SEBM018418

MACHINE MODEL SERIAL NUMBER

PC128US-2 5001 – 7730 avance

PC128US-2 7731 and up GALEO
PC138US-2 4501 and up GALEO
PC138USLC-2 1001 and up GALEO

• 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.

• PC128US-2, PC138US-2, PC138USLC-2 mounts the S4D102E and SAA4D95LE engine.

For details of the engine, see the 102 Series and 95 Series Engine Shop Manual.

© 2004
All Rights Reserved
Printed in Japan 10-04(02) 00-1
(18)
 CONTENTS

No. of page
01 GENERAL ................................................................................................................01-1

10 STRUCTURE AND FUNCTION .................................................................10-1

20 TESTING AND ADJUSTING .......................................................................20-1

30 DISASSEMBLY AND ASSEMBLY ..........................................................30-1

40 MAINTENANCE STANDARD .....................................................................40-1

90 OTHERS ....................................................................................................................90-1

00-2 PC128US-2
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30-40 (16) 30-91 (16) 30-143 (16) 40-24 90-7 (10)
30-41 (16) 30-92 (16) 30-144 (16) 40-25 (15) 90-7-2 (10)
30-42 (16) 30-94 (16) 30-145 (16) 40-26 (15) 90-9 (10)
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90-11 (10)
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PC128US-2 00-2-5
(18)
STRUCTURE AND FUNCTION HYDRAULIC PUMP

PC128US-2 Serial No.: 5001 – 7730

4) When the servo piston balances

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

PC128US-2 10-27-2
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP

PC128US-2 Serial No.: 7731 and up

PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up

4) When the servo piston balances

• The area receiving the pressure on the • At the time, the relations of areas receiv-
piston large diameter side is supposed to ing the pressure on the both ends of the
be A1, the one on the small diameter side servo piston (12) are A0 : A1 = 1 : 1.75,
is supposed to be A0 and the pressure and the ones
. of pressures applied on the
flowing to the piston large diameter side piston both. ends at the balancing time are
is supposed to be PEN. PP : PEN = 1.75 : 1 approximately.
• When the pump discharge pressure PP • The spring (4) force has been adjusted so
of the LS valve balances with the com- that the balance stop position of the spool
bined force of the LS pressure PLS and (6) is determined when PP – PLS = 2.21
the spring (4) force Z and the relations of Mpa {22.5 kg/cm2} is satisfied at the stan-
A0 x PP = A1 x PEN are satisfied, the dard center.
servo piston (12) stops at the position and • When port G is applied with PSIG (EPC
the swash plate is held at the intermedi- valve output pressure for LS valve of 0 –
ate position (stops where the opening 2.9 Mpa {10 – 30 kg/cm2}), however, the
from port D to port E of the spool (6) is balance stop position changes proportion-
almost equal to the one from port C to ally to the PSIG pressure in the range of
port D). PP – PLS from 2.1 to 0.6 Mpa {21.5 to 6.5
kg/cm2}.

10-27-3 PC128US-2
(18)
STRUCTURE AND FUNCTION HYDRAULIC PUMP

3) When the pump controller is out of order than the spring set force. So, the spool
and the PC redundant switch is set to ON (3) balances at a position in the left
a. In case of light load to main pump side.
• When the pump controller is out of • At the time, the C port has the same
order, set the PC redundant switch to pressure as the drain pressure at the
ON to change the circuit to the resis- D port, and the drain pressure PT is
tor side. In this case, since the cur- led to the large diameter side of the
rent is too large when the power is di- servo piston (9) through the LS valve.
rectly taken from the battery, the re- Then, the servo piston (9) moves in
sistor is connected to control the cur- the direction where the delivery in-
rent to the PC-EPC valve solenoid. creases because the pressure on the
• At the time, the current becomes con- small diameter side of the piston is
stant and the piston (2) pressing force large.
becomes constant as well.
• When the pump discharge pressure is
low, the combined force of the force
of the PC-EPC valve solenoid (1) and
the discharge pressure PP is smaller

PC128US-2 10-33
(18)
STRUCTURE AND FUNCTION HYDRAULIC PUMP

b. In case of heavy load to main pump

• When the PC redundant switch is set
to ON just like in the previous para-
graph, 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 bal-
ance 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 po-
sition further to the left than when the
pump is lightly loaded.

