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Komatsu Galeo PC138US-8, Руководство по ремонту

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50 Disassembly and assembly

SEN02709-00

PC138US, USLC-8

7

Special tool list

1

a

  Tools with part number 79

Q

T-

QQQ

-

QQQQ

 cannot be supplied (they are items to be locally manufactured).

a

  Necessity

: 

t

. . . . . . Cannot be substituted, must always be installed (used) 

: 

q

. . . . . . Extremely useful if available or, can be substituted with commercially available

part. 

a

  New/Remodel: N. . . . . . Tools with new part numbers, newly developed for this model.

: R. . . . . . Tools with upgraded part numbers, remodeled from items already available for

other models.

: Blank  . . Tools already available for other models, can be used without any modification

a

Tools marked with 

Q

 in the Sketch column are tools introduced in the sketches of the special (See Sketch-

es of special tools).

Component

Sym-

bol

Part  No.

Part  Name

Ne

ce

ss

ity

Q’

ty

Ne

w/re

m

od

e

l

Sk

etc

h

Nature of work, remarks

Engine front oil seal

A

1

790-101-5201 Push tool (Kit)

t

1

Instllation 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

790-101-5401 Push tool (Kit)

t

1

Instllation rear oil seal

790-101-5431 • Plate

1

790-101-5421 • Grip

1

01010-51240

• Bolt

1

Hydraulic oil tank

D

796-460-1210 Oil stopper

q

1

Stop oil supply from hydraulic 

tank

795-799-1131 Adapter

q

1

Swing machinery

F

1

790-201-2750 Spacer

t

1

Removal split collar

2

790-101-5201 Push puller (Kit)

q

1

Removal bearing

790-101-2510 • Block

1

790-101-2550 • Leg

1

790-101-2560 • Nut

2

790-101-2570 • Plate

4

790-101-3101 Bearing puller

q

1

790-101-4200 Puller

(294 kN {30 ton})

q

1

790-101-1102 Hydraulic oil pump

q

1

3

790-101-5401 Push tool (Kit) (C)

q

1

Instllation Bearing outer race

790-101-5461 • Plate

1

For main bearing

790-101-5441 • Plate

1

For sub bearing

790-101-5421 • Grip

1

01010-51240

• Bolt

1

4

790-201-2850 Spacer

t

1

Instllation Bearing inner race

5

790-201-2750 Spacer

t

1

6

796T-426-1140 Push tool

t

1

Q

Instllation oil seal

790-201-2680 Plate

q

1

Содержание Galeo PC138US-8

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 821: ...50 Disassembly and assembly SEN02710 00 PC138US USLC 8 33...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 835: ...50 Disassembly and assembly SEN02711 00 PC138US USLC 8 13...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 843: ...50 Disassembly and assembly SEN02712 00 PC138US USLC 8 7 7 Install O ring then install support 2 with dowel pin 1...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 873: ...50 Disassembly and assembly SEN02713 00 PC138US USLC 8 17 Disassembly and assembly of control valve assembly 1 Assembly...

Страница 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...

Страница 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...

Страница 876: ...SEN02713 00 50 Disassembly and assembly 20 PC138US USLC 8...

Страница 877: ...50 Disassembly and assembly SEN02713 00 PC138US USLC 8 21...

Страница 878: ...SEN02713 00 50 Disassembly and assembly 22 PC138US USLC 8...

Страница 879: ...50 Disassembly and assembly SEN02713 00 PC138US USLC 8 23...

Страница 880: ...SEN02713 00 50 Disassembly and assembly 24 PC138US USLC 8...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 899: ...50 Disassembly and assembly SEN02714 00 PC138US USLC 8 5...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 921: ...50 Disassembly and assembly SEN02715 00 PC138US USLC 8 21...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 933: ...50 Disassembly and assembly SEN02716 00 PC138US USLC 8 11...

Страница 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...

Страница 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...

Страница 936: ...3 SEN01980 00 PC138US USLC 8 Hydraulic circuit diagram PC138US 8 Hydraulic circuit diagram PC138US 8...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 942: ...SEN01981 01 90 Diagrams and drawings 2 PC138US USLC 8...

Страница 943: ...Electrical circuit diagram PC138US USLC 8 PC138US USLC 8 3 SEN01981 01 Electrical circuit diagram PC138US USLC 8...

Страница 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...

Страница 945: ...90 Diagrams and drawings SEN01981 01 PC138US USLC 8 7...

Страница 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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