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Komatsu PC138USLC-11 Shop Manual
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Komatsu PC138USLC-11 Shop Manual

Hydraulic excavator
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SEN06589-03
HYDRAULIC
PC138USLC
-11
EXCAVATOR
50001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu PC138USLC-11

  • Page 1 SEN06589-03 HYDRAULIC PC138USLC EXCAVATOR 50001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 00 INDEX AND FOREWORD PC138USLC-11 00-1 Find manuals at https://best-manuals.com...
  • Page 4 BATTERY DISCONNECT SWITCH ....................10-42 ENGINE SYSTEM ..........................10-43 LAYOUT DRAWING OF ENGINE SYSTEM ................... 10-43 ENGINE CONTROL SYSTEM ....................... 10-45 AUTO-DECELERATION SYSTEM ....................10-48 ENGINE AUTOMATIC WARM-UP SYSTEM .................. 10-50 OVERHEAT PREVENTION SYSTEM .................... 10-52 00-2 PC138USLC-11 Find manuals at https://best-manuals.com...
  • Page 5 CONTENTS ............................20-2 ABBREVIATION LIST ..........................20-3 STANDARD VALUE TABLE FOR ENGINE ..................... 20-9 STANDARD VALUE TABLE FOR ENGINE:PC138USLC-11 ............20-9 STANDARD VALUE TABLE FOR MACHINE..................20-13 STANDARD VALUE TABLE FOR MACHINE:PC138USLC-11 ............20-13 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......20-26 30 TESTING AND ADJUSTING ........................
  • Page 6 HANDLE BATTERY DISCONNECT SWITCH ................30-250 TEST DIODES ..........................30-251 Pm CLINIC............................30-252 Pm CLINIC SERVICE ........................30-252 40 TROUBLESHOOTING ..........................40-1 CONTENTS ............................40-2 ABBREVIATION LIST ........................... 40-12 RELATED INFORMATION ON TROUBLESHOOTING ................. 40-18 GENERAL TROUBLESHOOTING POINTS ................... 40-18 00-4 PC138USLC-11 Find manuals at https://best-manuals.com...
  • Page 7 FAILURE CODE [B@BAZG] ......................40-189 FAILURE CODE [B@BAZK]......................40-190 FAILURE CODE [B@BCNS] ......................40-192 FAILURE CODE [B@HANS] ......................40-193 FAILURE CODE [CA115] ......................40-195 FAILURE CODE [CA122] ......................40-196 FAILURE CODE [CA123] ......................40-198 FAILURE CODE [CA131] ......................40-200 FAILURE CODE [CA132] ......................40-202 PC138USLC-11 00-5 Find manuals at https://best-manuals.com...
  • Page 8 FAILURE CODE [CA1678] ......................40-294 FAILURE CODE [CA1682] ......................40-295 FAILURE CODE [CA1683] ......................40-299 FAILURE CODE [CA1684] ......................40-301 FAILURE CODE [CA1686] ......................40-303 FAILURE CODE [CA1691] ......................40-304 FAILURE CODE [CA1694] ......................40-306 FAILURE CODE [CA1695] ......................40-308 FAILURE CODE [CA1696] ......................40-309 00-6 PC138USLC-11 Find manuals at https://best-manuals.com...
  • Page 9 FAILURE CODE [CA3498] ......................40-412 FAILURE CODE [CA3543] ......................40-413 FAILURE CODE [CA3545] ......................40-419 FAILURE CODE [CA3547] ......................40-421 FAILURE CODE [CA3558] ......................40-422 FAILURE CODE [CA3559] ......................40-424 FAILURE CODE [CA3562] ......................40-426 FAILURE CODE [CA3563] ......................40-428 FAILURE CODE [CA3567] ......................40-431 PC138USLC-11 00-7 Find manuals at https://best-manuals.com...
  • Page 10 FAILURE CODE [CA4281] ......................40-560 FAILURE CODE [CA4459] ......................40-564 FAILURE CODE [CA4461] ......................40-567 FAILURE CODE [CA4533] ......................40-570 FAILURE CODE [CA4534] ......................40-571 FAILURE CODE [CA4731] ......................40-572 FAILURE CODE [CA4732] ......................40-573 FAILURE CODE [CA4739] ......................40-574 FAILURE CODE [CA4768] ......................40-575 00-8 PC138USLC-11 Find manuals at https://best-manuals.com...
