Komatsu PC138US-8/PC138USLC-8 Hydraulic Excavators OEM Service & Repair Manual

HYDRAULIC EXCAVATOR SEN01968-00 PC138US -8 PC138USLC -8 SERIAL NUMBERS PC138US- 20001 PC138USLC- 20001 and up

PC138US, USLC-8 1 SEN01977-00 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 Table of contents ............................................................................................................................................. 4

SEN01977-00 00 Index and foreword 2 PC138US, USLC-8 Composition of shop manual 1 The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows:  Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below:  File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Form Number Shop Manual, contents binder, binder label and tabs SEN01968-00 00 Index and foreword SEN01969-00 Index SEN01977-00 Foreword and general information SEN01978-00 01 Specification SEN01970-00 Specification and technical data SEN01979-00 10 Structure, function and maintenance standard SEN01971-00 Engine and cooling system SEN02545-00 Power train system SEN02546-00 Undercarriage and frame SEN02547-00 Hydraulic system, Part 1 SEN02548-00 Hydraulic system, Part 2 SEN02549-00 Hydraulic system, Part 3 SEN02550-00 Work equipment SEN02551-00 Cab and its attachments SEN02552-00 Electrical system SEN02553-00 20 Standard value table SEN01972-00 Standard service value table SEN02457-00 30 Testing and adjusting SEN01973-00 Testing and adjusting, Part 1 SEN02458-00 Testing and adjusting, Part 2 SEN02459-00 Testing and adjusting, Part 3 SEN02460-00 40 Troubleshooting SEN01974-00 Failure code table and fuse locations SEN02461-00 General information on troubleshooting SEN02462-00 Troubleshooting by failure code, Part 1 SEN02463-00 Troubleshooting by failure code, Part 2 SEN02464-00 Troubleshooting by failure code, Part 3 SEN02465-00 Troubleshooting by failure code, Part 4 SEN02466-00 Troubleshooting of electrical system (E-mode) SEN02467-00

00 Index and foreword SEN01977-00 PC138US, USLC-8 3 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02468-00 Troubleshooting of engine (S-mode) SEN02469-00 90 Diagrams and drawings SEN01976-00 Hydraulic circuit diagram SEN01980-00 Electrical circuit diagram SEN01981-00

SEN01977-00 00 Index and foreword 4 PC138US, USLC-8 Table of contents 1 00 Index and foreword Index SEN01977-00 Composition of shop manual ....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN01978-00 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard .......................................................................... 9 Handling electric equipment and hydraulic component ............................................................... 11 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN01979-00 Specification dimension drawings ............................................................................................... 2 Working range diagram ............................................................................................................... 3 Specifications .............................................................................................................................. 4 List of weights.............................................................................................................................. 10 List of lubricant and water to be filled .......................................................................................... 14 10 Structure, function and maintenance standard Engine and cooling system SEN02545-00 Engine mount .............................................................................................................................. 2 PTO ............................................................................................................................................. 3 Cooling system............................................................................................................................ 4 Power train system SEN02546-00 Power train .................................................................................................................................. 2 Swing circle ................................................................................................................................. 3 Swing machinery ......................................................................................................................... 4 Undercarriage and frame SEN02547-00 Track frame ................................................................................................................................. 2 Idler cushion ................................................................................................................................ 4 Idler ............................................................................................................................................. 6 Track roller................................................................................................................................... 7 Carrier roller ................................................................................................................................ 8 Sprocket ...................................................................................................................................... 9 Track shoe ................................................................................................................................... 10 Hydraulic system, Part 1 SEN02548-00 Hydraulic equipment layout drawing ........................................................................................... 2 Valve control ................................................................................................................................ 4 Hydraulic tank and filter ............................................................................................................... 6 Hydraulic pump ........................................................................................................................... 8 Hydraulic system, Part 2 SEN02549-00 Control valve ............................................................................................................................... 2 CLSS ........................................................................................................................................... 14 Functions and operation by valve................................................................................................ 18 Hydraulic system, Part 3 SEN02550-00 PPC valve.................................................................................................................................... 2 Swing motor ................................................................................................................................ 19

