Komatsu PC138USLC-11 Shop Manual SEN06589-18 – Complete PDF Service & Repair Guide

Description

Komatsu PC138USLC-11 Shop Manual — SEN06589-18

This is the complete Komatsu PC138USLC-11 Shop Manual, document number SEN06589-18. It covers the PC138USLC-11 hydraulic excavator in full workshop detail — from the SAA4D95LE-7 engine through the hydraulic system, electrical circuits, undercarriage and work equipment. Whether you are rebuilding a final drive, diagnosing a failure code, or checking a relief pressure, this manual gives you the procedures, values and diagrams that Komatsu technicians use.

File Details

• Manual type: Shop Manual
• Brand: Komatsu
• Model: PC138USLC-11
• Engine: Komatsu SAA4D95LE-7 diesel engine
• Document number: SEN06589-18
• Language: English
• File format: PDF
• Page count: 2,267 pages

Chapters Covered

• 00 Index and Foreword
• 01 Specifications
• 10 Structure and Function
• 20 Standard Value Table
• 30 Testing and Adjusting
• 40 Troubleshooting
• 50 Disassembly and Assembly
• 60 Maintenance Standard
• 80 Appendix
• 90 Circuit Diagrams

00 Index and Foreword

Safety notices, fire prevention, waste disposal, DEF handling precautions, hydraulic and electrical equipment handling, connector disconnection procedures, and the standard tightening torque tables. This section sets the groundwork for every job in the manual.

01 Specifications

Complete machine specifications for the PC138USLC-11, including specification drawings, working range drawings, weight tables, and a full table of fuel, coolant and lubricants. Engine specifications cover the SAA4D95LE-7 with bore, stroke, displacement, rated horsepower, torque and fuel consumption figures.

10 Structure and Function

The largest technical section — it explains how every major system on the PC138USLC-11 works. Coverage includes the Komatsu Urea SCR system (layout, diagram, DEF injection, purge and heating functions, inducement strategy), the engine control system, auto-deceleration, engine automatic warm-up, overheat prevention, automatic idle stop, the PTO, variable flow turbocharger, EGR system, KCCV system, exhaust throttle valve, KDOC, cooling system, control system (machine monitor, KomVision, KOMTRAX), hydraulic system (CLSS, engine and pump combined control), work equipment system (PPC lock, attachment oil flow adjuster, tool control), swing system, travel system, undercarriage, work equipment, and CAB related parts.

20 Standard Value Table

Standard values for engine and machine — engine speed at high and low idle, exhaust gas colour limits, valve clearance, compression pressure, blowby pressure, fuel pressure, engine oil pressure, fan belt tension, cooling fan speed, plus machine values for operating speeds, control lever travel, operating forces, relief pressures, cycle times, travel speeds, hydraulic drift limits and pump performance.

30 Testing and Adjusting

Every test and adjustment procedure for the PC138USLC-11. Engine tests include speed, exhaust gas colour, exhaust throttle valve clearance, valve clearance, compression pressure, blowby pressure, engine oil pressure, EGR valve cleaning, fuel pressure, fuel return rate and leakage, and air bleeding. Hydraulic tests cover relief pressures for work equipment, swing, travel and blade, control circuit pressure, pump PC and LS control circuits, solenoid valve pressures, PPC valve output pressure, travel deviation, hydraulic drift, oil leakage and air bleeding. Also includes SCR-related function tests — DEF pump raised pressure, DEF injector injection volume, DEF line heater relays, DEF tank heater valve, and SCR denitration efficiency — plus swing circle bearing clearance and track tension adjustment.

40 Troubleshooting

The troubleshooting section is divided into failure-code diagnostics, electrical system troubleshooting (E-mode), hydraulic and mechanical systems (H-mode), and engine (S-mode). The failure code table lists every code the machine can display, with detailed diagnostic procedures. E-mode covers symptoms like engine not cranking, preheating faults, monitor display issues, sensor problems and component failures. H-mode covers hydraulic and mechanical symptoms such as low work equipment speed, unusual pump noise, engine speed drop, boom/arm/bucket hydraulic drift, swing and travel problems. S-mode covers engine symptoms from hard starting to excessive oil consumption. Connector layouts, T-branch adapter tables, fuse locations and wiring harness diagnostic procedures are also included.

