This Complete Service Repair Workshop Manual PDF Download for the Komatsu PC128UU-2 Hydraulic Excavator (SN: 5001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu PC128UU-2 Excavator
Serial Numbers : 5001 and up
Engine : S4D102E-1
TABLE OF CONTENTS :
01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM018506
Total Pages : 623
This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
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COVER
CONTENTS
01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANTS AND COOLANT
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
SWING MOTOR
SOLENOID VALVE
EPC SOLENOID VALVE
PPC ACCUMULATOR
PPC VALVE
AIR CONDITIONER PIPING
ELECTRIC EQUIPMENT LAYOUT DRAWING
ENGINE CONTROL
ELECTRIC CONTROL SYSTEM
4-SYSTEM
MONITOR SYSTEM
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING FUEL CONTROL CABLE
ADJUSTING ENGINE STOP SOLENOID LINKAGE
TESTING CLEARANCE OF SWING CIRCLE BEARING
MEASURING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING PPC VALVE
TESTING AND ADJUSTING TRAVEL DEVIATION
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING OIL LEAKAGE FROM SWING MOTOR
MEASURING OIL LEAKAGE FROM TRAVEL MOTOR
BLEEDING FROM EACH PART
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK
PROCEDURE OF TESTING DIODE
RESETTING PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
REPLACEMENT PROCEDURE OF POTENTIOMETERS
PM CLINIC INSPECTION TABLE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECK BEFORE TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS
CONNECTOR ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
DISPLAY METHOD FOR MONITOR PANEL, CONTROLLER
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF CONTROLLER, ELECTRICAL SYSTEM (E MODE)
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR 4 SYSTEM
JUDGEMENT TABLE FOR CHASSIS RELATED PARTS
ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) IS DISPLAYED
A) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM
B) ABNORMALITY IN COMMUNICATIONS SYSTEMS
E-2 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTIOMETER SYSTEM) IS DISPLAYED
E-3 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM) IS DISPLAYED
E-4 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM) IS DISPLAYED
E-5 ERROR CODE [41](ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
E-6 ERROR CODE [51] (ABNORMALITY IN PPC HYDRAULIC LOCK SOLENOID SYSTEM) IS DISPLAYED
E-7 ERROR CODE [52] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED
E-8 ERROR CODE [54] (ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED
E-9 ERROR CODE [62] (ABNORMALITY IN OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED
E-10 ERROR CODE [64] (ABNORMALITY IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED
E-11 ERROR CODE [71] (ABNORMALITY IN BOOM RAISE STOP EPC SOLENOID SYSTEM) IS DISPLAYED
E-12 ERROR CODE [72] (ABNORMALITY IN BOOM LOWER STOP EPC SOLENOID SYSTEM) IS DISPLAYED
E-13 ERROR CODE [74] (ABNORMALITY IN PC-EPC SOLENOID SYSTEM) IS DISPLAYED
E-14 ERROR CODE [81] (ABNORMALITY IN ARM IN STOP SOLENOID SYSTEM) IS DISPLAYED
E-15 ERROR CODE [C1] (3 SECONDS PASSED AFTER BOOM LOWER AND RAISE PRESSURE SWITCHES WERE INPUT SIMULTANEOUSLY) IS DISPLAYED
E-16 ABNORMALITY IN TRAVEL SPEED SELECTION SOLENOID SYSTEM (TRAVEL SPEED DOES NOT RISE OR DOES NOT DECREASE)
A) TRAVEL SPEED DOES NOT RISE (BUT KEEPS LOW)
B) TRAVEL SPEED DOES NOT LOWER (BUT KEEPS HIGH)
E-17 WORK EQUIPMENT DOES NOT MOVE AFTER WORK EQUIPMENT LOCK LEVER IS RELEASED
