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40 Troubleshooting

SEN02462-00

PC138US, USLC-8

5

Classification and procedures for troubleshooting

1

Classification for troubleshooting

Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.

1.

Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:

If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding "

Display of code

" according to the displayed failure code.

2.

When electrical system error code or mechanical system error code is recorded in abnormality
record:

If a user code and a failure code are not displayed on the machine monitor, check a mechanical system
failure code and an electrical system failure code with the abnormality record function of the machine
monitor.
If a code is recorded, carry out troubleshooting for the corresponding "

Display of code

" according to

the recorded code.

a

If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.

a

An error code of the mechanical system cannot be deleted.

a

If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the
abnormality record function, carry out the corresponding troubleshooting in

E-mode

.

3.

When user code and failure code is not displayed and no failure code is recorded in abnormality
record:

If a user code and failure code are not displayed on the machine monitor and no failure code is recorded
in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the
electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "

E-mode

", "

H-mode

", or "

S-mode

".

Mode

Contents

Display of code

Troubleshooting by failure code

E-mode

Troubleshooting of electrical system

H-mode

Troubleshooting of hydraulic and mechanical system

S-mode

Troubleshooting of engine

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Summary of Contents for Galeo PC138US-8

Page 1: ...HYDRAULIC EXCAVATOR SEN01968 02 PC138US 8 PC138USLC 8 SERIAL NUMBERS PC138US 20001 PC138USLC 20001 and up...

Page 2: ......

Page 3: ...N01977 02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 00 Index and foreword 1 Index Composition of shop manual 2...

Page 4: ...ndex SEN01977 02 q Foreword and general information SEN01978 01 q 01 Specification SEN01970 01 Specification and technical data SEN01979 01 10 Structure function and maintenance standard SEN01971 02 E...

Page 5: ...General information on disassembly and assembly SEN02709 00 Engine and cooling system SEN02710 00 Power train SEN02711 00 Undercarriage and frame SEN02712 00 Hydraulic system SEN02713 00 Work equipme...

Page 6: ...6 01 Specification Specification and technical data SEN01979 01 Specification dimension drawings 2 Working range diagram 3 Specifications 4 List of weights 10 Table of fuel coolant and lubricants 14 1...

Page 7: ...pressure 13 Testing engine oil pressure 14 Handling fuel system parts 15 Releasing residual pressure from fuel system 15 Testing fuel pressure 16 Testing fuel return rate and fuel leakage 17 Bleeding...

Page 8: ...e code B BAZK Eng oil level low 8 Failure code B BCNS Eng coolant overheat 9 Failure code B HANS Hydr oil overheat 9 Failure code CA111 ECM critical internal failure 10 Failure code CA115 Eng Ne and B...

Page 9: ...2RMC CAN discon Pump controller detected 4 Failure code DAF8KB Short circuit in camera power supply 6 Failure code DAFGMC GPS module error 8 Failure code DAFRMC CAN discon Monitor detected 10 Failure...

Page 10: ...tioner does not operate normally including air conditioner abnormality record 39 E 23 While starting switch is in OFF position service meter is not displayed 51 E 24 Machine monitor cannot be set in s...

Page 11: ...lation of fuel supply pump assembly 2 Removal and installation of fuel injector assembly 4 Removal and installation of front oil seal 7 Removal and installation of rear oil seal 9 Removal and installa...

Page 12: ...ssembly 2 Removal and installation of operator s cab glass stuck glass 4 Removal and installation of front window assembly 13 Removal and installation of floor frame assembly 14 Electrical system SEN0...

Page 13: ...00 Index and foreword SEN01977 02 PC138US USLC 8 11...

Page 14: ...12 PC138US USLC 8 SEN01977 02 00 Index and foreword PC138US USLC 8 Hydraulic excavator Form No SEN01977 02 2007 KOMATSU All Rights Reserved Printed in Japan 10 07 02...

Page 15: ...ormation Safety notice 2 How to read the shop manual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Handling of connectors newly used for e...

Page 16: ...rts with a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before starting any step of t...

Page 17: ...ver which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen those bolts gradually and alternately to release the pressure and then remove the...

Page 18: ...ide hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load i...

Page 19: ...e while the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the...

Page 20: ...filling it you must be quali fied for handling the refrigerant and put on protective goggles 2 Connection 1 When installing the air conditioner cir cuit hoses and tubes take care that dirt dust water...

Page 21: ...he standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them...

Page 22: ...e indicated with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions a...

Page 23: ...the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in...

Page 24: ...that the interference is in the standard range 4 Repair limit and allowable value q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the...

Page 25: ...e more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likel...

Page 26: ...ater does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connect...

Page 27: ...pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip...

Page 28: ...this will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For co...

Page 29: ...re 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are s...

Page 30: ...n the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use...

Page 31: ...sconnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the p...

Page 32: ...Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing opening...

Page 33: ...ew oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and...

Page 34: ...ngines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1 towa...

Page 35: ...the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor wi...

Page 36: ...Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn hous...

Page 37: ...ndicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material...

Page 38: ...23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor...

Page 39: ...lue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red Whit...

Page 40: ...to use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and f...

Page 41: ...the cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for t...

Page 42: ...If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler...

Page 43: ...ter 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fi...

Page 44: ...he hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to di...

Page 45: ...d Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 an...

Page 46: ...ad diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 153 190 15 5 19 5 16 24 235 285 23 5 29...

Page 47: ...Width across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0...

Page 48: ...2 107 and 114 engine series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thr...

Page 49: ...Taper screws a Unless there are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque inch Nm kgm 1 16 3 1 0 31...

Page 50: ...so divide it 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...

Page 51: ...6 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141...

Page 52: ...173 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 6 397 8...

Page 53: ...7 1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877...

Page 54: ...2 12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5...

Page 55: ...00 Index and foreword SEN01978 01 PC138US USLC 8 41...

Page 56: ...42 SEN01978 01 PC138US USLC 8 Hydraulic excavator Form No SEN01978 01 2007 KOMATSU All Rights Reserved Printed in Japan 10 07 02...

Page 57: ...PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 01 Specification Specification and technical data Specification dimension drawings 2 Working range diagram 3 Spe...

Page 58: ...cket capacity m3 0 50 Engine type Komatsu SAA4D95LE 5 Diesel engine Engine rated output Net ISO 9249 SAE J1349 Gross SAE J1955 kW HP rpm 68 4 91 7 2 200 72 1 96 6 2 200 A Overall length Standard speci...

Page 59: ...B Maximum digging depth 5 480 5 480 C Maximum digging height 9 340 9 340 D Maximum vertical wall digging depth 4 900 4 900 E Maximum dumping height 6 840 6 840 F Minimum swing radius of work equipment...

Page 60: ...ucket kN kg 93 2 9 500 93 2 9 500 Swing speed rpm 11 0 11 0 Swing max slope angle Degree 19 0 19 0 Travel speed Low High km h 2 9 5 1 2 9 5 1 Gradeability deg 35 35 Ground pressure kPa kg cm2 42 2 0 4...

Page 61: ...15 150 5 480 5 480 4 900 4 900 8 300 8 300 8 180 8 180 9 340 9 340 6 840 6 840 470 490 93 2 9 500 93 2 9 500 11 0 11 0 19 0 19 0 2 9 5 1 2 9 5 1 35 35 35 3 0 36 37 3 0 38 7 390 8 040 2 590 2 590 2 85...

Page 62: ...d rpm 2 300 Low idling speed rpm 1 100 Min fuel consumption ratio g kWh g HPh 224 167 Starting motor 24 V 4 5 kW Alternator 24 V 35 A Battery 1 12 V 64 Ah x 2 Radiator core type 4 array aluminum mesh...

Page 63: ...1 100 224 167 24 V 4 5 kW 24 V 35 A 12 V 64 Ah x 2 4 array aluminum mesh core Aluminum mesh core 2 on each side 8 on each side Assembly type triple grouser shoe 46 on each side Assembly type road line...

Page 64: ...er Type Reciprocating piston type Reciprocating piston type Cylinder inner diameter mm 110 110 Piston rod diameter mm 75 75 Stroke mm 1 175 1 175 Max length between pins mm 2 798 2 798 Min length betw...

Page 65: ...ing piston type Reciprocating piston type 105 105 70 70 1 055 1 055 2 555 2 555 1 500 1 500 Reciprocating piston type Reciprocating piston type 110 110 75 75 1 175 1 175 2 798 2 798 1 623 1 623 Recipr...

Page 66: ...uel cooler excl fuel 90 6 90 6 Hydraulic tank excl hydraulic oil 79 5 79 5 Control valve 95 99 Counterweight 3 240 2 855 Added counterweight 500 500 Swing motor incl brake valve 20 20 Swing circle 152...

Page 67: ...x 2 82 2 82 2 7 9 7 9 10 2 10 2 8 1 8 1 0 7 0 7 1 400 1 400 375 375 39 39 90 6 90 6 79 5 79 5 95 99 3 240 2 855 500 500 20 20 152 6 152 6 71 6 71 6 28 6 43 6 2 540 2 680 1 460 1 600 79 x 2 79 x 2 71...

Page 68: ...ucket link assembly 85 6 85 6 Bucket assembly 955 mm width incl side cutter 980 mm width incl side cutter 399 399 Blade assembly Reinforced blade BOC type incl BOC 688 Blade edge welding type 668 Rein...

Page 69: ...tion SEN01979 01 PC138US USLC 8 13 Unit kg PC138USLC 8 Standard specification Blade specification 20001 and up 820 820 356 356 85 6 85 6 399 399 688 668 702 682 101 3 x 2 101 3 x 2 125 3 125 3 77 8 77...

Page 70: ...SEN01979 01 01 Specification 14 PC138US USLC 8 Table of fuel coolant and lubricants 1 a For details of the notes Note 1 Note 2 in the table see the Operation and Maintenance Manual...

Page 71: ...38US USLC 8 15 Unit l Reservoir Specified capacity Refill capacity Engine oil pan 11 5 11 0 Swing machinery case 2 5 2 5 Final drive case each side 2 1 2 1 PTO case 0 75 0 75 Hydraulic system 120 69 F...

Page 72: ...16 PC138US USLC 8 SEN01979 01 01 Specification PC138US USLC 8 Hydraulic excavator Form No SEN01979 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 73: ...YDRAULIC EXCAVATOR PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Engine and cooling system Engine m...

Page 74: ...SEN02545 01 10 Structure function and maintenance standard 2 PC138US USLC 8 Engine mount 1...

Page 75: ...ucture function and maintenance standard SEN02545 01 PC138US USLC 8 3 PTO 1 a PTO Abbreviation for Power Take Off 1 Flywheel 2 Coupling 3 Hydraulic pump shaft 4 Drain plug 5 Oil filler plug 6 Oil leve...

Page 76: ...SEN02545 01 10 Structure function and maintenance standard 4 PC138US USLC 8 Cooling system 1...

Page 77: ...adiator inlet hose 13 Aftercooler outlet hose 14 Fan guard 15 Oil cooler outlet 16 Aftercooler inlet hose 17 Drain plug Specifications Radiator Oil cooler Aftercooler Fuel cooler Core type 4 array alu...

Page 78: ...6 PC138US USLC 8 SEN02545 01 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02545 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 79: ...1 HYDRAULIC EXCAVATOR PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Power train Power train 2 Swing...

Page 80: ...ve 2b Pump merge divider valve 2c Travel junction valve 3 PPC lock solenoid valve 4 2nd travel speed select solenoid valve 5 Swing holding brake solenoid valve 6 Pump merge divider solenoid valve 7 Tr...

Page 81: ...g circle pinion lubrication 4 Outer race 5 Ball 6 Seal 7 Inner race Number of teeth 90 a Inner race soft zone position b Outer race soft zone position Specifications Unit mm No Item Criteria Remedy 1...

Page 82: ...ry case 6 No 2 planetary carrier 7 No 2 sun gear Number of teeth 17 8 Ring gear Number of teeth 61 9 No 1 planetary carrier 10 No 1 sun gear Number of teeth 14 11 Swing motor 12 No 1 planetary gear Nu...

Page 83: ...gear 0 15 0 34 0 7 4 Backlash between No 1 plane tary carrier and No 2 sun gear 0 14 0 34 0 7 5 Backlash between No 2 sun gear and No 2 planetary gear 0 13 0 31 0 6 6 Backlash between No 2 plane tary...

Page 84: ...6 PC138US USLC 8 SEN02546 01 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02546 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 85: ...8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Undercarriage and frame Track frame 2 Idler cushion 4 Idler 6...

Page 86: ...roller 6 Travel motor 7 Sprocket 8 Track roller 9 Idler cushion 10 Track shoe Unit mm No Item Criteria Remedy 1 Length at idler guide Standard size Repair limit Rebuilding Track frame 84 89 Idler sup...

Page 87: ...r 6 Travel motor 7 Sprocket 8 Track roller 9 Idler cushion 10 Track shoe Unit mm No Item Criteria Remedy 1 Length at idler guide Standard size Repair limit Rebuilding Track frame 84 89 Idler support 8...

Page 88: ...ecoil spring 6 Cylinder 7 U packing 8 Pilot 9 Nut 10 Valve 11 Grease fitting Specifications Unit mm No Item Criteria Remedy 1 Recoil spring Standard size Repair limit Replace Free length Installed len...

Page 89: ...pring 6 Cylinder 7 U packing 8 Pilot 9 Nut 10 Valve 11 Grease fitting Specifications Unit mm No Item Criteria Remedy 1 Recoil spring Standard size Repair limit Replace Free length Installed length Ins...

Page 90: ...ng or replace 7 Clearance between idler shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 54 0 250 0 280 0 074 0 0 250 0 354 1 5 8 Interference between bu...

Page 91: ...rance between Shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 50 0 220 0 240 0 190 0 030 0 250 0 430 1 5 7 Interference between roller and bushing Stand...

Page 92: ...andard clearance Clearance limit Replace Shaft Hole 40 0 055 0 035 0 261 0 200 0 145 0 226 4 Interference between collar and bushing Standard size Tolerance Standard interfer ence Interfer ence limit...

Page 93: ...No Item Criteria Remedy 1 Wear on tooth bottom diameter Standard size Tolerance Repair limit Rebuilding or replace 542 8 1 0 2 0 530 2 Wear on tooth tip diameter 607 5 595 3 Wear on tooth tip width 2...

Page 94: ...ture function and maintenance standard 10 PC138US USLC 8 Track shoe 1 Triple grouser shoe road liner city pad shoe 1 Triple grouser shoe city pad shoe 2 Road liner a P portion shows the link of bushin...

Page 95: ...size Repair limit Repair or replace 90 85 5 Link thickness bushing press fit part 23 9 18 9 Replace 6 Shoe bolt pitch 102 4 7 86 4 8 57 9 Link Internal width 52 4 Repair or replace 10 Overall width 35...

Page 96: ...Standard size Tolerance Standard interference Adjust or replace Shaft Hole 50 2 0 387 0 347 0 074 0 074 0 273 0 387 22 Interference between regular pin and link 32 0 150 0 050 0 188 0 250 0 238 0 400...

Page 97: ...US USLC 8 13 Triple grouser shoe Unit mm No Item Criteria Remedy 1 Grouser overall height Standard size Repair limit Rebuilding or replace 20 10 2 Shoe overall height 29 5 19 5 3 Plate thickness 9 5 4...

Page 98: ...andard 14 PC138US USLC 8 Single shoe Unit mm No Item Criteria Remedy 1 Grouser overall height Standard size Repair limit Rebuilding or replace 50 20 5 2 Shoe overall height 62 32 5 3 Plate thickness 1...

Page 99: ...10 Structure function and maintenance standard SEN02547 01 PC138US USLC 8 15...

Page 100: ...16 PC138US USLC 8 SEN02547 01 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02547 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 101: ...PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 1 Hydraulic equipment layout drawing 2 Va...

Page 102: ...valve 5 Accumulator for PPC circuit 6 Boom cylinder 7 Hydraulic tank 8 Swing motor 9 Hydraulic pump 10 R H travel motor 11 Oil cooler 12 L H travel motor 13 L H work equipment PPC valve 14 Blade PPC...

Page 103: ...10 Structure function and maintenance standard SEN02548 01 PC138US USLC 8 3...

Page 104: ...R H work equipment control lever for boom and bucket control 7 Blade control lever blade specification 8 L H work equipment control lever for arm and swing control 9 L H work equipment PPC valve 10 Lo...

Page 105: ...10 Structure function and maintenance standard SEN02548 01 PC138US USLC 8 5...

Page 106: ...tank and filter 1 1 Hydraulic tank 2 Suction strainer 3 Filter element 4 Bypass valve 5 Drain plug 6 Sight gauge 7 Oil filler cap combined with breather Specifications Hydraulic tank capacity l 99 Oi...

Page 107: ...ent this negative pressure generation seam valve 4 is opened to draw the atmo sphere to the tank Intake valve set pressure 0 0 49 kPa 0 0 005 kg cm Prevention of pressure rise in tank q When the hydra...

Page 108: ...SEN02548 01 10 Structure function and maintenance standard 8 PC138US USLC 8 Hydraulic pump 1 Type HPD56 56...

Page 109: ...is less reduced when the machine is steered q The double pump has simpler structure than the tandem pump BMP Breather mounting port IM PC mode selector current OCP Oil level check port P1T Travel dev...

Page 110: ...SEN02548 01 10 Structure function and maintenance standard 10 PC138US USLC 8 1 Shaft 2 Cradle 3 Case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 End cap 10 Servo piston 11 PC valve...

Page 111: ...constitute the spherical bearing q Rocker cam 4 has flat surface A and shoe 5 is always pressed against this surface while sliding in a circular movement q Rocker cam 4 conducts high pressure oil to t...

Page 112: ...is way piston 6 slides on the inside of cylinder block 7 so a difference between vol umes E and F is created inside cylinder block 7 q A single piston 6 suctions and discharges the oil by the amount F...

Page 113: ...ce rocker cam 4 slides on the surface while continuing revolving movement q Space of the pressure receiving area of servo piston 12 are not identical on the left side and right side Main pump discharg...

Page 114: ...PL Control pressure input port 6 Sleeve Function q The LS load sensing valve detects the load and controls the delivery q This valve controls main pump delivery Q according to differential pressure PL...

Page 115: ...ermine the position of spool 6 q Before the engine is started servo piston 12 is pushed to the left See the diagram on the right q If the control lever is at the neutral position when the engine is st...

Page 116: ...right by the combined force of LS pressure PLS and the force of spring 4 q When spool 6 moves port D and port E are interconnected and connected to the PC valve q The PC valve is connected to the dra...

Page 117: ...es delivery of servo piston 12 pump pressure PP pushes spool 6 to the left q When spool 6 moves main pump pressure PP flows from port C to port D and from port K it enters the large diameter end of th...

Page 118: ...ion ship is A0 PP A1 PEN servo pis ton 12 will stop in that position q The swash plate of the pump will be held at the intermediate position Spool 6 will be stopped at a position where the distance of...

Page 119: ...that it may not exceed the engine hose power q If the pump discharge pressure PP1 increases due to increased load during operation this valve decreases the pump delivery q And if the pump delivery pr...

Page 120: ...ve to output the signal pressure in order to modify the force pushing piston 2 q Spool 3 stops at a position where the com bined spool pushing force is balanced by the setting force of springs 4 and 6...

Page 121: ...10 Structure function and maintenance standard SEN02548 01 PC138US USLC 8 21...

Page 122: ...xtends or compresses springs 4 and 6 q If the command current X to PC EPC valve solenoid 1 changes so does the force push ing piston 2 q Spring load of springs 4 and 6 is also affected by the command...

