 kA2
Disconnect P07.
Defective engine coolant

temperature sensor
NO
Start engine.
*Max. 0.1 V
harness between PO1
(female) (3) -chassis ground
M-9
Replace
Is resistance
between PO7
(male) (1) and (2)
normal?
NO
Repair or replace
harness
clq-2 (SWPl2)
3
lonitor
panel
PO1 (04016)
_
Cbj-1 (SWP16)
3
E20
(SWP8)
PO7
(x2)
-----a
-3
Coolant
temperature
I
TJP02235
20-6 10
0
PC128UU-2
M-10
TROUBLESHOOTING
M-10 Abnormality
in fuel gauge
*
*
*

When the fuel level is normal.
a)
All segments
of fuel gauge go off

Cause
2 YES
12
Does fuel gauge
indicate full (Do all _
segments light
up)?
. Short PO1 (7) with

NO
(3).
*Wait for about 1 min.
-Turn starting switch ON.
* Short PO6 (female)

(1) with chassis
NO
ground.
Wait for about 1 min.
ON.
Remedy
Defective fuel level sensor

(Internal wire breakage)
7eolace
harness between PO1
(female) (7) - PO6 (female)
(1) or between (4 terminal
of fuel level sensor - chassi:
ground
lepair or replace
iarness
leolace
b)
Fuel gauge indicates full while fuel level is lowered
Cause
3 YES
Remedy
Replace

between PO1 (female) (7) PO6 (female) (1)
Repair or replace
harness
Defective fuel level sensor
Replace
harness between PO1
(female) (3) - chassis grounc
Repair or replace
harness
YES
2-r
YE
level sensor
normal?
etr
*Disconnect P06.
NO
Wait for about 1 min.
ON.
l
l
Is voltage between
PO1 (3) and chassis
* Start engine.
* Max. 0.1 V
PC128UU-2
. Remove
sensor.
* Move float with
hand and measure NO
resistance between PO6
(male) (1) and chassis
* %%~04; F. Max 1OR
* Position El Min.85R
* Disconnect PO6
20-611
0
M-10
TROUBLESHOOTING
c)
Fuel gauge does not indicate full even if fuel tank is full.
2 YES
YES
1
Is resistance
level sensor
normal?
of fuel
_
Is voltage between
PO1 (3) and chassis
ground normal?
p
* Start engine.
- Max. 0.1 V
Defective
monitor
panel
Replace
NO
* Remove sensor.
*rny;z;;;r;ith
handNO
disconnection
in wiring
harness between PO1
(female) (3) -chassis ground
Repair or replace
harness
Defective
Replace
fuel level sensor
resistance between
PO6 (male) (1) and
chassis ground.
* Position F: Max. 10R
* Disconnect P06.
M-10
Monitor
Panel
PO 1 (040 16)
CN-2
Fuel
level
sensor
TJP02236
20-612
0
PC1 28UU-2
M-l 1
TROUBLESHOOTING
M-II
*
Malfunction
of alarm buzzer

a)
Buzzer does not sound
Cause
Remedv
Replace
harness between PO4
(female) (1) - PO1 (female)
(15) or defective buzzer
NO
*20-30V
ON.

ON.
_...
b)
relay terminal M - PO4
(female) (2) or breakage of
fuse 5
Repair or replace
harness
Repair or replace !I
I
Buzzer does not stop sounding

Cause
YES
I
If PO1 is
disconnected, does buzzer stop?
NO
* Disconnect POl.
ON.
Remedy
Replace

between PO1 (female)
(15) PO4 (female)
(1)
Repair or replace
harness
M-l 1 Related electric circuit diagram
Fusible
Monitor
link
Panel
Buzzer
I
PO1 (04016)
output
GND
CN-2 (SWP12)
Battery
II
IIII
-11
I@
TJP02237
PC128UU-2
20-613
0
M-12
TROUBLESHOOTING
M-12 Service meter does not operate while engine is running

*
*

a)
When charge level caution lamp does not light up
I
Is voltage between
PO1 (female) (10)
and (3) normal?
* Start engine.
*20-30V
b)
YES
b2. Short circuit with

chassis ground in wiring
harness between PO1
(female) (10) - El7 (female)
(2)
NO
When charge level caution lamp lights up
Cause
Repair or replace
harness
Remedy
Replace

between PO1 (female) (10) alternator terminal R
Repair or replace
Insufficient generation
alternator
-
*-----I
Start engine.
. Measure voltage
NO
between alternator
terminal R and chassis
ground.
- 27.6 - 29.5 V
M-12
Replace
by
Replace
Monitor
Panel
PO1 (04016)
ck2
csWP12)
Alternator
El7 (X2)
---la I1
a3
0
TJP02238
20-614
0
PC1 28UU-2
M-13
TROUBLESHOOTING
M-13 Lamps do not light up at night

*
*

a)
Lamp for gauges does not light up

I.-. Remedy -.
Cause
Breakage of bulb for lighting

at night (inside monitor
panel)
YES
1
Is voltage between
PO1 (female) (16)
and (3) normal?
harness between PO1
[female) (16) - R03 (female)
15)
YES
lf relay R03 is
replaced with
*Disconnect POl.
_ another one of same *Turn starting
NO type, does lamp
switch ON.
light up normally?
*Turn light switch ON.
*Turn
starting switch NO
-2O-30V
ON.
. Turn light switch ON.
.20-30V
b)
Defective relay R03 for light
Replace
I
Repair or replace
hamess
Replace
Lamp for service meter does not light up

Remedy
Cause
M-13
Light
relay
Battery
R03 (R6)
Monitor
Panel
PO1 (04016)
FB1
d&T11
Battery
relay
Fuse
TJP92239
PC128UU-2
20-615
M-14
TROUBLESHOOTING
M-14 Electric system caution lamp keeps lighting up

:(Controller displays no abnormality
*
*
and operation is normal)

are properly
connectors before going on to the next step.
Cause
YES
1
Is voltage between
PO1 (11) and (3)
normal?
-
* Max. 1 V
* Turn starting
switch ON.
2 YES
)
If CO3 (female) (11)
is connected to
chassisground,
does caution lamp
go off?
NO

ON.
M-14
NO
inserted.
Remedy
Replace
Replace
harness between PO1
(female) (11) - CO3 (female)
(14)
Repair or replace
harness
Monitor
Controller
Panel
PO1 (04Oi6)
CO3 (04016)
TJP02238
20-6 16
0
PC1 28UU-2
M-15
TROUBLESHOOTING
M-15 Heater does not work

*
*

connectors
a)
Heater does not work in either position of Lo and Hi
See troubleshooting
heater.
+ Disconnect M06.
* Au,r,: starting switch N,
b)
of
harness between MO6
(female) (4) - chassis grc
Repair or replace
Defective heater switch
Replace
Heater does not work in only Lo position

Remedy
Cause
2 YES
Is there continuity
in harness
between Ml2
(female) (2) and
chassis ground?
Yf
1
NO
- Disconnect M12.
* Set heater switch to Lo
position.
- PFp starting switch
between MO6
(male) (3) and (4)?
- Disconnect M06.
See troubleshooting
heater.
of
harness between MO6
(female) (3) - Ml2 (female)
(2)
Iepair or replace
ieplace

OFF.
c)
Heater does not work in only Hi position
I
YES
1 Is there continuity
between MO6
(male) (2) and (4)?
See troubleshooting
Is there continuity
in harness
between Ml2
(female) (3) and
chassis ground?
NO
*Disconnect M12.
* Set heater switch to Hi
position.
* Disconnect M06.
- Set heater switch to
NO
Hi position.
OFF.
PC1 28UU-2
Remedy
of
b2. Defective contact or

harness between MO6
(female) (3) - Ml2 (female)
(2)
Repair or replace
Replace
20-6 17
0
M-15
TROUBLESHOOTING
M-15
switch
Heater
OFF LOW
1
_
HI
M~~(KES~
h112 (KES~ 3)
4)
Fuse
HYE__switch
I
I
--!
1
r%
TJP02241
20-618
0
PC128UU-2
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts ............................................................................................. 20-702

S- 1 Starting performance is poor (Starting always takes time) ...................................................... 20-706
S- 2 Engine does not start ................................................................................................................... 20-708
(1) Engine does not turn ............................................................................................................. 20-708
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .................... 20-709
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ................. 20-710
S- 3 Engine does not pick-up smoothly (Follow-up is poor) ............................................................ 20-711
S- 4 Engine stops during operations .................................................................................................. 20-712
S- 5 Engine does not rotate smoothly (Hunting) ............................................................................... 20-713
S- 6 Engine lacks output (or lacks power) .......................................................................................... 20-714
S- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-715
S- 8 Oil consumption is excessive (or exhaust gas is blue).............................................................. 20-716
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-717
S-10 Fuel consumption is excessive .................................................................................................... 20-718
S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-719
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ....................................................... 20-720
S-13 Oil level rises (Water, fuel in oil) ................................................................................................. 20-721
S-14 Water temperature becomes too high (Overheating) ............................................................... 20-722
S-15 Abnormal noise is made .............................................................................................................. 20-723
S-16 Vibration is excessive ................................................................................................................... 20-724
PC128UU-2
20-701
(6)
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items
that can be obtained from the user, depending
on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
Causes
Questions
(b) (2) (3)
(a)
w
w
(b)
w
(c)
(d)
c
c
Troubleshooting
Check items
(e)
20-702
(6)
i
ii
iii
b
b
b
PC128UU-2
inje
ctio
n)
Causes
Seiz
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with !, and of these, causes that have a high probability are marked with T.
Check each of the [Questions] and [Check items] in
turn, and marked the ! or T in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with # to use as reference
for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes.
2. Use the # in the Cause column as reference
for [Degree of use (Operated for long period)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
ed t
urbo
cha
Clog
rger
ged
, int
air c
erfe
lean
Wor
renc
er e
n pi
e
lem
ston
e
n
ring
Clog
t
, cyl
ged
inde
, sei
r
zed
Imp
inje
rope
ctio
r inj
n no
e
ctio
Defe
zzle
n tim
ctiv
e in
ing
ject
ion
pum
p (e
xces
sive
TROUBLESHOOTING
Confirm recent repair history
Degree of use
Operatred for long period
PC128UU-2
20-703
(6)
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel
Causes
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Seiz
ed t
Clog urboch
arge
ged
r, in
air
Wor
terfe
n pis cleaner
elem rence
ton
Clog
ring
ent
ged
, cyli
, se
nde
Imp
r
rope ized inje
r
c
tion
inje
Defe
ctio
ctiv
n tim nozzle
e
in
ing
Imp
rope jection
pum
r va
Cru
lve
p (e
she
c
xces
le
d, c
aran
sive
logg
Lea
ce
inje
kag
e
d
ctio
muf
e of
n)
fler
Defe
air b
ctiv
etw
e
e
e
con
n tu
Deff
t
a
r
ectiv
boc
ct o
harg
f va
e in
lve,
er a
ject
valv
ion
nd h
e se
pum
ead
at
p (ra
ck, p
lung
er s
eize
d)

Degree of use
Operated for long period
Questions
Suddenly became black

Color of exhaust gas
Gradually became black

Blue under light load
Engine oil must be added more frequently

Power was lost
Suddenly
Gradually
Non-specified fuel has been used

Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low

Speed of some cylinders does not change when operating
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
20-704
(6)
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does

not return
PC128UU-2
TROUBLESHOOTING
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
PC128UU-2
20-705
(6)
TROUBLESHOOTING
S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but
engine takes time to start
Defective electrical system
Insufficient supply of fuel
Improper selection of fuel
(At ambient temperature of -10C or below,
ASTM D975 No. 2 diesel fuel is used)
Causes
n pi
ston
Defe
ring
, cyl
ctive
inde
cont
Clog
r
act o
ged
f val
a
i
r
ve, v
clea
Clog
ner
ged
elem alve sea
fuel
t
Clog
ent
filte
ged
r, st
rain
feed
e
Elec
r
p
ump
trica
gau
l int
ze fi
ake
lter
air h
eate
r
fl Battery charging rate

Ambient
temperature
Charging rate
20C
0C
10C
90 %
80 %
75 %
70 %
1.28
1.29
1.30
1.26
1.27
1.28
1.24
1.25
1.26
1.23
1.24
1.25
1.22
1.23
1.24
The specific gravity should exceed the value for the

charging rate of 70% in the above table.
In cold areas the specific gravity must exceed the
value for the charging rate of 75% in the above table.
Wor
100 %
Questions

Degree of use of machine
Operated for long period
Ease of starting
Gradually became worse

Starts when warm
Indicator lamp does not light up

Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Check items
Engine does not pick up smoothly, and combustion is irregular

Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When air cleaner element is inspected directly, it is found to be clogged
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Heater mount does not become warm
Is voltage 2630V between alternator terminal B and terminal E
with engine at low idling?
Yes
No
Either specific gravity of electrolyte or voltage of battery is low

Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
20-706
(6)
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
Use a test stand
PC128UU-2
PC128UU-2
Replace
Replace
Clean
Correct
Replace
Adjust
Replace
Replace
Replace
Replace
Defe
ctive
regu
Defe
lato
ctive
r
a
ltern
Defe
ator
ctive
or d
Defe
eter
ctive
iora
ted
injec
Defe
batt
tion
tive
ery
nozz
injec
le
Defe
tion
tive
timi
injec
ng
Leak
tion
age,
p
ump
clog
(rac
Clog
ging
k, pl
ged
, air
ung
a
i
i
n
r
er st
brea
fuel
Defe
uck)
ther
pipi
ctive
ng
h
o
f
e
l
e in
ed p
Defe
fuel
ump
ctive
tank
boo
st co
mpe
nsat
or c
ance
l
TROUBLESHOOTING
S-1
Causes
20-707
(6)
TROUBLESHOOTING
S-2
S-2 Engine does not start

(1) Engine does not turn
Causes
General causes why engine does not turn
fl If internal parts of the engine are seized, carry

out troubleshooting for "Engine stops during
operations".
Defective electrical system
Failure in power train

Degree of use of machine Operated for long period
Condition of horn when
Horn sounds
starting switch is turned
Horn volume is low
ON
Speed of rotation is low
When starting switch is
Makes grating noise
turned to START, pinion
Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
move out
When starting switch is turned to ON, there is no clicking
sound
20-708
(6)
Replace
Replace
Remedy
Replace
For the following conditions 1) - 5), turn the starting switch

OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are
3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and
terminal E
When ring gear is inspected directly, tooth surface is found to
be chipped
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Troubleshooting
Specific gravity of electrolyte, voltage of battery is low
Replace
When battery is checked, battery electrolyte is found to be low
Replace
When starting switch is turned ON, linkage is not actuated
Replace
Battery terminal is loose
Replace
Check items
Questions
Defe
ctiv
ew
iring
Defe
ctiv
of s
e or
tarti
Defe
dete
ng c
ctiv
rior
ircu
e st
ated
it
artin
Bro
batt
ken
gm
ery
r
o
i
n
t
or
g ge
Defe
ar
ctiv
e sa
fety
Defe
rela
ctiv
y or
e ba
Defe
ttery
safe
ctiv
ty s
r
e
lay
e ba
witc
Defe
ttery
h
ctiv
t
e
rmin
e fu
el cu
al co
Defe
t so
nne
ctiv
leno
e st
ctio
artin
n
id
g sw
itch
Internal parts of engine seized
Troubleshooting of defective wiring in starting circuit
PC128UU-2
TROUBLESHOOTING
S-2
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust smoke
comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Standards for use of fuel

AMBIENT TEMPRATURE
KIND
OF FLUID
-4
-20
14
-10
32
0
50
10
68F
20C
ASTM D975 No.2
Diesel fuel
Bro
ASTM D975 No.1
ken
inje
ctio
Defe
n pu
ctiv
mp
e in
driv
ject
Seiz
ion
e sh
ed,
pum
aft,
brok
key
p (ra
en f
Clog
ck, p
eed
ged
p
lung
fuel
ump
Clog
er s
filte
pist
ged
eize
r, st
on
d)
feed
rain
Insu
e
p
r
u
ffici
mp
ent
stra
fuel
Clog
iner
in ta
ged
, lea
nk
Clog
king
ged
fuel
air b
pipi
Defe
reat
ng
ctiv
her
e
hole
fuel
Imp
in fu
cut
rope
sole
el ta
r fue
noid
nk
l us
ed
Causes
Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Check items
When starting switch is turned ON, linkage is not actuated

When fuel filter is drained, fuel does not come out
1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Troubleshooting
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
PC128UU-2
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
Cannot be moved by hand even when linkage of fuel cut

solenoid is disconnected
20-709
(6)
TROUBLESHOOTING
S-2
General causes why exhaust smoke comes out but

engine not start
Lack of rotating force due to defective electrical system

Improper selection of fuel and oil
Defe
Causes
ctive
, bro
Defe
ken
valv
ctiv
e sys
e in
ject
tem
Wor
ion
(valv
n pi
pum
e, ro
ston
p (ra
cker
Clog
ring
leve
ck, p
ged
, cyl
r, etc
lung
inde
fuel
Clog
.)
e
r
f
r
i
l
l
stuc
i
t
ner
ged
er, s
k)
f
t
e
r
a
e
iner
d pu
Clog
mp
ged
stra
air c
Defe
iner
l
e
ane
ctiv
r ele
e el
men
ectr
Defe
ical
t
ctiv
inta
e or
ke a
Lea
dete
i
kag
r he
rior
e, cl
ater
ated
ogg
Clog
b
a
i
n
ttery
ged
g, a
ir in
inje
Clog
ctio
fuel
n no
ged
syst
zzle
a
em
i
r br
Imp
,
defe
eath
rope
ctiv
er h
r fue
e
ole
spra
l us
in fu
y
ed
el ta
nk c
ap
(3) Exhaust smoke comes out but

engine does not start (Fuel is
being injected)

Questions
Suddenly failed to start

When engine is cranked, abnormal noise is heard from
around cylinder head
Non-specified fuel is being used
Operation Manual
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items

1) Little fuel comes out even when injection pump piping
sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
Troubleshooting
When exhaust manifold is touched immediately after starting

engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly
When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
20-710
(6)
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
PC128UU-2
TROUBLESHOOTING
S-3
S-3 Engine does not pick-up smoothly

(Follow-up is poor)
Causes
General causes why engine does not pick up smoothly

Improper condition of fuel injction
Improper fuel used
Clog
ged
air c
Clog
lean
ged
er e
lem
f
uel
Clog
ent
filte
ged
r, st
feed
rain
Clog
er
pum
ged
p st
inje
rain
Seiz
ctio
er
ed i
n no
njec
zzle
tion
, de
Wor
fect
pum
n pi
ive
p pl
ston
spra
Seiz
ung
ring
y
er
ed t
,
cylin
urbo
d
Imp
e
c
harg
r lin
rope
er
er, i
r va
nter
Clog
lve
fere
clea
ged
nce
ranc
air b
e
Clog
reat
her
ged
hole
, lea
Defe
king
in fu
ctiv
fuel
el ta
e co
nk c
pipi
ntac
ng
ap
t of
valv
e an
d va
lve
seat
Questions

Operation Manual
Engine pick-up suddenly became poor

Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
Troubleshooting

When air cleaner element is inspected directly, it is found to
be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
PC128UU-2
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
20-711
(6)
S-4
TROUBLESHOOTING
S-4 Engine stops during operations

General causes why engine stops during operations
Seized parts inside engine
Overheating
Causes
ken
, sei
zed
Bro
pist
ken
on,
, sei
co n
zed
Brok
nec
cran
en d
ting
ksha
ynam
ro d
ft be
Bro
i
c va
ken
a
ring
lve s
, sei
ys te
Bro
zed
m (
ken
gea
valv
pum
r tra
e, ro
in
p au
Bro
c k er
ken
x
leve
i
l
i
ary
fuel
r, et
equ
Insu
pum
c.)
ipm
ffici
p
driv
ent
ent
e sh
fuel
Clog
aft,
in ta
ged
key
nk
fuel
Clog
filte
ged
r, st
rain
feed
Bro
er
pum
ken
p st
, sei
rain
z
Clog
ed f
er
eed
ged
, lea
pum
king
Clog
p pi
ston
fuel
ged
pipi
air b
Defe
ng
r
e
a
ther
ctiv
e in
hole
ject
Fail
in fu
ion
ure
el ta
pum
in p
nk
owe
p (r a
r tra
c
k
,
in
plun
ger
stuc
k)
fl If there is overheating and the engine stops,

carry out troubleshooting for overheating.
Failure in power train
Bro
fl If the engine stops because of a failure in

the power train, carry out troubleshooting
for the chassis.
Questions

Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Engine stopped slowly
There was hunting and engine stopped
Replacement of filters has not been carried out according
to Operation Manual
Fuel level lamp lights up
Check items

