Komatsu PC138US-10 Hydraulic Excavator Shop Manual WENBM00010 PDF

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Komatsu PC138US-10 Hydraulic Excavator Shop Manual WENBM00010 –  PDF DOWNLOAD

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Komatsu PC138US-10 Hydraulic Excavator Shop Manual WENBM00010 –  PDF DOWNLOAD

Language : English
Pages : 1440
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC138US-10 Hydraulic Excavator Shop Manual WENBM00010 –  PDF DOWNLOAD

• SERIAL NUMBERS PC138US-10 F40003 and up

00 Index and foreword 3
Table of contents 4
Foreword, safety and general information . 17
Important safety notice 17
Fire prevention 22
Dispose of waste materials . 23
How to read the shop manual 24
Explanation of terms for maintenance standard 26
Handling equipment of fuel system devices 28
Handling of intake system parts 29
Handling of hydraulic equipment 30
Method of disconnecting and connecting of push-pull type coupler . 32
Type 1 . 32
Type 2 . 33
Type 3 . 34
Handling of electrical equipment . 35
How to read electric wire code . 43
Precautions when performing operation 46
Practical use of KOMTRAX . 51
Standard tightening torque table . 52
List of abbreviation . 58
Conversion table . 63
Contents . 70
Specifications . 71
Specification drawing 71
PC138US-10 . 71
2-Piece boom . 72
Working range drawings . 73
PC138US-10 . 73
Specifications . 74
PC138US-10 . 74
Weight table . 78
Table of fuel, coolant, and lubricants . 80
Contents . 82
Engine and cooling system 84
Engine related parts . 84
PTO 86
Specifications . 86
VFT 87
Specifications . 89
Operation 90
EGR system piping drawing 91
Function . 91
EGR system circuit diagram . 93
Operation 93
EGR valve 94
Structure 94
Operation 95
EGR cooler . 96
Operation 97
KCCV layout drawing 98
Operation 99
KCCV ventilator 100
Function . 100
Operation 100
CDR valve 101
KDOC muffler . 102
Structure 102
Function . 103
Cooling system . 104
Specifications . 105
Power train 106
Power train system . 106
Swing circle . 108
Specifications . 108
Swing machinery 109
Specifications . 110
Undercarriage and frame 111
Track frame 111
Specifications . 111
Idler cushion 112
Specifications . 112
Hydraulic system . 113
Hydraulic component layout . 113
Exterior . 113
Upper structure 114
Valve control 115
Hydraulic tank . 116
Specifications . 116
Oil filler cap . 117
CLSS . 118
Structure of CLSS 118
Features . 118
Configuration 118
Basic principle 119
Main pump 122
LS valve . 130
PC valve . 135
PC-EPC valve . 144
Check valve 147
Shuttle valve 148
Control valve 149
Unload valve . 169
Introduction of LS pressure 174
LS bypass plug . 176
Pressure compensation valve 179
Boom regeneration circuit 183
Arm regeneration circuit . 185
Merge-divider valve 187
LS separation valve 189
Self-pressure reducing valve . 191
Travel junction valve 192
Boom hydraulic drift prevention valve 194
Back pressure check valve 197
Oil cooler bypass valve 198
Swing motor 199
Swing parking brake 202
Relief valve . 204
Swing modulating relief valve function . 206
Swing motor reverse prevention valve . 208
Travel motor . 211
Structure 214
Operation of travel motor 215
Brake valve 217
Relief valve . 220
Work equipment and swing PPC valve . 222
Operation 225
Travel PPC valve . 229
Operation 231
Blade PPC valve 235
2-piece boom PPC valve . 237
1st-line attachment PPC valve (with EPC valve) . 239
EPC valve 242
Solenoid valve . 247
Operation 251
Attachment circuit selector valve (for low pressure circuit) . 253
Function . 253
Operation 254
Quick coupler control valve 256
Center swivel joint 260
Blade specifications . 260
PPC circuit accumulator 262
Specifications . 262
Function . 262
Attachment circuit accumulator (for low pressure circuit) 263
Specifications . 263
Function . 263
Work equipment . 264
Work equipment . 264
Work equipment shim 265
Structure 265
Function . 265
Bucket play adjustment shim 266
Structure 266
Cab and its attachments 267
Cab mount and cab tipping stopper 267
Structure 267
ROPS cab . 268
Function . 268
Take wiring harness out of cab . 269
Structure 269
Electrical system 270
Electrical control system 270
General system drawing . 270
Engine control function 273
Function . 273
Starting the engine 273
Engine speed control . 274
Engine stop 274
Stopping the engine with engine shutdown secondary switch 274
Engine and pump combined control function 275
Input/output signal 276
Function . 276
