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WEN00003-00
HYDRAULIC
EXCAVATOR
PC128US-8
SERIAL NUMBERS 20001 and up
aArm crane cannot be used on this machine.
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PC128US-8 00-1
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC128US-8
Machine model Serial number
PC128US-8 20001 and up
00 Index and foreword 1
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00-2 PC128US-8
00 Index and foreword
Table of contents
Index
Table of contents 1
00 Index and foreword
Index .................................................................................................................................................. 00-2
Table of contents............................................................................................................................ 00-2
Foreword and general information..................................................................................................... 00-9
Safety notice................................................................................................................................... 00-9
How to read the shop manual......................................................................................................... 00-14
Explanation of terms for maintenance standard............................................................................. 00-16
Handling of electric equipment and hydraulic component.............................................................. 00-18
Handling of connectors newly used for engines............................................................................. 00-27
How to read electric wire code ....................................................................................................... 00-30
Precautions when carrying out operation....................................................................................... 00-33
Method of disassembling and connecting push-pull type coupler.................................................. 00-36
Standard tightening torque table .................................................................................................... 00-39
Conversion table............................................................................................................................. 00-43
01 Specification
Specification and technical data......................................................................................................... 01-3
Specification dimension drawing.................................................................................................... 01-3
Working range diagram.................................................................................................................. 01-4
Specifications ................................................................................................................................. 01-5
Weight table.................................................................................................................................... 01-8
Table of fuel, coolant and lubricants............................................................................................... 01-10
10 Structure, function and maintenance standard
Engine and cooling system................................................................................................................ 10-4
Engine and cooling system............................................................................................................. 10-4
PTO................................................................................................................................................ 10-5
Cooling system............................................................................................................................... 10-6
Power train......................................................................................................................................... 10-8
Power train ..................................................................................................................................... 10-8
Swing circle .................................................................................................................................... 10-9
Swing machinery............................................................................................................................ 10-10
Undercarriage and frame................................................................................................................... 10-12
Track frame .................................................................................................................................... 10-12
Idler cushion................................................................................................................................... 10-13
Idler................................................................................................................................................. 10-14
Track roller...................................................................................................................................... 10-15
Carrier roller.................................................................................................................................... 10-16
Sprocket ......................................................................................................................................... 10-17
Track shoe...................................................................................................................................... 10-18
Hydraulic system................................................................................................................................ 10-24
Hydraulic equipment layout drawing............................................................................................... 10-24
Valve control................................................................................................................................... 10-26
Hydraulic tank and filter.................................................................................................................. 10-28
Hydraulic pump............................................................................................................................... 10-30
Control valve................................................................................................................................... 10-56
CLSS.............................................................................................................................................. 10-68
Functions and operation by valve................................................................................................... 10-72
PPC valve....................................................................................................................................... 10-102
Swing motor.................................................................................................................................... 10-119
Travel motor ................................................................................................................................... 10-127
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PC128US-8 00-3
00 Index and foreword
Table of contents
Center swivel joint.......................................................................................................................... 10-136
Solenoid valve................................................................................................................................ 10-140
PPC accumulator ........................................................................................................................... 10-144
Holding valve.................................................................................................................................. 10-146
