komatsu pc128uu-2 shop manual.pdf

2003 1All Rights ReservedPrinted in Japan 07-03(02)

SEBM018506

MACHINE MODEL SERIAL NUMBER

PC128UU-2 5001 and up

This shop manual may contain attachments and optional equipment that are not availablein your area. Please consult your local Komatsu distributor for those items you may re-quire.Materials and specifications are subject to change without notice.

PC128UU-2 mounts the S4D102E-1 engine.For details of the engine, see the 102 Series Engine Shop Manual.

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Revision Revision Revision Revision RevisionMark Page Mark Page Mark Page Mark Page Mark Pagenumber number number number number

PC128UU-2 00-2-1

The affected pages are indicated by the use of thefollowing marks. It is requested that necessary ac-tions be taken to these pages according to the tablebelow.

Mark Indication Action required

c Page to be newly added Add

b Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously re-vised or made aditions.

LIST OF REVISED PAGES


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00-300-400-500-600-700-800-900-1000-1100-1200-1300-1400-1500-1600-1700-1800-1900-2000-2100-22

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00-2-2 PC128UU-2

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PC128UU-2 00-2-3

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90-190-390-590-790-9

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SAFETY SAFETY NOTICE

00-3

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service andrepair techniques recommended by Komatsu and described in this manual are both effectiveand safe. Some of these techniques require the use of tools specially designed by Komatsu forthe specific purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this manual.The cautions accompanying these symbols should always be followed carefully. If any danger-ous situation arises or may possibly arise, first consider safety, and take the necessary actionsto deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.Read the Operation and Maintenance Manual care-fully BEFORE operating the machine.1. Before carrying out any greasing or repairs, read

all the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, alwayswear safety shoes and helmet. Do not wearloose work clothes, or clothes with buttonsmissing. Always wear safety glasses when hitting

parts with a hammer. Always wear safety glasses when grinding

parts with a grinder, etc.3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.

4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.

5. Keep all tools in good condition and learn thecorrect way to use them.

6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke while work-ing.

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine frommoving.

8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10.Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.

SAFETY SAFETY NOTICE

00-4

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.

12.The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carry-ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive () terminal first.

14.When raising heavy components, use a hoist orcrane.

Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.

15.When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.

16.When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.

17.When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.

18.As a general rule, do not use gasoline to washparts. In particular, use only the minimum ofgasoline when washing electrical parts.

19.Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts. When installing hoses and wires, be sure

that they will not be damaged by contactwith other parts when the machine is beingoperated.

20.When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.

21.When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.

23.When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24.Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.

FOREWORD GENERAL

00-5

FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman anaccurate understanding of the product and by showing him the correct way to perform repairs and make judge-ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a serviceworkshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-nance standards.

TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments tobe made at completion of the checks and repairs.Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.

MAINTENANCE STANDARDThis section gives the judgment standards for inspection of disassembled parts.The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERSThis section mainly gives hydraulic circuit diagrams and electric circuit diagrams.In addition, this section may give the specifications of attachments and options together.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without anyadvance notice. Use the specifications given in the book with the latest date.

FOREWORD HOW TO READ THE SHOP MANUAL

00-6

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine seriesElectrical volume: Attachments volume:

These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.

DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.

FILING METHOD1. See the page number on the bottom of the page.

File the pages in correct order.2. Following examples show how to read the page

number.Example 1 (Chassis volume):

10 - 3

Item number (10. Structure andFunction)Consecutive page number for eachitem.

Example 2 (Engine volume):

12 - 5

Unit number (1. Engine)Item number (2. Testing and Adjust-ing)Consecutive page number for eachitem.

3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example.Example:10-410-4-110-4-210-5

REVISED EDITION MARK

When a manual is revised, an edit ion mark(123....) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISEDPAGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.

Symbol Item Remarks

SafetySpecial safety precautionsare necessary when per-forming the work.

s

Caution

Special technical precau-tions or other precautionsfor preserving standardsare necessary when per-forming the work.

4 Weight

Weight of parts of sys-tems. Caution necessarywhen selecting hoistingwire, or when working pos-ture is important, etc.

3

Tighteningtorque

Places that require specialattention for the tighteningtorque during assembly.

2 CoatPlaces to be coated withadhesives and lubricants,etc.

5 Oil, waterPlaces where oil, water orfuel must be added, andthe capacity.

6 DrainPlaces where oil or watermust be dra ined, andquantity to be drained.

} Each issued as onevolume to cover allmodels

12-20312-203-112-203-212-204

Added pages

FOREWORD HOISTING INSTRUCTIONS

00-7

HOISTING INSTRUCTIONS

HOISTING

Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the DISASSEMBLYAND ASSEMBLY section, every partweighing 25 kg or more is indicated clearlywith the symbol 4

If a part cannot be smoothly removed from themachine by hoisting, the following checksshould be made:1) Check for removal of all bolts fastening the

part to the relative parts.2) Check for existence of another part causing

interference with the part to be removed.

WIRE ROPES1) Use adequate ropes depending on the

weight of parts to be hoisted, referring tothe table below:

Wire ropes(Standard "Z" or "S" twist ropes

without galvanizing)

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength ofthe rope used.

2) Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may causethe rope to slip off the hook during hoisting, anda serious accident can result. Hooks have max-imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound onto the load. Slinging with one rope may cause turning

of the load during hoisting, untwisting ofthe rope, or slipping of the rope from itsoriginal winding position on the load, whichcan result in a dangerous accident.

4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,the force subjected to each rope will increasewith the hanging angles. The table belowshows the variation of allowable load kN {kg}when hoisting is made with two ropes, each ofwhich is allowed to sling up to 9.8 kN {1000 kg}vertically, at various hanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}when two ropes make a 120 hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 39.2 kN {4000kg} if they sling a 19.6 kN {2000 kg} load at alifting angle of 150.

Rope diameter Allowable load

mm kN tons

1011.512.514161820

22.430405060

9.813.715.721.627.535.343.154.998.1176.5274.6392.2

1.01.41.62.22.83.64.45.6

10.018.028.040.0

SAD00479

41%71%79%88%100%

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-8

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, releasethe residual pressure from the hydraulic tank.For details, see TESTING AND ADJUSTING,Releasing residual pressure from hydraulictank.

Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.

Disconnection1) Release the residual pressure from the hydrau-

l ic tank. For detai ls , see TESTING ANDADJUSTING, Releasing residual pressure fromhydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1) The adapter can be pushed in about 3.5

mm. Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),press rubber cap portion (4) against (3) until itclicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.(See Fig. 3) Since some hydraulic oil flows out, prepare

an oil receiving container.

Connection1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with eachother. (See Fig. 4) Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5) When the hose is pulled back, the rubber

cap portion moves toward the hose about3.5 mm. This does not indicate abnormality,however.

Type 1

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-9

Type 2 Type 3D

isa

ssem

bly

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

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

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

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and pushuntil cover (3) contacts contact surface a ofthe hexagonal portion at the male end.

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

Conn

ectio

n

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

FOREWORD COATING MATERIALS

00-10

COATING MATERIALS

The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand assembly are listed below.

For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

Adhesives

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets,

rubber cushions, and cock plugfrom coming out.

LT-1B 790-129-9050 20 g(2 pcs.)Polyethylene

container

Used in places requiring an imme-diately effective, strong adhesive.Used for plastics (except polyeth-ylene, polyprophylene, tetrafluor-oethlene and vinyl chlor ide),rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylenecontainer

Features: Resistance to heat andchemicals

Used for anti-loosening and seal-ant purpose for bolts and plugs.