Engine rotates, but stops when power train is operated
Does not turn at all
When it is attempted to
turn by hand using
barring tool
Turns in opposite direction

Moves amount of backlash
Shaft does not turn
Troubleshooting of chassis

Metal particles are found when oil is drained
Remove oil pan and inspect directly
Troubleshooting
Remove head cover and inspect directly

When gear train is inspected, it does not turn
Rotates when pump auxiliary equipment is removed
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
20-712
(6)
Replace
Clean
Correct
Replace
Replace
Clean
Clean
Add
Replace
Replace
Replace
Replace
Remedy
Replace

does not return
PC128UU-2
S-5
TROUBLESHOOTING
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly
Air in fuel system
Defective governor mechanism
Defective electric governor mechanism
(engine with electric governor)
Causes
Defe
ctiv
e op
Defe
erat
ctiv
ion
e ad
of g
Defe
ove
just
rn o r
men
ctiv
e op
t of
gov
Low
erat
erno
ion
idlin
of c
r
g sp
Insu
ontr
eed
ffici
o
l rac
is to
ent
k
o
fuel
Clog
in ta low
ged
nk
feed
Clog
pum
ged
p st
fuel
rain
Clog
f
ilter
er
ged,
,
stra
air in
iner
Clog
c
i
rcuit
ged,
betw
air in
een
Clog
circu
fuel
ged
it be
tank
air b
t
w
and
een
reat
feed
feed
her
pum
pum
hole
p
p an
in fu
d no
el ta
zzle
nk
fl If hunting stops when electric governor rod is

disconnected, carry out troubleshooting for the
chassis.
Questions

Occurs at a certain speed range
Condition of hunting
Occurs at low idling

Occurs even when speed is raised
Occurs on slopes

to Operation Manual
Rust, water are found when fuel tank is drained
Check items

When feed pump is operated,
1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Troubleshooting
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
PC128UU-2
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust

found to be clogged
20-713
(6)
TROUBLESHOOTING
S-6
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output
Clog
fl If there is overheating and lack of output,

carry out troubleshooting for overheating.
Seiz

Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overtaking
ged
air c
lean
ed t
er e
urbo
lem
Wor
cha
ent
rger
n pi
, int
ston
erfe
Clog
ring
renc
ged
, cyl
e
inde
fuel
Clog
r
filte
ged
r
,
s
f
t
e
r
a
ed p
Clog
ump iner
ged
stra
inje
Seiz
iner
c
tion
ed i
noz
njec
zle,
Imp
tion
defe
rope
pum
ctiv
r va
p pl
e sp
Defe
lve
u
ray
nge
clea
ctiv
r
ranc
e co
e
ntac
Ben
t fue
t of
valv
l lev
Clog
e an
er li
ged
nka
d va
ge,
, lea
lve
d
k
seat
Clog
efec
ing
fuel
tive
ged
adju
pipi
a
i
r
brea
Defe
ng
stm
ther
ent
ctiv
e bo
hole
Defe
o
s
in fu
t co
ctiv
el ta
mpe
ew
estg
nk
nsa
t
ate
diap or diap
hrag
hrag
m
m
Causes

Questions
Power was lost
Suddenly
Gradually

to Operation Manual
Black

Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
High idling speed of engine is low
When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

found to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
20-714
(6)
Replace
Replace
Clean
Correct
Adjust
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
PC128UU-2
S-7
TROUBLESHOOTING
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black
Causes
Seiz
ed t
urbo
Clog
cha
rger
ged
, int
air c
Wor
erfe
lean
renc
n pi
er e
ston
e
lem
Clog
ent
ring
ged
, cyl
i
i
nde
njec
Imp
r
tion
rope
noz
r inj
zle,
Defe
ecti
o
ctiv
n tim defecti
e in
ve s
ing
Imp
ject
pray
i
rope
on p
r
u
v
m
a
Cru
p
l
v
(
e
e
she
xces
clea
d, c
ranc
sive
logg
Lea
e
inje
ed m
kag
ctio
e of
u
n)
f
fler
air b
Defe
e
ctiv
twe
e
en t
con
Defe
urbo
tact
ctiv
cha
of v
e in
rger
alve
ject
and
and
ion
hea
pum
valv
d
e se
p (ra
at
ck, p
lung
er s
eize
d)

Questions
Suddenly became black

Gradually became black


Power was lost
Suddenly
Gradually

Check items

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Timing lock on fuel injection pump does not match
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
PC128UU-2
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace

does not return
20-715
(6)
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
General causes why oil consumption is excessive

Abnormal combustion of oil
External leakage of oil
Wear of lubrication system
Bro
Causes
ken
pist
on r
Wor
ing
n pi
ston
Clog
ring
ged
, cyl
inde
brea
Lea
r (lin
ther
kag
er le
or b
e fro
ss e
reat
Lea
mo
ngin
her
kag
il fil
h
e)
e fro
ose
ter o
mo
Lea
r
o
i l co
il pi
kag
ping
e fro
oler
mo
Lea
kag
il dr
e fro
ain
plug
mo
Bro
ken
il pa
oil c
n or
oole
Wor
cylin
r
n se
der
al a
hea
t tur
Wor
d
bine
n se
a
e
l
n
at b
d
Wor
low
n, b
er e
roke
nd
n re
Dus
Turb
ar s
t su
eal,
cked
och
seal
arge
Wor
in fr
surf
r
n va
om
ace
inta
lve
(ste
ke s
m, g
yste
uide
m
), br
oke
n se
al
fl Do not run the engine at idling for more than 20

minutes continuously. (Both low and high idling)

Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Amount of blow-by gas
Excessive
None
Area around engine is dirty with oil

Check items
There is oil in engine cooling water

When exhaust pipe is removed, inside is found to be dirty with oil
When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose
Troubleshooting

When breather element is inspected, it is found to be
clogged with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
20-716
(6)
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be

dirty with oil
PC128UU-2
S-9
TROUBLESHOOTING
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
Improper oil used
Operation under excessive load
Causes
Wor
n pi
ston
Clog
ring
, cyl
ged
inde
brea
Clog
r lin
ther
ged
er
, bre
o
athe
i
l filt
Wor
r ho
er
n va
se
lve,
Clog
valv
ged
e gu
oil c
ide
Clog
oole
ged
r
turb
Defe
och
ctiv
arge
e se
r oil
Exh
al a
drai
aus
t tur
n tu
t sm
boc
be
harg
oke
is b
e
r
turb
lack
ine
end
Questions

Non-specified oil is being used

Black
Carry out troubleshooting for Exhaust smoke is black.
Check items
Excessive
Amount of blow-by gas
None
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly
When breather element is inspected directly, hose is

broken or is found to be clogged with dirty oil
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger oil drain tube is clogged
PC128UU-2
Replace
Clean
Clean
Replace
Replace
Remedy
Clean
Excessive play of turbocharger shaft

When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Troubleshooting
20-717
(6)
S-10
TROUBLESHOOTING
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Leakage of fuel
Defe
ctive
injec
tion
Defe
pum
ctive
p (ex
nozz
Defe
cess
le ho
ive i
ctive
lder
njec
spra
i
n
j
e
tion
Defe
ction
y
)
ctive
pum
fuel
p plu
Exte
injec
n
ger
rnal
tion
leak
timi
age
ng
Leak
from
age
fuel
of fu
pipin
el in
Defe
side
g, fu
ctive
el fil
h
oil s
ead
ter
Defe
e
c
a
o
l
v
insid
ctive
er
e fee
adju
d pu
stme
mp
nt o
(pist
f fue
on)
l con
trol
linka
ge
Causes
Questions

Condition of fuel
consumption
More than for other machines of same

model
Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
Check items
There is irregular combustion

When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive
Troubleshooting

When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found
to be incorrect
Remove feed pump and inspect directly
20-718
(6)
Adjust
Correct
Correct
Correct
Adjust
Replace
Replace
Remedy
Adjust
When engine speed is measured, low idling and high idling speeds
are found to be high
PC128UU-2
S-11
TROUBLESHOOTING
S-11 Oil is in cooling water, or water

spurts back, or water level goes
down
Causes
General causes why oil is in cooling water

Internal leakage in lubrication system
Internal leakage in cooling system
Brok
en o
il co
oler
Brok
cor e
en c
, O-r
ylind
ing
er h
Brok
e
en p
ad, h
owe
e
a
d
r tra
Hole
gask
in oi
s ca
et
l coo
used
ler
by p
Inter
ittin
nal c
g
rack
s in
cylin
der
bloc
k
Questions

Oil level
Suddenly increased
Gradually increased
Hard water is being used as cooling water
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
Pressure-tightness test of cylinder head shows there is leakage
PC128UU-2
Replace
Replace
Replace
Remedy
Replace
Replace
Troubleshooting
Check items
Engine oil level has risen, oil is cloudy white
20-719
(6)
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights

up (Drop in oil pressure)
General causes why oil pressure lamp lights up
Leakage, clogging, wear of lubricating system

Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating
fl Standards for engine oil selection
Type of oil
Selection of SAE No. according to

ambient temperature
30 20
10
10
20
30
Causes
40C
SAE10WCD
SAE10W-30CD
Clog
SAE15W-40CD
Wor
Engine oil
ged
oil f
ilter
n be
arin
Clog
g, jo
urna
ged
stra
l
Clog
iner
ged
insi
d
o
e oi
i
l pip
Bro
l pa
ken
e in
n
suct
side
ion
Defe
o
i
l
pipe
pan
ctiv
e oi
braz
Lack
l pu
ing
mp
of o
i
l in
Defe
oil p
ctiv
an
e re
gula
Defe
tor v
ctiv
e re
alve
lief
Lea
valv
king
e
, cru
Defe
she
d hy
ctiv
e oi
drau
l pre
Defe
lic p
ssur
ctiv
ipin
e oi
e se
g
l
n
leve
sor
Wat
l sen
er, f
sor
uel
in o
il
SAE30CD
Questions

Operation Manual
Caution lamp lights up
Lights up at low idling
Condition when oil
pressure lamp lights up
Lights up at low, high idling

Lights up on slopes
Check items
Sometimes lights up
There is crushing, leakage from hydraulic piping (external)
Oil level sensor lamp lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are stuck to oil filter element
Carry out troubleshooting

for Oil level rises.
Oil is cloudy white or smells of diesel oil

Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
20-720
(6)
Replace
Replace
Correct
Adjust
Adjust
Add
Replace
Correct
Clean
Clean
Remedy
Clean
When oil pressure is measured, it is found to be within

standard value
Clean
Troubleshooting
When oil filter is inspected, it is found to be clogged
PC128UU-2
S-13
TROUBLESHOOTING
S-13 Oil level rises (Water, fuel in oil)

fl If there is oil in the cooling water, carry out troubleshooting for Oil is in cooling water.
Water in oil (milky white)

Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component
Bro
ken
oil c
oole
Defe
r co
ctiv
re, O
e no
Bro
-ring
zzle
ken
hold
cylin
er s
Wor
der
leev
n, d
hea
e
ama
d, h
ead
Defe
ged
gas
rear
ctiv
ket
e pu
seal
Lea
mp
surf
kag
aux
ace
e of
i
l
iary
fuel
Defe
equ
from
ctiv
ipm
e pa
pipi
ent
Defe
rt in
n
seal
g in
ctiv
s
i
d
side
e
e th
i
n
hea
j
erm
ecti
Hole
d co
on p
osta
sm
ver
ump
t
ade
Crac
by p
ks in
ittin
g
side
cylin
der
bloc
k
General causes why oil level rises
Causes
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
Check items
Exhaust smoke is white

When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Oil level goes down in clutch, TORQFLOW transmission,
or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
PC128UU-2
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Remedy
Replace
Remove oil pan and check directly
20-721
(6)
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes too
high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature in power train
fl Carry out troubleshooting for chassis.
Bro
ken
wat
er p
Clog
ump
ged
, cru
Clog
she
d ra
ged
diat
radi
or fi
Defe
ator
ns
ctiv
core
e
ther
Defe
mos
ctiv
tat (
ew
doe
ater
Lack
s no
tem
of c
t op
pera
ooli
en)
Fan
ture
n
g
w
belt
g
a
aug
t
e
s
r
l
e
i
p
Clog
ping
ged
, wo
, bro
rn fa
Defe
ken
n pu
ctiv
oil c
lley
e pr
oole
essu
Bro
r
ken
r
e va
cylin
lve
Hole
der
sm
h
ead
ade
,
hea
Rise
by p
d ga
ittin
in to
sket
g
rque
con
vert
er o
il te
mpe
ratu
re
Causes

Questions

Condition of overheating
Suddenly overheated
Always tends to overheat
Water temperature
gauge
Rises quickly
Does not go down from red range
Radiator water level sensor lights up

Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Check items
Excessive air bubbles inside radiator, water spurts back

Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator tanks

is excessive
Temperature difference between top and bottom radiator tanks
is slight
When water filler port is inspected, core is found to be clogged
When function test is carried out on thermostat, it does not
open even at cracking temperature
Carry out troubleshooting for chassis.
Troubleshooting
Power train oil temperature enters red range faster than

engine water temperature
When water temperature is measured, it is found to be normal

When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
20-722
(6)
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
PC128UU-2
S-15
TROUBLESHOOTING
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an external
noise.
Abnormality due to defective parts

Abnormal combustion
Air sucked in from intake system
Exce
ssive
wea
Seiz
r of
ed t
pisto
urbo
n rin
Mis
c
g, cy
harg
sing
linde
er, i
, sei
r (lin
n
t
e
z
Clog
rfer
ed b
er le
enc
ged
ss en
ush
e
,
i
n
gine
s
g
e
Defe
ized
)
ctiv
i
n
ject
e in
i
on n
ject
Defe
ion
ctiv
pum ozzle
e in
p (ra
Defo
ject
ion
ck, p
rme
pum
d fa
lung
Defe
p (e
n, fa
er s
x
ctiv
n be
cess
eize
e ad
d)
lt in
ive
Brok
just
i
t
n
e
ject
r
fere
men
en d
ion)
nce
ynam
t of
valv
Imp
ic va
rope
e cl e
lve s
r ge
aran
yste
Leak
a
m (v
ce
r
train
age
alve
of ai
b
,
ackl
rock
r bet
Defe
er le
ash
wee
ct in
ver,
n tu r
side
etc.)
b o ch
muf
arg e
fler (
r an d
divid
ing b
cylin
o ard
d er h
out o
ead
f pos
ition
)
General causes why abnormal noise is made
Causes
Questions

Condition of abnormal
noise
Gradually occurred
Suddenly occurred


Black
Metal particles are found in oil filter

Check items

Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler
Troubleshooting
Remove gear cover and inspect directly

Speed does not change when operation of certain cylinders is
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
PC128UU-2
Replace
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
When muffler is removed, abnormal noise disappears
20-723
(6)
S-16
TROUBLESHOOTING
S-16 Vibration is excessive
General causes why vibration is excessive
Defective parts (abnormal wear, breakage)

Improper alignment
Abnormal combustion
Causes
Wor
n co
nne
ctin
Wor
g ro
n ca
d, m
m
bus
Loo
ain
hing
bea
se e
ring
ngin
Bro
e
mou
ken
ntin
part
g bo
Cen
insi
lts,
de o
ter o
brok
utpu
f en
en c
Imp
gine
t
s
h
ush
rope
a
a
f
t
nd p
ion
(dam
r ge
owe
Defe
a
per)
r
train
r tra
ctive
i
n
d
b
y
ackl
mis
nam
Defe
alig
ic va
ash
ctiv
ned
lve s
e in
ystem
ject
(valv
ion
e, ro
pum
cker
p (e
lever
xces
, etc.
sive
stuck
fuel
)
inje
ctio
n)
fl If there is abnormal noise together with the vibration, carry out troubleshooting also for Abnormal noise is made.
Questions

Condition of vibration
Suddenly increased
Gradually increased

Metal particles are found in oil filter
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black
Troubleshooting
Remove side cover and inspect directly

Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
20-724
(6)
Adjust
Replace
Correct
Correct
Replace
Replace
Replace
Remedy
Replace
PC128UU-2
30
Method of using manual . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions when carrying out operation . . .
Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sketches of special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE, MAIN PUMP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR, HYDRAULIC OIL COOLER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER SWIVEL JOINT
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . .
SWING MOTOR, SWING MACHINERY
SWING MACHINERY
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REVOLVING FRAME
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWING CIRCLE
RECOIL SPRING
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDLER
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRACK ROLLER
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRACK SHOE
HYDRAULIC TANK
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN PUMP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC1 28UU-2
30- 3
30- 4
30- 6
30- 10
30- 13
30-14
30- 15
30-16
30-17
30-18
30- 19
30-20
30-21
30-24
30-28
30-29
30-30
30-31
30-32
30-33
30-34
30-36
30-38
30-40
30-41
30-42
30-43
30-44
MAIN CONTROL VALVE

Removal and Installation . . . . . . . . . . . . . . . . . . . .. . . . . .
CONTROL VALVE
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LS SELECT VALVE
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . .
MAIN RELIEF VALVE
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WORK EQUIPMENT
PPC VALVE
(BOOM, BUCKET, ARM, SWING)
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVEL PPC
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ARM CYLINDER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OFFSET CYLINDER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC CYLINDER
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OFFSET CYLINDER
Disassembly
..............................................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WORK EQUIPMENT
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ARM
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECOND BOOM
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATOR CAB
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-45
30-46
30-51
30-57
30-58
30-59
30-60
30-61
30-62
30-63
30-64
30-65
30-66
30-67
30-68
30-71
30-75
30-77
30-79
30-81
30-82
30-85
30-86
30-89
30-91
30-92
30-l
0
FLOOR FRAME
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 93
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 95
AIRCONDITIONER
COMPRESSOR
Removal
and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . 30- 96
AIRCONDITIONER
CAPACITOR
Removal
and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . 30- 97
AIRCONDITIONER
UNIT
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 98
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 99
COUNTERWEIGHT
Removal
and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . 30- 100
30-2
0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
METHOD
1.
OF USING
METHOD
OF USING
MANUAL
MANUAL
When removing or installing unit assemblies

0
When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques
applying only to the installation
procedure are marked m,
and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL
OF 0000
ASSEMBLY
. . . . . . . . . . . . . . . Title of operation
.................... .................................................. Precautions
1.
2.
3.
related to safety when carrying out

the operation
XXXX(1)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepinoperation
* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember
when removing XXXX (1).
A A A A (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m
Indicates that a technique is listed for use
during installation
0 0 0 0 assembly (3)
.................................................................... Quantity
of oil or water
drained
INSTALLATION
OF 0000
ASSEMBLY
. . . . .Title of operation
Carry out installation in the reverse order to removal.
@
............................................................. Technique used during installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when
installing A A A A (2).
.
Adding water, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operation
+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point to remember when adding water or oil
&
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity
when
filling with oil and water
2.
General precautions when carrying out installation or removal (disassembly

are given together as PRECAUTIONS
WHEN CARRYING OUT OPERATION,
these precautions when carrying out the operation.
3.
Listing of special tools

@ For details of the description,
part number, and quantity of any tools (Al, etc.) that appear
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
PC1 28UU-2
or assembly) of units
so be sure to follow
in
30-3
0
DISASSEMBLY
PRECAUTIONS
AND ASSEMBLY
PRECAUTIONS
WHEN CARRYING
WHEN
CARRYING
OUT OPERATION
OUT OPERATION
[When carrying out removal or installation