Work equipment................................................................................................................................. 10-152
Work equipment............................................................................................................................. 10-152
Dimensions of components............................................................................................................ 10-154
Hydraulic cylinder........................................................................................................................... 10-158
Cab and its attachments.................................................................................................................... 10-160
Air conditioner ................................................................................................................................ 10-160
Electrical system................................................................................................................................ 10-172
Electronic control system ............................................................................................................... 10-172
Monitor system............................................................................................................................... 10-205
KOMTRAX system......................................................................................................................... 10-219
Sensor............................................................................................................................................ 10-221
20 Standard value table
Standard service value table.............................................................................................................. 20-3
Standard value table for engine related parts ................................................................................ 20-3
Standard value table for chassis related parts ............................................................................... 20-4
30 Testing and adjusting
Related information on testing and adjusting..................................................................................... 30-3
Tools for testing, adjusting, and troubleshooting............................................................................ 30-3
Sketches of special tools................................................................................................................ 30-7
Engine and cooling system................................................................................................................ 30-8
Testing engine speed..................................................................................................................... 30-8
Testing exhaust temperature.......................................................................................................... 30-9
Checking exhaust gas color ........................................................................................................... 30-10
Adjusting valve clearance............................................................................................................... 30-11
Testing compression pressure....................................................................................................... 30-13
Testing blow-by pressure............................................................................................................... 30-15
Testing engine oil pressure............................................................................................................ 30-16
Handling fuel system parts............................................................................................................. 30-17
Releasing residual pressure from fuel system ............................................................................... 30-17
Testing fuel pressure...................................................................................................................... 30-18
Testing fuel return rate and fuel leakage........................................................................................ 30-19
Bleeding air from fuel circuit........................................................................................................... 30-21
Checking fuel circuit for leakage .................................................................................................... 30-23
Testing and adjusting alternator belt tension.................................................................................. 30-24
Checking and adjusting air conditioner compressor belt tension................................................... 30-25
Power train......................................................................................................................................... 30-26
Testing swing circle bearing clearance .......................................................................................... 30-26
Undercarriage and frame................................................................................................................... 30-27
Checking and adjusting track shoe tension.................................................................................... 30-27
Hydraulic system................................................................................................................................ 30-29
Testing and adjusting oil pressure in work equipment, swing, and travel circuits.......................... 30-29
Testing control circuit basic pressure............................................................................................. 30-32
Testing and adjusting oil pressure in pump PC control circuit........................................................ 30-33
Testing and adjusting oil pressure in pump LS control circuit........................................................ 30-36
Testing solenoid valve output pressure.......................................................................................... 30-40
Testing PPC valve output pressure................................................................................................ 30-41
Adjusting play of work equipment and swing PPC valves.............................................................. 30-43
Checking parts which cause hydraulic drift of work equipment...................................................... 30-44
Testing and adjusting travel deviation............................................................................................ 30-46
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00-4 PC128US-8
00 Index and foreword
Table of contents
Releasing residual pressure from hydraulic circuit......................................................................... 30-48
Testing oil leakage.......................................................................................................................... 30-49
Bleeding air from each part ............................................................................................................ 30-52
Cab and its attachments .................................................................................................................... 30-54
Checking cab tipping stopper......................................................................................................... 30-54
Adjusting mirrors............................................................................................................................. 30-54
Electrical system................................................................................................................................ 30-56
Special functions of machine monitor............................................................................................. 30-56
Handling voltage circuit of engine controller................................................................................... 30-108