Control method in each mode 277
B and L mode . 278
Matching point . 278
Control function when traveling 279
Control function when emergency pump drive switch is “ON“ 280
Auto-deceleration function . 281
Function . 282
Operation 282
Engine automatic warm-up function 283
Function . 285
Overheat prevention function . 286
Turbocharger protection function . 288
Swing control function . 289
Function . 289
Travel control function 292
Function . 293
PPC lock function 296
Function . 296
System operating lamp function . 297
Function . 297
ON/OFF of system operating lamp 297
Battery disconnect switch function . 298
Function . 299
Precautions for using battery disconnect switch 299
Oil flow adjuster function for attachment 300
Function . 301
Machine monitor system . 302
Function . 302
Machine monitor 303
Precautions on the machine monitor display . 303
Input and output signals of machine monitor 304
Display 306
Gauges . 308
Alarm monitor 310
Pilot monitor 313
Switches . 315
Guidance icon and function switch 317
Operator mode functions 320
Service mode functions . 322
KOMTRAX system . 323
KOMTRAX terminal . 324
System component parts . 326
Pump controller 331
Fuel control dial 335
Resister for PC-EPC valve 336
CAN terminating resistor . 337
Engine oil pressure switch . 338
PPC oil pressure switch 339
Sensor . 340
Ambient pressure sensor 340
Charge (boost) pressure and temperature sensor . 341
Coolant temperature sensor . 342
Ne (crankshaft) speed sensor . 342
Bkup (camshaft) speed sensor . 343
Common rail pressure sensor 343
VFT motor (with position sensor) . 344
EGR valve (with position sensor) . 345
Mass air flow and temperature sensor . 346
Crankcase pressure sensor 346
Engine oil level sensor 347
Fuel level sensor 348
Hydraulic oil temperature sensor . 349
Oil pressure sensor of pump 350
PPC oil pressure sensor 351
20 Standard value tables . 353
Contents . 354
Standard service value table . 355
Standard value table for engine 355
Standard value table for machine . 356
Engine speed . 356
Travel of control lever 356
Control effort of control lever 357
Oil pressure . 358
Swing 360
Traveling 361
Work equipment . 362
Pump performance . 366
Machine posture and procedure for measuring performance 367
Standard value table for electrical system . 372
Controller . 372
Engine control . 373
Machine control 375
Machine monitor 377
30 Testing and adjusting . 379
Contents . 380
General information on testing and adjusting . 381
Tools for testing and adjusting 381
Sketch of tools for testing and adjusting 384
M4: Sensor adapter . 384
M4: Nipple . 384
M5: Sensor adapter . 385
-: Socket 385
Engine and cooling system 386
Testing engine speed . 386
Testing exhaust gas color 387
Testing and adjusting valve clearance 388
Testing compression pressure . 390
Testing blowby pressure 393
Testing engine oil pressure 394
Testing fuel pressure 395
Testing fuel return rate and leakage . 396
Bleeding air from fuel system 399
Testing fuel circuit for leakage . 401
Handling cylinder cutout mode operation 402
Handling no-injection cranking operation . 403
Checking and adjusting air conditioner compressor belt tension . 404
Replacing fan belt . 405
Writing compensation values at replacement of injector and engine controller . 406
Power train 410
Testing swing circle bearing clearance . 410
Undercarriage and frame 411
Testing and adjusting track shoe tension . 411
Hydraulic system . 412
Releasing remaining pressure from hydraulic circuit 412
Testing and adjusting oil pressure in work equipment, swing, and travel circuits . 413
Testing oil pressure of control circuit 416
Testing and adjusting oil pressure in pump PC control circuit 417
Testing and adjusting oil pressure in pump LS control circuit 420
Testing oil pressure with sensor adapter (special tool) 423
Testing outlet pressure of solenoid valve 425
Testing PPC valve output pressure 426
Connecting points of PPC piping 426
Adjusting play of work equipment and swing PPC valves 428
Isolating the parts causing hydraulic drift in work equipment 429
Testing and adjusting travel deviation . 430
Testing oil leakage 432
Bleeding air from hydraulic circuit 434
Cab and its attachments 437
Checking cab tipping stopper . 437
Testing, cleaning and lubricating slide door rail and roller . 438
Testing 438
Electrical system 441
Special functions of machine monitor . 441
Ordinary functions and special functions of machine monitor 443