Page 123: ...ecomes weaker q As the spring force is weakened spool 3 moves to the left the connecting between port C and port D is shut off and the pump dis charge pressure ports B and C are con nected q As a resu...

Page 124: ...t C and D through LS valve At the end this flow level of this pressure becomes approximately half of the main pump pressure PP Operation q When port E and port G of the LS valve are connected this pre...

Page 125: ...re because springs 4 and 6 form the double springs q The relationship between the average pump pressure PP1 PP2 2 and average pump delivery Q becomes as shown below q If command current X sent to PC E...

Page 126: ...t in between to con trol the current flowing to PC EPC valve sole noid 1 q The current becomes constant so the force pushing piston 2 is also constant q If the main pump pressures PP1 and PP2 are low...

Page 127: ...es constant q For this reason the force of piston 2 pushing spool 3 is constant q If main pump pressures PP1 and PP2 increase spool 3 moves further to the left than when the main pump load is light an...

Page 128: ...too the pump pressure PP and pump delivery Q have a relationship as shown with the curve in the figure correspond ing to the current sent to the PC EPC valve solenoid through the resistor q The curve...

Page 129: ...tructure function and maintenance standard SEN02548 01 PC138US USLC 8 29 PC EPC valve C To PC valve P From self pressure reducing valve T To tank 1 Connector 2 Coil 3 Body 4 Spring 5 Spool 6 Rod 7 Plu...

Page 130: ...sure in proportion to the size of the signal and outputs it to the PC valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the controller to c...

Page 131: ...and port T are connected q Spool 5 moves up and down so that the pro pulsion force of plunger 7 may be balanced with pressure of port C spring load of spring 4 q The circuit pressure between the EPC...

Page 132: ...e 2 Poppet valve Function q A set of 2 check valves is used to select and output the higher discharge pressure of the 2 main pumps Operation 1 When PA1 PA2 q Discharge pressures PA1 and PA2 of the mai...

Page 133: ...q The shuttle valve selects and outputs the lower discharge pressure of the 2 main pumps Operation q The discharge pressures PA1 and PA2 of the 2 main pumps are applied to poppet valves 1 and 2 respe...

Page 134: ...34 PC138US USLC 8 SEN02548 01 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02548 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 135: ...XCAVATOR PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 2 Control valve 2 CLSS...

Page 136: ...oler BP1 From boom raise PPC valve LS1 LS1 pressure pickup port LS2 LS2 pressure pickup port LS3 LS3 pressure pickup port PA1 From swing left PPC valve PA2 From blade lower PPC valve PA3 From left tra...

Page 137: ...10 Structure function and maintenance standard SEN02549 02 PC138US USLC 8 3...

Page 138: ...SEN02549 02 10 Structure function and maintenance standard 4 PC138US USLC 8...

Page 139: ...spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installed length Installed load Free length Installed load 46 8 7 5 40 6 5 49 N 0 56 kg 4 41 N 0 45...

Page 140: ...SEN02549 02 10 Structure function and maintenance standard 6 PC138US USLC 8...

Page 141: ...ssure compensation valve F Blade 13 Pressure compensation valve F Left travel 14 Pressure compensation valve F Right travel 15 Merge divider valve spool 16 Pressure compensation valve F Boom 17 Pressu...

Page 142: ...SEN02549 02 10 Structure function and maintenance standard 8 PC138US USLC 8...

Page 143: ...ssure compensation valve F 12 Suction valve 13 Suction valve 14 Spool 15 Pressure compensation valve R 16 LS check valve F Flow control valve R Pressure reducing valve Unit mm No Check item Criteria R...

Page 144: ...SEN02549 02 10 Structure function and maintenance standard 10 PC138US USLC 8...

Page 145: ...lve 17 Spool 18 Pressure compensation valve R F Flow control valve R Pressure reducing valve Unit mm No Check item Criteria Remedy 19 Spool return spring Standard size Repair limit If damaged or defor...

Page 146: ...SEN02549 02 10 Structure function and maintenance standard 12 PC138US USLC 8...

Page 147: ...re compensation valve R Service valve 12 Pressure compensation valve F 13 Suction safety valve 14 Suction safety valve 15 Spool 16 Pressure compensation valve R 17 Suction safety valve 18 Pressure rel...

Page 148: ...nfluenced by load q Controllability enabling digging even with fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q En...

Page 149: ...r is constant q LS differential pressure PLS Pump discharge pressure PP LS pressure PLS q The pump swash plate angle shifts toward the maximum position if LS differential pressure PLS is lower than th...

Page 150: ...side of the control valve to bal ance the load q When actuators are operated together the pressure difference P between the upstream inlet port and downstream outlet port of the spool of each valve be...

Page 151: ...10 Structure function and maintenance standard SEN02549 02 PC138US USLC 8 17...

Page 152: ...SEN02549 02 10 Structure function and maintenance standard 18 PC138US USLC 8 Functions and operation by valve 1 Hydraulic circuit diagram and the name of valves 1...

Page 153: ...e spool 17 Pressure compensation valve 18 Suction valve 19 LS service valve 20 Merge divider valve 21 Arm regeneration valve 22 Self pressure reducing valve 23 Travel junction valve 24 Lift check valv...

Page 154: ...ressures P1 and P2 are merged LS pressures LS1 LS2 and LS3 are also merged Operation q Pump discharge pressures P1 and P2 are applied to pump pressure receiving SA face of unload spool 1 q LS pressure...

Page 155: ...valve is at the merge position pump discharge pressures P1 and P2 are merged LS pressures LS1 LS2 and LS3 are also merged Operation q When any work equipment valve is operated for a long stroke LS pre...

Page 156: ...ate angle of the pump becomes maximum so the pump delivery becomes maximum For details see the sections on the pump merge divider valve Operation q When fine control is carried out on both travel valv...

Page 157: ...ecomes maximum For details see the sections on the pump merge divider valve Operation q When both travel valves are operated to the stroke ends LS pressures LS1 and LS2 are generated and act on the fa...

Page 158: ...ke end and right one is at HOLD q When the left travel valve is operated to the stroke end LS pressure LS1 is generated and acts on the face SB of unload spool 1 q The area of the openings of left tra...

Page 159: ...10 Structure function and maintenance standard SEN02549 02 PC138US USLC 8 25...

Page 160: ...ge divider valve 1 When oil is merged PS 0 kg cm2 Function q Pump discharge pressures P1 and P2 are merged in pump merge divider spool 3 LS1 LS2 and LS3 are also merged q At this time P1 P2 and LS1 LS...

Page 161: ...arge pressures P1 and P2 are divided in pump merge divider spool 3 LS1 LS2 and LS3 are also divided q At this time higher one of P1 and P2 is applied through pump merge divider spool 3 to the output p...

Page 162: ...e spool and bridge pas sage b to actuator circuit A q At the same time reducing valve 3 also moves to the right so pump discharge pres sure PP is reduced by the pressure loss at notch c It goes to LS...

Page 163: ...ssure PP flows from flow control valve 2 through notch a in the spool and bridge pas sage b to actuator circuit A q Actuator circuit pressure PA A is intro duced through the check valve 5 into LS cir...

Page 164: ...pressure PLS q This lowers the rising speed of LS pressure PLS In addition the discarded throttled flow causes a pressure loss in the throttled flow in the reducing valve and that lowers the effec tiv...

Page 165: ...only one travel valve Operation q Since pump merge divider spool 1 is at the separate position LS circuits PLS1 and PLS2 are separated q The hydraulic oil PLS1 flows from tip filter a of LS bypass va...

Page 166: ...SEN02549 02 10 Structure function and maintenance standard 32 PC138US USLC 8 Pressure compensation valve...

Page 167: ...f another actuator is applied to the spring chamber PLS1 and pushes the pressure reducing valve 1 and the flow control valve 2 to the left side q The flow control valve 2 throttles the opening area be...

Page 168: ...ea of the piston 3 S2 Area of the pressure reducing valve 1 area of the piston 3 Area ratio S1 S2 and compensation charac teristics q When the ratio is 1 00 The expression Pump discharge pres sure PP...

Page 169: ...B this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed Operation q When the boom is lowered and falls due to its own weight the bottom side pressure...

Page 170: ...om is in the load process the check valve 3 will be closed and the circuits on the head side and the bottom side will be interrupted Operation q When the boom is lowered and is in the load process the...

Page 171: ...igher than the bottom pressure B during arm digging this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed Operation q When the arm falls for digging du...

Page 172: ...om pressure B of the cylinder 1 rises above the head pressure A and the arm enters the digging process the check valve 3 will be closed and the circuits on the head side and the bottom side will be in...

Page 173: ...erated the hydraulic drift prevention valve prevents pres surized oil from leaking from the boom bottom through spool 1 to prevent the boom from drifting hydraulically Operation q If the boom is raise...

Page 174: ...eutral Operation q If the control lever is returned to the neutral position while the boom is raised out the hold ing pressure in the boom cylinder bottom and arm cylinder head is blocked by poppet 5...

Page 175: ...3 and the pressurized oil in chamber b in the poppet is drained q The pressurized oil in port Ab is raised by the pressurized oil from the boom cylinder bottom but the pressurized oil in chamber b is...

Page 176: ...lt pump circuit PP bleed off circuit and LS circuit are connected through piston 2 q Bleeding spool 3 moves to the left in propor tion as swing PPC pressure PA rises In the fine control area notch b c...

Page 177: ...ts the boom RAISE speed from reducing by securing the pump flow at the time of swing drive Operation q The pilot pressure is not generally applied to the pilot port BP except for boom RAISE operation...

Page 178: ...2 and reaches a pressure that is stron ger than the spring 3 the piston 2 will be pushed to the left side the valve 1 will close and the pump discharge pressure PP will not come to flow to the pressur...

Page 179: ...will travel straight q When the machine is steered outside pilot pressure PST closes the travel junction valve to secure high steering performance Operation When pilot pressure is turned ON q If the p...

Page 180: ...differential pressure is generated over orifice a in spool 4 and spool 4 moves in the direction to close the opening between ports P and PR The P pressure is lowered and controlled to a constant pres...

Page 181: ...sure will be as follows q PA PB Force of spring 3 Area of pis ton 2 at diameter d1 PB C 0 kg cm Cooler bypass valve Function q The cooler bypass valve protects oil cooler 4 from breakage when the ret...

Page 182: ...48 PC138US USLC 8 SEN02549 02 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02549 02 2007 KOMATSU All Rights Reserved Printed in Japan 10 07 02...

Page 183: ...del Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 3 PPC valve 2 Swing motor 19 Travel motor 27 Center swivel join...

Page 184: ...ing PPC valve 1 P From self pressure reducing valve P1 L H PPC valve Arm OUT port R H PPC valve Boom LOWER port P2 L H PPC valve Arm IN port R H PPC valve Boom RAISE port P3 L H PPC valve Swing LEFT p...

Page 185: ...10 Structure function and maintenance standard SEN02550 01 PC138US USLC 8 3...

Page 186: ...ria Remedy 10 Centering spring for ports P3 and P4 Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length Insta...

Page 187: ...P1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P...

Page 188: ...plied until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber D flows in from fine control hole f in...

Page 189: ...10 Structure function and maintenance standard SEN02550 01 PC138US USLC 8 7 Travel PPC valve P From self pressure reducing valve P1 L H reverse P2 L H forward P3 R H reverse P4 R H forward T To tank...

Page 190: ...SEN02550 01 10 Structure function and maintenance standard 8 PC138US USLC 8...

Page 191: ...Unit mm No Check item Criteria Remedy 7 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length Installation load Free length...

Page 192: ...t P1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port...

Page 193: ...lied until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber D flows in from fine control hole f in...

Page 194: ...SEN02550 01 10 Structure function and maintenance standard 12 PC138US USLC 8 Blade PPC valve 1 a For the details of operation see the paragraph of Work equipment and swing PPC valve...

Page 195: ...iston 3 Lever 4 Plate 5 Retainer 6 Body 7 Filter Unit mm No Check item Criteria Remedy 8 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter...

Page 196: ...EN02550 01 10 Structure function and maintenance standard 14 PC138US USLC 8 Attachment PPC valve with EPC valve 1 a For the details of operation see the paragraph of Work equipment and swing PPC valve...

Page 197: ...3 Lever 4 Plate 5 Retainer 6 Block 7 Body 8 EPC valve Unit mm No Check item Criteria Remedy 9 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diam...

Page 198: ...reducing valve T To hydraulic tank 1 Body 2 Plug 3 Spool 4 Push pin 5 Coil 6 Plunger 7 Connector Unit mm No Check item Criteria Remedy 8 Return spring Standard size Repair limit If damaged or deformed...

Page 199: ...ressure in proportion to the size of the signal and outputs it to the control valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the control...

Page 200: ...T are con nected q Spool 2 moves up and down so that the pro pulsion force of plunger 6 may be balanced with pressure of port C spring load of spring 3 q The circuit pressure between the EPC valve and...

Page 201: ...olding brake solenoid valve MA From control valve MB From control valve S From control valve T To tank 1 Reverse prevention valve 2 Safety valve Specifications Type KMF45ABE 5 Theoretical displacement...

Page 202: ...SEN02550 01 10 Structure function and maintenance standard 20 PC138US USLC 8...

Page 203: ...ve plate 13 Center shaft 14 Center spring 15 Check valve 16 Shuttle valve Unit mm No Check item Criteria Remedy 17 Check valve spring Standard size Repair limit If damaged or deformed replace spring F...

Page 204: ...ircuit T q Brake piston 8 is pushed down by brake spring 1 q Disc 5 and plate 6 are pushed together and the brake is applied 2 When solenoid valve is energized Operation q As the swing holding brake s...

Page 205: ...orque is generated in the motor and the motor starts to rotate q The pressurized oil from the outlet port of the motor passes from port MB through the con trol valve 6 and returns to the tank 2 When s...

Page 206: ...SEN02550 01 10 Structure function and maintenance standard 24 PC138US USLC 8 Reverse prevention valve...

Page 207: ...ndard SEN02550 01 PC138US USLC 8 25 MA From control valve MB From control valve T1 To tank T2 To tank 1 Valve body 2 Spool MA side 3 Spring MA side 4 Plug MA side 5 Spool MB side 6 Spring MB side 7 Pl...

Page 208: ...nce in areas of circles D1 D2 of spool 5 and moves spool 5 to the left side q Port MB o chamber e will be intercon nected q Since pressure MA is lower than the set pres sure of spring 3 spool 2 does n...

Page 209: ...swivel joint port B2 L H travel motor From center swivel joint port C2 R H travel motor B From center swivel joint port D2 L H travel motor From center swivel joint port A2 R H travel motor D To cente...

Page 210: ...f valve 6 End cover 7 Brake piston 8 Disc 9 Plate 10 Swash plate 11 Pivot 12 Bearing 13 Hub 14 Planetary pinion B 15 Planetary pinion A 16 Cover 17 Sun gear A 18 Carrier A 19 Sun gear B 20 Carrier B 2...

Page 211: ...ions stops the hydraulic motor smoothly prevents runway of hydraulic motor prevents generation of abnormally high pres sure when the hydraulic motor is stopped sud denly 4 2nd travel speed selector me...

Page 212: ...valve q Since 2nd travel speed select solenoid valve 1 is de energized the pressurized oil from self pressure reduction valve 11 is not fed to port P q Regulator valve 2 is pushed down with spring 3...

Page 213: ...valve 12 Brake valve q When 2nd travel speed select solenoid valve 1 is energized the pressurized oil from self pressure reduction valve 11 is fed to port P q Regulator valve 2 is pushed up with the...

Page 214: ...the hydraulic pressure This releases the parking brake and the motor starts to rotate Operation when pressure is shut off q When the travel lever is returned to its neutral position the hydraulic oil...

Page 215: ...aulic oil in chamber J tends to flow to port B through orifice h However the back pressure is generated by closing of orifice h controlling the return speed of counterbal ance valve 2 to the right q W...

Page 216: ...ydraulic pressure at port C at the inlet side is controlled so that the motor is smoothly started to rotate When stopping q When the hydraulic oil from the control valve is stopped ports A and C are c...

Page 217: ...10 Structure function and maintenance standard SEN02550 01 PC138US USLC 8 35...

Page 218: ...ARD C1 From control valve R H travel REVERSE D1 From control valve L H travel REVERSE E1 From 2nd travel speed select solenoid valve DR1 To hydraulic tank 1 Cover 2 Body 3 Slipper seal A2 To R H trave...

Page 219: ...e function and maintenance standard SEN02550 01 PC138US USLC 8 37 Unit mm No Item Criteria Remedy 1 Clearance between rotor and shaft Standard size Standard clearance Clearance limit Replace 80 0 056...

Page 220: ...ERSE E1 From 2nd travel speed select solenoid valve F1 From control valve blade LOWER G1 From control valve blade RAISE DR1 To hydraulic tank 1 Cover 2 Body 3 Slipper seal A2 To R H travel motor port...

Page 221: ...e function and maintenance standard SEN02550 01 PC138US USLC 8 39 Unit mm No Item Criteria Remedy 1 clearance between rotor and shaft Standard size Standard clearance Clearance limit Replace 80 0 056...

Page 222: ...SEN02550 01 10 Structure function and maintenance standard 40 PC138US USLC 8 Solenoid valve 1...

Page 223: ...solenoid valve 4 Pump merge divider solenoid valve 5 Travel junction solenoid valve Solenoid valve 6 Coil ON OFF type 7 Push pin 8 Valve spool 9 Sleeve 10 Block 11 Plug Check valve 12 Plunger 13 Plug...

Page 224: ...the pilot pres sure is not fed to the actuator through port A At the same time port T is opened allowing the oil from the actuator to drain to the hydrau lic tank When solenoid valve is energized circ...

Page 225: ...10 Structure function and maintenance standard SEN02550 01 PC138US USLC 8 43...

Page 226: ...is stopped with the work equipment is kept at an elevated position the pilot pressure is supplied to the control valve by the pressure of the com pressed nitrogen gas in the accumulator Therefore the...

Page 227: ...d piping Specifications Gas to be used Nitrogen gas Gas capacity 480 cc Sealed gas pressure 0 1 MPa 1 kg cm at 80 C Maximum operating pressure 0 69 MPa 7 kg cm For high pressure 1 Cap 2 Core 3 Locknut...

Page 228: ...SEN02550 01 10 Structure function and maintenance standard 46 PC138US USLC 8 Holding valve 1 For boom and arm...

Page 229: ...Safety valve 3 Check valve Unit mm No Check item Criteria Remedy 4 Check valve spring Standard size Repair limit If damaged or deformed replace spring Free length Outside diameter Installation length...

Page 230: ...e force of springs 2 and 3 q Chambers a and b are shut off q No pressurized oil flows between the control valve and the work equipment cylinder q Accordingly the work equipment is held in position q I...

Page 231: ...mbers a and b are interconnected q Pressurized oil flows from the control valve to the work equipment cylinder If the piping is bursted q If piping A between the control valve and the work equipment c...

Page 232: ...y position 1st stage stroke q At this point chambers a and b are not interconnected q Pilot pressure further rises and reaches Pilot pressure Force of spring 2 area of d q Spool 1 moves further to the...

Page 233: ...ction and maintenance standard SEN02550 01 PC138US USLC 8 51 Multi control valve 1 if equipped 1 JIS pattern 2 Backhoe pattern Control pattern switching diagram Port names correspond to the marks on t...