Preparation work for troubleshooting of electrical system.............................................................. 30-109
Procedure for testing diodes........................................................................................................... 30-114
Pm-Clinic............................................................................................................................................ 30-115
Pm Clinic service............................................................................................................................ 30-115
40 Troubleshooting
Related information on troubleshooting ............................................................................................. 40-6
Points to remember when performing troubleshooting................................................................... 40-6
How to proceed in troubleshooting................................................................................................. 40-8
Checks before troubleshooting....................................................................................................... 40-10
Classification and procedures for troubleshooting.......................................................................... 40-11
Information in troubleshooting table ............................................................................................... 40-12
Phenomena looking like troubles and troubleshooting Nos............................................................ 40-14
Connection table of connector by No. of pins................................................................................. 40-17
T-box and T-adapter list ................................................................................................................. 40-54
Failure code table........................................................................................................................... 40-58
Fuse locations ................................................................................................................................ 40-62
Troubleshooting by failure code......................................................................................................... 40-64
Failure code [989L00] Engine controller lock caution 1.................................................................. 40-64
Failure code [989M00] Engine controller lock caution 2................................................................. 40-64
Failure code [989N00] Engine controller lock caution 3................................................................. 40-65
Failure code [AB00KE] Charge voltage low ................................................................................... 40-66
Failure code [B@BAZG] Eng oil press. low.................................................................................... 40-68
Failure code [B@BAZK] Eng oil level low ...................................................................................... 40-68
Failure code [B@BCNS] Eng coolant overheat.............................................................................. 40-69
Failure code [B@HANS] Hydr oil overheat..................................................................................... 40-69
Failure code [CA111] ECM critical internal failure.......................................................................... 40-70
Failure code [CA115] Eng. Ne and Bkup speed sensor error ........................................................ 40-73
Failure code [CA122] Charge air press sensor high error.............................................................. 40-74
Failure code [CA123] Charge air press sensor low error ............................................................... 40-76
Failure code [CA131] Throttle sensor high error ............................................................................ 40-78
Failure code [CA132] Throttle sensor low error.............................................................................. 40-80
Failure code [CA144] Coolant temp. sensor high error.................................................................. 40-81
Failure code [CA145] Coolant temp. sensor low error.................................................................... 40-82
Failure code [CA153] Charge air temp. sensor high error.............................................................. 40-83
Failure code [CA154] Charge air temp. sensor low error............................................................... 40-84
Failure code [CA187] Sensor sup. 2 volt. low error........................................................................ 40-85
Failure code [CA221] Ambient air press. sensor high error............................................................ 40-86
Failure code [CA222] Ambient air press. sensor low error............................................................. 40-88
Failure code [CA227] Sensor sup. 2 volt. high error....................................................................... 40-90
Failure code [CA234] Eng. overspeed............................................................................................ 40-91
Failure code [CA238] Ne speed sensor sup. volt. error.................................................................. 40-92
Failure code [CA271] IMV/PCV1 short error .................................................................................. 40-94
Failure code [CA272] IMV/PCV1 open error .................................................................................. 40-95
Failure code [CA322] Injector #1 (L #1) system open/short error................................................... 40-96
Failure code [CA324] Injector #3 (L #3) system open/short error................................................... 40-98
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PC128US-8 00-5
00 Index and foreword
Table of contents
Failure code [CA331] Injector #2 (L #2) system open/short error .................................................. 40-100
Failure code [CA332] Injector #4 (L #4) system open/short error .................................................. 40-102
Failure code [CA351] Inj. drive circuit error.................................................................................... 40-104
Failure code [CA352] Sensor sup. 1 volt. low error........................................................................ 40-107
Failure code [CA386] Sensor sup. 1 volt. high error ...................................................................... 40-108
Failure code [CA435] Abnormality in engine oil pressure switch ................................................... 40-110
Failure code [CA441] Battery voltage low error.............................................................................. 40-111
Failure code [CA442] Battery voltage high error............................................................................ 40-111
Failure code [CA449] Rail press. very high error ........................................................................... 40-112
Failure code [CA451] Rail press. sensor high error ....................................................................... 40-114
Failure code [CA452] Rail press. sensor low error......................................................................... 40-116
Failure code [CA553] Rail press. high error................................................................................... 40-116
Failure code [CA559] Rail press. low error..................................................................................... 40-117
Failure code [CA689] Eng. Ne speed sensor error ........................................................................ 40-120
Failure code [CA731] Eng. Bkup speed sensor phase error.......................................................... 40-122
Failure code [CA757] All persistent data lost error......................................................................... 40-122