LT-3

790-129-9060(Set of

adhesive and hardening

agent)

Adhesive:1 kg

Hardening

agent:500 g

Can

Used as adhesive or sealant formetal, glass and plastic.

LT-4 790-129-9040 250 g Polyethylenecontainer Used as sealant for machined

holes.

HoltzMH 705 790-126-9120 75 g Tube

Used as heat-resisting sealant forrepairing engine.

Three bond1735 790-129-9140 50 g

Polyethylenecontainer

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of met-

als, rubbers, plastics and woods.

Aron-alpha201 790-129-9130 2 g


Quick hardening type adhesive Quick cure type (max. strength af-

ter 30 minutes) Used mainly for adhesion of rub-

bers, plastics and metals.

Loctite648-50 79A-129-9110 50 cc


Resistance to heat, chemicals Used at joint portions subject to

high temperatures.

Gasketsealant

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for

gaskets and packing of powertrain case, etc.

LG-5 790-129-9070 1 kg Can

Used as sealant for variousthreads, pipe joints, flanges.

Used as sealant for taperedplugs, elbows, nipples of hydrau-lic piping.

LG-6 790-129-9020 200 g Tube

Features: Silicon based, resist-ance to heat, cold

Used as sealant for flange sur-face, tread.

mab Used as sealant for oil pan,final drive case, etc.

FOREWORD COATING MATERIALS

00-11

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

AdhesivesLG-7 790-129-9070 1 g Tube

Ftures: Silicon based, quick hard-ening type

Used as sealant for flywheelhousing, intake manifold, oil an,thermostat housing, etc.

Three bond1211 790-129-9090 100 g Tube

Used as heat-resisting sealant forrepairing engine.

Molybdenum disulphide lubricant

LM-G 09940-00051 60 g Can Used as lubricant for sliding por-tion (to prevent from squeaking).

LM-P 09940-00040 200 g Tube

Used to prevent seizure or scuf-fling of the thread when press fit-ting or shrink fitting.

Used as lubricant for linkage,bearings, etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

Used for normal temperature,light load bearing at places in con-tact with water or steam.

Molybdenum disulphide lubricant

SYG2-400M400 g

(10 per case)

Belows type Used for places with heavy load

FOREWORD STANDARD TIGHTENING TORQUE

00-12

STANDARD TIGHTENING TORQUESTANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in

the table below.

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no

special instruction, tighten to the torque given inthe table below.

Thread diameter of bolt

Width across flats

mm mm Nm kgm

68101214

1013171922

13.2 0 1.431 0 366 0 7

113 0 10177 0 19

1.35 0 0.153.2 0 0.36.7 0 0.711.5 0 118 0 2

1618202224

2427303236

279 0 30382 0 39549 0 59745 0 83927 0 103

28.5 0 339 0 456 0 6

76 0 8.594.5 0 10.5

2730333639

4146505560

1320 0 1401720 0 1902210 0 2402750 0 2903290 0 340

135 0 15175 0 20225 0 25280 0 30335 0 35

Thread diameter of bolt

Width across flats

mm mm Nm kgm

681012

10131427

7.85 0 1.9518.6 0 4.940.2 0 5.9

82.35 0 7.85

0.8 0 0.21.9 0 0.54.1 0 0.68.4 0 0.8

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

1418222430333642

1924273236414655

24.5 0 4.949 0 19.6

78.5 0 19.6137.3 0 29.4176.5 0 29.4196.1 0 49245.2 0 49294.2 0 49

2.5 0 0.55 0 28 0 2

14 0 318 0 320 0 525 0 530 0 5

SAD00483

Sealing surface


00-13

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the

table below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

101216

141722

65.7 0 6.8112 0 9.8279 0 29

6.7 0 0.711.5 0 128.5 0 3

Norminal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm

0203, 0405, 0610, 12

14

1420243342

Varies depending on type of connector.

34.3 0 4.993.1 0 9.8

142.1 0 19.6421.4 0 58.8877.1 0 132.3

3.5 0 0.59.5 0 114.5 0 243 0 6

89.5 0 13.5

Norminal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm

08101214161820243033364252

08101214161820243033364252

141719222427303232n36nn

7.35 0 1.4711.27 0 1.4717.64 0 1.9622.54 0 1.96

29.4 0 4.939.2 0 4.949 0 4.9

68.6 0 9.8107.8 0 14.7127.4 0 19.6151.9 0 24.5210.7 0 29.4323.4 0 44.1

0.75 0 0.151.15 0 0.15

1.8 0 0.22.3 0 0.23 0 0.54 0 0.55 0 0.57 0 1

11 0 1.513 0 2

15.5 0 2.521.5 0 333 0 4.5


00-14

TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

2) EYE JOINTSUse these torques for eye joints (unit: mm) of Cummins Engine.

3) TAPERED SCREWSUse these torques for tapered screws (unit: inch) of Cummins Engine.

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. Apply the following torque when the threads are coated (wet) with engine oil.

Thread diameter Tightening torquemm Nm kgm

681012

10 0 224 0 443 0 6

77 0 12

1.02 0 0.202.45 0 0.414.38 0 0.617.85 0 1.22

Thread diameter Tightening torquemm Nm kgm

68101214

8 0 210 0 212 0 224 0 436 0 5

0.81 0 0.201.02 0 0.201.22 0 0.202.45 0 0.413.67 0 0.51

Thread diameter Tightening torqueinch Nm kgm

1 / 161 / 81 / 43 / 81 / 23 / 4

1

3 0 18 0 212 0 215 0 224 0 436 0 560 0 9

0.31 0 0.100.81 0 0.201.22 0 0.201.53 0 0.412.45 0 0.413.67 0 0.516.12 0 0.92

Nominal size of hose

Width across flats

Tightening torque (Nm {kgm}) Taper seal type Face seal type

Range Target Thread size (mm)Nominal thread

size - Threads per inch, Thread series

Root diameter (mm) (Reference)

02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 - 18UNF 14.3

0322 54 - 93 {5.5 - 9.5} 74 {4.5}

- 16UN 17.5

24 59 - 98 {6.0 - 10.0} 78 {8.0} 18

04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 - 16UN 20.7

05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4

06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 - 12UNF 30.3

(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 (12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 (14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42

9161116

1316

316

FOREWORD ELECTRIC WIRE CODE

00-15

ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.This wire code table will help you understand WIRING DIAGRAMS.Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Norminalnumber

Copper wireCable O.D.(mm)

Current rating(A) Applicable circuitNumber of

strandsDia. of strands(mm2)

Cross section(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Priori-ty

Circuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1 Pri-maryCode W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi-liary

Code WR n BW RW YR GW LW

Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White

3Code WB n BY RB YB GR LR

Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

4

Code WL n BR RY YG GY LY

Color White & Blue n Black & Red Red & Yellow Yellow & GreenGreen & Yellow Blue & Yellow

5Code WG n n RG YL GB LB

Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black

6Code n n n RL YW GL n

Color n n n Red & Blue Yellow & White Green & Blue n

FOREWORD CONVERSION TABLE

00-16

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of themethod of using the Conversion Table, see the example given below.

EXAMPLE Method of using the Conversion Table to convert from millimeters to inches1. Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal linefrom A.

(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line downfrom B.