Page 234: ...52 PC138US USLC 8 SEN02550 01 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02550 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 235: ...EXCAVATOR PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Work equipment Work equipment 2 Dimensions...

Page 236: ...and arm 70 0 030 0 100 0 145 0 065 0 095 0 245 0 8 3 Clearance between mounting pin and bushing of arm and bucket 60 0 030 0 080 0 129 0 074 0 104 0 209 0 8 4 Clearance between mounting pin and bushi...

Page 237: ...10 Structure function and maintenance standard SEN02551 00 PC138US USLC 8 3...

Page 238: ...SEN02551 00 10 Structure function and maintenance standard 4 PC138US USLC 8 Dimensions of components 1 Arm...

Page 239: ...Arm side 81 5 1 0 0 Cylinder head side 80 1 2 3 Boom side 226 0 5 0 Arm side 226 0 2 0 7 4 70 0 030 0 100 0 100 0 5 264 2 0 6 213 5 1 0 7 640 6 0 5 8 2 491 9 2 101 9 1 5 10 290 4 0 5 11 487 0 2 12 41...

Page 240: ...SEN02551 00 10 Structure function and maintenance standard 6 PC138US USLC 8 Bucket...

Page 241: ...o PC138US 8 PC138USLC 8 Measurement point Standard size Tolerance 1 371 3 0 5 2 51 6 0 5 3 97 9 4 374 9 5 1 226 6 6 190 2 7 5 8 0 9 60 0 2 0 10 64 11 80 0 25 0 12 261 1 0 13 50 14 85 15 380 1 0 0 16 1...

Page 242: ...SEN02551 00 10 Structure function and maintenance standard 8 PC138US USLC 8 Hydraulic cylinder 1 Boom cylinder Arm cylinder Bucket cylinder...

Page 243: ...0 250 0 055 0 085 0 326 0 426 Blade 75 0 030 0 076 0 279 0 065 0 095 0 355 0 455 2 Clearance between piston rod support shaft and bushing Boom 70 0 030 0 100 0 190 0 090 0 120 0 290 1 0 Arm 70 0 030...

Page 244: ...10 PC138US USLC 8 SEN02551 00 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02551 00 2007 KOMATSU All Rights Reserved Printed in Japan 01 07 02...

Page 245: ...N02552 01 HYDRAULIC EXCAVATOR PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Cab and its attachments...

Page 246: ...SEN02552 01 10 Structure function and maintenance standard 2 PC138US USLC 8 Air conditioner 1 Air conditioner piping diagram...

Page 247: ...troller 7 Sight glass 8 External air filter 9 Air conditioner unit 10 Internal air filter 11 Dual pressure switch 12 Hot water take out piping 13 Ambient temperature sensor 14 Hot water return piping...

Page 248: ...ssure switch Table of tightening torque for refrigerant piping adapter Unit Nm kgm No Item Criteria Remedy 7 Compressor refrigerant piping lock bolt 7 85 11 8 0 8 1 2 Screw size M6 1 0 Retighten 8 Con...

Page 249: ...10 Structure function and maintenance standard SEN02552 01 PC138US USLC 8 5...

Page 250: ...SEN02552 01 10 Structure function and maintenance standard 6 PC138US USLC 8 Air conditioner unit...

Page 251: ...Outline q The horizontal air conditioner unit on which evaporator 1 and heater core 2 is arranged in parallel Blower motor 4 is driven to to gen erate cool and hot air q Selecting the temperature on...

Page 252: ...a sig nal current from the air conditioner controller in order to open or close the mode selector damper through the link mechanism q The motor rotating direction is determined as the air conditioner...

Page 253: ...ator B Output 5 NC 21 Air mix dumper actuator A Output 6 Back up power supply Input 22 Air mix dumper actuator B Output 7 Blower feedback signal Input 23 Mode selector actuator A Output 8 Power transi...

Page 254: ...r to high pressure high temperature misty refrigerant so that it may be easily regenerated liquefied at normal temperature q Its built in magnet clutch turns on or off depending on the evaporator temp...

Page 255: ...n in heat dissipation q It eliminates foreign substances in the circula tion circuit and water content in the refrigerant by use of the built in filter and desiccating agent a If the fin crushes or is...

Page 256: ...used to control the blower motor and compres sor Output characteristics External air temperature sensor Outline q The external air temperature sensor is installed in the battery room at the rear left...

Page 257: ...10 Structure function and maintenance standard SEN02552 01 PC138US USLC 8 13...

Page 258: ...14 PC138US USLC 8 SEN02552 01 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02552 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 259: ...ATOR PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 10 Structure function and maintenance standard 1 Electrical system Electronic control system 2 Mo...

Page 260: ...SEN02553 01 10 Structure function and maintenance standard 2 PC138US USLC 8 Electronic control system 1 Machine control system diagram...

Page 261: ...10 Structure function and maintenance standard SEN02553 01 PC138US USLC 8 3 1...

Page 262: ...l 12 Safety relay 13 Starting motor 14 Fuel supply pump 15 Sensors 16 Engine controller power cut off relay A 17 Engine controller power cut off relay B 18 Machine monitor 19 KOMTRAX terminal Function...

Page 263: ...relay 9 cuts off the starting current to starting motor 13 q Upon receipt of the engine cut off command from the external source KOMTRAX terminal 19 sends the signal to machine monitor 18 Machine moni...

Page 264: ...Fuel supply pump 12 Sensors 13 Pump oil pressure sensor 14 Oil pressure sensor 15 Oil pressure switch 16 Hydraulic pump 16a Servo 16b LS valve 16c PC valve 17 Control valve 17a Pump merge divider valv...

Page 265: ...ending on the work In the default setting of the service mode only 3 modes P E L are available in which Without is selected for the attachment q According to the pump absorption torque set at each mod...

Page 266: ...and the pressure rises the engine speed N lowers At the time the controller reduces the pump deliv ery Q to increase the engine speed to the matching point If the pressure drops the con troller increa...

Page 267: ...ion torque to decrease the engine speed while keeping the engine torque at a constant level along the equal engine horsepower curve q The controller controls pump delivery Q so that the engine torque...

Page 268: ...work is possible because the hydraulic pump does not work properly operating emergency pump drive switch 1 temporarily enables to main tain functions of the machine with absorption torques quite simil...

Page 269: ...10 Structure function and maintenance standard SEN02553 01 PC138US USLC 8 11...

Page 270: ...rol dial 5 Fuel supply pump 6 Sensors 7 Oil pressure sensor 8 Oil pressure switch 9 Hydraulic pump 10 Control valve 10a Pump merge divider valve 10b Self pressure reducing valve 11 PPC lock solenoid v...

Page 271: ...all the control levers are set to NEUTRAL for 4 seconds or more with the engine speed exceeding approx 1 400 rpm the engine speed lowers down to the control speed approx 1 400 rpm and is held until th...

Page 272: ...mp drive switch 10 Fuel control dial 11 Fuel supply pump 12 Sensors 13 Hydraulic oil temperature sensor 14 Hydraulic pump 14a Servo 14b LS valve 14c PC valve 15 Control valve 15a Pump merge divider va...

Page 273: ...n 98 C Traveling status check ON Engine speed Remains same Travel speed Down Coolant temperature Max 98 C Hydraulic oil temperature Max 98 C The original conditions are restored if above requirements...

Page 274: ...ay be seized Controlling the engine speed prevents this problem q Duration of engine speed control depends on the coolant temperature A Start engine B Duration of turbocharger protection approx 0 20 s...

Page 275: ...lock switch 7 Pump controller 8 Machine monitor 9 Oil pressure switch 10 Hydraulic pump 11 Control valve 11a Pump merge divider valve 11b Self pressure reducing valve 12 Swing motor 13 Swing holding...

Page 276: ...work equipment control lever SWING Swing holding brake RELEASE B L H work equipment control lever NEUTRAL C Swing holding brake OPERATED D 5 sec Swing lock switch OFF ON Swing lock monitor OFF ON Fun...

Page 277: ...olding brake is not be released while the swing lock switch is set to ON a When the swing holding brake is released only the hydraulic brake with the safety valve is effective for swing So note that w...

Page 278: ...re reducing valve 11c Travel junction valve 11d Pump merge divider valve 12 Travel motor 13 2nd travel speed select solenoid valve 14 Travel junction solenoid valve 15 Pump merge divider solenoid valv...

Page 279: ...a flat or downhill with low speed caused by the automatic gear shift ing due to high pressure and the travel hydraulic pressure below 17 7 MPa 180 kg cm continues for 0 1 seconds or more the travel m...

Page 280: ...re satisfied P1 Min 1 6 16 P2 Min 1 6 16 P3 Min 1 6 16 P4 Min 1 6 16 Merge 2 Travel at normal speed One of following condi tions is satisfied P1 Min 1 8 18 P2 Min 1 8 18 P3 Min 1 8 18 P4 Min 1 8 18 St...

Page 281: ...9 Control valve 9a Pump merge divider valve 9b Self pressure reducing valve 10 PPC lock solenoid valve Function q Interlocked with the lock lever the PPC lock switch is turned OFF when operating the...

Page 282: ...ve 10b Self pressure reducing valve 11 PPC lock solenoid valve 12 Oil flow adjuster EPC valve for attachment 13 PC EPC valve 14 Attachment circuit selector valve 15 Attachment Input and output signals...

Page 283: ...10 Structure function and maintenance standard SEN02553 01 PC138US USLC 8 25...

Page 284: ...er Input and output signals q The following is the list of the symbols used for signal classification in the input output signal chart A Power supply B Input C Ground shield return D Output E Communic...

Page 285: ...Ambient pressure sensor B 50 NC 21 NC 51 Injector 4 C 22 NC 52 NC 23 NC 53 Injector 1 C 24 NC 54 NC 25 NC 55 Injector 3 D 26 Crankshaft speed sensor 5 V A 56 Injector 4 D 27 NC 57 Injector 1 D 28 NC 5...

Page 286: ...SEN02553 01 10 Structure function and maintenance standard 28 PC138US USLC 8 Pump controller...

Page 287: ...27 NC 67 Boom angle sensor Input 28 NC 68 NC 29 Hydraulic oil temperature sensor Input 69 L H travel FORWARD oil pressure sensor Input 30 NC 70 GND analog signal Input 31 Boom cylinder bottom oil pre...

Page 288: ...ht console box Potentiome ter 5 is installed inside knob 1 Turning knob 1 causes potentiometer 5 shaft to rotate q This rotation changes the resistance of the variable resistor within potentiometer 5...

Page 289: ...31 Resistor 1 Resistance 2 Connector Specifications For PC EPC valve 30 z Function q Sends an electric current to each EPC valve that is appropriate for each condition when the emergency pump drive sw...

Page 290: ...32 PC138US USLC 8 Engine oil pressure switch 1 Connector 2 Sensor 3 O ring Specifications Contact type Normal close Function q Installed in the cylinder block Detects engine oil pressure and turns the...

Page 291: ...t type Normal open Operating pressure to make contact point ON 490 98 1 kPa 5 0 1 0 kg cm2 Operating pressure to break contact point OFF 294 49 0 kPa 3 0 0 5 kg cm2 Function q Installed 8 places in th...

Page 292: ...SEN02553 01 10 Structure function and maintenance standard 34 PC138US USLC 8...

Page 293: ...ignals d Drive signal Outline q The monitor system keeps the operator informed of all machine functions by monitor ing the machine conditions using the sensors and switches installed in various parts...

Page 294: ...y Precautions on the machine monitor display q The LCD panel may have black points points which are not lighted and bright points points which do not go off for the reason of its char acteristics If t...

Page 295: ...2C CTS Input 2 For communication terminal RS232C RXD Input 11 For communication terminal RS232C RI Input 3 For communication terminal RS232C SG 12 GND communication terminal power supply 4 GND communi...

Page 296: ...o 16 are faulty after starting the engine monitor items are displayed on the screen in chronological order from the upper left q If the hydraulic oil temperature goes High or Low while the hydraulic o...

Page 297: ...F4 66 Blue F5 52 Blue F6 33 Red 3b Caution See the column Gauge 4 ECO gauge Segment Load level Indicates average load per minute on a scale of 1 to 10 Indicates when Default ECO display setting of the...

Page 298: ...al range below the specified value Light OFF Normal range When an error is detected with the engine running the monitor lights up on the screen and the alarm buzzer sounds at the same time 15 2 Engine...

Page 299: ...10 Structure function and maintenance standard SEN02553 01 PC138US USLC 8 41...

Page 300: ...Lo low speed i o Hi high speed 4 Buzzer cancel switch Numeric keypad 4 Stops the alarm buzzer Some alarm buzzer does not stop even if the switch is pressed Stops the alarm buzzer The alarm buzzer resu...

Page 301: ...ars 9 2 Auto switch Numeric keypad 9 Auto runs the air conditioner and air blower AUTO light ON Auto run Automatically controls the fan speed air outlet port internal external air flow accord ing to t...

Page 302: ...measurement of spilt fuel consump tion 5 Stop Stops function Used for stopping measurement of spilt fuel con sumption F2 1 Default Sets selected item back to default Used for screen adjustment 2 Move...

Page 303: ...US USLC 8 45 F5 1 Selecting maintenance screen Selects maintenance screen 2 Return Returns to the previous screen or condition F6 1 Selecting user mode screen Selects user mode screen 2 Fix Fixes sele...

Page 304: ...mode functions see the Operation and Maintenance Manual or Spe cial functions of machine monitor in Testing and adjusting a For how to set the engine start lock on off see Password setting cancel man...

Page 305: ...etting of the user mode q Oil flow level can be set as follows Language setting q The language used in the machine monitor can be changed in the Language setting of the user mode q The available langu...

Page 306: ...tions of machine monitor in Testing and adjusting Monitoring Abnormality record Mechanical systems Electrical systems Air conditioner system Maintenance record Change of maintenance mode Setting of te...

Page 307: ...s information of the machine via wireless communication It allows operators of the KOMTRAX to obtain the machine information from the office and to pro vide various services with the customers q The i...

Page 308: ...ormation via communication antenna q Conditions of the KOMTRAX terminal can be checked with the Display of KOMTRAX set ting in the service mode of the machine moni tor q Use of KOMTRAX terminal must b...

Page 309: ...ed in the bracket on the side face of the cylinder block Detects the ambient pressure and outputs variable voltage Boost pressure temperature sensor 1 Connector 2 Sensor 3 O ring Function q Installed...

Page 310: ...etects the temperature change and outputs signal as a resistance change Crankshaft speed sensor Camshaft speed sensor 1 Connector 2 Sensor 3 O ring Function q The crankshaft speed sensor is installed...

Page 311: ...tor Function q Installed in the common rail Detects the fuel pressure and outputs variable voltage Engine oil level sensor 1 Connector 2 Bracket 3 Float 4 Switch Function q The engine oil level sensor...

Page 312: ...7 Spacer Function q This sensor is installed on the side face of the fuel tank The float moves up and down according to the fuel level The float moves the variable resistor through the arm The resist...

Page 313: ...talled in the suction pipe of the hydraulic pump Detects the temperature change and outputs signal as a resistance change of the thermistor Pump oil pressure sensor 1 O ring 2 Sensor 3 Connector Funct...

Page 314: ...re sensor For travel and blade operation 1 O ring 2 Sensor 3 Connector Function q The PPC oil pressure sensor is installed in the control valve connecting part of the pilot circuit for travel and blad...

Page 315: ...10 Structure function and maintenance standard SEN02553 01 PC138US USLC 8 57...

Page 316: ...58 PC138US USLC 8 SEN02553 01 10 Structure function and maintenance standard PC138US USLC 8 Hydraulic excavator Form No SEN02553 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 317: ...ANUAL PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 20 Standard value table 1 Standard service value table Standard value table for engine related p...

Page 318: ...rature 40 60 C Engine speed 320 360 rpm SAE0W30E0S MPa kg cm2 Min 2 9 Min 30 2 0 20 Blow by pressure Coolant temperature operating range Arm IN relief kPa mmH2O Max 0 59 Max 60 0 98 100 Oil pressure H...

Page 319: ...control lever Boom control lever Engine at high idle Oil temperature 45 55 C Fit push pull scale to center of control lever knob to test Fit push pull scale to tip of control pedal to test Test max v...

Page 320: ...0 98 28 10 Travel rotating under no load Travel lever at half way position 2 2 0 1 22 5 1 Swing Overrun when stopping swing For testing posture see Swing 1 Engine at high idle Hydraulic oil temperatur...

Page 321: ...st time taken for next 5 turns with no load Lo sec Max 39 5 49 Hi Max 22 3 27 Travel speed actual run For testing posture see Travel 2 Engine at high idle Hydraulic oil temperature 45 55 C Run up for...

Page 322: ...maximum lifting height and test downward movement at edge of blade for 15 minutes Max 31 Max 47 Work equipment speed Boom Bucket teeth in contact with ground I I I I O O O O Cylinder fully extended F...

Page 323: ...Max 2 Max 2 Bucket For testing posture see Work equipment 8 Engine at low idle Hydraulic oil temperature 45 55 C Set top surface of boom horizontal retract arm cylinder fully then extend bucket cylind...

Page 324: ...ed on the machine if it is impossible to set the engine speed to the specified speed with the fuel control dial take the pump discharge amount and the engine speed at the point of test and use them as...

Page 325: ...performance and test procedure Swing 1 Swing brake angle time taken to start swing time taken to swing Swing 2 Hydraulic drift of swing Travel 1 Travel speed without load Travel 2 Travel speed actual...

Page 326: ...alue table 10 PC138US USLC 8 Work equipment 1 Hydraulic drift of work equipment Work equipment 2 Boom speed Work equipment 3 Arm speed Work equipment 4 Bucket speed Work equipment 5 Blade speed Work e...

Page 327: ...20 Standard value table SEN02457 01 PC138US USLC 8 11 Work equipment 7 Arm time lag Work equipment 8 Bucket time lag Work equipment 9 Blade time lag...

Page 328: ...12 PC138US USLC 8 SEN02457 01 20 Standard value table PC138US USLC 8 Hydraulic excavator Form No SEN02457 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 329: ...Testing exhaust temperature 7 Checking exhaust gas color 8 Adjusting valve clearance 9 Testing compression pressure 11 Testing blow by pressure 13 Testing engine oil pressure 14 Handling fuel system...

Page 330: ...oil pressure in pump PC control circuit 31 Testing and adjusting oil pressure in pump LS control circuit 34 Testing solenoid valve output pressure 38 Testing PPC valve output pressure 39 Adjusting pla...

Page 331: ...MPa 600 kg cm2 2 799 401 2320 Gauge 1 Pressure gauge 0 98 MPa 10 kg cm2 Testing fuel pressure F 1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204...

Page 332: ...pple 2 Size 10 x 1 25 mm 07002 11023 O ring 2 Testing solenoid valve out put pressure N 1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204 Digital...

Page 333: ...1 4200 799 601 9110 Adapter for DT 1 For DT12P Does not include 799 601 4100 and 799 601 4200 799 601 9220 Adapter for HD30 1 For HD30P Does not include 799 601 4100 and 799 601 4200 799 601 7000 or 7...

Page 334: ...control dial in the high idle MAX position 2 Set the working mode in the power mode P and turn the auto decelerator OFF 3 Set all the levers and pedals for work equipment control swing control and tra...

Page 335: ...compartment side cover and exhaust manifold cover 2 Remove exhaust temperature pickup plug 1 from the side of the center of the exhaust man ifold 3 Install sensor 1 of digital thermometer R and conne...

Page 336: ...ishing checking remove the test ing tools and return the removed parts 2 Checking with smoke meter A2 1 Insert probe 1 of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust pip...