E-18 WORK EQUIPMENT MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET IN LOCK POSITION
E-19 DEPTH MODE, HEIGHT MODE, OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHIN
E-20 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE, DEPTH MODE, HEIGHT MODE, OFFSET MODE
E-21 CANCEL SWITCH IS NOT TURNED ON, BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRICAL SYSTEM CAUTION LAMP FLASHES
E-22 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE, LOWER, ARM IN, LEFT OFFSET, RIGHT OFFSET (WHEN ERROR CODE [91] IS NOT
A) ALL OPERATIONS STOP IMMEDIATELY BEFORE INTERFERENCE
B) THERE IS INTERFERENCE
E-23 SWING DOES NOT WORK (WHEN NO ERROR DISPLAY IS GIVEN)
E-24 EXCESSIVE HYDRAULIC DRIFT OF SWING
E-25 OFFSET DOES NOT WORK (PARTICULARLY LEFT OFFSET)
E-26 OFFSET DOES NOT WORK (PARTICULARLY RIGHT OFFSET)
E-27 ENGINE DOES NOT START
A) WHEN STARTING MOTOR DOES NOT ROTATE
B) ENGINE STOP SOLENOID DOES NOT WORK
E-28 ENGINE DOES NOT STOP
E-29 WIPER DOES NOT OPERATE
E-30 ENGINE CONTROL IS ABNORMAL
A) WHEN ENGINE DOES NOT START OR IT STARTS BUT STOPS SOON
B) SWIFT SLOW-DOWN DOES NOT WORK
C) WORKS AT NEAR IDLING SPEED, BUT DOES NOT WORK UP TO FULL THROTTLE (LOAD BECOMES HIGH)
TROUBLESHOOTING OF CONTROLLER INPUT SIGNAL SYSTEM (F MODE)
F-1 MONITOR DOES NOT DISPLAY [P1] (BOOM RAISE PRESSURE SWITCH)
F-2 MONITOR DOES NOT DISPLAY [P2] (BOOM LOWER PRESSURE SWITCH)
F-3 MONITOR DOES NOT DISPLAY [P3] (SWING PRESSURE SWITCH)
F-4 MONITOR DOES NOT DISPLAY [P5] (ARM IN PRESSURE SWITCH)
F-5 MONITOR DOES NOT DISPLAY [P7] (TRAVEL PRESSURE SWITCH)
F-6 MONITOR DOES NOT DISPLAY [HI] (TRAVEL SPEED SELECTOR SWITCH)
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
TABLE OF FAILURE MODES AND CAUSES
H-1 ALL WORK EQUIPMENT, TRAVEL, AND SWING SPEED OR POWER IS LOW
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS
H-3 WORK EQUIPMENT DOES NOT MOVE AT ALL AND MACHINE DOES NOT TRAVEL OR SWING
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP)
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW
H-6 BOOM SPEED OR POWER IS LOW
H-7 ARM SPEED OR POWER IS LOW
H-8 BUCKET SPEED OR POWER IS LOW
H-9 BLADE SPEED OR POWER IS LOW
H-10 OFFSET SPEED OR POWER IS LOW
H-11 WORK EQUIPMENT (BOOM, ARM, BUCKET, OFFSET MECHANISM, OR BLADE) DOES NOT MOVE
H-12 HYDRAULIC DRIFT (BOOM, ARM, BUCKET, OR BLADE) IS LARGE
H-13 TIME LAG IS LONG (ENGINE SPEED IS LOW)
H-14 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDANTLY, OTHER WORK EQUIPMENT MOVE
H-15 SPEED IS HEAVIER OPERATION IS SLOWER DURING COMPOUND OPERATION
H-16 BOOM RAISE SPEED IS LOW DURING COMPOUND OPERATION OF BOOM SWING AND RAISE OPERATIONS
H-17 TRAVEL SPEED LOWERS DURING COMPOUND OPERATION OF WORK EQUIPMENT OR SWINGING AND TRAVEL
H-18 MACHINE DEVIATES
H-19 TRAVEL SPEED IS LOW
H-20 STEERING CONDITION IS BAD OR STEERING FORCE IS LOW
H-21 TRAVEL SPEED DOES NOT CHANGE
H-22 MACHINE DOES NOT TRAVEL (ONLY ONE SIDE)
H-23 MACHINE DOES NOT SWING
A) WHEN MACHINE DOES NOT SWING IN EITHER DIRECTION
B) WHEN MACHINE DOES NOT SWING IN ONLY ONE DIRECTION
H-24 SWING ACCELERATION OR SWING SPEED IS LOW
A) WHEN SWING ACCELERATION OR SWING SPEED IS LOW IN EITHER DIRECTION
B) WHEN SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION
H-25 WORK EQUIPMENT OVERRUNS
A) WHEN WORK EQUIPMENT OVERRUNS IN EITHER DIRECTION
B) WHEN WORK EQUIPMENT OVERRUNS IN ONLY ONE DIRECTION
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
A) WHEN SWING HOLDING BRAKE IS APPLIED
B) WHEN SWING HOLDING BRAKE IS RELEASED