Adjusting rearview camera angle 493
Handling voltage circuit of engine controller 495
Handling battery disconnect switch . 496
Testing diodes . 497
Pm clinic 498
Pm Clinic service 498
Check sheet 502
40 Troubleshooting . 505
Contents . 506
General information on troubleshooting . 512
Troubleshooting points . 512
Sequence of events in troubleshooting 514
Checks before troubleshooting 516
Inspection procedure before troubleshooting 518
Walk-around check 518
Testing in accordance with testing procedure . 519
Preparation for troubleshooting of electrical system . 535
Classification and procedure for troubleshooting . 539
Classification of troubleshooting 539
Procedure for troubleshooting 539
Symptom and troubleshooting numbers 542
Information in troubleshooting table . 545
Troubleshooting method for open circuit in wiring harness of pressure sensor system 547
Connector list and layout 549
Layout of connectors (1/6) . 553
Layout of connectors (2/6) . 554
Layout of connectors (3/6) . 555
Layout of connectors (4/6) . 556
Layout of connectors (5/6) . 557
Layout of connectors (6/6) . 558
Connector contact identification . 559
T-branch box and T-branch adapter table 596
Fuse location table 601
Locations of fusible links . 601
Locations of fuse boxes and fuse No 601
Connection table of fuse box . 601
Failure codes table 604
Troubleshooting by failure code (Display of code) 610
Failure code [879AKA] A/C Inner Sensor Open Circuit 610
Failure code [879AKB] A/C Inner Sensor Short Circuit . 611
Failure code [879BKA] A/C Outer Sensor Open Circuit 612
Failure code [879BKB] A/C Outer Sensor Short Circuit . 613
Failure code [879CKA] Ventilating Sensor Open Circuit 614
Failure code [879CKB] Ventilating Sensor Short Circuit . 615
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit 616
Failure code [879EMC] Ventilation Damper Abnormality . 617
Failure code [879FMC] Air Mix Damper Abnormality . 618
Failure code [879GKX] Refrigerant Abnormality 619
Failure code [989L00] Engine Controller Lock Caution 1 . 620
Failure code [989M00] Engine Controller Lock Caution 2 . 621
Failure code [989N00] Engine Controller Lock Caution 3 . 622
Failure code [AB00KE] Charge Voltage Low . 623
Failure code [B@BAZG] Eng Oil Press Low 625
Failure code [B@BAZK] Eng Oil Level Low 626
Failure code [B@BCNS] Eng Water Overheat . 627
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 628
Failure code [CA122] Chg Air Press Sensor High Error . 629
Failure code [CA123] Chg Air Press Sensor Low Error 631
Failure code [CA131] Throttle Sensor High Error 633
Failure code [CA132] Throttle Sensor Low Error . 635
Failure code [CA144] Coolant Temp Sens High Error 637
Failure code [CA145] Coolant Temp Sens Low Error . 639
Failure code [CA153] Chg Air Temp Sensor High Error 641
Failure code [CA154] Chg Air Temp Sensor Low Error . 643
Failure code [CA187] Sensor 2 Supply Volt Low Error 645
Failure code [CA221] Ambient Press Sensor High Error . 647
Failure code [CA222] Ambient Press Sensor Low Error 649
Failure code [CA227] Sensor 2 Supply Volt High Error . 651
Failure code [CA234] Eng Overspeed . 652
Failure code [CA238] Engine Speed Sensor Supply Volt Error . 653
Failure code [CA239] Engine Speed Sens Supply Volt High Error 654
Failure code [CA271] IMV/PCV1 Short Error 655
Failure code [CA272] IMV/PCV1 Open Error . 656
Failure code [CA322] Inj #1(L#1) Open/Short Error 657
Failure code [CA324] Inj #3(L#3) Open/Short Error 659
Failure code [CA331] Inj #2(L#2) Open/Short Error 661
Failure code [CA332] Inj #4(L#4) Open/Short Error 663
Failure code [CA343] ECM Critical Internal Failure . 665
Failure code [CA351] Injectors Drive Circuit Error . 666
Failure code [CA352] Sensor 1 Supply Volt Low Error 667
Failure code [CA356] Mass Air Flow Sensor High Error . 669
Failure code [CA357] Mass Air Flow Sensor Low Error 671
Failure code [CA386] Sensor 1 Supply Volt High Error . 673
Failure code [CA435] Eng Oil Press Sw Error 674
Failure code [CA441] Battery Voltage Low Error . 675
Failure code [CA442] Battery Voltage High Error 677
Failure code [CA449] Rail Press Very High Error 678
Failure code [CA451] Rail Press Sensor High Error 679
Failure code [CA452] Rail Press Sensor Low Error . 681
Failure code [CA466] KVGT Motor Driver Position Error 683
Failure code [CA515] Rail Press Sens Sup Volt High Error . 685
Failure code [CA516] Rail Press Sens Sup Volt Low Error 687