(disassembly
or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.1
1. Precautions when carrying out removal work
.
If the coolant contains antifreeze, dispose of it correctly.
.
After disconnecting
hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
.
When draining oil, prepare a container of adequate size to catch the oil.
.
Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling.
.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting
the connectors. Do not pull the wires.
.
Fit wires and hoses with tags to show their installation
position to prevent any mistake when
installing.
.
Check the number and thickness of the shims, and keep in a safe place.
.
When raising components,
be sure to use lifting equipment
of ample strength.
.
When using forcing screws to remove any components,
tighten the forcing screws uniformly in
turn.
.
Before removing any unit, clean the surrounding
area and fit a cover to prevent any dust or dirt
from entering after removal.
Precautions when handling piping during disassembly
*
Fit the following
blind plugs into the piping after disconnecting
it during disassembly
operations.
Nominal
number
I)
end)
Use the two items
07376-502
07221-20210
(Nut),
07222-00210
(Plug)
07376-50315
07221-20315
(Nut),
07222-00312
(Plug)
04
07376-50422
07221-20422
(Nut),
07222-00414
(Plug)
05
07376-50522
07221-20522
(Nut),
07222-00515
(Plug)
06
07376-50628
07221-20628
(Nut),
07222-00616
(Plug)
10
07376-51034
07221-21034
(Nut),
07222-01018
(Plug)
12
07376-51234
07221-21234
(Nut),
07222-01219
(Plug)
and
tubes
using
Flange
10
nut (elbow
03
Nominal
number
30-4
0
Sleeve
02
Hoses
2)
3)
Plug (nut end)
sleeve
(hose end)
below
as a set
nuts
Sleeve
head (tube end)
Split flange
04
07379-00400
07378-l
0400
0737 I-30400
05
07379-00500
07378-I
0500
0737 I-30500
Split flange type hoses and tubes

If the part is not under hydraulic pressure,
the following
corks can be used.
PC1 28UU-2
DISASSEMBLY
2.
.
.
.
.
AND ASSEMBLY
PRECAUTIONS
WHEN
CARRYING
OUT OPERATION
Precautions when carrying out installation

work
Tighten
all bolts and nuts (sleeve nuts) to the specified
(KES) torque.
Install the hoses without
twisting
or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive,
clean the part and remove
all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage,
then coat uniformly
with gasket sealant.
Clean all parts, and correct any damage,
dents, burrs, or rust.
Coat rotating
parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction
compound
(LM-P).
After fitting snap rings, check that the snap ring is fitted securely
in the ring groove.
When connecting
wiring
connectors,
clean the connector
to remove
all oil, dirt, or water, then
connect securely.
When using eyebolts,
check that there is no deformation
or deterioration,
screw them in fully, and
align the direction
of the hook.
When tightening
split flanges,
tighten
uniformly
in turn to prevent
excessive
tightening
on one
side.
When operating
the hydraulic
cylinders
for the first time after reassembling
cylinders,
pumps and
other hydraulic
equipment
removed
for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate
the work equipment
control
lever to operate
the hydraulic
cylinder
4 - 5 times,
stopping
the cylinder
100 mm from the end of its stroke.
3. Next, operate the hydraulic
cylinder
3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
+ When using the machine
for the first time after repair or long storage,
follow
the same
procedure.
3.
.
.
.
Precautions
when completing
the operation
If the coolant
has been drained,
tighten the drain valve, and add water to the specified
level. Run
the engine to circulate
the water through
the system. Then check the water level again.
If the hydraulic
equipment
has been removed
and installed
again, add engine oil to the specified
level. Run the engine to circulate
the oil through
the system. Then check the oil level again.
If the piping or hydraulic
equipment
have been removed,
always
bleed the air from the system
after reassembling
the parts.
+
Bleeding
air.
Add the specified
amount of grease (molybdenum
disulphide
grease) to the work equipment
parts.
PC1 28UU-2
30-5
0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST

-k
-k
Tools with part number 79OT-000-0000

cannot be supplied (they are items to be locally manufactured).
Necessity:
n : .......... Cannot be substituted, should always be installed (used)
0 : . . . . . . . . . . Extremely useful if available, can be substituted with commercially
available part
New/remodel:
N : . . . . . . . . . . Tools with new part numbers, newly developed for this model
R : . . . . . . . . . . Tools with upgraded part numbers, remodeled from items already available
for other models
Blank: . . . . Tools already available for other models, used without any modification
Tools marked 0 in the Sketch column are tools introduced in special sketches.
Component
NW/Ske.
5;ym bol
Part No.
Part Name
Disassembly,
assembly of engine
1795-799-1131 1Gear
IWII
1 Puller
3 I 795-799-1170
I Puller
4 I 790-331-I
110
I Wrench
796-460-I
210
Oil stopper
790-460-I
220
Rod
5
-
MII
MII
MII
2 1 795-799-1390
Removal of engine
main pump assembly
and engine assembly
I:; arv ;;ie, tch Nature
790-101-2560
Nut
790-101-2570
Plate
Rotation of crankshaft
I
I
I
Removal of fuel injection

pump drive gear
Removal
puller
790-101-1102
Hydraulic oil pump
n
n
796T-426-1140
Push tool
790-201-2680
Plate
of cylinder
Oil stopper
in hydraulic oil
I Extension
MII
ImIll
Grip
Bolt
2 I 791-635-3160
690-201-2800
Press fit of oil seal
I l790-101-5421
I 791-685-8006
Im I I I
Plate
I Installer
Push tool KIT
of bearing
I Compressor(B)
head
I
I
I
I
01010-51240
I III
I III
I III
MII
4 I l790-101-5441
Puller
(294 kN (30 ton})
1 I 791-675-1510
Disassembly,
assembly of idler
recoil spring assembly
ImI
790-101-4200
30-6
0
I Bearing
Tightening
Removal
I 790-101-3101
of nozzle holder
tank
Disassembly,
assembly of swing
machinery
assembly
of work, remarks
Press fit of bearing

race
inner
Press fit of bearing

race
l For main
bearing
l For sub-bearing
outer
Application
Compression
of floating
seal
of spring
PC1 28UU-2
Component
;ymbol
SPECIAL TOOL LIST
Part
Part
Name
New
!;
Ske
alty ;;ie, tch
790-101-1600
Cylinder
(686 kN (70 ton})
790-101-1102
Pump
No.
790-201-2770
Spacer
Disassembly,
assembly of idler
recoil spring assembly
Nature
of work,
Compression
remarks
of spring
Press fit of piston dust seal
Disassembly,
assembly of track
roller assembly
791-675-I
510
Installer
Application
Sealing of oil and checking

of air leak
M
2
791-601-1000
I 790-616-1040
Expansion,
installation of track
shoe assembly
Removal, installation
of main pump input
shaft oil seal
Oil pump
I Remover & installer I n I 1 I

Cylinder
(297 kN (30 ton})
791-101-1102
Pump
791-463-1141
Push tool
790-201-2740
Spacer
7go-105-1
loo
1 790-101-2501
.790-101-2510
Disassembly,
assembly of center
swivel joint assembly
. Block
791-101-2520
Screw
790-101-2540
Washer
1 l791-112-1180
1 Push puller
1 *Nut
of floating
seal
I
Removal,
pin
press fit of master
Press fit of oil seal
I.III
I III
I III
I III
I III
I
I
I
I
I
Disconnection
shaft
of rotor from
790-502-I
003
Repair stand
Pump
1
790-101-1102
I 790-102-4300
Disassembly,
assembly of hydraulic
cylinder assembly
I Wrench
assy
In I I I
Disassembly,
cylinder
I
Boom, arm,
bucket and
offset
cylinders
Offset cvlinder
(removal,
installation of
piston nut)
assembly
of
.Removal .
rnstallatron
n+ nic+nn
I
fJ.TL
U
1 790-201-1702
1 Push tool KIT
Im 1 1 1
Press fit of bucket cylinder

roll bushing
1
1
#n
PC1 28UU-2
790-201-1811
1 . Push tool
I III
Press fit of boom and offset

cylinder roll bushings
30-7
0
DISASSEMBLY
AND ASSEMBLY
Component
SPECIAL TOOL LIST
T T
I Symbol
NeWi
Ske.
Part No.
Part Name
790-101-5021
01010-50816
790-201-1702
Grip
1 Push tool KIT
790-201-1821
1 l Push tool
790-101-5021
01010-50816
1 Bolt
790-201-1500
arv ,,,$ tch Nature of work, remarks

1
1 Bolt
i;
Grip
1 Push tool KIT
I III
MII
I III
I III
I III
MII
I
I
I
I
I
I
Press fit of boom and offset

Press fit of arm and blade

Press fit of bucket cylinder

dust seal
790-201-1500
l
790-201-I
790-101-5021
01010-50816
4
Disassembly,
assembly of hydraulic
cylinder assembly
1 Push tool KIT

620
Plate
Grip
790-201-1500
1 Bolt
l
1 Push tool KIT
790-201-1630
Plate
790-101-5021
Grip
796-720-1660
1Ring
07281-01159
I Clamp
796-720-1670
1Ring
07281-01279
I Clamp
790-330-3802
I Wrench
796T-470-1150
I Spacer
796T-470-I
I Plate
Removal, installation,
disassembly, assembly
of work equipment ant
removal/installation
of
hydraulic cylinder
30-8
0
7
-
140
assy
Application
of boom and
offset cylinder dust seal
Application
of arm and
blade cylinder dust seal
stt
5
-
I
I
I
I
I
I
I
MII
I III
I III
I III
MII
I III
I III
0
I.III
I.III
bill
bill
MII
bill
MII
n
n
+#
790-I 01-2102
Puller
(294 kN (30 ton})
790-101-1102
Pump
Extension
of piston ring
Bucket
cylinder
I
I
I
I
I
lo
lo
Arm, boom
and blade
cylinders
Installation
of piston
ring
Offset cylinder
Removal, installation
cylinder head
Removal
trunnion
of
of arm cylinder
pin
PC1 28UU-2
DISASSEMBLY
AND
ASSEMBLY
Component
symbol
SPECIAL
Part
No.
Part
796F470-1120
2
Removal, installation,
disassembly, assembly
of work equipment ant
removal, installation of
hydraulic cylinder
1Screw
796F470-1110
I Plate
796F470-1
I Plate
I 30
3
-
of work,
remarks
I
ImlII lo
ImlII lo
IdII I
I Washer
790-101-2102
790-101-1102
Pump
796-900-I
Remover
790-101-4000
Puller
(490 kN (50 ton})
790-101-1102
Pump
799-703-1200
I Service
799-703-1100
I Vacuum pump(lOOV)I
799-703-I
790-703-I
200
Nature
LIST
I=111
Puller
(294 kN (30 ton))
1622
Removal
of offset pint
Removal
of boom foot pin
Recycle of air-conditioning
gas
I1 I
For Japan
110
I Vacuum pump(220V) In I 1 I
For overseas
120
I Vacuum pump(24OV) In I 1 I
For overseas
799-703-1400
PC1 28UU-2
Ske
alty m$e,tch
Nut
02215-I
Newi
!:;
Sleeve
790-438-I 110
790-101-2540
Recycle of new CFC

gas
Name
TOOL
tool KIT
I Gas leak tester
In I I I
IdII
30-9
0
DISASSEMBLY
SKETCHES
AND ASSEMBLY
OF SPECIAL
TOOLS
SKETCHES OF SPECIAL TOOLS

Note:
Komatsu
sketches.
cannot
accept
any responsibility
for
special
tools
manufactured
according
to
these
F2. Push tool
PUSH TOOL
*
VI.
Unless
otherwise
specified,
there shall be no burrs or flushes
at the corner.
Spacer
230
Ii!?
--------------------6'0"
(66)
160
I34
CLPO2176
HEAT TREATMENT
MATERIAL
9-
------------------------------
30-10
0
PC1 28UU-2
VI. Plate
CLPO2177
V2. Sleeve
_----_--------------------------
CLPOZl73
_-------------------------------
PC128UU-2
V2. Plate
.
<
2 _
c1
Ii-
s:
2
Lt
II
CLPOZl74
Cl
V2. Plate
.
<
Cl
CLPOZl75
30-12
0
PC128UU-2
DISASSEMBLY
AND
ASSEMBLY
ENGINE,
MAIN
PUMP
REMOVAL OF ENGINE, MAIN PUMP

ASSEMBLY
g Completely ground the work equipment.
g
Disconnect
tery.
the negative
(-) terminal
of the bat-
1. Remove the radiator, hydraulic oil cooler assembly by referring

to REMOVAL
OF RADIATOR,
HYDRAULIC
2. Disconnect
tanks.
3. Remove
OIL COOLER ASSEMBLY.

hose (I) between the radiator
bracket
(2) from
upper
the fuel tank together
with the reserve tank.

4. Disconnect bracket (3) from the main pump.
*
The EPC valve connector is attached to it.
5.
6.
7.
8.
Disconnect
Disconnect
Disconnect
Disconnect
PPC main pressure hose (4).

earth cable (5).
LS pressure input hose (6).
EPC valve connector (7) (C13).
9.
10.
11.
12.
Disconnect
Disconnect
suction tube (8) from the main pump.

main pump output hose (9).
Disconnect main pump pressure input hose (IO).

Disconnect case drain hose (11).
13. Disconnect engine oil filter (12) from the hydraulic oil tank and put it near the main pump.
14. Remove
15. Remove
16. Remove
17. Remove
stays (13), (14) and (15).

adiabatic cover (16).
muffler drain tube (17).
muffler (18).
+
Loosen the turbo charger clamp beforehand.
18. Disconnect heater outlet hose (19).
hose (20).
19. Disconnect air conditioner
*
Disconnect the hose after completely

bleeding the air conditioning
gas (R134a) using tool
X.
Apply the blind plug to prevent

from entering the hose.
Be careful
not to damage
dust or water
or lose the O-ring.
20. Disconnect
21. Disconnect
accelerator
cable (21).
fuel inlet hose (22) and return
(23).
22. Disconnect
air conditioner
hose clamp
m
hose
(24) at two
positions.
23. Disconnect engine connectors: (25) El 5, (26) E20,
(27) El6 and (28) E07 to remove clamp (29).
24. Disconnect fuel spill hose (30).
+
Apply
PC1 28UU-2
the blind plug to the hose.
30-l 3
0
DISASSEMBLY
AND ASSEMBLY
ENGINE,
MAIN
PUMP
25. Disconnect clamp (31) to remove hose (32).

26. Remove engine side cover (33)
27. Disconnect engine connectors (34) MO2 and (35)
E17.
28. Disconnect starter wire (36) El3 and safety
wire (37) E30.
29. Disconnect heater return hose (38).
30. Remove three of four engine mounts (39).
lift engine
31. Temporarily
remove the remaining
fully lift the assembly
Engine
&
relay
main pump assembly (40),

mounting
bolt and careto remove
main pump
it.
assembly
1121
: 270 kg
INSTALLATION OF ENGINE
MAIN PUMP ASSEMBLY
l
Installation
is performed
in the opposite
way to
removal.
Adjust
the cable
JUSTMENT
Install
length
by referring
OF FUEL CONTROL
the engine
main
pump
placing the engine mounting

in the figure
w
Engine
to AD-
CABLE.
assembly
by
rubber as shown
below.
mounting
tightening
277.0 I- 31.9 Nm {28.25
bolt
z 3.25 kgm)
Supplying water
Supply water from the water filler port to the
specified level, start the engine to circulate coolant and recheck the level.
Supplying
oil (hydraulic oil tank)
Supply oil from the oil filler port to the specified
level, start the engine to circulate oil in the piping
and recheck the oil level.
Bleeding air
Bleed air from the main pump by referring
to
BLEEDING AIR FROM EACH PART in INSPECTION AND
ADJUSTMENT.
Filling air conditioning

gas
Fill air conditioning
gas (R134a)
tioning
circuit using tool X.
i i
(Maln
in the air condi(Fan
side
PWIP
side
mount)
mount)
DXPOlO36
30-14
0
PC1 28UU-2
DISASSEMBLY
AND
ASSEMBLY
RADIATOR,
REMOVAL OF RADIATOR, HYDRAULIC

OIL COOLER ASSEMBLY
A Gradually loosen the hydraulic oil tank cap to
bleed the internal air after completely
grounding the work equipment
and stopping the engine.
1. Remove the counterweight
assembly
to REMOVAL
OF COUNTERWEIGHT
BLY.
2. Remove the hydraulic
the oil using tool A5.
+
by referring
ASSEM-
oil tank strainer
and stop
If tool A5 is not used, remove the drain plug

to drain the oil from the hydraulicoil
tankand
the piping.
:
oil : 100 Pi
Hydraulic
3. Drain coolant.
-
Coolant
4. Remove
5. Remove
: 15 e
stay (I).
stay (2).
Disconnect the accelerator

cable clamped to
stay (2).
6. Remove bracket (3) together with the washer tank.
+
Disconnect the washer motor connector

from the hose.
7. Remove two batteries (4).
8. Remove battery relay (5).
9. Remove silencer (6) and tube
cleaner assembly (8).
(M28)
(7) to remove
air
10. Remove bracket (9).

11. Disconnect air conditioner
capacitor pipings (IO)
and (11).
*
Disconnect the hose after completely
bleeding the air conditioning
X.
+
+
gas (R134a)
using tool
Apply the blind plug to prevent dust or water

from entering the hose.
Be careful not to damage or lose the O-ring.
Make sure to double-engage

the wrench before disconnection.
12. Remove the mounting
bolt to remove air conditioner capacitor assembly (12).
13. Remove clamp (13) to remove bracket (14).
14. Disconnect
oil cooler outlet hose (15) and inlet
hose (16).
15. Disconnect radiator outlet hose (17) and inlet hose
(18) as well as reserve tank hose (19).
PC1 28UU-2
HYDRAULIC
OIL COOLER
DISASSEMBLY
AND ASSEMBLY
RADIATOR,
HYDRAULIC
OIL COOLER
16. Temporarily
lift radiator, hydraulic oil cooler assembly (20) to remove the four mounting
bolts
on the bottom.
+
Carefully lift and remove the assembly after

slightly lifting it and pulling it to the opposite
side from the engine to make sure that it does
not come in contact with the fan.
&
Radiator/hydraulic
oil cooler
:
55 kg
assembly
INSTALLTION OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY
Installation
removal.
is performed
Supplying water
Supply water from
in the opposite
the water
specified level, start the engine

ant and recheck the level.
filler
way to
port to the
to circulate
cool-
Supplying
level, start the engine
to circulate
oil in the piping

gas

gas (R134a)
tioning circuit using tool X.
30-16
0
in the air condi-
PC1 28UU-2
FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
A Completely ground the work equipment.
A
Disconnect
the negative
(-) terminal
of the bat-
tery.
1.
Drain the fuel.

-
Fuel tank
: 140 e
2.
Remove two hand rails (I) to remove side covers

(2) and (3), and upper covers (4), (5), (6) and (7).
+
The shapes of the hand rails differ.
3.
Disconnect
4.
5.
ing bolt and bracket (9) together with the reserve

tank.
Disconnect engine fuel return hoses (IO) and (11).
Disconnect fuel sensor connector (12) (PO6) to re-
6.
hose (8) from the radiator,
the mount-
move clamp (13).

Remove brackets (14) and (15) on the left side of
the fuel tank.
7.
8.
Disconnect mounting bolt (16) on the right side.

Disconnect hoses (17) (to the fuel pump) and (18)
(for draining) from the bottom of the fuel tank.
+
Lift the fuel tank before disconnection.
9.
Temporarily
lift fuel tank (19), remove the mounting bolt and then carefully lift the tank to remove
it.
m
&
Fuel tank assembly
INSTALLATION
ASSEMBLY
l
Installation
removal.
&
: 100 kg
OF FUEL TANK
is performed
in the opposite
Fuel tank mounting
bolt screw
Liquefied
w
Supplying
Supply
PC1 28UU-2
oil (fuel tank)
fuel.
adhesive
Fuel tank mounting bolt :

277.0 + 31.9 Nm I28.25
way to
(LT-2)
+ 3.25 kgml
DISASSEMBLY
AND ASSEMBLY
CENTER
SWIVEL
JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
Gradually
loosen
the hydraulic
oil tank cap to
bleed the internal air after completely

grounding the work equipment
Disconnect
the negative
(-) terminal
of the bat-
tery.
1. Remove boom rear covers (I) and (2).