Failure code [CA778] Eng. Bkup speed sensor error..................................................................... 40-124
Failure code [CA1633] KOMNET datalink timeout error ................................................................ 40-126
Failure code [CA2185] Throttle sens. sup. volt. high error............................................................. 40-128
Failure code [CA2186] Throttle sens. sup. volt. low error .............................................................. 40-130
Failure code [CA2249] Rail press. very low error........................................................................... 40-130
Failure code [CA2311] Abnormality in IMV solenoid...................................................................... 40-131
Failure code [D110KB] Battery relay drive short............................................................................ 40-132
Failure code [D19JKZ] Personal code relay abnormality............................................................... 40-134
Failure code [D862KA] GPS antenna discon................................................................................. 40-136
Failure code [DA22KK] Pump solenoid power low error................................................................ 40-138
Failure code [DA25KP] 5V sensor 1 power abnormality................................................................ 40-140
Failure code [DA26KP] 5V sensor 2 power abnormality................................................................ 40-143
Failure code [DA2RMC] CAN discon (Pump controller detected).................................................. 40-144
Failure code [DAF8KB] Short circuit in camera power supply........................................................ 40-146
Failure code [DAFGMC] GPS module error................................................................................... 40-148
Failure code [DAFRMC] CAN discon (Monitor detected)............................................................... 40-150
Failure code [DGH2KB] Hydr oil sensor short................................................................................ 40-152
Failure code [DHPAMA] Pump press sensor abnormality.............................................................. 40-154
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality.................................. 40-156
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality ............................... 40-158
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality.................................. 40-160
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality................................ 40-162
Failure code [DHSKMA] Blade raise PPC press sensor abnormality............................................. 40-164
Failure code [DHSLMA] Blade lower PPC press sensor abnormality............................................ 40-166
Failure code [DHX1MA] Overload sensor abnormality (Analog).................................................... 40-168
Failure code [DV20KB] Travel alarm S/C....................................................................................... 40-169
Failure code [DW43KA] Travel speed sol discon........................................................................... 40-170
Failure code [DW43KB] Travel speed sol short ............................................................................. 40-171
Failure code [DW45KA] Swing brake sol discon............................................................................ 40-172
Failure code [DW45KB] Swing brake sol short .............................................................................. 40-174
Failure code [DW91KA] Travel junction sol discon ........................................................................ 40-176
Failure code [DW91KB] Travel junction sol short........................................................................... 40-177
Failure code [DWJ0KA] Merge-divider sol discon.......................................................................... 40-178
Failure code [DWJ0KB] Merge-divider sol short ............................................................................ 40-179
Failure code [DXA8KA] PC-EPC sol discon................................................................................... 40-180
Failure code [DXA8KB] PC-EPC sol short..................................................................................... 40-182
Failure code [DXE4KA] Service current EPC discon ..................................................................... 40-184
Failure code [DXE4KB] Service current EPC short........................................................................ 40-185
Failure code [DY20KA] Wiper working abnormality ....................................................................... 40-186
Failure code [DY20MA] Wiper parking abnormality ....................................................................... 40-188
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00-6 PC128US-8
00 Index and foreword
Table of contents
Failure code [DY2CKA] Washer drive discon................................................................................. 40-190
Failure code [DY2CKB] Washer drive short................................................................................... 40-192
Failure code [DY2DKB] Wiper drive (for) short............................................................................... 40-194
Failure code [DY2EKB] Wiper drive (rev) short.............................................................................. 40-196
Troubleshooting of electrical system (E-mode).................................................................................. 40-198
Before carrying out troubleshooting of electrical system................................................................ 40-198
Information in troubleshooting table ............................................................................................... 40-200
E-1 When starting switch turned ON, machine monitor displays nothing....................................... 40-202
E-2 When starting switch turned ON (before starting engine), basic check item lights up............. 40-204
E-3 Engine does not start (Engine does not turn) .......................................................................... 40-205
E-4 Preheater does not operate..................................................................................................... 40-208
E-5 Automatic warm-up system does not operate (in cold season)............................................... 40-210
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked............. 40-212
E-7 Precaution lights up while engine is running............................................................................ 40-214
E-8 Emergency stop item lights up while engine is running........................................................... 40-217
E-9 Engine coolant temperature gauge does not indicate normally............................................... 40-218
E-10 Hydraulic oil temperature gauge does not indicate normally................................................. 40-219
E-11 Fuel level gauge does not indicate normally.......................................................................... 40-221
E-12 Contents of display by machine monitor are different from applicable machine.................... 40-223
E-13 Machine monitor does not display some items...................................................................... 40-223
E-14 Function switch does not work............................................................................................... 40-223
E-15 Auto-decelerator does not operate normally.......................................................................... 40-224
E-16 Working mode does not change............................................................................................ 40-225
E-17 Travel speed does not change............................................................................................... 40-226