Failure code [CA553] Rail Press High Error . 689
Failure code [CA555] Crankcase Press High Error 1 690
Failure code [CA556] Crankcase Press High Error 2 691
Failure code [CA559] Rail Press Low Error 692
Failure code [CA689] Engine Speed Sensor Error . 695
Failure code [CA691] Intake Air Temp Sens High Error . 697
Failure code [CA692] Intake Air Temp Sens Low Error 699
Failure code [CA697] ECM Internal Temp Sensor High Error . 701
Failure code [CA698] ECM Int Temp Sensor Low Error . 702
Failure code [CA731] Eng Bkup Speed Sens Phase Error . 703
Failure code [CA778] Eng Bkup Speed Sensor Error . 704
Failure code [CA1117] Persistent Data Lost Error . 708
Failure code [CA1695] Sensor 5 Supply Volt High Error 709
Failure code [CA1696] Sensor 5 Supply Volt Low Error . 710
Failure code [CA1843] Crankcase Press Sens High Error 711
Failure code [CA1844] Crankcase Press Sens Low Error . 713
Failure code [CA1896] EGR Valve Stuck Error 715
Failure code [CA1942] Crankcase Press Sens In Range Error 716
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error 717
Failure code [CA2185] Throt Sensor Sup Volt High Error . 718
Failure code [CA2186] Throt Sensor Sup Volt Low Error 720
Failure code [CA2249] Rail Press Very Low Error 722
Failure code [CA2272] EGR Valve Pos Sens Low Error . 723
Failure code [CA2311] IMV Solenoid Error . 725
Failure code [CA2349] EGR Valve Solenoid Open Error 726
Failure code [CA2353] EGR Valve Solenoid Short Error . 728
Failure code [CA2357] EGR Valve Servo Error 730
Failure code [CA2765] Inj Trim Data Error 731
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error . 732
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 734
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 736
Failure code [CA3918] KVGT Stuck Error . 738
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error . 739
Failure code [CA3921] KVGT Servo Error 2 . 740
Failure code [CA3922] KVGT Motor Driver Open Error . 741
Failure code [CA3923] KVGT Motor Driver Short Error 743
Failure code [D110KB] Battery Relay Drive Short Circuit 745
Failure code [D19JKZ] Personal Code Relay Abnormality 747
Failure code [D811MC] KOMTRAX Error 750
Failure code [D862KA] GPS Antenna Open Circuit . 751
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 752
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) . 754
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 755
Failure code [DA20MC] Pump Controller Malfunction 757
Failure code [DA22KK] Pump Solenoid Power Low Error 758
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 760
Failure code [DA29KQ] Model Selection Abnormality 762
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) . 764
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) 766
Failure code [DA2QKR] CAN2 Discon (Pump Con) . 767
Failure code [DA2RKR] CAN1 Discon (Pump Con) . 769
Failure code [DAF0MB] Monitor ROM Abnormality 770
Failure code [DAF0MC] Monitor Error 771
Failure code [DAF8KB] Camera Power Supply Short Circuit 772
Failure code [DAF9KQ] Model Selection Abnormality 774
Failure code [DAFGMC] GPS Module Error . 775
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 776
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) . 778
Failure code [DAFQKR] CAN2 Discon (Monitor) 779
Failure code [DAZ9KQ] A/C Model Selection Abnormality 780
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) . 781
Failure code [DB2QKR] CAN2 Discon (Engine Con) . 785
Failure code [DB2RKR] CAN1 Discon (Engine Con) . 789
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality . 793
Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality . 795
Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality . 797
Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality . 799
Failure code [DFB3L8] Service Lever 1 Potentio Error . 801
Failure code [DFB4L8] Service Lever 2 Potentio Error . 802
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit . 803
Failure code [DHPAMA] Pump Press Sensor Abnormality 805
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality . 807
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality . 809
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality . 811
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality . 813
Failure code [DHSKMA] Blade Raise PPC Press Sensor Abnormality . 815
Failure code [DHSLMA] Blade Lower PPC Press Sensor Abnormality . 817
Failure code [DHX1MA] Overload Sensor Abnormality 819