2.
Disconnect 10 hoses (3) from

center swivel joint.
3.
Remove
4.
Disconnect 7 hoses (5) from the top of the center

swivel joint.
m
5.
Disconnect
connect
6.
elbow
the bottom
(4).
the cotter
pin and pin and then dis-
plate (6) from the center swivel
Temporarily
of the
lift the center
swivel
joint.
joint assembly
and remove the mounting

bolt from the bottom
to remove center swivel joint assembly (7).
&
Center
swivel
joint assembly
: 45 kg
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
l
Installation
removal.
&
is performed
Mounting
in the opposite
bolt screw
Liquefied
w
Mounting
way to
adhesive
(LT-2)
bolt :
98.1 - 123.0 Nm {IO.0 - 12.5 kgml

l
Supplying
level, start the engine to circulate oil in the piping
30-18
0
PC1 28UU-2
DISASSEMBLY
AND
ASSEMBLY
CENTER
SWIVEL
JOINT
DISASSEMBLY OF CENTER SWIVEL

JOINT ASSEMBLY
Remove
cover (1).
Remove
snap ring (2).
Using tool 0,
from swivel
Remove
pull out swivel
snap
and slipper
rotor (4) and ring (3)
shaft (5).
ring (6), then
remove
oil seal (7)
seal (8).
ASSEMBLY OF CENTER SWIVEL

JOINT ASSEMBLY
1. Assemble
2.
seal (8) to swivel
shaft (5).
Using push tool 0, press fit oil seal (7) to swivel

rotor (4), then install snap ring (6).
&
3.
slipper
Lip of oil seal
CWPO7964
: Grease (G2-LI)
Set swivel shaft (5) to block, and using push tool,

tap swivel rotor (4) with a plastic hammer to install.
Ir
Be extremely
careful not to damage
the oil seal and slipper seal when
the lip of
installing
the rotor.
4.
Install
5.
Fit O-ring
w
ring (3) and secure with snap ring (2).

and install cover (1).
Swivel
joint mounting bolt :

31.4 + 2.9 Nm 13.2 t 0.3 kgml
Cl PDT3146
CLPO2169
PC1 28UU-2
30-19
a
SWING MOTOR, SWING
MACHINERY
REMOVAL OF SWING MOTOR,

SWING MACHINERY ASSEMBLY
A Gradually loosen the hydraulic oil tank cap to
bleed
the internal
ing the work

gine.
A
Disconnect
tery.
1.
Remove
2.
Disconnect
air after completely
equipment
the negative
boom
ground-
and stopping
(-) terminal
rear covers
the en-
of the bat-
(I) and (2).
MB and MA port hoses (3) and (4), S
port hose (5), and B and T port hoses (6) and (7).
3.
Remove the mounting

bolt and tighten forcing
screw 0 to disconnect swing motor, swing machinery (8) from the revolving frame.
m
Ir
Temporarily
lift the swing motor/swing
machinery assembly and gradually lift it upward
according to the amount
forcing screw.
4.
Lift and
remove
assembly
(8).
&
swing
disconnected
motor/swing
Swung
motor, swing
.
by the
machinery
machinery
assembly
:lOOkg
INSTALLATION OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY
l
Installation
removal.
is performed
Swing
machinery
Gasket
Mounting
bolt
277.0
l
in the opposite
fitting
surface
sealant
way to
(LG-4 or LG-6)
+ 31.9 Nm I28.25
+ 3.25 kgml
Bleeding air
Bleed air from the swing motor by referring to
BLEEDING AIR FROM EACH PART in INSPECTION AND
30-20
0
ADJUSTMENT.
PC1 28UU-2
DISASSEMBLY
AND
SWING
ASSEMBLY
MACHINERY
OF SWING MACHINERY
DISASSEMBLY
ASSEMBLY
1.
Draining oil
Loosen drain
plug and drain oil from
swing
ma-
chinery.
2.
Swing
machinery
Swing motor
Remove swing
motor
case
assembly
: Approx.
2.5 Q
(1).
CLPO1647
3.
No. 1 carrier, No. 2 sun gear assembly

1) Remove No. 1 sun gear (2).
2)
Remove No. 1 carrier

sembly (3).
and No. 2 sun gear as-
CLPO2138
3)
Disassemble
No. 1 carrier
and No. 2 sun gear
assembly (3) as follows.

i)
Remove snap ring (4), then remove
washer
washer
(5), gear (6), bearing

(8).
thrust
(7), and thrust
11
IJ
CLPO2139
ii)
iii)
Knock in pin (9) and knock out shaft (10).

Ir
After removing the shaft, remove pin
(9).
Remove snap ring (1 I), then remove
2 sun gear (12) from carrier (13).
No.
PC1 28UU-2
CLPO2140
30-21
0
DISASSEMBLY
AND ASSEMBLY
4.
Ring gear
Remove ring gear (14).
5.
No. 2 carrier assembly

1) Remove spacer (15).
2)
Remove
No. 2 carrier
SWING
assembly
MACHINERY
(16).
14
CLPO2141
3)
CLP02142
Disassemble
as follows.
i)
Push in pin (17), and knock out shaft (18)
from carrier (19).
+
After removing the shaft, remove pin
ii)
(17).
Remove
bearing
thrust
washer
(20),
(22), and thrust washer
gear
(21),
(23).
CLPO2143
6.
Retainer, collar
1) Remove retainer
2)
3)
(24).
Set shaft and case assembly to press, push

split collar (25) with push tool 0, and press
fit bearing (26).
Ir
Operate the press gradually and press fit
the bearing to a point where
lar can be removed.
Remove split collar (25).
the split col-
CLPO2144
7.
Shaft
1)
assembly
Set block@
to shaft and case assembly
then using push tool 0,

bly (28) with press.
2)
Remove
bearing
remove
(27),
shaft assem-
(26).
CLPO2146
30-22
0
CLPO2146
CLPO2147
PC1 28UU-2
DISASSEMBLY
3)
AND
ASSEMBLY
SWING
Set shaft assembly to press, then using push

tool Fl, remove bearing (29) and collar (30)
from shaft (31).
8.
MACHINERY
CKPO314g
Oil seal, bearing outer race

1) Remove oil seal (32) from case (33).
CLPO2149
2)
Using puller 0, remove bearing

(34) and (35) from case (33).
outer
races
CLPO2160
PC1 28UU-2
30-23
0
DISASSEMBLY
AND ASSEMBLY
SWING
MACHINERY
ASSEMBLY OF SWING MACHINERY

ASSEMBLY
*
Clean all parts, and checkfor dirt or damage. Coat

the sliding surfaces of all parts with engine oil
before
installing.
1.
Bearing outer races

Using push tool, press fit outer races (34) and (35)
to case (33).
2.
Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
II
CLPO4760
shaft (31).
2)
Using push tool @, press fit bearing

press.
(29) with
3)
Set case assembly
4)
Using push tool 0, press fit bearing (26) with

a press to a point where split collar (25) enters.
+
Press-fitting
force : Max. 11.76 kN {I 200
Ir
(36) to shaft assembly
kg)
Press fit the bearing
slowly
while
CLPO2162
(28).
rotating
the case.
5)
6)
Install split collars
(25).
Screw bolt (12mm,
P=l.75mm)
into case, then
using push- pull scale @, measure

force in direction of rotation.
Ir
+
tangential
Tangential force : Max. 176.4 N (18 kg}

The tangential force is the maximum force
at the start of rotation.
25
CLPO2166
30-24
0
CLPO2166
PC1 28UU-2
3.
SWING
MACHINERY
Oil seal
Using push tool F2, press fit oil seal (32).
*
Replace the oil seal with a new part.
Lip of oil seal : Grease (G2-LI)
CLPO3160
4.
Retainer
Install
retainer
(24).
I
5.
DBP00217

1) Assemble
No. 2 carrier assembly as follows.
Assemble
bearing (22) to gear (21).
i)
ii) Fit top and bottom thrust washers (20) and
(23), then set gear assembly to carrier (19).
DBPOO218
iii)
Align position of pin holes of shaft

carrier, then tap with plastic hammer
install shaft (18).
*
When installing
the shaft,
rotate
planetary gear, and be careful

damage the thrust washers.
iv)
and
and
the
not to
Insert pin (17).

*
After inserting the pin, caulk the carrier pin portion.
OBPOO219
PC1 28UU-2
30-25
0
DISASSEMBLY
AND ASSEMBLY
SWING
2)
Install No. 2 carrier assembly

case assembly.
3)
Install spacer
MACHINERY
(16) to shaft and
(15).
Ring gear
Assemble O-ring to shaft and case assembly,
install ring gear (14).
and
DDPOOZZI
No. 1 carrier,
1) Assemble
No. 2 sun gear assembly

No. 1 carrier and No. 2 sun gear
assemblv as follows.
i) Assemble No. 1 carrier
ii)
iii)
(13) to No. 2 sun
gear (12), and install snap ring (11).

Align position of pin holes of shaft
and
carrier, then tap with a plastic hammer to

install shaft (IO).
Insert pin (9).
+
After inserting the pin, caulk the carrier pin portion.
+
Check that the stepped difference

a
between the shaft and carrier is less
than 0.2 mm.
thrust washer (8), bearing (7),
iv) Assemble
gear (6), and thrust
stall snap ring (4).
washer
(5), then
DBPOOZZ2
in-
DaPool98
30-26
0
PC1 28UU-2
DISASSEMBLY
2)
3)
8.
SWING
ASSEMBLY
Install No. 1 carrier and No. 2 sun gear

sembly (3).
Install No. 1 sun gear (2).
Swing motor assembly

Install swing motor assembly
w
AND
Refilling
with
Swing
PC1 28UU-2
oil (swing
machinery
+ 1.25 kgml
case)
the oil filler to the specified

machinery
case
as-
(1).
Mounting bolt :
110.25 + 12.5 Nm III.25
Add oil through
MACHINERY
: Approx.
level.
2.5 fi
30-27
0
DISASSEMBLY
AND ASSEMBLY
REVOLVING
FRAME
REMOVAL OF REVOLVING FRAME

ASSEMBLY
A
1.
Disconnect
tery.
the negative
(-) terminal
of the bat-
Remove the work equipment

assembly by referring to REMOVAL
OF WORK EQUIPMENT
ASSEMBLY.
2.
Disconnect
boom cylinder hoses (I) (right) and
(2) (left).
Ir
Be sure to apply the blind plug to the disconnected
3.
Remove
4.
Temporarily
hose.
covers
(3) and (4).
lift the boom cylinder
(5) on the bottom.

Ir
Check the number
to remove
and position
of the shims
mounted.
5.
Lift boom
&
6.
pins
cylinder
assembly
Boom cylinder
(6) to remove
assembly
it.
: 120 kg
Remove operator cab assembly

(7) by referring
to REMOVAL
OF OPERATOR CAB ASSEMBLY.
Disconnect seven hoses

center swivel joint.
Disconnect
the top of the
plate (8) from the center swivel joint.
Remove mounting
front and rear.
30-28
0
(8) from
bolts (9) except the two on the

1121
PC1 28UU-2
DISASSEMBLY
AND
REVOLVING
ASSEMBLY
FRAME
10. Lift revolving frame assembly

(16) to loosen remaining bolts (15).
Ir
Carefully remove the remaining
bolts by balancing them using the crane.
Ir
Carefully
lift and
remove
them
them from coming in contact

swivel joint or other parts.
Revolving
&
frame
to prevent
with the center
assembly
: 6,100
kg
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
l
Installation
removal.
is performed
Surface
in the opposite
inside bushing
during
way to
pin assem-
bly : Hyper white grease (GO-T, G2-T) or lubricant with molybdenum

disulfide (LM-P)
Greasing
after pin assembly
Hyper white grease (GO-T, G2-T) or lubricant with molybdenum

disulfide (LM-G)
Never put your finger in the pin hole when

adjusting the position.
Adjust the clearance

between the mount on
the boom cylinder bottom and the frame using the shims so that it becomes 1 mm or less.
circle contacting face :

Liquefied gasket
Swing
Revolving
Revolving
frame
(LG-1)
mounting bolt screw :

Liquefied adhesive (LT-2)
frame mounting bolt :

277.5 +. 32.4 Nm (28.3 +. 3.3 kgm}
Supplying
level, start the engine
to circulate
oil in the piping

l
Bleeding
air
Bleed air by referring to BLEEDING

AIR FROM
EACH PART in INSPECTION
AND ADJUSTMENT.
PC1 28UU-2
30-29
0
DISASSEMBLY
SWING
AND ASSEMBLY
REMOVAL OF SWING CIRCLE

ASSEMBLY
A Gradually loosen the hydraulic oil tank cap
bleed the air from the tank after grounding
work equipment
and stopping the engine
lock the safety
CIRCLE
to
the
and
lock lever.
Remove the revolving frame assembly

by referring to REMOVAL
OF REVOLVING
FRAME ASSEMBLY.
Temporarily
lift swing
move the 38 mounting

Remove
&
swing
Swing
circle assembly
bolts.
circle assembly
circle assembly
(1).
(I) to rem
m
: 170 kg
INSTALLATION OF SWING
CIRCLE ASSEMBLY
l
Installation
removal.
is performed
in the opposite
'RONT
way to
&
Swing
circle mounting bolt screw :

Liquefied adhesive (LT-2)
Swing
circle mounting bolt :

245 - 308.9 Nm I25 - 31.5 kgm)
Target
Lift swing
value
: 279.3
circle assembly
the track frame
OBPOO226
Nm 128.5 kgml
(1) and install it on
with the inner wheel
soft zone
S symbol of the inner race facing the right side

of the body as shown in the figure.
&
30-30
0
Amount
of circle grease sealed :

9.1 e (G2-LI grease)
PC1 28UU-2
RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
1.
Remove
valve
lock plate (I), then remove
seat (2) and
(3).
2.
Remove yoke piston

spring assembly (4).
3.
Disassembly
1)
DBPOOZZS
assembly
of recoil spring
(5) from
recoil
assembly
Set recoil spring assembly (4) to tool L2.

The recoil spring is under large installed
load, so be sure to set the tool prop-
erly. Failure to do this is dangerous.

Installed load of spring :
78.4 kN (8,000
2)
(Rubber shoe)
Apply hydraulic pressure slowly to compress
spring, then remove nut (6).
i
*
+
4.
Compress the spring to a point where the

nut becomes loose.
Release the hydraulic pressure slowly to
remove the spring tension.
Remove pilot (8), spacer @A) (for rubber
shoe specification
machine), cylinder (9),
and dust seal (IO) from spring (7).
Disassembly
1) Remove
2)
CLPO3166
kg)
of yoke piston assembly

wear ring (12) from yoke piston (11).
Remove snap ring (13), then remove

ing (14).
PC1 28UU-2
U-pack-
30-31
0
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
Assembly
1)
2)
of yoke piston
L3
assembly
Assembly
of recoil spring assembly
1) Using tool L3, install dust seal (IO) to cylinder
2)
IO
Assemble
U-packing (14) to yoke piston (1 I),
and secure with snap ring (13).
Assemble
wear ring (12).
(9).
Assemble
cylinder (9) and pilot (8) to spring
(7), and set to tool L2.
3)
Apply hydraulic pressure slowly to compress

spring, and tighten nut (6) so that installed
length of spring is dimension
a.
Installed length a of spring : 390 mm
+
4)
Remove
L2.
recoil spring
Fill inside of cylinderwith

grease.
6
Inside cylinder
Assemble
yoke
spring assembly
6
assembly
(4) from tool
a minimum
CLPO3167
Fill
with
grease
of 120 ccof
: Grease (G2-LI)
piston
(4).
Yoke piston sliding
assembly
(5) to recoil
portion
wear ring :
Grease (G2-LI)
DLPOO453
Fit valve (3) and seat (2), and secure with lock plate
(1).
+
Install the valve so that the direction
fitting is to the outside.
30-32
0
of the
PC1 28UU-2
IDLER
DISASSEMBLY OF IDLER ASSEMBLY

1.
2.
Remove
dowel
Remove floating
pin (I), then remove

seal (3) from support
support
(2).
(2) and idler
(4).
3.
Pull out idler (4) from
shaft
sembly (7).
+
It is filled with approx.
(5) and support
as-
90 cc. of oil, so drain
the oil at this point or lay a cloth to prevent

the area from becoming dirty.
4.
Remove floating seal (6) (on opposite side) from

idler (4) and shaft (5) and support assembly (7).
5.
Remove dowel
from shaft (5).
6.
Remove
pin (8), then
bushings
remove
(9) and (IO) from
support
DBP00233
(7)
idler (4).
CLPO2206
CLPO2207
PC1 28UU-2
CLPO2208
30-33
0
DISASSEMBLY
IDLER
AND ASSEMBLY
ASSEMBLY OF IDLER ASSEMBLY

Press fit bushings
(9) and (IO) to idler (4).
IO
CLPO2209
Fit O-ring and install support

dowel pin (8).
CLPO2210
(7) to shaft (5) with
Using tool Ll, install floating seal (6) to idler (4)

and shaft (5) and support assembly (7).
Ir
Coat the sliding surface of the floating seal
with oil, and be careful
dust get stuck to it.
+
not to let any dirt or
Remove all grease and oil from the contact

surface of the O-ring and the floating seal.
CLPO2.206
CLPO3164
CLPO2211
30-34
0
PC1 28UU-2
Assemble
idler (4).
IDLER
shaft (5) and support
Add oil between
assembly
(7) to
shaft (5) and idler (4).
Oil : 90 cc (E030-R)
Using tool Ll, install floating seal (3) to idler (4)

and support (2).
*
Coat the sliding surface of the floating seal
with oil, and be careful
*
not to let any dirt or
dust get stuck to it.

Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
CLPO2214
Install O-ring,
then install support
(2) with dowel
pin (1).
CLPO3155
PC1 28UU-2
DBPOO233
TRACK ROLLER
DISASSEMBLY OF TRACK ROLLER

ASSEMBLY
I
1.
2.
Remove
pin (I), then remove
Remove
floating
collar (2).
seal (3) from collar (2) and roller
(4).
II
3
CLPO2218
CLPO2219
CLPO2220
3.
Pull out roller (4) from shaft (5).

Ir
It is filled with 100 - 115 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

roller (4) and shaft (5).
side) from
CLPO2222
30-36
0
CLPO2221
CLPO2223
PC1 28UU-2
DISASSEMBLY
AND
TRACK
ASSEMBLY
5.
Remove
collar (8) from shaft (5).
6.
Remove
bushings
(9) and (IO) from
ROLLER
roller (4).
CLPO2226
PC1 28UU-2
30-37
0
DISASSEMBLY
AND ASSEMBLY
TRACK
ROLLER
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1.
Using push tool 0,

to roller (4).
2.
Assemble
3.
Using tool Ml,

+
install floating
seal (6) to shaft (5).
When assembling
the floating seal, clean the
contact surface of O-ring (6~) and floating seal
(6a), remove all grease and oil, and dry it.
Make sure that no dirt or dust sticks to the
surface
of the floating
CLPO3168
seal.
Using tool Ml, install floating seals (6) and (3)

to roller (4).
*
For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and (3d),
see
5.
(9) and (IO)
collar (8) to shaft (5).
contact
4.
press fit bushings
Assemble
the precautions
marked
for Step 3.
shaft (5) to roller (4).
6.
Turn over roller (4) and shaft (5) assembly.
7.
Using tool Ml, install floating seal (3) to collar (2).

*
For details of the precautions when installing
CLPO3169
CLPO2229
CLPO2230
CLPO3160
floating seals (3a) and (3c), see the precautions marked Ir for Step 3.
5
8.
Assemble
collar (2) to shaft (5), and install pin (1).
CLPO2232
30-38
0
PC1 28UU-2
DISASSEMBLY
AND
TRACK
ASSEMBLY
ROLLER
9. Using tool M2, apply standard pressure to roller

oil filler port and check air leakage.
Ir
Standard pressure :0.1 MPa {I kg/cm3
+
Method of checking
The standard pressure
10 seconds and the
shall not go down.
shall
be maintained
indicator
10. Using tool M2, fill track roller assembly

then tighten
for
of the gauge
with oil,
plug (11).
Track roller oil : 100 - 115 cc (E030-RI
CLPO3161
To vacuum
Pump
DJPOf042
CLP0223
PC128UU-2
30-39
0
DISASSEMBLY
TRACK
AND ASSEMBLY
SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
Lower
work
lubricator
A
equipment
to ground,
(I), and relieve
loosen
m
The adjustment
cylinder is under extremely
high pressure.
Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine
forwards.
Move
then
track tension.
machine
forward
backwards
so that position
ter pin is at front of idler, and set blocka

tion.
Using tool R, pull out master
Remove
and
of masin posi-
pin.
tool R, pull out temporary
pin, and re-
move dust seal, then drive machine

lay out track (2).
in reverse to
m
INSTALLATION OF TRACK SHOE

ASSEMBLY
l
Carry out installation

moval.
in the reverse
order
CLPO3163
to re-
m
*
Adjust the track tension.

