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KOMATSU GALEO PC138US-8 PC138USLC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU GALEO PC138US-8 PC138USLC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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Description
KOMATSU GALEO PC138US-8 PC138USLC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU GALEO PC138US-8 PC138USLC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 998
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU GALEO PC138US-8 PC138USLC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
00 Index and foreword.................................................................................... 3 Index................................................................................................ 3 Composition of shop manual....................................................................... 4 Table of contents................................................................................ 6 00 Index and foreword.................................................................................... 15 Foreword and general information..................................................................... 15 Safety notice.................................................................................... 16 How to read the shop manual...................................................................... 21 Explanation of terms for maintenance standard.................................................... 23 Handling of electric equipment and hydraulic component........................................... 25 Handling of connectors newly used for engines.................................................... 34 How to read electric wire code................................................................... 37 Precautions when carrying out operation.......................................................... 40 Method of disassembling and connecting push-pull type coupler.................................... 43 Standard tightening torque table................................................................. 46 Conversion table................................................................................. 50 01 Specification......................................................................................... 57 Specification and technical data..................................................................... 57 Specification dimension drawings................................................................. 58 Working range diagram............................................................................ 59 Specifications................................................................................... 60 List of weights.................................................................................. 66 Table of fuel, coolant and lubricants............................................................ 70 Engine mount..................................................................................... 74 PTO.............................................................................................. 75 Cooling system................................................................................... 76 Diesel particulate filter (SN 20940 and up)...................................................... 78 Diesel particulate filter - component parts...................................................... 79 System Description............................................................................... 80 Regeneration..................................................................................... 80 10 Structure, function and maintenance standard.......................................................... 73 Engine and cooling system............................................................................ 73 Power train...................................................................................... 84 Swing circle..................................................................................... 85 Swing machinery.................................................................................. 86 10 Structure, function and maintenance standard.......................................................... 83 Power train.......................................................................................... 83 Track frame...................................................................................... 90 Idler cushion.................................................................................... 92 Idler............................................................................................ 94 Track roller..................................................................................... 95 Carrier roller................................................................................... 96 Sprocket......................................................................................... 97 Track shoe....................................................................................... 98 10 Structure, function and maintenance standard.......................................................... 89 Undercarriage and frame.............................................................................. 89 Hydraulic equipment layout drawing...............................................................106 Valve control....................................................................................108 Hydraulic tank and filter........................................................................110 Hydraulic pump...................................................................................112 10 Structure, function and maintenance standard..........................................................105 Hydraulic system, Part 1.............................................................................105 Control valve....................................................................................140 CLSS.............................................................................................152 Functions and operation by valve.................................................................156 10 Structure, function and maintenance standard..........................................................139 Hydraulic system, Part 2.............................................................................139 PPC valve........................................................................................188 Swing motor......................................................................................205 Travel motor.....................................................................................213 Centre swivel joint..............................................................................222 Solenoid valve...................................................................................226 PPC accumulator..................................................................................230 Holding valve....................................................................................232 Multi-control valve..............................................................................237 10 Structure, function and maintenance standard..........................................................187 Hydraulic system, Part 3.............................................................................187 Work equipment...................................................................................240 Dimensions of components.........................................................................242 Hydraulic cylinder...............................................................................246 10 Structure, function and maintenance standard..........................................................239 Work equipment.......................................................................................239 Air conditioner..................................................................................250 10 Structure, function and maintenance standard..........................................................249 Cab and its