Page 337: ...er head cover 4 3 Remove plate 5 on the starting motor and insert gear B1 4 Remove compression top dead center TDC check plug 6 from the flywheel housing Rotate the crankshaft forward with gear B1 and...

Page 338: ...a degree that you can move the thickness gauge lightly 3 While fixing adjustment screw 1 tighten locknut 2 3 Locknut 24 4 Nm 2 45 0 41 kgm a After tightening the locknut check the valve clearance aga...

Page 339: ...ector 1 2 Move fuel scatter prevention cover 3 from the joint 3 Remove clamp 4 and high pressure pipe 5 4 Pull spill hose connector 6 out of injector 1 5 Remove holder 7 and injector 1 a If the inject...

Page 340: ...the engine controller cover the connector on the machine side with a vinyl sheet etc to prevent leak and ground fault 4 Rotate the engine with the starting motor and test the compression pressure a T...

Page 341: ...ver of the hydraulic pump 2 Install tool and adapter 1 of blow by checker D1 to breather hose 1 and connect gauge 2 3 Start the engine set the working mode in the power mode P and turn the swing lock...

Page 342: ...engine compartment side cover and oil pressure pickup plug 1 from the engine block 2 Install nipple 1 of hydraulic tester E1 and con nect hydraulic tester E2 3 Start the engine and turn the auto dece...

Page 343: ...entering it If a filter other than the genuine one is used the fuel system may have a trouble Accordingly never use such a filter Releasing residual pressure from fuel system 1 a Pressure is generate...

Page 344: ...cir cuit 1 Open the engine hood and remove fuel pressure pickup plug 1 from the fuel main filter 2 Install adapter F2 and nipple 1 of hydrau lic tester F1 and connect them to oil pres sure gauge 2 a U...

Page 345: ...t again a Be sure to fit the gaskets to both ends of the joint 4 Connect test hose G4 to the end of joint G2 5 Connect test hose G5 to connector 6 side of spill hose 4 a Bind the connecting part of th...

Page 346: ...keep the test hose on the pres sure limiter side connected and keep its end in the oil pan 1 Run the engine at the rated output 2 After the engine speed is stabilized test the return rate in 1 minute...

Page 347: ...level ground and lower the work equipment to the ground 1 Fill the fuel tank with fuel a Add fuel until the float of the sight gauge reaches the maximum position 2 Open the side cover of the pump roo...

Page 348: ...fuel circuit Fuel tank o Pre filter o Main filter o Feed pump o Metering unit o Fuel tank 1 Fuel tank 2 Priming pump 3 Pre filter with water separator 4 Main filter 5 Feed pump 6 IMV Inlet Metering V...

Page 349: ...ainly around the high pressure circuit parts coated with the color checker for fuel leakage a If any fuel leakage is detected repair it and check again from step 2 4 Run the engine at low idle 5 Check...

Page 350: ...t tension according to the follow ing procedure 1 Loosen alternator fixing bolts 1 and 2 a Loosen fixing bolt 2 from the rear side of the engine 2 Adjust the tension of alternator belt 4 by turn ing a...

Page 351: ...e bucket tip to the height of the under side of the revolving frame a At this time the front of the upper structure lowers and the rear rises 3 Set dial gauge H to the 0 point 4 Set the arm almost per...

Page 352: ...g to the following procedure 1 Loosen bolts 1 and 2 and locknut 6 2 Move compressor 3 and bracket 4 as a set with adjustment bolt 5 to adjust the belt ten sion 3 After positioning compressor 3 tighten...

Page 353: ...Standard maximum clearance a 10 30 mm Adjusting a If the track shoe tension is abnormal adjust it according to the following procedure 1 Increasing tension 1 Add grease through grease fitting 2 with a...

Page 354: ...osen the valve more than 1 turn If it is loosened more it may jump out because of the high pressure grease in it 2 To check that the tension is normal run the engine at low idle and move the machine f...

Page 355: ...quipment swing and travel circuits under the following condition q Hydraulic oil temperature Within operat ing range 1 Preparation work 1 Open the side cover of the pump room and remove oil pressure p...

Page 356: ...eve the swing motor and test the oil pressure a The pressure tested when the swing motor relief valve is relieved is indi cated a The swing relief pressure is lower than the main relief pressure 5 Tes...

Page 357: ...tment per turn of holder Approx 20 5 MPa Approx 209 kg cm2 4 While fixing holder 4 tighten locknut 5 3 Locknut 49 58 8 Nm 5 6 kgm 5 After finishing adjustment check again that the oil pressure is norm...

Page 358: ...le K2 and connect oil pressure gauge 1 of hydraulic tester K1 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 3 Start the engine set the working mode in the power mode P and turn the auto decelerato...

Page 359: ...emperature Within operating range 1 Testing PC valve output pressure servo piston inlet pressure a Test the PC valve output pressure servo piston inlet pressure and pump discharge pressure simultaneou...

Page 360: ...put pressure pickup plug 2 Install nipples L2 and connect them to oil pressure gauges 1 a Use the oil pressure gauges of 5 9 MPa 60 kg cm2 3 Start the engine and set the working mode in the power mode...

Page 361: ...pump performance 1 Loosen locknut 5 a Before loosening the locknut make counter mark at the adjustment screw end so that you can see the position of the locknut before the adjustment and you can retu...

Page 362: ...nlet pressure a Test the LS valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously and compare them 1 Open the side cover of the pump room and remove oil pressure...

Page 363: ...the merge divider valve in the constant merge state and stabilize the LS differential pres sure 2 Open the side cover of the pump room and remove oil pressure pickup plugs 1 and 2 q 1 Pump discharge p...

Page 364: ...control and travel in neutral and test the oil pressure at each speed Then operate the travel lever to run the track shoe idle and test the oil pressure k While checking the safety around the machine...

Page 365: ...ffer ential pressure a If the adjustment screw is q Turned to the right the differential pressure is increased q Turned to the left the differential pressure is decreased a Quantity of adjustment LS d...

Page 366: ...sure gauge of 5 9 MPa 60 kg cm2 a The figure shows the testing tools con nected to outlet hose 1 of the PPC lock solenoid valve 4 Start the engine 5 Run the engine at high idle operate the control lev...

Page 367: ...ual pressure from the hydraulic circuit For details see Releasing residual pressure from hydrau lic circuit a Before testing the PPC valve output pressure check that the basic pressure of the control...

Page 368: ...he oil pressure with the control lever in neutral and moved to the stroke end a If the output pressure is as follows the PPC valve is normal 6 After finishing test remove the testing tools and return...

Page 369: ...st them according to the follow ing procedure 1 Remove the work equipment and swing PPC valve assembly 2 Remove bellows 1 3 Loosen locknut 2 and tighten disc 3 until it touches the heads of 4 pistons...

Page 370: ...te the arm control lever in the IN position q If the lowering speed is increased at this time the cylinder packing is defective q If the lowering speed does not change at this time the control valve i...

Page 371: ...t the lowering distance a Operate the control lever while the starting switch is in the ON position a If the pressure in the accumulator is lost run the engine for about 5 seconds to heighten the pres...

Page 372: ...ture a To set the machine in the travel posture extract the bucket cylinder and arm cylin der fully and set the boom angle to 45 2 Set the working mode to P and travel speed to Lo 3 Run up for 10 m wi...

Page 373: ...r cap of the hydraulic tank slowly to release the residual pressure from the tank 1 Check the deviating direction and the locations of travel deviation adjusting plugs 1 and 2 q 1 Right deviation adju...

Page 374: ...e starting switch ON and set the lock lever in the FREE position and then operate the right and left work equipment control levers forward backward to the right and to the left a The control valve is...

Page 375: ...oom k Take care not to lower the boom 4 Start testing the oil leakage 30 seconds after relieving is started and test for 1 minute 5 After finishing test return the removed parts 2 Testing oil leakage...

Page 376: ...ose side 07376 70422 Plug 04 3 Run the engine at high idle and relieve the bucket circuit by curling the bucket k Take care not to dump the bucket 4 Start testing the oil leakage 30 seconds after reli...

Page 377: ...se side 07376 70422 Plug 04 4 Run the engine at high idle relieve the travel circuit and test the oil leakage k Before operating the travel lever check the position and locking direction of the locked...

Page 378: ...before connecting the work equipment In particular the boom cylinder does not move to the lowering stroke end if it is installed to the work equipment 1 Run the engine at low idle for about 5 min utes...

Page 379: ...d check that oil flows out of elbow 2 a If no oil flows out of the elbow per form step 1 again 4 Connect hose 1 under its normal condi tion 5 Bleeding air from travel motor 1 Remove the travel motor c...

Page 380: ...rent from that of a common bolt 30 mm in diameter Take care 3 Bolt 4 245 309 Nm 25 31 5 kgm Adjusting mirrors 1 Adjusting mirrors a1 and b1 Loosen bolts 1 and 2 of the mirrors and adjust the mirrors s...

Page 381: ...30 Testing and adjusting SEN02458 01 PC138US USLC 8 53...

Page 382: ...54 PC138US USLC 8 SEN02458 01 30 Testing and adjusting PC138US USLC 8 Hydraulic excavator Form No SEN02458 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 383: ...0 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 30 Testing and adjusting 1 Testing and adjusting Part 2 Special fun...

Page 384: ...SEN02459 00 30 Testing and adjusting 2 PC138US USLC 8 Special functions of machine monitor 1 Air conditioner specification...

Page 385: ...hat function switch is not working Lower section of machine monitor Switch sec tion 1 Numeral 1 input switch Auto decelerator switch 2 Numeral 2 input switch Working mode selector switch 3 Numeral 3 i...

Page 386: ...ary screen 8p A Display of end screen 8p B Selection of auto deceleration 8p B Selection of working mode 9p B Selection of travel speed 10p B Operation to stop alarm buzzer 10p B Operation of windshie...

Page 387: ...time when starting switch is turned ON to time when screen changes to ordi nary screen and display after starting switch is turned OFF B Display Function when switch of machine monitor is operated C...

Page 388: ...hanges to Display of inputting password or Display of check before starting a The following screen may be displayed instead of the above Display of inputting password screen a If this screen is displa...

Page 389: ...check before starting the screen changes to Display of check of working mode and travel speed a The monitors 3 pieces displayed on the screen are the items under the check before starting Display of w...

Page 390: ...at the right end of the screen It is turned ON and OFF in the ser vice mode Display of end screen When the starting switch is turned OFF the end screen is displayed for 5 seconds a Another message ma...

Page 391: ...q F6 Confirm selection and return to ordi nary screen Working mode selector switch q Press Move to lower working mode q Hold down Confirm selection and return to ordinary screen a If you do not touch...

Page 392: ...ops a Even if the alarm buzzer cancel switch is pressed the screen does not change Operation of windshield wiper While the ordinary screen is displayed if the wiper switch is pressed large wiper monit...

Page 393: ...ner specification Operation to display camera mode When a camera is installed if F3 is pressed the multi display changes to the camera image Set the connection of the camera in the service mode a If a...

Page 394: ...er and clock alternately a When the clock is selected adjust the time set 12 hour or 24 hour display and set the sum mer time with the user mode function Check of maintenance information While the mai...

Page 395: ...for the user and the other is for the service q For user A message transmitted from the KOMTRAX base station for the user If it is received the message monitor is displayed on the ordinary screen To s...

Page 396: ...monitor is displayed large for a moment and then displayed at a in the screen a On the camera mode screen the caution mon itor flashes at the left upper of the screen when the caution is generated Di...

Page 397: ...e to release it In any case have inspection carried out immediately E10 Engine controller power source error Engine controller drive system circuit error engine stopped Have inspection carried out imm...

Page 398: ...s points which do not go off for the reason of its characteristics If the number of the bright points and black points does not exceed 10 those points are not a failure or a defect a To return to the...

Page 399: ...nput numeral Return to ordi nary screen q F6 Confirm input numeral a Default password 000000 a If the input password is correct the screen changes to the next screen a If the input password is incorre...

Page 400: ...SEN02459 00 30 Testing and adjusting 18 PC138US USLC 8 5 If the screen to notify completion of setting is displayed and then the ordinary screen is dis played the password is changed successfully...

Page 401: ...on switches or numeral input switches q F3 Move to lower menu q F4 Move to upper menu q F5 Return to ordinary screen operator mode q F6 Confirm selection a You may enter a 2 digit code with the numera...

Page 402: ...ction switches Select an item with F3 or F4 and confirm it with F6 a Selection with numeral input switches Enter a 5 digit code and the item of that code is selected directly Confirm that item with F6...

Page 403: ...on switches q F3 Reset holding q F4 Hold information displayed data q F5 Return to monitoring selection menu screen 6 Changing machine setting mode To change the setting of the working mode travel spe...

Page 404: ...400 Rail pressure MPa kg cm2 psi ENG 37400 Ambient pressure kPa kg cm2 psi ENG 18500 Charge temperature C C F ENG 36500 Charge pressure abs kPa kg cm2 psi ENG All items including the ambient pressure...

Page 405: ...N OFF MON Light ON OFF MON 04501 Monitor input 2 Eng oil level ON OFF MON Battery charge ON OFF MON 04502 Monitor input 3 Swing brake sw ON OFF MON 04503 Monitor function switches F1 ON OFF MON F2 ON...

Page 406: ...ft angle mg st in the display unit is an abbreviation for milligram stroke a Component in charge MON The machine monitor is in charge of detection of monitoring information ENG The engine controller i...

Page 407: ...s speci fication are different from each other in the display of 03 Air conditioning System which may not be displayed in the heater less specification 3 Information displayed on abnormality record sc...

Page 408: ...n The heater specification and heaterless speci fication are different from each other in the display of 03 Air conditioning System which may not be displayed in the heater less specification 3 Inform...

Page 409: ...ect the item to be reset with F3 or F4 and press F6 a To reset all items together Press F2 and all the items are reset regardless of selection of the items a If E is displayed on the left of a fail ur...

Page 410: ...ENG Electrical system E14 CA132 Throttle sensor low error q ENG Electrical system E15 CA144 Coolant temp sensor high error q ENG Electrical system E15 CA145 Coolant temp sensor low error q ENG Electri...

Page 411: ...Electrical system E15 CA778 Eng Bkup speed sensor error q ENG Electrical system E0E CA1633 KOMNET datalink timeout error q ENG Electrical system E14 CA2185 Throttle sens sup volt high error q ENG Ele...

Page 412: ...Travel speed sol short PUMP Electrical system E03 DW45KA Swing brake sol discon q PUMP Electrical system E03 DW45KB Swing brake sol short q PUMP Electrical system DW91KA Travel junction sol discon PU...

Page 413: ...is notified to the operator the buzzer sounds The operator can stop the buzzer with the alarm buzzer cancel switch e Since the caution monitor is also turned ON its function sounds the buzzer a Compon...

Page 414: ...m selection a You may enter a 2 digit code with the numeral input switches to select the record of that code and confirm it with F6 3 Information displayed on abnormality record screen On the Air cond...

Page 415: ...q F1 Move to next page screen q F2 Move to previous page screen q F3 Move to lower item q F4 Move to upper item q F5 Return to service menu screen a You may enter a 2 digit code with the numeral input...

Page 416: ...owing items can be selected on the Change of maintenance mode screen 3 Contents of setting of Maintenance mode on off After selecting Maintenance Mode On Off if the screen is displayed set ON or OFF w...

Page 417: ...r ON Lower q F5 Cancel setting before confirmation and return to Maintenance mode change screen q F6 Confirm setting of upper or lower line a After the setting of the upper and lower lines is confirme...

Page 418: ...ging telephone No After the Phone Number Entry screen is dis played register or change the telephone No q F2 Reset all input No q F3 Move to left position if not blank q F4 Move to right position if n...

Page 419: ...s q Power Mode P is displayed when key is ON q Economy Mode E is displayed when key is ON q Lifting Mode L is displayed when key is ON q Breaker Mode B is displayed when key is ON q Attachment Mode AT...

Page 420: ...en 2 Selecting sub menu After the Default screen is displayed select Unit with the function switches or numeral input switches a Select this item similarly to an item on the Service Menu screen 3 Sele...

Page 421: ...Select this item similarly to an item on the Service Menu screen 3 Selecting With Without After the With Without Attachment screen is displayed select the setting with the function switches q Without...

Page 422: ...assword screen is displayed q F3 Move to lower item q F4 Move to upper item q F5 Cancel selection and return to Default screen q F6 Confirm selection and return to Default screen 4 Displaying attachme...

Page 423: ...al Image Image of connected cam era is displayed in origi nal position as in mirror used as back monitor q Reverse Image Image of connected cam era is displayed in reverse position as seen directly us...

Page 424: ...g display setting After the ECO Display screen is displayed select the setting with the function switches q ON Display ECO q OFF Do not display ECO q F3 Move to left item q F4 Move to right item q F5...

Page 425: ...similarly to an item on the Service Menu screen 3 Selecting absorption torque After the Pump Absorption Torque screen is displayed select a set value on the right side with the function switches q Se...

Page 426: ...tion switches or numeral input switches a Select this item similarly to an item on the Service Menu screen 3 Selecting distribution of oil flow After the screen of Attachment Flow Adjust ment is displ...

Page 427: ...llow a One or more cylinders can be Cut Out a In the cylinder Cut Out operation the auto deceleration function can be selected If the auto deceleration is turned ON auto deceleration monitor b is dis...

Page 428: ...e of the machine it may be worn or damaged because of insufficient lubrication with oil To prevent this the function to lubricate the engine before starting it by cranking it without injecting fuel is...

Page 429: ...rting motor 4 Finishing no injection cranking After completing the no injection cranking operation press F6 and finish of no injection cranking is displayed and the screen returns to the Service Menu...

Page 430: ...ate and time side and test starts a The display unit of the fuel changes according to the unit set with the default unit setting function SI and meter l h inch gal h 3 Display and function during test...

Page 431: ...creen is dis played select Terminal Status with the func tion switches or numeral input switches a Select this item similarly to an item on the Service menu screen a The following figure shows the dis...

Page 432: ...the function switches or numeral input switches a Select this item similarly to an item on the Service Menu screen a The following figure shows the display when Model TH300 KOMTRAX is installed When...

Page 433: ...No of the KOMTRAX communication MODEM 1 Selecting menu Select KOMTRAX Settings on the Service Menu screen 2 Selecting sub menu After the KOMTRAX Settings screen is dis played select Modem S N with th...

Page 434: ...tings on the service menu screen 2 Selecting sub menu After the KOMTRAX Settings screen is dis played select IP Address with the function switches or numeral input switches a Select this item similarl...

Page 435: ...rom a message transmitted to the operator in the operator mode a Since this message is special for the ser viceman the message monitor is not dis played when it is received as in the operator mode 3 D...

Page 436: ...54 PC138US USLC 8 SEN02459 00 30 Testing and adjusting PC138US USLC 8 Hydraulic excavator Form No SEN02459 00 2007 KOMATSU All Rights Reserved Printed in Japan 01 07 02...

Page 437: ...hine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 30 Testing and adjusting 1 Testing and adjusting Part 3 Handling voltage circuit of engine controller 2 Preparation work for tr...

Page 438: ...connec tor between the engine controller and engine be sure to turn the starting switch OFF 2 If a T adapter is inserted in or connected to a connector between the engine controller and engine for tro...

Page 439: ...figure shows the model of the arm crane specification equipped with a level If the machine which you are working on has the arm crane specification remove level 2 2 Remove 1 mounting bolt and duct 3 3...