10-34 PC128US-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, lessens the pres-
sure compensation accuracy of the travel cir-
cuit and limits reduction of the travel speed
to small extent.
• The bypass circuit is closed in case of inde-
pendent travel or independent operation of
an actuator.

Operation
• When the boom spool (1) is operated, the LS
circuit PLS will come to the same pressure as
the boom circuit pressure A1.
• At the same time, the LS circuit pressure PLS
is led to the spring chamber PLS1 of the pres-
sure reducing valve (2) of the travel valve.
• Since the travel spool is not operated, the
travel actuator circuit PA is closed and the
check valve (4) inside the flow control valve
(3) is also closed.
• Therefore, the travel LS bypass circuit is
closed in case of independent operation of the
boom.

PC128US-2 10-73
(18)
STRUCTURE AND FUNCTION CLSS

2. At operation of travel + other actuator

10-74 PC128US-2
STRUCTURE AND FUNCTION TRAVEL MOTOR

Specification

Type GM18VL-J GM20VL-J GM20VL-P GM20VL2-P

PC128US-2 Serial No. 5001 and up 5001 – 6072 6073 and up —
Spec. STD OPT(traction up) —
PC138US-2 Serial No. — — — 4501 and up
Spec. — — — STD
PC138USLC-2 Serial No. — — 1001 – 1500 1501 and up
Spec. — — STD STD
Theoretical delivery Hi 33.2 {33.2} 34.0 {34.0} 31.5 {31.5}
(cm3/rev{cc/rev}) Lo 52.7 {52.7} 55.8 {55.8}
Rated speed Hi 3,267.7 3,191 3,035 3,444
(rpm) Lo 2,147.3 2,028 1,929 2,025
Brake releasing pressure 0.68
(MPa{kg/cm2}) {6.94}

Hi-Lo switching pressure 2.94

(MPa{kg/cm2}) {30}
Final drive reduction ratio 72 75.7

OUTLINE
Travel speed selection

• Swash plate (14) has 2 faces (x, y) behind it,

and is supported by pivot(15).
• When pressure of control chamber a rises, it
pushes regulator piston (24), then swash plate
angle becomes minimum, then travel speed
goes high.

PC128US-2 10-95
(18)
STRUCTURE AND FUNCTION TRAVEL MOTOR

OPERATION
Operation of motor
At slow speed (the motor swash plate angle is maximized.)

• Since the travel 2nd speed selector solenoid

valve is demagnetized, the pressurized oil
from the main pump does not flow to the D
port.
• Therefore, the spring (10) has pressed the
regulator valve (9) to the left side.
• So, the regulator valve (9) stops the main pres-
surized 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 cylin-
der c chamber pushes the swash plate (14) in
the direction to maximize the swash plate
angle and the motor capacity is increased to
the maximum for slow speed travel.

10-96 PC128US-2
2
STRUCTURE AND FUNCTION TRAVEL MOTOR

At high speed (the motor swash plate angle is minimized.)

• When the travel 2nd speed selector solenoid

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

PC128US-2 10-97
2
STRUCTURE AND FUNCTION TRAVEL MOTOR

Operation of brake valve

• The brake valve consists of the check valves
(3a) and (3b), the counterbalance valve (5) and
the safety valve (6), and the circuit configura-
tion is as per the right figure.
• Functions and operations of these compo-
nents are as follows :

Counterbalance valve, check valve

Function
• When traveling down a slope, the machine
weight falling force will make the machine
travel faster than the motor rotation. So, trav-
eling with reduced engine speed is very dan-
gerous because the motor idles and runs
away.
These valves let the machine travel at a speed
appropriate for the engine speed (pump de-
livery) to prevent this danger.