(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-limeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

B

A

C


00-17

Millimeters to Inches1 mm = 0.03937 in

Kilogram to Pound1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

022.0544.0966.1488.18

110.23132.28154.32176.37198.42

2.2024.2546.3068.3490.39

112.44134.48156.53178.57200.62

4.4126.4648.5070.5592.59

114.64136.69158.73180.78202.83

6.6128.6650.7172.7594.80

116.85138.89160.94182.98205.03

8.8230.8651.9174.9697.00

119.05141.10163.14185.19207.24

11.0233.0755.1277.1699.21

121.25143.30165.35187.39209.44

13.23 35.27 57.32 79.37101.41

123.46145.51167.55189.60211.64

15.43 37.48 59.53 81.57103.62

125.66147.71169.76191.80213.85

17.64 39.68 61.73 83.78105.82

127.87149.91171.96194.01216.05

19.84 41.89 63.93 85.98108.03

130.07152.12174.17196.21218.26


00-18

Liter to U.S. Gallon1l = 0.2642 U.S. Gal

Liter to U.K. Gallon1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

0 2.642 5.283 7.92510.567

13.20915.85018.49221.13423.775

0.264 2.906 5.548 8.18910.831

13.47316.11518.75621.39824.040

0.528 3.170 5.812 8.45411.095

13.73716.37919.02021.66224.304

0.793 3.434 6.076 8.71811.359

14.00116.64319.28521.92624.568

1.057 3.698 6.340 8.98211.624

14.26516.90719.54922.19024.832

1.321 3.963 6.604 9.24611.888

14.52917.17119.81322.45525.096

1.585 4.227 6.869 9.51012.152

14.79517.43520.07722.71925.361

1.849 4.491 7.133 9.77412.416

15.05817.70020.34122.98325.625

2.113 4.755 7.39710.03912.680

15.32217.96420.60523.24725.889

2.378 5.019 7.66110.30312.944

15.58618.22820.87023.51126.153

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

0 2.200 4.399 6.599 8.799

10.99813.19815.39817.59819.797

0.220 2.420 4.619 6.819 9.019

11.28113.41815.61817.81820.017

0.440 2.640 4.839 7.039 9.239

11.43813.63815.83818.03720.237

0.660 2.860 5.059 7.259 9.459

11.65813.85816.05818.25720.457

0.880 3.080 5.279 7.479 9.679

11.87814.07816.27818.47720.677

1.100 3.300 5.499 7.969 9.899

12.09814.29816.49818.69720.897

1.320 3.520 5.719 7.91910.119

12.31814.51816.71818.91721.117

1.540 3.740 5.939 8.13910.339

12.52814.73816.93819.13721.337

1.760 3.950 6.159 8.35910.559

12.75814.95817.15819.35721.557

1.980 4.179 6.379 8.57910.778

12.97815.17817.37819.57721.777


00-19

kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

100110120130140

150160170180190

0 72.3144.7217.0289.3

361.7434.0506.3578.6651.0

723.3795.6868.0940.3

1012.6

1084.91157.31129.61301.91374.3

7.2 79.6151.9224.2296.6

368.9441.2513.5585.9658.2

730.5802.9875.2947.51019.9

1092.21164.51236.81309.21381.5

14.5 86.8159.1231.5303.8

376.1448.5520.8593.1665.4

737.8810.1882.4954.81027.1

1099.41171.71244.11316.41388.7

21.7 94.0166.4238.7311.0

383.4455.7528.0600.3672.7

745.0817.3889.7962.01034.3

1106.61179.01251.31323.61396.0

28.9101.3173.6245.9318.3

390.6462.9535.2607.6679.9

752.2824.6896.9969.2

1041.5

1113.91186.21258.51330.91403.2

36.2108.5180.8253.2325.5

397.8470.2542.5614.8687.1

759.5831.8904.1976.5

1048.8

1121.11193.41265.81338.11410.4

43.4115.7188.1260.4332.7

405.1477.4549.7622.0694.4

766.7839.0911.4983.7

1056.0

1128.31200.71273.01345.31417.7

50.6123.0195.3267.6340.0

412.3484.6556.9629.3701.6

773.9846.3918.6990.91063.2

1135.61207.91280.11352.61424.9

57.9130.2202.5274.9347.2

419.5491.8564.2636.5708.8

781.2853.5925.8998.21070.5

1142.81215.11287.51359.81432.1

65.1137.4209.8282.1354.4

426.8499.1571.4643.7716.1

788.4860.7933.11005.41077.7

1150.01222.41294.71367.01439.4


00-20

kg/cm2 to lb/in21kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

100110120130140

150160170180190

200210220230240

0 142.2 284.5 426.7 568.9

711.2 853.4 995.6

11381280

14221565170718491991

21342276241825602702

28452987312932713414

14.2 156.5 298.7 440.9 583.2

725.4 867.6

101011521294

14371579172118632005

21482290243225742717

28593001314332863428

28.4 170.7 312.9 455.1 597.4

739.6 881.8

102411661309

14511593173518772020

21622304244625892731

28733015315833003442

42.7 184.9 327.1 469.4 611.6

753.8 896.1

103811811323

14651607174918922034

21762318246026032745

28873030317233143456

56.9 199.1 341.4 483.6 625.8

768.1 910.3

105311951337

14791621176419062048

21902333247526172759

29013044318633283470

71.1 213.4 355.6 497.8 640.1

782.3 924.5

106712091351

14931636177819202062

22052347248926312773

29163058320033433485

85.3 227.6 369.8 512.0 654.3

796.5 938.7

108112231365

15081650179219342077

22192361250326462788

29303072321433573499

99.6 241.8 384.0 526.3 668.5

810.7 953.0

109512371380

15221664180619492091

22332375251826602802

29443086322933713513

113.8 256.0 398.3 540.5 682.7

825.0 967.2

110912521394

15361678182119632105

22472389253226742816

29583101324333853527

128.0 270.2 412.5 554.7 696.9

839.2 981.4

112412661408

15501693183519772119

22622404254626882830

29733115325733993542


00-21

TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.These figures refer to the temperature in either Fahrenheit or Centigrade degrees.If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table ofFahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8F

C F C F C F C F

40.437.234.431.728.9

28.327.827.226.726.1

25.625.024.423.923.3

22.822.221.721.120.6

20.019.418.918.317.8

17.216.716.115.615.0

14.413.913.312.812.2

4035302520

1918171615

1413121110

9 8 7 6 5

4 3 2 1 0

1 2 3 4 5

6 7 8 9 10

40.031.022.013.0 4.0

2.2 0.4 1.4 3.2 5.0

6.8 8.6 10.4 12.2 14.0

15.8 17.6 19.4 21.2 23.0

24.8 26.6 28.4 30.2 32.0

33.8 35.6 37.4 39.2 41.0

42.8 44.6 46.4 48.2 50.0

11.711.110.610.0 9.4

8.9 8.3 7.8 7.2 6.7

6.1 5.6 5.0 4.4 3.9

3.3 2.8 2.2 1.7 1.1

0.6 0

0.6 1.1 1.7

2.2 2.8 3.3 3.9 4.4

5.0 5.6 6.1 6.7 7.2

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

4142434445

51.8 53.6 55.4 57.2 59.0

60.8 62.6 64.4 66.2 68.0

69.8 71.6 73.4 75.2 77.0

78.8 80.6 82.4 84.2 86.0

87.8 89.6 91.4 93.2 95.0

96.8 98.6100.4102.2104.0

105.8107.6109.4111.2113.0

7.8 8.3 8.9 9.410.0

10.611.111.712.212.8

13.313.914.415.015.6

16.116.717.217.818.3

18.919.420.020.621.1

21.722.222.823.323.9

24.425.025.626.126.7

4647484950

5152535455

56575859 0

6162636465

6667686970

7172737475

7677787980

114.8116.6118.4120.2122.0

123.8125.6127.4129.2131.0

132.8134.6136.4138.2140.0

141.8143.6145.4147.2149.0

150.8152.6154.4156.2158.0

159.8161.6163.4165.2167.0

168.8170.6172.4174.2176.0

27.227.828.328.929.4

30.030.631.131.732.2

32.833.333.934.435.0

35.636.136.737.237.8

40.643.346.148.951.7

54.457.260.062.765.6

68.371.173.976.779.4

81 82 83 84 85

86 87 88 89 90

91 92 93 94 95

96 97 98 99100

105110115120125

130135140145150

155160165170175

117.8179.6181.4183.2185.0

186.8188.6190.4192.2194.0

195.8197.6199.4201.2203.0

204.8206.6208.4210.2212.0

221.0230.0239.0248.0257.0

266.0275.0284.0293.0302.0

311.0320.0329.0338.0347.0

FOREWORD UNITS

00-22

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:N {kg}Nm {kgm}MPa {kg/cm2}kPa {mmH2O}kPa {mmHg}kW/rpm {HP/rpm}g/kWh {g/HPh}