E-18 Alarm buzzer cannot be stopped........................................................................................... 40-227
E-19 Windshield wiper and window washer do not operate........................................................... 40-228
E-20 Swing holding brake does not operate normally.................................................................... 40-232
E-21 Travel alarm does not sound or does not stop sounding....................................................... 40-234
E-22 Air conditioner does not operate normally (including air conditioner abnormality record) ..... 40-235
E-23 While starting switch is in OFF position, service meter is not displayed................................ 40-247
E-24 Machine monitor cannot be set in service mode.................................................................... 40-247
E-25 Monitoring function does not display lever control signal normally........................................ 40-248
E-26 KOMTRAX system does not operate normally...................................................................... 40-264
Troubleshooting of hydraulic and mechanical system (H-mode)....................................................... 40-265
Information contained in troubleshooting table............................................................................... 40-265
System chart for hydraulic and mechanical systems...................................................................... 40-266
H-1 Speed or power of all work equipment, swing, and travel are low........................................... 40-268
H-2 Engine speed sharply drops or engine stalls........................................................................... 40-269
H-3 No work equipment, travel and swing move............................................................................ 40-270
H-4 Abnormal noise is heard from around hydraulic pump............................................................ 40-270
H-5 Fine control mode does not function........................................................................................ 40-271
H-6 Speed or power of boom is low ............................................................................................... 40-272
H-7 Speed or power of arm is low.................................................................................................. 40-273
H-8 Speed or power of bucket is low.............................................................................................. 40-274
H-9 Work equipment does not move in its single operation........................................................... 40-275
H-10 Hydraulic drift of work equipment is large.............................................................................. 40-276
H-11 Time lag of work equipment is large...................................................................................... 40-277
H-12 Work equipment loaded more is slower during compound operation.................................... 40-277
H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE........................ 40-277
H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel. 40-278
H-15 Machine deviates during travel.............................................................................................. 40-279
H-16 Travel speed is low................................................................................................................ 40-280
H-17 Machine cannot be steered easily or steering power is low .................................................. 40-281
H-18 Travel speed does not change or it is kept low or high.......................................................... 40-282
H-19 Track does not move (Only either side)................................................................................. 40-282
H-20 Machine does not swing........................................................................................................ 40-283
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PC128US-8 00-7
00 Index and foreword
Table of contents
H-21 Swing acceleration or swing speed is low............................................................................. 40-284
H-22 Excessive overrun when stopping swing............................................................................... 40-285
H-23 When upper structure stops swinging, it makes large shock................................................. 40-286
H-24 When upper structure stops swinging, it makes large sound ................................................ 40-286
H-25 Hydraulic drift of swing is large.............................................................................................. 40-287
H-26 Flow rate in attachment circuit cannot be adjusted ............................................................... 40-288
Troubleshooting of engine (S-mode) ................................................................................................. 40-290
Method of using troubleshooting chart........................................................................................... 40-290
S-1 Starting performance is poor ................................................................................................... 40-294
S-2 Engine does not start............................................................................................................... 40-295
S-3 Engine does not pick up smoothly........................................................................................... 40-298
S-4 Engine stops during operations............................................................................................... 40-299
S-5 Engine does not rotate smoothly............................................................................................. 40-300
S-6 Engine lacks output (or lacks power)....................................................................................... 40-301
S-7 Exhaust smoke is black (incomplete combustion)................................................................... 40-302
S-8 Oil consumption is excessive (or exhaust smoke is blue) ....................................................... 40-303
S-9 Oil becomes contaminated quickly.......................................................................................... 40-304
S-10 Fuel consumption is excessive.............................................................................................. 40-305
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .................................... 40-306
S-12 Oil pressure drops ................................................................................................................. 40-307
S-13 Oil level rises (Entry of coolant or fuel).................................................................................. 40-308
S-14 Coolant temperature becomes too high (overheating) .......................................................... 40-309
S-15 Abnormal noise is made........................................................................................................ 40-310
S-16 Vibration is excessive............................................................................................................ 40-311
50 Disassembly and assembly
General information on disassembly and assembly .......................................................................... 50-4
How to read this manual................................................................................................................. 50-4
Coating materials list...................................................................................................................... 50-6
Special tool list ............................................................................................................................... 50-9
Sketch of special tool ..................................................................................................................... 50-13