For details, see TESTING
ing and adjusting
AND ADJUSTING,
Test-
track tension.
Use tool C and press fit the master pin so that the
protrusion of the master pin is dimension
a.
Protrusion Ua of master pin : 5.5 f 2 mm
When assembling
the dust seal, coat the bushing
contact surface with grease (G2-LI).
If the rubber of the road liner (rubber pad type)
becomes
worn or broken and the head of the
mounting
bolt becomes
damaged,
replace the
shoe with a new part immediately.
If the head of
the mounting
bolt becomes flattened,
it will be
impossible
30-40
0
to remove
it.
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
REMOVAL OF HYDRAULIC
ASSEMBLY
TANK
Gradually loosen the hydraulic oil tank cap to

bleed the internal air after completely grounding the work equipment
Disconnect
tery.
the negative
1. Drain the hydraulic

-
Hydraulic
(-) terminal
of the bat-
oil.
oil : 100 Q
2. Remove the fuel tank assembly by referring to

REMOVAL OF FUEL TANK ASSEMBLY.
3. Disconnect the clamp from the swing machinery
oil level gauge pipe.
4. Disconnect inter-oil cooler hose (2) and inter-control valve hose (3) to disconnect hose clamp (4).
5.
6.
7.
8.
Disconnect main pump suction hose (5).

Disconnect PPC valve drain hose (6).
Disconnect harness clamp (7).
Disconnect engine oil filter bracket (8).
*
Move the filter assembly close to the engine.
+
Put the reserve tank on the main pump.
9. Disconnect
self pressure reducing valve drain
hose (91, swing motor drain hose (IO), boom lock
valve drain hose (1 I), solenoid valve drain hose
(121, main pump drain hose (13) and travel motor
drain hose (14).
10. Temporarily lift hydraulicoiItank(15)

and remove
the mounting bolt to slowly lift and remove it.
m
& kg
PC1 28UU-2
Hydraulic
oil tank assembly
:95 kg
TANK
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
TANK
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
l

moval.
in the reverse
of hydraulic
order to re-
tank mounting
Thread tightener
bolt :
(LT-2)
Thread
Hydraulic tank mounting bolt :

277.0 f 31.9 Nm I28.25 f 3.25 kgm}
Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
Bleeding air
Bleed the air.
For details,
see TESTING
Bleeding air from hydraulic
30-42
0
AND ADJUSTING,
cylinder.
PC1 28UU-2
DISASSEMBLY
MAIN
AND ASSEMBLY
REMOVAL OF MAIN PUMP

ASSEMBLY
a
Completely
ground
Drsconnect
.
tery.
the negative
the work equipment.

(-1 terminal
of the bat-
1. Remove the hydraulic oil tank strainer and stop

the oil using tool A5.
+ When tool A5 is not used, remove the drain
plug to drain the oil from the hydraulic oil tank
and the piping.
-
Hydraulic
oil : 100 i?
2. Remove the counterweight

assembly by referring
to REMOVAL
OF COUNTERWEIGHT
ASSEMBLY.
3. Disconnect hose (1) from the radiator upper tank
to remove bracket (2) from the fuel tank together
with the reserve tank.
4. Remove bracket (3).
+
An EPC valve connector is mounted to it.
5. Disconnect PPC main pressure hose (4).
6. Disconnect earth cable (5) from the pump side.
7. Disconnect LS pressure input hose (6).
8. Disconnect EPC valve connector (7) (C13).
9. Disconnect suction tube (8) from the pump.
10. Disconnect pump output hose (9).
11. Disconnect pump pressure input hose (IO).
12. Disconnect case drain hose (11).
13. Disconnect muffler drain tube (12).
14. Remove adiabatic cover (13).
15. Disconnect joint (14) between the turbo charger
and the muffler and remove muffler assembly(15)
by removing the mounting bolt.
16. Drain the oil from the flywheel case.
-
Flywheel
case : 0.75 e
lift the pump to remove the mount17. Temporarily

ing bolt and lift main pump assembly (16) to rem
move it.
*
Carefully remove it to prevent it from coming
in contact with the engine oil filter.
*
It can be removed easier by lifting it at two
points to make it parallel using a lever block.
& kg
PC1 28UU-2
Main pump assembly:
95 kg
PUMP
DISASSEMBLY
INSTALLATION
ASSEMBLY
l

moval.
MAIN
AND ASSEMBLY
Mating
PUMP
OF MAIN PUMP
in the reverse
order to re-
surface of pump case :

Gasket sealant
(LG-6)
Refilling with oil (PTO gear case)

Add engine oil through the oil filler to the specified level.
Bleeding air
Bleed the air from main pump.
For details,
see TESTING
AND
Bleeding air.
30-44
0
ADJUSTING,
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
MAIN
CONTROL
VALVE
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
a
A

Bleed the remaining pressure from the hydraulic circuit bv referring to BLEEDING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT.
Remove two hand rails (I), upper cover (2) and
side cover (3).
Disconnect the right and left PPC hoses, the control valve outlet hose, the hose between the pump
and the control valve and drain hose (4).
*
The main control valve hoses are arranged
as follows from the top :
0 (Service)
@ Offset
@ Bucket
@ Arm
@ Blade
@ Boom
0
Right travel
@ Left travel
@ Swing
+ When removing a hose, remove the nipple
as necessary.
+ Affix a label or the like to the disconnected
hose nipple.
Lift main control valve assembly (5) to remove it.
& kg
Main control valve assembly
: 120 kg
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
l

moval.
in the reverse order to re-

Bleeding air.
Bleed the air from the circuit between the valve
and the hydraulic cylinder.
For details,
see TESTING
AND ADJUSTING,
Bleeding air.
PC1 28UU-2
30-45
0
DISASSEMBLY
CONTROL VALVE
OF CONTROL VALVE ASSEMBLY
132
Offset
Bucket
Arm
Blade
Boom
R. H. travel
L H. travel
Swing
A
t
Y
DJP01043
30-46
0
PC1 28UU-2
CONTROL VALVE
DJPOlO44
PC1 28UU-2
30-47
0
CONTROL VALVE
(Boom)
DJPOlO46
30-48
0
PC1 28UU-2
DISASSEMBLY
-k
1.
2.
3.
4.
5.
6.
AND ASSEMBLY
CONTROL
Since pressure
is applied
to the suctionequipped safety valve circuit for a while after
the machine is stopped, release the internal
pressure by gradually loosening depressurizing plug (1).
Do not disassemble
the suction-equipped
safety valve when it is mounted on the machine since the pressure cannot be set in the
state.
Be sure to mark the spool and the pressure
compensation
valves (flow control valve, depressurizing
valve, piston) when removing
them since they are not interchangeable
among each valve and the direction of assembly is specified.
Valve assembly
1) Remove main relief valve assembly (2).
2) Remove suction-equipped
safety valve
assemblies (3), (4) and (5).
3) Remove unload valve assembly (6).
4) Remove ten suction valve assemblies (7).
5) Remove LS select valve assembly (8).
Lift check valve and cooler bypass valve
1) Remove case (9) to remove spring (IO),
piston (11) and sleeve (12).
2) Remove case (13) to remove spring (14),
piston (15) and sleeve (16).
Swing control valve
1) Remove two plugs (17) to remove two pistons (18).
2) Remove two cases (19) to remove two
springs (20) and two retainers (21).
3) Remove plug (22) to remove spool assembly (23).
*
Loosen plug (22) while spool (23) is
engaged.
Swing bleed valve
1) Remove flange (24).
2) Remove plug (25) to remove spring (26)
and spool (27).
3) Remove plug (28) to remove ball (29).
Left and right travel control valves
1) Remove two cases (30) to remove
springs (31) and retainer (32).
2) Remove spool (33).
two

1) Remove two plugs (24) to remove two
springs (35), two retainers (36) and two
spools (37).
PC1 28UU-2
2)
Remove two
balls (39).
plugs
VALVE
(38) to remove
two
7. Boom control valve

2) Remove plugs (43) and (44) to remove
spring (45), valve (46) and spool (47).
-k Loosen plugs (43) and (44) while spool
(47) is engaged.
+ When disassembling
the boom hydraulic
drift prevention valve by removing it from
the body, remove four bolts (48) and two
bolts (49).
The bolt (50) is designed to mount plate
+
1)
2)
3)
(51).
When disassembling
the boom hydraulic
drift prevention valve without removing
it from the body, remove four bolts (48)
and one bolt (50).
Remove plate (51) to remove spring (52),
piston (53) and valve (54).
Remove spring (55) to remove piston (56).
Remove plug (57) to remove sleeve (58).
9. Blade control valve

2) Remove plug (62) to remove spool (63).
*
engaged.
10. Arm control valve
2) Remove two plugs (67) to remove spool
assembly (68).
*
Loosen plugs (67) while spool (68) is
engaged.
11. Arm regeneration
valve
Remove plug (69) to remove
valve (71).
spring (70) and
12. Bucket control valve

*
engaged.
30-49
0
DISASSEMBLY
AND ASSEMBLY
CONTROL
13. Offset control valve

+
Remove plug (80) while spool (81) is
engaged.
VALVE
21. Combination
stud bolt (service valve added)
+
Disassemble
as follows when a service
valve is added :
1) Removefournuts(132)toremovethefour
stud bolts.
+
Use a flat-head screwdriver to remove
the bolts.
2) Remove cover (133).
14. Swing pressure compensation

valve
1) Remove plug (82) to remove valve (83)
and spring (84).
2) Remove plug (85) to remove spring (86),
15. Left and right travel pressure compensation
valves
1) Remove plug (89).
2) Remove bolt (90) to remove spring (91).
3) Remove plug (92) to remove valve (93).
4) Remove plug (94) to remove spring (95)
and valve (96).
16. Boom pressure compensation
valve
1) Remove plug (97) to remove valve
and spring (99).
2) Removeplug(100)toremovespring(101),
(98)
17. Blade pressure compensation

valve
and spring (106).
2) Remove plug (107) to remove spring (108),
piston (109) and valve (1 IO).
18. Arm pressure compensation
valve
1) Removeplug(Ill)toremovevalve(112)
and spring (113).
19. Bucket pressure compensation
valve
1) Remove plug (118) to removevalve
and spring (120).
(119)
20. Offset pressure compensation

valve
and spring (127).
2) Remove valve (128) to remove spring
(1291, piston (130) and valve (131).
30-50
0
PC1 28UU-2
ASSEMBLY
CONTROL VALVE
OF CONTROL VALVE ASSEMBLY
Offset
Bucket
Arm
Blade
Boom
R. H. travel
L H. travel
Swing
B
A
J
t
Y
DJP01043
PC1 28UU-2
30-5 1
0
CONTROL VALVE
DJPOlO44
30-52
0
PC1 28UU-2
CONTROL VALVE
F-F
(Blade)
(Arm)
L-L
K-K
PC1 28UU-2
(Offset)
DJPOlO45
30-53
0
DISASSEMBLY
AND ASSEMBLY
Apply engine oil to the sliding surface of each

part before assembly.
1.
Combination
stud bolt (service valve added)
*
Assemble as follows when a service valve
is added:
1) Temporarily tighten the four stud bolts.
2) Install the service valve assembly.
3) Install cover (133).
4) Engage the four washers and tighten nuts
(132).
+ Tighten nuts 0 to @ in the above sequence and by following the procedure below.
w
Nut:
Isttime
:58.8-68.6Nm{6-7kgmI
2nd time : 78.5 - 88.3 Nm I8 - 9 kgm}
3rd time :
98.1 - 113 Nm {IO- 11.5 kgm}
When tightening,
make sure
that the height from the upper
surface of the nut to that of the
stud bolt is between
0.5mm
and 3mm. If not, loosen the nut
and adjust the mounting length
of the stud bolt using a flathead screwdriver.
2.
3.
4.
CONTROL
5.
Blade pressure compensation

valve
1) Mountvalve (1 IO), piston (109) and spring
(108) to mount plug (107).
m
Plug (107) :
196 - 240 Nm I20 - 24.5 kgm}
2) Mount spring (106) and valve (105) to
mount plug (104).
m
Plug (104) :
147 - 186 Nm {I5 - 19 kgm}
6.
Boom pressure compensation

valve
1) Mount valve (103), piston (102) and spring
m
Plug (100) :
147 - 186 Nm {I5 - 19 kgm)
2) Mount spring (99) and valve (98) to mount
plug (97).
m
Plug (97) :
196 - 240 Nm I20 - 24.5 kgm}
7.
Arm pressure compensation

valve
1) Mountvalve(117),piston(116)andspring
m
Plug (114) :
147 - 186 Nm {I5 - 19 kgm}
mount plug (111).
m
Plug (111) :
147 - 186 Nm {I5 - 19 kgm}
30-54
0
Right and left travel pressure compensation

valves
1) Mount valve (96) and spring (95) to mount
2)
Offset pressure compensation

valve
1) Mountvalve
(131), piston (130) and spring
(129) to mount valve (128).
m
Valve: 196-240Nm{20-24.5kgmI
mount plug (125).
w
Plug : 147 - 186 Nm {I5 - 19 kgm)
Bucket pressure compensation
valve
1) Mountvalve
(124), piston (123) and spring
m
Plug (121) :
147 - 186 Nm {I5 - 19 kgm)
mount plug (118).
m
Plug (118) :
196 - 240 Nm I20 - 24.5 kgm)
VALVE
3)
4)
8.
plug (94).
w
Plug (94) :
147 - 186 Nm {I5 - 19 kgm)
Mount valve (93) to mount plug (92).
m
Plug (92) :
147 - 186 Nm {I5 - 19 kgm)
Mount spring (91) to mount bolt (90).
&
Apply a drop of liquefied adhesive
(Loctite 638) to the position 2mm
to 3mm away from the end of the
plug screw.
w
Bolt (90) :
11.8-14.7
Nm 11.2-1.5
kgm)
*
Completely degrease and dry the bolt
and the female screw using a drying
spray and do not pressurize them for
two hours after tightening.
Mount plug (89).
m
Plug (89) :
98 - 123 Nm {IO - 12.5 kgm)
Swing pressure compensation

valve
m
Plug (85) :
147 - 186 Nm {I5 - 19 kgm)
2) Mount spring (84) and valve (83) to mount
plug (82).
m
Plug (82) :
196 - 240 Nm I20 - 24.5 kgm)
PC128UU-2
DISASSEMBLY
AND ASSEMBLY
CONTROL
9. Offset control valve

1) Engage spool (81) with the body.
2) Mount plug (80).
+
Tighten plug (80) while spool (81) is engaged with the body.
6
Apply a drop of liquefied adhesive
(Loctite 638) to the position 2mm
to 3mm away from the end of the
plug screw.
m
Plug : 14.7 - 19.6 Nm Il.5 - 2 kgm}
*
Completely degrease and dry the bolt and
the valve chamber screw using a drying
spray and do not pressurize them for two
hours after tightening.
3) Mount two retainers (79) and two springs
(78) to mount two cases (77).
w
Mounting bolt :
11.8-14.7Nm{1.2-1.5kgml
*
Since the plug mounting
procedure
and the case tightening
torque are
common to all spools, refer to this
section (Offset control valve) for the
following parts.
10. Bucket control valve
2) Mount plug (75).
-k Tighten plug (75) while spool (76) is
engaged with the body.
11. Arm regeneration
valve
Mount valve (71) and spring
(70) to mount
12. Arm control valve

2) Mount two plugs (67).
-k Tighten plugs (67) while spool (68) is
engaged with the body.
1) Mount sleeve (58) to mount plug (57).
2) Mount piston (56) to mount spring (55).
(52) to mount plate (51).
m
Mounting bolts (48) and (49) :
27.4 - 34.3 Nm I2.8 - 3.5 kgm}
Mounting bolt (50) :
11.8-14.7Nm{1.2-1.5kgmI
PC1 28UU-2
14. Boom control valve

2) Mount plugs (43) and (44).
-k Tighten plugs (43) and (44) while spool
(47) is engaged with the body.
15. Travel junction valve
1) Mount two balls (39) to mount two plugs
(38).
m
2)
Plugs (38) :
5.9 - 8.8 Nm IO.6 Mount spool (37), retainer (36)
springs (35) to mount two plugs
m
Plugs (34) :
49 - 62.7 Nm I5.0 -
0.9 kgm1
and two
(34).
6.4 kgm}
16. Right and left travel control valves

17. Swing bleed valve
1) Mount ball (29) to mount plug (28).
m
Plug : 5.9 - 8.8 Nm IO.6 - 0.9 kgm}
2) Mount spool (27) and spring (26) to mount
3)
4)
plug (69).
VALVE
plug (25).
w
Plug : 24.5 -34.3
Mount flange (24).
w
Mounting bolt
11.8- 14.7
Mount plug (22).
-k Tighten plug (22)
engaged with the
Nm I2.5 - 3.5 kgm}
:
Nm Il.2 - 1.5 kgml
while spool (23) is
body.
18. Swing control valve

1) Mount spool (23) to the body.
19. Cooler bypass valve and lift check valve
1) Mount sleeve (16), piston (15) and spring
(14) to mount case (13).
w
Mounting bolt :
27.5 - 34.3 Nm I2.8 - 3.5 kgml
2) Mount sleeve (12), piston (11) and spring
(IO) to mount case (9).
w
Mounting bolt :
27.5 - 34.3 Nm {2.8- 3.5 kgml
30-55
0
DISASSEMBLY
AND ASSEMBLY
CONTROL
VALVE
20. Valve assembly

1) Mount LS select valve assembly (8).
w
LS select valve assembly :
108 - 147 Nm {II - 15 kgm}
2) Mount ten suction valve assemblies (7).
m
Suction valve assemblies :
137 - 157 Nm {I4 - 16 kgm}
3) Mount unload valve assembly (6).
w
Unload valve assembly :
147 - 186.3 Nm {I5 - 19 kgm}
4) Mount suction-equipped
safety valve assemblies (3), (4) and (5).
w
Suction-equipped
safety valve assembly (3) :
176.6 - 196.2 Nm {I8 - 20 kgm}
m
Suction-equipped
safety valve assemblies (4) and (5) :
137 - 157 Nm {I4 - 16 kgml
5) Mount main relief valve assembly (2).
m
Main relief valve assembly :
88.3 - 107.9 Nm 19 - 11 kgm}
21. Depressurizing
plug
Mount depressurizing
plug (1).
w
Depressurizing
plug :
34 - 44 Nm I3.5 - 4.5 kgm}
30-56
0
PC1 28UU-2
DISASSEMBLY
LS SELECT VALVE
OF LS SELECT VALVE
CLP02267
1.
Remove
sleeve (2) and spring (3) from sleeve (1).
2.
Remove O-rings
sleeve (1).
3.
Remove plug (71, then remove

and spring (IO).
4.
Remove O-ring (11) from plug (7), then remove

seal (12) and O-ring (13) from piston (9).
+
After disassembling,
if there is any abnormality in any part except O-rings (41, (51, (1 I), or
seal (6), replace the whole LS select valve assem bly.
ASSEMBLY
VALVE
(4) and (5), and seal (6) from
pistons (8) and (91,
OF LS SELECT
Before assembling
engine oil.
1.
Install O-ring (13) and seal (12) to piston (9), then

assemble piston (8) and spring (IO), and install in
sleeve (1).
2.
Assemble
O-ring
sleeve (1).
m
3.
4.
coat the sliding
surface with
(11) to plug (7) and install to
Plug : 68.6 f 9.8 Nm I7 f 1 kgm}
Assemble spring
sleeve (1).
Install O-rings
(3) to sleeve
(2), and install to
(4) and (51, and seal (6) to sleeve
(1).
PC1 28UU-2
30-57
0
DISASSEMBLY
MAIN
AND ASSEMBLY
DISASSEMBLY
RELIEF VALVE
OF MAIN RELIEF VALVE ASSEMBLY
DBP00273
1.
Remove
ring (1) to remove
valve (2) and spring
(3).
2.
Loosen nut (4) to remove plug (5) and remove

ring (6) and nut (4) from plug (5).
O-
3.
Loosen nut (7) to remove holder (8) and remove

retainer (9), O-ring (IO) and nut (7) from holder
(8).
4.
Remove spring (12) and puppet (13) from sleeve

(11) and remove sleeve (14) and seat (15).
5.
Remove
6.
Remove O-ring (18), seal (19) and O-ring (20) from

sleeve (11).
If any abnormality is detected on valve (2), holder
(8), retainer (9), sleeve (14), seat (15), ring (16), Oring (17) or sleeve (II), replace the entire main
relief valve assembly.
-k
30-58
0
ring (16) and O-ring (17) from seat (15).
PC1 28UU-2
ASSEMBLY
MAIN RELIEF VALVE
OF MAIN RELIEF VALVE ASSEMBLY
DBP00273
Apply engine oil to the sliding surface before

assembly.
8.
Mount O-ring (17) and ring (16) on seat (15)

to engage sleeve (11).
Engage sleeve (14) with sleeve (11).