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality 820
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality 822
Failure code [DV20KB] Travel Alarm Short Circuit . 823
Failure code [DW43KA] Travel Speed Sol Open Circuit 825
Failure code [DW43KB] Travel Speed Sol Short Circuit . 827
Failure code [DW45KA] Swing Brake Sol Open Circuit . 829
Failure code [DW45KB] Swing Brake Sol Short Circuit 832
Failure code [DW91KA] Travel Junction Sol Open Circuit . 834
Failure code [DW91KB] Travel Junction Sol Short Circuit 836
Failure code [DWA2KA] Attachment Sol Open Circuit 838
Failure code [DWA2KB] Attachment Sol Short Circuit . 840
Failure code [DWJ0KA] Merge-divider Sol Open Circuit . 842
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 844
Failure code [DXA8KA] PC-EPC Sol Open Circuit 846
Failure code [DXA8KB] PC-EPC Sol Short Circuit . 848
Failure code [DXE4KA] Attachment Flow EPC Open Circuit . 850
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 852
Failure code [DXEAKA] Service Current EPC1 Discon 854
Failure code [DXEAKB] Service Current EPC1 Short . 856
Failure code [DXE7KA] Service Current EPC2 Discon 858
Failure code [DXE7KB] Service Current EPC2 Short . 860
Failure code [DXE8KA] Service Current EPC3 Discon 862
Failure code [DXE8KB] Service Current EPC3 Short . 864
Failure code [DXE9KA] Service Current EPC4 Discon 866
Failure code [DXE9KB] Service Current EPC4 Short . 868
Failure code [DY20KA] Wiper Working Abnormality 870
Failure code [DY20MA] Wiper Parking Abnormality 872
Failure code [DY2CKB] Washer Drive Short Circuit . 874
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 876
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 878
Troubleshooting of electrical system (E-mode) 880
E-1 Engine does not start (Engine does not crank) 880
E-2 Manual preheating system does not work . 886
E-3 While preheating is working, preheating monitor does not light up 889
E-4 When starting switch is turned to ON position, machine monitor displays nothing 891
E-5 When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow 894
E-6 Engine coolant temperature monitor lights up in white while engine is running 895
E-7 Hydraulic oil temperature monitor lights up in white while engine is running . 896
E-8 Charge level monitor lights up while engine is running . 897
E-9 Fuel level monitor lights up in red while engine is running 898
E-10 Engine coolant temperature monitor lights up in red while engine is running . 899
E-11 Hydraulic oil temperature monitor lights up in red while engine is running 900
E-12 Engine oil pressure monitor lights up in red while engine is running 901
E-13 Fuel gauge display does not move from minimum or maximum 902
E-14 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 903
E-15 Engine coolant temperature gauge display does not move from minimum or maximum 904
E-16 Engine coolant temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) 905
E-17 Hydraulic oil temperature gauge does not move from minimum or maximum . 906
E-18 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) . 908
E-19 Some areas of machine monitor screen are not displayed 909
E-20 Function switch does not work . 910
E-21 Automatic warm-up system does not operate (in cold season) 911
E-22 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated . 912
E-23 Auto-deceleration function does not operate or is not canceled while lever is operated 913
E-24 Working mode selection screen is not displayed while working mode selector switch is operated . 914
E-25 Setting of engine and hydraulic pump is not changed while working mode is changed . 915
E-26 Travel speed monitor does not change while travel speed switch is operated 916
E-27 Travel speed does not change while travel speed selection is changed 917
E-28 Alarm buzzer does not stop sounding . 918
E-29 Service meter is not displayed, while starting switch is in OFF position 919
E-30 Service mode cannot be selected . 920
E-31 Any of work equipment, swing and travel does not work . 921
E-32 Any of work equipment, swing and travel cannot be locked 923
E-33 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position 925
E-34 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position 927
E-35 Alarm does not sound during travel 929
E-36 Alarm does not stop sounding while machine is stopped . 930
E-37 – Horn does not sound . 931
E-38 Horn does not stop sounding . 933