00 Index and foreword SEN01977-00 PC138US, USLC-8 5 Travel motor ................................................................................................................................ 27 Center swivel joint ....................................................................................................................... 36 Solenoid valve ............................................................................................................................. 40 PPC accumulator ........................................................................................................................ 44 Holding valve............................................................................................................................... 46 Multi-control valve ....................................................................................................................... 51 Work equipment SEN02551-00 Work equipment .......................................................................................................................... 2 Dimensions of components ......................................................................................................... 4 Hydraulic cylinder ........................................................................................................................ 8 Cab and its attachments SEN02552-00 Air conditioner ............................................................................................................................. 2 Electrical system SEN02553-00 Electronic control system ............................................................................................................ 2 Multi monitor system ................................................................................................................... 33 KOMTRAX terminal system ........................................................................................................ 47 Sensor ......................................................................................................................................... 49 20 Standard value table Standard service value table SEN02457-00 Standard value table for engine related parts.............................................................................. 2 Standard value table for chassis related parts ............................................................................ 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN02458-00 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Testing engine speed .................................................................................................................. 6 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 parts .......................................................................................................... 15 Releasing residual pressure from fuel system ............................................................................ 15 Testing fuel pressure ................................................................................................................... 16 Testing fuel return rate and fuel leakage ..................................................................................... 17 Bleeding air from fuel circuit ........................................................................................................ 19 Checking fuel circuit for leakage ................................................................................................. 21 Testing and adjusting alternator belt tension ............................................................................... 22 Testing swing circle bearing clearance........................................................................................ 23 Checking and adjusting air conditioner compressor belt tension ................................................ 24 Checking and adjusting track shoe tension................................................................................. 25 Testing and adjusting oil pressure in work equipment, swing, and travel circuits........................ 27 Testing control circuit basic pressure .......................................................................................... 30 Testing and adjusting 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 play of work equipment and swing PPC valves........................................................... 41 Checking parts which cause hydraulic drift of work equipment ................................................... 42 Releasing residual pressure from hydraulic circuit ...................................................................... 44 Testing oil leakage....................................................................................................................... 45 Bleeding air from each part ......................................................................................................... 48 Checking cab tipping stopper ...................................................................................................... 50 Adjusting mirrors ......................................................................................................................... 50

SEN01977-00 00 Index and foreword 6 PC138US, USLC-8 Testing and adjusting, Part 2 SEN02459-00 Special functions of machine monitor .......................................................................................... 2 Testing and adjusting, Part 3 SEN02460-00 Handling voltage circuit of engine controller ................................................................................ 2 Preparation work for troubleshooting of electrical system ........................................................... 3 Procedure for testing diodes ....................................................................................................... 8 Pm Clinic service ......................................................................................................................... 9 40 Troubleshooting Failure code table and fuse locations SEN02461-00 Failure code table ........................................................................................................................ 2 Fuse locations ............................................................................................................................. 6 General information on troubleshooting SEN02462-00 Points to remember when troubleshooting .................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3 Checks before troubleshooting.................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Information in troubleshooting table ............................................................................................ 6 Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8 Wiring table for connector pin numbers....................................................................................... 11 T-adapter box and T-adapter table .............................................................................................. 44 Troubleshooting by failure code, Part 1 SEN02463-00 Failure code [989L00] Engine controller lock caution 1............................................................... 3 Failure code [989M00] Engine controller lock caution 2.............................................................. 3 Failure code [989N00] Engine controller lock caution 3 .............................................................. 4 Failure code [AB00KE] Charge 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 [CA111] ECM critical internal failure ....................................................................... 10 Failure code [CA115] Eng. Ne and Bkup speed sensor error ..................................................... 13 Failure code [CA122] Charge air press sensor high error ........................................................... 14 Failure code [CA123] Charge air press sensor low error ............................................................ 16 Failure code [CA131] Throttle sensor high error ......................................................................... 18 Failure code [CA132] Throttle sensor low error........................................................................... 20 Failure code [CA144] Coolant temp. sensor high error ............................................................... 21 Failure code [CA145] Coolant temp. sensor low error ................................................................ 22 Failure code [CA153] Charge air temp. sensor high error........................................................... 23 Failure code [CA154] Charge air temp. sensor low error ............................................................ 24 Failure code [CA187] Sensor sup. 2 volt. low error ..................................................................... 24 Failure code [CA221] Ambient air press. sensor high error ........................................................ 26 Failure code [CA222] Ambient air 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 short error ............................................................................... 36 Failure code [CA272] IMV/PCV1 open error ............................................................................... 37 Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 38 Failure code [CA324] Injector #3 (L/B #3) system open/short error ............................................ 40 Failure code [CA331] Injector #2 (L/B #2) system open/short error ............................................ 42 Failure code [CA332] Injector #4 (L/B #4) system open/short error ............................................ 44 Troubleshooting by failure code, Part 2 SEN02464-00 Failure code [CA351] Inj. drive circuit error ................................................................................. 3 Failure code [CA352] Sensor sup. 1 volt. low error ..................................................................... 6 Failure code [CA386] Sensor sup. 1 volt. high error ................................................................... 8