Mount nut (7) and O-ring (10) on holder (8)
and assemble
retainer (9), poppet (13) and
spring (12) to engage them with sleeve (11).
+
Completely
engage the contacting faces
of seat (15) and poppet (13).
Tighten the nut (4) with the specified

w
torque.
Nut : 44.1 f 4.9 Nm I4.5 f 0.5 kgm}
After mounting it on the control valve assembly, adjust the pressure by referring to INSPECTION
AND ADJUSTMENT
OF WORK
EQUIPMENT,
SWING AND TRAVEL CIRCUIT
OIL PRESSURE
in INSPECTION
AND ADJUSTMENT.
Engage nut (4) and O-ring (6) with plug (5) to

mount them on holder (8).
Engage spring (3) and valve (2) with sleeve
(11) to mount ring (1) on them.
Mount O-rings
sleeve (11).
Tighten
m
PC1 28UU-2
(20) and (18) and seal (19) on
nut (7) with the specified
torque.
Nut : 68.8 f 4.9 Nm 16 f 0.5 kgml
30-59
0
DISASSEMBLY
WORK EQUIPMENT
AND ASSEMBLY
DISASSEMBLY OF WORK EQUIPMENT

(PPC VALVE FOR BOOM, BUCKET,
ARM, SWING CONTROL)
1.
Remove
nut (I), then remove
PPC VALVE
PPC VALVE ASSEMBLY
disc (2) and boot
(3).
2.
Remove bolts, then remove plate (5).

-k Do not remove joint (4) unless it is to be replaced.
3.
Remove
4.
Pull out piston (81, and remove retainer (91, springs

(IO) and (II), and shim (12).
*
Spring (lO),(ll)
consists of each one of two
types of springs with different installed loads
in four places, so check the mounting position (oil pressure port) and mark with tags to
prevent mistakes when installing.
5.
Pull out valve (13) from body (14).
seal (6) and collar (7).
CLP02285
30-60
0
PC1 28UU-2
DISASSEMBLY
WORK EQUIPMENT
AND ASSEMBLY
PPC VALVE
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY

(PPC VALVE FOR BOOM, BUCKET, ARM, SWING CONTROL)
1. Assemble
valve (13) to body (14).
2.
Assemble shim (12) and spring (11) to valve (13).

+ When assembling spring (1 I), set the end with
the small coil diameter (inside diameter) at
shim (12) end.
3.
Assemble spring (IO), retainer (9), and piston (8).

*
The number of loops in the coil for spring (IO)
is different for each of the hydraulic ports below, so be careful when installing.
Position of port
PI, P2
44.4mm
P3, P4
42.4mm
I
I
Free length of spring
The position of each port is marked on the

bottom of the valve body.
6
Piston : Grease (G2-LI)
* When assembling the piston, coat the outside
of the piston and the inside of the hole in the
body with grease.
4.
Fit O-ring to collar (7) and assemble

then install seal (6).
5.
Install plate (5).

w
Mounting bolt :
13.23 f 1.47 Nm Il.35
6.
m
*
-k
f 0.15 kgm}
Install joint (4).

&
Sliding portion of joint : Grease (G2-LI)
6
Female thread of body :
Thread tightener (LT-2)
*
7.
in body (141,
Coat two places on the female thread with one

drop each of Loctite as shown in the diagram
below.
Joint : 44.1 f 4.9 Nm I4.5 f 0.5 kgm}
Keep strictly to the tightening torque.
Assemble boot (3) and disc (21, and tighten with

nut (1).
w
Nut: 112.7 f 14.7 Nm Ill.5 f 1.5 kgm}
After assembling the disc, adjust the height of the
disc.
Adjusting PPC valve.
PC1 28UU-2
30-6 1
0
DISASSEMBLY
TRAVEL PPC VALUE
AND ASSEMBLY
DISASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Remove
screw (I) to remove
lever (2).
2.
Remove mounting
assembly (4).
3.
Remove mounting bolt (5) to remove plate (6) together with damper assembly (7).
-k Check the thickness and the mounting position of washer (18).
4.
Remove mounting bolt (8) to remove

sembly (7) from plate (6).
5.
Remove
6.
Remove
piston (11) to remove
retainer
(12),
springs (13) and (14) and shim (15).
-k Store shim (15) after checking the thickness
and the number of shims at each mounting
position.
7.
Remove
bolt (3) to remove
case shaft
damper
as-
seal (9) and collar (IO).
valve (16) from body (17).
CEP00533
Details of body (17)
CLPO1455
30-62
0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
TRAVEL PPC VALUE
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Engage valve (16) with body (17).
2.
Engage shim (15) and spring (14) with valve (16).

+
Mount shim (15) on the position which has
been checked at the time of disassembly with
the proper thickness and number.
Standard shim thickness : 0.3mm
*
Since spring (14) is not symmetric vertically,
engage it with the smaller diameter side facing the shim.
3.
Mount spring (13), retainer

6
Piston outside
(12) and piston (11).
perimeter
and body hole :

Grease
(G2-LI)
4.
Place the O-ring on collar (IO) to engage them

with body (17) and mount seal (9) on them.
5.
Mount
tighten
6.
(6) and
Mounting
bolt : Adhesive
Mounting
bolt :
4.4 f 0.5 Nm IO.45 f 0.05 kgm}
(LT-2)
Mount washer (18) together with damper assembly (7) and tighten mounting bolt (5).
*
Engage washer (18) with a standard washer
(1.6mm) beforehand.
After completing assembly, measure the difference in the angles when the left and right
levers are at full strokes.
If it is larger than
0.7, change the thickness of the washer (18)
to make it 0.7 or less.
l
Washer thickness : 1 .O, 1.3 or 1.6mm
*
Reducing the washer thickness by 0.3mm
increases the full stroke angle by 0.39.
Mounting bolt :
31.0 f 3.4 Nm I3.15 f 0.35 kgml
Mount case shaft assembly

ing bolt (3).
&
w
8.
(7) on plate
7.
damper assembly
mounting bolt (8).
(4) and tighten mount-
Shaft swaying part, and lever and piston

contacting part : Grease (G2-LI)
Mounting bolt :
28.0 f 3.4 Nm I2.85 f 30.35 kgm}
Mount
lever (2) and tighten
&
part :
Grease (G2-LI)
Screw : 8.8 f 1.0 Nm IO.9 f 0.1 kgm}
PC1 28UU-2
screw (1).
Lever pin and plate swaying
CEP00533
L
30-63
0
ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
a Pull in the bucket, lower the work equipment
completely to the ground,
with stand 0.
1. Sling arm cylinder
2.
and support the arm
(I), and remove
head pin (2).

m
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out.
a
Loosen the sleeve nut of the hose slowly and

check that no oil spurts out, then remove.
3.
Disconnect
4.
Using tool VI, pull out cylinder mounting

pins
(41, then lift off arm cylinder assembly (1). m
*
There are shims installed, so check the number and thickness, and keep in a safe place.
& kg
CLPO2306
hose (3).
Arm cylinder
assembly
: 140 kg
CLPO2306
30-64
0
DJPOt046
PC1 28UU-2
DISASSEMBLY
INSTALLATION
ASSEMBLY
l
ARM CYLINDER
AND ASSEMBLY

moval.
OF ARM CYLINDER
Inside surface of bushing when assembling pin :

Hyper white grease (GO-T, G2-T) or
molybdenum
disulphide lubricant (LM-PI
Greasing after assembling pin :
molybdenum
disulphide lubricant (LM-G)
aligning the position of the pin hole,
ALWhen
never insert your fingers in the pin hole.
+
shim thickness
: 1.0,2.0
mm
&

molybdenum
Greasing after assembling pin :

molybdenum
When aligning the position of the pin hole,

Standard shim thickness : 1.5 mm
*
l
Standard
Bleeding air
Bleed the air.
For details,
see TESTING
AND ADJUSTING,
cylinder.

Run the engine to circulate the oil through
system. Then add oil to the specified level.
PC1 28UU-2
the
30-65
0
DISASSEMBLY
OFFSET CYLINDER
AND ASSEMBLY
REMOVAL OF OFFSET CYLINDER

ASSEMBLY
a
Run the engine at low idling, operate the control levers to retract the arm cylinder and boom
cylinder, and lower the work equipment
completely to the ground. When doing this, be careful not to relieve the circuit at the end of the
cylinder stroke.
1. Sling offset cylinder (I), then using tool V2, rem

move head pin (2).
-k There are shims installed, so check the number and thickness, and keep in a safe place.
2.
a
3.
Disconnect
4.
Using tool V2, pull out bottom pin (4), then lift off
m
offset cylinder assembly (I).
& kg
30-66
0
CLPO2311
hose (3).
Offset cylinder
assembly
: 90 kg
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
ASSEMBLY
l

moval.
OFFSET CYLINDER
OF OFFSET CYLINDER

molybdenum
Grease after assembling pin :
molybdenum
When aligning the position of the pin hole, never

insert your fingers in the pin hole.
+
&

molybdenum
disulphide lubricant (LM-P)

molybdenum
When aligning the position of the pin hole, never

*
Bleeding air
Bleed the air.
For details,
see TESTING
AND ADJUSTING,
cylinder.

PC1 28UU-2
the
30-67
0
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY
CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
*
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 assemblv

1) Remove the piping from the cylinder assembly.
2) Remove the mounting bolt to disconnect head
assembly (1).
3) Remove piston rode assembly (2).
*
Place an oil pan or the like under the cylinder to receive oil.
4) Disassemble the piston rod assembly with the
following procedure.
i)
Set piston rod assembly (2) on tool Ul.
ii)
CLPO3941
Remove piston assembly lock screw (3).

Screw size
Ml2 x 1.75 pitch : Boom, arm and blade
Ml 0 x 1.5 pitch : Bucket
CLPO3779
If screw (3) is caulked too tightly to be removed, force the screw in once and then
tap it to remove it.
Tap
DXP01039
30-68
0
PC1 28UU-2
iii)
Use tool U2 to remove
HYDRAULIC CYLINDER
piston assembly
(4).
l
u2
If tool U2 is not used, use the four drill

holes (diameter
= IO) to loosen the
piston assembly.
I
iv) Remove
the head assembly
DJP01048
(5).
CWPO7942
v)
Remove cap (6) to remove eleven balls (7)

and cushion plunger (8).
l
For the arm cylinder only.
CWPO7943
2.
Sub-disassembly of piston assembly

1) Remove ring (9).
2)
3)
4)
Remove
Remove
Remove
wear ring (IO).

piston ring (11).
the O-ring and backup ring (12).
CWPO7944
PC1 28UU-2
30-69
0
DISASSEMBLY
3.
HYDRAULIC
AND ASSEMBLY
Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (13).
2) Remove snap ring (14), then remove dust seal
3)
4)
5)
(15).
Remove
Remove
Remove
rod packing (16).

buffer ring (17).
bushing (18).
CYLINDER
A20
I!
I7
18
CLP02322
30-70
0
PC1 28UU-2
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY
CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
*
*
1.
Be careful not to damage the packing, the dust

seal, the O-ring or the like
Do not forcibly insert the backup ring but make it
warm with hot water (50 to 60C) before insertion.
Sub-assembly
of cylinder head
1) Press fit bushing (18) using
2) Engage buffer ring (17).
3) Engage rod packing (16).
4) Mount dust seal (15) using
with snap ring (14).
5) Mount the backup ring and
assembly
tool U3.
tool U4 and fix it
CWPO7946
O-ring (13).
17
I6
CWPO7946
2.
Sub-assembly
of piston assembly
1) Expand piston ring (11) using tool U5.
+
Set the piston ring on tool U5 and expand
it by rotating the handle eight to ten times.
Reduce
piston ring (11) using tool U6.
2)
CWPO7947
3)
4)
5)
Mount the backup ring and O-ring (12).

Engage wear ring (IO).
Engage ring (9).
*
Be careful not to expand the ring abutment joint too much.
&
Ring groove : Grease (G2-LI)
CWPO7941
PC1 28UU-2
DISASSEMBLY
3.
AND ASSEMBLY
Piston rod assembly

1) Set piston rod assembly
2)
Engage
head assembly
HYDRAULIC
CYLINDER
(2) on tool Ul.
(5).
CWPO7942
3)
Set cushion plunger (8) on the piston rod and

engage 11 balls (7) and fix them using cap
(6).
4)
l
Assemble piston assembly (4) in the following procedure.
l
When the rod and piston assembly (4) are
reused
*
Completely wash them and clear them
of cut powder or dust.
i)
Screw piston assembly (4) and tighten
it using tool U2 until the screw hole
position completely fits.
-k Eliminate screw burrs using a file
or the like.
ii) Tighten screw (3).
6
m
[c
CWPO7943
Screw (3) : Liquefied adhesive

(Loctite 262 or its equivalent)
Screw (3) :
Boom, arm and blade :
58.9 - 73.6 Nm {S - 7.5 kgm}
Bucket :
27.5 - 34.3 Nm I2.8 - 3.5 kgm}
DJP01048
30-72
0
PC1 28UU-2
DISASSEMBLY
iii) Caulkthescrewatfour
punching.
l
HYDRAULIC
AND ASSEMBLY
CYLINDER
pointsthrough
When new rod and/or piston assembly (2)

are/is used
rod,
-k For the bottom cushion-equipped
markthe cushion plug position on the
rod end surface.
l
Punch
i)
Screw piston assembly

(4) until it
comes in contact with rod end surface
&
-k
Piston assembly (4) :

294 f 29.4 Nm I30 f 3.0 kgm}
After tightening the piston, make
sure that there is some play with
plunger.
For the boom and arm cylinders
only.
,f
ii)
Drill a hole for mounting screw (3).

*
Engage the drill with the screw Vshaped grooves of piston (4) and
rod (2) for horizontal processing.
-k Process
the bottom
cushionequipped cylinder (arm cylinder)
on other part than the cushion
plug position.
l
Screw processing dimensions (mm)
Bucket
8.5
27
IlOx1.5
20
CWPO7959
CWPO7948
iii) Clear it of cut powder and dust and

completely wash it after processing.
iv) Tighten screw (3).
Screw (3) : Liquefied adhesive
m
Screw (3) :
Boom, arm and blade :
58.9 - 73.6 Nm 16 - 7.5 kgm}
Bucket :
27.5 - 34.3 Nm I2.8 - 3.5 kgml
Caulkthescrewatfourpointsthrough
punching.
6
VI
CLPO377!
PC1 28UU-2
5)
Engage
&
piston rod assembly
HYDRAULIC CYLINDER
(2)
Seal : Grease (G2-LI)

Set the ring abutment joint horizontally
and align the axes of the piston rod assembly and the cylinder tube to insert
them.
After insertion, make sure that the ring is
not damaged or dropped and completely
push the piston rod.
End sap in ring

DJP01047
Mount head assembly (I) and tighten

the mounting bolt.
w
Mounting bolt :
7)
it with
Moun t the piping.

CLPO3941 I
30-74
0
PC1 28UU-2
DISASSEMBLY
OFFSET CYLINDER
AND ASSEMBLY
DISASSEMBLY OF OFFSET
CYLINDER ASSEMBLY
1.
Cylinder assembly
1) Set cylinder assembly (1) on tool Ul.
2) Use a hydraulic pump or a powerwrench
and
tool U7 to loosen head assembly (2).
3) Remove piston rod assembly (3).
-k Place an oil pan or the like under the cylinder to receive oil.
CWPO7936
CWPO-5577
2.
Piston rod assembly

1) Set piston rod assembly (3) on tool Ul.
2) Use a hydraulic pump or a powerwrench
tool U2 to remove nylon nut (4).
-k Width across nut flats: 80mm
3)
Remove
piston assembly
4)
(5).
Remove
head assembly
and
(6) from piston rod

(2).
CWPO7937
PC1 28UU-2
DISASSEMBLY
3.
AND ASSEMBLY
OFFSET CYLINDER
Sub-disassembly
of piston assembly
1) Remove wear ring (7).
2) Remove piston ring (8).
*
Remove the piston ring by applying
a
screwdriver or the like to it, and hitting its
handle using a hammer to cut it.
CWPO7938
4.
Sub-disassembly
of cylinder head assembly
1) Remove the O-ring and backup ring (9).
2) Remove O-ring (IO).
3) Remove snap ring (11) and dust seal (12).
4) Remove rod packing (13).
5) Remove bushing (14).
IO
II
CWPO7939
30-76
0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
OFFSET CYLINDER
ASSEMBLY OF OFFSET
CYLINDER ASSEMBLY
*
-k
Apply engine oil to the sliding surface of each part

and 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 - 60C) before insertion.
1. Sub-assemblv
of cvlinder head
1) Press fit bushing (14) using
2) Mount rod packing (13).
3) Mount dust seal (12) using
with snap ring (11).
4) Mount O-ring (IO).
5) Mount the backup ring and
assemblv
tool U6. _
tool U7 and fix it
CWPO7940
O-ring (9).
13
14
IO
I2
CWPO7939
2.
Sub-assembly
of piston assembly
1) Expand piston ring (8) using tool U5.
+
Set the piston ring on tool U5 and expand
it by rotating the handle eight to ten times.
2) Reduce piston ring (8) using tool U6.
CWPO7941
3)
Engage wear ring (7).

*
Be careful not to expand
ment joint too much.
the ring abut-
1:
CWPO7938
PC1 28UU-2
30-77
0
DISASSEMBLY
3.
AND ASSEMBLY
OFFSET CYLINDER
Piston rod assembly

1) Engage head assembly (2) with piston rod (5).
2) Engage piston assembly (6) with piston rod
3)
4)
(5).
Set piston rod assembly (3) on tool Ul.
Tighten nylon nut (4) using tool U2.
6
m
Nylon nut : Liquefied adhesive

Nylon nut :
3.97 f 0.40 kNm I405 f 40.5 kgm}
CWPO7937
CLPO7936
4.
Cylinder assembly
1) Set the cylinder on tool Ul.
2) Engage piston rod assembly (3).
*
Set the ring abutment joint horizontally
and align the axes of the piston rod assembly and the cylinder tube to insert
them.
*
After insertion, make sure that the ring is
not damaged or dropped and completely
push the piston rod.
0
\
3)
CWPO6677
Tighten head assembly (2) using a hydraulic

pump or a power wrench and tool U7.
m
Head assembly :
1.03 f 0.10 kNm II05
f 10.5 kgm}
CWPO7936
30-78
0
PC1 28UU-2
WORK EQUIPMENT
REMOVAL OF WORK EQUIPMENT

ASSEMBLY
a
Extend the arm and bucket fully, lower the work

equipment to the ground, and set the safety lock
lever to the LOCK position.
1. Disconnect
grease hose (1).
2.
Remove left and right working lamp connectors

(2), and disconnect ground connection (3).
3.
Sling boom cylinder assembly (4), and remove

head pin (51, then lower boom cylinder assembly
(4) on block (1).
m
*
a
CLPO2329
'02330
4.
Remove control valve cover, and disconnect

hoses (6) from control valve.
5.
Remove
6.
Disconnect
PC1 28UU-2
boom angle potentiometer

boom angle potentiometer
cover.
linkage (8).
DISASSEMBLY
AND ASSEMBLY
WORK EQUIPMENT
7.
Remove
8.
Raise work equipment

assembly, remove plate,
then remove foot pin (9) using tool V3, and remove work equipment assembly (IO).
m
& kg
lock plate (8).
Work equipment
assembly
: 3,200 kg
CWPO7916
30-80
0
CLPO2334
PC1 28UU-2
DISASSEMBLY
INSTALLATION
ASSEMBLY
l
WORK EQUIPMENT
AND ASSEMBLY

moval.
OF WORK EQUIPMENT
m
+
When tightening the locknut, tighten so that

the clearance between the plate and nut is 0.5
- 1.5 mm.

molybdenum
CLPO2303

molybdenum

Adjust the shim thickness so thatclearance
a
between cylinder rod (11) and 1st boom (12)
is less than 1 mm.
II
CLPO2336

molybdenum
molybdenum
AL When
never
+
*
l

Adjust the shim thickness so that clearance b
between 1st boom (12) and bracket (13) is less
than 0.5 mm.
Standard shim thickness : 0.5, 1.0 mm
Bleeding air
Bleed the air.
For details,
see TESTING
AND ADJUSTING,
cylinder.