E-39 – Wiper monitor does not light up, or does not go out, while wiper switch is operated . 934
E-40 Wiper does not operate while wiper switch is operated . 935
E-41 Window washer does not operate while window washer switch is operated . 937
E-42 Boom Lower is not displayed correctly with monitoring function 938
E-43 Arm OUT is not displayed correctly with monitoring function . 940
E-44 Arm IN is not displayed correctly with monitoring function 942
E-45 Boom Raise is not displayed correctly with monitoring function 944
E-46 Bucket Curl is not displayed correctly with monitoring function . 946
E-47 Bucket Dump is not displayed correctly with monitoring function . 948
E-48 Swing is not displayed correctly with monitoring function . 950
E-49 Travel is not displayed correctly with monitoring function 952
E-50 Service is not displayed correctly with monitoring function . 953
E-51 Attachment hydraulic circuit cannot be changed 956
E-52 KOMTRAX system does not operate normally 957
Troubleshooting of hydraulic and mechanical system (H-mode) 959
Information described in troubleshooting table (H-mode) 959
System chart of hydraulic and mechanical systems . 960
Failure mode and cause table . 962
H-1 All of work equipment, swing and travel operation lacks speed or power . 970
H-2 Engine speed drops significantly or engine stalls 972
H-3 Any of work equipment, swing and travel does not work 973
H-4 Unusual sound is heard from around hydraulic pump 974
H-5 Fine control performance or response is poor . 975
H-6 Boom speed or power is low . 976
H-7 Arm speed or power is low 979
H-8 Bucket speed or power is low . 981
H-9 Work equipment does not move in single operation . 983
H-10 Hydraulic drift of boom is large 984
H-11 Hydraulic drift of arm is large . 985
H-12 Hydraulic drift of bucket is large 986
H-13 Time lag of work equipment is large . 987
H-14 In combined operation of work equipment , equipment having heavier load moves slower 989
H-15 In combined operation of swing and boom RAISE, boom rising speed is low . 990
H-16 In combined operation of swing and travel, travel speed drops largely . 991
H-17 Machine does not travel straight 992
H-18 Travel speed is slow 994
H-19 Machine is hard to steer or travel power is low . 996
H-20 Travel speed does not change, or travel speed is too slow or fast . 999
H-21 One of tracks does not run 1000
H-22 Upper structure does not swing to the right or left .1002
H-23 Upper structure swing only to the right or left .1003
H-24 Swing acceleration or swing speed is low in both directions (right and left) 1004
H-25 Swing acceleration performance is poor or swing speed is slow in only one direction .1005
H-26 Upper structure overruns excessively when it stops swinging (both right and left) .1006
H-27 Upper structure overruns excessively when it stops swinging (either right or left) 1007
H-28 Shock is large when upper structure stops swinging 1008
H-29 Large unusual noise is heard when upper structure stops swinging 1009
H-30 Swing drift on a slope is large while swing parking brake is applied 1010
H-31 Swing drift on a slope is large while swing parking brake is released .1011
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed 1012
H-33 Oil flow in attachment circuit cannot be controlled .1013
Troubleshooting of engine (S-mode) .1014
Information mentioned in troubleshooting table (S mode) 1014
S-1 Engine does not crank when starting switch is turned to START position .1015
S-2 Engine cranks but no exhaust smoke comes out .1016
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .1017
S-4 Engine startability is poor 1018
S-5 Engine does not pick up smoothly .1020
S-6 Engine stops during operation 1022
S-7 Engine runs rough or is unstable .1024
S-8 Engine lacks power .1025
S-9 Exhaust smoke is black .1027
S-10 Engine oil consumption is excessive .1029
S-11 Oil becomes contaminated quickly 1030
S-12 Fuel consumption is excessive .1031
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1032
S-14 Oil pressure drops 1033
S-15 Fuel mixes into engine oil 1035
S-16 Water mixes into engine oil (milky) .1036
S-17 Coolant temperature rises too high (overheating) 1037
S-18 Unusual noise is heard 1038
S-19 Vibration is excessive 1039
S-20 Air cannot be bled from fuel circuit 1040
50 Disassembly and assembly 1041
Contents .1042
General information on disassembly and assembly 1044
How to read this manual 1044