Operation at oil supply

• When the travel lever is operated, the pres-
surized oil from the control valve will be sup-
plied to the PA port, push and open the check
valve (3a) and flow from the MA port on the
motor inlet side to the MB port on the motor
outlet side.
Since the motor outlet circuit is closed with
the check valve (3b) and the counterbalance
valve (5), however, the supply-side pressure
will rise.

10-98 PC128US-2
(18)
STRUCTURE AND FUNCTION ARM HYDRAULIC DRIFT PREVENTION VALVE

Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the
oil from flowing back from the work equipment
cylinder to prevent sudden fall of the work equip-
ment.

Operation
1. When work equipment is in neutral
[When piping is normal]
• Check valve (5) is closed by the work equip-
ment cylinder holding prssure applied
through port CY to chamber b.
• When the work equipment is in neutral, no
pilot pressure is applied from the PPC valve
to port Pi. Accordingly, pilot spool (1) is moved
to the left end by the force of springs (2) and
(3), then chambers a and b are shut off from
each other.
• By this operation, oil does not flow between
the main valve and the work equipment cyl-
inder, thus the work equipment cylinder is
held.
• If the pressure in the work equipment cylin-
der rises high abnormally, work equipment
cylinder holding pressure operates safety
valve (4).

[When piping bursts]

• Even if piping A between the main valve and
work equipment cylinder bursts, chamber a
is shut off from chamber b as in the case
where the piping is normal. Accordingly, the
work equipment cylinder is held.

PC128US-2 10-122-7
C
STRUCTURE AND FUNCTION ARM HYDRAULIC DRIFT PREVENTION VALVE

2. When oil is sent from main valve to cylinder

[When piping is normal]
• If pressure of the oil sent from the main valve
to chamber a is higher than the total of pres-
sure in chamber b connected to the work
equipment cylinder and the force of spring (6),
check valve (5) opens and chambers a and b
are connected to each other and the oil flows
from the main valve to the work equipment
cylinder.

[When piping bursts]

• If piping A between the main valve and work
equipment cylinder bursts, the oil in cham-
ber a flows out through the burst part and
pressure in chamber a lowers.
• If pressure lowers below the total of pressure
in chamber b and the force of spring (6), check
valve (5) closes and chambers a and b are shut
off from each other. Accordingly, pressure in
the cylinder is held and the work equipment
does not fall suddenly.

10-122-8 PC128US-2
(18)
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING

AIR CONDITIONER PIPING

PC128US-2 Serial No.: 5001 – 7730

1. Hot water take-off piping

2. Air conditioner compressor
3. Condenser
4. Refrigerant piping
5. Receiver tank
6. Air conditioner unit
7. Hot water return piping
8. Duct

A : Hot air/cold air spurting hole

B : Inner air circulation hole

PC128US-2 10-123
0
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING

PC128US-2 Serial No.: 7731 and up

PC138USLC-2 Serial No.: 1001 – 1500

A : Hot air/cold air spurting with outlet port

B : Internal air circulation port
C : External air inlet

1. Hot water drain piping 5. Receiver tank

2. Air conditioner compressor 6. Condenser
3. Hot water return piping 7. Air conditioner unit
4. Refrigerant piping 8. Duct

10-123-1 PC128US-2
(18)
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING

PC138US-2 Serial No.: 4501 and up

PC138USLC-2 Serial No.: 1501 and up

A: Hot air/cold air spurting with outlet port

B: Internal air circulation port
C: External air inlet
D: Refrigerant checking port

1. Hot water drain piping 5. Receiver tank

2. Air conditioner compressor 6. Condenser
3. Hot water return piping 7. Air conditioner unit
4. Refrigerant piping 8. Duct