PC1 28UU-2
CLP02336
the
30-8 1
0
REMOVAL
ARM
OF ARM ASSEMBLY
Swing the work equipment
for 180.
Set the back of the bucket facing down, lower

the work equipment
completely to the ground,
and set the safety lock lever to the LOCK position.
1.
Remove
band
(I).
\
2.
Remove
lock pin (2).
3.
Remove connecting
pin (3) between
link and
bucket.
4.
CLPO2157
CLPO2156
5.
Remove
band (4).
6.
Remove
lock pin (5).
7.
Remove
plate (6).
8.
Remove connecting
pin (7) between
arm and
bucket.
CLPO2159
9.
After raising work equipment,

nect bucket assembly (8).
& kg
Bucket assembly
swing
: 370 kg
to discon-
CLPO2160
v
0
CLPO2161
30-82
0
PC1 28UU-2
DISASSEMBLY
ARM
AND ASSEMBLY
10. Set block 0 under arm and bucket cylinder

sembly (91, and lower work equipment.
11. Remove
potentiometer
as-
cover (IO).
12. Sling arm cylinder (1 I), remove pin (12),then pull

in cylinder rod and lower on to 2nd boom (13).
113
13. Disconnect bucket cylinder hoses (14) and (15).

a
*
After disconnecting
the hoses, install blind
plugs in them.
14. Disconnect
arm angle potentiometer
15. Disconnect
wiring
16. Remove
connector
hose clamp (18).
(17).
linkage (16).
--cr
I8
\
hI
II 1
PC1 28UU-2
CWPO7912
30-83
0
DISASSEMBLY
ARM
AND ASSEMBLY
17. Remove connecting

offset bracket (20).
pin (21) between arm (19) and
18. Use cancel switch and raise boom, then swing

and remove arm and bucket cylinder assembly
(9).
it There are shims installed, so check the number and thickness, and keep in a safe place.
& kg
Arm, bucket cylinder
assembly
: 470 kg
CWPO7913
30-84
0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
l

moval.
&
&
A
+
&
&
A
+
+
ARM
OF ARM ASSEMBLY

molybdenum
molybdenum
Standard shim thickness : 1.0,2.0 mm
Inside surface of bushing when assembling

pin, inside surface, end face of collar :
molybdenum
molybdenum
Set the O-ring at the end face of the bucket
boss securely.
Standard shim thickness : 0.5,l.O mm

molybdenum
molybdenum
Standard shim thickness : 1.0,2.0 mm
d_l
AL
+

molybdenum
molybdenum
Adjust the shim thickness so that the clearante a between arm (19) and offset bracket
(20) is less than 0.5 mm.
Standard shim thickness : 0.5, 1.0 mm
AL
+
PC1 28UU-2
CWPO7914
Bleeding air
Bleed the air.
Bleeding air from hydraulic cylinder.
the system. Then add oil to the specified
level.
30-85
0
DISASSEMBLY
AND ASSEMBLY
SECOND
BOOM
REMOVAL OF SECOND BOOM

ASSEMBLY
Remove arm assembly.
For details, see REMOVAL
A
OF ARM ASSEMBLY.

Sling arm cylinder assembly (I), and disconnect

hose (2).
*
After disconnecting
the hoses, install blind
plugs in them.
CLPO2337
Using tool VI, pull out trunnion pins (3), then lift
off arm cylinder assembly (1).
m
& kg
Arm cylinder
assembly
VI
: 140 kg
--
CWPO
Sling offset cylinder assembly (4), and using tool

V2, remove head pin (5).
m
-k Start the engine, and retract the piston rod,
then tie the piston rod with wire to prevent it
from coming out,
*
Disconnect hoses (6), and using tool V2, pull out
bottom pin (71, then lift off offset cylinder assem1131
bly (4).
A kg
30-86
0
Offset cylinder
assembly
: 90 kg
CLPO2339
PC1 28UU-2
DISASSEMBLY
6.
AND ASSEMBLY
SECOND
BOOM
Remove arm potentiometer

wiring clamp (8), pull
out pins (9) and (IO), then remove offset link (11).
m
CLPO2341
7.
*
8.
Remove clamp (12) (wiring clamp for arm, bucket

cylinder hose and arm potentiometer).
m
Make marks to show the mounting positions of
the hoses.
Sling offset bracket (13), and using tool V2, pull

out top and bottom pins (14), then lift off offset
bracket (13).
m
There are shims installed, so check the num+
ber and thickness, and keep in a safe place.
f+ kg
Offset bracket : 220 kg
CWPO7919
9.
Disconnect
PC1 28UU-2
grease hose (15).
30-87
0
DISASSEMBLY
AND ASSEMBLY
10. Disconnect
grease hose (16).
11. Disconnect
connector
SECOND
BOOM
(17).
12. Remove offset angle potentiometer

move spacer.
(IS), then rem
46
13. Sling second boom assembly (19), and using tool

V2, pull out pins (201, then lift off second boom
1181
assembly (19).
*
*
The hoses pass through the inside of the
boom, so be careful when handling the 2nd
boom.
f3
kg
Second
boom : 350 kg
CLP02347
CWPO7920
30-88
0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
ASSEMBLY
l

moval.
SECOND
BOOM
OF SECOND BOOM

molybdenum
disulphide lubricant (LM-P)
molybdenum
a
*


molybdenum
molybdenum
AL When
never
+

&

molybdenum

molybdenum


molybdenum
molybdenum
AL When
never
+

PC1 28UU-2
30-89
0
DISASSEMBLY
-k
AND ASSEMBLY
Be sure to clamp
rectly.
SECOND
the hoses and wiring
BOOM
cor-

Hyper white grease (GO-T, G2-TI or
molybdenum
Hyper white grease (GO-T, G2-TI or
molybdenum
a
*
m
-k

After completing
all processes in the work of installing the 2nd boom assembly, reset the input
and output signals of the electrical system and
check the operation.
Procedure for resetting input and output signals of
electrical system and checking operation.

molybdenum
molybdenum
a
*

Bleeding air
Bleed the air.
For details,
see TESTING
AND ADJUSTING,
cylinder.

30-90
0
the
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
OPERATOR
REMOVAL OF OPERATOR CAB

ASSEMBLY
a
Completely
ground
Drsconnect
.
tery.
the negative
1. Remove
the work equipment.

(-1 terminal
of the bat-
louver (1).
2.
Remove four screws

switch panel (2).
3.
Remove
4.
Disconnect air conditioner connectors

M31) (5) and (6) to remove duct (4).
5.
Disconnect
6.
Disconnect window washer hose (8).

+
Bend it to prevent detergent liquid from flowing out of the washer tank.
air conditioner
screw (3) to slide duct (4) forward.
Disconnect
Remove
to remove
wiper
motor connector
radio connector
controller
housing
(Ml2
(CN-75)
and
(7).
(B3).
panel cover (9).
Remove mounting bolt (IO), disconnect panel assembly (11) from the operator cab and put it at
the rear of the operator seat.
PC1 28UU-2
CAB
DISASSEMBLY
AND ASSEMBLY
OPERATOR
10. Remove the mounting bolt and lift operator

assembly (12) to remove it.
& kg
Operator
cab assembly
CAB
cab
: 240 kg
INSTALLATION OF OPERATOR
CAB ASSEMBLY
l
Installation
removal.
30-92
0
is performed
in the opposite
way to
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
a
a

and stopping the enDrsconnect
g!ne.
tery.
the negative
(-1 terminal
of the bat-
1. Remove the operator cab assembly by referring

to REMOVAL OF OPERATOR CAB ASSEMBLY.
2. Remove
the left side cover.
3. Disconnect connectors CNI (I), CN2 (21, CN3 (31,

CN4 (4), CN5 (5) and CN6 (6).
Disconnect
earth cable (7).
Remove
hand rail (8).
Remove
covers (9) and (IO).
Lift and remove cover

frame and the engine.
(11)
between
the floor
8. Disconnect PPC hose (12) (bucket DUMP, arm IN,

boom LOWER and bucket TILT from the top).
9. Disconnect PPC hose (13) (arm IN, boom LOWER,
right and left SWING from the top).
+
If the colored tape is damaged and thus cannot be identified, attach a label or the like for
identification.
10. Disconnect
two travel (right-side)
11. Disconnect
two travel (left-side)
PC1 28UU-2
PPC hoses (14).

PPC hoses (15).
FLOOR FRAME
DISASSEMBLY
AND ASSEMBLY
12. Disconnect
va Ive.
four hoses (16) from the blade
13. Disconnect
va Ive.
four hoses (17) from the offset PPC
14. Disconnect
PPC main pressure
PPC
hose (18) (Al).
15. Disconnect PPC drain hose (19).

*
Drain the hydraulic oil.
-
Hydraulic
oil : 90 e
pipings (20).
16. Disconnect two air-conditioning
*
Disconnect the hoses after completely bleeding the air conditioning gas (R134a) using tool
X.
-k Apply the blind plug to prevent dust or water
from entering the hoses.
-k Be careful not to damage or lose the O-ring.
30-94
0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
FLOOR FRAME
17. Lift and remove floor frame assembly (21).

+
Be careful not to damage the PPC hose.
& kg
Floor frame assembly
: 65 kg
INSTALLATION OF FLOOR
FRAME ASSEMBLY
Installation
removal.
is performed
in the opposite
way to
Supplying oil (hydraulic oil tank)

Supply oil to the specified level after starting the
engine to circulate oil in the piping.
gas
gas (R134a)
PC1 28UU-2
in the air-condi-
30-95
0
DISASSEMBLY
AIR CONDITIONER
AND ASSEMBLY
COMPRESSOR
REMOVAL OF AIR CONDITIONER

COMPRESSOR ASSEMBLY
a
Completely
ground the work equipment.
Disconnect
tery.
the negative
(-) terminal
of the bat-
1. Open cover (1).
cover (2).
2.
Remove
3.
Disconnect hoses (3) and (4).

Disconnect the hoses after completely bleedgas (R134a) using tool
ing the air-conditioning
X.
4.
Disconnect
5.
bolt (6) and

adjustment
Loosen belt tension
(8).
belt
drive
remove
to
(7)
bolt
mounting
6.
Remove bolts (6) and (7) to remove air conditioner

compressor assembly (9).
connector
(5) (M34).
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
l
Installation
removal.
is performed
in the opposite
gas
(R134a)
gas
30-96
0
way to
in the air condi-
PC1 28UU-2
AIR CONDITIONER CAPACITOR
REMOVAL OF AIR CONDITIONER CAPACITOR ASSEMBLY
Completely
ground
Drsconnect
.
tery.
the negative
the work equipment.

(-1 terminal
of the bat-
1.
Remove the counterweight

assembly by referring
to REMOVAL
OF COUNTERWEIGHT
ASSEMBLY.
2.
Remove
covers (1) and (2).
3.
Remove
air cleaner
4.
Disconnect battery relay (4) from the bracket.

+
Move it forward after disconnection.
5.
Disconnect hose (6) coming from the air conditioner

compressor and hose (5) running to the receiver
tank.
X.
6.
Remove the mounting bolt to remove air conditioner

capacitor assembly (7).
+
Carefully remove it since the fin is soft.
assembly
(3).
INSTALLATION OF AIR CONDITIONER CAPACITOR ASSEMBLY

l
Installation
removal.
is performed
in the opposite
gas

gas (R134a)
PC1 28UU-2
way to
in the air condi-
30-97
0
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER
UNIT
REMOVAL OF AIR CONDITIONER

UNIT ASSEMBLY
a
Completely
Drsconnect
.
tery.
the negative
(-) terminal
1. Remove
floor mat (1).
2. Remove
covers (2) and (3).
of the bat-
3. Remove louver (4) and the four screws to remove

switch panel (5).
4. Remove
screw (6) to slide duct (7) forward.
Disconnect air conditioner switch connectors (8)

and (9) to remove duct (7).
Remove grommet (IO).
Remove the mounting bolt to disconnect duct (11)
from the air conditioner unit.
Disconnect
air conditioner
unit connector
(12)
(M26).
*
It is located on the bottom of the centralized
harness.
9. Disconnect heater hoses (13) and (14) at the rear
of the air conditioner unit.
*
Since coolant flows out, bend and disconnect
the hose and apply the blind plug to it.
10. Disconnect air conditioner hoses (15) and (16).
*
*
X.
-k Apply the blind plug to prevent dust or water
-k Be careful not to damage or lose the O-ring.
11. Disconnect
30-98
0
two relay connectors
(17).
PC1 28UU-2
AIR CONDITIONER UNIT
12. Remove the mounting
bolt to remove air conditioner unit assembly (18).

*
Make sure that duct (11) is completely disconnected and remove it by sliding it forward.
INSTALLATION
CONDITIONER
l
Installation
removal.
OF AIR
UNIT ASSEMBLY
is performed
in the opposite
gas

gas (R134a)
PC1 28UU-2
way to
in the air condi-
30-99
0
DISASSEMBLY
AND ASSEMBLY
COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
a
Completely
Drsconnect
.
tery.
the negative
1. Remove
engine
(-1 terminal
of the bat-
upper cover (1).
2.
Disconnect
flywheel
case oil filler hose (2).
3.
Remove fuel gauge connector (3) from the clamp.

*
This is intended to prevent it from coming in
contact with the frame when the counterweight is lifted.
4.
m
Remove three mounting bolts (4).
-k Bolt : Width across flats = 65mm
*
Lift the counterweight
assembly beforehand.
5.
Slowly
it.
lift counterweight
A kg
Counterweight
assembly
assembly
(5) to remove
: 1,880 kg
INSTALLATION OF
COUNTERWEIGHT
ASSEMBLY
l
Installation
removal.
is performed
Mounting bolt :
385.4 - 4,707.4
in the opposite
way to
Nm (393.0 - 480.0 kgm)
PC1 28UU-2
SWING MACHINERY
SWING MACHINERY
56.4*
56.4*
(5.79
14.2Nm
1.45bd
110.3*
(1 1.25*
277.0531.9Nm
t28.25* 3.25kom)
14.2Nm
(5.75* 1.45kml
12.3Nm
1.25koml
9JA01381
40-2
PC128UU-2
SWING MACHINERY
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.07 0.18
0.4
Backlash of swing motor

shaft and No. 1 sun gear
Backlash between No. 1

sun gear and No. 1 planetary gear
0.13 0.31
0.6

planetary gear and ring
gear
0.15 0.34
0.7

planetary carrier and No. 2
sun gear
0.14 0.34
0.7

planetary gear and ring
gear
0.15 0.34
0.7

sun gear and No. 2 planetary gear
0.13 0.31
0.7

planetary carrier and swing
pinion
0.08 0.19
0.4
Backlash between swing

pinion and swing circle
0.13 1.16
2.3
Wear on swing pinion

collars contact surface
against oil seal
PC128UU-2
Replace
Standard size
Tolerance
Repair limit
145
0
0.100
144.8
Apply
hardchrome
plating recondition, or replace
40-3
(6)
SWING CIRCLE
SWING CIRCLE
Unit: mm
No.
Check item
Clearance between bearing

and circle
40-4
(6)
Criteria
Remedy
Standard size
Clearance limit
0.5 1.6
2.6
Replace
PC128UU-2
MAINTENANCE
STANDARD
TRACK FRAME. IDLER CUSHION
TRACK FRAME, IDLER CUSHION
31.9Nm
.3.25koml
304.0*4.9Nm
(31.0* 0.5kml
9JBOOl67
Unit: mm
No<
-
Check item
Criteria
I
I
1
Idler guide top

and bottom width
Standard size
89
82
77
replace
Track
frame
185
193
Rebuild
Idler
support
183
Recoil spring
PC1 28UU-2
Rebuild or
Rebuild or
replace
I
Standard size
84
Idler
Idler guide left

and right width
Clearance limit
Rebuild
Track
frame
support
Remedy
Free length
l~$,a$~d
Installed
load
502
390
84.3 kN
(8,600 kg)
Repair limit
Free length
490
Installed
load
75.0 kN
(7,650 kg)
Replace
40-5
SPROCKET
SPROCKET
\\
SOP01827
Unit: mm
No
-
Wear on tooth bottom

diameter
Wear on addendum
diameter
Wear on addendum
Wear on tooth bottom

width
Tooth bottom wall thickness
547.4
I
width
607
27
+I.0
-2.0
535
595
I
I
I
111.7
Repair limit
Tolerance
Standard size
Remedy
Criteria
Check item
+ 1.5
+0.465
-1.160
22
Rebuild or
replace
39
105.5
PC128UU-2
TRACK SHOE
TRACK SHOE
TRIPLE SHOE, ROAD LINER, CITY PAD SHOE
1. Triple shoe and city pad shoe

2. Road liner
fl
P portion shows the link of bushing press fitting end.
PC128UU-2
40-13
5
TRACK SHOE
Unit: mm
No.
Check item
Criteria
Standard size
Repair limit
175.25
178.25
Link pitch
Bushing outer diameter

46.3
Link height
Link wall thickness

(at the section where
bushing is to be press fit)
Reverse or
replace
When turned
Standard size
2
Remedy
Normal load
Impact load
42.3
Standard size
Repair limit
86
81
Reverse or
replace
24
102.4
Replace
Shoe bolt pitch
86.4
57
8
9
Link
10
Inner width
52.4
Total width
35
30.1
Width of tread
11
Pin protrusion volume
5.5
12
Regular bushing
protrusion volume
3.75
13
Total pin length
173
14
Total bushing length

(master bushing)
86.7
15
Bushing wall thickness
7.8
16
Spacer thickness
17
18
Bushing
Press fitting
Regular pin
force
19
Master pin
Reverse or
replace
Adjust or
replace
39.2 137.3 kN {4 14 ton}

78.5 186.3 kN {8 19 ton}
39.2 98.1 kN {4 10 ton}
Items with marking are applicable to the dry type shoe.
40-14
5
PC128UU-2
TRACK SHOE
Unit: mm
No.
Check item
Criteria
Remedy
Tightening torque (Nm {kgm}) Additional tightening angle (deg)
a. Regular link
Triple
City pat
196.1 19.6
{20 2}
90 10
147 10
{15 1}
50 5
Road liner
Shoe bolt
20
Retighten
Tightening torque
(Nm {kgm})
Additional tightening angle (deg)
Lower limit torque

(Nm {kgm})
b. Master link
Number of shoes
(on one side)
Tolerance
Standard size
21
22
Hole
46
+0.387
+0.347
+0.062
0
0.285 0.387
30
+0.150
0
0.198
0.250
0.198 0.400
Tolerance
Standard size
23
Clearance between regular

pin and bushing
30
24
Interference between
master pin and link
Clearance between master

pin and bushing
Grouser
height
a. Road liner
Shaft
Hole
+0.150
0
+0.830
+0.330
0.180 0.830
Shaft
Hole
Standard
interference
+0.020
0.020
0.198
0.250
0.178 0.270
Shaft
Hole
Standard
clearance
0.200
0.300
+0.630
+0.230
Tolerance
Standard size
30
26
Standard
clearance
Tolerance
Standard size
30
25
Standard
interference
Shaft
bushing and link
regular pin and link
42
Adjust or
replace
0.430 0.930
Standard size
Repair limit
58
21
Replace
Items with marking are applicable to the dry type shoe.
PC128UU-2
40-15
5
TRACK SHOE
Triple shoe and city pat shoe
Unit: mm
No.
Check item
Grouser height
Shoe height
Plate thickness
Criteria
Standard size
Repair limit
25
15
33
23
8
24
Grouser base length