attachments..............................................................................249 Electronic control system........................................................................264 Monitor system...................................................................................297 KOMTRAX system...................................................................................311 Sensor...........................................................................................313 10 Structure, function and maintenance standard..........................................................263 Electrical system....................................................................................263 10 Structure, function and maintenance standard..........................................................321 Auto Grease system...................................................................................321 Outline of Auto Grease System....................................................................322 Standard value table for engine related parts....................................................338 Standard value table for chassis related parts...................................................339 20 Standard value table..................................................................................337 Standard service value table.........................................................................337 30 Testing and adjusting.................................................................................349 Testing and adjusting, Part 1........................................................................349 Tools for testing, adjusting, and troubleshooting................................................351 Testing engine speed.............................................................................354 Testing exhaust temperature......................................................................355 Checking exhaust gas colour......................................................................356 Adjusting valve clearance........................................................................357 Testing compression pressure.....................................................................359 Testing blow-by pressure.........................................................................361 Testing engine oil pressure......................................................................362 Handling fuel system parts.......................................................................363 Releasing residual pressure from fuel system.....................................................363 Testing fuel pressure............................................................................364 Testing fuel return rate and fuel leakage........................................................365 Bleeding air from fuel circuit...................................................................367 Checking fuel circuit for leakage................................................................369 Testing and adjusting alternator belt tension....................................................370 Testing swing circle bearing clearance...........................................................371 Checking and adjusting air conditioner compressor belt tension...................................372 Checking and adjusting track shoe tension........................................................373 Testing and adjusting oil pressure in work equipment, swing, and travel circuits.................375 Testing control circuit basic pressure...........................................................378 Testing and adjusting oil pressure in pump PC control circuit....................................379 Testing and adjusting oil pressure in pump LS control circuit....................................382 Testing solenoid valve output pressure...........................................................386 Testing PPC valve output pressure................................................................387 Adjusting play of work equipment and swing PPC valves............................................389 Checking parts which cause hydraulic drift of work equipment.....................................390 Testing and adjusting travel deviation...........................................................392 Releasing residual pressure from hydraulic circuit...............................................394 Testing oil leakage..............................................................................395 Bleeding air from each part......................................................................398 Checking cab tipping stopper.....................................................................400 Adjusting mirrors................................................................................400 30 Testing and adjusting.................................................................................403 Testing and adjusting, Part 2........................................................................403 Special functions of machine monitor.............................................................404 30 Testing and adjusting.................................................................................457 Testing and adjusting, Part 3........................................................................457 Handling voltage circuit of engine controller....................................................458 Preparation work for troubleshooting of electrical system........................................459 Procedure for testing diodes.....................................................................464 Pm Clinic service................................................................................465 Failure code table...............................................................................472 Fuse locations...................................................................................476 40 Troubleshooting.......................................................................................471 Failure code table and fuse locations................................................................471 40 Troubleshooting.......................................................................................479 General information on troubleshooting...............................................................479 Points to remember when troubleshooting..........................................................480 Sequence of events in troubleshooting............................................................482 Checks before troubleshooting....................................................................483 Classification and procedures for troubleshooting................................................484 Information in troubleshooting table.............................................................485 Phenomena looking like troubles and troubleshooting Nos..........................................487 Wiring table for connector pin numbers...........................................................490 T-adapter box and T-adapter table................................................................524 Failure code [989L00] Engine controller lock caution 1...........................................531 Failure code [989M00] Engine controller lock caution 2...........................................531 Failure code [989N00] Engine controller lock caution 3...........................................532 Failure code [AB00KE] Charge voltage low.........................................................534 Failure code [B@BAZG] Eng oil press. low.........................................................536 Failure code [B@BAZK] Eng oil level low..........................................................536 Failure code [B@BCNS] Eng coolant overheat.......................................................537 Failure code [B@HANS] Hydr oil overheat..........................................................537 Failure code [CA111] ECM critical internal failure...............................................538 Failure code [CA115] Eng. Ne and Bkup speed