PC128US-2 10-123-2
(18)
STRUCTURE AND FUNCTION ELECTRIC COMPONENT LAYOUT

ELECTRIC COMPONENT LAYOUT

PC128US-2 Serial No.: 5001 – 7730

10-124 PC128US-2
0
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

PC128US-2 Serial No.: 7731 and up

PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up

1. Battery 11. LS-EPC valve

2. Battery relay 12. Engine speed sensor
3. Fusible link 13. Coolant temperature sensor
4. Starting switch 14. Control valve
5. Fuse box 14a. Self pressure reducing valve
6. Controller 14b. Main relief valve
7. Resistor (for driving pump in an emergency) 15. Hydraulic pump
8. Emergency pump drive switch 15a. Servo valve
9. Monitor panel 15b. LS valve
10. PC-EPC valve 15c. PC valve

Input/Output signals
a. Controller power supply e. PC-FPC valve drive signal
b. Solenoid power supply f. LS-FPC valve drive signal
c. Monitor panel power supply g. Coolant temperature signal
d. S-NET signal h. Engine speed signal

PC128US-2 10-138-1
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

Function
• This function is for selecting any of the three
working modes "A," "B" and "E" with the work-
ing mode selector switch on the monitor
panel. The controller can select optimum
engine torques or pump absorption torques
for works to be expected.

• The controller detects the engine governor

speed set with the fuel control dial depend-
ing on the pump absorption torques set in
each mode and detects actual engine speeds.
Then, the controller controls all torques at
each output point of the engine so that the
pump can absorb them.

• When an engine speed was lowered, the con-

troller prevents the engine from stopping by
throttling the pump absorption torque.

10-138-2 PC128US-2
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

FUNCTION
Swing lock, swing holding brake
• Swing lock holds swing at any position, and
swing holding brake works to prevent swing
drift.
fl Be careful when using the machine in this
condition. When the swing holding brake is
released, the swing is held only by a brake
operated hydraulically by the swing safety
valve, so therre may be hydraulic drift when
the swing is stopped on a slope.
fl Release the swing holding brake also during
arm IN operations.

Swing Swing
lock lock Function Operation
switch lamp

• When the swing control lever is returned

Swing to the neutral position, the swing holding
ON Gose out holding brake is actuated after approx. 4 seconds.
• When the swing control lever is operated,
brake
the swing holding brake is released, and
it is possible to operate the swing freely.

• If abnormality occurs in the swing hold-

ing brake system and OFF, the swing hold-
ing brake is canceled and it becomes pos-
OFF Lights up Swing sible to operate the swing.
lock • However, even when the swing control
level is returned to the nertral position, the
swing holding brake is not actuated.

PC128US-2 10-141
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

Swing holding brake release

• When there is a problem in the controller and
swing holding brake dosn't work properly,
swing holding brake can be released and then
swing can be operated by operating swing
holding brake release switch to ON.
(1) OFF position : Release
(2) ON position : Automatic
fl When swing lock switch is turned ON, even it
swing holding brake switch is turned ON,
swing holding brake is not released.

Swing holding ON OFF

breake release (When abnormality) (When controlleris
switch safe)
Swing lock
switch ON OFF ON OFF

Swing
Swing Swing Swing holding
Swing brake lock lock lock
breake
operates released operates
operates

Input/Output Signal time chart

10-142 PC128US-2
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

SELF DIAGNOSIS FUNCTION

PC128US-2 Serial No.: 7731 and up
PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up

1. Error code display/Alarm functions

• Controller always watches electronic de-
vices which constitutes the system, in-
cluding controller itself, each potentiom-
eter which issues input signals, each so-
lenoid valve which receives output sig-
nals, and EPC valves, to check for they nor-
mal operation.
• If problem occurred in any of these de-
vices, the controller diagnoses it and dis-
play the results on display (1) of monitor
panel as a "USER CODE" or "Service
code", sounding alarm buzzer at the same
time to notify the problem to operator.
fl Refer to the "TROUBLESHOOTING" sec-
tion as for the details of display and mea-
sures to be taken.