5
19
18
Grouser edge length
7
8
Remedy
Rebuild or
replace
11
18
40-16
5
PC128UU-2
HYDRAULIC PUMP
HYDRAULIC PUMP
MODEL : HPV95 (for 105 cc/rev)
40-18
PC128UU-2
MAINTENANCE
CONTROL VALVE
STANDARD
CONTROL VALVE
8-SPOOL VALVE (WITHOUT
SERVICE VALVE)
(l/10)
P2
III
PC128UU-2
--I_
lT0
P4
9JYOOO39
40-19
MAINTENANCE
CONTROL VALVE
STANDARD
(2/10)
147*9.8lNm
~15.0*1.0kom1
4
\
5
\\I
.8lNm
.OkSd
147*9
115.0 f 1
186*9.81Nm
(19.0*
l.Okaml
186i9.81N-m
~l9.0*l.Okoml
\
3
A-A
9JYOO310
Unit: mm
Criteria
Check item
1
Repair limit
Standard size
Installed
length
Installed
load
46.8 x 7.50
40.6
5.50f0.40N
{0.56HI.O4kg}
4.40 N
(0.45 kg}
Suction valve spring
16.0 x 16.0
12.0
5.70 N
(0.58 kg)
4.50 N
{0.46 kg)
Piston spring
10.5 x 7.0
5.7
2.65 N
(0.27 kg)
2.16 N
(0.22 kg)
Free length
20.0 x 7.0
Piston spring
40-20
Replace
spring if any
damages or
deformations
are found
1.67 N
(0.17 kg}

5
Installed
load
Free length
x O.D.
Remedy
14.0
1.18 N
(0.12 kg}
0.98 N
(0.10 kg}
PC1 28UU-2
MAINTENANCE
CONTROL VALVE
STANDARD
(3/10)
B-B
9JYOO31 I
Unit: mm
Remedy
Check item
Repair limit
Standard size
Fr,$;gth
1
Spool return spring
ItxA$d
. .
Installed
load
Free length
Installed
load
45.6 x 28.0
43.0
230f14.7N
{23.5&l .50kg)
184N
08.8 kg)
45.7 x 28.0
43.0
222+13.7N
{22.6+1.40kg}
178 N
(18.1 kg)
2 1 Spool return spring
PC128UU-2
Replace
spring if any
damages or
deformations
are found
40-21
MAINTENANCE
CONTROL VALVE
STANDARD
(4/10)
216*19.6Nm
~22.0*2.Okaml
106*9.6lNm~
1 I l.O* l.Okoml
,--
19.6Nm
2.0ksml
--
._. 19.6Nm
117.0*2.0koml
t22.0*2.0koml
D-D
9JYOO312
Unit: mm
Criteria
Check item
No.
Remedy
Repair limit
Standard size
I
Installed
load
Free length
x O.D.
installed
length
Installed
load
36.2 x 5.30
32.0
9.81zL0.98N
{I .MO.IOkg}
7.85 N
(0.80 kg)
Pressure reduction valve

spring
27.5 x 14.2
18.0
17.7k0.98N
(I .8&0.1 Okg}
13.7 N
{I .40 kg}
Pressure reduction valve

spring
28.2 x 14.5
26.0
29.4k2.94N
(3.0f0.30kg)
23.5 N
(2.40 kg}
Flow control valve spring
40-22
Free length
Replace
spring if any
damages or
deformations
are found
PC1 28UU-2
MAINTENANCE
STANDARD
CONTROL VALVE
(5110)
.23.5*3.92Nm
(2.40*0.40kPml
39.2*4.90Nm
(4.0_t0.50koml
55.9*6.86Nm
(5.70~0.70kml
23.5*3.92Nm
i2.40*0.40kml
55.956.86Nm
9JYOO313
Unit: mm
No.
Standard size
Fry$;gth
1
Check valve spring
Remedy
Criteria
Check item
Itxs;i$d
. .
41.5 x 8.50
Repair limit
Free length
nEAed
31.5
5.88 N
(0.60 kg)
15.6
3.14 N
(0.32 kg)
nEAed
4.71 N
(0.48 kg)
I
Check valve spring
PC1 28UU-2
20.3 x 13.7
Replace
spring if any
damages or
deformations
are found
2.25 N
(0.26 kg)
40-23
MAINTENANCE
CONTROL VALVE
STANDARD
(6/10)
F-F
!fTY
9JYOOO62
Unit: mm
No.
Remedy
Criteria
Check item
Repair limit
Standard size
Bleed spool return spring
Installed
load
Installed
length
Installed
load
72.7 x 20.6
42.5
135f4.90N
{I 3.8f0.50kgI
113N
(1 I.5 kg)
23.3 x 12.5
23.0
3.92*0.98N
(0.40fO.lOkgI
2.94 N
(0.30 kg)
Fr,$;gth
Lift check valve spring
Cooler bypass valve spring
. .
Free length
Replace
spring if any
damages or
deformations
are found
40-24
PC1 28UU-2
MAINTENANCE
CONTROL VALVE
STANDARD
(7/10)
9JYOOO63
J-J
Unit: mm
No,
-
Remedy
Criteria
Check item
Repair limit
Standard size
Fry$;gth
Travel junction spool

return spring
. .
17.7 x 8.20
PC1 28UU-2
I1,st,&$d
13.0
Installed
load
13.7fO.lON
{I .4MO.l Okg)
Free length
Installed
load
10.1 N
(1.10 kg)
Replace
spring if any
damages or
deformations
are found
40-25
CONTROL VALVE
(8/W
\
K-K
9JYOO314
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Lift check valve spring
40-26
Repair limit
Free length
x O.D.
Installed
length
Installed
load
26.1 x 17.0
25.0
26.5&l .57N
{2.7&0.16kg)
Free length
Installed
load
21.2 N
(2.16 kg}
Replace
spring if any
damages or
deformations
are found
PC128UU-2
MAINTENANCE
STANDARD
CONTROL VALVE
(9/10)
~5.4*0.6koml
M-M
9JYOO315
Unit: mm
No.
Check item
Check valve spring
PC128UU-2
Criteria
Remedy
Standard size
Repair limit
Free length
x O.D.
Installed
length
Installed
load
41.5 x 8.50
31.5
5.88 N
(0.60 kg}
Free length
Installed
load
4.71 N
(0.48 kg)
I
Replace
spring if any
damages or
deformations
are found
I
40-27
MAINTENANCE
CONTROL VALVE
STANDARD
(lO/lO)
39.2k4.90Nm
i4.0*0.50kPml
/
19.6Nm
:Z.Okaml
AA-AA
cc-cc
9JYOO316
40-28
PC128UU-2
MAINTENANCE
STANDARD
SUCTION
SAFETY VALVE
SUCTION SAFETY VALVE

FOR SERVICE VALVE
(15.0*
l.Okpml
9JYOOO66
Unit: mm
No,
-
Check item
Repair limit
Standard size
1
Piston spring
PC1 28UU-2
Installed
load
Free length
x O.D.
Installed
length
Installed
load
16.3 x 21.3
9.50
2.06 N
(0.21 kg)
1.57 N
(0.16 kg}
20.0 x 7.0
14.0
2.06 N
(0.21 kg}
1.57 N
(0.16 kg}
Free length
Replace
40-29
MAINTENANCE
SELF PRESSURE REDUCTION
STANDARD
VALVE
SELF PRESSURE REDUCTION VALVE
A-A
\
9JUOOO66
Unit: mm
ssure reduction
Spring (safety valve)
40-30
deformations
16.1
7.80
13.4
61.7 N
(6.30 kg}
58.8 N
16.0 kg)
PC1 28UU-2
MAINTENANCE
TRAVEL MOTOR
STANDARD
TRAVEL MOTOR
GM18VL-J
14.7Nm
127.5*
113.0*1.5ksml
78.5*19.6Nm
(8.0*2.0kPml
PC1 28UU-2
15.7Nm
102.0-t
(10.4*1.6hl
9.8Nm
57.95
t5.9* I.Okoml
\
127.5*19.6Nm 29.4i 4.9Nm 353.0*39.2Nm
i13.0i2.0koml (3.0*0.5koml (36.0*4.0koml
A-A
98.1f 19.6Nm
IlO.O*2.0lwm)
686.5*49.0Nm
~70.0*5.0koml
58.8* 19.6Nm
{6.0*2.0ksml
9JA01387
40-31
MAINTENANCE
STANDARD
SWING
MOTOR
SWING MOTOR
yMODEL:
KMF40AEL-3
29.4*4.9Nm
13*0,5kPml
30.9*i.4Nm
(3.15*0.35koml
166.7519.6Nm
i17.0*2.OkPml
A-A
9JYOO317
Unit: mm
Check item
Remedy
Criteria
Repair limit
Standard size
1
Check valve spring
Shuttle valve spring
40-32
Free length
x O.D.
Installed
load
installed
length
Installed
load
33.0 x 13.8
23.0
1.28 N
(0.13 kg}
0.98 N
(0.10 kg}
33.0 x 13.8
19.5
1.77 N
(0.18 kg}
1.47 N
(0.15 kg}
Free length
Replace
spring if any
damages or
deformations
are found
PC1 28UU-2
MAINTENANCE
SOLENOID
STANDARD
VALVE
SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECTOR, SWING AND PARK BRAKE, AND 2STAGE RELIEF SOLENOID VALVE
(2.2*0.22bml
B-B
9JA01388
PC128UU-2
40-33
MAINTENANCE
STANDARD
EPC SOLENOID
VALVE
EPC SOLENOID VALVE

FOR 4-SYSTEM
CONTROL
8.34i0.98Nm
{0.85~O.l!-aml
/
A-A
3.92i0.49Nm
{0.4*0.05kPml
5.39*0.49Nm
(0.55*0.05koml
A-A
9JBOO168
40-34
PC1 28UU-2
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
142.2234.3Nm
{14.5*3.5koml
31.4*2.9Nm
~3.2*0.3kamI
19.6*4.9Nm
{2*0.5km)
9JA01391
No.
Check item
Standard size
Clearance between rotor

and shaft
PC128UU-2
Remedy
Criteria
Standard clearance
clearance limit
0.056 - 0.105
0.111
Replace
80
40-35
MAINTENANCE
PPC VALUE
STANDARD
PPC VALVE
FOR WORK EQUIPMENT,
FOR SWING
13.2i 1.47Nm
~1.35*0.15kahl
A-A
9JYOOO5i
E-E
Unit: mm
No.
Remedy
Criteria
Check item
Centering spring
(for P3 and P4 ports)
I42.4 x 15.5
2
34.0
29.4 N
(3.0 kg}
23.5 N
(2.40 kg)
Replace
spring if any
damages or
deformations
are found
40-36
24.9
16.7 N
(1.70 kg}
13.7 N
{I .40 kg)
PC128UU-2
MAINTENANCE
STANDARD
PPC VALVE
@
n
A-A
9JYOOO57
D-D
c-c
Unit: mm
No.
Remedy
Criteria
Check item
Repair limit
Standard size
Fre,ecz;gth
1
Metering spring
Centering spring
PC128UU-2
Ins&A$d
. .
Installed
load
Free length
Installed
load
13.7 N
26.5 x 8.15
24.7
16.7 N
(1.70 kg)
{la40 kg)
48.1 x 15.5
32.5
108N
(11.0 kg)
86.3 N
(8.80 kg)
Replace
spring if any
damages or
deformations
are found
40-37
MAINTENANCE
STANDARD
PPC VALVE
FOR BLADE, FOR SERVICE
Unit: mm
Check item
Criteria
Remedy
Repair limit
Standard size
FrF$;gth
1
Centering spring
Metering spring
40-38
l~~tal$d
. .
YZed
33.9 x 15.3
28.4
125 N
(12.7 kg}
22.7 x 8.10
22.0
16.7 N
(1.70 kg)
Free length
Installed
load
100 N
(10.2 kg)
13.3 N
(I.36 kg)
Replace
spring if any
damages or
deformations
are found
PC128UU-2
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
9JBOO169
ARM CYLINDER
95800170
OFFSET CYLINDER
9JBOO171
PC128UU-2
40-39
MAINTENANCE
STANDARD
HYDRAULIC
CYLINDER
BUCKET CYLINDER
9JB00172
BLADE CYLINDER
9JA01395
40-40
PC128UU-2
MAINTENANCE
No .
STANDARD
Check item
Clearance between piston rodI and bushing
Clearance between piston rot

support shaft anI
bushing
Clearance between cylinder

bottom support
shaft and bushin
Criteria
Boom
Arm
Cylinder head
tightening torqu e
Offset
Cylinder piston
tightening torque3
Cylinder piston
lock screw tightening torque
PC128UU-2
269.7 + 39.2 Nm (27.5 f 4.0 kgm)

1,029.7 f 103.0 Nm {I 05.0 + 10.5 kgm)
171.6 + 24.5 Nm (17.5 + 2.5 kgm)
Blade _
269.7 + 39.2 Nm (27.5 + 4.0 kgm)
Boom
294.2 f 29.4 Nm (30.0 k 3.0 kgm)
Offset
Remedy
171.6 * 24.5 Nm (17.5 + 2.5 kgm)
Bucket
Arm
5
CYLINDER
Unit: mm
HYDRAULIC
294.2 f 29.4 Nm (30.0 + 3.0 kgm)

3,971.7 + 397.2 Nm (405.0 f 40.5 kgm)
Bucket
294.2 + 29.4 Nm (30.0 f 3.0 kgm)
Blade
294.2 f 29.4 Nm (30.0 f 3.0 kgm}
Boom
66.2 f 7.4 Nm (6.75 f 0.75 kgm}
Arm
66.2 + 7.4 Nm (6.75 f 0.75 kgm)
Offset
Bucket
30.9 f 3.4 Nm (3.15 f 0.35 kgm)
Blade
66.2 + 7.4 Nm (6.75 f 0.75 kgm)
Re-tightening
40-41
WORK EQUIPMENT
WORK EQUIPMENT
QJBOO173
PC128UU-2
40-43
WORK EQUIPMENT
B-B
G-G
R-R
P-P
H-H
IO
N-N
s-s
T-T
II
9JBOO174
40-44
PC1 28UU-2
MAINTENANCE
WORK EQUIPMENT
STANDARD
Unit: mm
No.
Criteria
Check item
Clearance between 1 st
boom and revolving frame
mounting pin and bushing
Shaft
Hole
Standard
clearance
Clearance
limit
- 0.030
-0.104
+0.240
+0.174
0.204 0.344
0.8
110
-0.036
- 0.090
+0.207
+0.120
0.156 0.297
0.8
110
-0.036
- 0.090
+0.207
+0.120
0.156 0.297
0.8
60
- 0.030
-0.104
+0.197
+0.137
0.167 0.301
0.8
60
- 0.030
-0.104
+0.197
+0.137
0.167 0.301
0.8
70
- 0.030
-0.100
+0.141
+0.074
0.104 0.241
0.8
60
- 0.030
- 0.080
+0.129
+0.074
0.1040.209
0.8
0.030
- 0.080
+0.135
+0.074
0.1040.215
0.8
65
- 0.030
- 0.080
+0.133
+0.074
0.1040.213
0.8
60
- 0.030
-0.080
+0.130
+0.074
0.1040.210
0.8
-0.030
-0.100
+0.198
+O. 124
0.154
0.298
0.8
Standard
size
0 80
Clearance between 1 st
boom and 2nd boom
Clearance between 2nd

boom and 3rd bracket
Clearance between 1st

boom and sub-link mounting pin and bushing
Clearance between 3rd

bracket and sub-link
Clearance between 3rd

bracket and arm mounting
pin and bushing
Clearance between arm

and bucket mounting pin
and bushing
Clearance between arm

and link mounting pin and
bushing
0 60
Clearance between link and

link mounting pin and
bushing
10
Clearance between link and

bucket mounting pin and
bushing
11
Clearance between blade

and track frame mounting
pin and bushing
0 70
PC1 28UU-2
Tolerance
Remedy
Replace
bushing,
pin
40-45
MAINTENANCE
STANDARD
DIMENSION
DIMENSION
OF WORK EQUIPMENT
OF WORK EQUIPMENT
ARM
B-B
9JBOOl77
40-46
PC128UU-2
MAINTENANCE
STANDARD
DIMENSION
OF WORK EQUIPMENT
Unit: mm
PC1 28UU-2
No.
Measuring
position
Tolerance
Standard size
Shaft
0 70
Hole
-0.030
-0.104
Arm side
82.5
+I.0
0
Cylinder head side
80
+1.2
Boom side
226
+0.5
0
Arm side
226
+O.lOO
0
-0.2
-0.7
220.4
f2.0
271.3
+1.0
501.3
f0.5
2,108.6
2,111.6
f2.5
10
289.6
+0.5
11
487
f0.2
12
415
f0.5
13
374.9
14
1,175.l
15
0 60
Link side
16
Bucket side
17
0 70
-0.030
-0.104
+O.lOO
0
-0.030
-0.080
259
+0.200
0
J.0
+1.0
261
0 60
Arm side
226
-:.5
Bucket side
274
- 0.030
-0.080
+0.200
0
18
Min.
1,378
f2.0
Max.
2,263
19
PC128UU-2
40-47
DIMENSION OF WORK EQUIPMENT
BUCKET
9JA01399
40-48
PC1 28UU-2
MAINTENANCE
STANDARD
DIMENSION
OF WORK EQUIPMENT
Unit: mm
PC1 28UU-2
No.
Measuring
-
1
2
3
position
I
I
I
I
Standard size
Tolerance
371.3
* 0.5
51.6
97.9
I
I
f 0.5
-
374.9
1,I 59.6
190.5
0 60
+0.2
0
10
0 64
11
0 80
+0.25
0
12
261
f 1.0
13
50
14
85
16
0 18
0 110
18
0 130
19
pr 132
20
0 108
21
274
22
51
23
34
24
106.7
25
124.3
26
74
27
65
17
PC128UU-2
40-49
90
OTHERS
90-3
Hydraulic circuit diagram ..............................
(l/2)
.90-5
Electric circuit diagram
.........................
Electric circuit diagram (2/2). ........................ .90-7
Air conditioner circuit diagram .................... .90-9
PC1 28UU-2
90-l
OTHERS
AIR CONDITIONER
AIR CONDITIONER
Temperature
controllino
swi
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
Air
4
B
L-
-.
Electronic
thermostat
L---
---
Valve
Pressure
COntaCtOr
(Compressor)
cut
Switch
Register
El ower
Valve
T.--T
Xir caadiliantr Unit1
______G-__._______________
____-__-__-__Motor
Contactor
(Condenser)
'III
I
I
__________________-________-__-__-..
DC24V_
SVPO7770
PC128UU-2
90-9
TO:
Komatsu
subsidiary
Komatsu
Liaison
Office
PROPOSAL
NAME
DEPARTMENT/SECTION:
5
:
NAME:
FOR MANUAL
OF COMPANY:
MANUAL
NAME:
MANUAL
No.:
Given in upper right hand corner
MACHINE
1. Details
Attached
2. Include
photo
your
request
or opinion?
3.
Include
users opinion?
or sketch.
1. One sheet should
sheet.
be used for each proposal.

in blue ink.
2.
Please do not write
3.
If there is no manual
09-94(03)30001
of cover.)
MODEL:
If you need more space, use another
KS-9OE
REVISION
No., please write
machine
model,
type and date of publication.

Komatsu PC128UU-2 Shop Manual PDF

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SEBM018506

PC128UU-2 mounts the S4D102E-1 engine.

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised or made aditions.

LIST OF REVISED PAGES

To prevent injury to workers, the symbol

Always wear safety glasses when hitting

3. If welding repairs are needed, always have a

6. Decide a place in the repair workshop to keep

PRECAUTIONS DURING WORK

19.Be sure to assemble all parts again in their original places.

STRUCTURE AND FUNCTION

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

Chassis volume: Issued for every machine model

Revised pages are shown in the LIST OF REVISED

Special safety precautions

Special technical precautions or other precautions

Weight of parts of systems. Caution necessary

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

Slinging near the edge of the hook may cause

3) Do not sling a heavy load with one rope alone,

4) Do not sling a heavy load with ropes forming a

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

1) Hold the mouthpiece of the tightening portion

1) Hold the mouthpiece of the tightening portion

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

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

3) Hold in the condition in Steps 1) and 2), and

3) Hold in the condition in Steps 1) and 2), and

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening portion

Main applications, featuresr

Used to prevent rubber gaskets,

Used in places requiring an immediately effective, strong adhesive.

Features: Resistance to heat and

Used as adhesive or sealant for

Used as sealant for machined

Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Resistance to heat, chemicals

Used as adhesive or sealant for

Used as sealant for various

Features: Silicon based, resistance to heat, cold

Main applications, featuresr

Used as heat-resisting sealant for

Used as lubricant for sliding portion (to prevent from squeaking).

Ftures: Silicon based, quick hardening type

General purpose type

Used for normal temperature,