Page 440: ...connectors C01 and C02 of pump control ler 12 a Install the adapters to only the wiring harness side a The pump controller connector has a special locking mechanism Discon nect it according to procedu...

Page 441: ...Oil pressure switch a a a a Disconnection and connection of con nectors The connectors of the engine Ne speed sensor engine Bkup speed sensor engine oil pressure switch have a special locking mechanis...

Page 442: ...d troubleshooting 7 Supply pump IMV solenoid Fuel regulator a a a a Disconnection and connection of con nector The connector of the supply pump IMV solenoid has a special locking mecha nism Disconnect...

Page 443: ...rding to steps a b and connect it according to steps c d as shown below Disconnection a Unlock b Discon nect connector Connection c Connect connector d Lock 9 Engine coolant temperature sensor Cool an...

Page 444: ...iode does not have conductivity Defective q The indicated value changes The diode has conductivity Normal Note In the case of a silicon diode a value in the range from 460 to 600 is indi cated 2 When...

Page 445: ...Engine oil T Hydraulic oil When necessary T Damper case oil T Final drive case oil T Machinery case oil T Ambient temperature Altitude C m Operator s opinion Result of visual inspection Mechanical equ...

Page 446: ...ition Unit Standard value for new machine Service limit value Mea sured value Good Bad Fuel control dial Work ing mode Checking posture etc 1 Boom RAISE MAX P Work equipment extended fully sec 3 5 4 1...

Page 447: ...F Right travel lock Right reverse relief F Left travel lock Left forward relief F Left travel lock Left reverse relief F Standard value Checked oil pressure Unit Standard value for new machine Service...

Page 448: ...in F pump F R pump R LS EPC 8 PC EPC valve MIN P All levers in neutral J1 J1 MAX J2 J2 E J3 J3 L J4 J4 B J5 J5 Standard value Checked oil pressure Unit Standard value for new machine Service limit val...

Page 449: ...30 Testing and adjusting SEN02460 01 PC138US USLC 8 13...

Page 450: ...14 PC138US USLC 8 SEN02460 01 30 Testing and adjusting PC138US USLC 8 Hydraulic excavator Form No SEN02460 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 451: ...HYDRAULIC EXCAVATOR 1SHOP MANUAL PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 40 Troubleshooting 1 Failure code table and fuse locations Failure c...

Page 452: ...E11 CA123 Charge air press sensor low error q ENG Electrical system E14 CA131 Throttle sensor high error q ENG Electrical system E14 CA132 Throttle sensor low error q ENG Electrical system E15 CA144...

Page 453: ...G Electrical system E15 CA731 Eng Bkup speed sensor phase error q ENG Electrical system E10 CA757 All persistent data lost error q ENG Electrical system E15 CA778 Eng Bkup speed sensor error q ENG Ele...

Page 454: ...sol discon PUMP Electrical system DW43KB Travel speed sol short PUMP Electrical system E03 DW45KA Swing brake sol discon q PUMP Electrical system E03 DW45KB Swing brake sol short q PUMP Electrical sys...

Page 455: ...otified to the operator the buzzer sounds The operator can stop the buzzer with the alarm buzzer cancel switch e Since the caution monitor is also turned ON its function sounds the buzzer a Component...

Page 456: ...wer supply Fusible link Fuse No Fuse capacity Destination of power Switch power supply F02 45A 1 10A Emergency operating circuit 2 30A Solenoid valve 3 15A Cigarette lighter 4 10A Windshield washer 5...

Page 457: ...40 Troubleshooting SEN02461 01 PC138US USLC 8 7 Locations of fusible links Location of fuse box and fuse Nos...

Page 458: ...8 PC138US USLC 8 SEN02461 01 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02461 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 459: ...General information on troubleshooting Points to remember when troubleshooting 2 Sequence of events in troubleshooting 3 Checks before troubleshooting 4 Classification and procedures for troubleshooti...

Page 460: ...also lose the confidence of the user or operator For this reason when carrying out troubleshooting it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accord...

Page 461: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 3 Sequence of events in troubleshooting 1...

Page 462: ...or looseness and corrosion Retighten or replace 3 Check of starting motor terminals and wiring for looseness and corrosion Retighten or replace Hydraulic Mechanical equipment 1 Check for abnormal nois...

Page 463: ...cording to the recorded code a If an electrical system failure code is recorded delete all the codes and reproduce them and then see if the trouble is still detected a An error code of the mechanical...

Page 464: ...y Contents of description Standard value in normal state to judge possible causes Remarks on judgment Troubles in wiring harness Disconnection Connector is connected imperfectly or wiring harness is b...

Page 465: ...ctric circuit diagram related to trouble shooting q Connector No Indicates Model Number of pins and Color q Connector No and pin No from each branching merging point Shows the ends of branch or source...

Page 466: ...ombustion S 7 12 Oil consumption is excessive or exhaust smoke is blue S 8 13 Oil becomes contaminated quickly S 9 14 Fuel consumption is excessive S 10 15 Oil is in coolant or coolant spurts back or...

Page 467: ...ps swinging it makes large sound H 24 51 Swing holding brake does not operate normally Hydraulic drift of swing is large E 20 H 25 Phenomena related to machine monitor 52 When starting switch turned O...

Page 468: ...EN02462 00 40 Troubleshooting 10 PC138US USLC 8 Other phenomena 68 KOMTRAX system does not operate normally E 26 No Phenomena looking like troubles Troubleshooting Display of code E mode H mode S mode...

Page 469: ...N02462 00 PC138US USLC 8 11 Wiring table for connector pin numbers a The terms of male and female refer to the pins while the terms of male housing and female housing refer to the mating portion of th...

Page 470: ...SEN02462 00 40 Troubleshooting 12 PC138US USLC 8...

Page 471: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 13...

Page 472: ...SEN02462 00 40 Troubleshooting 14 PC138US USLC 8...

Page 473: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 15...

Page 474: ...SEN02462 00 40 Troubleshooting 16 PC138US USLC 8...

Page 475: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 17...

Page 476: ...SEN02462 00 40 Troubleshooting 18 PC138US USLC 8...

Page 477: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 19...

Page 478: ...SEN02462 00 40 Troubleshooting 20 PC138US USLC 8...

Page 479: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 21...

Page 480: ...SEN02462 00 40 Troubleshooting 22 PC138US USLC 8...

Page 481: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 23...

Page 482: ...SEN02462 00 40 Troubleshooting 24 PC138US USLC 8...

Page 483: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 25...

Page 484: ...SEN02462 00 40 Troubleshooting 26 PC138US USLC 8...

Page 485: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 27...

Page 486: ...SEN02462 00 40 Troubleshooting 28 PC138US USLC 8...

Page 487: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 29...

Page 488: ...SEN02462 00 40 Troubleshooting 30 PC138US USLC 8...

Page 489: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 31...

Page 490: ...SEN02462 00 40 Troubleshooting 32 PC138US USLC 8...

Page 491: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 33...

Page 492: ...SEN02462 00 40 Troubleshooting 34 PC138US USLC 8...

Page 493: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 35...

Page 494: ...SEN02462 00 40 Troubleshooting 36 PC138US USLC 8...

Page 495: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 37...

Page 496: ...SEN02462 00 40 Troubleshooting 38 PC138US USLC 8...

Page 497: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 39...

Page 498: ...SEN02462 00 40 Troubleshooting 40 PC138US USLC 8...

Page 499: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 41...

Page 500: ...SEN02462 00 40 Troubleshooting 42 PC138US USLC 8...

Page 501: ...40 Troubleshooting SEN02462 00 PC138US USLC 8 43...

Page 502: ...dapter for BENDIX MS 14 MS 14P q 799 601 3470 Case q 799 601 2710 Adapter for MIC 5 MIC 5P q q q 799 601 2720 Adapter for MIC 13 MIC 13P q q q 799 601 2730 Adapter for MIC 17 MIC 17P q q q q q q 799 6...

Page 503: ...TM2 q q 799 601 9020 Adapter for DT 2 DT2 q q q q 799 601 9030 Adapter for DT 3 DT3 q q 799 601 9040 Adapter for DT 4 DT4 q q q q 799 601 9050 Adapter for DT 6 DT6 q q 799 601 9060 Adapter for DT Gray...

Page 504: ...799 601 4160 Adapter for engine CRI T3 Oil pressure switch 2 4160 q q 799 601 4180 Adapter for engine CRI T3 PEVA 3 4180 q q 799 601 4190 Socket for engine CRI T3 Commonrail pressure 3 1 2 3L q q 799...

Page 505: ...48 PC138US USLC 8 SEN02462 00 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02462 00 2007 KOMATSU All Rights Reserved Printed in Japan 01 07 02...

Page 506: ...harge voltage low 6 Failure code B BAZG Eng oil press low 8 Failure code B BAZK Eng oil level low 8 Failure code B BCNS Eng coolant overheat 9 Failure code B HANS Hydr oil overheat 9 Failure code CA11...

Page 507: ...r press sensor low error 28 Failure code CA227 Sensor sup 2 volt high error 30 Failure code CA234 Eng overspeed 32 Failure code CA238 Ne speed sensor sup volt error 34 Failure code CA271 IMV PCV1 shor...

Page 508: ...of machine monitor This trouble may be caused by replacement of machine monitor User code Failure code Trouble Engine controller lock caution 2 Machine monitor system 989M00 Contents of trouble Engine...

Page 509: ...esetting If cause of failure disappears system resets itself Problem that appears on machine Related information Method of reproducing failure code Failure code is not reproduced since system is reset...

Page 510: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 5...

Page 511: ...battery may not be charged Related information Signal voltage of alternator can be checked with monitoring function Code 04300 Charge voltage Method of reproducing failure code Start engine Possibleca...

Page 512: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 7 Circuit diagram related...

Page 513: ...l pressure switch system may be defective Carry out troubleshooting for failure code CA435 User code Failure code Trouble Engine oil level low Machine monitor system B BAZK Contents of trouble When st...

Page 514: ...system If cause 1 is not detected engine coolant temperature sensor sys tem may be defective Carry out troubleshooting for failure codes CA144 and CA145 User code Failure code Trouble Hydraulic oil o...

Page 515: ...t relay a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE02 female 55 32 Resis tance 185 265 z 3 Disconnection in wiring h...

Page 516: ...Resis tance Min 1 Mz Wiring harness between CE02 female 32 R23 2 and chassis ground Resis tance Min 1 Mz Wiring harness between CE02 female 32 R24 2 and chassis ground Resis tance Min 1 Mz Wiring har...

Page 517: ...SEN02463 01 40 Troubleshooting 12 PC138US USLC 8 Circuit diagram related...

Page 518: ...marks on troubleshooting 1 Defective Ne speed sensor system Carry out troubleshooting for failure code CA689 2 Defective Bkup speed sen sor system Carry out troubleshooting for failure code CA778 3 De...

Page 519: ...ch OFF then turn starting switch ON or start engine and carry out troubleshooting PTIM Voltage Between 2 4 Power supply 4 75 5 25 V Sensor voltage is measured with wiring harness connected Accordingly...

Page 520: ...ring harness between CE01 female 19 PTIM female 1 and wiring harness between CE01 female 36 PTIM female 2 Resis tance Min 1 Mz Wiring harness between CE01 female 19 PTIM female 1 and wiring harness be...

Page 521: ...Fixes charge pressure 400 kPa 4 08 kg cm2 and continues operation Problem that appears on machine Acceleration performance of engine drops Related information Signal voltage of charge pressure sensor...

Page 522: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 17...

Page 523: ...carry out troubleshoot ing without turning starting switch ON P20 male Resistance Between 1 3 4 0 6 0 kz Between 2 1 0 25 5 0 kz Between 2 3 0 25 5 0 kz 3 Disconnection in wiring har ness Disconnecti...

Page 524: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 19 Circuit diagram related...

Page 525: ...than fuel control dial signal and continues operation depending on each model Problem that appears on machine Engine speed cannot be controlled with fuel control dial Related information Signal voltag...

Page 526: ...al trouble a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON TWTR male Coolant temperature Resistance Between 1 2 10 100 C 0 6 20 kz 2 Disconnection...

Page 527: ...tion of controller Fixes coolant temperature 90 C and continues operation Problem that appears on machine Related information Signal voltage of coolant temperature sensor can be checked with monitorin...

Page 528: ...are with starting switch OFF then carry out troubleshoot ing without turning starting switch ON PTIM male Intake air temperature Resistance Between 3 4 10 100 C 0 5 20 kz Between 3 chassis ground All...

Page 529: ...iblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry out troubleshooting failure code CA153 User code Failure code Trouble Sensor sup 2 v...

Page 530: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 25...

Page 531: ...itch OFF then turn starting switch ON and carry out troubleshooting PAMB Voltage Between 1 3 Power supply 4 75 5 25 V Between 2 3 Signal 0 3 4 7 V Sensor voltage is measured with wiring harness connec...

Page 532: ...ween CE01 female 36 PAMB female 1 and wiring harness between CE01 female 20 PAMB female 2 Resis tance Min 1 Mz Wiring harness between CE01 female 36 PAMB female 1 and wiring harness between CE01 femal...

Page 533: ...roller Sets oil pressure to default value 52 44 kPa 0 53 kg cm2 and continues operation Problem that appears on machine Output drops Related information Signal voltage of ambient pressure sensor can b...

Page 534: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 29...

Page 535: ...a defect in it Bkup speed sensor CAM connector Atmospheric pressure sensor PAMB connector Charge pressure sensor PTIM connector 3 Disconnection in wiring har ness Disconnection in wiring or defective...

Page 536: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 31 Circuit diagram related...

Page 537: ...e speed can be checked with monitoring function Code 01002 Engine speed Method of reproducing failure code Run engine at high idle Possiblecauses and standard value in normal state Cause Standard valu...

Page 538: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 33...

Page 539: ...ce has a defect in it Ne speed sensor NE connector 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troub...

Page 540: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 35 Circuit diagram related...

Page 541: ...ween 1 2 2 3 5 3 z Between 1 2 chassis ground Min 1 Mz 2 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turn...

Page 542: ...en 1 2 chassis ground Min 1 Mz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without...

Page 543: ...ar ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 fem...

Page 544: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 39 Circuit diagram related...

Page 545: ...har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 fe...

Page 546: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 41 Circuit diagram related...

Page 547: ...har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 fe...

Page 548: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 43 Circuit diagram related...

Page 549: ...har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 fe...

Page 550: ...40 Troubleshooting SEN02463 01 PC138US USLC 8 45 Circuit diagram related...

Page 551: ...46 PC138US USLC 8 SEN02463 01 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02463 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 552: ...essure switch 10 Failure code CA441 Battery voltage low error 11 Failure code CA442 Battery voltage high error 11 Failure code CA449 Rail press very high error 12 Failure code CA451 Rail press sensor...

Page 553: ...il press very low error 30 Failure code CA2311 Abnormality in IMV solenoid 31 Failure code D110KB Battery relay drive short 32 Failure code D19JKZ Personal code relay abnormality 34 Failure code D862K...

Page 554: ...is turned OFF circuit probably has ground fault 3 Defective power supply cut out relay a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring har...

Page 555: ...Resis tance Min 1 Mz Wiring harness between CE02 female 32 R23 2 and chassis ground Resis tance Min 1 Mz Wiring harness between CE02 female 32 R24 2 and chassis ground Resis tance Min 1 Mz Wiring har...

Page 556: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 5 Circuit diagram related...

Page 557: ...ensor power supply 1 5 V circuit Action of controller Limits output of common rail pressure sensor and continues operation Limits common rail pres sure Problem that appears on machine Output drops Rel...

Page 558: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 7...

Page 559: ...rail pres sure sensor PFUEL connector 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing w...

Page 560: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 9 Circuit diagram related...

Page 561: ...ive engine oil pressure switch a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON POIL Male Resistance Between 1 chassis ground Max 1 z 2 Disconnecti...

Page 562: ...itch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry out troubleshooting for failure code CA111 User code Failure code Troubl...

Page 563: ...essure level 2 Action of controller Limits output and continues operation Limits common rail pressure Problem that appears on machine Output drops Related information Common rail pressure can be check...

Page 564: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 13...

Page 565: ...switch ON or start engine and carry out troubleshooting PFUEL Voltage Between 1 3 Power supply 4 75 5 25 V Between 2 3 Signal 0 25 4 6 V Sensor voltage is measured with wiring harness connected Accord...

Page 566: ...n CE01 female 36 PFUEL female 1 and wiring harness between CE01 female 29 PFUEL female 2 Resis tance Min 1 Mz Wiring harness between CE01 female 36 PFUEL female 1 and wiring harness between CE01 femal...

Page 567: ...ail pressure sensor circuit detected abnormally high pressure level 1 Action of controller None in particular Problem that appears on machine Output drops Related information Common rail pressure can...

Page 568: ...high viscosity 3 Clogging of fuel filter a If a fuel filter is clogged replace it 4 Defective low pressure cir cuit device a For contents of troubleshooting see Note 1 For check of pres sure in fuel l...

Page 569: ...rating CA 7 Boost pressure Equivalent to rating kPa 8 Engine coolant temperature Low idle C 9 Fuel temperature Low idle C 5 Check of reduced cylinder mode operation Engine speed Function Reduced cylin...

Page 570: ...ing Special functions of machine monitor Monitoring items table A limit value is the value mentioned above but a standard value in normalcy is 0 cc min no leak Rating or equivalent Relieve the circuit...

Page 571: ...3 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring har...

Page 572: ...ssible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 7 Defective engine controller If causes 1 6 are not detected engine controller may be...

Page 573: ...Standard value in normal state Remarks on troubleshooting 1 Defective engine Ne speed sensor system Engine Ne speed sensor may be defective Carry out trouble shooting for failure code CA698 2 Defecti...

Page 574: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 23...

Page 575: ...ort circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 female 36 CAM female 1 and chassis groun...

Page 576: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 25 Circuit diagram related...

Page 577: ...e 1 K02 female A Resis tance Max 1 z Wiring harness between CM02 female 10 C01 female 64 CE02 female 21 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circui...

Page 578: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 27 Circuit diagram related...

Page 579: ...ect in it Fuel control dial P20 connector 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot i...

Page 580: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 29 Circuit diagram related...

Page 581: ...d of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting Carry out troubleshooting for f...

Page 582: ...OFF then carry out troubleshoot ing without turning starting switch ON PREG Male Resistance Between 1 2 Max 1 z Between 2 chassis ground Min 1 Mz 3 Disconnection in wiring har ness Disconnection in wi...

Page 583: ...state Remarks on troubleshooting 1 Defective battery relay Internal defect a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Battery relay Resistanc...

Page 584: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 33 Circuit diagram related...

Page 585: ...personal code relay Internal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Troubleshooting for relay unit R07 mal...

Page 586: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 35 Circuit diagram related...

Page 587: ...in particular If cause of failure disappears system resets itself Problem that appears on machine GPS cannot measure position Related information Method of reproducing failure code Turn starting switc...

Page 588: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 37...

Page 589: ...1 Defective fuse F01 If fuse is broken circuit probably has ground fault See Cause 3 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starti...

Page 590: ...40 Troubleshooting SEN02464 01 PC138US USLC 8 39 Circuit diagram related...

Page 591: ...shooting Disconnect sensors at right in order and carry out operation to reproduce trouble If E of fail ure code goes off when a sensor is disconnected that sensor is defective Bucket DUMP PPC pressur...

Page 592: ...tem Voltage Max 1 V Wiring harness between C01 female 53 P03 female 2 P03 female 1 J03 ground T08 Swing LEFT PPC pressure sensor system Voltage Max 1 V Wiring harness between C01 female 73 P04 female...