2. Error code memory function

• Controller takes in memory the error code
diagnosed about problem which occurred
in advanced system.
fl Refer to the "TESTING AND ADJUSTING"
section as for the details of display and
how to reset.

PC128US-2 10-144-7
(18)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

SYSTEM COMPONENTS
ENGINE SPEED SENSOR

Function 1. Wire
PC128US-2 Serial No.: 5001 – 7730 2. Magnet
• The engine speed sensor is installed on the 3. Terminal
ring gear of the engine flywheel. It electri- 4. Housing
cally counts number of gear teeth that pass 5. Connector
its front side and sends the counting to the
pump controller.

PC128US-2 Serial No.: 7731 and up

PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
• The engine speed sensor is installed on the
ring gear of the engine flywheel. It electri-
cally counts number of gear teeth that pass
its front side and sends the counting to the
controller.

Remarks : Number of ring gear teeth is 127.

• For the count, a magnet is used which gener-

ates current every time a gear tooth passes
its front side.

PC128US-2 10-145
(15)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM

PPC HYDRAULIC SWITCH

Specification 1. Plug
Contact structre : Normally opened 2. Switch
Operating (ON) pressure : 3. Connector
490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure :
294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}

Function
PC128US-2 Serial No.: 5001 – 7730
• 3 switches installed to control valve sense
operating condetion of each actuator, and
send it to swing holding brake controller.
• 1 switch installed to travel PPC valve sense
travel operating condition, and operates 2-
stage relief solenoid valve.

PC128US-2 Serial No.: 7731 and up

PC138US-2 Serial No.: 4501 and up
PC138USLC-2 Serial No.: 1001 and up
• 8 switches installed to control valve sense
operating condition of each actuator, and send
it to controller.
• 1 switch installed to travel PPC valve sense
travel operating condition, and send it to con-
troller.

10-146 PC128US-2
(18)
STRUCTURE AND FUNCTION MONITOR SYSTEM

MONITOR SYSTEM
PC128US-2 Serial No.: 5001 – 7730

• This system monitors the machine status us-

ing 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 fol-
lowing blocks:
1. Monitor block that generates alarms
should the machine fail.
2. Pilot block that displays status of the ma-
chine during operation.
3. Gauge block that constantly displays sta-
tus of the machine status through in and
out of operation.
• The monitor panel also equips with the 4-sys-
tem indicator and its operation switches.

PC128US-2 10-149
0
STRUCTURE AND FUNCTION MONITOR SYSTEM

MONITOR PANEL
PC128US-2 Serial No.: 5001 – 7730

Outline
• Monitor panel has monitoring function, gauge • It has LCD display in gauge display position.
display function, service meter function and • It has lamps in monitor display position.
switching function.
• CPU (Central Processing Unit) is installed in
it.

Input and output signals

AMP040-16P [CN-P01]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 Power source (24V) — 9 Engine oil pressure Input
2 Power source (24V) — 10 Battery charging level Input
3 GND — 11 Spare caution —
4 GND — 12 Swing lock Input
5 Starting signal Input 13 Preheating Input
6 Coolant temperature Input 14 — —
7 Fuel level Input 15 Alarm buzzer Output
8 — — 16 Lighting Input

KES-4P(1) [CX-P02] KES-3P [CN-C12]

Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 — — 1 — —
2 Work light Output 2 Car heater Hi Output
3 Lighting Output 3 Car heater Lo Output
4 Power source (24V) — 4 Car heater Hi —

10-150 PC128US-2
(18)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC128US-2

Cate- Standard value Service limit

gory Item Measurement conditions Unit Serial No. for new value
machine
Total work fl See Fig. G
equipment
(hydraulic drift • Place in above posture and measure Max. 500 Max. 700
at tip of bucket extension or retraction of each cyl-
teeth) inder and downward movement at
Hydraulic drift of work equipment

Boom cylinder tip of bucket teeth.