01 GENERAL

General assembly drawing.. .......................... 01-2 Specifications .. . .............................................. 01-4 Weight table .................................................... 01-7 List of lubricants and coolant ........................ 01-S

PC1 28UU-2 01-l

GENERAL GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING

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

Unit : mm

2490

t--J 1245

9JB00124

The sizes in ( ) are applicable when the machine is equipped with the iron shoe.

%l : indicates the size when the offset is 0. %2 : indicates the size when the cab is prevented from interference.

01-2 PC1 28UU-2

GENERAL GENERAL ASSEMBLY DRAWING

600mm-WIDE SHOE SPEClFlCATlOh

Unit : mm

c 7435 4960 2475

SJPO7601

The sizes in ( ) are applicable when the machine is equipped with the iron shoe. II : indicates the size when the offset is 0. %2 : indicates the size when the cab is prevented from interference.

PC1 28UU-2 01-3

GENERAL SPECIFICATIONS

SPECIFICATIONS

Machine model

Serial No.

Bucket capacity (SAE)

Operating weight -

8 c 2

z E

P

-

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach st ground level

Max. digging height

Max. dumping height

Bucket offset amount (left/right)

Max. blade lifting amount

Max. blade lowering amount

Max. digging force (bucket)

Swing speed

Swing max. slope angle

Travel speed (Hi/Lo)

Gradeability

Ground pressure (standard shoe width: 500 mm)

Overall length (for transport)

Overall width

Overall width of track

Overall height (for transport)

Overall height to top of cab

Ground clearance of counterweight

Min. ground clearance

Tail swing radius

Min. swing radius of work euipment (when the offset is 0) Height of work equipment at min. swing radius

Distance between centers of idler and sprocket

Track gauge

Overall length of track

Machine cab height

Blade width x height

he values shown in the [ ] are tt * The value marked with % indicates the size when the cab is prevented from interference.

01-4 PC1 28UU-2

F PC1 28UU-2 5001 and up 500mm-wide shoe specification

0.45 m3

kg 13,400

mm 4,865 [4,800]

mm 3,305 [3,240]

mm 7,285

mm 7,135

mm 8,150 [8,215]

mm 5,850 [5,915]

mm 1,170/1,150

mm 465 [530]

mm 520 [455]

KN (kg] 84.3 (8,600)

rpm 10

deg. 16

km/h 4.613.2

deg. 35

kPa {kg/cm*] 36.7 (0.37)

mm 7,400

mm 2,490

mm 2,490

mm 2,755 [2,795]

mm 2,730 [2,795]

mm 855 [920]

mm 390 [4551

mm 1,480

mm 1,345 (% 1,450)

mm 6,285 [6,350]

6% 6,260 [6,325])

mm 2,750

mm 1,990

mm 3,480 [3,560]

mm 1,935 [2,0001

mm 2,490 x 590

lose for the machines when the road I

600mm-wide shoe specification

0.45

13,500

4,865 [4,880]

3,305 [3,240]

7,285

7,145 [7,1351

8,150 [8,215]

5,850 [5,715]

1,170/1,150

465 [530]

520 [455]

84.3 (8,600)

10

16

4.613.2

35

36.7 (0.37)

7,455 [7,4001

2,590

2,755 [2,795]

2,730 [2,795]

855 [920]

390 [4551

1,480

1,345 (% 1,450)

6,285 [6,350] (% 6,260 [6,325])

2,750

1,990

3,480 [3,560]

1,935 [2,000]

2,490 x 590

ter shoe is equipped.


Machine model PC1 28UU-2

Serial No.

Model.

Type

No. of cylinders-bore x stroke

Piston displacement

Flywheel horsepower

Maximum torpue

High idling speed

Low idling speed

Min. fuel consumption ratio

Starting motor

Alternator

Battery

Radiator type

Carrier roller

Track roller

Track shoe

Type x no.

Discharge

Set pressure (at operation)

(at traveling)

Type x no. 8-spool type x 1

Control method Hydraulic type

Travel motor

Swing motor

Hydraulic tank

Hydraulic filter

Hydraulic oil cooler

he values shown in the [ 1 are

5001 and up 500mm-wide 600mm-wide shoe specification shoe specification

S4D102E-1

mm

Q {cc}

4-cycle, water-cooled, in-line, vertical, direct injection, with turbochatger

4-102xl2u

3.92 (3,920)

IV/rpm{HP/rpm)

rpm

vm j/kWh{g/HPh}

7

64/2,200 (8712,200)

329/I ,300 {33.5/1,300)

2,400

950

224 {I 65)

24U, 4.5 kw

24U, 25A

12U,64Ahx2 I 12U, 72Ah x 2

I CFI 9-4 1 on each side

7 on each side

Asembly-type triple grouster, 42 on each side [Road liner, 42 on each side]

Q /min

VI Pa {kg/cm?

HPU95 (105cc/rev.)

Variable displacement piston type x 1

226

31.9 (325)

34.8 (355)

GM18UL-J

Variable displacement piston type (with brake valve, parking brake) x 2

KMF40AEL-3 Fixed displacement piston type (with shockless safety valve, holding brake) x 1

lose for the machines when the road liner shoe is equipped.

PC1 28UU-2


Machine model PC128UU-2

Serial No.

Type

cylinder (inside diameter)

Diameter of pistonrod

Stroke

Max. distance between pins

Min. distance between pins

fype

Cylinder (inside diameter)


Stroke



Type



Stroke



Type



Stroke


iin. distance between pins

Type



Stroke



mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

5001 and up

Reciprocating piston

105

70

1,055

2,555

1,500


115

75

272.5

1,230.5

958


90

60

885

2,263

1,378


130

70

346

1,818

1,472


115

75

181

870

689

01-6 PC1 28UU-2

GENERAL WEIGHT TABLE

WEIGHT TABLE

A This mass list is for reference in handling or transporting these components. Unit: ko Machine model PC1 28UU-2

Serial No. 5001 and up

510

385

5.8

4.1

80

54

1,500

220

12.6

98

92

106

4.8

1,880

26

155

72.2

43.6

2,590

1,438

81 x2

72.9 x 2

11 x2

21 x 14

144x2

33.7 x 2

Engine assembly (without water and oil)

l Engine (without water and oil)

l Engine mount

l PTO

l Hydraulic pump

Radiator/oil cooler assembly

Revolving frame

Operator cab

Operator seat

Fuel tank (without fuel)

Hydraulic tank (without hydraulic oil)

Control valve

Self pressure reducing valve

Counterweight

Swing motor (with brake valve)