Page 593: ...SEN02464 01 40 Troubleshooting 42 PC138US USLC 8 Circuit diagram related...

Page 594: ...cing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Ground fault in wiring har ness Short circ...

Page 595: ...44 PC138US USLC 8 SEN02464 01 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02464 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 596: ...t 12 Failure code DHPAMA Pump press sensor abnormality 14 Failure code DHSFMA Travel left forward PPC press sensor abnormality 16 Failure code DHSGMA Travel right forward PPC press sensor abnormality...

Page 597: ...A Swing brake sol discon 32 Failure code DW45KB Swing brake sol short 34 Failure code DW91KA Travel junction sol discon 36 Failure code DW91KB Travel junction sol short 37 Failure code DWJ0KA Merge di...

Page 598: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 3...

Page 599: ...ale 8 9 C01 female 45 CE02 female 1 K02 female A Resis tance Max 1 z Wiring harness between CM02 female 10 C01 female 64 CE02 female 21 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ne...

Page 600: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 5 Circuit diagram related...

Page 601: ...short circuit a Disconnect camera with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect camera and perform failure reproduction operation If failure code disa...

Page 602: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 7 Circuit diagram related...

Page 603: ...s started Action of machine monitor None in particular If cause of failure disappears system resets itself Problem that appears on machine Related information Method of reproducing failure code Turn s...

Page 604: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 9...

Page 605: ...Resis tance Max 1 z Wiring harness between CM02 female 10 C01 female 64 CE02 female 21 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with...

Page 606: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 11 Circuit diagram related...

Page 607: ...tion Code 04402 Hydraulic oil temperature sensor voltage Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks...

Page 608: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 13...

Page 609: ...nsor Internal defect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P25 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2...

Page 610: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 15 Circuit diagram related...

Page 611: ...nsor Inter nal defect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P10 Voltage Between 3 1 Power supply 4 5 5 5 V Between...

Page 612: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 17 Circuit diagram related...

Page 613: ...sensor Inter nal defect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P09 Voltage Between 3 1 Power supply 4 5 5 5 V Betwe...

Page 614: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 19 Circuit diagram related...

Page 615: ...nsor Inter nal defect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P27 Voltage Between 3 1 Power supply 4 5 5 5 V Between...

Page 616: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 21 Circuit diagram related...

Page 617: ...sensor Inter nal defect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P26 Voltage Between 3 1 Power supply 4 5 5 5 V Betwe...

Page 618: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 23 Circuit diagram related...

Page 619: ...epare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P28 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If vo...

Page 620: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 25 Circuit diagram related...

Page 621: ...epare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P11 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If vo...

Page 622: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 27 Circuit diagram related...

Page 623: ...monitor is displayed Action of controller None in particular If cause of failure disappears system resets itself Problem that appears on machine Related information Method of reproducing failure code...

Page 624: ...tandard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Travel alarm defective Internal defect a Turn the engine starting switch OFF for the preparations and ke...

Page 625: ...oid 1 Method of reproducing failure code Start engine Set travel speed to High Operate travel lever Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on tr...

Page 626: ...ring function Code 02300 Solenoid 1 Method of reproducing failure code Start engine Set travel speed to High Operate travel lever Possiblecauses and standard value in normal state Cause Standard value...

Page 627: ...ding brake solenoid Internal dis connection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V03 male Resistance Between 1 2 20 60 z 2 Defective as...

Page 628: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 33 Circuit diagram related...

Page 629: ...swing holding brake solenoid can be checked with monitoring function Code 02300 Solenoid 1 Method of reproducing failure code Start engine Swing with left work equipment control lever Possiblecauses...

Page 630: ...40 Troubleshooting SEN02465 01 PC138US USLC 8 35 Circuit diagram related...

Page 631: ...re code Start engine Steer machine with right and left travel levers Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective trave...

Page 632: ...f reproducing failure code Start engine Steer machine with right and left travel levers Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshootin...

Page 633: ...Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge divider EPC solenoid Internal disconnec tion a Prepare with startin...

Page 634: ...n starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge divider EPC solenoid Internal short cir cuit or...

Page 635: ...40 PC138US USLC 8 SEN02465 01 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02465 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 636: ...XA8KA PC EPC sol discon 2 Failure code DXA8KB PC EPC sol short 4 Failure code DXE4KA Service current EPC discon 6 Failure code DXE4KB Service current EPC short 7 Failure code DY20KA Wiper working abno...

Page 637: ...arting switch OFF then carry out troubleshoot ing without turning starting switch ON V11 male Resistance Between 1 2 7 14 z 2 Defective emergency pump drive switch Internal discon nection a Prepare wi...

Page 638: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 3 Circuit diagram related...

Page 639: ...PC EPC solenoid Internal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V11 male Resistance Between 1 2 7 14 z Bet...

Page 640: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 5 Circuit diagram related...

Page 641: ...Turn starting switch ON Set in attachment mode ATT Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid I...

Page 642: ...ducing failure code Turn starting switch ON Set in attachment mode ATT Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective ser...

Page 643: ...ion a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M05 female Wiper blade Resistance Between 6 5 Operating range top Max 1 z Other than operating...

Page 644: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 9 Circuit diagram related...

Page 645: ...n carry out troubleshoot ing without turning starting switch ON M05 female Wiper blade Resistance Between 4 5 Storage area Max 1 z Working area Min 1 Mz Between 1 3 All range Max 20 z Wiring harness b...

Page 646: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 11 Circuit diagram related...

Page 647: ...ing starting switch ON M06 male Resistance Between 1 2 5 20 z Between 1 2 chassis ground Min 1 Mz 3 Defective assembled type diode D02 Internal short cir cuit a Prepare with starting switch OFF then c...

Page 648: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 13 Circuit diagram related...

Page 649: ...of reproducing failure code Turn starting switch ON Turn washer switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective...

Page 650: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 15 Circuit diagram related...

Page 651: ...rting switch ON Set wiper switch to INT or ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal short...

Page 652: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 17 Circuit diagram related...

Page 653: ...switch ON Set wiper switch to INT or ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal short circu...

Page 654: ...40 Troubleshooting SEN02466 00 PC138US USLC 8 19 Circuit diagram related...

Page 655: ...20 PC138US USLC 8 SEN02466 00 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02466 00 2007 KOMATSU All Rights Reserved Printed in Japan 01 07 02...

Page 656: ...ne basic check item lights up 8 E 3 Engine does not start Engine does not turn 9 E 4 Preheater does not operate 12 E 5 Automatic warm up system does not operate in cold season 14 E 6 All work equipmen...

Page 657: ...eld wiper and window washer do not operate 32 E 20 Swing holding brake does not operate normally 36 E 21 Travel alarm does not sound or does not stop sounding 38 E 22 Air conditioner does not operate...

Page 658: ...d normally Type of power supply Fusible link Fuse No Fuse capacity Destination of power Switch power supply F02 45A 1 10A Emergency operating circuit 2 30A Solenoid valve 3 15A Cigarette lighter 4 10A...

Page 659: ...SEN02467 00 40 Troubleshooting 4 PC138US USLC 8 Locations of fusible links Location of fuse box and fuse Nos...

Page 660: ...source 24 V circuit is in contact with power source 24 V circuit Short circuit Independent wiring harnesses are in contact with each other abnormally Precautions for troubleshooting 1 Method of indic...

Page 661: ...ection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harnes...

Page 662: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 7 Circuit diagram related...

Page 663: ...if necessary 2 Defective engine oil level switch Internal disconnec tion a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON P44 male Engine oil level...

Page 664: ...without turning starting switch ON S14 female Lock lever Resistance Between 1 3 Free Min 1 Mz Lock Max 1 z 5 Defective starting motor cut out relay R06 or R07 Inter nal disconnection or short circuit...

Page 665: ...C starting motor C E10 Resis tance Max 1 z Wiring harness between F01 20 S14 male 1 Resis tance Max 1 z Wiring harness between S14 male 3 R06 female 1 Resis tance Max 1 z Wiring harness between R06 f...

Page 666: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 11 Circuit diagram related...

Page 667: ...ting switch Voltage Between 16 chassis ground OFF Max 1 V HEAT 20 30 V Trouble 2 When starting switch is turned to HEAT position intake air heater mounting part does not become warm Related informatio...

Page 668: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 13 Circuit diagram related...

Page 669: ...10 C turbocharger protection function operates to keep the engine speed at low idle Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1...

Page 670: ...ale Resistance Between 1 2 20 60 z Between 1 chassis ground Min 1 Mz 4 Defective assembled type diode D01 Internal short cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing wit...

Page 671: ...leshooting 1 Defective lock lever switch Internal short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON S14 female Lock lever Resistance B...

Page 672: ...L chas sis ground Middle or higher 27 5 29 5 V 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troublesh...

Page 673: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 19 Circuit diagram related...

Page 674: ...s up white engine coolant temperature may be low below about 30 C Warm up engine Lighting up white Engine coolant temperature is low Lighting up blue Engine coolant temperature is proper 2 Defective e...

Page 675: ...re input to pump controller and then transmitted to machine monitor through communication system Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraulic oil temperature...

Page 676: ...ture sensor sys tem may be defective Carry out troubleshooting for failure codes CA144 and CA145 2 Defective machine monitor If cause 1 is not detected machine monitor may be defective Since trouble i...

Page 677: ...ound Min 1 Mz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting...

Page 678: ...emperature sensor are input to pump controller and then transmitted to machine monitor through communication system Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraul...

Page 679: ...7 11 z EMPTY 85 95 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning s...

Page 680: ...tion Signal voltage of fuel level sensor can be checked with monitoring function Code 04200 Fuel level sensor voltage Possiblecauses and standard value in normal state Cause Standard value in normal s...

Page 681: ...not lighted and bright points points which do not go off for the reason of its characteristics If the number of the bright points and black points does not exceed 10 those points are not a failure or...

Page 682: ...al state Cause Standard value in normal state Remarks on troubleshooting 1 Defective PPC pressure sig nal a Start engine and carry out troubleshooting with monitoring function Monitoring code Item Nor...

Page 683: ...troubleshooting 1 Defective machine monitor Machine monitor may be defective Since trouble is in system troubleshooting cannot be carried out Trouble 2 When working mode is changed setting of engine...

Page 684: ...peed is shifted actual travel speed does not change Related information If cause 1 occurs actual travel speed does not lower when travel speed is shifted to Lo Possiblecauses and standard value in nor...

Page 685: ...signal of alarm buzzer cancel switch can be checked with monitoring function Code 04504 Monitor 1st 2nd line switches Possiblecauses and standard value in normal state Cause Standard value in normal...

Page 686: ...ed to front Min 1 Mz When retracted to rear Max 1 z 2 Defective wiper motor Inter nal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch O...

Page 687: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 33 Circuit diagram related...

Page 688: ...on of window washer switch signal can be checked with monitoring function Code 04504 Monitor 1st 2nd line switches Possiblecauses and standard value in normal state Cause Standard value in normal stat...

Page 689: ...out troubleshoot ing without turning starting switch ON Wiring harness between CM02 female 5 J01 S04 female 5 C01 female 19 Resis tance Min 1 Mz 4 Defective machine monitor a Prepare with starting swi...

Page 690: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 37 Circuit diagram related...

Page 691: ...or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between C02 female 107 M14 female 1 Resis tance...

Page 692: ...See cause 4 2 Defective fuse in unit If fuse in unit is broken circuit in unit probably has ground fault See cause 4 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in...

Page 693: ...gh 3 Defective blower motor Internal defect a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting MB wiring side Air conditioner switch Voltage Between 1 2 Air...

Page 694: ...1 Mz Wiring harness between R20 female 2 MB wiring side 1 Resis tance Min 1 Mz Wiring harness between MB wiring side 2 PTR wiring side 3 Resis tance Min 1 Mz Wiring harness between PTR wiring side 2 A...

Page 695: ...tive compressor Inter nal defect Compressor may be defective Check it directly 6 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting swi...

Page 696: ...D circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between N10 male 1 CM02 female 8 9 C01 female 45 CE02 female 1 K02 female...

Page 697: ...n air conditioner A C switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective internal air sensor Internal disconnection...

Page 698: ...eshooting 1 Defective air flow sensor Internal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON THF device side Resi...

Page 699: ...iring harness between ACW wiring side 36 P31 female 1 Resis tance Max 1 z Wiring harness between ACW wiring side 15 P31 female 2 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit wit...

Page 700: ...MV1 wiring side 7 ACW wiring side 24 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without tur...

Page 701: ...ring side 7 ACW wiring side 22 Resis tance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning s...

Page 702: ...may be insufficient Check it directly 2 Defective high and low pres sure switches Internal dis connection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting sw...

Page 703: ...SEN02467 00 40 Troubleshooting 50 PC138US USLC 8 Circuit diagram related...

Page 704: ...is turned ON if machine monitor displays nothing backup power supply system may be defective In this case carry out troubleshooting for E 1 When starting switch turned ON machine monitor displays noth...

Page 705: ...r a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between C01 female 53 P03 female 2 Resis tance Max 1 z Wiring harness between P03...

Page 706: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 53 Circuit diagram related...

Page 707: ...hen carry out troubleshoot ing without turning starting switch ON Wiring harness between C01 female 17 P05 female 1 Resis tance Max 1 z Wiring harness between P05 female 1 chassis ground T08 Resis tan...

Page 708: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 55 Circuit diagram related...

Page 709: ...then carry out troubleshoot ing without turning starting switch ON Wiring harness between C01 female 73 P04 female 2 Resis tance Max 1 z Wiring harness between P04 female 1 chassis ground T08 Resis t...

Page 710: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 57 Circuit diagram related...

Page 711: ...then carry out troubleshoot ing without turning starting switch ON Wiring harness between C01 female 34 P01 female 2 Resis tance Max 1 z Wiring harness between P01 female 1 chassis ground T08 Resis t...

Page 712: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 59 Circuit diagram related...

Page 713: ...then carry out troubleshoot ing without turning starting switch ON Wiring harness between C01 female 14 P06 female 2 Resis tance Max 1 z Wiring harness between P06 female 1 chassis ground T08 Resis ta...

Page 714: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 61 Circuit diagram related...

Page 715: ...hen carry out troubleshoot ing without turning starting switch ON Wiring harness between C01 female 15 P02 female 2 Resis tance Max 1 z Wiring harness between P02 female 1 chassis ground T08 Resis tan...

Page 716: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 63 Circuit diagram related...

Page 717: ...without turning starting switch ON Wiring harness between C01 female 16 P07 female 2 or P08 female 2 Resis tance Max 1 z Wiring harness between P07 female 1 or P08 female 2 chassis ground T08 Resis ta...

Page 718: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 65 Circuit diagram related...

Page 719: ...tive contact in con nector a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between C01 female 52 P14 female 1 P15 female 1 Resis ta...

Page 720: ...40 Troubleshooting SEN02467 00 PC138US USLC 8 67 Circuit diagram related...

Page 721: ...arks on troubleshooting 1 Defective communication 1 a Turn starting switch ON and check Setting condition or termi nal screen Check item Normal display Communication start check Completion 2 Defective...

Page 722: ...70 PC138US USLC 8 SEN02467 00 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02467 00 2007 KOMATSU All Rights Reserved Printed in Japan 01 07 02...

Page 723: ...equipment swing and travel are low 6 H 2 Engine speed sharply drops or engine stalls 7 H 3 No work equipment travel and swing move 8 H 4 Abnormal noise is heard from around hydraulic pump 8 H 5 Fine...

Page 724: ...teered easily or steering power is low 19 H 18 Travel speed does not change or it is kept low or high 20 H 19 Track does not move Only either side 20 H 20 Machine does not swing 21 H 21 Swing accelera...

Page 725: ...chine Related information Information on occurred failures and troubleshooting Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Cause...

Page 726: ...SEN02468 01 40 Troubleshooting 4 PC138US USLC 8 System chart for hydraulic and mechanical systems 1...

Page 727: ...g SEN02468 01 PC138US USLC 8 5 a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart Use it as a reference material when troubleshooting the hydraulic and me...

Page 728: ...ns and keep it running at high idle during the troubleshooting Control levers Control circuit basic pressure All levers in NEUTRAL 3 2 0 5 MPa 33 5 kg cm2 4 Defective adjustment or operation of PC val...

Page 729: ...parations and keep it running at high idle during the troubleshooting Measured oil pressure Measurement conditions Oil pressure ratio Pump discharge pressure Swing lock ON Arm Relieved in IN direction...

Page 730: ...ion or an internal failure Diagnose it in the following manner Remove the main oil pressure measurement plug and crank the engine If oil flows out it is in normal condition 4 Damper defective It is pr...

Page 731: ...ce itself 2 Defective adjustment or mal function of LS valve a Stop engine for preparations Start troubleshooting at engine high idle Oil pressure to be measured Oil pressure ratio All control levers...

Page 732: ...control valve spool The spool of the boom control valve may have a malfunction Check it directly Including stroke limiting mechanism on RAISE side 5 Malfunction of boom control valve pressure compensa...

Page 733: ...alfunction of pump merge divider valve The pump merge divider valve of the control valve may have a malfunction Check it directly 4 Malfunction of arm control valve spool The spool of the arm control...

Page 734: ...4 3 43 MPa 29 35 kg cm2 3 Malfunction of pump merge divider valve The pump merge divider valve of the control valve may have a malfunction Check it directly 4 Malfunction of bucket control valve spool...

Page 735: ...rmation Set the working mode at P mode for the troubleshooting Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of PPC va...

Page 736: ...g Arm cylinder Leakage from cylinder Relieved in IN direction 15 cc min 2 Defective sealing of arm con trol valve spool Sealing of the spool of the arm control valve may be defective Check it directly...

Page 737: ...operation Related information Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of pressure com pensation valve of work eq...

Page 738: ...ol levers Solenoid output pressure All levers in NEUTRAL 0 MPa 0 kg cm2 Position for travel only On either or both sides 2 84 3 43 MPa 29 35 kg cm2 2 Malfunction of pump merge divider valve The pump m...

Page 739: ...ravel junction solenoid valve a Keep the engine stopped for the preparations and keep it running at high idle during the troubleshooting Travel lever Solenoid valve output pressure All levers in NEUTR...

Page 740: ...levers in NEUTRAL 0 MPa 0 kg cm2 Position for travel only On either or both sides 2 84 3 43 MPa 29 35 kg cm2 4 Malfunction of unload valve a Keep the engine stopped for the preparations and keep it r...

Page 741: ...e All levers in NEUTRAL 0 MPa 0 kg cm2 Position for travel only on either side 2 84 3 43 MPa 29 35 kg cm2 4 Malfunction of hydraulic pump check valve The check valve of the hydraulic pump may have a m...

Page 742: ...Track does not move only either side Related information Conduct the troubleshooting in working mode P Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on...

Page 743: ...defect in it Check it directly It may be checked by abnormal sound abnormal heating metal chips in drain oil etc Trouble Machine does not swing 2 Machine does not swing in only one direction Related i...

Page 744: ...leration or swing speed is low 2 Swing acceleration or swing speed is low in only one direction Related information Conduct the troubleshooting in working mode P Possiblecauses and standard value in n...

Page 745: ...the preparations and keep it running at high idle during the troubleshooting Left work equipment control lever PPC valve output pressure In NEUTRAL 0 MPa 0 kg cm2 Operated for swing Above 2 7 MPa Abo...

Page 746: ...changing with each other and checking change of the phenomenon 3 Malfunction of swing motor safety valve The safety valve of the swing motor may have malfunction Check it directly Trouble When upper s...