Engine and cooling system................................................................................................................ 50-15
Removal and installation of fuel supply pump assembly................................................................ 50-15
Removal and installation of fuel injector assembly......................................................................... 50-17
Removal and installation of front oil seal........................................................................................ 50-20
Removal and installation of rear oil seal......................................................................................... 50-22
Removal and installation of cylinder head assembly...................................................................... 50-25
Removal and installation of radiator assembly............................................................................... 50-32
Removal and installation of aftercooler assembly.......................................................................... 50-34
Removal and installation of work equipment oil cooler assembly .................................................. 50-36
Removal and installation of engine and work equipment pump assembly..................................... 50-39
Removal and installation of fuel tank assembly ............................................................................. 50-44
Power train......................................................................................................................................... 50-46
Removal and installation of travel motor and final drive assembly................................................. 50-46
Disassembly and assembly of travel motor and final drive assembly ............................................ 50-48
Removal and installation of swing motor and swing machinery assembly..................................... 50-84
Disassembly and assembly of swing motor and swing machinery assembly ................................ 50-86
Removal and installation of swing circle assembly ........................................................................ 50-92
Undercarriage and frame................................................................................................................... 50-93
Disassembly and assembly of track roller...................................................................................... 50-93
Disassembly and assembly of idler assembly................................................................................ 50-96
Disassembly and assembly of recoil spring ................................................................................... 50-99
Spreading and installation of track shoe assembly........................................................................ 50-102
Removal and installation of sprocket.............................................................................................. 50-104
Removal and installation of revolving frame assembly .................................................................. 50-105
Removal and installation of counterweight assembly (Machine without add-on weight)................ 50-107
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00-8 PC128US-8
00 Index and foreword
Table of contents
Removal and installation of counterweight assembly (Machine with add-on weight)..................... 50-109
Hydraulic system................................................................................................................................ 50-111
Removal and installation of center swivel joint assembly............................................................... 50-111
Disassembly and assembly of center swivel joint assembly .......................................................... 50-113
Removal and installation of hydraulic tank assembly..................................................................... 50-114
Removal and installation of hydraulic pump assembly................................................................... 50-117
Removal and installation of control valve assembly....................................................................... 50-121
Disassembly and assembly of control valve assembly................................................................... 50-126
Disassembly and assembly of work equipment PPC valve assembly............................................ 50-136
Disassembly and assembly of travel PPC valve assembly............................................................ 50-139
Disassembly and assembly of hydraulic cylinder assembly........................................................... 50-141
Work equipment................................................................................................................................. 50-147
Removal and installation of work equipment assembly.................................................................. 50-147
Cab and its attachments .................................................................................................................... 50-150
Removal and installation of operator cab assembly....................................................................... 50-150
Removal and Installation of operator's cab door............................................................................ 50-152
Removal and installation of operator's cab glass (stuck glass)...................................................... 50-155
Removal and installation of front window assembly....................................................................... 50-164
Removal and installation of floor frame assembly.......................................................................... 50-165
Electrical system................................................................................................................................ 50-172
Removal and installation of air compressor assembly ................................................................... 50-172
Removal and installation of air conditioner condenser................................................................... 50-173
Removal and installation of air conditioner unit assembly.............................................................. 50-174
Removal and installation of machine monitor assembly................................................................. 50-177
Removal and installation of pump controller assembly .................................................................. 50-178
Removal and installation of engine controller assembly................................................................. 50-179
Removal and installation of KOMTRAX communications module.................................................. 50-180
90 Diagrams and drawings
Hydraulic diagrams and drawings...................................................................................................... 90-3
Symbols used in hydraulic circuit diagrams.................................................................................... 90-3
Hydraulic circuit diagram................................................................................................................ 90-5
Electrical diagrams and drawings ...................................................................................................... 90-9
Symbols used in electric circuit diagrams.......................................................................................90-9
Electrical circuit diagram ................................................................................................................ 90-13
Connectors table and arrangement drawing .................................................................................. 90-25
Index ..................................................................................................................................................... 1
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