Swing circle

Swing machinery

Center swivel joint

Track frame assembly

l Track fram.e

l Idler assembly

l Recoil spring assembly

l Carrier roller

l Track roller

l Travel motor (with speed reducer)

l Sprocket

Track shoe assembly

l Road liner (500mm)

l Triple grouser shoe (500mm)

l Triple grouser shoe (600mm)

l Triple grouser shoe (700)

l Swamp shoe (750mm)

l Flat shoe (480mm)

PC1 28UU-2

770 x 2

740 x 2

830 x 2

925 x 2

875 x 2

760 x 2

01-7

GENERAL WEIGHT TABLE

Unit: kg

Machine model PC1 28UU-2

Serial No. 5001 and up

Boom assembly

l 1st boom

l 2nd boom

536

337

l 3rd bracket 217

l Sub-link 51

Arm assembly 300

Bucket link assembly 85.6

Bucket assembly (with 955mm-wide side cutter) 369

Blade assembly 647

Boom cylinder assembly 106.3x2

Arm cylinder assembly 136.9

Bucket cylinder assembly 75.8

Offset cylinder assembly 86.1

Blade cylinder assembly 67.2 x 2

01-8 PC1 28UU-2

GENERAL LIST OF LUBRICANTS AND COOLANT

LIST OF LUBRICANTS AND COOLANT

T KIND OF FLUID

AMBIENT TEMPERATURE 22 -4 14 32 50 68 86 104F 30 -20 -10 0 10 20 30 40C

CAPACITY (!2) RESERVOIR

jpecified Refill

Engine oil pan 17.0

0.75

17.5

0.75 PTO case

2.5

2.5

Swing machiney case

Final drive casse (each)

2.5

2.5 !ngine oil

iydraulic Iii

- Idler (each)

Track roller (each)

0.090

~.lOO-0.115 -

I I I I I I I I Carrier roller (each) 0.072

120

-

69 Hydraulic system

Fuel tank 3iesel fue 195 -

- Cooling system Zoolant Add antifreeze I I 18.2

PC1 28UU-2 01-9

GENERAL LIST OF LUBRICANTS AND COOLANT

NOTE:

(1)

(2)

(3)

(4)

(5)

*

When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in manual. Change oil according to the following table if fuel sulphur content is above 0.5%.

Fuel sulphur content Change interval of oil in enaine oil Dan

0.5 to 1 .O% l/2 of regular interval

Above 1.0% l/4 of regular interval

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

ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute

Specified capacity: Total amount of oil including oil for components and oil in piping.

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

01-10 PC1 28UU-2

10 STRUCTURE AND FUNCTION

PTO .............................................................. IO- 2 Radiator and oil cooler ............................... lo- 3 Power train.. ................................................ lo- 5 Swing circle ................................................ IO- 6 Swing machinery ....................................... lo- 7 Track frame ................................................. lo- 8 Idler cushion ............................................... lo- 9 Hydraulic equipment layout drawing.. ..... lo- IO Valve control ............................................... IO- 12 Hydraulic tank and filter.. ........................... IO- 13 Hydraulic pump (Piston pump). ................ lo- 14 Control valve.. ............................................. lo- 35 Suction safety valve ................................... lo- 46 CLSS ............................................................ lo- 47 Self pressure reducing valve.. ................... lo- 84 Center swivel joint.. .................................... lo- 90 Travel motor ....................... t.. ..................... IO- 91 Swing motor.. ............................................. IO-100 Solenoid valve ............................................ 1 O-l 08 EPC solenoid valve ..................................... 1 O-l 10 PPC accumulator ........................................ IO-1 15 PPC valve .................................................... 1 O-l 16 Air-conditioner piping ....... .; ....................... lo-127 Electric equipment layout drawing.. ......... lo-128 Engine control ............................................ lo-132 Electric control system.. ............................. IO-140 Qsystem ...................................................... 1 O-l 51 Monitor system ................. .: ....................... lo-174

PC1 28UU-2 10-l

STRUCTURE AND FUNCTION PTO

PTO

A-A

B-B

1. Coupling 2. Shaft 3. Breather 4. Gauge

5. Hydraulic pump 6. Oil filler plug 7. Level plug

9JA01326

1 o-2 PC1 28UU-2

STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

RADIATOR AND OIL COOLER

PC1 28UU-2

9JA01327

1 o-3

STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

Y

1. Oil cooler 2. Radiator 3. Shroud 4. Reservoir tank 5. Oil cooler outlet 6. Oil cooler inlet

* 7. Radiator cap 8. Radiator inlet hose 9. Radiator outlet hose

10. Drain valve 11. Fan

9JA01328

SPECIFICATION Radiator Core type : CF19-4 Fin pitch : 3.5/2 mm Total heat dissipation surface : 34.06 m* Pressure valve cracking pressure :

49.0 + 14.7 kPa (0.5 & 0.15 kg/cm? Vacuum valve cracking pressure :

-4.9 - 0 kPa (-0.05 - 0 kg/cm*)

Oil cooler Core type : CF40-1 Fin pitch : 4.512 mm Total heat dissipation surface : 8.79 m*

1 o-4 PC1 28UU-2

STRUCTURE AND FUNCTION POWER TRAIN

POWER TRAIN

1. Idler 2. Control valve 3. Self pressure reducing valve 4. PPC lock solenoid valve 5. 2-speed travel changeover solenoid valve 6. Swing hold brake solenoid valve 7. 2-stage relief solenoid valve

8. Travel motor 9. Hydraulic pump

10. Engine 11. Swing motor 12. Center swivel joint 13. Swing machinery 14. Swing circle

9JAOl329

PC1 28UU-2 1 o-5

STRUCTURE AND FUNCTION SWING CIRCLE

SWING CIRCLE

- - -

- -

I l--A

1. Greasing to swing circle bearing 2. Greasing to swing circle pinion 4. Seal 5. Ball 6. Inner race

a. Inner race soft zone position b. Outer race soft zone position

5

4

3 A-A

B-B c-c

9JA01330

Specification Reduction ratio : 90/l 1 = 8.182 Grease : G2-LI Amount of filled grease : 9.1 f?

1 O-6 PC1 28UU-2

STRUCTURE AND FUNCTION SWING MACHINERY

SWING MACHINERY

1. 2. 3. 4. 5. 6. 7. 8. 9.

IO. 11. 12. 13.

---I --L iK c : \ l\i \ A I t

0

A-A . I

9JA01331

Swing pinion (number of teeth : 1 I)

Case No. 2 sun gear (number of teeth : 17)

No. 2 planetary carrier (number of teeth : 17)

Ring gear (number of teeth : 61)

No. 1 planetary carrier (number of teeth : 17)

No. 1 sun gear (number of teeth : 14)

Oil filler port Swing motor Level gauge No. 1 planetary gear (number of teeth : 24)

No. 2 planetary gear (number of teeth : 22)

Drain plug

Specification Reductionratio:(14+61)/14x(17+61)/17=24.58

Swing reduction ratio : 201.11

Swing speed : 12 rpm Lubricating oil : EOBO-CD

Lubricating oil amount : 2.5 k?