  • Page 11 FAILURE CODE [DAFQKR] ......................40-679 FAILURE CODE [DAZ9KQ]......................40-683 FAILURE CODE [DAZQKR] ......................40-684 FAILURE CODE [DB2QKR] ......................40-688 FAILURE CODE [DB2RKR] ......................40-693 FAILURE CODE [DB90MC] ......................40-698 FAILURE CODE [DBP0KM] ......................40-699 FAILURE CODE [DBP0KT] ......................40-700 FAILURE CODE [DBPQKR]......................40-701 FAILURE CODE [DDNRKA]......................40-706 FAILURE CODE [DDNRKY]......................40-709 PC138USLC-11 00-9...
  • Page 12 FAILURE CODE [DWK2KB]......................40-803 FAILURE CODE [DWK2KY]......................40-805 FAILURE CODE [DWN5KA]......................40-807 FAILURE CODE [DWN5KB]......................40-809 FAILURE CODE [DWN5KY]......................40-811 FAILURE CODE [DWNSKA] ......................40-813 FAILURE CODE [DWNSKB] ......................40-815 FAILURE CODE [DWNSKY] ......................40-817 FAILURE CODE [DXA8KA]......................40-818 FAILURE CODE [DXA8KB]......................40-820 FAILURE CODE [DXE4KA]......................40-822 FAILURE CODE [DXE4KB]......................40-824 00-10 PC138USLC-11...
  • Page 13 E-31 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ..40-881 E-32 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK..40-884 E-33 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING ............................40-886 PC138USLC-11 00-11...
  • Page 14 H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED ........40-952 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER ........................40-953 H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY ................................40-954 00-12 PC138USLC-11...
  • Page 15 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION......40-1007 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ..............40-1008 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ............40-1010 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)......40-1011 50 DISASSEMBLY AND ASSEMBLY......................50-1 CONTENTS ............................50-2 ABBREVIATION LIST ..........................50-7 PC138USLC-11 00-13...
  • Page 16 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY ..............50-410 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........50-415 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ..........50-418 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ............50-422 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY............50-428 HYDRAULIC SYSTEM.........................50-439 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..........50-439 00-14 PC138USLC-11...
  • Page 17 MAINTENANCE STANDARD OF HYDRAULIC TANK ..............60-26 MAINTENANCE STANDARD OF MAIN PUMP................60-27 MAINTENANCE STANDARD OF PC-EPC VALVE................. 60-31 MAINTENANCE STANDARD OF SWING MOTOR................ 60-32 MAINTENANCE STANDARD OF TRAVEL MOTOR ..............60-35 MAINTENANCE STANDARD OF CONTROL VALVE..............60-36 PC138USLC-11 00-15...
  • Page 18 TESTING FRESH/RECIRC AIR CHANGEOVER.................. 80-51 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER ..........80-51 TEST SUNLIGHT SENSOR........................80-52 METHOD FOR TESTING SUNLIGHT SENSOR................80-52 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT..............80-53 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT......80-53 TEST RELAYS............................80-55 00-16 PC138USLC-11...
  • Page 19 ELECTRICAL CIRCUIT DIAGRAM (2/9)..................90-21 ELECTRICAL CIRCUIT DIAGRAM (3/9)..................90-23 ELECTRICAL CIRCUIT DIAGRAM (4/9)..................90-25 ELECTRICAL CIRCUIT DIAGRAM (5/9)..................90-27 ELECTRICAL CIRCUIT DIAGRAM (6/9)..................90-29 ELECTRICAL CIRCUIT DIAGRAM (7/9)..................90-31 ELECTRICAL CIRCUIT DIAGRAM (8/9)..................90-33 ELECTRICAL CIRCUIT DIAGRAM (9/9)..................90-35 INDEX..................................1 PC138USLC-11 00-17...