Page 747: ...y Trouble Hydraulic drift of swing is large 2 When swing holding brake is released Related information If the swing holding brake release is in the emergency position the swing holding brake is releas...

Page 748: ...e Operation manual Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of attachment flow rate adjustment EPC valve The atta...

Page 749: ...40 Troubleshooting SEN02468 01 PC138US USLC 8 27...

Page 750: ...28 PC138US USLC 8 SEN02468 01 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02468 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 751: ...ick up smoothly 12 S 4 Engine stops during operations 13 S 5 Engine does not rotate smoothly 14 S 6 Engine lacks output or lacks power 15 S 7 Exhaust smoke is black incomplete combustion 16 S 8 Oil co...

Page 752: ...SEN02469 01 40 Troubleshooting 2 PC138US USLC 8 S 15 Abnormal noise is made 24 S 16 Vibration is excessive 25...

Page 753: ...40 Troubleshooting SEN02469 01 PC138US USLC 8 3...

Page 754: ...their level Check items Simple check items used by the serviceman to narrow the causes They correspond to C in the chart on the right Causes Items to be narrowed from the questions and check items The...

Page 755: ...40 Troubleshooting SEN02469 01 PC138US USLC 8 5...

Page 756: ...haust gas is black Let us assume that a trouble of Exhaust gas is black occurred and we checked the Questions and Check items and found the following 3 items to be the causal symptoms Exhaust gas slow...

Page 757: ...sal relationship between 3 items in the Questions and Check items sections and 5 items in the Causes section The method of pinpointing the cause from the causal relationship and approaching the troubl...

Page 758: ...or when temperature is low preheating monitor does not indicate normally w During operation charge level monitor indicates abnormal charge w w Dust indicator is red w Air breather hole of fuel tank c...

Page 759: ...Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion moves out but Speed of rotation is low w Makes grati...

Page 760: ...w Replacement of filters has not been carried out according to Operation and Maintenance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogg...

Page 761: ...lly w Dust indicator is red w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w When fuel filter is removed there is not fuel in it w Fuel is leaking...

Page 762: ...Dust indicator is red w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from fuel piping w When priming pump is operated it makes...

Page 763: ...There was hunting and engine stopped w Q Q Q Q Q Q Non specified fuel is being used Q Q Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w w Fuel level...

Page 764: ...e Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carried out according to Operation and Maintenance Manual w When fuel t...

Page 765: ...Oil must be added more frequently Q Q Dust indicator is red w w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Output becomes insufficient after short stop of opera...

Page 766: ...y w Q Q Q Gradually Q Q Q Q Dust indicator is red w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operated in low temperature mode at...

Page 767: ...E Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in int...

Page 768: ...history Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Oil must be added more frequently w Metal particles are found when oil filter is drained Q Q w Ins...

Page 769: ...e model Q Q Q Q Gradually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check...

Page 770: ...oler core O ring Questions Confirm recent repair history Degree of use of machine Operated for long period E E Oil level Suddenly rose Q Q Gradually rose Q Q Hard water is being used as coolant Q Q Oi...

Page 771: ...f filters has not been carried out according to Operation and Maintenance Manual w Oil pressure monitor if installed Indicates pressure drop at low idle w Indicates pressure drop at low high idle Q w...

Page 772: ...frequently w w Coolant must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Chec...

Page 773: ...hen fan pulley is turned it has play w Milky oil is floating on coolant w There are excessive air bubbles in radiator coolant spurts back w When light bulb is held behind radiator core no light passes...

Page 774: ...of use of machine Operated for long period E Condition of abnormal noise Gradually occurred Q Q Suddenly occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal par...

Page 775: ...damper Questions Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specified oil is bei...

Page 776: ...26 PC138US USLC 8 SEN02469 01 40 Troubleshooting PC138US USLC 8 Hydraulic excavator Form No SEN02469 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 777: ...PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual 2 List of...

Page 778: ...in Japan i e locally made parts a General tools that are necessary for removal or installation are described as 1 2 etc and their part names part numbers and quantities are not described Removal q The...

Page 779: ...of special tools starting with 79 T means that they can not be supplied from Komatsu in Japan i e locally made parts a General tools that are necessary for dis assembly and assembly are described as 1...

Page 780: ...140 50 g Polyethylene container Quick setting adhesive Setting time Within 5 sec to 3 min Used mainly to stick metals rubbers plastics and woods Aron alpha 201 790 129 9130 2 g Polyethylene container...

Page 781: ...gion SYG2 400T A SYG2 16CNT SYG0 400T A SYG0 16CNT 400 g 16 kg Bellows type Can Higher anti seizure and heat resistance than grease with molybdenum disulphide Body dirt is not distinctive due to white...

Page 782: ...giun super 560 22M 54 27210 320 ml ECOCART special con tainer To be used as glass adhesive compound Term of validity 6 months after manufac turing Coaking compound Sunstar pengiun seal No 2505 417 926...

Page 783: ...tllation front oil seal 790 101 5271 Plate 1 790 101 5221 Grip 1 01010 51225 Bolt 1 Engine rear oil seal 2 795 931 1100 Seal puller assembly q 1 Removal rear oil seal Engine rear oil seal 3 790 101 54...

Page 784: ...Oil pump q 1 Sealing of oil and checking of air leak Expansion installation of track shoe R 791 616 1110 Frame t 1 Removal pressfit of master pin 791 616 1121 Plate t 1 791 616 1131 Plate t 1 791 616...

Page 785: ...dust seal 790 201 1610 Push tool 1 790 101 5021 Grip 1 01010 50816 Bolt 1 790 201 1500 Push tool Kit q 1 Application of boom cylinder dust seal 790 201 1620 Push tool 1 790 101 5021 Grip 1 01010 5081...

Page 786: ...assembly aircondi tioner unit assembly X 3 799 703 1200 Service tool Kit t 1 Charging of air conditioning gas 799 703 1100 Vacuum pump 100V t 1 799 703 1111 Vacuum pump 220V t 1 790 703 1121 Vacuum p...

Page 787: ...US USLC 8 11 Sketche of special tool 1 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches F6 Push tool a Unless otherwise specified there shall be...

Page 788: ...12 PC138US USLC 8 SEN02709 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02709 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 789: ...nstallation of fuel injector assembly 4 Removal and installation of front oil seal 7 Removal and installation of rear oil seal 9 Removal and installation of cylinder head assembly 12 Removal and insta...

Page 790: ...nnect pump regulator sensor con nector PREG 5 2 Disconnect wiring clamps 6 7 and 8 3 Disconnect clamp 10 from fuel hoses 9 4 Disconnect fuel hose 9 from the fuel fil ter 5 Remove two boots 11 from the...

Page 791: ...e tightened to the specified torque k Be sure to install the boot to the sleeve nut after installing the high pressure pipe a Before installing a high pressure pipe confirm the following points If any...

Page 792: ...mpressor hose clamps 2 and 3 and keep the hose out of the way 2 Disconnect aftercooler hose 4 on the side of the air intake connector and keep it out of the way 3 Removal of the high pressure pipe a T...

Page 793: ...clamp used for fixing a high pressure pipe must be a genuine Komatsu part and it must be tightened to the specified torque k Be sure to install the boot to the sleeve nut after installing the high pr...

Page 794: ...SEN02710 00 50 Disassembly and assembly 6 PC138US USLC 8 4 q When reusing injector always replace Oring 15 and gasket 16 with new ones...

Page 795: ...t 1 and remove fan 2 3 Loosen fan belt adjust bolt 3 and remove fan belt 4 1 4 Remove engine speed sensor connector 5 5 Remove speed sensor mounting bolt 6 and remove speed sensor 7 2 6 Remove cranksh...

Page 796: ...he oil seal 2 Fill about 2 cc of grease to between the oil seal lips 2 Front oil seal grease G2 LI 2 Install the crankshaft pulley a Align key a of crankshaft 12 with key groove b of crankshaft pulley...

Page 797: ...arily lift flywheel 3 3 Remove 7 flywheel mounting bolts 4 except one 2 4 Loosen flywheel mounting bolt 4 k Leave 3 threads or 4 engaged to prevent the flywheel from suddenly shooting out in the follo...

Page 798: ...r oil seal to flywheel housing a Fill about 3 cc of grease to between the rear oil seal lips 2 Front oil seal grease G2 LI 2 For the following installation work carry out the installation in the rever...

Page 799: ...edle a Check that the position of needle remains in its original position after the flywheel is rotated one full turn Radial runout Max 0 15 mm q Measuring face runout of flywheel 1 As with the measur...

Page 800: ...6 at two locations a Do not disconnect the air conditioner hoses 3 Remove air conditioner compressor drive belt protective cover 7 4 Loosen air conditioner compressor mount ing bolts 8 and remove driv...

Page 801: ...25 tightens grounding 29 together 2 Remove electrical intake air heater assembly 30 4 10 Removal of high pressure pipe and air intake manifold 1 Remove coolant temperature sensor wir ing clamp 31 2 Re...

Page 802: ...47 and 48 5 Remove muffler drain tube 49 a Remove the lower clamp in advance 6 Remove 4 bracket mounting bolts 50 7 Lift muffler bracket assembly 51 and remove it 4 Muffler bracket assembly 22 kg 13 R...

Page 803: ...er hose from the turbocharger 7 Remove 8 exhaust manifold mounting bolts 62 13 8 Lift turbocharger and exhaust manifold assembly 63 and remove them 4 Turbocharger and exhaust manifold assembly 15 kg 1...

Page 804: ...p 81 for the air conditioner compressor together a When installing bracket mounting bolts 18 tighten wiring clamp 21 for the injector together 3 4 q When installing air intake connector 27 and electri...

Page 805: ...mp side 18 23 Nm 1 9 2 3 kgm 3 Sleeve nut on the common rail side 25 5 29 4 Nm 2 6 3 0 kgm 7 a Apply gasket sealant to the air intake manifold before installation Apply gasket sealant for about 1 mm o...

Page 806: ...e clearance refer to Adjusting valve clearance in Testing and adjusting 17 q Tightening procedure for the cylinder head mounting bolt Apply molybdenum disulphide lubricant LM P to the threads of cylin...

Page 807: ...ve lower cover 1 2 Open the coolant drain valve 2 to drain 1 6 Coolant 12 4 l l l l 3 Remove 2 plate 3 mounting bolts 4 and remove the cover 4 Disconnect radiator lower hose 5 2 5 Remove 4 cover mount...

Page 808: ...ation in the reverse order of removal 1 5 Coolant 12 4 l l l l 2 3 3 Radiator hose clamp bolt Both upper and lower hoses 8 8 0 5 Nm 0 9 0 05 kgm 4 a When installing the radiator assembly align the con...

Page 809: ...lower cover 1 2 Remove 2 mounting bolts 2 and disconnect the air aftercooler lower hose 3 3 Remove 2 mounting bolts 4 and remove plate 5 4 Loosen 2 clamps 6 and disconnect the air aftercooler upper h...

Page 810: ...out the installation in the reverse order of removal 1 a Take care not to damage sponge on the sides when installing the aftercooler a When installing the radiator assembly align the convex portion a...

Page 811: ...tion to prevent any mistakes when re installing 1 Remove the radiator assembly referring to Removal and Installation of Radiator Assem bly 2 Remove the air aftercooler assembly referring to Removal an...

Page 812: ...PC138US USLC 8 6 Remove air cleaner 5 7 Remove connector 6 8 Remove air cleaner hose clamp 7 9 Remove 2 hose mounting bolts 8 and discon nect oil cooler upper hose 9 10 Remove 2 oil cooler mounting bo...

Page 813: ...2710 00 PC138US USLC 8 25 Installation q Carry out the installation in the reverse order of removal 1 3 Hydraulic oil drain plug 13 58 8 78 4 Nm 6 8 kgm Target 68 6 Nm 7 kgm 5 Hydraulic tank 69 l l l...

Page 814: ...oosen the hydraulic oil tank cap gradually to release the pressure in the tank 1 Remove lower cover 1 2 Drain coolant from the coolant drain port 2 1 6 Coolant 12 4 l l l l 3 Open fuel drain valve 3 t...

Page 815: ...er p a Keep wiring 17 out of the way 6 Disconnect resistor connector K02 18 7 Remove bracket mounting bolt 19 and disconnect the wiring mounting bracket 8 Remove frame mounting bolts 20 21 and 22 9 Li...

Page 816: ...ector E01 38 4 Disconnect clamps 40 at 2 locations on wiring 39 and disconnect wiring 39 from the engine 5 Disconnect fuel hose 41 from the fuel tank 6 Disconnect starting motor wiring terminals 42 an...

Page 817: ...e the assembly with a string to keep it out of the way 14 Disconnecting work equipment pump wir ing and hoses 1 Remove rubber cover 53 2 Disconnect oil temperature sensor wiring connector P22 53 and E...

Page 818: ...8 kgm Target 68 6 Nm 7 kgm 5 Hydraulic tank 69 l l l l Specified capacity 120 l l l l 3 3 Hose clamps between the turbocharger and air cleaner 10 8 1 Nm 1 1 0 1 kgm 4 3 Aftercooler hose clamp 10 8 0 5...

Page 819: ...en fuel drain valve 1 to drain fuel Fuel When fuel tank is full 195 l l l l 2 Disconnect fuel level sensor connector P21 2 3 Disconnect fuel level sensor wiring 3 4 Disconnect hose 4 from the radiator...

Page 820: ...Remove 4 fuel tank front mounting bolts 17 9 Lift fuel tank assembly 18 and remove it 1 4 Fuel tank assembly 95 kg Installation q Carry out the installation in the reverse order of removal 1 2 Fuel ta...

Page 821: ...50 Disassembly and assembly SEN02710 00 PC138US USLC 8 33...

Page 822: ...34 PC138US USLC 8 SEN02710 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02710 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 823: ...d up PC138USLC 8 20001 and up 50 Disassembly and assembly Power train Removal and installation of travel motor and final drive assembly 2 Removal and installation of swing motor and swing machinery as...

Page 824: ...n loosen the oil filler cap slowly to release the pressure inside the hydraulic tank 2 Swing work equipment 90 then push up cha sis with work equipment and set block 1 between track frame and track sh...

Page 825: ...read of travel motor and final drive assembly mounting bolt Thread tightener LT 2 3 Travel motor and final drive assembly mounting bolt 235 285 Nm 23 5 29 5 kgm a Bleed the air from the travel motor F...

Page 826: ...circuit in Testing and adjusting k Disconnect the negative terminal of the battery beforehand a a a a Fasten tags to respective piping for identifi cation to prevent any mistakes when re installing 1...

Page 827: ...removal q Refilling oil Hydraulic tank a Fill oil up to the specified level start the engine to circulate oil in the pipe and check the oil level again q Bleeding air a Bleed air from the piping refe...

Page 828: ...3 Carrier No 1 and Sun gear No 2 assembly 1 Remove sun gear No 1 5 2 Remove carrier No 1 and sun gear No 2 assembly 6 Sym bol Part No Part name Necessity Q ty New Remodel Sketch F 1 790 201 2750 Spac...

Page 829: ...ar No 2 15 from carrier 16 4 Ring gear Remove ring gear 17 5 Carrier No 2 assembly 1 Remove spacer 18 2 Remove carrier No 2 assembly 19 3 Sub disassembly of carrier No 2 assem bly 1 Press pin 20 in an...

Page 830: ...sembly 30 to block 2 and remove shaft assembly 31 with the press using push tool 3 2 Remove bearing 29 3 Use tool F2 to remove bearing 32 and collar 33 from shaft 34 8 Oil seal and bearing outer race...

Page 831: ...can be entered a Press fit force 11 760 N 1 200kg a Press the bearing gradually by rotat ing the case 5 Install 2 piece collar 28 6 Screw in bolt 12 mm P 1 75 to the case Using push pull scale 5 to me...

Page 832: ...a Insert the pin then caulk the pin of the carrier 2 Install carrier No 2 assembly 19 to the shaft and case assembly 3 Install spacer 18 6 Ring gear Install O ring 40 to the shaft and case assem bly a...

Page 833: ...After installation check that the snap ring is firmly in place 2 Install carrier No 1 and sun gear No 2 assembly 6 to the shaft case assembly 3 Install sun gear No 1 5 8 Swing motor assembly 1 Instal...

Page 834: ...embly 2 Temporarily lift swing circle assembly 1 to remove the 38 mounting bolts 1 3 Remove swing circle assembly 1 2 4 Swing circle assembly 155 kg Installation q Installation is performed in the opp...

Page 835: ...50 Disassembly and assembly SEN02711 00 PC138US USLC 8 13...

Page 836: ...14 PC138US USLC 8 SEN02711 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02711 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 837: ...of track roller 2 Disassembly and assembly of idler assembly 5 Disassembly and assembly of recoil spring 8 Removal and installation of of track shoe assembly 11 Removal and installation of sprocket 1...

Page 838: ...oller 4 from shaft 5 a It is filled with 75 85 cc of oil so drain the oil at this point or lay a cloth to prevent the area from becoming dirty 4 Remove floating seal 6 on opposite side from roller 4 a...

Page 839: ...For details of the precautions when install ing floating seals 6b and 6d and 3b and 3d see the precautions marked a for Step 3 5 Assemble shaft 5 to roller 4 6 Turn over roller 4 and shaft 5 assembly...

Page 840: ...SEN02712 00 50 Disassembly and assembly 4 PC138US USLC 8 10 Using tool M2 fill track roller assembly with oil then tighten plug 11 5 Track roller oil 75 85 cc EO30 CD...

Page 841: ...er 4 from shaft 5 and support assembly 7 a It is filled with approx 90 cc of oil so drain the oil at this point or lay a cloth to prevent the area from becoming dirty 4 Remove floating seal 6 on oppos...

Page 842: ...reful not to let any dirt or dust get stuck to it a Remove all grease and oil from the con tact surface of the O ring and the floating seal 4 Assemble shaft 5 and support assembly 7 to idler 4 5 Add o...

Page 843: ...50 Disassembly and assembly SEN02712 00 PC138US USLC 8 7 7 Install O ring then install support 2 with dowel pin 1...

Page 844: ...embly 4 3 Disassembly of recoil spring assembly 4 1 Set recoil spring assembly 4 to tool L2 k The recoil spring is under large installed load so be sure to set the tool properly Failure to do this is...

Page 845: ...the spring to a point where the nut becomes loose a Release the hydraulic pressure slowly to remove the spring tension 3 Remove pilot 8 and spring 7 4 Remove snap ring 10 dust seal 11 and bush 12 from...

Page 846: ...ring 7 and set to tool L2 4 Apply hydraulic pressure slowly to com press spring and tighten nut 6 so that installed length of spring is dimension a a Installed length a of spring 390 mm 5 Remove recoi...

Page 847: ...tion of mas ter pin is at front of idler and set block 1 in position 3 Using tool R pull out master pin 2 4 Remove tool R pull out temporary pin and remove dust seal then drive machine in reverse to l...

Page 848: ...the protrusion of the master pin is dimension a Protrusion a of master pin 5 5 2 mm 3 a When assembling the dust seal coat the bush ing contact surface with grease G2 LI a If the rubber of the road l...

Page 849: ...ssembly 2 Swing the work equipment by 90 and push up the machine with it and then set blocks 1 between the track frame and track shoe 3 Remove the 15 mounting bolts and lift off sprocket 1 1 4 Sprocke...

Page 850: ...linder to remove pins 5 on the bottom a Check the number and position of the shims mounted 1 5 Lift boom cylinder assembly 6 to remove it 4 Boom cylinder assembly 120 kg 6 Remove operator cab assembly...