sensor error.........................................541 Failure code [CA122] Charge air press sensor high error..........................................542 Failure code [CA123] Charge air press sensor low error...........................................544 Failure code [CA131] Throttle sensor high error..................................................546 Failure code [CA132] Throttle sensor low error...................................................548 Failure code [CA144] Coolant temp. sensor high error.............................................549 Failure code [CA145] Coolant temp. sensor low error..............................................550 Failure code [CA153] Charge air temp. sensor high error..........................................551 Failure code [CA154] Charge air temp. sensor low error...........................................552 Failure code [CA187] Sensor sup. 2 volt. low error...............................................552 Failure code [CA221] Ambient air press. sensor high error........................................554 Failure code [CA222] Ambient air press. sensor low error.........................................556 Failure code [CA227] Sensor sup. 2 volt. high error..............................................558 Failure code [CA234] Eng. overspeed..............................................................560 Failure code [CA238] Ne speed sensor sup. volt. error............................................562 Failure code [CA271] IMV/PCV1 short error........................................................564 Failure code [CA272] IMV/PCV1 open error.........................................................565 Failure code [CA322] Injector #1 (L #1) system open/short error..................................566 Failure code [CA324] Injector #3 (L #3) system open/short error..................................568 Failure code [CA331] Injector #2 (L #2) system open/short error..................................570 Failure code [CA332] Injector #4 (L #4) system open/short error..................................572 40 Troubleshooting.......................................................................................529 Troubleshooting by failure code, Part 1..............................................................529 Failure code [CA351] Inj. drive circuit error....................................................577 Failure code [CA352] Sensor sup. 1 volt. low error...............................................580 Failure code [CA386] Sensor sup. 1 volt. high error..............................................582 Failure code [CA435] Abnormality in engine oil pressure switch...................................584 Failure code [CA441] Battery voltage low error...................................................585 Failure code [CA442] Battery voltage high error..................................................585 Failure code [CA449] Rail press. very high error.................................................586 Failure code [CA451] Rail press. sensor high error...............................................588 Failure code [CA452] Rail press. sensor low error................................................590 Failure code [CA553] Rail press. high error......................................................590 Failure code [CA559] Rail press. low error.......................................................591 Failure code [CA689] Eng. Ne speed sensor error..................................................594 Failure code [CA731] Eng. Bkup speed sensor phase error..........................................596 Failure code [CA757] All persistent data lost error..............................................596 Failure code [CA778] Eng. Bkup speed sensor error................................................598 Failure code [CA1633] KOMNET datalink timeout error..............................................600 Failure code [CA2185] Throttle sens. sup. volt. high error.......................................602 Failure code [CA2186] Throttle sens. sup. volt. low error........................................604 Failure code [CA2249] Rail press. very low error.................................................604 Failure code [CA2311] Abnormality in IMV solenoid................................................605 Failure code [D110KB] Battery relay drive short..................................................606 Failure code [D19JKZ] Personal code relay abnormality............................................608 Failure code [D862KA] GPS antenna discon.........................................................610 Failure code [DA22KK] Pump solenoid power low error..............................................612 Failure code [DA25KP] 5V sensor 1 power abnormality..............................................614 Failure code [DA26KP] 5V sensor 2 power abnormality..............................................617 40 Troubleshooting.......................................................................................575 Troubleshooting by failure code, Part 2..............................................................575 Failure code [DA2RMC] CAN discon (Pump controller detected)......................................622 Failure code [DAF8KB] Short circuit in camera power supply.......................................624 Failure code [DAFGMC] GPS module error...........................................................626 Failure code [DAFRMC] CAN discon (Monitor detected)..............................................628 Failure code [DGH2KB] Hydr oil sensor short......................................................630 Failure code [DHPAMA] Pump press sensor abnormality..............................................632 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality...........................634 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality..........................636 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality...........................638 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality..........................640 Failure code [DHSKMA] Blade raise PPC press sensor abnormality...................................642 Failure code [DHSLMA] Blade lower PPC press sensor abnormality...................................644 Failure code [DHX1MA] Overload sensor abnormality (Analog).......................................646 Failure code [DV20KB] Travel alarm S/C...........................................................647 Failure code [DW43KA] Travel speed sol discon....................................................648 Failure code [DW43KB] Travel speed sol short.....................................................649 Failure code [DW45KA] Swing brake sol discon.....................................................650 Failure code [DW45KB] Swing brake sol short......................................................652 Failure code [DW91KA] Travel junction sol discon.................................................654 Failure code [DW91KB] Travel junction sol short..................................................655 Failure code [DWJ0KA] Merge-divider sol discon...................................................656 Failure code [DWJ0KB] Merge-divider sol short....................................................657 40 Troubleshooting.......................................................................................619 Troubleshooting by failure code, Part 3..............................................................619 Failure code [DXA8KA] PC-EPC sol discon..........................................................660 Failure code [DXA8KB] PC-EPC sol short...........................................................662 Failure code [DXE4KA] Service current EPC discon.................................................664 Failure code [DXE4KB] Service current EPC short..................................................665 Failure code [DY20KA] Wiper working abnormality..................................................666 Failure code [DY20MA] Wiper parking abnormality..................................................668 Failure code [DY2CKA] Washer drive discon........................................................670 