  • Page 20: Abbreviation List

    (provides better Sensing System combined operation than OLSS). Engine controller electronically controls supply pump, common rail, and injector. This function Common Rail Injection Engine maintains optimum fuel injection amount and fuel injection timing. 00-18 PC138USLC-11...
  • Page 21 Technology tronic control and communication. This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel Inlet Metering Actuator Engine discharged volume of supply pump. (Same as IMV) PC138USLC-11 00-19...
  • Page 22 Inlet Metering Valve Engine discharged volume of supply pump. (Same as IMA) This mechanism separates oil in blowby gas and Komatsu Closed Crank- KCCV Engine returns it to the intake side to combust it there. It case Ventilation primarily consists of filters.
  • Page 23 Tip-Over Protectuive chine when it is overtuned.(Hydraulic excavator TOPS Cab and canopy Structure tip-over protective structure) Structure which is standardized as ISO 12117. Solenoid valve that switches over direction of 2-Way Valve Hydraulic system flow. PC138USLC-11 00-21...
  • Page 24 Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection Steering STRG Signal Solenoid Standard Option PRESS Pressure 00-22 PC138USLC-11...
  • Page 25 00 INDEX AND FOREWORD ABBREVIATION LIST Abbreviation Actual word spelled out SPEC Specification Switch TEMP Temperature Torque Converter Transmission PC138USLC-11 00-23...

  • Page 26: Troubleshooting

    REMARK • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice. • Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.

  • Page 27: Signal Word

    REMARK Remark This signal word contains useful information to know. Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }. PC138USLC-11 00-25...

  • Page 28: Safety Matters

    Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...

  • Page 29: Precautions During Work

    Then, disconnect the quick release battery terminal (-). REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-). PC138USLC-11 00-27...
  • Page 30 • Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic- ular. 00-28 PC138USLC-11...
  • Page 31 • Hanging angle must be 60 ° or smaller as a rule. • When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook. PC138USLC-11 00-29...
  • Page 32 Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane When raising a heavy component (heavier than 25 kg), use a hoist or crane. 00-30 PC138USLC-11...
  • Page 33 Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope ( mm) Allowable load ( kN { t} ) 8.8 {0.9} 12.7 {1.3} 17.3 {1.7} 22.6 {2.3} 28.6 {2.9} 35.3 {3.6} 55.3 {5.6} 79.6 {8.1} 141.6 {14.4} 221.6 {22.6} 318.3 {32.4} PC138USLC-11 00-31...
  • Page 34 When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). 00-32 PC138USLC-11...
  • Page 35 • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping". PC138USLC-11 00-33...
  • Page 36 Fire around the machine due to highly heated exhaust gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 37 • When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. • When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual. PC138USLC-11 00-35...
  • Page 38 Be sure to wear rubber gloves when handling the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton work gloves, wear rubber gloves under them. 00-36 PC138USLC-11...
  • Page 39 Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people. • When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products. PC138USLC-11 00-37...
  • Page 40 This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
  • Page 41 If it gets on your skin, thoroughly wash it off with water. Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws. PC138USLC-11 00-39...
  • Page 42 If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper- ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze. Drain AdBlue/DEF to prevent it from freezing. 00-40 PC138USLC-11...
  • Page 43 Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap- propriately. REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs. PC138USLC-11 00-41...
  • Page 44 Cleaning operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine. 00-42 PC138USLC-11...
  • Page 45 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT REMARK The oil cleaning equipment can remove the ultra fine (approxi- mately 3 μm) particles that the filter built in the hydraulic equip- ment cannot remove. So, it is very effective device. PC138USLC-11 00-43...
  • Page 46 Introduction of parts for the disassembly of the face seal type hoses and tubes Hose side Pipe joint side Nominal No. O-ring (3) Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 00-44 PC138USLC-11...
  • Page 47 Split flange Sleeve head Flange (1) 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032 PC138USLC-11 00-45...
  • Page 48 Introduction of parts for the removal of O-ring boss type joint Nominal No. Plug (1) O-ring (2) 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 00-46 PC138USLC-11...
  • Page 49 When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening. • As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. PC138USLC-11 00-47...
  • Page 50 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 51 • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY". PC138USLC-11 00-49...
  • Page 52 The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage. 00-50 PC138USLC-11...
  • Page 53 • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from. PC138USLC-11 00-51...
  • Page 54 If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
  • Page 55 Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter it. PC138USLC-11 00-53...
  • Page 56 To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor. 00-54 PC138USLC-11...
  • Page 57 Provide an oil container to receive a quantity of hydraulic oil which may flow out. Connection Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4). PC138USLC-11 00-55...
  • Page 58 While keeping the condition of step 1, turn lever (3) to the right (clockwise). While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. 00-56 PC138USLC-11...
  • Page 59 While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. PC138USLC-11 00-57...
  • Page 60 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. 00-58 PC138USLC-11...
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