Coating materials list .1046
Adhesive .1046
Liquid gasket 1047
Molybdenum disulfide lubricant .1047
Seizure prevention compound 1048
Grease .1048
Primer .1049
Adhesive .1049
Caulking material 1049
Special tools list .1050
Sketches of special tools 1054
Engine and cooling system 1056
Removal and installation of supply pump assembly .1056
Removal and installation of injector assembly 1060
Removal and installation of cylinder head assembly .1066
Removal and installation of radiator assembly 1077
Removal 1077
Removal and installation of hydraulic oil cooler assembly 1079
Removal and installation of aftercooler assembly .1082
Removal 1082
Removal and installation of engine and main pump assembly 1084
Removal and installation of engine front oil seal 1089
Removal and installation of engine rear oil seal .1090
Removal and installation of fuel cooler assembly .1092
Removal and installation of fuel tank assembly .1093
Removal and installation of KDOC assembly 1096
Removal and installation of KCCV assembly 1097
Removal and installation of air cleaner assembly .1098
Removal and installation of fan belt .1100
Power train system .1102
Removal and installation of travel motor and final drive assembly 1102
Disassembly and assembly of travel motor and final drive assembly 1103
Disassembly 1111
Assembly .1124
Removal and installation of swing motor and swing machinery assembly .1137
Disassembly and assembly of swing machinery assembly .1139
Removal and installation of swing circle assembly 1145
Undercarriage and frame 1146
Separation and connection of track .1146
Removal and installation of sprocket .1149
Removal 1149
Removal and installation of idler and idler cushion assembly .1150
Disassembly and assembly of idler assembly .1151
Disassembly and assembly of idler cushion assembly .1154
Disassembly 1155
Assembly .1156
Disassembly and assembly of track roller assembly 1157
Removal and installation of revolving frame assembly .1160
Removal 1160
Removal and installation of counterweight assembly [For machines with additional counterweight] 1162
Hydraulic system .1165
Removal and installation of center swivel joint assembly .1165
Disassembly and assembly of center swivel joint assembly .1167
Removal and installation of hydraulic tank assembly 1168
Removal and installation of main pump assembly .1171
Removal and installation of control valve assembly .1175
Disassembly and assembly of control valve assembly .1181
Assembly of control valve assembly .1182
Disassembly and assembly of work equipment PPC valve assembly 1183
Assembly .1184
Disassembly and assembly of travel PPC valve assembly 1185
Disassembly 1185
Work equipment .1187
Removal and installation of work equipment assembly 1187
Disassembly and assembly of work equipment cylinder assembly .1191
Assembly .1193
Cab and its attachments 1196
Removal and installation of operator’s cab assembly 1196
Removal and installation of operator’s cab door 1199
Removal and installation of operator’s cab glass (adhered glass) .1201
Removal 1203
Removal and installation of front window assembly 1211
Removal and installation of floor frame assembly .1212
Removal and installation of air conditioner unit assembly 1219
Removal and installation of air conditioner compressor assembly 1223
Removal and installation of air conditioner condenser assembly .1225
Removal and installation of operator’s seat 1227
Removal and installation of seat belt 1228
Removal and installation of front wiper assembly .1229
Electrical system 1235
Removal and installation of engine controller assembly .1235
Removal and installation of pump controller assembly .1236
Removal and installation of machine monitor assembly .1238
Removal and installation of mass air flow and temperature sensor .1240
Removal and installation of KOMTRAX terminal assembly 1241
60 Maintenance standard 1243
Contents .1244
Engine and cooling system 1245
Engine mount .1245
PTO 1246
Cooling system .1247
Power train 1248
Swing circle .1248
Swing machinery 1249
Sprocket .1250
Undercarriage and frame 1251
Track frame 1251
Idler cushion 1252
Idler 1253
Track roller .1254
Carrier roller .1255
Track shoe .1256
Triple grouser shoe 1259
Road liner .1260
Hydraulic system .1261
Hydraulic tank .1261
Main pump 1262
PC-EPC valve .1264
Control valve 1265
Swing motor 1276
Travel motor .1279
Work equipment and swing PPC valve .1280
Travel PPC valve .1283
Blade PPC valve 1286