Failure code [DY2CKB] Washer drive short.........................................................672 Failure code [DY2DKB] Wiper drive (for) short....................................................674 Failure code [DY2EKB] Wiper drive (rev) short....................................................676 40 Troubleshooting.......................................................................................659 Troubleshooting by failure code, Part 4..............................................................659 40 Troubleshooting.......................................................................................679 Troubleshooting of electrical system (E-mode)........................................................679 Before carrying out troubleshooting of electrical system.........................................681 Information in troubleshooting table.............................................................683 E-1 When starting switch turned ON, machine monitor displays nothing.............................684 E-2 When starting switch turned ON (before starting engine), basic check item lights up..........686 E-3 Engine does not start (Engine does not turn).................................................687 E-4 Preheater does not operate...................................................................690 E-5 Automatic warm-up system does not operate (in cold season)...................................692 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked..............694 E-7 Precaution lights up while engine is running.................................................696 E-8 Emergency stop item lights up while engine is running........................................699 E-9 Engine coolant temperature gauge does not indicate normally..................................700 E-10 Hydraulic oil temperature gauge does not indicate normally..................................701 E-11 Fuel level gauge does not indicate normally.................................................703 E-12 Contents of display by machine monitor are different from applicable machine................705 E-13 Machine monitor does not display some items.................................................705 E-14 Function switch does not work...............................................................705 E-15 Auto-decelerator does not operate normally..................................................706 E-16 Working mode does not change................................................................707 E-17 Travel speed does not change................................................................708 E-18 Alarm buzzer cannot be stopped..............................................................709 E-19 Windshield wiper and window washer do not operate...........................................710 E-20 Swing holding brake does not operate normally...............................................714 E-21 Travel alarm does not sound or does not stop sounding.......................................716 E-22 Air conditioner does not operate normally (including air conditioner abnormality record)....717 E-23 While starting switch is in OFF position, service meter is not displayed....................729 E-24 Machine monitor cannot be set in service mode...............................................729 E-25 Monitoring function does not display lever control signal normally..........................730 E-26 KOMTRAX system does not operate normally....................................................746 Information contained in troubleshooting table...................................................751 System chart for hydraulic and mechanical systems................................................752 H-1 Speed or power of all work equipment, swing, and travel are low..............................754 H-2 Engine speed sharply drops or engine stalls..................................................755 H-3 No work equipment, travel and swing move.....................................................756 H-4 Abnormal noise is heard from around hydraulic pump...........................................756 H-5 Fine control mode does not function..........................................................757 H-6 Speed or power of boom is low................................................................758 H-7 Speed or power of arm is low.................................................................759 H-8 Speed or power of bucket is low..............................................................760 H-9 Work equipment does not move in its single operation.........................................761 H-10 Hydraulic drift of work equipment is large..................................................762 H-11 Time lag of work equipment is large.........................................................763 H-12 Work equipment loaded more is slower during compound operation..............................763 H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE.........................763 H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel......764 H-15 Machine deviates during travel..............................................................765 H-16 Travel speed is low.........................................................................766 H-17 Machine cannot be steered easily or steering power is low...................................767 H-18 Travel speed does not change or it is kept low or high......................................768 H-19 Track does not move (Only either side)......................................................768 H-20 Machine does not swing......................................................................769 H-21 Swing acceleration or swing speed is low....................................................770 H-22 Excessive overrun when stopping swing.......................................................771 H-23 When upper structure stops swinging, it makes large shock...................................772 H-24 When upper structure stops swinging, it makes large sound...................................772 H-25 Hydraulic drift of swing is large...........................................................773 H-26 Flow rate in attachment circuit cannot be adjusted..........................................774 40 Troubleshooting.......................................................................................749 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................749 40 Troubleshooting.......................................................................................777 Troubleshooting of engine (S-mode)...................................................................777 Method of using troubleshooting chart............................................................780 S-1 Starting performance is poor.................................................................784 S-2 Engine does not start........................................................................785 S-3 Engine does not pick up smoothly.............................................................788 S-4 Engine stops during operations...............................................................789 S-5 Engine does not rotate smoothly..............................................................790 S-6 Engine lacks output (or lacks power).........................................................791 S-7 Exhaust smoke is black (incomplete combustion)...............................................792 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................793 S-9 Oil becomes contaminated quickly.............................................................794 S-10 Fuel consumption is excessive...............................................................795 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).......................796 S-12 Oil pressure drops..........................................................................797 S-13 Oil level rises (Entry of coolant or fuel)..................................................798 S-14 Coolant temperature becomes too high (overheating)..........................................799 S-15 Abnormal noise