14. Swing circle (number of teeth : 90)

PC1 28UU-2 1 o-7

STRUCTURE AND FUNCTION TRACK FRAME

TRACK FRAME

d i

1. idler 2. Track frame 3. Carrier roller 4. Travel motor

9JEOO125

5. Sprocket 6. Track roller 7. Idler cushion 8. Track shoe

1 O-8 PC1 28UU-2

STRUCTURE AND FUNCTION IDLER CUSHION

IDLER CUSHION

F==--- -__

__~__

______

1. Idler 2. support 3. Yoke 4. Cylinder 5. Recoil spring 6. U-packing 7. Pilot 8. Nut 9. Valve

10. Grease fitting

95800126

Specification Grease : G2-LI Amount of filled grease : 140 cc

PC1 28UU-2 1 o-9

STRUCTURE AND FUNCTION HYDRAULIC EQUIPMENT LAYOUT DRAWING

HYDRAULIC EQUIPMENT LAYOUT DRAWING

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16.

17. 18. 19. 20.

Bucket cylinder

-I-

Arm cylinder Offset cylinder Boom cylinder Hydraulic tank Swing motor Hydraulic pump Oil cooler L.H. travel motor L.H. work equipment PPC valve Blade PPC valve R.H. work equipment PPC valve Center swivel joint Travel PPC valve Offset PPC valve 5-spool EPC solenoid valve l Boom lower stop EPC valve l Arm curl stop EPC valve l Boom raise stop EPC valve l Offset left stop solenoid valve l Offset right stop solenoid valve Blade cylinder Self pressure reducing valve Control valve 4-spool solenoid valve

PPC lock solenoid valve 2-speed travel changeover solenoid valve Swing holding brake solenoid valve 2-stage relief solenoid valve

9JBOO127 +

10-10 PC1 28UU-2

STRUCTURE AND FUNCTION HYDRAULIC EQUIPMENT LAYOUT DRAWING

+

P;c128UU-2

9J800128

10-11

STRUCTURE AND FUNCTION VALVE CONTROL

VALVE CONTROL

7

1. 2. 3. 4. 5. 6.

7. 8.

9.

Control valve R.H. work equipment PPC valve Blade PPC valve 5-spool EPC solenoid valve 4-spool solenoid valve R.H. work equipment control lever -(for controlling boom and bucket) Blade control lever L.H. work equipment control lever (for controlling arm and swing) L.H. work equipment PPC valve

10. Safety lock lever 11. Travel accelerator pedal 12. L.H. travel pedal 13. R.H. travel pedal 14. Travel PPC valve 15. Left travel lever 16. Right travel lever 17. Offset PPC valve 18. Offset pedal

I6 I5 i4 13 I2 II 9JBOO129

Lever and pedal position (I) HOLD (2) Boom LOWER (3) Boom RAISE (4) Bucket CURL (5) Bucket DUMP (6) HOLD (7) Arm DUMP (8) Arm CURL (9) Swing LEFT

(10) Swing RIGHT (11) L.H. travel FORWARD (12) L.H. travel REVERSE (13) R.H. travel FORWARD (14) R.H. travel REVERSE (15) PPC FREE (16) PPC LOCK . (17) Blade RAISE (18) Blade LOWER (I 9) Travel Lo (20) Travel Hi (21) Offset LEFT (22) Offset RIGHT

10-12 PC1 28UU-2

STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER

HYDRAULIC TANK AND FILTER

1. Hydraulic tank 2. Filter rlement 3. Bypass valve 4. Bypass strainer 5. Suction strainer 6. Drain plug 7. Sight gauge 8. Oil filler cap 9. Pressure valve

10. Vacuum valve

8 9 10

A-A

9JA01337

Specification Tank capacity : 99 f? Hydraulic oil amount in tank : 69 f? Pressure valve cracking pressure :

16.7 + 6.9 kPa (0.17 f 0.07 kg/cm? Vacuum valve cracking pressure :

-0.49 - 0 kPa (-0.005 - 0 kg/cm*} Bypass valve set pressure :

103 f 19.6 kPa (1.05 f 0.2 kg/cm*}

PC1 28UU-2 10-13

STRUCTURE AND FUNCTION HYDRAULIC PUMP

HYDRAULIC PUMP (PISTON PUMP)

MAIN PUMP Type : HPV95 (for 105cdrev.j

+ X PLS

/

PD PB PA

A

_i

1. Main pump 2. LS valve 3. PC valve 4. Fixed throttle valve 5. PC-EPC valve (for changing PC mode)

Y 9JUOOO74

IM : PC mode changeover current PA : Main pump delivery PB : Main pump pressure input PD : Main pump drain PEPC : EPC valve source pressure inlet PLS : Control valve LS pressure inlet PS : Main pump absorption

10-14 PC1 28UU-2


1. Shaft 2. Cradle 3. Case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block

A-A IO

D-D

B-B

8. Valve plate 9. End cap 10. Spring 11. Servo last chance filter 12. Servo piston 13. Slider

D4

9JUOOO76

PC128UU-2 10-15


Function l This pump converts engine rotation and

torque transmitted to the pump shaft into hydraulic energy anddischarges pressurized oil according to load.

l This pump can change delivery when the swash plate angle is changed.

IO A-A 9JUOOO77

Structure l The cylinder block (7) is supported to the shaft

(1) with the spline a, and the shaft (1) is supported with the front and rear bearings.

l The shoe (5) is punched to the tip of the piston (6) with a concave ball so that the piston (6) and the shoe (5) form a spherical bearing.

l The shoe (5) is always pressed to the plane A of the rocker cam (4) and slides in a circle. The rocker cam (4) leads highly pressurized oil together with the cylindrical plane B with the cradle (2) fixed to the case, forms a static pressure bearing and slides.

l The piston (6) moves in the axial direction relatively in each cylinder of the cylinder block

(7). l The cylinder block (7) rotates relatively while

sealing pressurized oil against the valve plate (8), and the plane is designed to balance the oil pressure properly.

l Oil in each cylinder of the cylinder block (7) is absorbed and discharged through the valve plate (8).

JO-16 PC1 28UU-2


Operation . 1. Pump Operation

l The shaft (1) rotates together with the cylinder block (71, and the shoe (5) slides on the plate A. When the rocker arm (4) moves along the cylindrical plane B, the inclination ato the centerline X of the rocker cam (4) and the axial direction of the cylinder block (7) changes. The inclination a is called swash plate angle.

B SLPOOl63

l When the swash plate angle of the center line X of the rocker cam (4) is a to the axial direction of the cylinder block (71, the plane A works like the cam against the shoe (5).

l Therefore, the piston (6) slides inside the cylinder block (71, and the capacities E and F of the cylinder block (7) come to change differ- ently. Then, the pump absorbs and discharges the difference E-F.

l When the capacity in the E chamber contracts as the cylinder block (7) rotates, the pump discharges oil during the process. On the other hand, when the capacity in the F chamber in- SLPOOl64 creases, the pump absorbs oil during the process. (The figure shows the end of the absorbing process in the Chamber F and the end of the discharging process in the Chamber E.

l When the centerline X of the rocker cam (4) F

comes to the axial direction of the cylinder block (7) (when the swash plate angle is 01, the difference between the capacities E and F in the cylinder block (7) comes to 0. And the X pump comes to stop absorbing or discharging oil, i.e., the pump stops. (However, the swash plate angle never comes to 0 practi- cally.)

l In the other words, the swash plate angle a 4 7

and the pump delivery are in the proportional 9JUOOO80

relations.

PC1 28UU-2 10-17


Delivery Control

When the swash plate angle a increases, the

difference between the capacities E and F becomes larger and the delivery Q increases.

The servo piston (12) changes the swash plate

angle a. The servo piston moves in the direction of

straight reciprocation according to signal

pressures of the PC and LS valves. This

straight motion is transmitted to the rocker

arm (4) through the slider (131, and the rocker cam (4), which is supported with the cylindri-

cal plane to the cradle (2), slides in the direc-

tion of rotation.