Page 851: ...2 Greasing after pin assembly Hyper white grease G2 T k Never put your finger in the pin hole when adjusting the position a Adjust the clearance between the mount on the boom cylinder bottom and the f...

Page 852: ...e battery 1 Remove monitor camera wiring protection cover 1 2 Remove engine upper covers 2 to 5 3 Disconnect monitor camera wiring 7 4 Disconnect flywheel case lubrication hose 8 5 Demporarily lift th...

Page 853: ...SEN02712 00 PC138US USLC 8 17 Installation q Carry out installation in the reverse order to removal 1 2 Counterweight mounting bolt Adhesive LT 2 3 Counterweight mounting bolt 3 430 4 212 Nm 350 430...

Page 854: ...out add on weight 2 Remove the 2 monitor camera mounting bolts to remove the monitor camerai1j 3 Remove mounting bolt 2 on the top of the add on weight 4 Sling add on weight 3 and remove 2 mount ing b...

Page 855: ...top bolt 2 and tighten it lightly 2 Add on weight mounting bolt Adhesive LT 2 3 Adjust clearance a to 10 3 and install side bolts 4 2 Add on weight mounting bolt Adhesive LT 2 3 Add on weight mountin...

Page 856: ...20 PC138US USLC 8 SEN02712 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02712 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 857: ...sassembly and assembly of center swivel joint assembly 4 Removal and installation of hydraulic tank assembly 5 Removal and installation of hydraulic pump assembly 8 Removal and installation of control...

Page 858: ...sembly 3 for attachment specification 3 Disconnect hoses 4 9 between travel motor and swivel joint 4 Remove elbow 10 5 Disconnect drain hose 11 6 Disconnect hoses 12 15 between control valve and swive...

Page 859: ...q Installation is performed in the opposite way to removal 1 2 Mounting bolt screw Liquefied adhesive LT 2 3 Mounting bolt 98 1 123 0 Nm 10 0 12 5 kgm q q q q Bleeding air Bleed air from the swing mo...

Page 860: ...n fit it by using push tool and hitting swivel rotor 4 lightly with plastic hammer 2 Contact surfaces of rotor and shaft Grease G2 LI a When installing the rotor take care not to damage the slipper se...

Page 861: ...aulic circuit in Testing and adjusting k Disconnect the negative terminal of the battery beforehand 1 Loosen hydraulic drain plug 1 and drain the hydraulic oil 1 6 Hydraulic oil tank 69 l l l l Capaci...

Page 862: ...ses 12 to 19 in front of the tank a Record the installed position of respective hoses 5 Disconnect swing machinery oil level pipe clamp 20 6 Disconnect 2 drain hoses 21 and clamps 22 7 Removal of hydr...

Page 863: ...nk assembly 95 kg Installation q Carry out the installation in the reverse order of removal 1 3 Drain plug 1 58 8 78 4 Nm 6 8kgm Target 68 6 Nm 7 kgm 5 Hydraulic oil tank 69 l l l l Capacity 120 l l l...

Page 864: ...rcuit in Testing and adjusting k Disconnect the negative terminal of the battery beforehand 1 Loosen hydraulic drain plug 1 and drain the hydraulic oil 1 6 Hydraulic oil tank 69 l l l l Capacity 120 l...

Page 865: ...1 Disconnect EPC solenoid wiring connec tor V11 14 and hydraulic oil temperature sensor wiring connector P22 15 2 Removes suction tube 16 from hydraulic pump 4 Disconnect 6 hoses 17 to 22 a Record the...

Page 866: ...Pull chain block 1 up and loosen wire rope 2 3 Disconnect wire rope 2 from the work equipment pump 4 Install wire rope 2 to the work equipment pump from outside the counterweight a Apply rubber plates...

Page 867: ...SEN02713 00 PC138US USLC 8 11 8 Disconnect chain block from the work equipment pump shift the work equip ment pump 23 forward to the front and remove it Installation q Carry out the installation in t...

Page 868: ...tags to respective connecters and pip ing for identification to prevent any mistakes when re installing 1 Loosen hydraulic drain plug 1 and drain the hydraulic 1 6 Hydraulic oil tank 69 l l l l Capaci...

Page 869: ...assembly 25 4 Removal of pressure switch connector 1 Disconnect wiring connectors 26 to 32 26 P01 Bucket dump switch 27 P02 Arm dump switch 28 P03 Boom raise switch 29 P04 Bucket digging switch 30 P05...

Page 870: ...e of control valve 40 P64 Bucket digging switch 41 P65 Arm digging switch 42 P66 Boom lower switch 2 Disconnect connectors 43 to 47 from left side operator cab side of control valve 43 P61 Bucket dump...

Page 871: ...Brown Yellow 5 Disconnect all of hoses 68 to 83 back side engine side of control valve 68 White 69 Brown 70 Red 71 Blue 72 Orange 73 Green 74 75 Black 76 77 78 Yellow Black 79 Yellow Green 80 Yellow...

Page 872: ...acket mounting bolt 87 and remove multi valve assembly mounting bracket 88 10 Loosen 4 control valve mounting bolt 89 and lift and remove control valve assembly 90 4 Control valve assembly 95 kg Insta...

Page 873: ...50 Disassembly and assembly SEN02713 00 PC138US USLC 8 17 Disassembly and assembly of control valve assembly 1 Assembly...

Page 874: ...ower PPC valve PA3 From left travel forward PPC valve PA4 From right travel forward PPC valve PA5 From boom raise PPC valve PA6 From arm dump PPC valve PA7 From bucket dump 1 PPC valve PA8 From servic...

Page 875: ...ver 1 Tighten the 4 nuts 17 in the diagonal order 1 4 according to the following procedure 1st time 3 58 8 68 6 Nm 6 7 kgm 2nd time 3 78 5 88 3 Nm 8 9 kgm 3rd time 3 98 1 113 Nm 10 11 5 kgm a The heig...

Page 876: ...SEN02713 00 50 Disassembly and assembly 20 PC138US USLC 8...

Page 877: ...50 Disassembly and assembly SEN02713 00 PC138US USLC 8 21...

Page 878: ...SEN02713 00 50 Disassembly and assembly 22 PC138US USLC 8...

Page 879: ...50 Disassembly and assembly SEN02713 00 PC138US USLC 8 23...

Page 880: ...SEN02713 00 50 Disassembly and assembly 24 PC138US USLC 8...

Page 881: ...valve R Boom DD7 Pressure compensation valve R Right travel DD8 Pressure compensation valve R Left travel DD9 Pressure compensation valve R Blade DD10 Pressure compensation valve R Swing DD11 Pressur...

Page 882: ...ic drift prevention valve Boom JJ16 Suction valve Boom JJ17 Spool Boom JJ18 Pressure compensation valve R Boom NN1 Pressure compensation valve F Arm NN2 Suction valve Arm NN3 Suction valve Arm NN4 Spo...

Page 883: ...e plate 5 a Do not remove joint 10 unless it is to be replaced 3 Remove seal 16 and collar 17 4 Pull out piston 8 and remove retainer 18 springs 7 6 and 5 and shim 4 a Spring 6 5 and spring 7 5 consis...

Page 884: ...ted from the body surface 3 Plug 3 6 11 Nm 0 6 1 1 kgm 3 When installing piston 8 apply grease G2 LI to its outside and the inside of the body hole 4 Install spring 5 with its small diameter side on t...

Page 885: ...No 641 to each of the points shown below 8 Apply grease G2 LI to the rocking part of joint 10 and the contact surfaces of disc 12 and piston 8 2 Quantity of grease G2 LI 1 Rocking part of joint 2 4 c...

Page 886: ...case 5 Remove lever 7 bushing 4 and pin 5 from the case 6 Remove mounting bolt 16 to remove plate 18 together with damper assembly 19 a Check the thickness and the mounting position of washer 10 7 Re...

Page 887: ...he contact surfaces of lever 7 and piston 1 and the contact surfaces of plate 8 and pin of lever 9 2 Quantity of grease G2 LI Rocking part of shaft 4 8 cc periphery Contact surfaces of lever and pisto...

Page 888: ...piston rod assembly 2 on tool U1 Sym bol Part No Part name Necessity Q ty New Remodel Sketch U 1 790 502 1003 Repair stand t 1 790 101 1102 Pump t 1 2 790 102 4300 Wrench assembly t 1 790 201 4310 Pin...

Page 889: ...is not used use the four drill holes diameter 10 to loosen the piston assembly 4 Remove plunger 5 q Arm cylinder and boom cylinder 5 Remove collar 6 q Arm cylinder and boom cylinder 6 Remove the head...

Page 890: ...emove bushing 20 Assembly a Be careful not to damage the packing the dust seal the O ring or the like a Do not forcibly insert the backup ring but make it warm with hot water 50 to 60 C before inserti...

Page 891: ...llar 6 and assemble q Arm cylinder and boom cylinder 4 Assemble plunger 5 q Arm cylinder and boom cylinder a Check that there is a small amount of play at the tip of the plunger 5 Set cushion plunger...

Page 892: ...ger q For the boom and arm cylinders only 2 Drill a hole for mounting screw 3 a Engage the drill with the screw V shaped grooves of piston 4 and rod 2 for horizontal processing a Process the bottom cu...

Page 893: ...d assembly and the cylinder tube to insert them a After insertion make sure that the ring is not damaged or dropped and completely push the piston rod 8 Mount head assembly 1 and tighten it with the m...

Page 894: ...38 PC138US USLC 8 SEN02713 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02713 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 895: ...DRAULIC EXCAVATOR 1SHOP MANUAL PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 50 Disassembly and assembly1 Work equipment Body Removal and installati...

Page 896: ...and 12 Bucket cylinder head a Since the engine will be started be sure to plug the disconnected hoses 6 Disconnect grease tube 13 7 Remove lock bolt 14 1 8 Remove plate and push out pin 15 to the opp...

Page 897: ...t installation in the reverse order to removal 1 a When tightening the locknut tighten so that the clearance a between the plate and nut is 0 5 1 5 mm 2 2 Inside surface of bushing when assembling pin...

Page 898: ...pin hole never insert your fingers in the pin hole a Adjust the shim thickness so that clearance c between boom 23 and bracket 24 is less than 0 5 mm a Standard shim thickness 0 5 1 0 2 0 mm q Bleedin...

Page 899: ...50 Disassembly and assembly SEN02714 00 PC138US USLC 8 5...

Page 900: ...6 PC138US USLC 8 SEN02714 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02714 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 901: ...8US 8 20001 and up PC138USLC 8 20001 and up 50 Disassembly and assembly1 Cab and its attachments Removal and installation of operator cab assembly 2 Removal and installation of operator s cab glass st...

Page 902: ...ove floor mat 1 2 Remove machine monitor 2 referring to Removal and installation of machine monitor assembly 3 Remove covers 3 to 6 a When removing cover 5 simultaneously remove cigar lighter wiring c...

Page 903: ...22n tightens floor frame together 2 Remove L H side cover 23 3 Remove lock plate mounting bolt 24 and remove plate 25 4 Remove cab tip over stopper mounting bolt 26 14 Lift and remove operator cab ass...

Page 904: ...ow glass 5 remove front window assembly 6 It is impossible to replace only the front window glass while the front window assembly is installed to the oper ator s cab For the procedure for replacing th...

Page 905: ...riors 3 etc or hold them by winding them onto something and move the wire to the right and left to cut the adhesive and both sided adhesive tape Since the wire may be broken by the frictional heat app...

Page 906: ...ing the sticking surfaces leave them for at least 5 minutes to dry 3 Apply primer 10 a The using limit of primer 10 is 4 months after the date of manufacture Do not use primer 10 after this limit a Us...

Page 907: ...over dimension a q Dimension to apply primer a 25 mm a As for right side window glass 1 apply the primer to only the periphery of the glass to stick the both sided adhesive tapes and the areas out of...

Page 908: ...a Do not remove the release tape of the both sided adhesive tape on the glass sticking side before stiking the glass a When sticking the both sided adhesive tape do not touch the cleaned surface as l...

Page 909: ...mes 17 j Retract by 3 0 mm from the end of front frame 17 5 Possition the new window glass 1 Check the clearance between the window glass and the operator s cab on the right left upper and lower sides...

Page 910: ...0 SUPER W a The using limit of the adhesive is 4 months after the date of manufacture Do not use the adhesive after this limit a Keep the adhesive in a dark place where the temperaure is below 25 C a...

Page 911: ...apply the adhesive to the outside of the both sided adhesive tape on the periphery of the glass 7 Install the window glass 1 Install window glass 9 matching it to the lines of the positioning tapes d...

Page 912: ...rator s cab of PC200 7 The figure shows the operator s cab of PC200 7 2 Using styrene foam blocks 9 and rubber bands 10 fix the window glass and both sided adhesive tape of fit them completely The fig...

Page 913: ...eiling and fix it with the rear locks on both sides 1 2 Remove left lower block 1 and right lower block 2 2 3 Reset the lock at the rear of the cab 4 Lower front window assembly 3 carefully a lit tle...

Page 914: ...in Testing and adjusting k Disconnect the negative terminal of the battery beforehand a Fasten tags to respective connecters and pip ing for identification to prevent any mistakes when re installing...

Page 915: ...d the solenoid valves connected to wring 7 8 V01 PPC basic pressure 9 V02 Travel HI LO 10 V03 Swing paring brake 11 V04 Travel junction valve 12 V05 Merge divider valve selection signal 13 P25 Pump pr...

Page 916: ...he multi valve connector P08 is positioned under P07 of the pressure switch con nector mounting bracket 29 P12 Pressure sensor 2 Remove wiring mounting clamps and dis connect wiring 19 from the pressu...

Page 917: ...from the oper ation pattern select valve assembly Machine with the select valve From the upper side of operator cab 47 Brown Swing right 48 Green Arm digging 49 White Swing left 50 Orange Arm dump Fro...

Page 918: ...sure sensor con nector P46 58 11 Disconnect wiring clamp 59 and disconnect the wiring 12 Disconnect buzzer wiring connector 60 13 Disconnect buzzer wiring clamp 61 and dis connect the buzzer wiring a...

Page 919: ...erator cab assembly 15 Disconnecting floor lower wiring and clamps 1 Disconnect wiring and hose clamps 62 to 73 2 Disconnect air conditioner Hi Lo pressure switch wiring connector 74 3 Disconnect air...

Page 920: ...ently 4 Floor frame assembly Approx 210 kg Installation q Carry out the installation in the reverse order of removal 1 a Care must be exercised in the installation so that dusts dirt or water may not...

Page 921: ...50 Disassembly and assembly SEN02715 00 PC138US USLC 8 21...

Page 922: ...22 PC138US USLC 8 SEN02715 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02715 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 923: ...stem Removal and installation of air compressor assembly 2 Removal and installation of air conditioner condenser 3 Removal and installation of air compressor unit assembly 4 Removal and installation o...

Page 924: ...nd remove air compressor assembly 9 2 Installation q Carry out the installation in the reverse order of removal 1 q q q q Precautions when installing piping a Care must be exercised in the installatio...

Page 925: ...ve the wire harness clamp 2 4 Disconnect 2 hoses 3 a Put blind caps to prevent the entry of dirt or water into hoses and compressor 5 Remove 4 bolts and remove condenser 4 Installation q Carry out ins...

Page 926: ...2 of the air con ditioner high and low pressure switch 3 Disconnect air conditioner hoses 3 and 4 4 Disconnect heater hoses 5 and 6 5 Remove floor mat 7 6 Remove machine monitor 8 referring to Remova...

Page 927: ...emove covers 18 and 19 13 Disconnect connectors 20 21 and 22 and disconnect the wiring clamps 14 Remove cover 23 15 Remove 3 cover mounting bolts 24 on the left and right 16 Lift cover 25 using 3 forc...

Page 928: ...val 1 q q q q Precautions when installing piping a Care must be exercised in the installation so that dusts dirt or water may not enter the hose of the air conditioner circuit q q q q Filling of air c...

Page 929: ...ed inside the cap on the right of the daylight sensor a While removing cover 1 simultaneously disconnect wiring connector P31 of the daylight sensor a A level gauge is installed to the top of the moni...

Page 930: ...tive terminal of the battery beforehand 1 Remove cover 1 2 Remove cover 2 3 Remove duct 3 4 Remove cover 4 5 Disconnect wiring 5 and 6 a Pull each connector lever a and b inward 6 Remove 4 mounting bo...

Page 931: ...2 DReferring to Removal and installation of air compressor assembly disconnect air condi tioner compressor 1 a Do not disconnect the air conditioner hoses from the air conditioner compres sor 3 Remove...

Page 932: ...Disconnect the negative terminal of the battery beforehand 1 Remove cover 1 2 Remove cover 2 3 Remove duct 3 4 Remove cover 4 5 Disconnect wiring connector CK02 5 CK01 6 and antenna 7 6 Remove 4 mount...

Page 933: ...50 Disassembly and assembly SEN02716 00 PC138US USLC 8 11...

Page 934: ...12 PC138US USLC 8 SEN02716 00 50 Disassembly and assembly PC138US USLC 8 Hydraulic excavator Form No SEN02716 00 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

Page 935: ...01980 00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 90 Diagrams and drawings 1 Hydraulic circuit diagram Hydraul...

Page 936: ...3 SEN01980 00 PC138US USLC 8 Hydraulic circuit diagram PC138US 8 Hydraulic circuit diagram PC138US 8...

Page 937: ...EN01980 00 PC138US USLC 8 Hydraulic circuit diagram PC138US 8 Blade specification and machine ready for attachment Hydraulic circuit diagram PC138US 8 Blade specification and machine ready for attachm...

Page 938: ...USLC 8 Hydraulic circuit diagram PC138USLC 8 KA specification Blade specification and machine ready for attachment Hydraulic circuit diagram PC138USLC 8 KA specification Blade specification and machin...

Page 939: ...USLC 8 Hydraulic circuit diagram PC138US 8 KUK specification Blade specification and machine ready for attachment Hydraulic circuit diagram PC138US 8 KUK specification Blade specification and machine...

Page 940: ...12 PC138US USLC 8 SEN01980 00 90 Diagrams and drawings PC138US USLC 8 Hydraulic excavator Form No SEN01980 00 2007 KOMATSU All Rights Reserved Printed in Japan 01 07 02...

Page 941: ...OR 1SHOP MANUAL PC138US 8 PC138USLC 8 Machine model Serial number PC138US 8 20001 and up PC138USLC 8 20001 and up 90 Diagrams and drawings 1 Electrical diagrams and drawings Electrical circuit diagram...

Page 942: ...SEN01981 01 90 Diagrams and drawings 2 PC138US USLC 8...

Page 943: ...Electrical circuit diagram PC138US USLC 8 PC138US USLC 8 3 SEN01981 01 Electrical circuit diagram PC138US USLC 8...

Page 944: ...re switch Boom down A 5 P07 X 2 Pressure switch Left swing A 4 P08 X 2 Pressure switch Right swing A 4 P09 AMP 3 C 1 P10 AMP 3 D 1 P11 AMP 3 D 1 P12 DT T 6 Intermediate connector B 1 P13 X 2 Intermedi...

Page 945: ...90 Diagrams and drawings SEN01981 01 PC138US USLC 8 7...

Page 946: ...8 PC138US USLC 8 SEN01981 01 90 Diagrams and drawings PC138US USLC 8 Hydraulic excavator Form No SEN01981 01 2007 KOMATSU All Rights Reserved Printed in Japan 02 07 02...

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