is made......................................................................800 S-16 Vibration is excessive......................................................................801 S-17 Diesel Particulate Filter System............................................................802 40 Troubleshooting.......................................................................................805 Troubleshooting of Auto Grease system................................................................805 50 Disassembly and assembly..............................................................................813 General information on disassembly and assembly......................................................813 How to read this manual..........................................................................814 List of adhesives................................................................................816 Special tool list................................................................................819 Sketch of special tool...........................................................................823 Removal and installation of fuel supply pump assembly............................................826 Removal and installation of fuel injector assembly...............................................828 Removal and installation of front oil seal.......................................................830 Removal and installation of rear oil seal........................................................832 Removal and installation of cylinder head assembly...............................................835 Removal and installation of radiator assembly....................................................842 Removal and installation of aftercooler assembly.................................................844 Removal and installation of work equipment oil cooler assembly...................................846 Removal and installation of engine and work equipment pump assembly..............................849 Removal and installation of fuel tank assembly...................................................854 50 Disassembly and assembly..............................................................................825 Engine and cooling system............................................................................825 Removal and installation of travel motor and final drive assembly................................858 Removal and installation of swing motor and swing machinery assembly.............................860 Disassembly and assembly of swing machinery assembly.............................................862 Removal and installation of swing circle assembly................................................868 50 Disassembly and assembly..............................................................................857 Power train..........................................................................................857 Disassembly and assembly of track roller.........................................................872 Disassembly and assembly of idler assembly.......................................................875 Disassembly and assembly of recoil spring........................................................878 Removal and installation of track shoe assembly..................................................881 Removal and installation of sprocket.............................................................883 Removal and installation of revolving frame assembly.............................................884 Removal and installation of counterweight assembly (Machine without add-on weight)...............886 Removal and installation of counterweight assembly (Machine with add-on weight)..................887 50 Disassembly and assembly..............................................................................871 Undercarriage and frame..............................................................................871 Removal and installation of centre swivel joint assembly.........................................892 Disassembly and assembly of centre swivel joint assembly.........................................894 Removal and installation of hydraulic tank assembly..............................................896 Removal and installation of hydraulic pump assembly..............................................899 Removal and installation of control valve assembly...............................................903 Disassembly and assembly of control valve assembly...............................................908 Disassembly and assembly of work equipment PPC valve assembly....................................918 Disassembly and assembly of travel PPC valve assembly............................................921 Disassembly and assembly of hydraulic cylinder assembly..........................................923 50 Disassembly and assembly..............................................................................891 Hydraulic system.....................................................................................891 Removal and installation of work equipment assembly..............................................932 50 Disassembly and assembly..............................................................................931 Work equipment Body..................................................................................931 Removal and installation of operator cab assembly................................................938 Removal and installation of operator's cab glass (stuck glass)...................................940 Removal and installation of front window assembly................................................949 Removal and installation of floor frame assembly.................................................950 50 Disassembly and assembly..............................................................................937 Cab and its attachments..............................................................................937 Removal and installation of air compressor assembly..............................................960 Removal and installation of air conditioner condenser............................................961 Removal and installation of air compressor unit assembly.........................................962 Removal and installation of machine monitor assembly.............................................965 Removal and installation of pump controller assembly.............................................966 Removal and installation of engine controller assembly...........................................967 Removal and installation of KOMTRAX communications module........................................968 50 Disassembly and assembly..............................................................................959 Electrical system....................................................................................959 90 Diagrams and drawings.................................................................................971 Hydraulic circuit diagram............................................................................971 Hydraulic circuit diagram........................................................................973 90 Diagrams and drawings.................................................................................983 Electrical diagrams and drawings.....................................................................983 Electrical circuit diagram (1/5).................................................................985 Electrical circuit diagram (2/5).................................................................987 Electrical circuit diagram (3/5).................................................................989 Electrical circuit diagram (4/5).................................................................991 Electrical circuit diagram (5/5).................................................................993 Connectors table and arrangement drawing PC138US, USLC-8.........................................995
DESCRIPTION:
KOMATSU GALEO PC138US-8 PC138USLC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
S.S 22/12/24