9JUOOO81

l The servo pistons (12) area receiving the pres- 12 I3 sure is different on the right and left sides,

and the discharge (self) pressure PP from the

main pump is always led to the pressure

chamber of the small diameter piston.

l The output pressure Pen of the LS valve is

led to the pressure chamber of the large diameter piston.

l Motions of the servo piston are controlled ac-

. cording to the relations between the small

diameter piston pressure PP and the large di-

ameter piston pressure Pen and the rate of area receiving pressure of the small diameter

piston to that of the large diameter piston.

9JUOOO82

lo-18 PC1 28UU-2


LS AND PC VALVES LS Valve

PiS PA PLP PPL PD PS IG PA

9JUOOO84

1. Plug 2. Lock nut 3. Sleeve

A : Pump discharge pressure inlet PD

4. Spring 5. Seat 6. Spool 7. Piston 8. Sleeve

: Drain pressure outlet PLP : LS valve signal pressure outlet PLS : Control valve LS pressure inlet PPL : PC valve signal pressure inlet PSIG : EPC valve output pressure inlet of LS control

PC Valve

9JUOOO85

1. Piston 2. Spring 3. Seat 4. Spring 5. Seat 6. Spool 7. Piston 8. Sleeve 9. Lock nut

10. Plug 11. Lock nut

PA : Pump discharge pressure inlet PA2 : Pump discharge pressure inlet PD : Drain pressure outlet PM : PC mode switching pressure inlet PPL : PC valve signal pressure outlet

PC1 28UU-2 10-19


FIXED THROTTLE VALVE

POUT PIN

9JUOOO86

1. Plug 2. Plug

PA : Drain pressure outlet POUT : Control pressure outlet PIN : LS valve signal pressure inlet

1 O-20 PC1 28UU-2


Function 1. .

.

.

.

2. .

.

.

.

.

LS Valve The LS valve controls pump delivery to stroke of the control lever, i.e., requested flows of

k/m i n)

I the actuator. The LS valve detects requested flow of the actuator from the differential pressure, APLS, between the pump discharge pressure, PP, and the control valve outlet pressure, PLS, to control the pump delivery Q. (Discharge pressure is called PP, the LS pressure PLS and the LS differential pressure APLS.) This valve detects pressure loss (=LS differential pressure APLS) caused by pump flow passing through the opening area of the control valve spool, controls the pump delivery Q so that the pressure loss remains constant all the time and supplies pump deliveries requested by the actuator. The relations between the LS differential pressure (APLS) between the pump discharge pressure PP and the LS pressure (PLS) and the pump delivery Q are as shown in the right figure.

z c

I

2. 2122. 51 IMPaIta/cll)

LS differential Dressure SVPO7602

PC Valve When the pump discharge pressure PP rises, the control valve spool stroke will increase

Q

and the opening area will enlarge. So, the PC c z valve controls the pump delivery Q so that

X=0. 26A :

the delivery Q does not increase above a cer- tain level depending on the discharge pressure PP. The valve also controls the pump absorbing hydraulic horsepower to approxi- mately equal horsepower so that the pump absorbing horsepower does not exceed the engine horsepower. This means that, when a load to the actuator increases during operation and the pump discharge pressure PP rises, this valve will reduce the pump delivery 0, or when the pump discharge pressure PP drops, this valve will increase the delivery 0. In this case, the relations between the pump discharge pressure PP and the pump delivery Qchange as shown in the right figure since the current value given to the PC-EPC valve solenoid is regarded as a parameter. However, some PC valves have the function to sense actual engine speeds in the heavy- duty operation mode and to reduce the pump delivery and recover the speed when the speed reduces due to increase of load. In the other words, when an increase of load reduces the engine speed below the set value, the command current from the controller to the PC-EPC valve solenoid will increase as the engine speed reduces and will reduce the pump swash plate angle.

PumP discharge Pressure PP

SDP02556

PC1 28UU-2 10-21


Operation

Direction to

small diameter

1. LS Valve 1) When the control valve is at the center

value position l The LS valve is a 3-way selector valve, and

the pressure PLS (LS pressure) from the

control valve inlet is being led to the

spring chamber B and the pump dis-

charge pressure PP is being led to the H

port of the sleeve (8). l The spool (6) position is determined de-

pending on the force of the LS pressure

PLS + the force of spring (4) 2 and the force

of the pump discharge pressure (self-pres-

sure) PP.

lin ve

SVPO7604

1 o-22 PC1 28UU-2


l Before the engine starts, the servo piston (12) is pressed to the right side. (See the right figure.)

l If the control lever is at the centervalue position when the engine starts, the LS pressure PLS will be 0 MPa (0 kg/cm*). (The LS valve interconnects to the drain circuit through the control valve spool.)

l At the time, the spool (6) is pressed to the left side and the C port is connected to the D port. The pump discharge pressure enters from the K port to the piston large diameter side and from the J port to the piston small diameter side respectively. So, the area difference of the servo piston (12) minimizes the swash plate angle. A-A 9JUOOO89

PC1 28UU-2 1 O-23


a .

.

PLS

@--I

Operation in the direction to increase pump delivery When the difference between the pump l Therefore, the pressure on the large di- discharge pressure PP and the LS pres- ameter side of the servo piston (12) be- sure PLS, i.e., LS differential pressure comes equal to the drain pressure PT. APLS, reduces (for example, when the Since the pump discharge pressure PP is control valve opening area increases and applied to the J port on the small diam- the discharge pressure PP drops), the eter side, the servo piston (12) is pushed combined force of the LS pressure PLS to the right side and the swash plate is and the spring (4) force will push the spool moved in the direction where the deliv- (6) to the right side. ery increases. When the spool (6) moves, the circuit between the D port and the E port will open and the LS valve will be connected to the PC valve. At the time, the PC valve is connected to the drain port, and the drain pressure PT is applied to the circuit D-K. (The operation of the PC valve will be ex- plained later.)

t

Direction to large diameter SVPO7605

1 O-24 PC1 28UU-2


PLS

@--I

PC valve PT

3) Operation in the direction to reduce pump delivery

l When the servo piston (12) moves to the left side (in the direction to reduce the pump delivery), the LS differential pressure APLS will increase (for example, the control valve opening area decreases and the pump discharge pressure PP increases) and the force of the discharge pressure PP will push the spool (6) to the left side.

l When the spool (6) moves, the pump discharge pressure PP will be forwarded from the C port to the D port and will come from the K port to the piston large diameter side.

Direction to small diameter

lin ve

SVPO7606

l Since the pump discharge pressure PP is applied to the J port on the piston small diameter side, the servo piston (12) is pressed to the left side due to the area difference between the large diameter side and the small diameter side of the servo piston (12). So, the swash plate is moved in the direction where the delivery is reduced.

PC1 28UU-2 1 O-25


4) When the servo piston balances l Suppose that the area receiving pressure

on the piston large diameter side is Al, the area on the piston small diameter side is A0 and the pressure applied to the piston large diameter side is PEN.

l When the pump discharge pressure PP of the LS valve balances with the combined force of the LS pressure PLS and the spring (4) force 2 and the relations A0 x PP = Al x PEN hold, the servo piston (12) will stop at the position and the swash plate angle will be held at the 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.)

ii

in ve

PEN

-0

SVPO7607

At the time, the relations of the areas receiving pressure at the both ends of the servo piston are A0 : Al = 1 : 1.75. When they balance with each other, the pressures applied to the both ends of the piston are related as follows: PP : PEN + 1.75 : 1. The spring (4) force has been adjusted so that the spool (6) balance stop position is determined at the center of the standard when PP-PLS = 2.21 MPa (22.5kg/cm2).