H-29 ERROR CODE[91] IS DISPLAYED ON MONITOR PANEL AND ALL OF BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS STOP JUST BEFORE
H-30 BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS DO NOT STOP AUTOMATICALLY AND MACHINE INTERFERES
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)
ELECTRIC CIRCUIT DIAGRAM OF MONITOR SYSTEM
M-1 AFTER STARTING SWITCH IS TURNED TO ON POSITION, NOTHING IS DISPLAYED
M-2 AFTER STARTING SWITCH IS TURNED TO ON POSITION, SELF-CHECK ITEMS (WHICH SHOULD LIGHT UP FOR 3 SECS) ARE TURNED ON BUT NOT
M-3 AFTER STARTING SWITCH IS TURNED TO ON POSITION, SOME OF SELF-CHECK ITEMS (WHICH SHOULD LIGHT UP FOR 3 SEC) ARE NOT TURNED
A) NO GAUGES (FUEL, ENGINE COOLANT TEMPERATURE) ARE TURNED ON PRE-HEATING PILOT LAMP DOES NOT LIGHT UP
B) CAUTION LAMPS (ENGINE OIL PRESSURE, CHARGE) DO NO LIGHT UP
C) ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP
M-4 AFTER STARTING SWITCH IS TURNED TO ON POSITION (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP
M-5 AFTER STARTING SWITCH IS TURNED TO ON POSTION (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT
M-6 AFTER STARTING SWITCH IS TURNED TO HEAT POSITION, PRE-HEATING PILOT LAMP DOES NOT LIGHT UP
M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING
M-8 CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING
M-9 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE
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 OF FUEL GAUGE GO OFF
B) FUEL GAUGE INDICATES FULL WHILE FUEL LEVEL IS LOWERED
C) FUEL GAUGE DOES NOT INDICATE FULL EVEN IF FUEL TANK IS FULL
M-11 MALFUNCTION OF ALARM BUZZER
A) BUZZER DOES NOT SOUND
B) BUZZER DOES NOT STOP SOUNDING
M-12 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING
A) WHEN CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP
B) WHEN CHARGE LEVEL CAUTION LAMP LIGHTS UP
M-13 LAMPS DO NOT LIGHT UP AT NIGHT
A) LAMP FOR GAUGES DOES NOT LIGHT UP
B) LAMP FOR SERVICE METER DOES NOT LIGHT UP
M-14 ELECTRICAL SYSTEM CAUTION LAMPS KEEPS LIGHTING UP
M-15 HEATER DOES NOT WORK
TROUBLESHOOTING OF ENGINE (S MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
1) ENGINE DOES NOT TURN
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
30 DISASSEMBLY AND ASSEMBLY
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
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY
REMOVAL AND INSTALLATION
SWING MACHINERY
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL
INSTALLATION
SWING CIRCLE
REMOVAL AND INSTALLATION
RECOIL SPRING
DISASSEMBLY
ASSEMBLY
IDLER
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
DISASSEMBLY
ASSEMBLY
TRACK SHOE
REMOVAL AND INSTALLATION
HYDRAULIC TANK
REMOVAL
INSTALLATION
MAIN PUMP
REMOVAL
INSTALLATION
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
FLOOR FRAME
REMOVAL
INSTALLATION
AIR CONDITIONER COMPRESSOR
REMOVAL AND INSTALLATION
AIR CONDITIONER CAPACITOR
REMOVAL AND INSTALLATION
AIR CONDITIONER UNIT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
40 MAINTENANCE STANDARD
SWING MACHINERY
SWING CIRCLE
TRACK FRAME, IDLER CUSHION
IDLER
CARRIER ROLLER
TRACK ROLLER
SPROCKET
TRACK SHOE
HYDRAULIC PUMP
CONTROL VALVE
SUCTION SAFETY VALVE
SELF PRESSURE REDUCTION VALVE
TRAVEL MOTOR
SWING MOTOR
SOLENOID VALVE
EPC SOLENOID VALVE
CENTER SWIVEL JOINT
PPC VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM
ELECTRONIC CIRCUIT DIAGRAM (1/2)
ELECTRONIC CIRCUIT DIAGRAM (2/2)
AIR CONDITIONER CIRCUIT DIAGRAM
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