(amount of • Horizontal, flat ground
retraction of • Bucket: Rated load (450 kg) Max. 15 Max. 23
cylinder) • Levers at HOLD
• Engine stopped
Arm cylinder • Hydraulic oil temperature: 45 – 55°C
(amount of • Start measuring immediately after
extension of setting. mm 5001 and up Max. 50 Max. 75
cylinder) • Measure hydraulic drift every 5 min-
utes, and judge from results for 15
Bucket cylinder minutes.
(amount of
retraction of Max. 40 Max. 60
cylinder)

• Engine stopped
Blade • Hydraulic oil temperature: 45 – 55°C
(hydraulic drift • Set blade at maximum lifting height Max. 31 Max. 47
at tip of blade) and measure downward movement
at edge of blade for 15 minutes.

Boom fl See Fig. H

3.8 ± 0.3
RAISE

Bucket teeth in Max. 4.4

• Engine at full throttle (Until touching (Until touching
contact with cushion) cushion)
Work equipment

ground • Hydraulic oil temperature

: 45 – 55°C
LOWER

Cylinder fully 3.1 ± 0.3 Max. 4.2

extended

fl See Fig. I
Arm 3.2 ± 0.3 Max. 4.0
IN

• Engine at full throttle (Until touching (Until touching

Cylinder fully cushion) cushion)
retracted • Hydraulic oil temperature
: 45 – 55°C
Work equipment speed

3.1 ± 0.3 Max. 3.7

OUT

(Until touching (Until touching

Fully extended cushion) cushion)
Sec 5001 and up
fl See Fig. J
CURL

Bucket
Cylinder fully • Engine at full throttle 2.9 ± 0.3 Max. 3.7
retracted • Hydraulic oil temperature
: 45 – 55°C
DUMP

Fully extended 2.3 ± 0.2 Max. 2.9

fl See Fig. K
RAISE

Blade
Blade in contact • Engine at full throttle 1.3 ± 0.3 Max. 2.5
with ground • Hydraulic oil temperature
: 45 – 55°C
LOWER

Blade fully 1.3 ± 0.3 Max. 2.5

raised

PC128US-2 20-7
(18)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC128US-2

Cate- Standard value Service limit

gory Item Measurement conditions Unit Serial No. for new value
machine
fl See Fig. L
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Fully retract arm and bucket
Boom cylinders, then lower boom from Max. 3 Max. 3
maximum height and measure
time taken from point where
bucket contacts ground to point
where chassis rises from ground

fl See Fig. M
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Set top surface of boom horizon-
Arm tal, retract bucket cylinder fully, Max. 2 Max. 2
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.
Time lag

Sec
fl See Fig. N
Work equipment

• Engine at low idling

• Hydraulic oil temperature
: 45 – 55°C
• Set top surface of boom horizon-
Bucket tal, retract arm cylinder fully, then 5001 and up Max. 2 Max. 2
extend bucket cylinder and
measure time taken for bucket to
start moving again after stopping
at bottom.

fl See Fig. O
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Lower blade from maximum
height and measure time taken Max. 2 Max. 2
Blade from point where blade contacts
ground to point where chassis
rises from ground.