1 O-26 PC1 28UU-2


Direct ibn to Di rect;on to small diameter large diameter

Emergency Pump drive switch

// I^ 0 F F ,, Pump I, _ I,

ON

controller I

Resistor

2. PC Valve 1) When the pump controller is normal, the

load to the actuator is small and the pump discharge pressure PP is low a. Function of PC-EPC Valve Solenoid (1) l The pump controller provides a com-

mand current to the PC-EPC valve solenoid (1). This command current ac- tuates the PC-EPC valve and outputs a signal pressure. When receiving the signal pressure, the PC valve changes the force given to the piston (2).

l The spool (3) stops where the force to the piston (2) balances with the combined force of the spring setting force of the springs (4) and (6) on the oppo- site side and the force given to the spool (3) by the pump discharge pres-

0 m va

-

ain IVe

SVPO7608

sure PP. And the pressure output from the PC valve (the pressure at the C port) varies with the spool position.

l The value of the command current X is determined depending on type of work (lever control), selection of working mode, set point of engine speed and actual speed.

PC1 28UU-2 1 O-27


Pi lot Pressure

Emergency pump drive switch

b. Function of Spring l The loads to the springs (4) and (6) of

the PC valve are determined depending on swash plate position.

l As the servo piston (9) moves, the piston (7) connected to the slider (8) moves to the right or the left.

l When the piston (7) moves to the left, the spring (6) will be contracted. If the piston moves further to the left, the spring will be brought to the seat (5) and be fixed there. Thereafter, the spring (4) will only move. This means that the spring load changes as the piston (7) extends or contracts the springs (4) and (6).

main valve -

SVPO7609

l Also, since the pressing force of the piston (2) changes as the command current input to the PC-EPC valve solenoid (1) changes, the load to the springs (4) and (6) changes depending on the value of the command current.

1 O-28 PC1 28UU-2


l The C port of the PC valve is connected to the E port of the LS valve. The self pressure PP is provided to the A port, the small diameter side of the servo piston (9) and the B port.

l When the pump discharge pressure PP is small, the spool is located at a position in the left direction. At the time, the C port is connected to the D port, and the pressure to the LS valve becomes the drain pressure PT. If the E port of the LS valve is connected to the G port at the time, the pressure from the J port to the large diameter side of the piston will become the drain pressure PT. And the servo piston will moves to the right side. Then, the pump delivery will come to increase.

l Also, as the servo piston (9) operates, the slider (8) moves the piston (7) to the right side, and the spring force becomes weak because the springs (4) and (6) expand. As the spring force becomes weak, the spool (3) moves to the right side to disconnect the C port from the D port. Then, the pump discharge pressure ports B and C are connected.

l As a result, the pressure at the C port rises and the pressure on the large diameter side of the piston rises as well, and the servo piston (9) stops moving to the right side. This means that the stop position of the servo piston (9) (= pump delivery) is determined where the pressing force caused the pressure PP to the spool (3), the pressing force of the PC-EPC valve solenoid and the forces of the springs (4) and (6) balance with each other.

PC1 28UU-2 1 O-29


Pilot pressure

0 main valve

-

r

Emergency Pump

SVPO7610

2) When the pump controller is normal, the load to actuator is large and the pump discharge pressure PP is high

l When the load is large and the pump discharge pressure is high, the force push- ing the spool (3) to the left side increases and the spool (3) comes to the position shown in the above figure.

l Then, the pressure flowing from the C port to the LS valve becomes about 315 of the pump discharge pressure PP because the pressure from the A port partly flows from the C port to the D port through the LS valve as shown in the above figure.

l When the E port of the LS valve is connected to the G port, this pressure is led from the J port to the large diameter side of the servo piston (9) and the servo piston comes to stop.

l When the pump discharge pressure PP increase and the spool (3) moves further to the left side, the discharge pressure PP will flow to the C port so as to minimize the pump delivery.

1 O-30 PC1 28UU-2


l When the servo piston (9) moves to the left side, the piston (7) will move to the left. Then, the springs (4) and (6) will be compressed and will push the spool (3) back. If the piston (7) moves further to the left, the ports C and D will open wide.

l As a result, the pressure at the port C (= J) will drop, and the servo piston (9) will move to the left and will stop. At the time, the servo piston (9) is located further to the left than where it is when the pump discharge pressure PP is low.

l The positional relations between the pump discharge pressure PP and the servo piston (9) are shown by a broken line because the springs (4) and (6) are 2- stage ones. And the relations between the discharge pressure PP and the pump delivery Q are as shown in the right figure.

l Also, when the command current X to the PC-EPC valve solenoid increases, the relations between the pump discharge pressure PP and the pump delivery Q will move in parallel in relation to the push- ing force of the PC-EPC valve solenoid. Therefore, the force of the PC-EPC valve solenoid (1) will be added to the leftward pressing force of the discharge pressure PP to the spool (31, and the relations between PP and Q will move from @ to @ as X increases.

Pump discharge pressure PP SDP02559

Pump discharge pressure PP SDP02560

PC1 28UU-2 10-31


Pilot Dressure

Direction to large diameter

3) When the pump controller is out of order and the PC redundant switch is set to ON a. .

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

To Main

SVPO7611

than the spring set force. So, the spool (3) balances at a position in the left side.

l At the time, the C port has the same pressure as the drain pressure at the D port, and the drain pressure PT is led to the large diameter side of the servo piston (9) through the LS valve. Then, the servo piston (9) moves in the diction where the delivery increases because the pressure on the small diameter side of the piston is large.

1 O-32 PC1 28UU-2


Pilot pressure -

Direction to small diameter

in ve

SVPO7612

b. In case of heavy load to main pump l 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.

l When the pump discharge pressure PP rises, the spool will moves further to the left side than when the main pump is lightly loaded and will balance at the position shown in the above figure.

l In this case, since the pressure from the A port is led to the C port, the servo piston (9) will move to the left side (small delivery) and will stop at a position further to the left than when the pump is lightly loaded.

PC1 28UU-2 1 o-33


l This means that the current, which is sent to the PC-EPC valve solenoid through the resistor when the PC re- Q

dundant switch is set to On, deter- x

mines the curve between the pump al 5 .-

discharge pressure PP and the deliv- -

cry Q as shown in the figure. 4

l When the PC redundant switch is set ;

to ON, the curve @ is further to the z

left than the curve 0 drawn when the pump controller is normal.

PUnID discharge Pressure PP ~~~07613

1 o-34 PC1 28UU-2

STRUCTURE AND FUNCTION CONTROL VALVE

CONTROL VALVE

OUTLINE The following two control valves have been set in the system : l 8-spool valve (without service valve) l 9-spool valve (8-spool valve + service valve) * Each service valve is of the add-on type and

can be added and removed halfway. Appearance and section are shown for 8-spool valve (without service valve) only.

1. Swing bleed valve 2. Travel junction valve 3. Arm regeneration valve 4. Boom hydraulic drift prevention valve 5. Cover 6. Offset valve 7. Bucket valve 8. Arm valve 9. Blade valve

10. Boom valve 11. R.H. travel valve 12. L.H. travel valve 13. Swing valve 14. PT port block

AA : Pressure sensor port (with pressure sensor) Al :

komatsu pc128uu-2 shop manual.pdf

Documents

added addb page

series engine shop manual

affected pages

use of thefollowing

optional equipment

rights reservedprinted

local komatsu distributor

necessary actions