50 Disassembly and Assembly

Step-by-step removal, installation, disassembly and assembly procedures for all major components. Engine and cooling system procedures cover supply pump, injector, cylinder head, EGR valve, EGR cooler, starter, belts, radiator, hydraulic oil cooler, aftercooler, fan clutch, engine and main pump assembly, oil seals, fuel cooler, KDOC, SCR assembly, fuel tank, DEF tank and related components. Power train covers travel motor and final drive, swing motor and machinery, and swing circle. Undercarriage covers track assembly, sprocket, idler, idler cushion, track roller and revolving frame. Hydraulic system covers centre swivel joint, hydraulic tank, main pump, control valve, work equipment PPC valve and travel PPC valve. Work equipment covers blade, work equipment assembly and cylinder assembly. CAB related parts covers operator cab, slide door, glass, floor frame, air conditioner unit, seat and control lever.

60 Maintenance Standard

Maintenance standards for every major component — engine mount, PTO, swing circle, swing machinery, sprocket, track frame, idler, idler cushion, track roller, carrier roller, track shoes, triple shoes, road liner, hydraulic tank, main pump, PC-EPC valve, swing motor, travel motor, control valve, work equipment PPC valve, blade PPC valve, travel PPC valve, 1st-line attachment PPC valve, solenoid valve, variable back pressure solenoid valve, attachment circuit selector valve, attachment circuit accumulator, centre swivel joint, work equipment linkage, boom cylinder, arm cylinder, bucket cylinder, blade cylinder and CAB mount.

80 Appendix — Air Conditioner System

The air conditioner appendix covers refrigerant precautions, component parts, refrigeration cycle, air conditioner unit, controller, compressor, condenser, sensors, circuit diagrams, connector pin configurations, self-diagnosis function, vent mode changeover, fresh/recirc air changeover, sunlight sensor, refrigerant pressure switch, relay testing and a complete air conditioner troubleshooting chart.

90 Circuit Diagrams

Hydraulic circuit diagrams for all machine configurations — blade less, blade, arm crane, multi-control valve and tool control system. Electrical circuit diagrams for machines with KOMTRAX terminal and machines with gateway function controller, covering all nine sheets of the electrical schematic.

What This Manual Enables You to Do

With the Komatsu PC138USLC-11 Shop Manual, you can perform complete mechanical, hydraulic and electrical repairs on the machine. You can diagnose failure codes through the full troubleshooting tables, test and adjust hydraulic pressures, rebuild cylinders, service the engine and fuel system, repair the swing and travel systems, troubleshoot the SCR and DEF systems, and check maintenance standards against measured values. The manual provides torque values, clearances, adjustment procedures and component illustrations that let you work to factory specifications rather than guesswork.

Every procedure is written for the PC138USLC-11 with the SAA4D95LE-7 engine. Serial number ranges are noted where specifications or procedures differ. The structure follows the Komatsu shop manual standard — index, specifications, structure and function, standard values, testing and adjusting, troubleshooting, disassembly and assembly, maintenance standards, appendix and circuit diagrams — so you can move from a symptom to the exact procedure without searching through unrelated information.

Why Technicians Use This Shop Manual

Hydraulic excavators like the PC138USLC-11 rely on precise hydraulic pressures, correct assembly clearances and properly calibrated electronic controls. A repair made without the correct specifications can lead to premature failure, poor performance, or damage to other components. This manual removes that risk. It gives you the relief pressure ranges, the hydraulic drift limits, the cylinder leakage allowances, the engine speed values and the failure code diagnostics that tell you whether a component is within specification or needs replacement.

The troubleshooting sections are particularly valuable — instead of replacing parts on suspicion, you can follow the diagnostic flow for each failure code or symptom. The electrical system coverage includes connector layouts, T-branch adapter tables and fuse locations, so you can trace circuits accurately. The hydraulic circuit diagrams show every valve, cylinder, motor and line, making it possible to understand how the system routes oil in every operating condition.

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Instant PDF Delivery — No Shipping, No Waiting

This Komatsu PC138USLC-11 Shop Manual (SEN06589-18) is delivered as a PDF download immediately after purchase. There is no physical book to ship, no waiting for delivery, and no shipping cost. The file works on any device — laptop, tablet, or smartphone — and can be printed if you prefer a paper copy in the workshop. Keep it on your service computer, load it on a tablet at the machine, or print the specific pages you need for a job. Either way, you get the complete manual with every chapter, diagram and table intact.