00 Index and foreword SEN01977-00 PC138US, USLC-8 7 Failure code [CA435] Abnormality in engine oil pressure 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 high error .................................................................... 14 Failure code [CA452] Rail press. sensor low error...................................................................... 16 Failure code [CA553] Rail press. high error ................................................................................ 16 Failure code [CA559] Rail press. low error ................................................................................. 17 Failure code [CA689] Eng. Ne speed sensor error ..................................................................... 20 Failure code [CA731] Eng. Bkup speed sensor phase error ....................................................... 22 Failure code [CA757] All persistent data lost error ...................................................................... 22 Failure code [CA778] Eng. Bkup speed sensor error .................................................................. 24 Failure code [CA1633] KOMNET datalink timeout error ............................................................. 26 Failure code [CA2185] Throttle sens. sup. volt. high error .......................................................... 28 Failure code [CA2186] Throttle sens. sup. volt. low error ........................................................... 30 Failure code [CA2249] Rail 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 [D862KA] GPS antenna discon .............................................................................. 36 Failure code [DA22KK] Pump solenoid power low error ............................................................. 38 Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................. 40 Failure code [DA26KP] 5V sensor 2 power abnormality ............................................................. 43 Troubleshooting by failure code, Part 3 SEN02465-00 Failure code [DA2RMC] CAN discon (Pump con 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 code [DGH2KB] Hydr oil sensor short ............................................................................. 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 ............................ 18 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality............................... 20 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................. 22 Failure code [DHSKMA] Blade raise PPC press sensor abnormality ......................................... 24 Failure code [DHSLMA] Blade lower PPC press sensor abnormality ......................................... 26 Failure code [DHX1MA] Overload sensor abnormality (Analog) ................................................. 28 Failure code [DV20KB] Travel alarm S/C .................................................................................... 29 Failure code [DW43KA] Travel speed sol discon ........................................................................ 30 Failure code [DW43KB] Travel speed sol short .......................................................................... 31 Failure code [DW45KA] 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-divider sol discon ....................................................................... 38 Failure code [DWJ0KB] Merge-divider sol short ......................................................................... 39 Troubleshooting by failure code, Part 4 SEN02466-00 Failure code [DXA8KA] 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 abnormality .................................................................... 8 Failure code [DY20MA] Wiper parking abnormality .................................................................... 10 Failure code [DY2CKA] Washer drive discon.............................................................................. 12 Failure code [DY2CKB] Washer drive short ................................................................................ 14 Failure code [DY2DKB] Wiper drive (for) short ........................................................................... 16 Failure code [DY2EKB] Wiper drive (rev) short ........................................................................... 18