2-piece boom PPC valve .1288
1st-line attachment PPC valve (with EPC valve) .1290
EPC valve 1292
Solenoid valve .1293
Attachment circuit selector valve (for low pressure circuit) .1294
Center swivel joint 1295
Blade specifications .1295
Cab and its attachments 1296
Cab mount and cab tipping stopper 1296
Work equipment .1297
Work equipment (standard boom specification) .1297
Dimensions of arm 1302
Dimensions of bucket .1304
Boom cylinder (for standard boom) 1306
Arm cylinder (for standard boom) .1307
Bucket cylinder 1308
Blade cylinder .1309
Boom cylinder (for 2-piece boom) .1310
Arm cylinder (for 2-piece boom) 1311
2-piece boom cylinder 1312
80 Appendix 1313
Contents .1314
Air conditioner components .1315
Precautions for refrigerant 1315
Air conditioner component 1316
Specifications .1318
Configuration and function of refrigeration cycle 1319
Outline of refrigeration cycle .1320
Air conditioner unit .1322
Function .1323
Functions of major components 1324
Dual pressure switch .1327
Function .1327
Air conditioner controller .1328
Compressor .1329
Specification 1329
Function .1329
Air conditioner condenser 1330
Specification 1330
Function .1330
Sunlight sensor 1332
Function .1332
Output characteristics .1332
Outer temperature sensor (outside air temperature sensor) 1333
Function .1333
Procedure for testing and troubleshooting 1334
Circuit diagram and arrangement of connector pins 1336
System diagram .1338
Input and output signals of the air conditioner controller .1339
Function .1339
Air conditioner unit .1341
Parts and connectors layout 1343
Details 1343
Testing air leakage (duct) .1349
Testing 1349
Testing with self-diagnosis function .1352
Testing outline 1352
How to open the electrical system abnormality record screen in service mode of the machine monitor .1352
Testing vent (mode) changeover .1355
Testing 1355
Testing FRESH/RECIRC air changeover 1356
Testing 1356
Testing sunlight sensor 1357
Testing 1357
Testing (dual) pressure switch for refrigerant .1358
Testing 1358
Testing relays .1360
Testing 1360
Troubleshooting chart 1 1361
Troubleshooting chart 2 1362
Information in troubleshooting table .1365
Information in troubleshooting table .1365
Failure code list related to air conditioner .1366
Failure code [879AKA] A/C Inner Sensor Open Circuit 1367
Failure code [879AKB] A/C Inner Sensor Short Circuit .1368
Failure code [879BKA] A/C Outer Sensor Open Circuit 1369
Failure code [879BKB] A/C Outer Sensor Short Circuit .1371
Failure code [879CKA] Ventilating Sensor Open Circuit 1373
Failure code [879CKB] Ventilating Sensor Short Circuit .1374
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 1375
Failure code [879EMC] Ventilation Damper Abnormality .1377
Failure code [879FMC] Air Mix Damper Abnormality .1378
Failure code [879GKX] Refrigerant Abnormality 1379
A-1 Troubleshooting for power supply system (Air conditioner does not operate) .1380
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1382
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .1385
A-4 Troubleshooting for FRESH/RECIRC air changeover 1387
Troubleshooting with gauge pressure 1389
Connection of service tool .1392
Precautions for disconnecting and connecting refrigerant piping 1394
Handling of compressor oil .1396
Desiccant replacement 1398
90 Diagrams and drawings .1401
Contents .1402
Hydraulic circuit diagram 1403
Symbols in hydraulic circuit diagram .1403
Hydraulic circuit diagram (1/2) 1407
Hydraulic circuit diagram (2/2) 1409
Electric circuit diagram .1411
Symbols in electric circuit diagram 1411
Electrical circuit diagram – Standard boom (1/6) .1415
Electrical circuit diagram – Standard boom (2/6) .1417
Electrical circuit diagram – Standard boom (3/6) .1419
Electrical circuit diagram – Standard boom (4/6) .1421
Electrical circuit diagram – Standard boom (5/6) .1423
Electrical circuit diagram – Standard boom (6/6) .1425
Electrical circuit diagram – 2-piece boom (1/6) 1427
Electrical circuit diagram – 2-piece boom (2/6) 1429
Electrical circuit diagram – 2-piece boom (3/6) 1431
Electrical circuit diagram – 2-piece boom (4/6) 1433
Electrical circuit diagram – 2-piece boom (5/6) 1435
Electrical circuit diagram – 2-piece boom (6/6) 1437
Electrical circuit diagram for air conditioner unit 1439

DESCRIPTION:

Komatsu PC138US-10 Hydraulic Excavator Shop Manual WENBM00010 –  PDF DOWNLOAD

• SERIAL NUMBERS PC138US-10 F40003 and up

G.B 27/12/24