• Hydraulic oil temperature

Internal leakage level

: 45 – 55 ºC
• Engine full Max. 3.5 Max. 15
Each cylinder • Circuit to be measured is relieved.
cc/
min
Center swivel
Max. 10 Max. 50
joint

20-8 PC128US-2
7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC138USLC-2

Cate- Standard value

gory Item Measurement conditions Unit Service limit value
for new machine

fl See Fig. H
Boom 3.8 ± 0.3

RAISE
Max. 4.4
Bucket teeth in • Engine at full throttle (Until touching (Until touching
contact with • Hydraulic oil temperature cushion) cushion)
ground : 45 – 55°C

LOWER
Cylinder fully 3.1 ± 0.3 Max. 4.2
extended

fl See Fig. I
3.2 ± 0.3 Max. 4.0
IN
Arm • Engine at full throttle (Until touching (Until touching
Cylinder fully • Hydraulic oil temperature cushion) cushion)
retracted : 45 – 55°C
Work equipment speed

3.1 ± 0.3 Max. 3.7

OUT

Fully extended (Until touching (Until touching

cushion) cushion)

Sec.
fl See Fig. J
CURL

Bucket • Engine at full throttle 3.2 ± 0.3 Max. 4.0

Cylinder fully • Hydraulic oil temperature
retracted : 45 – 55°C
Work equipment

DUMP

Fully extended 2.6 ± 0.2 Max. 3.2

fl See Fig. K
RAISE

Blade • Engine at full throttle 1.3 ± 0.3 Max. 2.5

Blade in contact • Hydraulic oil temperature
with ground : 45 – 55°C
LOWER

Blade fully 1.3 ± 0.3 Max. 2.5

raised

fl See Fig. L
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Fully retract arm and bucket
cylinders, then lower boom from
Time lag

maximum height and measure

Boom time taken from point where Sec. Max. 3 Max. 3
bucket contacts ground to point
where chassis rises from ground

PC128US-2 20-8-5
(18)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC138USLC-2

Cate- Standard value

gory Item Measurement conditions Unit Service limit value
for new machine

fl See Fig. M
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Set top surface of boom horizon-
Arm tal, retract bucket cylinder fully, Max. 2 Max. 2
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.

fl See Fig. N
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
Time lag

• Set top surface of boom horizon-

Bucket tal, retract arm cylinder fully, then Sec Max. 2 Max. 2
extend bucket cylinder and
measure time taken for bucket to
Work equipment

start moving again after stopping

at bottom.

fl See Fig. O
• Engine at low idling
• Hydraulic oil temperature
: 45 – 55°C
• Lower blade from maximum Max. 2 Max. 2
Blade height and measure time taken
from point where blade contacts
ground to point where chassis
rises from ground.

• Hydraulic oil temperature

Internal leakage level

: 45 – 55 ºC
Eachcylinder • Engine full Max. 3.5 Max. 15
• Circuit to be measured is relieved.
cc/
min
Center swivel
joint Max. 10 Max. 50

20-8-6 PC128US-2
(17)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Pump performance curve

• TVC current: 0.4 A

• Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)

Test pump Discharge Average Standard value Judgement

Check point discharge pressure of pressure for discharge standard lower
pressure other pump amount limit
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) Q (¬/min) Q (¬/min)
P1 + P2
As desired P1 P2 See graph See graph
2

fl As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average
pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
fl When measuring with the pump mounted on the machine, if it is impossible to set the engine speed
to the specified speed with the fuel control dial, take the pump discharge amount and the engine
speed at the point of measurement, and use them as a base for calculating the pump discharge
amount at the specified speed.

PC128US-2 20-11
(18)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

PC128US-2 Serial No.: 5001 – 7730
Sys- Name of Connector Inspec- Measurement
tem component No. tion Judgment table
method conditions

Measure voltage
If the condition is as shown in the table 1) Turn starting
below, it is normal switch ON.
2) Insert T-adapter.
Power source voltage C01 Between (1) – (8) 20 – 30 V

If the condition is as shown in the table 1) Turn starting

below, it is normal
Measure voltage
switch ON.
Engine Diesel mode 0–5V 2) Insert T-adapter.
Controller

at full Between
PC-EPC solenoid C01 throttle Kerosene mode 0 – 7 V
(7) –
Engine chassis Diesel mode
at low 6 – 13 V
idling Kerosene mode

If the condition is as shown in the table 1) Turn starting

Measure voltage

below, it is normal switch ON.