SEN01977-00 00 Index and foreword 8 PC138US, USLC-8 Troubleshooting of electrical system (E-mode) SEN02467-00 Before carrying out troubleshooting of electrical system ............................................................. 3 Information in troubleshooting table ............................................................................................ 5 E-1 When starting switch turned ON, machine monitor displays nothing.................................... 6 E-2 When starting switch turned ON (before starting engine), 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 equipment, swing, and travel mechanism do not move or cannot be locked .......... 16 E-7 Precaution lights up while engine is running......................................................................... 18 E-8 Emergency stop item lights up while engine is running ........................................................ 21 E-9 Engine coolant temperature gauge does not indicate normally ............................................ 22 E-10 Hydraulic oil temperature gauge does not indicate normally .............................................. 23 E-11 Fuel level gauge does not indicate normally ....................................................................... 25 E-12 Contents of display by machine monitor are different from applicable machine ................. 27 E-13 Machine monitor does not display some items ................................................................... 27 E-14 Function switch does not work............................................................................................ 27 E-15 Auto-decelerator does not operate normally....................................................................... 28 E-16 Working mode does not change ......................................................................................... 29 E-17 Travel speed does not change............................................................................................ 30 E-18 Alarm buzzer cannot be stopped ........................................................................................ 31 E-19 Windshield 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 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 service mode ................................................................ 51 E-25 Monitoring function does not display lever control signal normally ..................................... 52 E-26 KOMTRAX system does not operate normally ................................................................... 68 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02468-00 Information contained in troubleshooting table............................................................................ 3 System chart for hydraulic and mechanical systems .................................................................. 4 H-1 Speed or power of all work 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 control mode does not function .................................................................................... 9 H-6 Speed or power of boom is low ............................................................................................ 10 H-7 Speed or power of arm is low ............................................................................................... 11 H-8 Speed or power of bucket is low ........................................................................................... 12 H-9 Work equipment does not move in its single operation ........................................................ 13 H-10 Hydraulic drift of work equipment is large........................................................................... 14 H-11 Time lag of work equipment is large ................................................................................... 15 H-12 Work equipment loaded more is slower during compound operation................................. 15 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE ..................... 15 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel .. 16 H-15 Machine deviates during travel ........................................................................................... 17 H-16 Travel speed is low ............................................................................................................. 18 H-17 Machine cannot be steered 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 acceleration or swing speed is low .......................................................................... 22 H-22 Excessive overrun when stopping swing ............................................................................ 23 H-23 When upper structure stops swinging, it makes large shock.............................................. 24 H-24 When upper structure stops swinging, it makes large sound ............................................. 24 H-25 Hydraulic drift of swing is large ........................................................................................... 25 H-26 Flow rate in attachment circuit cannot be adjusted ............................................................ 26

00 Index and foreword SEN01977-00 PC138US, USLC-8 9 Troubleshooting of engine (S-mode) SEN02469-00 Method of using troubleshooting chart ........................................................................................ 4 S-1 Starting performance is poor ................................................................................................ 8 S-2 Engine does not start ............................................................................................................ 9 S-3 Engine does not pick 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 consumption is excessive (or exhaust smoke is blue) .................................................... 17 S-9 Oil becomes contaminated quickly ....................................................................................... 18 S-10 Fuel consumption is excessive ........................................................................................... 19 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20 S-12 Oil pressure drops .............................................................................................................. 21 S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 22 S-14 Coolant temperature becomes too high (overheating) ....................................................... 23 S-15 Abnormal noise is made ..................................................................................................... 24 S-16 Vibration is excessive ......................................................................................................... 25 90 Diagrams and drawings Hydraulic circuit diagram SEN01980-00 Hydraulic circuit diagram............................................................................................................. 3 Electrical circuit diagram SEN01981-00 Electrical circuit diagram ............................................................................................................. 3

Komatsu PC138US-8/PC138USLC-8 Hydraulic Excavators OEM Service & Repair Manual

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