2) Insert T-adapter.
Kerosene mode C01 In standard 4–6V
mode Between
(11) –
In kerosene chassis 0–1V
mode

If the condition is as shown in the table 1) Turn starting

below, it is normal switch ON.
Note : “Actuated” indicates that the
solenoid (relay) is actuated. 2) Insert T-adapter.
Measure voltage

When carrying out testing and

adjusting of the actuation at the
machine end, see MEASURING
One-touch deceleration SOLENOID VALVE OUTPUT
controller K18
PRESSURE.

When 20 – 30 V
actuated Between
(16) –
When not chassis 0–3V
actuated

If the condition is as shown in the table 1) Turn starting

resistance

below, it is normal
Measure

switch OFF.
PPC hydraulic lock V07 2) Disconnect
solenoid (male) Between (1) – (2) 37 – 60 Ω
Machine control

connector.
Between (1), (2) – chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting

resistance

below, it is normal
Measure

switch OFF.
Swing holding brake V04
solenoid Between (1) – (2) 37 – 60 Ω 2) Disconnect
(male) connector.
Between (1), (2) – chassis Min. 1 MΩ

20-12 PC128US-2
0
 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

Adjusting
1. Adjusting main relief valve
• Disconnect high pressure hose.
1) Adjusting high pressure setting
• Loosen locknut (2) of main relief valve (1),
then turn holder (3) to adjust.
fl Turn the holder to adjust as follows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl After adjusting, use the measurement pro-
cedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
fl When the high pressure setting is ad-
justed, the low pressure setting will also
change, so adjust the low pressure set-
ting also.
2) Adjusting low pressure setting
• Loosen locknut (4) of main relief valve (1),
then turn holder (5) to adjust.
fl Turn the holder to adjust as follows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl After adjusting, use the measurement pro-
cedure above to check the oil pressure
again.
fl Amount of adjustment for one turn of
holder : Approx. 12.6 MPa {128 kg/cm2}
9 Locknut :
39.2 – 49.0 Nm {4 – 5 kgm}

2. Adjusting swing motor safety valve

fl If the swing relief pressure is not normal, ad-
just the swing motor safety valve as follows.
1) Loosen locknut (7) of swing motor safety valve
(6), then turn adjustment screw (8) to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
fl Amount of adjustment for one turn of ad-
justment screw : 14.0 MPa {143 kg/cm2}

PC128US-2 20-115
(18)
 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

2) After adjusting, tighten locknut (7).

9 Locknut
: 53.9 – 73.5 Nm {5.5 – 7.5 kgm}
fl After completion of adjustment, use the
measurement procedure above to check
the oil pressure again.

20-116 PC128US-2
7
 TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)

TESTING AND ADJUSTING OUTPUT PRESSURE

OF PC VALVE (SERVO PISTON
INPUT PRESSURE)
Measuring
fl Oil temperature when measuring : 45 – 55 ºC

1. Remove pressure measurement plugs (1) and (2)

(Thread dia.= 10 mm, Pitch=1.25 mm), and install
oil pressure gauge C1 (39.2 MPa {400 kg/cm2}).

2. Turn the swing lock switch ON.

3. Run the engine at full throttle and measure the

oil pressure when the arm IN circuit is relieved.

[Reference]
If there is any abnormality with problem in the
LS valve or servo piston, the servo piston input
pressure becomes a value close to 0 or the same
pressure as the pump discharge pressure.

PC128US-2 20-117
(18)
 TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)

Adjusting
fl If the load increases and the engine speed drops,
or if the engine speed is normal but the work
equipment speed is slow, adjust PC valve (6) as
follows if the pump discharge pressure and LS
differential pressure are normal.
1) Remove nut (3) and disconnect hose.
2) Loosen locknut (4), and if the work equipment
speed is slow, turn screw (5) clockwise; if the
engine speed drops, turn the screw counter-
clockwise.

20-118 PC128US-2
7